WO2024069565A1 - Algorithmes chirurgicaux à actions sensorielles incrémentielles - Google Patents

Algorithmes chirurgicaux à actions sensorielles incrémentielles Download PDF

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Publication number
WO2024069565A1
WO2024069565A1 PCT/IB2023/059766 IB2023059766W WO2024069565A1 WO 2024069565 A1 WO2024069565 A1 WO 2024069565A1 IB 2023059766 W IB2023059766 W IB 2023059766W WO 2024069565 A1 WO2024069565 A1 WO 2024069565A1
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WO
WIPO (PCT)
Prior art keywords
motor
speed
control circuit
instance
sensory
Prior art date
Application number
PCT/IB2023/059766
Other languages
English (en)
Inventor
Iv Frederick E. Shelton
Jason L. Harris
Kevin M. Fiebig
Matthew D. COWPERTHWAIT
Nicholas J. ROSS
Shane R. Adams
Original Assignee
Cilag Gmbh International
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US17/958,024 external-priority patent/US20240108340A1/en
Application filed by Cilag Gmbh International filed Critical Cilag Gmbh International
Publication of WO2024069565A1 publication Critical patent/WO2024069565A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/068—Surgical staplers, e.g. containing multiple staples or clamps
    • A61B17/072—Surgical staplers, e.g. containing multiple staples or clamps for applying a row of staples in a single action, e.g. the staples being applied simultaneously
    • A61B17/07207—Surgical staplers, e.g. containing multiple staples or clamps for applying a row of staples in a single action, e.g. the staples being applied simultaneously the staples being applied sequentially
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00017—Electrical control of surgical instruments
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00017—Electrical control of surgical instruments
    • A61B2017/00115—Electrical control of surgical instruments with audible or visual output
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00367—Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like
    • A61B2017/00398—Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like using powered actuators, e.g. stepper motors, solenoids
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00—Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/06—Measuring instruments not otherwise provided for
    • A61B2090/064—Measuring instruments not otherwise provided for for measuring force, pressure or mechanical tension

Definitions

  • the present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments and staple cartridges for use therewith that are designed to staple and cut tissue.
  • FIG. 1 is a perspective view of a powered surgical stapling system
  • FIG. 2 is a perspective view of an interchangeable surgical shaft assembly of the powered surgical stapling system of FIG. 1 ;
  • FIG. 3 is an exploded assembly view of portions of a handle assembly of the powered surgical stapling system of FIG. 1 ;
  • FIG. 4 is an exploded assembly view of the interchangeable surgical shaft assembly of FIG. 2;
  • FIG. 5 is another partial exploded assembly view of a portion of the interchangeable surgical shaft assembly of FIG. 4;
  • FIG. 6 is a perspective view of a shaft assembly in accordance with at least one embodiment
  • FIG. 7 is an exploded view of a distal end of the shaft assembly of FIG. 6;
  • FIG. 8 is a perspective view of a surgical instrument assembly comprising a proximal control interface, a shaft assembly, and an end effector assembly;
  • FIG. 9 is a bottom perspective view of the surgical instrument assembly of FIG. 8;
  • FIG. 10 is a perspective view of an example of one form of robotic controller according to one aspect of this disclosure.
  • FIG. 11 is a perspective view of an example of one form of robotic surgical arm cart/manipulator of a robotic surgical system operably supporting a plurality of surgical tools according to one aspect of this disclosure
  • FIG. 12 is a side view of the robotic surgical arm cart/manipulator depicted in FIG. 11 according to one aspect of this disclosure
  • FIG. 13 illustrates a block diagram of a surgical system for use with one or more surgical instruments, tools, and/or robotic systems in accordance with one or more aspects of the present disclosure
  • FIG. 14 illustrates a block diagram of a surgical system for use with one or more surgical instruments, tools, and/or robotic systems in accordance with one or more aspects of the present disclosure
  • FIG. 15 is a graph depicting a firing stroke performed by a motor system that includes a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs a sensory, or interrogation, action during a firing stroke in order to determine if the speed of the motor is capable of being increased to a target speed;
  • FIG. 16 is a graph depicting several firing strokes performed by a motor system that includes a motor, a drive train, and a motor control circuit, wherein different sensory actions are performed with different outcomes;
  • FIG. 17 is a graph depicting a firing stroke performed by a motor system that includes a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs multiple discrete sensory actions and, in response to the sensory actions, performs a reaction a period of time after the completion of the sensory actions;
  • FIG. 18 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs a sensory action and, in response to the sensory action, performs a reaction a period of time after the completion of the sensory action;
  • FIG. 19 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein multiple sensory actions are performed, each including a different target speed magnitude and different time periods;
  • FIG. 20 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs a sensory action and, in response to the sensory action, after a predefined time period, performs a reaction;
  • FIG. 21 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs multiple sensory actions by increasing a target motor duty cycle and, after the completion of the sensory actions, performs a functional action or reaction;
  • FIG. 22 is a logic flow chart depicting a process executable by a control circuit, wherein the process includes actions for controlling the motor of a surgical instrument system, wherein the control circuit is configured to perform a plurality of sensory action sequences during a precompression stage to determine a firing speed of the motor for a staple firing stroke;
  • FIG. 23 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein multiple sensory actions are performed by incrementally increasing the target motor duty cycle and, after the sensory actions are complete, performs a reaction;
  • FIG. 24 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs multiple sensory actions by linearly increasing a target speed magnitude for each subsequent sensory action, wherein the motor control circuit is configured to revert the target speed of the motor back to a target speed achieved during a prior successful sensory action;
  • FIG. 25 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs multiple sensory actions by increasing a target speed magnitude for each subsequent sensory action with consecutively smaller target speed magnitudes, wherein the motor control circuit is configured to revert the target speed of the motor back to a target speed achieved during a prior successful sensory action;
  • FIG. 26 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs multiple sensory actions by logarithmically increasing a target speed magnitude for each subsequent sensory action, wherein the motor control circuit is configured to revert the target speed of the motor back to a target speed achieved during a prior successful sensory action;
  • FIG. 27 is a graph depicting several firing strokes performed by a motor system including a motor, a drive train, and a motor control circuit, wherein different sensory action sequences are performed by modulating a motor duty cycle of the motor;
  • FIG. 28 is a graph depicting a primary sensory metric and a second sensory metric of a motor control circuit configured to control the speed of a motor;
  • FIG. 29 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit employs a speed control algorithm during the firing stroke, and wherein the speed control algorithm utilizes a lockout period upon satisfying a lockout condition;
  • FIG. 30 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs sensory actions and functional actions;
  • FIG. 31 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit performs a sensory action and, in response to the monitored actual speed of the motor during the sensory action gradually declining, performs multiple functional actions to reduce the speed of the motor;
  • FIG. 32 is a logic flow chart depicting a process executable by a control circuit, wherein the process includes actions which interrogate a motor system to determine whether or not excess capacity exists within the motor system during a drive stroke of a drive train;
  • FIG. 33 is a graph depicting a firing stroke performed by a motor control circuit of a motor system, wherein the motor control circuit employs a lockout time period after a failed sensory action to prevent a subsequent action from occurring during the lockout time period;
  • FIG. 34 is a logic flow chart depicting a process executable by a control circuit for use in a surgical instrument system, wherein the control circuit is configured to adjust a parameter of a subsequent sensory action, wherein the adjustment is based on a monitored result of a first sensory action;
  • FIG. 35 is a logic flow chart depicting a process executable by control circuit for use in a surgical instrument system, wherein the control circuit is configured to adjust a parameter of one or more sensory actions performed during a second staple firing stroke, and wherein the adjustment is based on a monitored result of a first sensory action performed during a first staple firing stroke;
  • FIG. 36 is a logic flow chart depicting a process executable by control circuit for use in a surgical instrument system, wherein the control circuit is configured to adjust a parameter of one or more subsequent sensory actions, wherein the adjustment is based on a monitored success status of one or more first sensory actions;
  • FIG. 37 is a graph depicting a firing stroke performed by a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit is configured to set maximum torque output limits during different periods of the firing stroke;
  • FIG. 38 is a schematic representation of different motor duty cycles for a motor of a surgical instrument;
  • FIG. 39 depicts a control process of a motor control circuit of a surgical instrument configured to utilize both monitored motor duty cycle and monitored motor speed and/or firing member speed as inputs for adjusting the speed of the motor during a drive stroke;
  • FIG. 40 is a graph depicting various types of signal variables affected by PID controller parameters adjustments
  • FIG. 41 is a logic flow chart depicting a process executable by a control circuit configured to adjust motor control parameters based on monitored parameters of a motor system;
  • FIG. 42 Is a graph depicting a firing stroke of a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit segments the firing stroke into multiple portions and adjusts one or more motor control parameters of the motor according to each segment;
  • FIG. 43 is a graph depicting a firing stroke of a motor system including a motor, a drive train, and a motor control circuit, wherein the motor control circuit segments the firing stroke into multiple portions and adjusts one or more motor control parameters of the motor according to expected loads and/or monitored location of firing member within the firing stroke;
  • FIG. 44 is a logic flow chart depicting a process executable by a control circuit configured to control a motor of a motor system
  • FIG. 45 is a logic flow chart depicting a process executable by a control circuit configured to control a motor system of a surgical instrument system;
  • FIG. 46 is a control diagram of a delta-sigma modulator
  • FIG. 47 is a graph of an analog signal and a resulting pulse amplitude modulation signal
  • FIG. 48 is a comparison of motor current at two different pulse width modulation frequencies, wherein each signal includes the same duty cycle;
  • FIG. 49 is a graph illustrating motor current at different duty cycles and pulse width modulation frequencies.
  • FIG. 50 is a logic flow chart depicting a process executable by a control circuit configured to control a motor system of a surgical instrument system, wherein the control circuit is configured to initiate an oscillating drive signal to a motor of the motor system upon detecting that current through the motor exceeds a predetermined threshold.
  • proximal and distal are used herein with reference to a clinician manipulating the handle portion of the surgical instrument.
  • proximal refers to the portion closest to the clinician and the term “distal” refers to the portion located away from the clinician.
  • distal refers to the portion located away from the clinician.
  • spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings.
  • surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.
  • Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures.
  • the various methods and devices disclosed herein can be used in numerous surgical procedures and applications including, for example, in connection with open surgical procedures.
  • the reader will further appreciate that the various instruments disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc.
  • the working portions or end effector portions of the instruments can be inserted directly into a patient’s body or can be inserted through an access device that has a working channel through which the end effector and elongate shaft of a surgical instrument can be advanced.
  • a surgical stapling system can comprise a shaft and an end effector extending from the shaft.
  • the end effector comprises a first jaw and a second jaw.
  • the first jaw comprises a staple cartridge.
  • the staple cartridge is insertable into and removable from the first jaw; however, other embodiments are envisioned in which a staple cartridge is not removable from, or at least readily replaceable from, the first jaw.
  • the second jaw comprises an anvil configured to deform staples ejected from the staple cartridge.
  • the second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which the first jaw is pivotable relative to the second jaw.
  • the surgical stapling system further comprises an articulation joint configured to permit the end effector to be rotated, or articulated, relative to the shaft.
  • the end effector is rotatable about an articulation axis extending through the articulation joint.
  • Other embodiments are envisioned which do not include an articulation joint.
  • the staple cartridge comprises a cartridge body.
  • the cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end.
  • the staple cartridge is positioned on a first side of the tissue to be stapled and the anvil is positioned on a second side of the tissue.
  • the anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck.
  • staples removably stored in the cartridge body can be deployed into the tissue.
  • the cartridge body includes staple cavities defined therein wherein staples are removably stored in the staple cavities.
  • the staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples may be possible.
  • the staples are supported by staple drivers in the cartridge body.
  • the drivers are movable between a first, or unfired position, and a second, or fired, position to eject the staples from the staple cavities.
  • the drivers are retained in the cartridge body by a retainer which extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body.
  • the drivers are movable between their unfired positions and their fired positions by a sled.
  • the sled is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end.
  • the sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil.
  • the sled is moved distally by a firing member.
  • the firing member is configured to contact the sled and push the sled toward the distal end.
  • the longitudinal slot defined in the cartridge body is configured to receive the firing member.
  • the anvil also includes a slot configured to receive the firing member.
  • the firing member further comprises a first cam which engages the first jaw and a second cam which engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck of the staple cartridge and the anvil.
  • the firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramped surfaces such that the staples are ejected ahead of the knife.
  • FIG. 1 illustrates the surgical instrument 1010 that includes an interchangeable shaft assembly 1200 operably coupled to a housing 1012.
  • FIG. 2 illustrates the interchangeable shaft assembly 1200 detached from the housing 1012 or handle 1014.
  • the handle 1014 may comprise a pair of interconnectable handle housing segments 1016 and 1018 that may be interconnected by screws, snap features, adhesive, etc.
  • the handle housing segments 1016, 1018 cooperate to form a pistol grip portion 1019.
  • FIGS. 1 and 3 depict a motor-driven surgical cutting and fastening instrument 1010 that may or may not be reused.
  • the instrument 1010 includes a proximal housing 1012 that comprises a handle 1014 that is configured to be grasped, manipulated and actuated by the clinician.
  • the housing 1012 is configured for operable attachment to an interchangeable shaft assembly 1200 that has a surgical end effector 1300 operably coupled thereto that is configured to perform one or more surgical tasks or procedures.
  • an interchangeable shaft assembly 1200 that has a surgical end effector 1300 operably coupled thereto that is configured to perform one or more surgical tasks or procedures.
  • housing may also encompass a housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system that is configured to generate and apply at least one control motion which could be used to actuate the interchangeable shaft assemblies disclosed herein and their respective equivalents.
  • various components may be “housed” or contained in the housing or various components may be “associated with” a housing. In such instances, the components may not be contained within the housing or supported directly by the housing.
  • the term “frame” may refer to a portion of a handheld surgical instrument.
  • the term “frame” may also represent a portion of a robotically controlled surgical instrument and/or a portion of the robotic system that may be used to operably control a surgical instrument.
  • interchangeable shaft assemblies disclosed herein may be employed with various robotic systems, instruments, components and methods disclosed in U.S. Patent No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, that is incorporated by reference herein in its entirety.
  • the proximal housing 1012 depicted in FIG. 1 is shown in connection with an interchangeable shaft assembly 1200 (FIGS. 2, 4 and 5) that includes an end effector 1300 that comprises a surgical cutting and fastening device that is configured to operably support a surgical staple cartridge 1301 therein.
  • the housing 1012 may be configured for use in connection with interchangeable shaft assemblies that include end effectors that are adapted to support different sizes and types of staple cartridges, have different shaft lengths, sizes, and types, etc.
  • the housing 1012 may also be effectively employed with a variety of other interchangeable shaft assemblies including those assemblies that are configured to apply other motions and forms of energy such as, for example, radio frequency (RF) energy, ultrasonic energy and/or motion to end effector arrangements adapted for use in connection with various surgical applications and procedures.
  • RF radio frequency
  • the end effectors, shaft assemblies, handles, surgical instruments, and/or surgical instrument systems can utilize any suitable fastener that can be gripped and manipulated by the clinician.
  • the handle 1014 operably supports a plurality of drive systems therein that are configured to generate and apply various control motions to corresponding portions of the interchangeable shaft assembly that is operably attached thereto.
  • the handle 1014 may further include a frame 1020 that operably supports a plurality of drive systems.
  • the frame 1020 can operably support a “first” or closure drive system, generally designated as 1030, which may be employed to apply closing and opening motions to the interchangeable shaft assembly 1200 that is operably attached or coupled thereto.
  • the closure drive system 1030 may include an actuator in the form of a closure trigger 1032 that is pivotally supported by the frame 1020. More specifically, as illustrated in FIG. 3, the closure trigger 1032 is pivotally coupled to the handle 1014 by a pin 1033.
  • the closure drive system 1030 further includes a closure linkage assembly 1034 that is pivotally coupled to the closure trigger 1032.
  • the closure linkage assembly 1034 may include a first closure link 1036 and a second closure link 1038 that are pivotally coupled to the closure trigger 1032 by a pin 1035.
  • the second closure link 1038 may also be referred to herein as an “attachment member” and include a transverse attachment pin 1037.
  • the first closure link 1036 may have a locking wall or end 1039 thereon that is configured to cooperate with a closure release assembly 1060 that is pivotally coupled to the frame 1020.
  • the closure release assembly 1060 may comprise a release button assembly 1062 that has a distally protruding locking pawl 1064 formed thereon.
  • the release button assembly 1062 may be pivoted in a counterclockwise direction by a release spring (not shown).
  • the closure release assembly 1060 serves to lock the closure trigger 1032 in the fully actuated position.
  • the clinician simply pivots the closure release button assembly 1062 such that the locking pawl 1064 is moved out of engagement with the locking wall 1039 on the first closure link 1036.
  • the closure trigger 1032 may pivot back to the unactuated position.
  • Other closure trigger locking and release arrangements may also be employed.
  • An arm 1061 may extend from the closure release button assembly 1062.
  • a magnetic element 1063 such as a permanent magnet, for example, may be mounted to the arm 1061.
  • the circuit board 1100 can include at least one sensor that is configured to detect the movement of the magnetic element 1063.
  • a “Hall Effect” sensor (not shown) can be mounted to the bottom surface of the circuit board 1100.
  • the Hall Effect sensor can be configured to detect changes in a magnetic field surrounding the Hall Effect sensor caused by the movement of the magnetic element 1063.
  • the Hall Effect sensor can be in signal communication with a microcontroller, for example, which can determine whether the closure release button assembly 1062 is in its first position, which is associated with the unactuated position of the closure trigger 1032 and the open configuration of the end effector, its second position, which is associated with the actuated position of the closure trigger 1032 and the closed configuration of the end effector, and/or any position between the first position and the second position.
  • a microcontroller for example, which can determine whether the closure release button assembly 1062 is in its first position, which is associated with the unactuated position of the closure trigger 1032 and the open configuration of the end effector, its second position, which is associated with the actuated position of the closure trigger 1032 and the closed configuration of the end effector, and/or any position between the first position and the second position.
  • the handle 1014 and the frame 1020 may operably support another drive system referred to herein as a firing drive system 1080 that is configured to apply firing motions to corresponding portions of the interchangeable shaft assembly attached thereto.
  • the firing drive system 1080 may also be referred to herein as a “second drive system”.
  • the firing drive system 1080 may employ an electric motor 1082 that is located in the pistol grip portion 1019 of the handle 1014.
  • the motor 1082 may be a DC brushed driving motor having a maximum rotation of, approximately, 25,000 RPM, for example.
  • the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor.
  • the motor 1082 may be powered by a power source 1090 that in one form may comprise a removable power pack 1092.
  • the power pack 1092 may comprise a proximal housing portion 1094 that is configured for attachment to a distal housing portion 1096.
  • the proximal housing portion 1094 and the distal housing portion 1096 are configured to operably support a plurality of batteries 1098 therein.
  • Batteries 1098 may each comprise, for example, a Lithium Ion (“LI”) or other suitable battery.
  • the distal housing portion 1096 is configured for removable operable attachment to the circuit board 1100 which is also operably coupled to the motor 1082.
  • a number of batteries 1098 may be connected in series may be used as the power source for the surgical instrument 1010.
  • the power source 1090 may be replaceable and/or rechargeable.
  • the electric motor 1082 can include a rotatable shaft (not shown) that operably interfaces with a gear reducer assembly 1084 that is mounted in meshing engagement with a set, or rack, of drive teeth 1122 on a longitudinally movable drive member 1120.
  • a voltage polarity provided by the power source 1090 can operate the electric motor 1082 in a clockwise direction wherein the voltage polarity applied to the electric motor by the battery can be reversed in order to operate the electric motor 1082 in a counter-clockwise direction.
  • the drive member 1120 will be axially driven in the distal direction “DD”.
  • the handle 1014 can include a switch which can be configured to reverse the polarity applied to the electric motor 1082 by the power source 1090. As with the other forms described herein, the handle 1014 can also include a sensor that is configured to detect the position of the drive member 1120 and/or the direction in which the drive member 1120 is being moved.
  • Actuation of the motor 1082 can be controlled by a firing trigger 1130 that is pivotally supported on the handle 1014.
  • the firing trigger 1130 may be pivoted between an unactuated position and an actuated position.
  • the firing trigger 1130 may be biased into the unactuated position by a spring 1132 or other biasing arrangement such that when the clinician releases the firing trigger 1130, it may be pivoted or otherwise returned to the unactuated position by the spring 1132 or biasing arrangement.
  • the firing trigger 1130 can be positioned “outboard” of the closure trigger 1032 as was discussed above.
  • a firing trigger safety button 1134 may be pivotally mounted to the closure trigger 1032 by the pin 1035.
  • the safety button 1134 may be positioned between the firing trigger 1130 and the closure trigger 1032 and have a pivot arm 1136 protruding therefrom.
  • the safety button 1134 When the closure trigger 1032 is in the unactuated position, the safety button 1134 is contained in the handle 1014 where the clinician cannot readily access it and move it between a safety position preventing actuation of the firing trigger 1130 and a firing position wherein the firing trigger 1130 may be fired. As the clinician depresses the closure trigger 1032, the safety button 1134 and the firing trigger 1130 pivot down wherein they can then be manipulated by the clinician.
  • the longitudinally movable drive member 1120 has a rack of teeth 1122 formed thereon for meshing engagement with a corresponding drive gear 1086 of the gear reducer assembly 1084.
  • At least one form also includes a manually- actuatable “bailout” assembly 1140 that is configured to enable the clinician to manually retract the longitudinally movable drive member 1120 should the motor 1082 become disabled.
  • the bailout assembly 1140 may include a lever or bailout handle assembly 1142 that is configured to be manually pivoted into ratcheting engagement with teeth 1124 also provided in the drive member 1120.
  • U.S. Patent No. 8,608,045 entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM, discloses bailout arrangements and other components, arrangements and systems that may also be employed with the various instruments disclosed herein.
  • U.S. Patent No. 8,608,045 is hereby incorporated by reference herein in its entirety.
  • the interchangeable shaft assembly 1200 includes a surgical end effector 1300 that comprises an elongate channel 1310 that is configured to operably support a staple cartridge 1301 therein.
  • the end effector 1300 may further include an anvil 2000 that is pivotally supported relative to the elongate channel 1310.
  • the interchangeable shaft assembly 1200 may further include an articulation joint 3020 and an articulation lock 2140 which can be configured to releasably hold the end effector 1300 in a desired position relative to a shaft axis SA. Examples of various features of at least one form of the end effector 1300, the articulation joint 3020 and articulation locks may be found in U.S. Patent Application Serial No.
