Systems and methods for controlling motor velocity of a surgical stapling and cutting instrument

• US 10,624,633 B2
• Filed: 06/20/2017
• Issued: 04/21/2020
• Est. Priority Date: 06/20/2017
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Shelton, IV, Frederick E., Yates, David C., Harris, Jason L.
• Primary Examiner(s): Chukwurah, Nathaniel C
• Application Number:
  US15/628,075
• Publication Number:
  US 20180360447A1
• Time in Patent Office: 1,036 Days
• Field of Search: 2271751, 2271761, 2271781, 2271801, 227 19
• CPC Class Codes: A61B 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/0686 having a forming anvil staying below the tissue during stapling
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/1114 of the digestive tract, e.g. bowels or oesophagus
• CPC Class Codes: A61B 17/1626 Control means; Display units
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00075 Motion
• CPC Class Codes: A61B 2017/00115 with audible or visual output
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/07285 characterised by its cutter
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2090/064 for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 90/03 Automatic limiting or abutting means, e.g. for safety

Abstract

A motorized surgical instrument is provided. The surgical instrument includes a displacement member. A motor is coupled to the displacement member. A control circuit is coupled to the motor. A position sensor is coupled to the control circuit. A timer circuit is coupled to the control circuit to measure elapsed time. The control circuit is configured to receive the position of the displacement member from the position sensor, receive elapsed time from the timer circuit, and control velocity of the motor based on the position of the displacement member and the elapsed time. A method of controlling motor velocity of the surgical instrument also is disclosed.

Claims

1. A surgical instrument, comprising:

a displacement member configured to translate within the surgical instrument;

a motor coupled to the displacement member to translate the displacement member;

a control circuit coupled to the motor;

a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member;

a timer/counter circuit coupled to the control circuit, the timer/counter circuit configured to measure elapsed time;

wherein the control circuit is configured to;

receive the position of the displacement member from the position sensor;

receive the elapsed time from the timer/counter circuit;

correlate the position of the displacement member and the elapsed time; and

control velocity of the motor based on the correlation of the position of the displacement member and the elapsed time.

2. The surgical instrument of claim 1, wherein the control circuit is configured to:

set the velocity of the motor to a first velocity;

receive an initial position A_o of the displacement member from the position sensor;

receive a reference time t₁ from the timer/counter circuit corresponding to the initial position A_o of the displacement member; and

determine an anticipated position A₁ of the displacement member at a time t₂ based on the first velocity.

3. The surgical instrument of claim 2, wherein the control circuit is configured to:

receive an actual position B₁ of the displacement member at the time t₂ from the position sensor;

compare the actual position B₁ of the displacement member at the time t₂ with the anticipated position A₁ of the displacement member at the time t₂; and

adjust the velocity of the motor to a second velocity based on a difference between the actual position B₁ of the displacement member at the time t₂ and the anticipated position A₁ of the displacement member at the time t₂.

4. The surgical instrument of claim 3, wherein the control circuit is configured to:

increase the velocity of the motor when the actual position B₁ of the displacement member at the time t₂ is greater than the anticipated position A₁ of the displacement member at the time t₂.

5. The surgical instrument of claim 3, wherein the control circuit is configured to:

decrease the velocity of the motor when the actual position B₁ of the displacement member at the time t₂ is less than the anticipated position A₁ of the displacement member at the time t₂.

6. The surgical instrument of claim 3, wherein the control circuit is configured to:

determine actual tissue thickness based on a difference between the actual position B₁ of the displacement member at the time t₂ and the anticipated position A₁ of the displacement member at the time t2.

7. The surgical instrument of claim 6, wherein the control circuit is configured to:

determine that the actual tissue thickness is less than anticipated when the actual position B₁ of the displacement member at the time t₂ is greater than the anticipated position A₁ of the displacement member at the time t₂.

8. The surgical instrument of claim 6, wherein the control circuit is configured to:

determine that the actual tissue thickness is greater than anticipated when the actual position B₁ of the displacement member at the time t₂ is less than the anticipated position A₁ of the displacement member at the time t₂.

9. A surgical instrument, comprising:

an I-beam member configured to translate within an end effector of the surgical instrument;

a motor coupled to the I-beam member to translate the I-beam member within the end effector;

a control circuit coupled to the motor;

a position sensor coupled to the control circuit, the position sensor configured to measure a position of the I-beam member;

a timer/counter circuit coupled to the control circuit, the timer/counter circuit configured to measure elapsed time;

wherein the control circuit is configured to;

receive the position of the I-beam member from the position sensor;

receive the elapsed time from the timer/counter circuit;

correlate the position of the I-beam member and the elapsed time; and

control velocity of the motor based on the correlation of the position of the I-beam member and the elapsed time.

