Closed loop feedback control of motor speed of surgical stapling and cutting instrument based on magnitude of speed error measurement

文档序号：1524750 发布日期：2020-02-11 浏览：4次中文

阅读说明：本技术 基于速度误差测量的大小的对外科缝合和切割器械的马达速度的闭环反馈控制 (Closed loop feedback control of motor speed of surgical stapling and cutting instrument based on magnitude of speed error measurement ) 是由 R·E·帕费特 S·R·亚当斯 F·E·谢尔顿四世 J·L·哈里斯于 2018-05-16 设计创作，主要内容包括：本发明公开了一种机动化外科器械。外科器械包括位移构件。马达联接到位移构件和控制电路。位置传感器联接到控制电路和定时器电路以测量流逝时间。控制电路被配置为能够确定位移构件的位置,确定定向速度和实际速度之间的误差,并且基于与一个或多个阈值相比的误差来调整定向速度。控制电路还被配置为能够基于一个或多个阈值来调整定向速度的变化率。控制电路还被配置为能够确定位移构件所处的区域,并基于位移构件所处的区域来设定定向速度。(The invention discloses a motorized surgical instrument. The surgical instrument includes a displacement member. The motor is coupled to the displacement member and the control circuit. The position sensor is coupled to the control circuit and the timer circuit to measure the elapsed time. The control circuit is configured to be able to determine a position of the displacement member, determine an error between the orientation velocity and the actual velocity, and adjust the orientation velocity based on the error compared to one or more thresholds. The control circuit is further configured to be able to adjust a rate of change of the directional velocity based on one or more thresholds. The control circuit is further configured to be able to determine a region in which the displacement member is located and to set the orientation speed based on the region in which the displacement member is located.)

1. A surgical instrument, comprising:

a displacement member configured to translate over a plurality of predefined regions within the surgical instrument;

a motor coupled to the displacement member to translate the displacement member;

a control circuit coupled to the motor;

a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member; and

a timer circuit coupled to the control circuit, the timer/counter circuit configured to be capable of measuring an elapsed time;

wherein the control circuitry is configured to be capable of:

determining a position of the displacement member;

determining a region in which the displacement member is located; and

setting an orientation speed of the displacement member based on the area in which the displacement member is located.

2. The surgical instrument of claim 1, wherein the control circuit is configured to:

receiving the position of the displacement member from the position sensor;

receiving an elapsed time from the timer circuit; and

setting a duty cycle of the motor based on the region in which the displacement member is located.

3. The surgical instrument of claim 2, wherein the control circuit is configured to determine an actual velocity of the displacement member.

4. The surgical instrument of claim 3, wherein the control circuit is configured to determine an error between the directional velocity of the displacement member and the actual velocity of the displacement member.

5. The surgical instrument of claim 4, wherein the control circuit is configured to set a new orientation speed of the displacement member based on the error.

6. The surgical instrument of claim 4, wherein the error is based on at least one of a short term error (S), a cumulative error (C), a rate of change error (R), and an overshoot number error (N).

7. The surgical instrument of claim 1, comprising an end effector, wherein the displacement member is configured to translate within the end effector.

8. A surgical instrument, comprising:

a displacement member configured to translate within the surgical instrument;

a motor coupled to the displacement member to translate the displacement member;

a control circuit coupled to the motor;

a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member; and

a timer circuit coupled to the control circuit, the timer/counter circuit configured to be capable of measuring an elapsed time;

wherein the control circuitry is configured to be capable of:

setting a directional velocity of the displacement member;

determining a position of the displacement member;

determining an actual velocity of the displacement member;

comparing the directional velocity of the displacement member to the actual velocity of the displacement member;

determining an error between the displacement member and the actual velocity of the displacement member; and

adjusting the directional velocity of the displacement member based on the error.

9. The surgical instrument of claim 8, wherein the control circuit is configured to compare the error to an error threshold.

10. The surgical instrument of claim 9, wherein the control circuit is configured to maintain the directional velocity of the displacement member when the error is within the error threshold.

11. The surgical instrument of claim 9, wherein the control circuit is configured to adjust the directional velocity of the displacement member to change the directional velocity when the error exceeds the error threshold.