  • the interchangeable shaft assembly 1200 can further include a proximal housing or nozzle 1201 comprised of nozzle portions 1202 and 1203.
  • the interchangeable shaft assembly 1200 can further include a closure system or closure member assembly 3000 which can be utilized to close and/or open the anvil 2000 of the end effector 1300.
  • the shaft assembly 1200 can include a spine 1210 that is configured to, one, slidably support a firing member therein and, two, slidably support the closure member assembly 3000 which extends around the spine 1210.
  • a distal end 1212 of spine 1210 terminates in an upper lug mount feature 1270 and in a lower lug mount feature 1280.
  • the upper lug mount feature 1270 is formed with a lug slot 1272 therein that is adapted to mountingly support an upper mounting link 1274 therein.
  • the lower lug mount feature 1280 is formed with a lug slot 1282 therein that is adapted to mountingly support a lower mounting link 1284 therein.
  • the upper mounting link 1274 includes a pivot socket 1276 therein that is adapted to rotatably receive therein a pivot pin 1292 that is formed on a channel cap or anvil retainer 1290 that is attached to a proximal end portion 1312 of the elongate channel 1310.
  • the lower mounting link 1284 includes lower pivot pin 1286 that adapted to be received within a pivot hole 1314 formed in the proximal end portion 1312 of the elongate channel 1310. See FIG. 5.
  • the lower pivot pin 1286 is vertically aligned with the pivot socket 1276 to define an articulation axis AA about which the surgical end effector 1300 may articulate relative to the shaft axis SA. See FIG. 2.
  • the surgical end effector 1300 is selectively articulatable about the articulation axis AA by an articulation system 2100.
  • the articulation system 2100 includes proximal articulation driver 2102 that is pivotally coupled to an articulation link 2120.
  • an offset attachment lug 2114 is formed on a distal end 2110 of the proximal articulation driver 2102.
  • a pivot hole 2116 is formed in the offset attachment lug 2114 and is configured to pivotally receive therein a proximal link pin 2124 formed on the proximal end 2122 of the articulation link 2120.
  • a distal end 2126 of the articulation link 2120 includes a pivot hole 2128 that is configured to pivotally receive therein a channel pin 1317 formed on the proximal end portion 1312 of the elongate channel 1310.
  • proximal articulation driver 2102 can be held in position by an articulation lock 2140 when the proximal articulation driver 2102 is not being moved in the proximal or distal directions. Additional details regarding an example of an articulation lock 2140 may be found in U.S. Patent Application Serial No. 15/635,631 , now U.S. Patent Application Publication No. 2019/0000464, as well as in other references incorporated by reference herein.
  • the spine 1210 can comprise a proximal end 1211 which is rotatably supported in a chassis 1240.
  • the proximal end 1211 of the spine 1210 has a thread 1214 formed thereon for threaded attachment to a spine bearing 1216 configured to be supported within the chassis 1240. See FIG. 4.
  • Such an arrangement facilitates rotatable attachment of the spine 1210 to the chassis 1240 such that the spine 1210 may be selectively rotated about a shaft axis SA relative to the chassis 1240.
  • the interchangeable shaft assembly 1200 includes a closure shuttle 1250 that is slidably supported within the chassis 1240 such that it may be axially moved relative thereto.
  • the closure shuttle 1250 includes a pair of proximally-protruding hooks 1252 that are configured for attachment to the attachment pin 1037 (FIG. 3) that is attached to the second closure link 1038 as will be discussed in further detail below.
  • the closure member assembly 3000 comprises a proximal closure member segment 3010 that has a proximal end 3012 that is coupled to the closure shuttle 1250 for relative rotation thereto.
  • a U shaped connector 1263 is inserted into an annular slot 3014 in the proximal end 3012 of the proximal closure member segment 3010 and is retained within vertical slots 1253 in the closure shuttle 1250.
  • Such an arrangement serves to attach the proximal closure member segment 3010 to the closure shuttle 1250 for axial travel therewith while enabling the proximal closure member segment 3010 to rotate relative to the closure shuttle 1250 about the shaft axis SA.
  • a closure spring 1268 is journaled on the proximal closure member segment 3010 and serves to bias the proximal closure member segment 3010 in the proximal direction “PD” which can serve to pivot the closure trigger 1032 into the unactuated position when the shaft assembly is operably coupled to the handle 1014.
  • the interchangeable shaft assembly 1200 may further include an articulation joint 3020.
  • Other interchangeable shaft assemblies may not be capable of articulation.
  • a distal closure member or distal closure tube segment 3030 is coupled to the distal end of the proximal closure member segment 3010.
  • the articulation joint 3020 includes a double pivot closure sleeve assembly 3022.
  • the double pivot closure sleeve assembly 3022 includes an end effector closure tube 3050 having upper and lower distally projecting tangs 3052, 3054.
  • An upper double pivot link 3056 includes upwardly projecting distal and proximal pivot pins that engage respectively an upper distal pin hole in the upper proximally projecting tang 3052 and an upper proximal pin hole in an upper distally projecting tang 3032 on the distal closure tube segment 3030.
  • a lower double pivot link 3058 includes upwardly projecting distal and proximal pivot pins that engage respectively a lower distal pin hole in the lower proximally projecting tang 3054 and a lower proximal pin hole in the lower distally projecting tang 3034. See FIGS. 4 and 5.
  • the closure member assembly 3000 is translated distally (direction “DD”) to close the anvil 2000, for example, in response to the actuation of the closure trigger 1032.
  • the anvil 2000 is opened by proximally translating the closure member assembly 3000 which causes the end effector closure sleeve to interact with the anvil 2000 and pivot it to an open position.
  • the interchangeable shaft assembly 1200 further includes a firing member 1900 that is supported for axial travel within the spine 1210.
  • the firing member 1900 includes an intermediate firing shaft portion 1222 that is configured for attachment to a distal cutting portion or knife bar 1910.
  • the intermediate firing shaft portion 1222 may include a longitudinal slot 1223 in the distal end thereof which can be configured to receive a tab 1912 on the proximal end of the distal knife bar 1910.
  • the longitudinal slot 1223 and the proximal end tab 1912 can be sized and configured to permit relative movement therebetween and can comprise a slip joint 1914.
  • the slip joint 1914 can permit the intermediate firing shaft portion 1222 of the firing member 1900 to be moved to articulate the end effector 1300 without moving, or at least substantially moving, the knife bar 1910.
  • the intermediate firing shaft portion 1222 can be advanced distally until a proximal sidewall of the longitudinal slot 1223 comes into contact with the tab 1912 in order to advance the knife bar 1910 and fire the staple cartridge 1301 positioned within the channel 1310.
  • the knife bar 1910 includes a knife portion 1920 that includes a blade or tissue cutting edge 1922 and includes an upper anvil engagement tab 1924 and lower channel engagement tabs 1926.
  • Various firing member configurations and operations are disclosed in various other references incorporated herein by reference.
  • Embodiments are also envisioned where, in lieu of a slip joint 1914, a shifter assembly can be used. Details of such a shifter assembly and corresponding components, assemblies, and systems can be found in U.S. Patent Application No. 15/635,521 , entitled SURGICAL INSTRUMENT LOCKOUT ARRANGEMENT, which is incorporated by reference herein in its entirety.
  • the shaft assembly 1200 further includes a switch drum 1500 that is rotatably received on proximal closure member segment 3010.
  • the switch drum 1500 comprises a hollow shaft segment 1502 that has a shaft boss formed thereon for receiving an outwardly protruding actuation pin therein.
  • the actuation pin extends through a longitudinal slot provided in the lock sleeve to facilitate axial movement of the lock sleeve when it is engaged with the articulation driver.
  • a rotary torsion spring 1420 is configured to engage the boss on the switch drum 1500 and a portion of the nozzle housing 1203 to apply a biasing force to the switch drum 1500.
  • the switch drum 1500 can further comprise at least partially circumferential openings 1506 defined therein which can be configured to receive circumferential mounts extending from the nozzle portions 1202, 1203 and permit relative rotation, but not translation, between the switch drum 1500 and the nozzle 1201.
  • the mounts also extend through openings 3011 in the proximal closure member segment 3010 to be seated in recesses 1219 in the spine 1210.
  • Rotation of the switch drum 1500 about the shaft axis SA will ultimately result in the rotation of the actuation pin and the lock sleeve between its engaged and disengaged positions.
  • the rotation of the switch drum 1500 may be linked to the axial advancement of the closure tube or closure member.
  • actuation of the closure system may operably engage and disengage the articulation drive system with the firing drive system in the various manners described in further detail in U.S.
  • the closure member segment 3010 will have positioned the switch drum 1500 so as to link the articulation system with the firing drive system.
  • the closure tube has been moved to its distal position corresponding to a “jaws closed” position, the closure tube has rotated the switch drum 1500 to a position wherein the articulation system is delinked from the firing drive system.
  • the shaft assembly 1200 can comprise a slip ring assembly 1600 which can be configured to conduct electrical power to and/or from the end effector 1300 and/or communicate signals to and/or from the end effector 1300, for example.
  • the slip ring assembly 1600 can comprise a proximal connector flange 1604 that is mounted to a chassis flange 1242 that extends from the chassis 1240 and a distal connector flange that is positioned within a slot defined in the shaft housings.
  • the proximal connector flange 1604 can comprise a first face and the distal connector flange can comprise a second face which is positioned adjacent to and movable relative to the first face.
  • the distal connector flange can rotate relative to the proximal connector flange 1604 about the shaft axis SA.
  • the proximal connector flange 1604 can comprise a plurality of concentric, or at least substantially concentric, conductors defined in the first face thereof.
  • a connector can be mounted on the proximal side of the connector flange and may have a plurality of contacts wherein each contact corresponds to and is in electrical contact with one of the conductors. Such an arrangement permits relative rotation between the proximal connector flange 1604 and the distal connector flange while maintaining electrical contact therebetween.
  • the proximal connector flange 1604 can include an electrical connector 1606 which can place the conductors in signal communication with a shaft circuit board 1610 mounted to the shaft chassis 1240, for example.
  • a wiring harness comprising a plurality of conductors can extend between the electrical connector 1606 and the shaft circuit board 1610.
  • the electrical connector 1606 may extend proximally through a connector opening 1243 defined in the chassis flange 1242. See FIG. 4. Further details regarding slip ring assembly 1600 may be found in U.S. Patent Application Serial No. 13/803,086, entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. Patent Application Publication No.
  • the shaft assembly 1200 can include a proximal portion which is fixably mounted to the handle 1014 and a distal portion which is rotatable about a longitudinal axis.
  • the rotatable distal shaft portion can be rotated relative to the proximal portion about the slip ring assembly 1600, as discussed above.
  • the distal connector flange of the slip ring assembly 1600 can be positioned within the rotatable distal shaft portion.
  • the switch drum 1500 can also be positioned within the rotatable distal shaft portion. When the rotatable distal shaft portion is rotated, the distal connector flange and the switch drum 1500 can be rotated synchronously with one another.
  • the switch drum 1500 can be rotated between a first position and a second position relative to the distal connector flange.
  • the articulation drive system When the switch drum 1500 is in its first position, the articulation drive system may be operably disengaged from the firing drive system and, thus, the operation of the firing drive system may not articulate the end effector 1300 of the shaft assembly 1200.
  • the switch drum 1500 When the switch drum 1500 is in its second position, the articulation drive system may be operably engaged with the firing drive system and, thus, the operation of the firing drive system may articulate the end effector 1300 of the shaft assembly 1200.
  • the switch drum 1500 When the switch drum 1500 is moved between its first position and its second position, the switch drum 1500 is moved relative to the distal connector flange.
  • the shaft assembly 1200 can comprise at least one sensor configured to detect the position of the switch drum 1500.
  • the chassis 1240 includes at least one, and preferably two, tapered attachment portions 1244 formed thereon that are adapted to be received within corresponding dovetail slots 1702 formed within a distal attachment flange portion 1700 of the frame 1020. See FIG. 3. Each dovetail slot 1702 may be tapered or, stated another way, be somewhat V-shaped to seatingly receive the attachment portions 1244 therein. As can be further seen in FIG. 4, a shaft attachment lug 1226 is formed on the proximal end of the intermediate firing shaft portion 1222.
  • the shaft attachment lug 1226 is received in a firing shaft attachment cradle 1126 formed in a distal end 1125 of the longitudinal drive member 1120. See FIG. 3.
  • Various shaft assembly embodiments employ a latch system 1710 for removably coupling the shaft assembly 1200 to the housing 1012 and more specifically to the frame 1020.
  • the latch system 1710 includes a lock member or lock yoke 1712 that is movably coupled to the chassis 1240.
  • the lock yoke 1712 has a U-shape with two spaced downwardly extending legs 1714.
  • the legs 1714 each have a pivot lug 1715 formed thereon that are adapted to be received in corresponding holes 1245 formed in the chassis 1240.
  • Such arrangement facilitates pivotal attachment of the lock yoke 1712 to the chassis 1240.
  • the lock yoke 1712 may include two proximally protruding lock lugs 1716 that are configured for releasable engagement with corresponding lock detents or grooves 1704 in the distal attachment flange portion 1700 of the frame 1020. See FIG. 3.
  • the lock yoke 1712 is biased in the proximal direction by spring or biasing member (not shown). Actuation of the lock yoke 1712 may be accomplished by a latch button 1722 that is slidably mounted on a latch actuator assembly 1720 that is mounted to the chassis 1240.
  • the latch button 1722 may be biased in a proximal direction relative to the lock yoke 1712.
  • the lock yoke 1712 may be moved to an unlocked position by biasing the latch button in the distal direction which also causes the lock yoke 1712 to pivot out of retaining engagement with the distal attachment flange portion 1700 of the frame 1020.
  • the lock lugs 1716 are retainingly seated within the corresponding lock detents or grooves 1704 in the distal attachment flange portion 1700.
  • an interchangeable shaft assembly that includes an end effector of the type described herein that is adapted to cut and fasten tissue, as well as other types of end effectors
  • the clinician may actuate the closure trigger 1032 to grasp and manipulate the target tissue into a desired position. Once the target tissue is positioned within the end effector 1300 in a desired orientation, the clinician may then fully actuate the closure trigger 1032 to close the anvil 2000 and clamp the target tissue in position for cutting and stapling. In that instance, the first drive system 1030 has been fully actuated.
  • One form of the latch system 1710 is configured to prevent such inadvertent detachment.
  • the lock yoke 1712 includes at least one and preferably two lock hooks 1718 that are adapted to contact corresponding lock lug portions 1256 that are formed on the closure shuttle 1250.
  • the lock yoke 1712 may be pivoted in a distal direction to unlock the interchangeable shaft assembly 1200 from the housing 1012.
  • the lock hooks 1718 do not contact the lock lug portions 1256 on the closure shuttle 1250.
  • the lock yoke 1712 is prevented from being pivoted to an unlocked position.
  • the clinician were to attempt to pivot the lock yoke 1712 to an unlocked position or, for example, the lock yoke 1712 was inadvertently bumped or contacted in a manner that might otherwise cause it to pivot distally, the lock hooks 1718 on the lock yoke 1712 will contact the lock lug portions 1256 on the closure shuttle 1250 and prevent movement of the lock yoke 1712 to an unlocked position.
  • the clinician may position the chassis 1240 of the interchangeable shaft assembly 1200 above or adjacent to the distal attachment flange portion 1700 of the frame 1020 such that the tapered attachment portions 1244 formed on the chassis 1240 are aligned with the dovetail slots 1702 in the frame 1020.
  • the clinician may then move the shaft assembly 1200 along an installation axis that is perpendicular to the shaft axis SA to seat the attachment portions 1244 in “operable engagement” with the corresponding dovetail slots 1702.
  • the shaft attachment lug 1226 on the intermediate firing shaft portion 1222 will also be seated in the cradle 1126 in the longitudinally movable drive member 1120 and the portions of the pin 1037 on the second closure link 1038 will be seated in the corresponding hooks 1252 in the closure shuttle 1250.
  • operble engagement in the context of two components means that the two components are sufficiently engaged with each other so that upon application of an actuation motion thereto, the components may carry out their intended action, function and/or procedure.
  • At least five systems of the interchangeable shaft assembly 1200 can be operably coupled with at least five corresponding systems of the handle 1014.
  • a first system can comprise a frame system which couples and/or aligns the frame 1020 or spine 1210 of the shaft assembly 1200 with the frame 1020 of the handle 1014.
  • Another system can comprise a closure drive system 1030 which can operably connect the closure trigger 1032 of the handle 1014 and a closure tube of the shaft assembly 1200.
  • the closure shuttle 1250 of the shaft assembly 1200 can be engaged with the pin 1037 on the second closure link 1038.
  • Another system can comprise the firing drive system 1080 which can operably connect the firing trigger 1130 of the handle 1014 with the intermediate firing shaft portion 1222 of the shaft assembly 1200.
  • the shaft attachment lug 1226 can be operably connected with the cradle 1126 of the longitudinal drive member 1120.
  • Another system can comprise an electrical system which can signal to a controller in the handle 1014, such as microcontroller, for example, that a shaft assembly, such as shaft assembly 1200, for example, has been operably engaged with the handle 1014 and/or, two, conduct power and/or communication signals between the shaft assembly 1200 and the handle 1014.
  • the shaft assembly 1200 can include an electrical connector 1810 that is operably mounted to the shaft circuit board 1610.
  • the electrical connector 1810 is configured for mating engagement with a corresponding electrical connector 1800 on the circuit board 1100. Further details regarding the circuitry and control systems may be found in U.S. Patent Application Serial No.
  • the fifth system may consist of the latching system for releasably locking the shaft assembly 1200 to the handle 1014.
  • the anvil 2000 in the illustrated example includes an anvil body 2002 that terminates in an anvil mounting portion 2010.
  • the anvil mounting portion 2010 is movably or pivotably supported on the elongate channel 1310 for selective pivotal travel relative thereto about a fixed anvil pivot axis PA that is transverse to the shaft axis SA.
  • a pivot member or anvil trunnion 2012 extends laterally out of each lateral side of the anvil mounting portion 2010 to be received in a corresponding trunnion cradle 1316 formed in the upstanding walls 1315 of the proximal end portion 1312 of the elongate channel 1310.
  • the anvil trunnions 2012 are pivotally retained in their corresponding trunnion cradle 1316 by the channel cap or anvil retainer 1290.
  • the channel cap or anvil retainer 1290 includes a pair of attachment lugs that are configured to be retainingly received within corresponding lug grooves or notches formed in the upstanding walls 1315 of the proximal end portion 1312 of the elongate channel 1310. See FIG. 5.
  • the distal closure member or end effector closure tube 3050 employs two axially offset, proximal and distal positive jaw opening features 3060 and 3062.
  • the positive jaw opening features 3060, 3062 are configured to interact with corresponding relieved areas and stepped portions formed on the anvil mounting portion 2010 as described in further detail in U.S. Patent Application Serial No. 15/635,631 , entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSURE MEMBER, now U.S. Patent Application Publication No. 2019/0000464, the entire disclosure which has been herein incorporated by reference.
  • Other jaw opening arrangements may be employed.
  • a shaft assembly 100 is illustrated in FIGS. 6 and 7.
  • the shaft assembly 100 comprises an attachment portion 110, a shaft 120 extending distally from the attachment portion 110, and an end effector 130 attached to the shaft 120.
  • the shaft assembly 100 is configured to clamp, staple, and cut tissue.
  • the attachment portion 110 is configured to be attached to a handle of a surgical instrument and/or the arm of a surgical robot, for example.
  • the shaft assembly 100 comprises cooperating articulation rods 144, 145 configured to articulate the end effector 130 relative to the shaft 120 about an articulation joint 160.
  • the shaft assembly 100 further comprises an articulation lock bar 148, an outer shaft tube 162, and a spine portion 123.
  • the shaft assembly 100 comprises a firing shaft 150 including a firing member 156 attached to a distal end of the firing shaft 150.
  • the firing member 156 comprises upper camming flanges configured to engage an anvil jaw 133 and lower camming members configured to engage a cartridge jaw 132.
  • the firing shaft 150 is configured to be advanced distally through a closure stroke to clamp the anvil jaw 133 relative to the cartridge jaw 132 with the camming members. Further advancement of the firing shaft 150 through a firing stroke is configured to advance the firing member 156 through the cartridge jaw 132 to deploy staples from the cartridge jaw 132 and cut tissue during the firing stroke. More details of the shaft assembly 100 can be found in U.S. Patent Application No.
  • FIGS. 8 and 9 depict a surgical instrument assembly 200 configured to be used with a surgical robot.
  • the surgical instrument assembly 200 is configured to staple and cut tissue, although the surgical instrument assembly 200 could be adapted to treat tissue in any suitable way, such as by applying heat energy, electrical energy, and/or vibrations to the tissue, for example.
  • the surgical instrument assembly 200 comprises a proximal control interface 210 configured to be coupled to a robotic arm of a surgical robot and a shaft assembly 220 configured to be attached to the proximal control interface 210.
  • the shaft assembly 220 comprises an end effector 230 configured to clamp, cut, and staple tissue.
  • the proximal control interface 210 comprises a plurality of drive discs 211 , each for actuating one or more functions of the surgical instrument assembly 200.
  • Each drive disc 211 can be independently driven and/or cooperatively driven with one or more other drive discs 211 by one or more motors of the surgical robot and/or robotic arm of the surgical robot. More details about the surgical instrument assembly 200 can be found in U.S. Patent Application No. 15/847,297, entitled SURGICAL INSTRUMENTS WITH DUAL ARTICULATION DRIVERS, which is incorporated by reference in its entirety.
  • FIG. 10 depicts one version of a master controller 301 that may be used in connection with a robotic arm slave cart 310 of the type depicted in FIG. 11.
  • Master controller 301 and robotic arm slave cart 310, as well as their respective components and control systems are collectively referred to herein as a robotic system 300.
  • Examples of such systems and devices are disclosed in U.S. Patent No. 7,524,320, entitled MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTIC SURGICAL TOOLS, as well as U.S. Patent No.
  • the master controller 301 generally includes master controllers (generally represented as 303 in FIG. 10) which are grasped by the surgeon and manipulated in space while the surgeon views the procedure via a stereo display 302.
  • the master controllers 301 generally comprise manual input devices which preferably move with multiple degrees of freedom, and which often further have an actuatable handle for actuating tools (for example, for closing grasping jaws, applying an electrical potential to an electrode, or the like).