10. The surgical instrument of claim 9, wherein the control circuit is configured to:

set the velocity of the motor to a first velocity;

receive an initial position A_o of the I-beam member from the position sensor;

receive a reference time t₁ from the timer/counter circuit corresponding to the initial position A_o of the I-beam member; and

determine an anticipated position A₁ of the I-beam member at a time t₂ based on the first velocity.

11. The surgical instrument of claim 10, wherein the control circuit is configured to:

receive an actual position B₁ of the I-beam member at the time t₂ from the position sensor;

compare the actual position B₁ of the I-beam member at the time t₂ with the anticipated position A₁ of the I-beam member at the time t₂; and

adjust the velocity of the motor to a second velocity based on a difference between the actual position B₁ of the I-beam member at the time t₂ and the anticipated position A₁ of the I-beam member at the time t₂.

12. The surgical instrument of claim 11, wherein the control circuit is configured to:

increase the velocity of the motor when the actual position B₁ of the I-beam member at the time t₂ is greater than the anticipated position A₁ of the I-beam member at the time t₂.

13. The surgical instrument of claim 11, wherein the control circuit is configured to:

decrease the velocity of the motor when the actual position B₁ of the I-beam member at the time t₂ is less than the anticipated position A₁ of the I-beam member at the time t₂.

14. The surgical instrument of claim 11, wherein the control circuit is configured to:

determine actual tissue thickness based on a difference between the actual position B₁ of the I-beam member at the time t₂ and the anticipated position A₁ of the I-beam member at the time t₂.

15. The surgical instrument of claim 14, wherein the control circuit is configured to:

determine that the actual tissue thickness is less than anticipated when the actual position B₁ of the I-beam member at the time t₂ is greater than the anticipated position A₁ of the I-beam member at the time t₂.

16. The surgical instrument of claim 14, wherein the control circuit is configured to:

determine that the actual tissue thickness is greater than anticipated when the actual position B₁ of the I-beam member at the time t₂ is less than the anticipated position A₁ of the I-beam member at the time t₂.

17. A method of controlling motor velocity in a surgical instrument, the surgical instrument comprising a displacement member configured to translate, a motor coupled to the displacement member to translate the displacement member, a control circuit coupled to the motor, a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member, a timer/counter circuit coupled to the control circuit, the timer/counter circuit configured to measure elapsed time, the method comprising:

receiving, by the control circuit, the position of the displacement member from the position sensor;

receiving, by the control circuit, the elapsed time from the timer/counter circuit;

correlating, by the control circuit, the position of the displacement member and the elapsed time; and

controlling, by the control circuit, the motor velocity based on the correlation of the position of the displacement member and the elapsed time.

18. The method of claim 17, comprising:

setting, by the control circuit, the motor velocity to a first velocity;

receiving, by the control circuit, an initial position A_o of the displacement member from the position sensor;

receiving, by the control circuit, a reference time t₁ from the timer circuit corresponding to the initial position A_o of the displacement member; and

determining, by the control circuit, an anticipated position A₁ of the displacement member at a time t₂ based on the first velocity.

19. The method of claim 18, comprising:

receiving, by the control circuit, an actual position B₁ of the displacement member at the time t₂ from the position sensor;

comparing, by the control circuit, the actual position B₁ of the displacement member at the time t₂ with the anticipated position A₁ of the displacement member at the time t₂; and

adjusting, by the control circuit, the motor velocity to a second velocity based on a difference between the actual position B₁ of the displacement member at the time t₂ and the anticipated position A₁ of the displacement member at the time t₂.

20. The method of claim 19, comprising:

increasing, by the control circuit, the motor velocity when the actual position B₁ of the displacement member at the time t₂ is greater than the anticipated position A₁ of the displacement member at the time t₂.

21. The method of claim 19, comprising:

decreasing, by the control circuit, the motor velocity when the actual position B₁ of the displacement member at the time t₂ is less than the anticipated position A₁ of the displacement member at the time t₂.

22. The method of claim 19, comprising:

determining, by the control circuit, actual tissue thickness based on a difference between the actual position B₁ of the displacement member at the time t₂ and the anticipated position A₁ of the displacement member at the time t₂.

23. The method of claim 22, comprising:

determining, by the control circuit, that the actual tissue thickness is less than anticipated when the actual position B₁ of the displacement member at the time t₂ is greater than the anticipated position A₁ of the displacement member at the time t₂.

24. The method of claim 22, comprising:

determining, by the control circuit, that the actual tissue thickness is greater than anticipated when the actual position B₁ of the displacement member at the time t₂ is less than the anticipated position A₁ of the displacement member at the time t₂.