Sensor arrangements for absolute positioning system for surgical instruments

• US 9,808,244 B2
• Filed: 03/14/2013
• Issued: 11/07/2017
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Leimbach, Richard L., Overmyer, Mark D., Swensgard, Brett E., Adams, Shane R.
• Primary Examiner(s): Lopez, Michelle
• Application Number:
  US13/803,210
• Publication Number:
  US 20140263538A1
• Time in Patent Office: 1,699 Days
• Field of Search: 2271751, 2271761
• CPC Class Codes: A61B 17/064 Surgical staples, i.e. penetrating the tissue
• 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 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 17/32 Surgical cutting instruments A61B18/042 takes precedence; suture cutters A61B17/0467; instruments for ligaturing or cutting A61B17/128; instruments for rupturing the amniotic membrane A61B17/4208; specially adapted knives for eye surgery A61F9/0133
• 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 2017/00119 alarm; indicating an abnormal situation
• CPC Class Codes: A61B 2017/00123 and automatic shutdown
• 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 2017/00389 Button or wheel for performing multiple functions, e.g. rotation of shaft and end effector
• 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 2017/00716 simulating physical properties
• 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 2017/2913 : cams or guiding means
• CPC Class Codes: A61B 2017/2923 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2927 : the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2931 : with releasable head
• CPC Class Codes: A61B 2017/2943 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2018/00172 : Connectors and adapters therefor
• CPC Class Codes: A61B 2018/00297 : Means for providing haptic feedback
• CPC Class Codes: A61B 2018/00303 : active, e.g. with a motor creating vibrations
• CPC Class Codes: A61B 2018/1455 : having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: A61B 2034/2059 : Mechanical position encoders
• CPC Class Codes: A61B 2090/064 : for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 2090/067 : for measuring angles
• CPC Class Codes: A61B 2090/0808 : for indicating correct assembly of components, e.g. of the surgical apparatus
• 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 2090/0814 : Preventing re-use
• CPC Class Codes: A61B 34/30 : Surgical robots
• CPC Class Codes: A61B 34/76 : Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: G01D 5/145 : influenced by the relative movement between the Hall device and magnetic fields see G01R33/06

Abstract

A surgical instrument is disclosed. The surgical instrument may include an absolute position sensor system. The absolute position sensor system includes a sensor element operatively coupled to a movable drive member of the surgical instrument. A position sensor is operably coupled to the sensor element and is configured to sense the absolute position of the sensor element.

Claims

1. An absolute position sensor system for a surgical instrument, the absolute position sensor system comprising:

a sensor element operatively coupled to a movable drive member of the surgical instrument;

a position sensor operably coupled to the sensor element, the position sensor configured to sense the absolute position of the sensor element by generating a unique position signal for each position of the movable drive member; and

a gear assembly to couple the sensor element to the movable drive member, wherein the gear assembly is located between the sensor element and the movable drive member.

2. The absolute position sensor system of claim 1, comprising a microcontroller operatively coupled to the position sensor, the microcontroller configured to receive a unique position signal from the position sensor, wherein the unique position signal represents an absolute position angle of the sensor element over one revolution of the sensor element.

3. The absolute position sensor system of claim 1, wherein the movable drive member is a longitudinally-movable drive member.

4. The absolute position sensor system of claim 3, wherein a full stroke of the movable drive member corresponds to less than a single rotation of the sensor element.

5. The absolute position sensor system of claim 3, wherein a full stroke of the movable drive member corresponds to a single rotation of the sensor element.

6. The absolute position sensor system of claim 3, wherein a partial stroke of the movable drive member corresponds to a single rotation of the sensor element.

7. The absolute position sensor system of claim 1, wherein the sensor element is a magnet and the position sensor is a magnetic position sensor comprising at least one magnetic sensor element disposed in proximity to the magnet.

8. The absolute position sensor system of claim 7, wherein the magnetic sensor element comprises one or more Hall-effect elements.

9. An absolute position sensor system for a surgical instrument, the absolute position sensor system comprising:

a sensor element operatively coupled to a movable drive member of the surgical instrument;

a position sensor operably coupled to the sensor element, the position sensor configured to sense the absolute position of the sensor element by generating a unique position signal for each position of the movable drive member; and

a gear assembly to couple the sensor element to the movable drive member, wherein the gear assembly is located between the sensor element and the movable drive member.

10. A surgical instrument, comprising:

an absolute position sensor system comprising;

a sensor element operatively coupled to a movable drive member of the surgical instrument,

a position sensor operably coupled to the sensor element, the position sensor configured to sense the absolute position of the sensor element by generating a unique position signal for each position of the movable drive member, and

a gear assembly to couple the sensor element to the movable drive member, wherein the gear assembly is located between the sensor element and the movable drive member; and

a motor operatively coupled to the movable drive member.

11. The surgical instrument of claim 10, comprising a microcontroller operatively coupled to the position sensor, the microcontroller configured to receive a unique position signal from the position sensor, wherein the unique position signal represents an absolute position angle of the sensor element over one revolution of the sensor element.

12. The surgical instrument of claim 10, wherein the movable drive member is a longitudinally-movable drive member.

13. The surgical instrument of claim 12, wherein a full stroke of the movable drive member corresponds to a single rotation of the sensor element.

14. The surgical instrument of claim 12, wherein a partial stroke of the movable drive member corresponds to a single rotation of the sensor element.

15. The surgical instrument of claim 10, wherein the sensor element is a magnet and the position sensor is a magnetic position sensor comprising at least one magnetic sensor element disposed in proximity to the magnet.

16. The surgical instrument of claim 15, wherein the magnetic sensor element is a Hall-effect element.

17. An absolute position sensor system for a surgical instrument, the absolute position sensor system comprising:

a sensor element operatively coupled to a movable drive member of the surgical instrument;

a gear assembly to couple the sensor element to the movable drive member, wherein the gear assembly is located between the sensor element and the movable drive member;

a holder to hold the sensor element, wherein the holder and the sensor element are rotationally coupled; and

a position sensor operably coupled to the sensor element, the position sensor configured to sense the absolute position of the sensor element by generating a unique position signal for each position of the movable drive member, wherein the position sensor is fixed relative to the rotation of the holder and the sensor element.

18. The absolute position sensor system of claim 17, comprising a microcontroller operatively coupled to the position sensor, the microcontroller configured to receive a unique position signal from the position sensor, wherein the unique position signal represents an absolute position angle of the sensor element over one revolution of the sensor element.

19. The absolute position sensor system of claim 17, wherein the gear assembly comprises a gear reduction ratio such that a full stroke of the movable drive member corresponds to a single revolution of the sensor element.

20. The absolute position sensor system of claim 17, comprising at least one switch coupled to the movable drive member, wherein a full stroke of the movable drive member corresponds to more than one revolution of the sensor element and an output signal of the switch.

21. An absolute position sensor system for a surgical instrument, the absolute position sensor system comprising:

a sensor element operatively coupled to a movable drive member of the surgical instrument; and

a position sensor operably coupled to the sensor element, the position sensor configured to sense the absolute position of the sensor element; and

a gear assembly to couple the sensor element to the movable drive member, wherein the gear assembly is located between the sensor element and the movable drive member.