  • the robotic arm cart 310 may be configured to actuate one or more surgical tools, generally designated as 330.
  • Various robotic surgery systems and methods employing master controller and robotic arm cart arrangements are disclosed in U.S. Patent No. 6,132,368, entitled MULTI-COMPONENT TELEPRESENCE SYSTEM AND METHOD the entire disclosure of which is hereby incorporated by reference herein.
  • the robotic arm cart 310 includes a base 312 from which, in the illustrated embodiment, surgical tools may be supported.
  • the surgical tool(s) may be supported by a series of manually articulatable linkages, generally referred to as set-up joints 314, and a robotic manipulator 316.
  • the linkage and joint arrangement may facilitate rotation of a surgical tool around a point in space, as more fully described in issued U.S. Patent No. 5,817,084, entitled REMOTE CENTER POSITIONING DEVICE WITH FLEXIBLE DRIVE, the entire disclosure of which is hereby incorporated by reference herein.
  • the parallelogram arrangement constrains rotation to pivoting about an axis 322a, sometimes called the pitch axis.
  • the links supporting the parallelogram linkage are pivotally mounted to set-up joints 314 (FIG. 11) so that the surgical tool further rotates about an axis 322b, sometimes called the yaw axis.
  • the pitch and yaw axes 322a, 322b intersect at the remote center 324, which is aligned along an elongate shaft of a surgical tool.
  • the surgical tool may have further degrees of driven freedom as supported by manipulator 316, including sliding motion of the surgical tool along the longitudinal axis “LT-LT”.
  • remote center 324 remains fixed relative to base 326 of manipulator 316.
  • Linkage 318 of manipulator 316 may be driven by a series of motors 340. These motors actively move linkage 318 in response to commands from a processor of a control system.
  • the motors 340 may also be employed to manipulate the surgical tool.
  • Alternative joint structures and set up arrangements are also contemplated. Examples of other joint and set up arrangements, for example, are disclosed in U.S. Patent No. 5,878,193, entitled AUTOMATED ENDOSCOPE SYSTEM FOR OPTIMAL POSITIONING, the entire disclosure of which is hereby incorporated by reference herein.
  • FIG. 13 illustrates a block diagram of a surgical system 1930 for use with one or more surgical instruments, tools, and/or robotic systems in accordance with one or more aspects of the present disclosure.
  • the system 1930 includes a control circuit 1932.
  • the control circuit 1932 includes a microcontroller 1933 comprising a processor 1934 and a storage medium such as, for example, a memory 1935.
  • a motor assembly 1939 includes one or more motors, driven by motor drivers.
  • the motor assembly 1939 operably couples to a drive assembly 1941 to drive, or effect, one or more motions at an end effector 1940.
  • the drive assembly 1941 may include any number of components suitable for transmitting motion to the end effector 1940 such as, for example, one or more linkages, bars, tubes, and/or cables, for example.
  • One or more of sensors 1938 provide real-time feedback to the processor 1934 about one or more operational parameters monitored during a surgical procedure being performed by the surgical system 1930.
  • the operational parameters can be associated with a user performing the surgical procedure, a tissue being treated, and/or one or more components of the surgical system 1930, for example.
  • the sensor 1938 may comprise any suitable sensor, such as, for example, a magnetic sensor, such as a Hall effect sensor, a strain gauge, a pressure sensor, an inductive sensor, such as an eddy current sensor, a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor.
  • the sensors 1938 may comprise any suitable sensor for detecting one or more conditions at the end effector 1940 including, without limitation, a tissue thickness sensor such as a Hall Effect Sensor or a reed switch sensor, an optical sensor, a magneto-inductive sensor, a force sensor, a pressure sensor, a piezo-resistive film sensor, an ultrasonic sensor, an eddy current sensor, an accelerometer, a pulse oximetry sensor, a temperature sensor, a sensor configured to detect an electrical characteristic of a tissue path (such as capacitance or resistance), or any combination thereof.
  • a tissue thickness sensor such as a Hall Effect Sensor or a reed switch sensor, an optical sensor, a magneto-inductive sensor, a force sensor, a pressure sensor, a piezo-resistive film sensor, an ultrasonic sensor, an eddy current sensor, an accelerometer, a pulse oximetry sensor, a temperature sensor, a sensor configured to detect an electrical characteristic of a tissue path (such as capacitance or resistance
  • the sensors 1938 may include one or more sensors located at, or about, an articulation joint extending proximally from the end effector 1940.
  • sensors may include, for example, a potentiometer, a capacitive sensor (slide potentiometer), piezo- resistive film sensor, a pressure sensor, a pressure sensor, or any other suitable sensor type.
  • the sensor 1938 may comprise a plurality of sensors located in multiple locations in the end effector 1940.
  • the system 1930 includes a feedback system 1952 which includes one or more devices for providing a sensory feedback to a user.
  • Such devices may comprise, for example, visual feedback devices (e.g., an LCD display screen, a touch screen, LED indicators), audio feedback devices (e.g., a speaker, a buzzer) or tactile feedback devices (e.g., haptic actuators).
  • the microcontroller 1933 may be programmed to perform various functions such as precise control over the speed and position of the drive assembly 1941.
  • the microcontroller 1933 may be any single-core or multicore processor such as those known under the trade name ARM Cortex by Texas Instruments.
  • the main microcontroller 1933 may be an LM4F230H5QR ARM Cortex-M4F Processor Core, available from Texas Instruments, for example, comprising an on-chip memory of 256 KB single-cycle flash memory, or other non-volatile memory, up to 40 MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB single-cycle SRAM, and internal ROM loaded with Stel laris Ware® software, a 2 KB EEPROM, one or more PWM modules, one or more QEI analogs, and/or one or more 12-bit ADCs with 12 analog input channels, details of which are available for the product datasheet.
  • LM4F230H5QR ARM Cortex-M4F Processor Core available from Texas Instruments, for example, comprising an on-chip memory of 256 KB single-cycle flash memory, or other non-volatile memory, up to 40 MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB single-cycle SRAM
  • the microcontroller 1933 may be configured to compute a response in the software of the microcontroller 1933.
  • the computed response is compared to a measured response of the actual system to obtain an “observed” response, which is used for actual feedback decisions.
  • the observed response is a favorable, tuned value that balances the smooth, continuous nature of the simulated response with the measured response, which can detect outside influences on the system.
  • the motor assembly 1939 includes one or more electric motors and one or more motor drivers.
  • the electric motors can be in the form of a brushed direct current (DC) motor with a gearbox and mechanical links to the drive assembly 1941.
  • a motor driver may be an A3941 available from Allegro Microsystems, Inc.
  • the motor assembly 1939 includes a brushed DC driving motor having a maximum rotational speed of approximately 25,000 RPM.
  • the motor assembly 1939 may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor.
  • the motor driver may comprise an H-bridge driver comprising field-effect transistors (FETs), for example.
  • the motor assembly 1939 can be powered by a power source 1942.
  • the power source 1942 includes one or more batteries which may include a number of battery cells connected in series that can be used as the power source to power the motor assembly
  • the battery cells of the power assembly may be replaceable and/or rechargeable.
  • the battery cells can be lithium-ion batteries which can be couplable to and separable from the power assembly.
  • the end effector 1940 includes a first jaw 1921 and a second jaw 1931. At least one of the first jaw 1921 and the second jaw 1931 is rotatable relative to the other during a closure motion that transitions the end effector 1940 from an open configuration toward a closed configuration. The closure motion may cause the jaws 1921 , 1931 to grasp tissue therebetween.
  • sensors such as, for example, a strain gauge or a micro-strain gauge, are configured to measure one or more parameters of the end effector
  • the amplitude of the strain exerted on the one or both of the jaws 1921 , 1931 during a closure motion which can be indicative of the closure forces applied to the jaws 1921 , 1931.
  • the measured strain is converted to a digital signal and provided to the processor 1934, for example.
  • sensors such as, for example, a load sensor, can measure a closure force and/or a firing force applied to the jaws 1921 , 1931 .
  • a current sensor can be employed to measure the current drawn by a motor of the motor assembly 1939.
  • the force required to advance the drive assembly 1941 can correspond to the current drawn by the motor, for example.
  • the measured force is converted to a digital signal and provided to the processor 1934.
  • strain gauge sensors can be used to measure the force applied to the tissue by the end effector 1940, for example.
  • a strain gauge can be coupled to the end effector 1940 to measure the force on the tissue being treated by the end effector 1940.
  • the strain gauge sensors can measure the amplitude or magnitude of the strain exerted on a jaw of an end effector 1940 during a closure motion which can be indicative of the tissue compression. The measured strain is converted to a digital signal and provided to a processor 1934.
  • a memory e.g. memory 1935
  • a technique, an equation, and/or a lookup table which can be employed by the microcontroller 1933 in the assessment.
  • the system 1930 may comprise wired or wireless communication circuits to communicate with surgical hubs (e.g. surgical hub 1953), communication hubs, and/or robotic surgical hubs, for example. Additional details about suitable interactions between a system 1930 and the surgical hub 1953 are disclosed in U.S. Patent Application Serial No. 16/209,423 entitled METHOD OF COMPRESSING TISSUE WITHIN A STAPLING DEVICE AND SIMULTANEOUSLY DISPLAYING THE LOCATION OF THE TISSUE WITHIN THE JAWS, now U.S. Patent Application Publication No. 2019/0200981 , the entire disclosure of which is incorporated by reference in its entirety herein.
  • control circuit 1932 can be configured to implement various processes described herein.
  • the control circuit 1932 may comprise a microcontroller comprising one or more processors (e.g., microprocessor, microcontroller) coupled to at least one memory circuit.
  • the memory circuit stores machine-executable instructions that, when executed by the processor, cause the processor to execute machine instructions to implement various processes described herein.
  • the processor may be any one of a number of single-core or multicore processors known in the art.
  • the memory circuit may comprise volatile and non-volatile storage media.
  • the processor may include an instruction processing unit and an arithmetic unit.
  • the instruction processing unit may be configured to receive instructions from the memory circuit of this disclosure.
  • control circuit 1932 can be in the form of a combinational logic circuit configured to implement various processes described herein.
  • the combinational logic circuit may comprise a finite state machine comprising a combinational logic configured to receive data, process the data by the combinational logic, and provide an output.
  • control circuit 1932 can be in the form of a sequential logic circuit.
  • the sequential logic circuit can be configured to implement various processes described herein.
  • the sequential logic circuit may comprise a finite state machine.
  • the sequential logic circuit may comprise a combinational logic, at least one memory circuit, and a clock, for example.
  • the at least one memory circuit can store a current state of the finite state machine.
  • the sequential logic circuit may be synchronous or asynchronous.
  • the control circuit 1932 may comprise a combination of a processor (e.g., processor 1934) and a finite state machine to implement various processes herein.
  • the finite state machine may comprise a combination of a combinational logic circuit (and the sequential logic circuit, for example.
  • FIG. 14 illustrates a block diagram of a surgical system 600 for use with one or more surgical instruments, tools, and/or robotic systems in accordance with one or more aspects of the present disclosure.
  • the surgical system 600 is similar in many respects to the surgical system 1930, which are not repeated herein at the same of detail for brevity.
  • the surgical system 600 includes a control circuit comprising a microcontroller 620 comprising a processor 622 and a memory 624, sensors 630, and a power source 628, which are similar, respectively, to the microcontroller 1933, the processor 1934, the memory 1935, and the power source 1942.
  • the surgical system 600 includes a plurality of motors and corresponding driving assemblies that can be activated to perform various functions.
  • a first motor can be activated to perform a first function
  • a second motor can be activated to perform a second function
  • a third motor can be activated to perform a third function
  • a fourth motor can be activated to perform a fourth function
  • the plurality of motors can be individually activated to cause firing, closure, and/or articulation motions in an end effector 1940, for example.
  • the firing, closure, and/or articulation motions can be transmitted to the end effector 1940 through a shaft assembly, for example.
  • the system 600 may include a firing motor 602.
  • the firing motor 602 may be operably coupled to a firing motor drive assembly 604 which can be configured to transmit firing motions, generated by the motor 602 to the end effector, in particular to displace the I-beam element.
  • the firing motions generated by the motor 602 may cause the staples to be deployed from a staple cartridge into tissue captured by the end effector 1940 and/or the cutting edge of the I-beam element to be advanced to cut the captured tissue, for example.
  • the I-beam element may be retracted by reversing the direction of the motor 602.
  • the system 600 may include a closure motor 603.
  • the closure motor 603 may be operably coupled to a closure motor drive assembly 605 which can be configured to transmit closure motions, generated by the motor 603 to the end effector 1940, in particular to displace a closure tube to close an anvil and compress tissue between the anvil and the staple cartridge.
  • the closure motions may cause the end effector 1940 to transition from an open configuration to an approximated configuration to grasp tissue, for example.
  • the end effector 1940 may be transitioned to an open position by reversing the direction of the motor 603.
  • the system 600 may include one or more articulation motors 606a, 606b, for example.
  • the motors 606a, 606b may be operably coupled to respective articulation motor drive assemblies 608a, 608b, which can be configured to transmit articulation motions generated by the motors 606a, 606b to the end effector.
  • the articulation motions may cause the end effector to articulate relative to a shaft, for example.
  • the system 600 may include a plurality of motors which may be configured to perform various independent functions.
  • the plurality of motors of the surgical instrument or tool can be individually or separately activated to perform one or more functions while the other motors remain inactive.
  • the articulation motors 606a, 606b can be activated to cause the end effector to be articulated while the firing motor 602 remains inactive.
  • the firing motor 602 can be activated to fire the plurality of staples, and/or to advance the cutting edge, while the articulation motor 606 remains inactive.
  • the closure motor 603 may be activated simultaneously with the firing motor 602 to cause the closure tube and the I-beam element to advance distally as described in more detail hereinbelow.
  • the system 600 may include a common control module 610 which can be employed with a plurality of motors of the surgical instrument or tool.
  • the common control module 610 may accommodate one of the plurality of motors at a time.
  • the common control module 610 can be couplable to and separable from the plurality of motors of the robotic surgical instrument individually.
  • a plurality of the motors of the surgical instrument or tool may share one or more common control modules such as the common control module 610.
  • a plurality of motors of the surgical instrument or tool can be individually and selectively engaged with the common control module 610.
  • the common control module 610 can be selectively switched from interfacing with one of a plurality of motors of the surgical instrument or tool to interfacing with another one of the plurality of motors of the surgical instrument or tool.
  • the common control module 610 can be selectively switched between operable engagement with the articulation motors 606a, 606b and operable engagement with either the firing motor 602 or the closure motor 603.
  • a switch 614 can be moved or transitioned between a plurality of positions and/or states.
  • the switch 614 may electrically couple the common control module 610 to the firing motor 602; in a second position 617, the switch 614 may electrically couple the common control module 610 to the closure motor 603; in a third position 618a, the switch 614 may electrically couple the common control module 610 to the first articulation motor 606a; and in a fourth position 618b, the switch 614 may electrically couple the common control module 610 to the second articulation motor 606b, for example.
  • separate common control modules 610 can be electrically coupled to the firing motor 602, the closure motor 603, and the articulations motor 606a, 606b at the same time.
  • the switch 614 may be a mechanical switch, an electromechanical switch, a solid- state switch, or any suitable switching mechanism.
  • Each of the motors 602, 603, 606a, 606b may comprise a torque sensor to measure the output torque on the shaft of the motor.
  • the force on an end effector may be sensed in any conventional manner, such as by force sensors on the outer sides of the jaws or by a torque sensor for the motor actuating the jaws.
  • the common control module 610 may comprise a motor driver 626 which may comprise one or more H-Bridge FETs.
  • the motor driver 626 may modulate the power transmitted from a power source 628 to a motor coupled to the common control module 610 based on input from a microcontroller 620 (the “controller”), for example.
  • the microcontroller 620 can be employed to determine the current drawn by the motor, for example, while the motor is coupled to the common control module 610, as described above.
  • the processor 622 may control the motor driver 626 to control the position, direction of rotation, and/or velocity of a motor that is coupled to the common control module 610. In certain instances, the processor 622 can signal the motor driver 626 to stop and/or disable a motor that is coupled to the common control module 610.
  • the memory 624 may include program instructions for controlling each of the motors of the surgical instrument 600 that are couplable to the common control module 610.
  • the memory 624 may include program instructions for controlling the firing motor 602, the closure motor 603, and the articulation motors 606a, 606b.
  • Such program instructions may cause the processor 622 to control the firing, closure, and articulation functions in accordance with inputs from algorithms or control programs of the surgical instrument or tool.
  • one or more mechanisms and/or sensors such as, for example, sensors 630 can be employed to alert the processor 622 to the program instructions that should be used in a particular setting.
  • the sensors 630 may alert the processor 622 to use the program instructions associated with firing, closing, and articulating the end effector.
  • the sensors 630 may comprise position sensors which can be employed to sense the position of the switch 614, for example.
  • the processor 622 may use the program instructions associated with firing the I-beam of the end effector upon detecting, through the sensors 630 for example, that the switch 614 is in the first position 616; the processor 622 may use the program instructions associated with closing the anvil upon detecting, through the sensors 630 for example, that the switch 614 is in the second position 617; and the processor 622 may use the program instructions associated with articulating the end effector upon detecting, through the sensors 630 for example, that the switch 614 is in the third or fourth position 618a, 618b.
  • one or more mechanical outputs of a motor system including a motor and a drive train connected to the motor can be used as an input to a motor control circuit which controls the motor to increase the efficiency of the motor system.
  • the drive train includes a closure member coupled to a motor configured to clamp tissue with an end effector.
  • the drive train includes a firing member coupled to a motor configured to move a firing member through a firing stroke.
  • the firing stroke includes a staple firing stroke.
  • the firing stroke includes a portion of which where the firing member clamps tissue with jaws of the end effector and another portion of which where the firing member deploys staples from the end effector to staple and cut the tissue clamped with the end effector.
  • Mechanical outputs of the motor can include any suitable mechanical output.
  • mechanical outputs may include the actual speed of the motor, the actual displacement of the motor (measured with an encoder, for example), and/or the amount of elapsed time the motor runs.
  • mechanical outputs may include heat generated by the motor and/or forces generated with the drive train, for example. Such outputs can be measured in any suitable fashion directly and/or indirectly.
  • a motor system including a motor and a drive train connected to the motor may be underutilized (the motor speed can be increased without fear of overstraining the motor system, for example), over utilized (the motor is running at a speed which may be close to, or is already, overstraining the motor system, for example), and/or adequately utilized (the motor is running at a speed where the motor system is not overstrained nor is there room for a speed increase of the motor, for example).
  • the motor system is operating below maximum, or optimal, capacity, motor system is operating at maximum capacity, and/or the motor system is operating beyond its maximum capacity.
  • adjustments can be made by a motor control circuit so as to increase the efficiency of the motor system, for example.
  • Such adjustments can include dynamic adjustments of the motor.
  • the adjustments include dynamic control of the speed of the motor.
  • Overstraining the motor system may include running a motor at a duty cycle outside of a threshold duty cycle range which may cause a motor to fail sooner than expected, for example.
  • the capacity of the motor system can be measured to determine the degree of utilization of the motor system.
  • Duty cycles of pulse width modulation (PWM) motor control can differ in width percentage and magnitude, for example.
  • a motor control circuit is configured to interrogate and/or determine the relative capacity of a motor system.
  • interrogation of the relative capacity of the motor system includes monitoring a parameter of one or more components of the drive train and/or the motor.
  • the relative capacity of the motor system may be monitored at any suitable time, for example.
  • the relative capacity of the motor system is automatically monitored prior to a clamping stroke, during the clamping stroke, after the clamping stroke but before a staple firing stroke, during the staple firing stroke, near an end of the staple firing stroke, and/or after the end of the staple firing stroke.
  • interrogation of the relative capacity of the motor system is manually initiated by a user of the instrument.
  • Relative capacity of the motor system can be also be referred to as the unused, or available, capacity of the motor and/or motor system relative to a maximum capacity, for example.
  • Adjustments of the motor system can be made by a motor control circuit at any suitable time. For example, adjustments of the motor system can be made simultaneously, and/or at least substantially simultaneously, when the motor system is interrogated and the relative capacity of the motor system is determined. Interrogation of the motor system may be referred to as the interrogation action, a sensory action, and/or a micro-step. These actions can also be referred to as steps such as, for example, interrogation steps and/or sensory steps. In at least one instance, adjustments of the motor system can be made after a predetermined set time interval measured from the time of the interrogation action and/or after the completion of the interrogation action, for example.
  • the relative capacity of a motor system is repeatedly monitored, and/or measured, over a period of time at a desired frequency. Further to the above, adjustments can be made to the motor system based on the measured relative capacity. Such adjustments can be made with the same and/or different frequency as the frequency at which the relative capacity of the motor system is measured. Each frequency can be adjusted automatically and/or manually to better suit different scenarios, for example. For example, the frequency at which the relative capacity of a motor system which clamps a jaw of an end effector is measured may be higher than the frequency at which a motor system which deploys a firing member or vice versa.
  • the frequency at which the relative capacity of a motor system which deploys a firing member is monitored is higher than the corresponding frequency at which adjustments are made to the same motor system.
  • Such an arrangement can increase the stability of the motor system during the staple firing stroke, for example.
  • Various types of adjustments can be made upon determining the relative capacity of the motor system. For example, the motor system can be paused, a lockout can be activated, the motor can be slowed down, the motor can be sped up, the speed of the motor can be kept the same, and/or another interrogation action can be performed to verify the previously determined relative capacity.
  • the speed of the motor is increased incrementally at a frequency in an effort to maximize the operational efficiency of the motor system, for example.
  • the relative capacity of the motor system is determined by measuring an actual mechanical output of the motor system such as, for example, the actual speed of the motor.
  • the actual speed of the motor can be used to determine if the motor system is operating at a predicted, or anticipated, state in response to each incremental increase in motor speed. For example, if the actual speed of the motor is as anticipated after an incremental speed increase is made to the motor, it may be determined that the motor system is operating at or below its maximum, or optimal, capacity. In such an instance, the speed of the motor is, again, increased incrementally and the relative capacity of the motor system is, again, determined. After one or more incremental speed increases, the actual speed of the motor may be not as anticipated and it may be determined that the motor system is operating beyond its maximum capacity. In such an instance, a variety of things can happen, discussed in greater detail below.
  • the motor system can be adjusted in any suitable manner, and/or no adjustments are made to the motor system.
