Multiple processor motor control for modular surgical instruments

• US 9,554,794 B2
• Filed: 03/01/2013
• Issued: 01/31/2017
• Est. Priority Date: 03/01/2013
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery LLC (Johnson & Johnson)
• Inventors: Baber, Daniel L., Leimbach, Richard L., Ulrich, Daniel J.
• Primary Examiner(s): Lopez, Michelle
• Application Number:
  US13/782,460
• Publication Number:
  US 20140246478A1
• Time in Patent Office: 1,432 Days
• Field of Search: 227/175.1, 227/176.1, 227/180.1
• 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 17/072 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 17/1155 Circular staplers comprising a plurality of staples
• CPC Class Codes: A61B 17/32002 with continuously rotating, oscillating or reciprocating cutting instruments
• CPC Class Codes: A61B 18/085 Forceps, scissors
• CPC Class Codes: A61B 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• 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 2017/00026 Conductivity or impedance, e.g. of tissue
• CPC Class Codes: A61B 2017/00039 Electric or electromagnetic phenomena other than conductivity, e.g. capacity, inductivity, Hall effect
• CPC Class Codes: A61B 2017/00075 Motion
• CPC Class Codes: A61B 2017/00115 with audible or visual output with imaging means A61B90/37, A61B34/20
• CPC Class Codes: A61B 2017/00123 and automatic shutdown
• CPC Class Codes: A61B 2017/00128 related to intensity or progress of surgical action
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00221 with wireless transmission of data, e.g. by infrared radiation or radiowaves
• CPC Class Codes: A61B 2017/00314 Separate linked members
• CPC Class Codes: A61B 2017/00323 Cables or rods
• CPC Class Codes: A61B 2017/00327 with actuating members moving in opposite directions
• CPC Class Codes: A61B 2017/00367 : Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like
• CPC Class Codes: A61B 2017/00393 : with means for switching between functions
• 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 for prosthetic joint-implanting tools A61F2/4603
• CPC Class Codes: A61B 2017/00464 : for use with different instruments with hole for different instruments A61B2017/22072
• CPC Class Codes: A61B 2017/00473 : Distal part, e.g. tip or head A61B2017/00464 takes precedence
• CPC Class Codes: A61B 2017/00477 : Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00482 : with a code
• CPC Class Codes: A61B 2017/0069 : with universal joint, cardan joint
• CPC Class Codes: A61B 2017/00734 : battery operated
• CPC Class Codes: A61B 2017/07271 : characterised by its cartridge
• CPC Class Codes: A61B 2017/07278 : characterised by its sled or its staple holder
• CPC Class Codes: A61B 2017/2903 : transferring rotary motion
• CPC Class Codes: A61B 2017/2923 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2925 : Pistol grips
• CPC Class Codes: A61B 2017/2927 : the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2929 : with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/2943 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/320069 : for ablating tissue
• CPC Class Codes: A61B 2017/320071 : with articulating means for working tip
• CPC Class Codes: A61B 2017/320089 : node location
• CPC Class Codes: A61B 2017/320093 : additional movable means performing cutting operation
• CPC Class Codes: A61B 2017/320094 : additional movable means performing clamping operation
• CPC Class Codes: A61B 2017/320095 : with sealing or cauterizing means
• CPC Class Codes: A61B 2017/320097 : with stapling means
• CPC Class Codes: A61B 2018/00607 : Coagulation and cutting with the same instrument
• CPC Class Codes: A61B 2018/00619 : Welding
• CPC Class Codes: A61B 2018/00791 : Temperature
• CPC Class Codes: A61B 2018/00875 : Resistance or impedance
• CPC Class Codes: A61B 2018/1455 : having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: A61B 2034/742 : Joysticks
• CPC Class Codes: A61B 2090/033 : Abutting means, stops, e.g. abutting on tissue or skin
• CPC Class Codes: A61B 2090/034 : abutting on parts of the device itself
• CPC Class Codes: A61B 2090/061 : for measuring dimensions, e.g. length
• CPC Class Codes: A61B 2090/064 : for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 2090/065 : for measuring contact or contact pressure
• 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
• CPC Class Codes: A61B 34/74 : Manipulators with manual electric input means
• CPC Class Codes: A61B 90/90 : Identification means for patients or instruments, e.g. tags
• CPC Class Codes: A61B 90/98 : using electromagnetic means, e.g. transponders
• CPC Class Codes: G05G 2009/04777 : with additional push or pull action on the handle
• CPC Class Codes: G05G 9/04796 : for rectilinear control along the axis of the controlling member
• CPC Class Codes: Y02A 90/10 : Information and communication technologies [ICT] supporting adaptation to climate change, e.g. for weather forecasting or climate simulation