12. The surgical instrument of claim 8, wherein the actual velocity of the displacement member is given by the expression:

where A, B and D are coefficients, and S is the short term error, C is the accumulated error, and R is the rate of change error.

13. The surgical instrument of claim 8, comprising an end effector, wherein the displacement member is configured to translate within the end effector.

14. A surgical instrument, comprising:

a displacement member configured to translate within the surgical instrument;

a motor coupled to the displacement member to translate the displacement member;

a control circuit coupled to the motor;

a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member; and

a timer circuit coupled to the control circuit, the timer/counter circuit configured to be capable of measuring an elapsed time;

wherein the control circuitry is configured to be capable of:

setting a directional velocity of the displacement member;

determining a position of the displacement member;

determining an actual velocity of the displacement member;

comparing the directional velocity of the displacement member to the actual velocity of the displacement member;

determining an error between the displacement member and the actual velocity of the displacement member; and

adjusting the directional velocity of the displacement member at a rate of change based on the error.

15. The surgical instrument of claim 14, wherein the control circuit is configured to compare the error to a plurality of error thresholds.

16. The surgical instrument of claim 15, wherein the control circuit is configured to adjust the directional velocity of the displacement member at a plurality of rates of change based on the error.

17. The surgical instrument of claim 15, wherein the control circuit is configured to:

comparing the error to a first error threshold; and

maintaining the directional velocity when the error is within the first error threshold.

18. The surgical instrument of claim 17, wherein the control circuit is configured to:

comparing the error to a second error threshold;

adjusting the directional velocity at a first rate of change when the error exceeds the first error threshold and is within the second error threshold.

19. The surgical instrument of claim 17, wherein the control circuit is configured to:

comparing the error to a second error threshold;

adjusting the directional velocity at a second rate of change when the error exceeds both the first error threshold and the second error threshold.

20. The surgical instrument of claim 14, wherein the error is based on at least one of a short term error (S), a cumulative error (C), a rate of change error (R), and an overshoot number error (N).

Technical Field

The present disclosure relates to surgical instruments and, in various instances, to surgical stapling and cutting instruments and staple cartridges therefor that are designed for stapling and cutting tissue.

Background

In motorized surgical stapling and cutting instruments, it may be useful to control the speed of the cutting member or to control the speed of articulation of the end effector. The velocity of the displacement member may be determined by measuring the elapsed time of the displacement member at predetermined intervals of positions or measuring the position of the displacement member at predetermined intervals of time. Control may be open loop or closed loop. Such measurements may be used to assess tissue conditions such as tissue thickness, and to adjust the speed of the cutting member during the firing stroke to account for the tissue conditions. The tissue thickness may be determined by comparing the expected speed of the cutting member with the actual speed of the cutting member. In some cases, it may be useful to articulate the end effector at a constant articulation speed. In other cases, it may be useful to drive the end effector at an articulation speed that is different from the default articulation speed at one or more regions within the scanning range of the end effector.

During use of a motorized surgical stapling and cutting instrument, speed control system errors may occur between the commanded speed and the actual measured speed of the cutting or firing member. Accordingly, it is desirable to provide a closed-loop feedback system that adjusts the speed of the cutting member or firing member based on the magnitude of one or more error terms determined from the difference between the actual speed and the commanded speed over a specified time/distance increment.

Disclosure of Invention

In one aspect, the present disclosure provides a surgical instrument. The surgical instrument comprises: a displacement member configured to translate over a plurality of predefined regions within the surgical instrument; a motor coupled to the displacement member to translate the displacement member; a control circuit coupled to the motor; a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member; a timer circuit coupled to the control circuit, the timer/counter circuit configured to be capable of measuring an elapsed time; wherein the control circuitry is configured to be capable of: determining a position of a displacement member; determining the area where the displacement member is located; the orientation speed of the displacement member is set based on the region in which the displacement member is located.

In another aspect, the surgical instrument includes a displacement member configured to translate within the surgical instrument; a motor coupled to the displacement member to translate the displacement member; a control circuit coupled to the motor; a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member; a timer circuit coupled to the control circuit, the timer/counter circuit configured to be capable of measuring an elapsed time; wherein the control circuitry is configured to be capable of: setting the directional speed of the displacement member; determining a position of a displacement member; determining an actual velocity of the displacement member; comparing the directional velocity of the displacement member with the actual velocity of the displacement member; determining an error between the displacement member and the actual velocity of the displacement member; the directional velocity of the displacement member is adjusted based on the error.