  • the speed of the motor is reduced back to its previous speed. For example, if the motor undergoes five incremental speed increases from a starting speed and at the fifth incremental speed increase it is determined that the motor system is operating beyond its maximum capacity, the speed of the motor can be reverted back to the speed set for the fourth incremental speed increase. In at least one instance, the reversion speed is equal to the speed set for the fourth incremental speed increase.
  • the reversion speed is a percentage of the speed set for the fourth incremental speed increase so as to not operate the motor system near its maximum capacity, but, operate the motor system a percentage below maximum capacity.
  • Such an arrangement may increase the longevity of the motor system, for example, by rarely operating the motor system at its maximum capacity.
  • the maximum capacity is predefined below an actual maximum capacity, such as absolute mechanical capacity, for example, of the motor system.
  • the actual maximum capacity of the motor system may be manufacturer-suggested, for instance.
  • the incremental speed increases are not noticeable, or imperceptible, to a user.
  • imperceptibility can be measured by vibration yield of the surgical instrument system, for example, being below a predefined perceptible threshold, for example.
  • a time period with which a speed increase is executed is below a perceptible time threshold so as to reduce the likelihood of a user noticing the speed increase.
  • the frequency at which the speed is increased is high but the magnitude of each incremental speed increase is low compared to the actual speed of the motor.
  • the motor system is capable of constantly adjusting the speed of the motor to improve efficiency and/or maintain maximum efficiency, for example, while not effecting the user’s experience.
  • Such an arrangement may prevent jerkiness of a system which increases the speed of a motor substantially during a staple firing stroke, for example.
  • a delay is employed so as to not immediately reinitiate the interrogation of the motor system. In at least one instance, a delay is not employed and the motor system is constantly interrogated regardless of the adjustments made to the motor.
  • Interrogating the relative capacity of the motor system may also be referred to as sensing the relative capacity of the motor system. One or more sensory actions can be performed to determine when the speed of the motor can be increased, for example.
  • FIG. 15 is a graph 13000 depicting an example of a sensory action 13004 performed in order to determine if the speed of the motor is capable of being increased.
  • the target speed 13001 is increased at the beginning of the stroke 13003 (position 0) to a first target, or set, speed.
  • the measured speed 13002 increases until the motor reaches a first measured speed.
  • the first measured speed is as anticipated and thus a sensory action can be performed.
  • the first target speed and the first measured speed may or may not be identical.
  • the speed of the motor is increased a predetermined amount to a second target speed.
  • the measured speed 13002 gradually increases to a second measured speed.
  • the measured, or actual, speed 13002 may vary due to a variety of factors such as, for example, motor performance, type of tissue encountered, and/or drive train backlash.
  • the second target speed is maintained to run the motor at the second target speed. It may be determined that additional, or excess, capacity was, in fact, present based on the difference, or magnitude of deviation, between the actual measured speed of the motor relative to the second target speed. In at least one instance, the target speed may be reverted back to the first target speed if excess capacity is not available.
  • a sensory action leads into a permanent action where a final, or optimal, speed is set by a control circuit.
  • the increase in speed of the motor performed during the interrogation action of the motor system is maintained for the rest of a stroke or, in the case where a target speed, or predetermined percentage of the target speed, is not attained upon the performance of the sensory action, it is determined that additional capacity is not available and the speed of the motor is reverted back to the speed at which the motor was operating prior to the speed increase.
  • FIG. 16 is a graph 13010 depicting different staple firing strokes 13011 , 13012, and 13013 and the results of interrogating a motor system performing the different staple firing strokes 13011 , 13012, and 13013 in an effort to determine the relative capacity of the motor system.
  • Closure load (the load experienced by clamping the jaws) and stroke position (the position of the firing member throughout the closure stroke and firing stroke) are also depicted.
  • the force required to fire a firing member for example, is also depicted for each staple firing stroke 13011 , 13012, and 13013.
  • the initial force to fire for stroke 13011 is F0
  • the initial force to fire for stroke 13012 is F1
  • the initial force to fire for stroke 13013 is F2.
  • various events corresponding to a surgical stapling instrument are also illustrated on the graph 13010: the clamping time period (with a partial clamp indicator Tpc and a fully clamp indicator Tfc), the pre-fire, or pause, time period, and the fire time period.
  • the actual speed, or velocity, of the i-beam, or firing member for example is depicted for each staple firing stroke 13011 , 13012, and 13013 as well as the target speed 13020 utilized in the sensory action for each firing stroke.
  • the target speed 13020 increases from zero to V0 in the beginning of the firing stroke by a motor control circuit, for example.
  • Speed V0 can be used to apply full clamping pressure to the jaws of an end effector with an i-beam, for example.
  • a sensory action is performed by the motor control circuit and an attempt is made to increase the speed of the motor to V1 for each staple firing stroke 13011 , 13012, and 13013.
  • the force to fire is relatively low and, thus, the actual speed 13021 of the motor remains at or within an acceptable percentage of the target speed of V1.
  • the actual speed 13021 is measured and, once it is determined that the actual speed 13021 of the motor is at or within the acceptable percentage of the target speed of V1 , a motor control circuit maintains the target speed of V1 through the rest of the staple firing stroke 13011.
  • the actual speed of the motor remains within an acceptable level relative to the target speed V1 .
  • the actual speed of the staple firing stroke 13012 is represented as being identical to the actual speed 13021.
  • the motor control circuit maintains the target speed of V1 through the rest of the staple firing stroke 13012.
  • the actual speed 13023 of the motor is not able to achieve the target speed of V1 nor is the actual speed 13023 of the motor able to achieve a speed within the acceptable percentage of the target speed of V1.
  • the motor control circuit reverts the target speed of the motor back to target speed V0 after a time period t2.
  • the motor control circuit reverts the target speed of the motor back to a predetermined percentage of target speed V0 and/or a predetermined magnitude of speed above and/or below the target speed V0.
  • the magnitude of the adjustment is based on the magnitude of the deviation between the actual measured speed and the target speed.
  • the sensory action performed during the staple firing strokes 13011 , 13012, and 13013 includes a time period of t2.
  • target speed V1 may be held at V1 for the time period t2.
  • the time period t2 may be any suitable time period.
  • the sensory action occurs before, or prior to, a reaction, or permanent action, for example.
  • the speed of the motor is increased, the relative capacity of the motor system is determined, the speed of the motor is reverted back to its original speed and, later during the staple firing stroke, the speed of the motor is increased in response to the determined relative capacity of the motor system attained during the sensory action.
  • a plurality of sensory actions are performed prior to a reaction.
  • FIG. 17 is a graph 13040 depicts actual speed 13042 of a staple firing stroke relative to a target speed 13041 of the staple firing stroke. The relative capacity of the motor system is interrogated during interrogation actions 13043.
  • the interrogation actions 13043 occur prior to a reaction, or optimized action, 13044.
  • the interrogation actions 13043 each include an increase in motor speed.
  • the interrogation actions 13043 include different target speeds.
  • the target speed of subsequent interrogation actions 13043 is set based on the response, or determined relative capacity, of the motor system during previous interrogation actions 13043.
  • the target speed is increased after the completion of one or more interrogation actions during the reaction, or optimized action, 13044.
  • a period of time elapses after the last interrogation action 13043 before the target speed of the motor is increased during the reaction action 13044.
  • a user is alerted prior to a reaction, or optimized action, being performed. For example, a user may be notified through a user interface that the motor system is operating below maximum capacity after a motor control circuit performs one or more unnoticeable interrogation actions. A user may then be able to select whether or not to perform a recommended reaction and/or modify the recommended reaction, for example.
  • FIG. 18 is a graph 13050 depicting a target speed 13051 and an actual speed 13052 of a staple firing stroke including an interrogation action 13053 and a reaction 13054.
  • the speed of the motor is increased to a first target speed from a first current speed during the interrogation action 13053.
  • a reaction 13054 takes place where, upon determining that the relative capacity of the motor system is not near, at, or above maximum capacity during the interrogation action 13053, the speed of the motor is increased to a second target speed which is greater than the first target speed.
  • the ratio of the first target speed and second target speed is predefined.
  • the target speed of the interrogation action may include between about 10% and 90% of the target speed of the reaction, for example.
  • the target speed of the interrogation action may include half of, a quarter of, and/or a third of the target speed of the reaction, for example. Any suitable ratio can be utilized.
  • the target speed of the interrogation action is greater than the target speed of the reaction.
  • FIG. 19 is a graph 13060 depicting a staple firing stroke 13061 of a motor system undergoing a plurality of interrogation actions.
  • Closure load the load experienced by clamping the jaws
  • stroke position the position of the firing member throughout the closure stroke and firing stroke
  • the force required to fire a firing member is also depicted for the staple firing stroke 13061.
  • the actual, or response, speed, or velocity 13065, of the i-beam, or firing member for example is depicted for the staple firing stroke 13061 as well as the target speed 13063.
  • a plurality of sensory actions are performed targeting speed V1 , V2, and V3.
  • Target speed V1 is interrogated for time t2
  • target speed V2 is interrogated for time t4
  • target speed V3 is interrogated for time t6.
  • the time periods t2, t4, and t6 are different. In at least one instance, the time periods of each sensory action are identical. As can be seen in graph 13060, the times t2, t4, and t6 get gradually longer for each subsequent sensory action. As can be also be seen in graph 13060, the magnitude of each target speed increase gradually increases for each subsequent sensory action. During the staple firing stroke 13061 , the actual speed 13065 of the motor is within an acceptable level relative to the target speed 13063 for each sensory action. As can be seen in FIG.
  • the control circuit determines that the motor system can be run at the target speeds V1, V2, and V3 with the load. In at least one instance, however, the actual speed may vary if the load increases and, as a result, the motor system may not achieve the target speeds V1 , V2, and/or V3. In at least one instance, the target speed V3 is a final, optimal, speed set by the control circuit as a result of achieving target speeds V1 and M2.
  • the time period at which a target speed is maintained for each sensory action doubles for each subsequent sensory action.
  • the magnitude of the target speed for each sensory action is identical until the target speed can be achieved.
  • the speed of the motor is permanently set at the target speed and a new target speed is set for subsequent sensory actions until the new target speed can be achieved.
  • the collection of target speeds selected for sensory actions during a staple firing stroke can be referred to as a target speed profile.
  • the target speed profile can be preselected for different types of instruments and/or predefined by a user.
  • a surgical stapling instrument with a 60mm cartridge may include a first target speed profile while a surgical stapling instrument with a 45mm cartridge may include a second target speed profile which is different than the first target speed profile.
  • one surgical stapling instrument may require sensory actions which include target speeds having a greater magnitude than another surgical stapling instrument to increase operating efficiency of each corresponding motor.
  • a motor of one system designed to operate at a higher speed as compared to a motor of a second system designed to operate at a lower speed may require sensory actions with target speeds having greater magnitude than the second system to have more effective reactions during a staple firing stroke, for example.
  • the time period of each sensory action includes a length which is imperceptible to a user during use of a surgical stapling instrument, for example.
  • the magnitude of the target speed of each sensory action includes a magnitude which is imperceptible to a user during use of a surgical stapling instrument, for example.
  • FIG. 20 is a graph 13070 depicting a target speed 13071 and an actual speed 13072 of a staple firing stroke including an interrogation action 13073 and a reaction 13074.
  • the speed of the motor is increased to a first interrogation target speed during the interrogation action 13073.
  • a reaction 13074 takes place where, upon determining that the relative capacity of the motor system is not near, at, or above maximum capacity during the interrogation action by comparing an interrogation response speed to the first interrogation target speed, the speed of the motor is increased to a second reaction target speed which is greater than the first interrogation target speed.
  • a time period 13075 is set to alert a user, for example, that a reaction is about to take place. Because the first interrogation target speed was achieved, or at least an acceptable percentage of the first interrogation target speed was achieved, during the interrogation action 13073, the motor control circuit alerts a user that a condition has been met to set a reaction, or permanent action, within the time period 13075.
  • the time period 13075 includes audibly alerting a user at the beginning of the time period 13075 and, at the end of the time period 13075, the reaction 13074 is initiated (the motor is set to the second reaction target speed).
  • a sensory action involves a motor control circuit setting a sensory, or interrogation, target speed for a motor to achieve.
  • any suitable variable of the motor system can be set.
  • displacement of a firing member is set and measured.
  • a target displacement may be set and actual displacement measured and compared to the target displacement to determine if the motor system is below, near, at, and/or above maximum capacity.
  • motor current, motor voltage, motor duty cycle, and/or motor displacement are used to set a target variable and compare a measured, or response, variable against the target variable.
  • FIG. 21 is a graph 13080 depicting a target speed 13081 and an actual speed 13082 of a staple firing stroke including a plurality of incremental interrogation actions 13083 and a reaction, or functional action, 13084.
  • the graph 13080 also illustrates the set duty cycle 13085 of a pulse width modulation circuit of the motor during the staple firing stroke.
  • the set duty cycle incrementally increases 13086 during the sensory, or interrogation, actions 13083 and the set duty cycle is increased substantially 13087 during the reaction 13084.
  • the duty cycle may be incrementally increased at any suitable rate at any suitable magnitude.
  • the rate of change of the duty cycle and/or the magnitude of the duty cycle changes is based on the length of the interrogation actions, the length of the staple firing stroke, and/or the desired speed of the staple firing stroke.
  • the delta between each set duty cycle is small enough to be imperceptible to a user during a staple firing stroke.
  • an incremental increase of 5% is made to the duty cycle during each interrogation action and an increase to 95% is made during the reaction.
  • the incremental increase includes increasing the duty cycle between about 1 % and about 10%, for example.
  • the increase made to the duty cycle during the reaction includes increasing the duty cycle a predefined percentage (between about 25% and about 50%, for example). In at least one instance, the increase made to the duty cycle during the reaction includes increasing the duty cycle to a maximum percentage such as, for example, about 85%, about 90%, about 95%, and/or about 99%.
  • type, thickness, and/or toughness of tissue, force to fire a firing member during a staple firing stroke, and/or system losses can be the deciding factor for determining whether or not the motor system can handle a substantive speed increase during either a subsequent interrogation action and/or a reaction.
  • thicker tissue may cause higher forces to fire which may place the motor system at, near, and/or above its maximum capacity.
  • Thinner tissue may cause lower forces to fire which may place the motor system well below its maximum capacity.
  • the magnitude of the set variable of the reaction can be substantially increased to reflect the increased relative capacity of the motor system.
  • the relative capacity of the motor system can be determined in any suitable manner.
  • the relative capacity of the motor system can be determined by monitoring a relationship between a set target variable and the corresponding actual measured variable during either an interrogation action and/or a reaction.
  • a first target speed is set and the corresponding actual speed is measured.
  • This speed can be measured at the motor output (the speed of the output shaft) and/or within the end effector (the speed of the firing member, knife and/or sled, for example).
  • the actual speed of the motor output shaft as well as the actual speed of the firing member within the end effector are compared and averaged.
  • the actual speed of the motor output shaft for example, is compared to the set first target speed.
  • the difference in target speed and actual measured speed can reflect relative capacity of the motor system.
  • a 10% difference in speed indicates that the motor system is not at full capacity (and/or anywhere between about 5% and about 95%, for example).
  • the 10% difference may be a result of system losses such as heat and/or backlash, for example. If the difference in target speed and actual measured speed is 15% (greater difference than at 10%), this may indicate less relative capacity of the motor system is available. If the difference in target speed and actual measured speed is near or at about 100%, this may indicate that the motor system is near, at, or beyond maximum capacity.
  • a threshold magnitude is set by a user, automatically set by a control circuit, or predetermined for one or more sensory actions and/or one or more reactions.
  • the threshold magnitudes for the sensory actions and/or the reactions are tuned based on the type of instrument, a length of the staple cartridge, the size of the staples in the staple cartridge, the type of tissue being incised and stapled, and/or the articulated position of the end effector.
  • firing shafts are flexible and traverse an articulation joint into the end effector. In such an instance, the firing shaft may experience increased load when the end effector is in an articulated position such as, for example, a fully articulated position.
  • the threshold magnitude of a target variable for the sensory actions and/or the reactions can be reduced so as to prevent overstraining the motor system more quickly.
  • a control circuit monitors the articulation position based on inputs from one or more sensors.
  • the control circuit may select the threshold magnitude of a target variable for the sensory actions and/or the reactions based on the inputs from the one or more sensor that are indicative of the articulation position.
  • the threshold magnitude of the target parameter (such as target speed, for example) for one or more sensory actions when the end effector is in an articulated position so as to reach optimal efficiency at a similar rate at which optimal efficiency is attained while the end effector is in its straight configuration.
  • more torque may be required to drive a flexible firing member, for example, through an articulation joint when the end effector is articulated and, thus, through a staple firing stroke.
  • a control circuit can determine that, notwithstanding any other variable, more motor capacity is going to be used to deploy the firing member through a staple firing stroke when the end effector is in an articulated position.
  • the control circuit can automatically reduce the target speed, for example, when the end effector is articulated relative to a target speed at which the control circuit would set for an end effector in a straight configuration in an effort to reduce one or more failed sensory actions.
  • the duration of the sensory actions may be tuned based on the type of instrument, a length of the staple cartridge, the size of the staples in the staple cartridge, the type of tissue being incised and stapled, and/or the articulated position of the end effector, for example.
  • a maximum time threshold is set for the duration of the sensory actions.
  • a minimum time threshold is set for the initiation of a reaction, or functional action. For example, a request for an increase in speed of the motor, by a user or automatically by a motor control circuit, can be made at which point a timer is set so as to prevent a reaction from occurring until the timer has concluded. In at least one instance, a reaction including a further increase of speed is delayed until the timer has concluded. In at least one instance, a reaction including a decrease in speed is delayed until the timer has concluded.
  • a sensory action is performed on a motor system by a motor control circuit during pre-compression.
  • pre-compression is referred to as the time after the tissue is initially clamped but before the beginning of the staple firing stroke where additional clamping load may be applied to the tissue.
  • the I- beam within an end effector is configured to travel a predefined amount of distance prior to the beginning of the firing stroke (such as, for example, prior to contacting an unfired sled and/or a lockout) and after the tissue is initially clamped.
  • the firing and clamping functions may be actuated independently with separate and distinct drive systems.
  • the firing and clamping functions may be actuated with a single firing drive member. Pre-compression may be present in each of these arrangements. In at least one instance, pre-compression is defined as the time, or distance, between partially clamping tissue and fully clamping tissue.
  • one or more sensory actions may be performed to determine a speed at which to deploy the firing member through the staple firing stroke.
  • the firing member is driven forward, reversed, and forward again one or more times within the predefined amount of distance so as to continuously monitor the relative capacity of the motor system prior to beginning the staple firing stroke, for example.
  • the number of times the firing member is driven forward and reversed to perform the one or more sensory actions is dependent on the tissue clamped within the end effector.
  • the tissue clamped within the end effector can require time to settle and/or stabilize, for example.
  • the firing member is repeatedly cycled through a forward and reverse cycle until the tissue is stabilized.
  • This initial movement of the firing member prior to contacting the sled may provide an arrangement which is capable of assessing initial firing loads to be expected during the staple firing stroke.
  • the length, time, and/or speed of this initial movement in addition to the sensory actions and/or reactions occurring within the initial movement of the firing member may be selected, set, and/or defined so as to be imperceptible to a user.
  • FIG. 22 is a logic flow chart depicting a process 13210 executable by a control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, for controlling the motor of a motor system of a surgical instrument system such as those disclosed herein.
  • the control circuit is configured to initiate 13211 a firing speed interrogation sequence of a firing member within a pre-compression zone.
  • the control circuit is configured to perform 13212 one or more sensory actions within the pre-compression zone. During the one or more sensory actions, the control circuit is configured to monitor 13213 one or more response parameters of the motor system.
  • the control circuit is configured to reverse 13214 the firing member to a home position.
  • the control circuit is configured to perform 13215 one or more additional sensory actions within the pre-compression zone. During the one or more additional sensory actions, the control circuit is configured to monitor 13216 one or more response parameters of the motor system.
  • the firing speed interrogation sequence occurs one or more times such as, for example, 3, 5, and/or about 10 times, for example. In at least one instance, the firing speed interrogation sequence occurs a predetermined number of times before a firing speed is selected for a subsequent staple firing stroke. Nonetheless, the control circuit is configured to select 13217 a firing speed profile based on the monitored parameters of the cyclical sensory actions performed within the precompression zone. In at least one instance, the firing speed interrogation sequence occurs within a clamping zone of the firing member and/or after clamping but before firing any staples, for example.
  • cycling the firing member in the manner discussed above during the pre-compression stage can also help identify and understand the process of the tissue stabilization. For example, if relatively thick tissue is clamped, a firing member cycled during the pre-compression stage in the manner discussed herein may reveal that the motor system is near, at, and/or above maximum, or optimal, capacity prior to firing, for example, indicating that relatively thick tissue has been clamped and/or indicating that the relatively thick tissue clamped within the end effector is taking longer than expected to stabilize. Adjustments can be made to various parameters of the motor system based on information gleaned from the initial movement of the firing member during the pre-compression stage.
  • the parameters and variables of the sensory actions and/or the reactions can be tuned based on the detection of the thick tissue during the pre-compression stage, for example.
  • the information gleaned from the initial movement of the firing member during the pre-compression stage can also be used to decide how long to allow the tissue to stabilize. Referring to FIG. 22, the information is gleaned from monitoring 13213 and monitoring 13216 one or more parameters of the motor system during the sensory actions and the additional sensory actions, for example.
  • an imperceptible sensory, or interrogation, action is skipped and reactions, or functional actions, are performed to determine if there exists excess capacity within the motor system.
  • the speed of the motor can be increased a perceptible amount. Similar to the sensory actions discussed above, a motor control circuit can determine if the perceptible increased speed is achieved or not achieved by measuring the actual speed attained in response to the perceptible speed increase. In at least one instance, a functional action configured to increase the speed of the motor until it is determined that the target speed cannot be realized is terminated once it is determined that the target speed cannot be realized. For example, the functional action may gradually increase the speed of the motor in a stepped and/or continuous fashion until the actual speed of the motor deviates from the target speed below a differential threshold.
  • sensory actions and/or functional actions are performed throughout an entire staple firing stroke in an effort to maintain optimal operational efficiency of the motor system.
  • the speed of a firing motor may be slowed down and sped up constantly while the relative capacity of the motor system is constantly monitored and evaluated.
  • a limited number of sensory actions and/or functional actions are performed.
  • the limited number is set by a user and/or a motor control program, for example. The limited number may be based on the age of the instrument and/or the motor system, the type of the instrument, the function of which the motor system actuates, or any suitable parameter, for example.
