Methods and systems for detecting clamping or firing failure

• US 9,226,750 B2
• Filed: 01/13/2012
• Issued: 01/05/2016
• Est. Priority Date: 02/15/2011
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC), Smith & Nephew Incorporated (Smith & Nephew PLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Weir, David, Durant, Kevin, Flanagan, Patrick, Robinson, David
• Primary Examiner(s): Smith, Scott A.
• Application Number:
  US13/350,512
• Publication Number:
  US 20120205419A1
• Time in Patent Office: 1,453 Days
• Field of Search: 227/19, 227/175.1, 227/176.1, 227/178.1, 227/180.1, 227/175.2, 606/139, 606/153, 606/219
• US Class Current: 1/1
• 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 17/072 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 2017/00115 with audible or visual output
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/07214 Stapler heads
• 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

Abstract

Systems and methods are provided for detecting failure in clamping of a material and/or firing of a staple into a clamped material and indicating such failure to a user on a user interface. The system and methods are particularly suited for use with end effectors having closing and/or firing mechanisms coupled to an actuator. By monitoring a driving parameter of an actuator that effects the clamping and/or firing, the systems and methods provide an indication of failure in response to the monitored drive parameter. In some embodiments, an indication of failure is output when the monitored drive parameter is outside an acceptable range of desired driving parameters during clamping and/or firing. The disclosed systems and methods are particularly beneficial when used for minimally invasive surgery.

Claims

1. An apparatus comprising:

an end effector having a first jaw and a second jaw for clamping a material, and a staple for stapling the material clamped between the first and second jaws;

a drive system operatively coupled to the end effector such that driving an actuator of the drive system actuates the end effector for either a surgical or non-surgical method, wherein the drive system moves the first jaw toward the second jaw so as to clamp the material between the jaws such that a clamping force is applied, and wherein the drive system is coupled to the staple such that driving the actuator to staple produces a firing force so as to fire the staple into the material clamped between the first and second jaws;

a sensor for monitoring a drive parameter of the drive system when the actuator induces the clamping force, the firing force, or both the clamping force and the firing force;

a processor which continuously monitors the drive parameter of the drive system and compares the drive parameter to an acceptable range of drive parameters as the drive system drives the jaws to clamp at a desired clamping force; and

a user interface having an indicator for indicating success or failure of clamping or firing, wherein the indicator is of failure when the drive parameter during clamping is outside of an acceptable range of desired drive parameters for clamping or when the drive parameter during firing is outside an acceptable range of desired drive parameters for firing.

2. The apparatus of claim 1, wherein the indicator is of a likelihood of failure, wherein the likelihood corresponds to a probability of failure or success of clamping or firing.

3. The apparatus of claim 1, wherein the method is non-surgical in nature, and wherein clamping or firing comprises clamping a compliant material and firing a staple through the clamped compliant material.

4. The apparatus of claim 1, wherein the method is surgical in nature and clamping comprises clamping a body tissue and firing comprises firing a staple into the clamped body tissue.

5. The apparatus of claim 4, wherein the tissue comprises any of an outer skin, a bowel, a stomach, and any internal body organ or structure.

6. The apparatus of claim 1, wherein the drive system is operatively coupled to the end effector by one or more driving mechanisms.

7. The apparatus of claim 6, wherein the mechanisms comprises any or all of a cable, hypotube, drive shaft, universal, single or double cardan joint, and a leadscrew.

8. The apparatus of claim 6, wherein the sensor monitors a displacement of the actuator, a displacement of the one or more driving mechanisms, or both the displacement of the actuator and the displacement of the one or more driving mechanisms.

9. The apparatus of claim 1, wherein the indicator comprises any or all of an audio, visual, or other sensory indicator for communication failure to a user on the user interface.

10. The apparatus of claim 1, wherein the actuator comprises one or more actuators, including any or all of an electric motor, a hydraulic actuator, a pneumatic actuator, and a variable torque output actuator.

11. The apparatus of claim 1, wherein the processor terminates the clamping or firing force when the sensor detects that the drive parameter during clamping or firing is different from the acceptable range of drive parameters for clamping or firing.

12. The apparatus of claim 1, wherein the processor terminates the firing force and maintains the clamping force when the sensor detects the firing force is greater than the acceptable range of firing forces.