Drawings

The novel features believed characteristic of the aspects described herein are set forth with particularity in the appended claims. However, these aspects, both as to organization and method of operation, may be better understood by reference to the following description, taken in conjunction with the accompanying drawings.

Fig. 1 is a perspective view of a surgical instrument having an interchangeable shaft assembly operatively coupled thereto according to one aspect of the present disclosure.

Fig. 2 is an exploded assembly view of a portion of the surgical instrument of fig. 1, according to one aspect of the present disclosure.

FIG. 3 is an exploded assembly view of portions of an interchangeable shaft assembly according to one aspect of the present disclosure.

FIG. 4 is an exploded view of an end effector of the surgical instrument of FIG. 1 according to one aspect of the present disclosure.

Fig. 5A-5B are block diagrams of control circuitry of the surgical instrument of fig. 1 spanning two drawn sheets according to one aspect of the present disclosure.

Fig. 6 is a block diagram of the control circuit of the surgical instrument of fig. 1 illustrating the interface between the handle assembly and the power assembly, and between the handle assembly and the interchangeable shaft assembly, according to one aspect of the present disclosure.

Fig. 7 illustrates a control circuit configured to control aspects of the surgical instrument of fig. 1, according to one aspect of the present disclosure.

Fig. 8 illustrates a combinational logic circuit configured to control aspects of the surgical instrument of fig. 1, according to one aspect of the present disclosure.

Fig. 9 illustrates a sequential logic circuit configured to control aspects of the surgical instrument of fig. 1, according to one aspect of the present disclosure.

Fig. 10 is a diagram of an absolute positioning system of the surgical instrument of fig. 1, wherein the absolute positioning system includes a controlled motor drive circuit arrangement having a sensor arrangement, according to one aspect of the present disclosure.

Fig. 11 is an exploded perspective view of a sensor arrangement of an absolute positioning system showing the relative alignment of elements of the sensor arrangement and the control circuit board assembly, according to one aspect of the present disclosure.

FIG. 12 is a diagram of a position sensor including a magnetic rotary absolute positioning system according to one aspect of the present disclosure.

Fig. 13 is a cross-sectional view of an end effector of the surgical instrument of fig. 1 illustrating firing member travel relative to tissue grasped within the end effector, according to one aspect of the present disclosure.

Fig. 14 illustrates a block diagram of a surgical instrument programmed to control distal translation of a displacement member according to one aspect of the present disclosure.

Fig. 15 shows a graph plotting two exemplary displacement member strokes performed in accordance with an aspect of the present disclosure.

Fig. 16 is a graph depicting velocity (v) of a displacement member as a function of displacement (δ) of the displacement member, according to one aspect of the present disclosure.

Fig. 17 is a graph depicting velocity (v) of a displacement member as a function of displacement (δ) of the displacement member, according to one aspect of the present disclosure.

Fig. 18 is a graph of velocity (v) of a displacement member as a function of displacement (δ) of the displacement member depicting conditions for a threshold change in directional velocity, according to one aspect of the present disclosure.

Fig. 19 is a graph illustrating conditions for changing the directional velocity 8506 of a displacement member, according to an aspect of the present disclosure.

Fig. 20 is a logic flow diagram depicting a process of a control program or logic configuration for controlling a velocity of a displacement member based on a measured error between an orientation velocity of the displacement member and an actual velocity of the displacement member, according to one aspect of the present disclosure.

Fig. 21 is a logic flow diagram depicting a process of a control program or logic configuration for controlling a velocity of a displacement member based on a measured error between an orientation velocity of the displacement member and an actual velocity of the displacement member, according to one aspect of the present disclosure.

Fig. 22 is a logic flow diagram of a process of a control program depicting a logic configuration for controlling a velocity of a displacement member based on a measured error between an orientation velocity of the displacement member and an actual velocity of the displacement member, according to one aspect of the present disclosure.

