Modular battery powered handheld surgical instrument with motor control limit profile

• US 10,299,821 B2
• Filed: 12/16/2016
• Issued: 05/28/2019
• Est. Priority Date: 01/15/2016
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Shelton, IV, Frederick E., Yates, David C., Houser, Kevin L., Harris, Jason L., Strobl, Geoffrey S.
• Primary Examiner(s): Islam, Muhammad S
• Application Number:
  US15/382,257
• Publication Number:
  US 20170202593A1
• Time in Patent Office: 893 Days
• CPC Class Codes: A61B 17/320068 using mechanical vibrations, e.g. ultrasonic A61B17/22012 takes precedence; dental tooth drilling devices operated by vibration A61C3/03; removing intra-ocular material using mechanical vibrations A61F9/00745
• CPC Class Codes: A61B 17/320092 with additional movable means for clamping or cutting tissue, e.g. with a pivoting jaw
• CPC Class Codes: A61B 18/1206 Generators therefor
• 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 18/1447 wherein sliding surfaces cause opening/closing of the end effectors
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• 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 2017/00084 Temperature
• CPC Class Codes: A61B 2017/00119 alarm; indicating an abnormal situation
• CPC Class Codes: A61B 2017/00123 and automatic shutdown
• CPC Class Codes: A61B 2017/0023 disposable
• CPC Class Codes: A61B 2017/003 Steerable
• CPC Class Codes: A61B 2017/00323 Cables or rods
• 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 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/00876 magnetic
• CPC Class Codes: A61B 2017/320072 : Working tips with special features, e.g. extending parts
• CPC Class Codes: A61B 2017/320073 : probe
• CPC Class Codes: A61B 2017/320074 : blade
• CPC Class Codes: A61B 2017/320078 : Tissue manipulating surface
• 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 2018/00297 : Means for providing haptic feedback
• CPC Class Codes: A61B 2018/00601 : Cutting
• CPC Class Codes: A61B 2018/00607 : Coagulation and cutting with the same instrument
• CPC Class Codes: A61B 2018/0063 : Sealing
• CPC Class Codes: A61B 2018/00684 : using lookup tables
• CPC Class Codes: A61B 2018/00767 : Voltage
• CPC Class Codes: A61B 2018/00791 : Temperature
• CPC Class Codes: A61B 2018/00827 : Current
• CPC Class Codes: A61B 2018/00875 : Resistance or impedance
• CPC Class Codes: A61B 2018/00898 : Alarms or notifications created in response to an abnormal condition
• CPC Class Codes: A61B 2018/00904 : Automatic detection of target tissue
• CPC Class Codes: A61B 2018/00946 : slidable
• CPC Class Codes: A61B 2018/00988 : Means for storing information, e.g. calibration constants, or for preventing excessive use, e.g. usage, service life counter
• CPC Class Codes: A61B 2018/00994 : combining two or more different kinds of non-mechanical energy or combining one or more non-mechanical energies with ultrasound
• CPC Class Codes: A61B 2018/1226 : powered by a battery
• CPC Class Codes: A61B 2018/1455 : having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: A61B 2034/252 : indicating steps of a surgical procedure
• CPC Class Codes: A61B 2090/061 : for measuring dimensions, e.g. length
• CPC Class Codes: A61B 2560/0209 : adapted for power saving
• CPC Class Codes: A61B 2560/0475 : Special features of memory means, e.g. removable memory cards
• CPC Class Codes: A61B 2562/0219 : Inertial sensors, e.g. accelerometers, gyroscopes, tilt switches
• CPC Class Codes: H01M 10/425 : Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/46 : Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 : Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 2220/30 : Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/213 : adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/247 : specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 6/02 : Details of electrodes H01M4/00; of non-active parts H01M50/00
• CPC Class Codes: H01M 6/5044 : Cells or batteries structurally combined with cell condition indicating means
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

A surgical instrument comprises a shaft assembly comprising a shaft and an end effector coupled to a distal end of the shaft; a handle assembly coupled to a proximal end of the shaft; a battery assembly coupled to the handle assembly; a driver configured to drive movement of at least one component of the surgical instrument; a motor powered by the battery assembly and configured to actuate the driver using an output of the motor; and a controller for the motor, configured to perform a first limiting operation to the output of the motor when a first limiting condition is met, wherein the first limiting condition defines a maximum control variable profile of the motor over a range of the movement of the at least one component.