  • FIG. 23 is a graph 13090 illustrating a clamping stroke and a firing stroke of a surgical instrument system.
  • the clamping and firing strokes are performed by separate drive members.
  • the clamping and firing stroke are performed by a single drive member.
  • a force-to-fire 13091 is depicted for the staple firing stroke.
  • the target speed 13093 and actual speed 13092 of the firing member during the staple firing stroke are also depicted.
  • the PWM signal, 13094 of the motor is also illustrated. As can be seen in the graph 13090, the PWM signal 13094 is incrementally increased 13095, by increasing the duty cycle, for example.
  • sensory actions are also performed during retraction of a firing member through an end effector.
  • Such an arrangement can provide a quicker retraction stroke without increasing the speed of the motor to, or beyond, its maximum, or optimal, capabilities, which could cause instability in a motor system.
  • FIG. 24 is a graph 13100 depicting a target speed 13101 and an actual speed 13102 of a staple firing stroke of a motor system including a plurality of discrete interrogation actions 13103.
  • each interrogation action 13103 includes an identical magnitude of change such as, for example, an identical increase in speed.
  • the step size can increase linearly among the discrete interrogations. In other instances, the step size can vary among the discrete interrogations.
  • the plurality of discrete interrogations 13103 includes a final interrogation action 13104.
  • the speed of the motor is increased incrementally during each interrogation action 13103.
  • a motor control circuit reverts the speed of the motor back to the target speed of the previous interrogation action 13103.
  • the motor control circuit determines that a response is not realized where the difference between the actual speed 13102 and the set target speed is beyond a predetermined threshold.
  • FIG. 25 is a graph 13110 depicting a target speed 13111 and an actual speed 13112 of a staple firing stroke of a motor system including a plurality of discrete interrogation actions 13113.
  • the magnitude of each interrogation action 13113 decreases with each subsequent action. For example, the increase in speed of the motor for each subsequent interrogation action 13113 decreases.
  • the decrease in magnitude of each interrogation action 13113 corresponds to the determination of the relative capacity of the motor system through the actual speed, or response profile, 13112 relative to the target speed, or target profile, 13111.
  • the rate at which the magnitude of each interrogation action 13113 decreases is selected by a motor control circuit based on the rate of deviation of the actual speed 13112 relative to the target speed 13111.
  • the plurality of discrete interrogation actions 13113 includes a final action 13114. At the final action 13114, the target speed 13111 is not realized and, thus, the motor control circuit reverts the speed of the motor back to the target speed of the previous interrogation action 13113.
  • FIG. 26 is a graph 13120 depicting a target speed 13121 and an actual speed 13123 of a staple firing stroke of a motor system including a target profile including a logarithmic increase in a control metric of the firing stroke such as, for example, a speed or PWM, and a response action 13124.
  • Logarithmically increasing the control metric, e.g. PWM or speed, of the motor may reduce overshoot, for example.
  • the target speed 13121 is held constant for a period of time following the logarithmic interrogation.
  • a motor control circuit can hold the target speed 13121 constant upon determining a threshold deviation between the target speed 13121 and the actual speed 13123 has been reached.
  • the period of time may provide the motor system time to settle or overcome an unexpected section of tissue, for example, thus giving the actual speed 13123 time to settle.
  • the actual speed 13123 never recovers and the response action 13124 is initiated.
  • the actual speed 13123 recovers to at least a certain degree and the motor system reinitiates interrogation of the motor system and continues to increase the speed of the motor.
  • the target speed 13121 is reduced a predefined amount and/or reverted back to a previous target speed threshold.
  • the magnitude of the reduction of speed at the response action 13124 is based on the magnitude of deviation between the target speed 13121 and the actual speed 13123.
  • logarithmically increasing the speed of the motor to interrogate the relative capacity of the motor system can increase efficiency and reduce the amount of deviation between actual speed and target speed.
  • FIG. 27 is a graph 13130 illustrating a clamping stroke and a firing stroke of a surgical instrument system.
  • the clamping and firing strokes are performed by separate drive members.
  • the clamping and firing stroke are performed by a single drive member.
  • a force-to-fire is depicted for the staple firing stroke, as well as the closure stroke and the closure load.
  • Three different scenarios are illustrated for interrogating the motor system which drives the firing member. In scenario one, a percentage PWM signal of the motor is increased in discrete linear steps 13132 including an identical magnitude speed increase for each step resulting in a linearly increasing firing member velocity 13131.
  • the percentage PWM signal of the motor is increased in discrete steps 13134; however, the magnitude of each speed increase decreases with each subsequent step resulting in a logarithmically increasing firing member velocity 13133.
  • the percentage PWM signal of the motor is increased logarithmically 13136 resulting in a logarithmically increasing firing member velocity 13135.
  • FIG. 28 is a graph 13140 depicting a primary sensory metric 13141 and a secondary sensory metric 13142.
  • the primary sensory metric 13141 is similar to that of others disclosed herein.
  • the primary sensory metric 13141 involves incrementally increasing the target speed of the motor, monitoring the actual speed of the motor and, upon detecting that the actual speed of the motor deviates from the target speed beyond a predetermined threshold percentage, for example, the motor control circuit reverts the speed of the motor back to a target speed of a prior successful sensory action.
  • the motor control circuit selects a new target speed based on the failed sensory action which is different than the target speed of the prior successful sensory action and, rather, based on the rate at which the motor deviated from the target speed over time, for example.
  • the secondary sensory metric 13142 is used by the motor control circuit as a redundancy, for example, to reinforce the detected output of the primary sensory metric 13141 .
  • a PWM percentage signal 13143 of the motor can be monitored and, upon determining that the PWM percentage signal 13143 exceeds 13145 a predetermined threshold 13144, the motor control circuit determines that the motor system is at or above capacity. In such an instance, this determination coincides with the determination made within the primary sensory metric 13141.
  • the PWM percentage signal 13143 is attained by converting one or more analog output parameters such as motor speed, for example, to a digital PWM signal.
  • FIG. 29 is a graph 13160 of an example staple firing stroke performed by a motor system illustrating target speed 13161 , actual speed 13162, and pulse width modulation signal 13163 of a motor of the motor system.
  • the motor system performs sensory actions, or interrogation actions, 13164 in an attempt to increase the speed of the motor within a capacity limit of the motor system.
  • the sensory actions 13164 end when the actual speed 13162 deviates from the target speed 1361 beyond a predetermined threshold, for example.
  • the pulse width modulation signal 13163 is increased in an attempt to maintain motor speed through a thick section of tissue, for example. After traversing the thick section of tissue, the PWM signal 13163 is reduced causing a reduction 13165 in speed 13162.
  • a time delay and/or a lockout period may be instituted by the motor system to prevent the motor system from initiating additional sensory actions, for example. After the time delay and/or the lockout period, the motor system may resume interrogating the relative capacity of the motor system in an effort to achieve an optimal efficiency speed.
  • Such an arrangement may allow for locally optimal speed throughout the length of a staple firing stroke, for example.
  • a cutting member may encounter a thicker section of tissue but only for a certain length of the staple firing stroke.
  • the tissue may be thinner after the thicker section and, thus, capacity for increasing the speed of the firing stroke may increase after the cutting member passes the thicker section of tissue.
  • the motor system can reinitiate an interrogation sequence in an effort to maximize the speed of the motor along the entire length of the staple firing stroke.
  • interrogation sequences initiated after a lockout or time delay is employed may vary in length of time and magnitude as compared to interrogation sequences which occurred prior to the lockout or time delay.
  • FIG. 30 is a graph 13170 of a staple firing stroke performed by a motor system including a motor and a firing member configured to be actuated by the motor.
  • the closure load and closure stroke are illustrated.
  • the force to fire 13171 the firing member is also illustrated.
  • the force to fire the firing member increases 13172 between t1 , t2, t3, and t4 and decreases 13173 at t4.
  • the actual speed 13176 of the firing member as well as the target speed 13175 of the firing member are also depicted. In at least one instance, the actual speed includes the actual speed of the motor. Further to the above, the PWM percentage 13177 is also depicted.
  • the relative capacity of the motor system is interrogated by increasing the PWM percentage 13177 in discrete steps 13178 in an effort to achieve a set speed.
  • the set speed is achieved at t2.
  • the actual speed 13176 of the firing member does not deviate from the target speed 13175.
  • the PWM percentage 13177 remains unchanged and the actual speed 13176 begins to deviate from the target speed 13175.
  • the motor system tries to compensate to re-attain the set speed by sharply increasing the PWM percentage 13177.
  • the PWM percentage 13177 is unchanged 13179 between t2 and t3 because the actual speed 13176 started to deviate from the target speed 13175.
  • the force to fire 13171 the firing member increases between t2 and t3 which may cause the deviation between the actual speed 13176 and the target speed 13175.
  • the increase in the force to fire can be due to a change in tissue thickness.
  • a functional action 13180 is taken by the motor control circuit where the PWM percentage 13177 is sharply increased in an effort to increase the speed 13176 of the motor and/or firing member, for example, back to the previously attained set target speed.
  • the speed 13176 of the firing member increases and, while the speed 13176 has not attained the new target speed 13175 of V2, the firing member has reattained and surpassed the previously attained set speed.
  • not being able to attain the new speed of M2 is a result of yet another increase in firing force 13171 experienced by the firing member between t3 and t4.
  • the PWM percentage 13177 is slightly reduced 13181 (not reverted back to the PWM percentage 13177 utilized between t2 and t3) to achieve optimal efficiency and maintain the optimal speed.
  • the PWM percentage is reduced and can be triggered by the reduction in force to fire at t4.
  • the actual speed 13176 and the target speed 13175 are equal or at least do not deviate beyond a threshold deviation, for example.
  • the PWM percentage 13177 is held constant until the end of the staple firing stroke.
  • the set speed is modified during the staple firing stroke based on the response of the motor system to the sharp increase in duty cycle.
  • the set speed is decreased after the sharp increase in duty cycle.
  • the set speed is increased after the sharp increase in duty cycle.
  • one or more predetermined shifting thresholds are utilized during a sensory action.
  • a relative capacity of the motor system can be defined as a quantifiable amount. For example, it may be determined that the motor system is operating at 50% capacity and has 50% available capacity.
  • a first predetermined shifting threshold can be set at a first percentage of available capacity, for example, to set a threshold for determining that a target speed which is greater than an current speed can be set.
  • the system performs another sensory action and, if there still exists the first percentage of available capacity or more, the speed of the motor is increased again.
  • an additional predetermined shifting threshold is set to determine when to shift the speed of the motor to a decreased new speed. For example, 5% available capacity can be set as a second predetermined shifting threshold. Thus, when 5% available capacity or less is detected, the motor control circuit can reduce the speed of the motor to the decreased new speed. As discussed herein, the percent deviation from the threshold values can be utilized to determine the magnitude of the new speeds. For example, if there exists 75% relative capacity in a system with a 25% first predetermined shifting threshold, the relatively large availability in capacity can cause the motor control circuit to increase the magnitude of the motor speed increase accordingly.
  • 0% capacity exists and/or the motor system is beyond maximum capacity (0%, for example)
  • a large magnitude of speed decrease can be utilized to more appropriately adjust the motor toward an optimum operating speed, for example, in response to being at or beyond maximum motor capacity.
  • FIG. 31 is a graph 13180 of an example staple firing stroke performed by a motor system illustrating target speed 13181 and actual speed 13182.
  • the motor control circuit is configured to reduce the speed of the motor upon determining that a threshold deviation between the actual speed 13182 and the target speed 13181 is detected.
  • the rate at which the deviation between the actual speed 13182 and the target speed 13181 increases and/or decreases is monitored and, upon reaching a rate of change threshold (e.g. the actual speed 13182 is falling too quickly relative to the target speed 13181), speed adjustments are made through one or more reactions.
  • the motor system initiates 13191 the firing sequence and sets the target speed 13181 to a first target speed.
  • the motor system then performs a sensory action 13192 by increasing the target speed 13181 of the motor to a second target speed for a specific time period during which the actual speed 13182 and/or percent deviation between the actual speed 13182 and second target speed is monitored.
  • a sensory action 13192 by increasing the target speed 13181 of the motor to a second target speed for a specific time period during which the actual speed 13182 and/or percent deviation between the actual speed 13182 and second target speed is monitored.
  • a reduction reaction 13194 is initiated.
  • the actual speed 13182 gradually decreases 13193 after the second target speed is attempted.
  • the rate at which the actual speed 13182 decreases can trigger the reduction reaction.
  • the motor system reduces the target speed 13181 of the motor to one or more new reduced target speeds relative to the second target speed.
  • the target speed of the motor is reduced in steps. At such point, additional monitoring of the actual speed relative to the new target speeds can be performed so as to analyze the effect of the reduction reactions on the relative capacity of the motor and determine whether or not further adjustments are necessary.
  • FIG. 32 is a logic flow chart depicting a process 13200 executable by a control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, configured to interrogate a motor system to determine whether or not excess capacity exists, for example, within the motor system during a firing sequence of a drive train. In this instance, the control circuit controls a firing sequence.
  • a control circuit such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, configured to interrogate a motor system to determine whether or not excess capacity exists, for example, within the motor system during a firing sequence of a drive train.
  • the control circuit controls a firing sequence.
  • the control circuit initiates 13201 the firing sequence, increases 13202 the target speed of the motor to a first target speed for a time period, measures 13203 the actual speed of the motor during the time period, compares 13204 the measured actual speed to the first target speed, determines 13205 the relative capacity of the motor system based on the comparison 13204, and sets 13206 a new speed based on the determined 13205 relative capacity. In at least one instance, the new speed is equal to the first target speed.
  • a motor control circuit can perform the interrogation actions and/or reactions during a closure stroke and/or a firing stroke.
  • the motor control circuit can also measure the speed of the motor in response to the increase in target speed during any suitable time period.
  • the time period of each interrogation, or sensory, action may be predetermined and/or preselected.
  • the time period of each interrogation action may vary from one interrogation action to the next. Comparing the target speed to the actual speed can involve analyzing the percent deviation between the target speed and the actual speed. In at least one instance, a fixed threshold speed is utilized to determine whether or not to perform additional interrogation actions or set a new speed.
  • a pause can be utilized between interrogation actions. In at least one instance, no pause is utilized.
  • a pause may include a time period during which no interrogation actions are performed.
  • a pause may include a pause in motion of a firing member, for example, between interrogation actions.
  • the motor system automatically interrogates the relative capacity of the motor system during an entire stroke of the drive train in an effort to maximum the efficiency of the motor system throughout the entire stroke. In such an instance, a series of speed increases and decreases can occur throughout the stroke.
  • the control circuits disclosed herein can employ any of the steps and/or actions disclosed herein.
  • the processes can be performed by any suitable components such as those disclosed in FIGS. 13 and 14.
  • the processes disclosed herein can be performed utilizing any suitable drive train such as those disclosed herein in FIGS. 1-12, for example.
  • the processes executable by a control circuit may include any suitable additional steps and/or actions, eliminate one or more steps and/or actions, and/or modify one or more of the steps and/or actions according to any of the scenarios discussed herein.
  • a motor control circuit can be configured to perform any combination of and any number of sensory actions, interrogation actions, and/or functional actions, among others in an effort to control the speed, for example, of a motor of a motor system during a drive stroke of a drive train of the motor system.
  • these actions can be referred to as speed control actions.
  • speed is one variable capable of being controlled, adjusted, and/or monitored during these actions, any suitable variable can be used such as those disclosed herein, for example.
  • the outcome of each of these actions can be utilized to modify future actions and/or trigger other events, as discussed in greater detail below.
  • Functional actions may be automatically triggered by one or more events and/or manually triggered by a user.
  • a user may manually trigger a speed increase during a drive stroke at which point a motor control circuit can be configured to increase the target speed of the motor and determine if the target speed can be and/or is achieved.
  • Reactions to the manual increase in speed can include any suitable reactions such as those disclosed herein.
  • further speed adaptations and/or speed control actions can be halted if one or more conditions are satisfied as a result of one or more previous actions.
  • the outcomes, or results, of the previous actions can be constantly monitored.
  • the outcomes, or results include whether or not the target speed of the previous action was achieved or the target speed was not achieved. Not achieving the target speed can be considered a failed action, for example.
  • the outcome, or result includes whether or not the target speed of the previous action was achieved within a predefined deviation percentage, and/or the magnitude of failure and/or success of the previous action.
  • further actions can be halted temporarily and/or permanently, for example.
  • further actions to automatically control the speed of a motor can be automatically and/or manually re-activated.
  • further actions are automatically reactivated when a new firing stroke is initiated, for example.
  • a motor control circuit can be configured to prevent further speed control actions from occurring whether triggered automatically and/or manually for a predetermined time period. In at least one instance, the motor control circuit is configured to prevent further speed control actions from occurring automatically but not manually or from occurring manually but not automatically. [0190] Prevention of further speed control actions, or motor control adjustment actions, from occurring can protect from oscillation and/or hysteresis, for example, where without a pause, or lockout time period, after a previous action, a motor control circuit can incidentally perform undesirable adjustments based on a default control algorithm, for example.
  • a motor control circuit is configured to lockout any adjustment action from occurring during a lockout time period after a failed action occurs (a target speed was not achieved, for example).
  • FIG. 33 depicts a graph 16000 depicting an example firing stroke performed by a motor control circuit of a motor system where target speed 16001 and actual monitored speed 16002 are illustrated. As can be seen in the graph 16000, the motor control circuit performs a sensory, or functional, action 16003 attempting to increase the speed of the motor to a new target speed 16001. The actual speed 16002 is monitored and it is determined that there is not capacity to run the motor system at the new target speed. The target speed 16001 is reverted back to the speed prior to the new target speed.
  • the success of the sensory action can be referred to the actual speed reaching a desired percentage of the new target speed, for example.
  • a failure of the sensory action can be referred to the actual speed not reaching a desired percentage of the new target speed.
  • a successful sensory action indicates that there exists excess capacity to permit the motor system to run at the new target speed.
  • a failed sensory action indicates there does not exist excess capacity to run the motor system at the new target speed.
  • the motor control circuit employs a lockout time period 16004 configured to prevent any subsequent actions from occurring during the lockout time period 16004.
  • the lockout time period 16004 is predefined.
  • the magnitude of the lockout time period depends on one or more variables of the outcome of the previous failed sensory action. For example, if the magnitude of the previous sensory action fails by a large margin, the lockout time period may be longer as compared to if the sensory action fails by a smaller margin. The magnitude of the failure can be measured in percent deviation as discussed herein. Deviation thresholds can be utilized to determine the length of the lockout time period. After the lockout time period, one or more additional actions 16005 can be performed.
  • the number of additional actions which can be performed and/or the magnitude of the additional actions which can be performed is limited based on the failed sensory action where, if no failed sensory action occurred, additional actions may not be limited in any way. In at least one instance, additional actions are not limited regardless of the occurrence of a failed sensory action, for example.
  • the length of the timeout, or lockout time period depends on a current speed of the motor.
  • the magnitude of the current speed of the motor can be used to determine the magnitude of the lockout time period.
  • a faster speed triggers a longer timeout period whereas a slower speed triggers a shorter lockout time period.
  • a faster speed triggers a shorter timeout period and a slower speed triggers a longer lockout time.
  • the success status of one or more previous speed control actions triggers different length timeout periods.
  • a lockout period may be employed during a drive stroke for a successful speed control action and an unsuccessful, or failed, speed control action. In such an instance, the lockout time period may be shorter for the successful speed control action as compared to the lockout time for failed speed control action.
  • a prevention, or lockout time period can prevent inadvertent reshifting immediately after the motor control circuit intentionally performs a functional action. For example, a user can choose to increase the speed of a motor from a first speed to a second speed. The motor control circuit may determine that the second speed was not achieved. However, instead of reverting back to the first speed, the motor control circuit can employ a lockout time period as result of the manual input change of speed so as not to automatically undo the speed change desired by the user, for example. In at least one instance, the motor control circuit is configured to undo the user desired speed change regardless of the fact that the user manually inputted the speed change. In at least one instance, further intentional manual speed change inputs are prohibited during the lockout time period.
  • a motor control circuit is configured to disable automatic speed control after a predetermined number of lockout time periods are triggered during a firing stroke. Such an arrangement can prevent a motor system from continuously being adjusted when a certain adjustment constantly results in a failed action.
  • a lockout distance period is employed by a motor control circuit.
  • the motor control circuit is configured to prevent any speed control action from occurring during a predefined distance of a drive stroke.
  • the motor control circuit can prevent any speed control actions, or adjustments, from occurring for the following 10mm after the previous failed action is complete.
  • the magnitude of the lockout distance may vary based on the magnitude of the failed action, for example. For example, if the actual speed of the motor deviates from the target speed above a threshold deviation percentage, the lockout distance can be set at a first distance. If the actual speed of the motor deviates from the target speed below a threshold deviation percentage but still fails, the lockout distance can be set at a second distance which is less than the first distance. In at least one instance, the second distance is half of the first distance.
  • speed adjustment actions are prohibited from occurring prior to the staple firing stroke.
  • speed adjustment actions are prohibited from occurring between an unfired position of a firing member and a defeated lockout position of the firing member.
  • the defeated lockout position may be the position at and/or just after the firing member has passed a lockout of a surgical stapling instrument such as, for example, a no cartridge lockout and/or a spent cartridge lockout.
  • speed adjustments are prohibited from occurring when the firing member is positioned within a zone immediately preceding an end of the staple firing stroke and/or the end of the staple cartridge.
  • Firing members discussed herein may refer to any suitable component such as, for example, any combination of an I-beam of a firing shaft and/or any portion thereof, a sled configured to eject staples from a staple cartridge and/or any portion thereof, a firing shaft and/or any portion thereof, a firing rod and/or any portion thereof, and/or any portion of a firing drive train.
  • the average actual speed monitored during the time period of the sensory, functional, and/or interrogation action can be utilized to determine if the target speed is achieved or not achieved.
  • the maximum actual speed monitored during the time period of the sensory, functional, and/or interrogation action can be utilized to determine if the target speed is achieved or not achieved.
  • the minimum actual speed monitored during the time period of the sensory, functional, and/or interrogation action can be utilized to determine if the target speed is achieved or not achieved.
  • any combination of the aforementioned metrics can be utilized to determine if the target speed is achieved or not achieved.
  • Predetermined deviation percentages can be stored in a memory and can be accessed when determining if the target speed is achieved or not achieved. Predetermined deviation percentages can change for different types, such as length and/or staple height, for example, of staple cartridges being fired.