Description

The applicant of the present application owns the following patent applications filed concurrently herewith and each incorporated herein by reference in its entirety:

attorney docket number END8191USNP/170054 titled control MOTOR vehicle position OF a SURGICAL STAPLING AND CUTTING INSTRUMENT basic OF artificial OF cultivation, filed 2017 on 20.6.2017 by Frederick e.shelton, IV et al.

Attorney docket number END8192USNP/170055 titled SURGILINSTRUMENT WITH VARIABLE DURATION TRIGGER ARRANGEMENT, filed 2017 on 20.6.2017 by inventor Frederick e.shelton, IV et al.

Attorney docket number END8193USNP/170056 titled SYSTEMSAND METHODS FOR CONTROLLING DISPLACEMENT MEMBER MOTION OF A SURGICAL STAPLINGAND CUTTING INSTRUMENT filed 2017 on 20.6.2017 by inventor Frederick e.shelton, IV et al.

Attorney docket number END8194USNP/170057 entitled SYSTEMSAND METHODS FOR CONTROLLING MOTOR VELOCITY OF A SURGICAL STAPLING AND cuttingtotal available TO artificial tissue and OF END EFFECTOR, filed by inventor Frederick e.shelton, IV et al on 2017, month 6 and 20.

Attorney docket number END8195USNP/170058 entitled SYSTEMSAND METHODS FOR CONTROLLING MOTOR VELOCITY OF A SURGICAL STAPLING AND cutting accession number, filed by inventor Frederick e.shelton, IV et al on 2017 on 20/6.

Attorney docket number END8196USNP/170059 titled SURGILIN SURRUMENT HAVING CONTROL ARTICULATION VELOCITY filed 2017 on 20.6.7 by inventor Frederick E.shelton, IV et al.

Attorney docket number END8197USNP/170060, titled SYSTEMSAND METHODS FOR CONTROLLING VELOCITY OF A DISPLACEMENT MEMBER OF a surgicaltplling AND curdling instumment, filed by inventor Frederick e.shelton, IV et al on 2017 at 20.6 months.

Attorney docket number END8198USNP/170061 titled SYSTEMSAND METHODS FOR CONTROLLING DISPLACEMENT MEMBER VELOCITY FOR A SURGICALINSTRUMENT, filed 2017 on 20.6.2017 by inventor Frederick e.shelton, IV et al.

Attorney docket number END8222USNP/170125 titled control MOTOR vehicle OF surface STAPLING AND CUTTING insulation basic on earth OF organic OF 20 filed on 20.6.2017 by inventor Frederick e.shelton, IV et al.

Attorney docket number END8199USNP/170062M titled TECHNIQUES FOR ADAPTIVE CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND DCUTTING INSTRUMENT, filed 2017 on 20.6.2017 by Frederick E.Shelton, IV et al.

Attorney docket number END8275USNP/170185M titled TECHNIQUEFOR CLOSED LOOP CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING SYSTEN filed 2017 on 20.6.7 by inventor Raymond E.Parfett et al.

Attorney docket number END8276 user/170187 entitled CLOSED loop CONTROL OF MOTOR vehicle ON MEASURED TIME OVER A SPECIFIED DISPLACEMENT DISTANCE filed 2017 ON 20.6.2017 by the inventor Jason l harris et al.

A attorney docket number END8266USNP/170188 entitled CLOSED LOOP FEEDBACK CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING TRANSTRUMENT BASED ON MEASURED DISPLACEMENT DISTANCE TRAVELED OVER A SPECIFIEDTIME INTERVAL filed 2017 ON 20.6.2017 by Frederick E.Shelton, IV et al.

A attorney docket NUMBER END8267USNP/170189 entitled CLOSED LOOP FEEDBACK CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING TRANSFORMENT BASED ON MEASURED TIME OVER A SPECIFIED NUMBER OF SHAFT ROTATONS filed ON 20.6.2017 by Frederick E.Shelton, IV et al.

Attorney docket number END8269USNP/170190 entitled SYSTEMS and methods FOR CONTROLLING DISPLAYING MOTOR vehicle FOR a SURGICAL instument, filed 2017, 20/6 by the inventor, Jason l harris et al.

