METHODS AND SYSTEMS FOR DETECTING STAPLE CARTRIDGE MISFIRE OR FAILURE

• US 20120248167A1
• Filed: 05/15/2012
• Published: 10/04/2012
• Est. Priority Date: 02/15/2011
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Weir, David W., FLANAGAN, Patrick
• Granted Patent: US 9,393,017 B2
• Time in Patent Office: Days
• US Class Current: 227/2
• 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 17/072 for applying a row of staples in a single action , e.g. the staples being applied simultaneously
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/115 Staplers for performing anastomosis in a single operation
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00022 Sensing or detecting at the treatment site
• CPC Class Codes: A61B 2017/00115 with audible or visual output
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07271 characterised by its cartridge
• CPC Class Codes: A61B 2090/064 for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 2090/0811 for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument
• CPC Class Codes: A61B 34/30 Surgical robots

Abstract

Systems and methods are provided for detecting misfire of a surgical staple cartridge and for indicating such misfire to a user on a user interface. An actuation force applied to a staple cartridge is measured and compared to a threshold actuation force. In response to the comparison, a controller determines if there has been a misfire of the surgical staple cartridge. A determination that misfire has occurred is made when the measured actuation force is greater than a maximum threshold force or less than a minimum threshold force, and under such circumstances, the controller terminates the staple firing sequence.

Claims

1. A method of controlling a surgical stapler system, comprising:

receiving data at a processor indicative of an initial actuation force applied to a staple cartridge by the surgical stapler system;

comparing the initial actuation force to a threshold actuation force; and

controlling a continued application of the actuation force to the cartridge based on the comparison.

2. The method of claim 1, wherein controlling a continued application of the actuation force comprises terminating application of the actuation force if the threshold actuation force is greater than the initial actuation force.

3. The method of claim 2, wherein terminating application of the actuation force comprises providing an indication of stapler misfire or failure on a user interface.

4. The method of claim 3, wherein terminating application of the actuation force comprises terminating deployment of a cutting blade from the staple cartridge.

5. The method of claim 2, wherein the threshold actuation force and the initial applied actuation force comprise rotational forces.

6. The method of claim 1, wherein controlling a continued application of the actuation force comprises permitting continued application of the actuation force when the threshold actuation force is less than the applied force.

7. The method of claim 6, wherein permitting continued application of the actuation force comprises receive data indicative of subsequent actuation force applied to the staple cartridge by the surgical stapler system and comparing the subsequent actuation force to a second threshold force.

8. The method of claim 7, wherein controlling a continued application of the actuation force further comprises terminating application of the actuation force if the second threshold actuation force is less than the applied force.

9. The method of claim 1, wherein controlling a continued application of the actuation force comprises permitting deployment of a cutting blade from the cartridge.

10. The method of claim 1, wherein receiving data indicative of the initial actuation force includes measuring the initial actuation force applied to the cartridge.

11. The method of claim 1, wherein receiving data indicative of the initial actuation force includes sensing the initial actuation force applied to the cartridge.

12. A method of monitoring staple formation in a robotic stapler system, comprising:

receiving at a processor data indicative of an measured actuation force applied to a staple forming system;

comparing the measured actuation force to a minimum threshold actuation force; and

controlling a staple firing sequence based on the comparison.

13. The method of claim 12, wherein receiving data indicative of a measured actuation force includes measuring an actuation force applied to a staple cartridge of the staple forming system.

14. The method of claim 12, wherein controlling a staple firing sequence comprises terminating the firing sequence if the minimum threshold actuation force is greater than the measured actuation force.

15. The method of claim 14, wherein terminating the firing sequence comprises providing an indication of staple deployment failure on a user interface.

16. The method of claim 14, wherein terminating the firing sequence includes stopping deployment of a cutting blade coupled with the staple forming system.

17. The method of claim 12, further comprising comparing the measured actuation force to a maximum threshold actuation force.

18. The method of claim 17, wherein controlling a staple firing sequence comprises terminating the firing sequence if the maximum threshold actuation force is less than the measured actuation force.

19. A surgical stapler system comprising:

an end effector comprising a portion that removably receives a staple cartridge;

a drive system configured to apply an initial actuation force to the staple cartridge;

a sensor configured to measure an actuation force applied to the staple cartridge; and

a controller communicatively coupled to the sensor and the drive system to receive a signal indicative of the measured actuation force applied to the staple cartridge and to control a staple firing sequence based on a comparison of the measured actuation force and at least one threshold actuation force.

20. The system of claim 19, wherein the controller is configured to stop the firing sequence if a minimum threshold actuation force is greater than the measured actuation force.

21. The system of claim 20, wherein the controller is communicatively coupled to a user interface and provides an indication of staple deployment failure on the user interface if the minimum threshold actuation force is greater than the measured actuation force.

22. The system of claim 19, wherein the staple cartridge comprises a staple deployment element and a surgical blade.

23. The system of claim 22, wherein the controller is configured to stop deployment of the surgical blade if the minimum threshold actuation force is greater than the measured actuation force.

24. The system of claim 22, further comprising a plurality of staples in the staple cartridge, wherein the controller permits the firing sequence to continue to deploy the staples if the minimum threshold actuation force is less than the initial actuation force.

25. The system of claim 19, wherein the controller is configured to control a staple firing sequence based on a second comparison of the measured actuation force and a maximum threshold actuation force.

26. The system of claim 25, wherein the controller is configured to stop the firing sequence if the maximum threshold actuation force is less than the measured actuation force.

27. The system of claim 26, wherein a measured actuation force that is greater than the maximum threshold actuation force is indicative of jamming within the system.