  • a motor control circuit is configured to halt, or prohibit, motor control parameter adjustments (such as PID controller parameters, for example) during the lockout time periods and/or lockout distance. In at least one instance, PID controller parameter adjustments could be frozen for a period of time which is the same as or different than the predefined lockout time period.
  • the thresholds and/or conditions required to be met by the motor control circuit to change one or more of the PID controller parameters during a drive stroke can be widened or softened, for example, to minimize the number of noticeable, or perceptible, re-adjustments of speed after a failed action. For example, a greater error may be required in order to trigger an adjustment of one or more PID controller parameters after a failed action than an error required in order to trigger an adjustment prior to the failed action.
  • the motor control circuit is configured to learn over time and adjust future speed control actions of future drive strokes according to previous drive stroke data.
  • certain outputs monitored during a drive stroke can be utilized to identify opportunities to update feedforward network weights.
  • the network weights can include thresholds. The thresholds can indicate an out of bounds condition.
  • a motor control circuit is configured to revert the motor system back to a last known good state. This can be triggered by a failed action, for example.
  • the last known good state includes a state where the motor system was running adequately and not near and/or at full capacity.
  • a motor control circuit is configured to perform speed control actions during firing member advancement and/or firing member retraction.
  • a motor control circuit is configured to alter a speed control algorithm in response to a cumulative sequence of events and/or triggers, for example.
  • a predetermined number of failed actions have to occur, failed actions have to occur at a predetermined frequency, and/or a predetermined plurality of failed actions have to fail by a certain percentage before the motor control circuit reacts. Any suitable reaction can occur such as those disclosed herein.
  • parameters of further actions can be adjusted, lockout time periods and/or lockout zones can be employed, PID motor controller parameters can be adjusted etc.
  • both a sequence of events must occur in addition to a predetermined single event to cause the motor control circuit to react.
  • Such an arrangement can provide greater situation-specific control of a motor system during a firing stroke.
  • a predetermined plurality of sensory actions may fail. While this alone will not trigger further action, this in combination with a single event such as, for example, a single sensory action fails below a certain threshold, may trigger a cool down period or a pause.
  • the sequence of failed actions in addition to the larger failed action may indicate that the motor was struggling to perform the firing stroke to begin with and, at the detection of the larger failed action, indicated to the motor control circuit that the motor may have been overheating and/or operating beyond its maximum, or optimal, capacity.
  • the automatic activation of a cool down period can allow tissue to relax as well as the motor to cool down, for example.
  • a motor control circuit is configured to utilize events of previous firings of an instrument to adjust and/or alter speed control algorithms of a subsequent firing.
  • a first cartridge may be used with an instrument and, during the firing of the first cartridge, data collected about the outcomes of various speed control actions, for example, performed during the firing stroke of the first cartridge.
  • the motor control circuit can then be configured to adjust one or more parameters of the firing stroke of a second cartridge to be fired based on the data collected about the outcomes of the various speed control actions performed during firing of the first cartridge.
  • Such an arrangement can allow a motor control circuit of a specific motor system to be more efficiently operated between multiple different staple cartridges by monitoring events of each cartridge firing and optimizing each subsequent firing based on the performance of previous firings.
  • a motor control circuit utilizing data from multiple different firings as discussed herein is discussed below.
  • a motor system of a surgical instrument fires two different staple cartridges.
  • the motor control circuit detects an irregularity in the firing stroke. In at least one instance, there is a speed discrepancy detected at the 50mm mark. In at least one instance, there is a displacement discrepancy detected between the motor and the firing member at the 50mm mark.
  • the motor control circuit is configured to adjust any subsequent firing of another staple cartridge to increase the speed of the motor prior to the 50mm mark such as, for example, at the 45mm mark.
  • the motor control circuit is configured to perform a speed burst at and/or near the 50mm mark. In at least one instance, the motor control circuit is configured to pulse an additional burst of power to the motor just before the 50mm mark and only for a short period of time. In at least one instance, the motor control circuit is configured to adjust a speed control algorithm of subsequent firings in an effort to maintain a constant speed through the 50mm mark and eliminate the irregular stroke. Such a configuration can overcome recurring stroke irregularities between firings which may distract a user, cause abnormal cutting of tissue, and/or unpredictable staple formation.
  • a predetermined level of repeatability threshold must be met before speed control adjustments are made to subsequent firing strokes.
  • a motor control circuit can determine a stroke irregularity, or anomaly, at a 30mm mark during both an advancement stroke and a retraction stroke. This may indicate a location where interfacing components (such as I-beam and channel and/or anvil, for example) have a tighter interference. Such a tighter interference can be caused by tissue ingress and/or a manufacturing anomaly, for example, which are increasing forces to fire at this location. Because of this stroke irregularity, staple formation and/or tissue cutting may not be as predictable.
  • a motor control circuit adjusts parameters for all subsequent strokes at this location to reduce the force to fire at this location in an effort to more predictably form staples and/or cut tissue, for example.
  • the adjusted parameters could be reverted back to normal after passing this location; either during advancement and/or during retraction, for example.
  • the motor control circuit is configured to anticipate the previously detected stroke irregularity during subsequent strokes by adjusting parameters of subsequent strokes to specifically look for the stroke irregularity but not taking any action unless the newly monitored irregularity is detected.
  • spikes in force are monitored and associated with stroke irregularities.
  • a sequence of stroke irregularities are detectable and acted upon to adjust motor control of a drive stroke.
  • a motor control circuit can detect a plurality of force spikes within the motor system each time a staple leg contacts an anvil to be formed. In at least one instance, this initial contact can cause the largest spike in the motor system within the staple formation process which can be detectable and stand out in a plurality of force spikes of a firing stroke. This spike can be detected by the motor control circuit as being the highest peak force during the formation of each staple each of which include a known location relative to the firing stroke.
  • the motor control circuit can perform one or more speed control actions to reduce the spike in force for each leg-anvil contact event.
  • the spike exceeding a threshold during initial leg-anvil contact could indicate that the leg is not hitting the anvil in an anticipated and/or desired location.
  • Such a spike could indicate that tissue is being bunched up by the knife and pushing the staple legs distally relative to the anvil causing the tips of the staples to miss target pocket locations and, as a result, increasing the force to fire the staples and, also, causing staple malformation, for example.
  • Reducing the speed of the motor to increase the likelihood of the tips of the staples contacting their intended target location can reduce the force to fire and increase the likelihood of proper staple formation.
  • a motor control circuit is configured to monitor the number of failed/successful speed control actions and, once a predetermined number of failed/successful speed control actions occur, adjust a magnitude of subsequent speed control actions. For example, a motor control circuit can place a limit on target speeds of subsequent speed control actions when a predetermined number of failed actions occur. In at least one instance, a user can try to increase the speed of the motor by a certain amount; however, the motor control circuit can set a target speed threshold which cannot be surpassed automatically and/or manually, for example.
  • the motor control circuit can automatically adjust the actual target speed down to the threshold target speed and attempt to increase the speed of the motor to the threshold target speed.
  • such a configuration can prevent a user and/or a motor control circuit from increasing the speed of an already struggling motor beyond a certain threshold based on a plurality of previously failed speed increase actions, for example.
  • the limit threshold target speed can be removed, or lifted.
  • the limit threshold target speed cannot be lifted and/or removed until a new staple cartridge is installed and/or a new firing stroke is performed.
  • the limit threshold target speed is never lifted for that surgical instrument.
  • a motor control circuit is configured to monitor a pattern of outcomes of speed control actions and based on the pattern, make adjustments to one or more future speed control actions based on the monitored pattern. For example, during a first firing, a plurality of failed actions can occur. If the degree of failure increases for each subsequent failed action to correspond to a predetermined pattern of increased failure, the motor control circuit can detect the predetermined pattern of increased failure and adjust subsequent firings accordingly. In at least one instance, magnitudes and/or frequency of speed control actions of subsequent firings are adjusted. In at least one instance, the motor control circuit is configured to place a limit on the number of subsequent firings permitted of the surgical instrument based on the detected predetermined pattern of increased failure.
  • a lockout time period is employed and the magnitude, or length, of the lockout time period can be increased based on the detected predetermined pattern of increased failure.
  • Such a configuration can provide an amount of time for the motor system to reduce its power use and/or mechanical energy burden.
  • a motor control circuit is configured to adjust the frequency of subsequent sensory actions based on detecting a predetermined, cumulative, amount of sensory action failures. For example, after detecting the predetermined amount of sensory action failures, the motor control circuit can reduce the frequency at which speed control adjustments are automatically and/or manually made for the rest of the firing and/or subsequent firings. In at least one instance, the motor control circuit is configured to adjust the definition of a failed action for subsequent firings or the rest of a firing based on detecting a predetermined, cumulative, amount of sensory action failures. For example, the motor control circuit can increase the threshold required to be considered a successful sensory action, for example. [0211] FIG.
  • the motor control circuit is configured to perform 16011 a first sensory action.
  • the first sensory action is performed during a staple firing stroke.
  • the sensory action may be manually initiated and/or automatically initiated.
  • the sensory action is performed in an attempt to increase the speed of the motor.
  • the motor control circuit is configured to monitor 16012 the result of the first sensory action.
  • the monitored result can include any suitable outcome, or response, of the surgical system as a result of the first sensory action.
  • the monitored result includes a success status of the first sensory action and/or a percent deviation between a target speed relative to an actual speed of the motor, for example.
  • the motor control circuit is further configured to adjust, or modify, 16013 a parameter of a subsequent sensory action based on the monitored result of the first sensory action. Any suitable parameter can be adjusted such as, for example, the timing of the subsequent sensory action (length of the action, when the action occurs relative to the stroke, etc.), the target of the subsequent sensory action (target speed, target displacement, etc.), and/or the existence of the subsequent sensory action (perform the subsequent sensory action vs. do not perform the subsequent sensory action).
  • the motor control circuit is further configured to perform 16014 the subsequent sensory action with the adjusted parameter. In at least one instance, the subsequent sensory action is performed during the current stroke. In at least one instance, the subsequent sensory action is performed during a subsequent stroke of the surgical instrument system.
  • FIG. 35 is a logic flow chart depicting a process 16020 executable by a motor control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, for use in a surgical instrument system such as those described herein.
  • the motor control circuit is configured to actuate 16021 a firing member through a first staple firing stroke, perform 16022 a first sensory action during the first staple firing stroke, and monitor 16023 a result of the first sensory action.
  • the motor control circuit is further configured to actuate 16024 the firing member through a second staple firing stroke, adjust 16025 a parameter of a second sensory action based on the monitored result of the first sensory action, and actuate 16026 the firing member through the second staple firing stroke.
  • the motor control circuit is further configured to perform 16027 the subsequent sensory action with the adjusted parameter during the second staple firing stroke.
  • FIG. 36 is a logic flow chart depicting a process 16030 executable by a motor control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, for use in a surgical instrument system such as those described herein.
  • the motor control circuit is configured to actuate 16031 a firing member through a firing stroke, perform 16032 a plurality of first sensory actions during the firing stroke, and monitor 16033 a success status of each of the first sensory actions.
  • the motor control circuit is further configured to adjust 16034 one or more parameters of one or more subsequent sensory actions based on the monitored success status of each of the first sensory actions. In at least one instance, adjustments are based on how many previous sensory actions failed as compared to succeeded.
  • the control circuit is further configured to adjust the parameter according to a first adjustment profile upon monitoring a threshold number of successful first sensory actions. In at least one instance, the threshold number can be automatically determined and/or manually set.
  • a motor control circuit is utilized to control a motor of a motor system including a drive train such as, for example, a firing drive train.
  • the motor control circuit is operable within a set of adjustable parameters.
  • the motor control circuit may set a minimum speed threshold at a first speed and a maximum speed threshold at a second speed which is greater than the first speed to begin a staple firing stroke.
  • These threshold speeds can be adjusted and/or fine-tuned during the staple firing stroke of the motor system to optimize operation of the motor system and/or maximize the efficiency of the motor system within a single drive stroke in real-time.
  • adjusting the adjustable parameters during the staple firing stroke can account, mitigate, and/or compensate for things like drive train backlash and/or heat loss within the motor, for example.
  • the magnitude of the adjustment made to these threshold speeds can be based on a variety of factors. For instance, any suitable parameter or combination of parameters of the motor system can be monitored. In such an instance, a new threshold speed can be determined based on the magnitude of the monitored parameter and/or the rate at which the monitored parameter changes over a period time, for example. In at least one instance, multiple monitored parameters are compared and analyzed to determine an appropriate adjustment to the adjustable parameters.
  • a maximum motor current limit is set by a motor control circuit to limit the amount of current drawn by the motor to a predetermined threshold current.
  • the predetermined threshold current can be changed in different portions of a drive stroke such as, for example, a staple firing stroke.
  • a first portion of the stroke can include a first threshold current limit and a second portion of the stroke can include a second threshold current limit which is different than the first threshold current limit.
  • a lower current limit threshold is utilized in the beginning of a drive stroke where a drive member may encounter a lockout condition so as to prevent a relative large amount of current draw during a lockout condition which is detectable based on a small uptick in current and, thus does not need large amounts of current that can unnecessarily overstress the system, for example.
  • Such an arrangement may provide some protection to the drive train through the beginning of a firing stroke.
  • a threshold current limit for the retraction stroke of a drive member is set relatively high as compared to a threshold current limit set for an advancement part of the stroke so as to ensure the motor can retract the drive member, even if the threshold current limit was met during the advancement part of the stroke.
  • FIG. 37 is a graph 14000 depicting various parameters of a motor control algorithm executable by a control circuit of a staple firing stroke.
  • the graph 14000 illustrates motor torque limits 14001 and motor current limits 14002 during various stages of use of a surgical instrument system.
  • the torque limits 14001 and current limits 14002 vary through different portions of the drive stroke.
  • the torque limit 14001 and the current limit 14002 peak during the staple firing stroke portion of the drive stroke.
  • the limits 14001 , 14002 can be adjusted during the drive stroke based on at least one monitored parameter and at a variety of different times throughout the drive stroke to fine-tune the limits 14001 , 14002 in real time during the drive stroke.
  • duty cycle ranges of pulse width modulation (PWM) motor control are set by a motor control circuit.
  • the motor duty cycle ranges are adjusted during a drive stroke based on one or more monitored parameters.
  • FIG. 38 illustrates a plurality of motor duty cycles 14010.
  • a motor control circuit employs a 25% minimum duty cycle 14013 so that the motor runs with at least a 25% duty cycle and the motor control circuit employs a 75% optimal duty cycle 14012 so that the motor does not run beyond a 75% duty cycle.
  • An optimal duty cycle 14011 may include 50%, for example.
  • the motor control circuit is configured to base any speed adjustments based on the optimal duty cycle 14011 . Adjustment of PWM duty cycles as disclosed herein can be referred to as PWM speed control.
  • a motor performance curve of the motor is utilized to determine an optimal duty cycle range.
  • the motor performance curve of the motor is utilized to set a maximum duty cycle threshold and a minimum duty cycle threshold.
  • the motor performance curve can be used to determine the most efficient range of duty cycles.
  • the minimum duty cycle limit is set based on frictional losses and/or inertial properties of the drive train in an effort to eliminate jerkiness, oscillation, and/or vibration of the motor system.
  • the maximum duty cycle limit is set based on heat generation of the motor. Further to the above, an older motor may generate more heat over time.
  • the maximum duty cycle limit is adjusted for the increased heat generation owing to the age and/or overall life of the motor, or motor performance degradation over time, for example. Setting the maximum duty cycle limit in such a manner can consistently minimize heat generation in the motor between strokes and/or even during a single stroke, for example.
  • an ideal range of duty cycle limits includes a maximum duty cycle limit of about 85% and a minimum duty cycle limit of about 25%.
  • a maximum range of duty limit includes a maximum duty cycle limit of about 90% and a minimum duty cycle limit of about 10%.
  • a motor stall condition is set and, once detected, a control circuit can turn off the motor after a predetermined amount of non-moving torque application. For example, if the firing member encounters a piece of tissue which is so thick that the firing member stops moving, the predetermined amount of non-moving torque can be exceeded, which causes the control circuit to cause the motor to shut down reducing inadvertent heat generation upon meeting the motor stall condition.
  • motor duty cycle and/or displacement are used to adapt and/or select target motor speeds. For example, a decreased target motor speed may be triggered in an instance where the motor duty cycle is relatively high in percentage and/or magnitude in an attempt to reduce the percentage and/or magnitude of the motor duty cycle. Similarly, an increased target speed may be triggered in an instance where the motor duty cycle is relatively low in percentage and/or magnitude in attempt to increase the utilization of the motor system, for example.
  • FIG. 39 depicts a control process 14020 configured to utilize both monitored duty cycle 14021 and monitored motor speed and/or firing member speed, for example, 14022 as inputs for adjusting the speed of the motor during a drive stroke, for example.
  • the higher the duty cycle utilization is (for example, close to maximum, or optimal, capacity, for example) when a target velocity and/or target displacement, for example, is not achieved the higher the magnitude of the speed decrease adjustment will be in an effort to bring the motor system well within its optimal operating range in response to the missed target.
  • the magnitude of the speed increase adjustment is selected based on the determined level of utilization of the motor system.
  • a firing member is moving at 10mm/sec, for example, in thick tissue and is succeeding in meeting its displacement and/or speed target(s), for example.
  • the firing member then encounters a calcified portion of extra thick tissue and misses one or more displacement targets, for example.
  • the motor control circuit determines that the motor should be slowed down to allow the tissue to relax, settle, loosen, and/or creep in front of the firing member such as, for example, the cutting knife. In other words, slowing the firing member down relieves some of the load on the firing member applied by a tight, bunched up portion, for example, of extra thick portion of tissue.
  • the duty cycle is also already at nearly 100% when the displacement target was missed indicating that the motor system may have been already been nearly missing its displacement targets prior to the actual detection of the missed displacement target.
  • the system can then slow the firing member down 150% of its target speed of 10mm/sec, for example.
  • the motor control circuit determines to slow down the firing member to 5.5mm/sec (150% of the original 3mm/sec anticipated slow down action - 4.5%) because the motor system both missed the displacement target and the motor system was nearly at 100% utilization when the displacement target was missed.
  • a motor control circuit is configured to set target travel lengths, or displacement targets, which the firing member is expected to travel during a predetermined time period.
  • the motor control circuit utilizing a PID controller, for example, can monitor the error terms (proportional, integral, and derivative terms, for example) and uses these error terms as inputs to the motor control circuit to make adjustments to the motor control.
  • the error terms include displacement error, velocity error, and overshoot error. Any combination of these errors terms can be utilized as inputs by a motor control circuit.
  • one or more parameters are monitored during a firing stroke, for example, and are utilized as inputs into a motor control circuit including a PID controller, for example, for adjusting motor control.
  • PID controller parameters such as proportional, integral, and/or derivative, parameters are adjusted, or fine-tuned, based on one or moor monitored parameters within a motor system.
  • monitored parameters can include motor response, firing member load, speed, displacement, and/or tissue properties, for example.
  • a PID feedback control system includes a PID controller comprising a proportional element (P), an integral element (I), and a derivative element (D).
  • P proportional element
  • I integral element
  • D derivative element
  • the outputs of the P, I, D elements are summed by a summer, which provides the control variable to a process.
  • the output of the process is the process variable.
  • the summer calculates the difference between a desired set point and a measured process variable.
  • the PID controller continuously calculates an error value (e.g., difference between closure force threshold and measured closure force) as the difference between a desired set point (e.g., closure force threshold) and a measured process variable (e.g., velocity and direction of closure tube) and applies a correction based on the proportional, integral, and derivative terms calculated by the proportional element (P), integral element (I), and derivative element (D), respectively.
  • the PID controller attempts to minimize the error e(t) over time by adjustment of the control variable (e.g., velocity and direction of the closure tube).
  • the “P” element accounts for present values of the error. For example, if the error is large and positive, the control output will also be large and positive.
  • the error term is the difference between a reference, or target, speed, for example and an actual output speed.
  • the “I” element accounts for past values of the error. For example, if the actual speed does not achieve the target speed over a period of time, the integral of the error will accumulate over time, and the controller will respond by applying a stronger action.
  • the “D” element accounts for possible future trends of the error, based on its current rate of change.
  • Fine tuning the PID controller parameters can provide greater motor control in a variety of scenarios.
  • the PID controller parameters can be adjusted corresponding to the type and/or thickness of tissue that is to be stapled and cut.
  • the PID controller parameters can be adjusted based on the type of cartridge installed within an end effector, size of staples within the installed cartridge, and/or length of the installed cartridge, for example.
  • an expected compressive clamping load pressure owing to clamped tissue within a predefined tissue gap between the cartridge and the anvil
  • PID tuning, or control, parameters For example, if the expected compressive clamping load is exceeded during the clamping stage of the end effector, the PID controller parameters can be adjusted accordingly to compensate. Similarly, if the excepted compressive clamping load is not exceeded during the clamping stage of the end effector, the PID controller parameters can be set accordingly or, in at least one instance, not adjusted from a preset parameter profile which was set prior to clamping the tissue.
  • outcomes of anticipated stroke events can trigger one or more adjustments to the PID controller parameters.
  • portions of the stroke where anticipated impacts occur end of stroke where the firing member may ram the end of the staple cartridge, initial contact between the firing member and the sled during the beginning of the stroke, and/or engagement between the jaw camming surfaces which control a tissue gap between the jaws
  • PID control parameter adjustments For example, a load within the motor system may be detected as the firing member contacts the sled during the beginning of the stroke and, depending on the magnitude of the detected load, the PID controller parameters can be set according to the magnitude of the detected load.
  • maximum acceptable inertial impacts are set, or predetermined, and, if exceeded, PID controller parameters are adjusted and/or safety motor control algorithms are initiated, for example.
  • overshoot is monitored throughout a stroke and PID controller parameters are adjusted according to the overshoot during the stroke so as to reduce the possibility of the firing member from traveling too far and/or not far enough.
  • PID controller parameters are adjusted so the firing member of the motor system does not crash into the end of the staple cartridge and/or end effector.
  • PID controller parameters are adjusted so the firing member of the motor system does not stop prematurely before achieving its expected full firing stroke distance, for example.
  • Such an arrangement can reduce unnecessary load on the motor system and/or an unfinished staple firing stroke, for example.
  • the PID controller parameters are adjusted to place a motor of the motor system into a different efficiency band of the motor curve. Such an arrangement can reduce motor heat generation and performance degradation over time.