Abstract

In various forms, the modular motor control system may comprise one or more motor controllers each having an associated motor. The one or more motor controllers may be in communication with a master controller. The master controller is configured to provide control signals to the motor controllers to control the associated motors. In some forms, the one or more motor controllers and the associated motors may be located within a surgical module. The surgical module may provide a communications interface between the master controller and the one or more motor controllers.

Claims

1. A modular motor control system comprising:

a master controller;

a first motor configured to control a first movement of a surgical instrument;

a first motor controller operatively coupled to the first motor, wherein the first motor controller and the master controller are in electrical communication, wherein the master controller provides a first control signal to the first motor controller, wherein the first motor controller controls the first motor in response to the first control signal;

a second motor configured to control a second movement of the surgical instrument;

a second motor controller operatively coupled to the second motor, wherein the second motor controller and the master controller are in electrical communication, wherein the master controller provides a second control signal to the second motor controller, wherein the second motor controller controls the second motor in response to the second control signal; and

a slave controller electrically coupled to the master controller;

wherein the slave controller generates the second control signal for the second motor controller in response to a master control signal received from the master controller.

2. The modular motor control system of claim 1, wherein the master controller is configured to execute a main control process.

3. The modular motor control system of claim 2, wherein the main control process comprises communicating with the first and second motor controllers synchronously.

4. The modular motor control system of claim 1, wherein the first and second motor controllers comprise a closed-loop control process having one or more independent controls for the first and second motors.

5. The modular motor control system of claim 4, wherein the one or more independent controls comprise a proportional-integral-derivative control process.

6. The modular motor control system of claim 4, wherein the one or more independent controls comprise a fault detection control process.

7. The modular motor control system of claim 4, wherein the one or more independent controls comprise a force limiting control process.

8. The modular motor control system of claim 4, wherein the one or more independent controls comprise an independent verification process configured to provide verification of the first and second control signals received by the first and second motor controllers.

9. The modular motor control system of claim 1, wherein the master controller is configured to execute a main control process comprising a load balancing process to selectively associate the first and second motor controllers with the master or slave controller.

10. The modular motor control system of claim 1, comprising:

a plurality of motors configured to control one or more operations of the surgical instrument;

a plurality of motor controllers operatively coupled to the plurality of motors, the plurality of motor controllers configured to control the plurality of motors; and

wherein a plurality of control signals is transmitted to the plurality of motor controllers, wherein the plurality of motor controllers control the plurality of motors in response to the plurality of control signals.

11. The modular motor control system of claim 1, wherein the first motor control comprises a processor configured to receive the first control signal, and wherein the processor controls the first motor in response to the first control signal.

12. A modular motor control system comprising:

a master controller;

a plurality of motors configured to control one or more operations of a surgical instrument, wherein the plurality of motors comprises;

a distal roll motor;

an articulation motor;

a proximal roll motor; and

a transection motor;

a plurality of motor controllers operatively coupled to the plurality of motors wherein the plurality of motor controllers and the master controller are in electrical communication, wherein a plurality of control signals is transmitted to the plurality of motor controllers, wherein the plurality of motor controllers control the plurality of motors in response to the plurality of control signals, wherein the plurality of motor controllers comprises;

a distal roll motor controller;

an articulation motor controller;

a proximal roll motor controller; and

a transection motor controller; and

a slave controller electrically coupled to the master controller, wherein the slave controller generates at least one of the plurality of control signals in response to a master control signal received from the master controller.