Claims

1. A modular surgical instrument comprising:

a modular handle assembly configured to receive a battery assembly, a shaft assembly, and a transducer assembly, wherein the transducer assembly comprises a first modular movable component, and wherein the shaft assembly comprises a second modular movable component;

a motor configured to actuate the first and second modular movable component, wherein the first modular movable component is associated with a first motor current profile and a first motor current limiting condition and the second modular movable component is associated with a second motor current profile and a second motor current limiting condition; and

a control circuit located in the modular handle assembly, wherein the control circuit is electrically coupled to the motor, wherein;

the control circuit comprises a motor current sensor configured to transmit a signal to the control circuit indicative of a current drawn by the motor;

the control circuit is configured to monitor the current drawn by the motor according to the first and second motor current profile;

the control circuit is configured to perform a first limiting operation to the current drawn by the motor to limit actuation of the first modular movable component based on reaching the first motor current limiting condition; and

the control circuit is configured to perform a second limiting operation to the current drawn by the motor to limit actuation of the second modular movable component based on reaching the second motor current limiting condition.

2. The modular surgical instrument of claim 1, wherein the first limiting operation comprises reducing the current drawn by the motor to zero.

3. The modular surgical instrument of claim 1, wherein the second limiting operation comprises reducing the current drawn by the motor to a level that does not exceed the second motor current limiting condition.

4. The modular surgical instrument of claim 1, wherein each of the first and second motor current profile is a non-linear control profile.

5. The modular surgical instrument of claim 1, further comprising:

an end effector comprising a first and a second jaw, wherein the first jaw is configured for pivotal movement between a closed position and an open position; and

wherein the motor is configured to drive the pivotal movement.

6. The modular surgical instrument of claim 1, wherein:

actuation of the first modular movable component comprises applying torque to the first modular movable component to couple the transducer assembly to the modular handle assembly; and

actuation of the second modular movable component comprises articulation of the shaft assembly relative to an articulation joint of the modular surgical instrument.

7. The modular surgical instrument of claim 1, wherein:

actuation of the first modular movable component comprises applying torque to the first modular movable component to couple the transducer assembly to the modular handle assembly; and

actuation of the second modular movable component comprises axial rotation of the shaft assembly.

8. The modular surgical instrument of claim 5, wherein actuation of the second modular movable component comprises pivotal movement of the first jaw.

9. A modular surgical instrument comprising:

a modular handle assembly configured to receive a battery assembly, a shaft assembly, and a transducer assembly, wherein the transducer assembly comprises a first modular movable component, and wherein the shaft assembly comprises a second modular movable component;

a motor configured to actuate the first and second modular movable component, wherein the first modular movable component is associated with a first control variable profile and a first control variable limiting condition and the second modular movable component is associated with a second control variable profile and a second control variable limiting condition;

a control circuit located in the modular handle assembly, wherein the control circuit is electrically coupled to the motor, wherein the control circuit comprises a motor current sensor configured to transmit a signal to the control circuit indicative of a current drawn by the motor, wherein the control circuit is configured to monitor the current drawn by the motor according to the first and second control variable profile; and

wherein;

the control circuit is configured to perform a first limiting operation to the current drawn by the motor to limit actuation of the first modular movable component based on reaching the first control variable limiting condition, and

the control circuit is configured to perform a second limiting operation to the current drawn by the motor to limit actuation of the second modular movable component based on reaching the second control variable limiting condition.

10. The modular surgical instrument of claim 9, wherein the first control variable profile is a velocity profile and the second control variable profile is a current profile, voltage profile, power profile, torque profile, position profile, inertia profile or acceleration profile.

11. The modular surgical instrument of claim 9, wherein the first control variable profile is a velocity profile that decreases over time when a rate of increase of the current drawn by the motor is above a first threshold, and

the second control variable profile is a velocity profile that increases over time when the rate of increase of the current drawn by the motor is above a second threshold.

12. The modular surgical instrument of claim 9, wherein the first control variable profile is a velocity profile and the velocity profile defines:

a first limited velocity zone near a first end of a range of movement of the first modular movable component,

a second limited velocity zone near a second end of the range of movement of the first modular movable component, and

a full velocity zone between the first and second limited velocity zones.

13. A method of operating a modular surgical instrument, the modular surgical instrument comprising:

a modular handle assembly configured to receive a battery assembly, a shaft assembly, and a transducer assembly;

a motor; and

a control circuit located in the modular handle assembly, the method comprising;

actuating, by the motor, a first modular movable component and a second modular movable component, wherein the first modular movable component is associated with a first motor current profile and a first motor current limiting condition and the second modular movable component is associated with a second motor current profile and a second motor current limiting condition;

transmitting, by a motor current sensor of the control circuit, a signal to the control circuit indicative of a current drawn by the motor;

monitoring, by the control circuit, the current drawn by the motor according to the first and second motor current profile;

performing, by the control circuit, a first limiting operation to the current drawn by the motor to limit actuation of the first modular movable component based on reaching the first motor current limiting condition; and

performing, by the control circuit, a second limiting operation to the current drawn by the motor to limit actuation of the second modular movable component based on reaching the second motor current limiting condition.

14. The method of claim 13, wherein the first modular movable component comprises an ultrasonic transducer.

15. The method of claim 13, wherein the shaft assembly comprises the second modular movable component.