Attorney docket number END8270USNP/170191, titled system and methods FOR CONTROLLING MOTOR SPEED acquisition TO USER INPUT FOR a SURGICALINSTRUMENT, filed 2017, 20/6 by the inventor Jason l.

Attorney docket number END8271USNP/170192 entitled "closed loop FEEDBACK CONTROL OF MOTOR vehicle position OF a minor STAPLING AND cutstating base SYSTEM CONDITIONS" filed 2017 ON 20.6.2017 by Frederick e.shelton, IV et al.

The applicant of the present application owns the following U.S. design patent applications filed concurrently herewith and each incorporated herein by reference in its entirety:

attorney docket number END8274USDP/170193D titled GRAPHICAL USERINTERFACE FOR A DISPLAY OR PORTION THEREOF filed 2017 on 20.6.h by inventor Jason l.

Attorney docket number END8273USDP/170194D titled GRAPHICAL USERINTERFACE FOR A DISPLAY OR PORTION THEREOF filed 2017 on 20.6.h by inventor Jason l.

Attorney docket number END8272USDP/170195D titled GRAPHICAL USER INTERFACE FOR A DISPLAY OR PORTION THEREOF filed 2017 on 20.6.2017 by inventor Frederick e.shelton, IV et al.

Certain aspects are shown and described to provide an understanding of the structure, function, manufacture, and use of the disclosed apparatus and methods. Features shown or described in one example may be combined with features of other examples, and modifications and variations are within the scope of the disclosure.

The terms "proximal" and "distal" are relative to a clinician manipulating a handle of a surgical instrument, where "proximal" refers to a portion closer to the clinician and "distal" refers to a portion positioned farther from the clinician. For convenience, the spatial terms "vertical," "horizontal," "upward," and "downward" used with respect to the drawings are not intended to be limiting and/or absolute, as the surgical instrument may be used in many orientations and positions.

Exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, such devices and methods may be used for other surgical procedures and applications, including, for example, open surgical procedures. The surgical instrument may be inserted through a natural orifice or through an incision or puncture formed in the tissue. The working portion or end effector portion of the instrument can be inserted directly into the body or through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument can be advanced.

Fig. 1-4 depict a motor-driven surgical instrument 10 for cutting and fastening that may or may not be reusable. In the illustrated example, the surgical instrument 10 includes a housing 12, the housing 12 including a handle assembly 14 configured to be grasped, manipulated and actuated by a clinician. The housing 12 is configured to be operably attached to an interchangeable shaft assembly 200, the interchangeable shaft assembly 200 having an end effector 300 operably coupled thereto, the end effector 300 being configured to perform one or more surgical tasks or procedures. In accordance with the present disclosure, various forms of interchangeable shaft assemblies can be effectively used in conjunction with robotically controlled surgical systems. The term "housing" may encompass a housing or similar portion of a robotic system that houses or otherwise operatively supports at least one drive system configured to generate and apply at least one control motion that can be used to actuate the interchangeable shaft assembly. The term "frame" may refer to a portion of a hand-held surgical instrument. The term "frame" may also refer to a portion of a robotically-controlled surgical instrument and/or a portion of a robotic system that may be used to operably control a surgical instrument. The interchangeable shaft assemblies can be used WITH various robotic systems, instruments, components and methods disclosed in U.S. patent 9,072,535 entitled SURGICAL systems WITH rotable stage manufacture, which is hereby incorporated by reference in its entirety.

Fig. 1 is a perspective view of a surgical instrument 10 having an interchangeable shaft assembly 200 operatively coupled thereto according to one aspect of the present disclosure. The housing 12 includes an end effector 300, the end effector 300 including a surgical cutting and fastening device configured to operatively support a surgical staple cartridge 304 therein. Housing 12 can be configured to be used in conjunction with interchangeable shaft assemblies including end effectors of different shaft lengths, sizes, and types adapted to support different sizes and types of staple cartridges. Housing 12 may be employed with a variety of interchangeable shaft assemblies, including assemblies configured to apply other motions and other forms of energy, such as Radio Frequency (RF) energy, ultrasonic energy, and/or motions, to end effector arrangements suitable for use in connection with various surgical applications and procedures. The end effector, shaft assembly, handle, surgical instrument, and/or surgical instrument system may utilize any suitable fastener or fasteners to fasten tissue. For example, a fastener cartridge including a plurality of fasteners removably stored therein can be removably inserted into and/or attached to an end effector of a shaft assembly.