  • the PID controller parameters are adjusted, or modified, such as PID controller gain, for example, based on any number of variables.
  • one or more PID controller parameters are adjusted based on the activation of a no-cartridge lockout.
  • the one or more PID controller parameters are adjusted based on an accuracy of the motor.
  • motor performance may vary over time.
  • a rotary position sensor such as a cross over gear encoder, for example, may be used to measure the accuracy of the motor.
  • the gain, for example, of the PID controller can be modified according to the measured accuracy and, in at least one instance, modified to compensate for an increasing decline in accuracy, for example.
  • the one or more PID controller parameters are modified based on the position of a cutting edge. In at least one instance, the one or more PID controller parameters are modified based on the set values of the PI D parameters themselves. For example, if a PI D controller parameter is automatically adjusted beyond a threshold, for example, a new set of values may be selected for the PID controller parameters. In at least one instance, the one or more PID controller parameters are modified based on where the end of the staple firing stroke is. In at least one instance, the end of the staple firing stroke is predetermined. In at least one instance, the end of the staple firing stroke changes per use. For example, a user may not actuate a firing member through a full staple firing stroke. The actual end of the firing stroke can be utilized to adjust the gain of the PID controller.
  • the one or more PID controller parameters are adjusted based on one or more staple cartridge characteristics such as, for example, the type of cartridge installed.
  • a sensor is used to determine the color of the cartridge color and one or more PID controller parameters are adjusted to values corresponding to the detected cartridge color. For example a cartridge of a first color may require more force to fire its staples than a cartridge of a second color.
  • the one or more PID controller parameters can be adjusted to compensate for the increased force requirement, for example.
  • the one or more PID controller parameters are adjusted based on motor impedance, the variation of Kt (motor torque constant)/Ke(back EMF constant) from a nominal Kt/Ke of the motor due to self-heating, and/or demagnetization of the motor due to prolonged use in heated conditions, for example.
  • the one or more PID controller parameters are adjusted based on detected stress within the system.
  • traces are employed on a printed circuit board, or printed circuit board assembly, of a surgical instrument system to infer bending stresses within the system.
  • the printed circuit board may be positioned within a surgical instrument handle.
  • the PID controller parameters can be adjusted to compensate for the detected bending stresses, for example.
  • heat buildup within the system can be detected and one or more PID controller parameters can be adjusted accordingly.
  • output motor torque may be implicated by heat build up and, upon detecting a magnitude and/or threshold rate of heat build up that would, in turn, cause a certain threshold torque loss to be experienced, one or more PID controller parameters can be adjusted to reduce heat build up and/or compensate for loss in torque, for example.
  • PID controller parameters are adjusted based on where a firing member is within its firing stroke.
  • a motor control circuit can adjust the PID controller parameters automatically when the firing member has been deployed through two thirds of the full staple firing stroke.
  • the force increases within the last third of the staple firing stroke and, thus, the PID controller parameters can be set to compensate for the expected increase in required firing force, for example.
  • one or more PID controller parameters are adjusted based on where, longitudinally, tissue is clamped between the jaws. Tissue clamped between the jaws near the distal end may require more force to cut and staple than tissue clamped between the jaws near the proximal end, for example.
  • the one or more PID controller parameters can be adjusted accordingly.
  • system load, distal node system efficiency, and/or torsional drive shaft stiffness can be utilized to adjust the PID controller parameters.
  • one or more strain gauges are utilized to detect stress within the system.
  • one or more PID controller parameters are adjusted based on the number of firings performed by a motor system, for example. For instance, an older motor may generate more heat during firings and, thus, the PID controller parameters can be adjusted so as to account for the increased heat risk.
  • new values for PID controller parameters can be estimated by neural networks so as to anticipate the optimal value for the PID controller parameters for future firings, for example.
  • schedules are used by the motor control circuit to determine when to change the PID controller parameters. For example, after a predetermined amount of firings, the PID controller parameters can be adjusted automatically based on reaching the predetermined amount of firings.
  • previous uses of similar motors are logged and analyzed to determine PID controller parameters for a local motor system.
  • PID controller parameters are tuned to adapt during use of a motor system to increase motor efficiency and/or improve firing stroke outcomes, for example.
  • a graph 14030 is shown to describe various setpoint implications of a PID controller, for example.
  • rise time, percent overshoot, settling time, steady-state error can all be optimized, or improved, by adjusting the PID tuning parameters of a PID controller configured to control a motor of surgical instrument motor system. Adjustments can be made based on any combination of the methods and systems disclosed herein. For example, in the context of firing member displacement, automatically tuning the PID controller parameters to reduce percent overshoot (of displacement, for example) can reduce the likelihood of ramming a firing member into the end of a staple cartridge.
  • FIG. 41 is a logic flow chart depicting a process 14040 executable by a control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, herein utilizing close loop control.
  • a control circuit such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, herein utilizing close loop control.
  • feedback is generated from one or more system sensors and an input signal is adjusted to optimize motor control.
  • a first set of motor control parameters are selected 14041.
  • the motor control parameters include PID controller parameters.
  • the motor control parameters include PWM controller parameters.
  • the motor control parameters include a range of duty cycles.
  • the motor control parameters include any combination of proportional, integral, and derivative tuning parameters of the motor controller.
  • the motor control parameters may include any suitable combination of control parameters disclosed herein.
  • one or more parameters of the motor system are monitored 14043.
  • the one or more monitored parameters may include any suitable parameters such as, for example, position of the firing member, actual measured speed of the firing member, actual measured speed of the motor, and/or type of cartridge installed within the end effector.
  • the monitored parameter may include any combination of parameters disclosed herein.
  • the motor controller parameters are adjusted 14044 to a new set of motor controller parameters based on the monitored parameter(s). For example, a tighter or greater range of duty cycles is selected and/or PID tuning parameter values are adjusted. Any suitable adjustment can be made such as those disclosed herein.
  • the motor control circuit is configured to deploy a firing member through a staple firing stroke.
  • the staple firing stroke includes an active stroke portion and an inactive stroke portion, where no adjustments are made to the motor controller parameters during the inactive stroke portion and adjustments are able to be made during the active stroke portion.
  • the magnitude of the adjustment made to the motor controller parameters is based on a magnitude of the monitored parameter(s).
  • the magnitude of the adjustment made to the motor controller parameters is based on a rate at which the monitored parameter(s) changes during a portion of the staple firing stroke.
  • the new set of motor controller parameters includes a first magnitude upon detecting that the firing member, or motor, is decelerating. In such an instance, the new set of motor controller parameters includes a second magnitude which is different than the first magnitude upon detecting that the firing member, or motor, is accelerating.
  • a motor control circuit is configured to activate and/or deactivate one or more motor control circuits and/or algorithms such as those disclosed herein, for example.
  • the motor control circuit is configured to deactivate motor control adjustments during any suitable portion of a drive stroke of a motor system. For instance, motor system capacity interrogation and corresponding adjustments may be prohibited from occurring during one or more portions of the stroke of a firing member and only able to occur during one or more other portions of the stroke of the firing member. In at least one instance, motor control adjustments may only occur while the firing member is deploying staples within a staple deployment zone of the stroke.
  • only certain motor control adjustments corresponding to clamping tissue can occur during the clamping of tissue while other certain motor control adjustments corresponding to firing staples and cutting tissue can occur during the staple firing stroke.
  • the position of the firing member triggers active and/or inactive stages of motor control algorithms and circuits, such as those disclosed herein. For instance, once the firing member reaches a first position, which may be detectable in any suitable manner such as for example, with a position sensor, a first set of motor control algorithms can be activated. Similarly, when the firing member reaches a second position, a second set of motor control algorithms can be activated. Finally, when the firing member reaches a third position, real time motor control adjustments can be prohibited from being made.
  • portions of a stroke can permit PWM speed control adjustments while other portions of a stroke can prohibit PWM speed control adjustments.
  • a motor control circuit is employs PWM speed control adjustments during the clamping of tissue and the articulation of an end effector while prohibiting PWM speed control adjustments during retraction of a firing member, unclamping of tissue, and/or de-articulating an end effector to a neutral position, for example.
  • Various motor control circuits and/or algorithms disclosed herein which are configured to modify the speed of a motor of a motor system during a drive stroke may be referred to as active speed control. In various instances, active speed control is disabled for one or more reasons.
  • active speed control can be disabled due to an unforeseen event such as, for example, a detected spike in motor current.
  • the disabling of active speed control can be overridden and re-activated.
  • active speed control can be manually disabled and/or enabled by a user, for example.
  • disabling active speed control is configured to directly link a power source to the motor thereby removing any smart control of the motor.
  • PWM speed control can be deactivated and, in such an instance, the duty cycle of the motor is set to a fixed value such as, for example, 100% and no PWM motor controller adjustments are made.
  • motor control profiles are reset from stroke to stroke, patient to patient, and/or cartridge to cartridge. In at least one instance, motor control profiles are not reset.
  • motor control circuits and algorithms disclosed herein are configured to maintain a constant speed of the firing member rather than constantly change the speed of the firing member as the firing member traverse through tissue, for example.
  • a staple cartridge and/or a staple firing stroke is defined into multiple segments where certain motor control adjustments are confined to a predetermined adjustment range, for example.
  • Such a control circuit can also be used during a closure stroke of a drive shaft, for example.
  • Each segment corresponds to certain motor controller adjustments.
  • a control circuit may only be able to make a first range of adjustments to one or more motor controller parameters such as, for example, PID tuning parameters.
  • the control circuit may only be able to make a second range of adjustments to the one or more motor controller parameters.
  • the control circuit may only be able to make a third range of adjustments to the one or more motor controller parameters.
  • the range of adjustments which may be made during the first third of the staple firing stroke may include a greater range as compared to the adjustment ranges of the second third and/or the third third. This can reduce the possibility of large motor control adjustments from being made during the final stages of the staple firing stroke where a user may not want a firing member to be increasing its speed toward the end of the staple firing stroke risking crashing the firing member into the end of the staple cartridge, for example, which can cause the firing member to get stuck or jam.
  • no limits are placed on motor controller adjustments during the first third of the staple firing stroke.
  • no motor controller adjustments can be made during the final third of the staple firing stroke.
  • the segmented sections of the staple firing stroke can be separated into any desired fraction.
  • the staple firing stroke may be segmented into fourths, fifths, hundredths, for example.
  • the staple firing stroke is split into two regions.
  • the segments vary in length.
  • the segments are broken into a beginning segment, a plurality of intermediate segments, and an ending segment.
  • FIG. 42 is a graph 14050 illustrating a staple firing stroke of a motor system.
  • a control circuit divides the staple firing stroke, or the cartridge, into segments: a first third, a second third, and a third third. The control circuit increases the target speed 14051 of the motor to a safe speed to initiate firing.
  • the control circuit then increases the target speed 14051 of the motor by increasing the duty cycle to a relatively high duty cycle during the first third of the cartridge.
  • overshoot error of the actual speed 14052 is increased during rapid acceleration of the firing member.
  • the actual speed 14052 of the firing member steadies toward the end of the first third of the cartridge.
  • the target speed 14051 is brought down to another safe target speed 14051 .
  • the load 14053 during the first third of the cartridge is relatively low as compared to the other segments of the cartridge.
  • the control circuit sets the target speed 14051 and the actual speed 14052 of the firing member rises at a rate which lower than the rate of speed increase during the first third of the cartridge. This also results in less overshoot error.
  • the target speed 14051 is set and the firing member accelerates slowly to reduce overshoot within the third third of the cartridge.
  • the duty cycle of the motor decreased for each segment to reduce overshoot. High overshoot may cause damage to tissue or the firing system itself. Reducing overshoot during higher load conditions can reduce the possibility of damage to the tissue and/or the firing system.
  • the loads 14053, 14054, and 14055 are measured while the motor runs at safe speeds prior to increasing the target speed 14052 of the firing member for each segment of the cartridge.
  • the speed of the firing member is adjusted according to the magnitude of the measured load where higher loads result in lower set speeds and lower loads result in increased set speeds.
  • the speed can be increased substantially during low load conditions as there can be reduced risk to the tissue and/or firing system at high speeds with low detected loads. An increased overshoot error during higher load conditions can result in an additional unintended speed increase from a target speed where no tissue or system damage was expected at the target speed but would occur if the increased speed was achieved when overshooting the target speed.
  • PID controller parameters are adjusted automatically to reduce overshoot in higher load conditions. In lower load conditions, the PID controller parameters can be automatically adjusted to optimize speed where overshoot is not an issue. In at least one instance, a threshold of the proportional limit value of a PID controller is lowered in higher load conditions to reduce overshoot. In at least one instance, a threshold of the integral value and a threshold of the derivative value of the PID controller are lowered to reduce overshoot. In various instances, the rate at which the speed of the firing member changes is monitored to determine motor control adjustments such as, for example, PID tuning value adjustments, for the rest of the segment.
  • overshoot and/or irregular motor response may be acceptable and/or anticipated during certain portions of a firing stroke.
  • the motor control circuit can specifically tune the PID controller values accordingly.
  • a predicted amount of overshoot is acceptable during a certain portion of the firing stroke.
  • the PID controller values are adjusted accordingly.
  • the PID controller values are not adjusted at all during such portion of the firing stroke.
  • firing strokes include a predicted force to fire spike location where the force to fire increases at the spike location every time the firing member passes the spike location.
  • Such a location may include where an i-beam contacts and traverses a metal irregularity in a cartridge channel which is the result of the manufacturing process of the cartridge channel.
  • a motor control circuit is configured to not adjust PID controller values as the firing member passes the spike location.
  • the location of the firing member can be used to determine when the firing member is going to pass the spike location to prevent the motor control circuit from adjusting the motor controller parameters as the firing member passes this spike location/as a result of the spike in force to fire.
  • the motor control circuit adjusts the PID controller values at the spike location; however, the magnitude of the adjustment is lower than if the same spike in force was detected during other portions of the staple firing stroke.
  • FIG. 43 is a graph 14060 illustrating a firing stroke of a motor system.
  • Target, or set, speed 14061 , actual measured speed 14062, and firing loads 14063, 14064, and 14065 are illustrated.
  • the speed of the motor is increased at the beginning A_1 of the firing stroke.
  • overshoot concern is low and, thus, the motor control circuit sets the motor control parameters accordingly (to permit overshoot, for example).
  • the overshoot concern is low because, at this stage of the firing stroke, no tissue is being cut or stapled. Rather, the firing member moves from an unfired position A_1 to a lockout location where the firing member is either locked out from continuing or defeats the lockout. During this stage, the overshoot concern is low. Prior to reaching the lockout location, the speed 14061 is decreased. During this decrease, undershoot is not a concern and, thus, the motor control parameters are set/can be adjusted accordingly. The speed 14061 may be decreased just before the firing member reaches the lockout location to decrease the effective speed before the firing member either locks out or defeats the lockout.
  • the increased speed prior to the decrease in speed at A_2 increases the operating efficiency of the motor prior to the firing member reaching the lockout location.
  • the load 14063 during stage 1 may be known and/or predicted with acceptable accuracy such that there may be no unpredictable load increases/decreases during this stage. Because the load is predicted within this stage, the motor controller parameters can be set accordingly.
  • stage 2 begins.
  • the speed 14061 is increased because the load 14064 is unknown.
  • the load 14064 is unknown because at any point during stage 2, the firing member (or cutting member) can hit tissue.
  • overshoot is of a higher concern than of stage 1 . Overshoot when hitting tissue during this stage can cause tissue damage by applying a higher than predicted inertial force. This higher than predicted inertial force is because of the initial spike of input speed experienced (overshoot) beyond the set target speed. Because overshoot is of higher concern, the motor control parameters can be set accordingly to decrease the rate at which the speed of the firing member increases.
  • dynamic breaking can be employed by a motor control circuit to reduce overshoot.
  • actual speed is monitored and compared to the target speed and, as the actual speed approaches the target speed, the motor can be slowed or braked dynamically to reduce and/or eliminate overshoot and/or undershoot.
  • dynamic breaking is used in combination with acceleration limiting to control overshoot.
  • inertia of a motor system is monitored during a firing stroke and is used to determine acceleration limit adjustments.
  • an importance magnitude is utilized in a motor control circuit.
  • the importance magnitude is a value assigned to predetermined sections of a firing stroke, for example.
  • the value indicates the importance, or lack thereof, of reducing overshoot and/or undershoot, for example during the identified firing stroke section.
  • an importance magnitude at position B_1 can be assigned a “1” being the most important location to reduce overshoot
  • an importance magnitude at positions A_1 , A_2, and B_2 can be assigned [0258] a “2” indicating a lower importance of reducing overshoot and/or undershoot, for example.
  • the rate of change of speed can be monitored (by way of PWM duty cycle, PWM frequency, PWM amplitude (voltage)) relative to a target threshold to adjust motor control parameters to reduce and/or eliminate overshoot, for example.
  • a motor control circuit is configured to monitor the magnitude of PID deviation from an instantaneous target over time at a certain frequency and monitor the rate of change of PID deviation during the period of time to determine if the motor system is falling behind further with each subsequent target or if the motor system is accelerating closer to the target with each subsequent target. This determination can be used in conjunction with how far away from the target the actual value is at each target to dampen the acceleration/deceleration to prevent overshoot/undershoot.
  • the rate of change of speed is monitored at the initial part of each stage, cycle, or firing stroke section, and/or at the end part of each stage, cycle, or firing stroke section, for example.
  • FIG. 44 is a logic flow chart depicting a process 14070 executable by a control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, configured to control a motor of a motor system.
  • the motor control circuit is configured to monitor 14071 a position of the firing member.
  • the position of the firing member may be monitored in any suitable manner such as, for example, by a position sensor, a displacement sensor, and/or an encoder configured to measure motor rotation.
  • the motor control circuit is further configured to determine 14072 a stage of the firing stroke within which the firing member is position based on the monitored position of the firing member.
  • the motor control circuit based on the monitored position of the firing member, can determine that the firing member is within a first third of the cartridge, or first segment of three segments of the firing stroke, for example.
  • the motor control circuit is further configured to determine 14073 a corresponding importance magnitude of the determined stage as it relates to the level of concern of overshoot occurring within the determined stage.
  • the importance magnitude includes a scale including low importance, medium importance, and high importance. Low importance indicates that the occurrence of overshoot is of little concern. High importance indicates that the occurrence of overshoot is of high concern. High importance may be associated with a stage of the firing stroke where load on the firing member is high. In at least one instance, the importance magnitude is determined based on the position of the firing member.
  • load on the firing member is monitored and is used to determine the importance magnitude. Higher load on the firing member can be associated with a high level of concern of overshoot, for example.
  • the motor control circuit is further configured to adjust 14074 one or more motor control parameters according to the determined importance magnitude to control a rate at which the speed of the firing member changes during the determined stage.
  • the one or more parameters may include any suitable parameters such as motor controller parameters, PID controller tuning parameters, and/or PWM duty cycle ranges, for example.
  • motor control parameters, circuits, and/or algorithms such as those disclosed herein, are adjusted in an effort to limit loads experienced within an end effector.
  • loads can be caused by thick and/or tough tissue, for example.
  • Loads can be experienced by the motor through various stages of the use of a surgical instrument. For example, loads can be experienced by the motor through a firing member as the firing member is advanced through a staple firing stroke, by the motor through a closure member during the clamping of tissue, for example.
  • Load levels can be detected in any suitable manner such as, for example, by monitoring motor current of a motor configured to drive a firing member and/or through a force sensor, such as a strain gauge, for example, positioned on a firing member. In at least one instance, the speed of the motor of a motor system is decreased to decrease load experienced by the firing member.
  • a motor control circuit is configured to modulate torque (force) and speed (voltage) of the motor simultaneously in an effort to reduce load experienced by a drive train.
  • the speed of the motor is reduced to decrease the load experienced within the end effector.
  • controlled pause, or wait, periods are utilized to decrease the load experienced within the end effector.
  • FIG. 45 is a logic flow chart depicting a process 15000 executable by a control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, for use with a surgical instrument system such as those disclosed herein.
  • the control circuit is configured to control the motor of a motor system within a surgical instrument system.
  • the control circuit is configured to receive one or more inputs and produce an output signal to the motor corresponding to the one or more inputs.
  • the control circuit is configured to monitor one or more electrical and/or mechanical parameters of the motor system such as, for example, rotational output speed of the motor, linear output speed of a firing member, current draw of the motor, and/or load experienced by the motor system.
  • control circuit is configured to convert one or more analog outputs such as motor speed, current draw, firing member speed, etc., to a digital signal.
  • a digital control signal is configured to be converted to an analog input signal for the motor.
  • the one or more analog output signals are configured to be converted to digital signals which can be fed back into the control circuit and be utilized as inputs of the control circuit.
  • the control circuit is configured to initiate 15001 a drive stroke such as, for example, a staple firing stroke.
  • the drive stroke includes a closure stroke, a retraction stroke, and/or any portion of any stroke within a surgical instrument system.
  • the control circuit is configured to adjust one or more motor control parameters while the motor is not running, prior to a drive stroke, and/or after a drive stroke, for example.
  • the motor control circuit is further configured to monitor 15002 one or more parameters of the motor system such as those disclosed herein.
  • the motor control circuit is configured to convert an analog signal of the one or more monitored parameters to a digital signal and feed the digital signal back into the control circuit.
  • the motor control circuit is further configured to determine 15003 if one or more motor control parameters require an adjustment based on the one or more monitored parameters. Any suitable trigger and/or threshold can be employed such as those disclosed herein.
  • a load threshold is employed and, when the load threshold is exceeded, the control circuit adjusts 15004 one or more motor control parameters.
  • a load threshold is triggered, for example, it can be determined that a section of stiff, or thick, tissue is being encountered by the firing member.
  • the control circuit adjusts one or more motor control parameters to power through the stiff tissue.
  • an oscillating signal is delivered to the motor causing the motor to repeatedly impact the tissue for a period of time in an effort to burst through the thick tissue.
  • a PWM signal is used to provide motor oscillation.
  • the motor oscillation involves a sequence of quick bursts of energy.
  • control circuit is configured to move the firing member in a proximal direction prior to each burst of energy in an effort to increase the moment of inertia while impacting thick tissue.
  • control circuit is configured to move the firing member in a proximal direction prior to each burst of energy in an effort to increase the moment of inertia while impacting thick tissue.
  • pulse width modulation in addition to pulse amplitude modulation are utilized.
  • the width (time) of each pulse can be adjusted based on the one or more monitored parameters such as, for example, the magnitude of the load experienced by the firing member.
