Method of operating a powered surgical instrument

A method of operating a surgical instrument is disclosed. The surgical instrument includes an electronic system comprising an electric motor coupled to the end effector; a motor controller coupled to the motor; a parameter threshold detection module configured to monitor multiple parameter thresholds; a sensing module configured to sense tissue compression; a processor coupled to the parameter threshold detection module and the motor controller; and a memory coupled to the processor. The memory stores executable instructions that when executed by the processor cause the processor to monitor multiple levels of action thresholds and monitor speed of the motor and increment a drive unit of the motor, sense tissue compression, and provide rate and control feedback to the user of the surgical instrument.

Time dependent evaluation of sensor data to determine stability, creep, and viscoelastic elements of measures

A powered surgical cutting and stapling instrument is disclosed. The instrument includes at least one sensor to measure at least one parameter associated with the instrument, at least one processor, and a memory operatively associated with the processor. The memory includes machine executable instructions that when executed by the processor cause the processor to monitor the at least one sensor over a predetermined time period and determine a rate of change of the measured parameter.

Overlaid multi sensor radio frequency (RF) electrode system to measure tissue compression

A tissue compression sensor system is disclosed. The tissue compression system includes an RF electrode positioned on an end-effector; a first electrical contact positioned on one of an anvil or a channel frame of the end-effector; and a first filter communicatively coupled to the first electrical contact.

Surgical instrument comprising a lockable battery housing

A surgical instrument can comprise a handle including a battery cavity and electrical contacts and, in addition, a battery removably positionable in the battery cavity. The battery is configured to engage and supply power to the electrical contacts when the battery is operably seated in the battery cavity. The handle further comprises diagnostic means for assessing whether the handle is in a suitable operating and a battery lockout configured to permit the battery from being operably seated in the battery cavity if the diagnostic means determines that the handle is not in a suitable operating condition. Additionally or alternatively, the handle can comprise a battery lock configured to prevent the battery from being disengaged from the electrical contacts when the handle is transmitting an operating motion to a shaft assembly attached to the handle, for example. Either one system or two systems can comprise the battery lockout and battery lock.

System for detecting the mis-insertion of a staple cartridge into a surgical stapler

A surgical instrument system can include an end effector and a staple cartridge which is removably insertable into the end effector. The staple cartridge includes a sled movable from an unfired position to a fired position to eject staples removably stored in the staple cartridge. In various instances, the sled can be inadvertently advanced from its unfired position when the staple cartridge is positioned in the end effector, for example. The surgical instrument system further comprises one or more sensors configured to detect whether the sled is in its unfired position and/or whether the staple cartridge has been mis-inserted into the end effector. The one or more sensors can also determine whether the staple cartridge has been fully seated in the cartridge channel.

Signal and power communication system positioned on a rotatable shaft

A surgical instrument assembly can comprise a handle including an electric motor, a shaft assembly including a drive member, and a magnet configured to generate a magnetic field. The surgical instrument assembly further comprises, one, a rotatable output shaft operably coupled with the electric motor and the drive member and, two, a wire coil wound around the output shaft which is positioned in the magnetic field. The wire coil is rotated within the magnetic field when the output shaft is rotated about a longitudinal axis which induces a current in the wire coil. The surgical instrument assembly further comprises a strain gauge mounted to the output shaft configured to detect strain created within the output shaft and, in addition, a circuit mounted to the output shaft, wherein the circuit and/or the strain gauge is powered by the current induced in the wire coil.

Smart sensors with local signal processing

A device including smart sensors with a local signal processor is disclosed. The device includes an end-effector including at least one sensor and a signal processing component corresponding to the at least one sensor; and a handle configured to receive processed information from the signal processing component. The processed information is generated by the signal processing component at the end-effector based on data received from the at least one sensor at the end-effector.

Multiple level thresholds to modify operation of powered surgical instruments

Thresholds can be assigned for one or more parameters in connection with the operation of a surgical device. An ultimate threshold can trigger a desired action, including cessation of operations or modification of operations, if the ultimate threshold is reached, or predicted to be reached. In addition, a marginal threshold can trigger a desired action, including improving operations such as slowing operations where the value of a parameter is measured to be between the values defined by a marginal threshold and an ultimate threshold. Multiple thresholds, based on multiple parameters, can be defined, further enabling calibrated usage, such as slowing operations based on exceeding both a marginal threshold based on number of sterilization cycles and exceeding a marginal threshold based on extent to which current draw exceeds a certain value.

Adaptive tissue compression techniques to adjust closure rates for multiple tissue types

A mechanism is disclosed for adapting operations of a surgical instrument based on data from actual, expected or predicted properties of tissue, data from measuring operation of the surgical instrument itself, and data based on clinician conduct. The adaptive measures can be based on predetermined control measures such as algorithms stored in operative communication with the surgical instrument, based on dynamically generated control measures, or a combination of both. Utilizing such mechanisms can help to adjust closure and firing algorithms based on tissue properties, improve battery usage, and learn from user operations, enhancing functioning of the instrument within an operational envelope.

Monitoring speed control and precision incrementing of motor for powered surgical instruments

Motor speed control systems are disclosed that include a motor having an output shaft, a motor speed control system, a sensor to detect the speed of the motor, and a controller to receive a signal from the sensor and to control the speed of the output shaft. A gear reduction assembly is operably coupled to the output shaft and a detectable element located in the gear reduction assembly. The sensor senses the detectable element. The sensor is placed in the radial path of the detectable element. Another system includes a brushless motor having a housing and an output shaft, the brushless motor comprising electromagnetic field coils arrayed radially around a central magnetic shaft, a gear reduction assembly operably coupled to the output shaft, and a sensor placed in proximity to the brushless motor. The sensor communicates with a controller to control the speed of the output shaft.