The handle assembly 14 may include a pair of interconnectable handle housing segments 16, 18 interconnected by screws, snap features, adhesives, or the like. The handle housing segments 16, 18 cooperate to form a pistol grip 19 that can be grasped and manipulated by a clinician. The handle assembly 14 operatively supports a plurality of drive systems configured to be capable of generating and applying control motions to corresponding portions of the interchangeable shaft assembly operatively attached thereto. A display may be provided under the cover 45.

Fig. 2 is an exploded assembly view of a portion of the surgical instrument 10 of fig. 1, according to one aspect of the present disclosure. The handle assembly 14 may include a frame 20 that operatively supports a plurality of drive systems. The frame 20 is configured to operatively support a "first" or closure drive system 30, which first "or closure drive system 30 is configured to impart closing and opening motions to the interchangeable shaft assembly 200. The closure drive system 30 may include an actuator, such as a closure trigger 32, pivotally supported by the frame 20. The closure trigger 32 is pivotally coupled to the handle assembly 14 by a pivot pin 33 such that the closure trigger 32 can be manipulated by a clinician. The closure trigger 32 is pivotable from a starting or "unactuated" position to an "actuated" position and more specifically to a fully compressed or fully actuated position when the clinician grasps the pistol grip 19 of the handle assembly 14.

The handle assembly 14 and frame 20 operatively support a firing drive system 80, the firing drive system 80 configured to apply firing motions to corresponding portions of the interchangeable shaft assembly attached thereto. The firing drive system 80 may employ an electric motor 82 located in the pistol grip portion 19 of the handle assembly 14. For example, the electric motor 82 may be a direct current brushed motor having a maximum rotational speed of about 25,000 RPM. In other arrangements, the motor may comprise a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The electric motor 82 may be powered by a power source 90, and the power source 90 may include a removable power pack 92. The removable power pack 92 may include a proximal housing portion 94 configured to be attachable to a distal housing portion 96. The proximal housing portion 94 and the distal housing portion 96 are configured to operatively support a plurality of batteries 98 therein. Batteries 98 may each include, for example, a Lithium Ion (LI) or other suitable battery. The distal housing portion 96 is configured to be removably operatively attached to a control circuit board 100, the control circuit board 100 being operatively coupled to the electric motor 82. A number of batteries 98 connected in series may power the surgical instrument 10. The power source 90 may be replaceable and/or rechargeable. The display 43, located below the cover 45, is electrically coupled to the control circuit board 100. The cover 45 may be removed to expose the display 43.

The electric motor 82 may include a rotatable shaft (not shown) operatively interfacing with a gear reducer assembly 84, the gear reducer assembly 84 being mounted in meshing engagement with a set or rack of drive teeth 122 on a longitudinally movable drive member 120. The longitudinally movable drive member 120 has drive teeth 122 formed thereon for a rack of teeth in meshing engagement with the corresponding drive gear 86 of the gear reducer assembly 84.

In use, the polarity of the voltage provided by the power source 90 may operate the electric motor 82 in a clockwise direction, wherein the polarity of the voltage applied by the battery to the electric motor may be reversed in order to operate the electric motor 82 in a counterclockwise direction. When the electric motor 82 is rotated in one direction, the longitudinally movable drive member 120 will be driven axially in the distal direction "DD". When the electric motor 82 is driven in the opposite rotational direction, the longitudinally movable drive member 120 will be driven axially in the proximal direction "PD". The handle assembly 14 may include a switch that may be configured to reverse the polarity applied to the electric motor 82 by the power source 90. The handle assembly 14 may include a sensor configured to detect the position of the longitudinally movable drive member 120 and/or the direction in which the longitudinally movable drive member 120 moves.

Actuation of the electric motor 82 is controlled by a firing trigger 130 pivotally supported on the handle assembly 14. The firing trigger 130 is pivotable between an unactuated position and an actuated position.