  • the amplitude (voltage) of each pulse can be adjusted based on the one or more monitored parameters such as, for example, the magnitude of the load experienced by the firing member.
  • the width of each pulse and/or the amplitude of each pulse are varied as the firing member is traversing thick tissue.
  • the firing member is oscillated in the manner described above for a period of time, paused, and oscillated again.
  • the duration of the oscillating motor operation can be dependent on the one or more monitored parameters.
  • a delay is employed by the control circuit so as to ensure the firing member is beyond the section of thick tissue, allowing the oscillating signal to power the firing member a predetermined distance beyond the moment that the load on the firing member falls below the predetermined threshold.
  • a delta-sigma modulation based bit-stream controller is utilized in the control circuit to drive the motor.
  • Such a controller can utilize an analog output and generate a digital control signal.
  • a delta-sigma modulator 15010 can be seen in FIG. 46.
  • the delta-sigma modulator 15010 is a second-order delta-sigma modulator.
  • two feedback loops 15011 are utilized in addition to two integrators 15012.
  • a 1 -bit DAC 15013 is also used.
  • a digital filter 15014 is employed to form a higher- resolution digital output.
  • pulse amplitude modulation can also be used by a control circuit to control the motor.
  • FIG. 47 depicts a graph 15020 depicting a first signal 15021 and a pulse amplitude modulation signal 15022 representing the first signal 15021.
  • Pulse amplitude modulation can supply varying voltage amplitudes for motor control.
  • a combination of variable output forces can be achieved by moving up and/or down on the torquepower curve of the motor.
  • duty cycle is also used in conjunction with pulse amplitude modulation to regulate voltage and/or power into the motor to control motor speed.
  • pulse width frequency modulation is used to control the speed of a motor in a surgical instrument system.
  • a control circuit is configured to monitor the current through a motor.
  • the control circuit can be configured to modulate the frequency of the pulse. The modulation of the frequency of the pulse can be adjusted according to one or more monitored parameters of a drive stroke, for example.
  • the control circuit is configured to adjust the frequency of the pulse to a first frequency upon detecting a first parameter threshold and a second frequency upon detecting a second parameter threshold.
  • the first frequency is different than the second frequency and the first parameter threshold is different than the second parameter threshold.
  • a faster frequency may reduce current draw through the motor.
  • FIG. 48 depicts two graphs 15030, 15040 of PWM signals 15031 , 15041 at two different frequencies relative to current draw (I) through the motor. As can be seen in FIG. 48, the current draw 15032 is greater than the current draw 15042 for the same 50% duty cycle.
  • pulse frequency modulation can be beneficial in a brushless DC motor where multiple electromagnets are used in a frequency cascade. Speed of the brushless DC motor can be controlled with little to no impact to motor torque output.
  • FIG. 49 is a graph 15050 of various signals 15051 , 15052, and 15053 depicting duty cycle of the signal relative to current draw through the motor at different frequencies F1 (the frequency of signal 15051), F2 (the frequency of signal 15052), and F3 (the frequency of signal 15053). In at least one instance, F1 is greater than F2, and F2 is greater than F3. In at least one instance, a higher frequency can reduce current draw through a motor.
  • a control circuit configured to control the motor of a motor system is configured to use pulse amplitude modulation and/or pulse width frequency modulation in conjunction with wait, or pause, periods.
  • the control circuit is configured to monitor current through the motor and adjust, based on the monitored current, a pulse width frequency and/or a pulse amplitude based on the monitored current.
  • the adjustment occurs after a wait, or pause, period.
  • the wait, or pause, period is predetermined.
  • the wait period varies.
  • the wait period depends on the magnitude of the monitored current.
  • a control circuit can set a wait period to a first time period after a first current is monitored and set a wait period to a second time period which is greater than the first time period after a second current is monitored which is greater than the first current.
  • controlled wait, or pause, times can reduce the load experienced by a firing member during a firing stroke upon surpassing a predetermined level of current through the motor. Setting the magnitude of the time period corresponding to the level of current detected through the motor can allow for situational specific wait times where a longer wait period, for example, may not be necessary at a lower current threshold.
  • FIG. 50 is a logic flow chart depicting a process 15060 executable by a control circuit, such as the control circuit 1932 illustrated in FIG. 13 and/or the control circuit illustrated in FIG. 14, for example, configured to control a motor of a motor system of a surgical instrument system.
  • the control circuit is configured to initiate 15061 a drive stroke of the motor system. Such a drive stroke can include a staple firing stroke of a firing member, for example.
  • the control circuit is configured to monitor 15062 current draw of the motor. Any suitable monitoring method can be used such as, for example, utilizing a current transducer.
  • the control circuit is configured to determine 15063 when the monitored current exceeds a predetermined threshold.
  • the predetermined threshold can indicate an over-current situation where thick tissue, for example, has been encountered by the firing member thereby increasing the load on the firing member and, thus, the current draw by the motor.
  • the control circuit Upon determining that the predetermined threshold has been exceeded, the control circuit is configured to initiate 15064 an oscillating impact signal sequence to the motor.
  • the oscillating impact signal sequence includes a digital motor control signal.
  • a pulse width, a pulse amplitude, and/or a pulse frequency is preselected.
  • a pulse width, a pulse amplitude, and/or a pulse frequency is selected upon determining that the predetermined current threshold has been exceeded.
  • the pulse width, the pulse amplitude, and/or the pulse frequency is selected based on one or more monitored parameters of the motor system such as, for example, the magnitude at which the current exceeded the predetermined current threshold, for example.
  • each pulse delivered to the motor can correspond to a distal impact motion of the firing member.
  • a reversing movement, or pulse can be utilized for each distal pulse movement so as to allow the firing member a certain amount of distance to gain momentum in an effort to pass the thick section of tissue, for example.
  • the oscillating impact signal sequence further includes a pause period configured to allow for tissue to relax.
  • a predetermined number of distal pulse movements of the firing member occur prior to the pause period.
  • several pause periods can be used until the thick tissue is traversed by the firing member.
  • Example 1 A surgical instrument system comprising a motor system, comprising a motor and a drive train movable by the motor to actuate a firing member through a staple firing stroke.
  • the surgical instrument system further comprises a control circuit coupled to the motor, wherein, during the staple firing stroke, the control circuit is configured to perform a first sensory action to determine if a speed of the motor can be increased to a first target speed, monitor a result of the first sensory action, adjust a parameter of a subsequent sensory action based on the monitored result of the first sensory action, and perform the subsequent sensory action with the adjusted parameter.
  • Example 2 The surgical instrument system of Example 1 , wherein the parameter comprises a second target speed, wherein the first target speed and the second target speed are different, and wherein performing the subsequent sensory action comprises determining if the speed of the motor can be increased to the second target speed.
  • Example 3 The surgical instrument system of Examples 1 or 2, wherein performing the first sensory action comprises drive the speed of the motor toward a first target speed, monitor the speed of the motor, and compare the monitored speed to the first target speed.
  • Example 4 The surgical instrument system of any one of Examples 1-3, wherein monitoring the result of the first sensory action comprises monitoring the speed of the motor relative to the first target speed.
  • Example 5 The surgical instrument system of any one of Examples 1-4, wherein monitoring the result of the first sensory action comprises determining a success status of the first sensory action.
  • Example 6 The surgical instrument system of any one of Examples 1-5, wherein the control circuit is further configured to prevent the subsequent sensory action from being performed for a predetermined period of time.
  • Example 7 The surgical instrument system of any one of Examples 1-6, wherein the control circuit is further configured to prevent the subsequent sensory action from being performed when the result of the first sensory action indicates a failure status.
  • Example 8 The surgical instrument system of any one of Examples 1-7, wherein the control circuit is further configured to prevent adjustment of motor controller parameters during a predetermined period of time when the result of the first sensory action indicates a failure status.
  • Example 9 The surgical instrument system of any one of Examples 1-8, wherein the control circuit is further configured to automatically adjust the motor control parameters after the predetermined period of time.
  • Example 10 The surgical instrument system of any one of Examples 1-9, wherein the motor control parameters comprise PID controller parameters.
  • Example 11 The surgical instrument system of any one of Examples 1-10, wherein adjusting the parameter of the subsequent sensory action comprises setting a second target speed of the subsequent sensory action to be equal to the first target speed upon failure of the first sensory action.
  • Example 12 The surgical instrument system of any one of Examples 1-11 , wherein the control circuit is further configured to perform a plurality of the subsequent sensory actions until the second target speed is achieved.
  • Example 13 The surgical instrument system of any one of Examples 1-12, wherein the control circuit is further configured to perform additional first sensory actions, and wherein adjusting the parameter of the subsequent sensory action is based on a monitored cumulative result of the first sensory action and the additional first sensor actions.
  • Example 14 A surgical instrument system comprising a first replaceable staple cartridge, a second replaceable staple cartridge, and a motor system comprising a motor, and a drive train movable by the motor to actuate a firing member through a first staple firing stroke through the first replaceable staple cartridge and a second staple firing stroke through the second replaceable staple cartridge upon replacing the first replaceable staple cartridge with the second replaceable staple cartridge.
  • the surgical instrument system further comprises a control circuit coupled to the motor, wherein the control circuit is configured to drive the motor to actuate the firing member through the first staple firing stroke, perform a first sensory action during the first staple firing stroke, monitor a result of the first sensory action, drive the motor to actuate the firing member through the second staple firing stroke, adjust a parameter of a second sensory action based on the monitored result of the first sensory action, drive the motor to actuate the firing member through the second staple firing stroke, and perform the subsequent sensory action with the adjusted parameter during the second staple firing stroke.
  • Example 15 The surgical instrument system of Example 14, wherein the parameter comprises a magnitude of a target speed.
  • Example 16 The surgical instrument system of Examples 14 or 15, wherein the result indicates a success status of the first sensory action.
  • Example 17 A surgical instrument system comprising a motor system comprising a motor and a drive train movable by the motor to actuate a firing member through a staple firing stroke.
  • the surgical instrument system further comprises a control circuit coupled to the motor, wherein, during the staple firing stroke, the control circuit is configured to perform a plurality of first sensory actions, monitor a success status of each of the first sensory actions, and adjust a parameter of subsequent sensory action based on the monitored success status of each of the first sensory actions.
  • Example 18 The surgical instrument system of Example 17, wherein the control circuit is further configured to determine when a predetermined number of successful first sensory actions is achieved and adjust the parameter according to a first adjustment profile upon determining when the predetermined number of successful first sensory actions is achieved.
  • Many of the surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. In certain instances, the motors disclosed herein may comprise a portion or portions of a robotically controlled system.
  • any of the end effectors and/or tool assemblies disclosed herein can be utilized with a robotic surgical instrument system.
  • U.S. Patent Application Serial No. 13/118,241 entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Patent No. 9,072,535, for example, discloses several examples of a robotic surgical instrument system in greater detail, and is incorporated herein by reference in its entirety.
  • an end effector in accordance with various embodiments can comprise electrodes configured to heat and seal the tissue.
  • an end effector in accordance with certain embodiments can apply vibrational energy to seal the tissue.
  • Instructions used to program logic to perform various disclosed aspects can be stored within a memory in the system, such as dynamic random access memory (DRAM), cache, flash memory, or other storage. Furthermore, the instructions can be distributed via a network or by way of other computer readable media.
  • DRAM dynamic random access memory
  • cache cache
  • flash memory or other storage.
  • the instructions can be distributed via a network or by way of other computer readable media.
  • a machine-readable medium may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer), but is not limited to, floppy diskettes, optical disks, compact disc, read-only memory (CD-ROMs), and magneto-optical disks, read-only memory (ROMs), random access memory (RAM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic or optical cards, flash memory, or a tangible, machine-readable storage used in the transmission of information over the Internet via electrical, optical, acoustical or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.).
  • the non-transitory computer-readable medium includes any type of tangible machine-readable medium suitable for storing or transmitting electronic instructions or information in a form readable by a machine (e.g., a computer).
  • control circuit may refer to, for example, hardwired circuitry, programmable circuitry (e.g., a computer processor including one or more individual instruction processing cores, processing unit, processor, microcontroller, microcontroller unit, controller, digital signal processor (DSP), programmable logic device (PLD), programmable logic array (PLA), or field programmable gate array (FPGA)), state machine circuitry, firmware that stores instructions executed by programmable circuitry, and any combination thereof.
  • programmable circuitry e.g., a computer processor including one or more individual instruction processing cores, processing unit, processor, microcontroller, microcontroller unit, controller, digital signal processor (DSP), programmable logic device (PLD), programmable logic array (PLA), or field programmable gate array (FPGA)
  • state machine circuitry firmware that stores instructions executed by programmable circuitry, and any combination thereof.
  • the control circuit may, collectively or individually, be embodied as circuitry that forms part of a larger system, for example, an integrated circuit (IC), an application-specific integrated circuit (ASIC), a system on-chip (SoC), desktop computers, laptop computers, tablet computers, servers, smart phones, etc.
  • IC integrated circuit
  • ASIC application-specific integrated circuit
  • SoC system on-chip
  • control circuit includes, but is not limited to, electrical circuitry having at least one discrete electrical circuit, electrical circuitry having at least one integrated circuit, electrical circuitry having at least one application specific integrated circuit, electrical circuitry forming a general purpose computing device configured by a computer program (e.g., a general purpose computer configured by a computer program which at least partially carries out processes and/or devices described herein, or a microprocessor configured by a computer program which at least partially carries out processes and/or devices described herein), electrical circuitry forming a memory device (e.g., forms of random access memory), and/or electrical circuitry forming a communications device (e.g., a modem, communications switch, or optical-electrical equipment).
  • a computer program e.g., a general purpose computer configured by a computer program which at least partially carries out processes and/or devices described herein, or a microprocessor configured by a computer program which at least partially carries out processes and/or devices described herein
  • electrical circuitry forming a memory device
  • a microcontroller may generally comprise a memory and a microprocessor (“processor”) operationally coupled to the memory.
  • the processor may control a motor driver circuit generally utilized to control the position and velocity of a motor, for example.
  • the processor can signal the motor driver to stop and/or disable the motor, for example.
  • the microcontroller may be an LM 4F230H5QR, available from Texas Instruments, for example.
  • the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Core comprising on-chip memory of 256 KB single-cycle flash memory, or other non-volatile memory, up to 40 MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB single-cycle serial random access memory (SRAM), internal read-only memory (ROM) loaded with StellarisWare® software, 2 KB electrically erasable programmable read-only memory (EEPROM), one or more pulse width modulation (PWM) modules, one or more quadrature encoder inputs (QEI) analog, one or more 12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels, among other features that are readily available for the product datasheet.
  • SRAM serial random access memory
  • ROM internal read-only memory
  • EEPROM electrically erasable programmable read-only memory
  • PWM pulse width modulation
  • QEI quadrature encoder inputs
  • ADC Analog-
  • processor includes any suitable microprocessor, or other basic computing device that incorporates the functions of a computer's central processing unit (CPU) on an integrated circuit or at most a few integrated circuits.
  • the processor is a multipurpose, programmable device that accepts digital data as input, processes it according to instructions stored in its memory, and provides results as output. It is an example of sequential digital logic, as it has internal memory. Processors operate on numbers and symbols represented in the binary numeral system.
  • the processor may be any single core or multicore processor such as those known under the trade name ARM Cortex by Texas Instruments. Nevertheless, other suitable substitutes for microcontrollers and safety processor may be employed, without limitation.
  • logic may refer to an app, software, firmware and/or circuitry configured to perform any of the aforementioned operations.
  • Software may be embodied as a software package, code, instructions, instruction sets and/or data recorded on non-transitory computer readable storage medium.
  • Firmware may be embodied as code, instructions or instruction sets and/or data that are hard-coded (e.g., nonvolatile) in memory devices.
  • the terms “component,” “system,” “module” and the like can refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution.
  • an “algorithm” refers to a self-consistent sequence of steps leading to a desired result, where a “step” refers to a manipulation of physical quantities and/or logic states which may, though need not necessarily, take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It is common usage to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. These and similar terms may be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities and/or states.
  • Various instruments, tools, hubs, devices and/or systems may be capable of communicating with each other using a selected packet switched network communications protocol.
  • One example communications protocol may include an Ethernet communications protocol which may be capable permitting communication using a Transmission Control Protocol/lnternet Protocol (TCP/IP).
  • TCP/IP Transmission Control Protocol/lnternet Protocol
  • the Ethernet protocol may comply or be compatible with the Ethernet standard published by the Institute of Electrical and Electronics Engineers (IEEE) titled “IEEE 802.3 Standard”, published in December, 2008 and/or later versions of this standard.
  • the communication devices may be capable of communicating with each other using an X.25 communications protocol.
  • the X.25 communications protocol may comply or be compatible with a standard promulgated by the International Telecommunication Union-Telecommunication Standardization Sector (ITU-T).
  • the communication devices may be capable of communicating with each other using a frame relay communications protocol.
  • the frame relay communications protocol may comply or be compatible with a standard promulgated by Consultative Committee for International Circuit and Telephone (CCITT) and/or the American National Standards Institute (ANSI).
  • transceivers may be capable of communicating with each other using an Asynchronous Transfer Mode (ATM) communications protocol.
  • ATM communications protocol may comply or be compatible with an ATM standard published by the ATM Forum titled “ATM-MPLS Network Interworking 2.0” published August 2001 , and/or later versions of this standard.
  • ATM-MPLS Network Interworking 2.0 published August 2001
  • One or more motor assemblies employ one or more electric motors.
  • the electric motors may be a DC brushed driving motor, for example.
  • the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor.
  • the electric motors may be powered by a power source that in one form may comprise a removable power pack. Batteries may each comprise, for example, a Lithium Ion (“LI”) or other suitable battery.
  • the electric motors can include rotatable shafts that operably interface with gear reducer assemblies, for example.
  • a voltage polarity provided by the power source can operate an electric motor in a clockwise direction wherein the voltage polarity applied to the electric motor by the battery can be reversed in order to operate the electric motor in a counterclockwise direction.
  • a microcontroller controls the electric motor through a motor driver via a pulse width modulated control signal.
  • the motor driver can be configured to adjust the speed of the electric motor either in clockwise or counter-clockwise direction.
  • the motor driver is also configured to switch between a plurality of operational modes which include an electronic motor braking mode, a constant speed mode, an electronic clutching mode, and a controlled current activation mode. In electronic braking mode, two terminal of the drive motor are shorted and the generated back EMF counteracts the rotation of the electric motor allowing for faster stopping and greater positional precision.
  • a wireless transmission such as, for example, a wireless communication or a wireless transfer of a data signal can be achieved, by a device including one or more transceivers.
  • the transceivers may include, but are not limited to cellular modems, wireless mesh network transceivers, Wi-Fi® transceivers, low power wide area (LPWA) transceivers, and/or near field communications transceivers (NFC).
  • LPWA low power wide area
  • NFC near field communications transceivers
  • the device may include or may be configured to communicate with a mobile telephone, a sensor system (e.g., environmental, position, motion, etc.) and/or a sensor network (wired and/or wireless), a computing system (e.g., a server, a workstation computer, a desktop computer, a laptop computer, a tablet computer (e.g., iPad®, GalaxyTab® and the like), an ultraportable computer, an ultramobile computer, a netbook computer and/or a subnotebook computer; etc.
  • a coordinator node e.g., a coordinator node.
  • the transceivers may be configured to receive serial transmit data via respective universal asynchronous receiver-transmitters (UARTs) from a processor to modulate the serial transmit data onto an RF carrier to produce a transmit RF signal and to transmit the transmit RF signal via respective antennas.
  • the transceiver(s) can be further configured to receive a receive RF signal via respective antennas that includes an RF carrier modulated with serial receive data, to demodulate the receive RF signal to extract the serial receive data and to provide the serial receive data to respective UARTs for provision to the processor.
  • Each RF signal has an associated carrier frequency and an associated channel bandwidth. The channel bandwidth is associated with the carrier frequency, the transmit data and/or the receive data.
  • Each RF carrier frequency and channel bandwidth is related to the operating frequency range(s) of the transceiver(s).
  • Each channel bandwidth is further related to the wireless communication standard and/or protocol with which the transceiver(s) may comply.
  • each transceiver may correspond to an implementation of a selected wireless communication standard and/or protocol, e.g., IEEE 802.11 a/b/g/n for Wi-Fi® and/or IEEE 802.15.4 for wireless mesh networks using Zigbee routing.
  • One or more components may be referred to herein as “configured to,” “configurable to,” “operable/operative to,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc.
  • “configured to” can generally encompass active-state components and/or inactive-state components and/or standby-state components, unless context requires otherwise.
  • proximal and distal are used herein with reference to a clinician manipulating the handle portion of the surgical instrument.
  • proximal refers to the portion closest to the clinician and the term “distal” refers to the portion located away from the clinician.
  • distal refers to the portion located away from the clinician.
  • spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings.
  • surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.
  • any reference to “one aspect,” “an aspect,” “an exemplification,” “one exemplification,” and the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect.
  • appearances of the phrases “in one aspect,” “in an aspect,” “in an exemplification,” and “in one exemplification” in various places throughout the specification are not necessarily all referring to the same aspect.
  • the particular features, structures or characteristics may be combined in any suitable manner in one or more aspects.
  • a range of “1 to 10” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.
  • all ranges recited herein are inclusive of the end points of the recited ranges.
  • a range of “1 to 10” includes the end points 1 and 10.
  • Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

Abstract

L'invention concerne un système d'instrument chirurgical comprenant un système de moteur et un circuit de commande. Le système de moteur comprend un moteur et un train d'entraînement mobile par le moteur pour actionner un élément de déclenchement par l'intermédiaire d'une course de déclenchement d'agrafe. Le circuit de commande est couplé au moteur, dans lequel, pendant la course de déclenchement d'agrafe, le circuit de commande est configuré pour effectuer une première action sensorielle pour déterminer si une vitesse du moteur peut être augmentée à une première vitesse cible, surveiller un résultat de la première action sensorielle, ajuster un paramètre d'une action sensorielle ultérieure sur la base du résultat surveillé de la première action sensorielle, et effectuer l'action sensorielle ultérieure avec le paramètre ajusté.
PCT/IB2023/059766 2022-09-29 2023-09-29 Algorithmes chirurgicaux à actions sensorielles incrémentielles WO2024069565A1 (fr)

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US202263411445P 2022-09-29 2022-09-29
US63/411,445 2022-09-29
US17/958,024 US20240108340A1 (en) 2022-09-29 2022-09-30 Surgical algorithms with incremental sensory actions
US17/958,024 2022-09-30

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