13. A surgical instrument comprising:

a handle;

a master controller;

a shaft extending distally from the handle;

an end effector coupled to a distal end of the shaft;

a first motor mounted in the handle, the first motor configured to control a first movement of the surgical instrument;

a first motor controller electrically coupled to the first motor, the first motor controller configured to control the first motor, wherein the first motor controller controls the first motor in response to a first control signal provided to the first motor controller by the master controller;

a second motor mounted in the handle, the second motor configured to control a second movement of the surgical instrument;

a second motor controller electrically coupled to the second motor, the second motor controller configured to control the second motor; and

a slave controller mounted in the handle, the slave controller in electrical communication with the master controller, the slave controller configured to provide a second control signal to the second motor controller, wherein the second motor controller controls the second motor in response to the second control signal, wherein the slave controller generates the second control signal in response to a master control signal received from the master controller.

14. The surgical instrument of claim 13, wherein the master controller is configured to execute a main control process.

15. The surgical instrument of claim 14, wherein the main control process comprises the master controller communicating with the first and second motor controllers and the slave controller synchronously.

16. The surgical instrument of claim 14, wherein the main control process comprises the master controller communicating with the first and second motor controllers and the slave controller asynchronously.

17. The surgical instrument of claim 13, wherein the first and second motor controllers comprise a closed-loop control process having one or more independent controls for the first and second motors.

18. The surgical instrument of claim 13, comprising:

a plurality of motors configured to control one or more operations of the surgical instrument;

a plurality of motor controllers operatively coupled to the plurality of motors, the plurality of motor controllers configured to control the plurality of motors; and

wherein a plurality of control signals is transmitted to the plurality of motor controllers by the master controller, wherein the plurality of motor controllers control the plurality of motors in response to the plurality of control signals.

19. The surgical instrument of claim 13, wherein the first motor control comprises a processor configured to receive the first control signal, and wherein the processor controls the first motor in response to the first control signal.

20. A surgical instrument comprising:

a handle;

a master controller;

a shaft extending distally from the handle;

an end effector coupled to a distal end of the shaft;

a plurality of motors configured to control one or more operations of the surgical instrument, wherein the plurality of motors comprises;

a distal roll motor;

an articulation motor;

a proximal roll motor; and

a transection motor;

a plurality of motor controllers operatively coupled to the plurality of motors, the plurality of motor controllers configured to control the plurality of motors, wherein the plurality of motor controllers comprises;

a distal roll motor controller;

an articulation motor controller;

a proximal roll motor controller; and

a transection motor controller;

wherein a plurality of control signals is transmitted to the plurality of motor controllers by the master controller, wherein the plurality of motor controllers control the plurality of motors in response to the plurality of control signals; and

a slave controller electrically coupled to the master controller, wherein the slave controller generates at least one of the plurality of control signals in response to a master control signal received from the master controller.

21. A surgical instrument, comprising:

an end effector configured to interact with tissue;

a modular motor control system comprising;

a master controller;

an articulation motor configured to control at least one articulation movement of the end effector;

an articulation motor controller operatively coupled to the articulation motor, wherein the articulation motor controller and the master controller are in electrical communication, wherein the master controller provides an articulation control signal to the articulation motor controller, wherein the articulation motor controller controls the articulation motor in response to the articulation control signal;

a transection motor configured to control a transection movement of the end effector;

a transection motor controller operatively coupled to the transection motor, wherein the transection motor controller and the master controller are in electrical communication, wherein a transection control signal is transmitted to the transection motor controller, wherein the transection motor controller controls the transection motor in response to the transection control signal; and

a slave controller electrically coupled to the master controller, wherein the slave controller generates the transection control signal in response to a master control signal received from the master controller.