Returning to fig. 1, the interchangeable shaft assembly 200 includes an end effector 300, the end effector 300 including an elongate channel 302 configured to operatively support a surgical staple cartridge 304 therein. The end effector 300 may include an anvil 306 that is pivotally supported relative to the elongate channel 302. The interchangeable shaft assembly 200 can include an articulation joint 270. The configuration and operation of the end effector 300 and ARTICULATION joint 270 is set forth in U.S. patent application publication 2014/0263541 entitled ARTICULATION SURGICAL INSTRUMENTC OMPRIMING AN ARTICULATION LOCK, which is hereby incorporated by reference in its entirety. The interchangeable shaft assembly 200 can include a proximal housing or nozzle 201 comprised of nozzle portions 202, 203. The interchangeable shaft assembly 200 can include a closure tube 260 extending along a shaft axis SA, which closure tube 260 can be used to close and/or open the anvil 306 of the end effector 300.

Returning to FIG. 1, the closure tube 260 is translated distally (direction "DD") to close the anvil 306, for example, in response to actuation of the closure trigger 32 in the manner described in the aforementioned referenced U.S. patent application publication 2014/0263541. The anvil 306 is opened by translating the closure tube 260 proximally. In the anvil open position, the closure tube 260 is moved to its proximal position.

Fig. 3 is another exploded assembly view of portions of an interchangeable shaft assembly 200 according to one aspect of the present disclosure. The interchangeable shaft assembly 200 can include a firing member 220 supported for axial travel within the spine 210. The firing member 220 includes an intermediate firing shaft 222 configured to be attached to a distal cutting portion or knife bar 280. The firing member 220 may be referred to as a "second shaft" and/or a "second shaft assembly". The intermediate firing shaft 222 can include a longitudinal slot 223 in a distal end, the longitudinal slot 223 configured to receive a tab 284 on a proximal end 282 of the knife bar 280. The longitudinal slot 223 and the proximal end 282 may be configured to allow relative movement therebetween and may include a slip joint 286. This sliding interface 286 may allow the intermediate firing shaft 222 of the firing member 220 to articulate the end effector 300 about the articulation joint 270 without moving, or at least substantially without moving, the knife bar 280. Once the end effector 300 has been properly oriented, the intermediate firing shaft 222 can be advanced distally until the proximal sidewall of the longitudinal slot 223 contacts the tab 284 in order to advance the knife bar 280 and fire a staple cartridge positioned within the channel 302. The spine 210 has an elongated opening or window 213 therein to facilitate assembly and insertion of the intermediate firing shaft 222 into the spine 210. Once the intermediate firing shaft 222 has been inserted into the shaft frame, the top frame segment 215 may be engaged with the shaft frame 212 to enclose the intermediate firing shaft 222 and knife bar 280 therein. Operation of the firing member 220 can be found in U.S. patent application publication 2014/0263541. The spine 210 may be configured to slidably support a firing member 220 and a closure tube 260 that extends around the spine 210. The spine 210 can slidably support an articulation driver 230.

The interchangeable shaft assembly 200 can include a clutch assembly 400, the clutch assembly 400 configured to selectively and releasably couple the articulation driver 230 to the firing member 220. The clutch assembly 400 includes a lock collar or lock sleeve 402 positioned about the firing member 220, wherein the lock sleeve 402 is rotatable between an engaged position, wherein the lock sleeve 402 couples the articulation driver 230 to the firing member 220, and a disengaged position, wherein the articulation driver 230 is not operatively coupled to the firing member 220. When the locking sleeve 402 is in the engaged position, distal movement of the firing member 220 can move the articulation driver 230 distally, and, correspondingly, proximal movement of the firing member 220 can move the articulation driver 230 proximally. When the locking sleeve 402 is in the disengaged position, movement of the firing member 220 is not transmitted to the articulation driver 230, and thus, the firing member 220 may move independently of the articulation driver 230. The nozzle 201 may be used to operatively engage and disengage an articulation drive system from a firing drive system in various ways described in U.S. patent application publication 2014/0263541.

Interchangeable shaft assembly 200 can include a slip ring assembly 600, for example, which slip ring assembly 600 can be configured to conduct electrical power to and/or from end effector 300, and/or to transmit signals to and/or receive signals from end effector 300. Slip ring assembly 600 may include a proximal connector flange 604 and a distal connector flange 601 positioned within slots defined in nozzle portions 202, 203. The proximal connector flange 604 can include a first face and the distal connector flange 601 can include a second face positioned adjacent to and movable relative to the first face. The distal connector flange 601 is rotatable relative to the proximal connector flange 604 about an axis SA-SA (FIG. 1). The proximal connector flange 604 may include a plurality of concentric or at least substantially concentric conductors 602 defined in a first face thereof. The connector 607 may be mounted on the proximal side of the distal connector flange 601 and may have a plurality of contacts, each of which corresponds to and is in electrical contact with one of the conductors 602. This arrangement allows relative rotation between the proximal connector flange 604 and the distal connector flange 601 while maintaining electrical contact therebetween. The proximal connector flange 604 may include an electrical connector 606, which electrical connector 606 may place the conductor 602 in signal communication with the shaft circuit board. In at least one example, a wire harness including a plurality of conductors may extend between the electrical connector 606 and the shaft circuit board. The electrical connector 606 may extend proximally through a connector opening defined in the base mounting flange. U.S. patent application publication 2014/0263551, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, is hereby incorporated by reference in its entirety. U.S. patent application publication 2014/0263552, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, is hereby incorporated by reference in its entirety. More details regarding slip ring assembly 600 may be found in U.S. patent application publication 2014/0263541.

The interchangeable shaft assembly 200 can include a proximal portion that can be fixedly mounted to the handle assembly 14 and a distal portion that can be rotated about a longitudinal axis. The rotatable distal shaft portion may be rotated relative to the proximal portion about the slip ring assembly 600. The distal connector flange 601 of the slip ring assembly 600 may be positioned within the rotatable distal shaft portion.

Fig. 4 is an exploded view of one aspect of the end effector 300 of the surgical instrument 10 of fig. 1, according to one aspect of the present disclosure. The end effector 300 may include an anvil 306 and a surgical staple cartridge 304. The anvil 306 may be coupled to the elongate channel 302. Apertures 199 may be defined in the elongate channel 302 to receive pins 152 extending from the anvil 306 to allow the anvil 306 to pivot from an open position to a closed position relative to the elongate channel 302 and the surgical staple cartridge 304. The firing bar 172 is configured to longitudinally translate into the end effector 300. The firing bar 172 may be constructed of one solid section or may comprise a laminate material including a stack of steel plates. The firing bar 172 includes an I-beam 178 and a cutting edge 182 at a distal end of the I-beam 178. A distal protruding end of the firing bar 172 may be attached to the I-beam 178, which I-beam 178 helps space the anvil 306 apart from the surgical staple cartridge 304 positioned in the elongate channel 302 when the anvil 306 is in the closed position. The I-beam 178 may include a sharp cutting edge 182, the cutting edge 182 being configured to sever tissue as the I-beam 178 is advanced distally by the firing bar 172. In operation, the I-beam 178 can actuate or fire the surgical staple cartridge 304. The surgical staple cartridge 304 can comprise a molded cartridge body 194, the cartridge body 194 holding a plurality of staples 191, the staples 191 disposed on staple drivers 192, the staple drivers 192 located in respective upwardly open staple cavities 195. The wedge sled 190 is driven distally by the I-beam 178 to slide over the cartridge tray 196 of the surgical staple cartridge 304. The wedge sled 190 cams staple drivers 192 upward to extrude staples 191 into deforming contact with the anvil 306 while the cutting edges 182 of the I-beam 178 sever clamped tissue.

The I-beam 178 may include an upper pin 180 that engages the anvil 306 during firing. The I-beam 178 can include intermediate pins 184 and feet 186 that engage portions of the cartridge body 194, the cartridge tray 196, and the elongate channel 302. When the surgical staple cartridge 304 is positioned within the elongate channel 302, the slot 193 defined in the cartridge body 194 can be aligned with the longitudinal slot 197 defined in the cartridge tray 196 and the slot 189 defined in the elongate channel 302. In use, the I-beam 178 can be slid through the aligned longitudinal slots 193, 197, and 189, as indicated in fig. 4, wherein the foot 186 of the I-beam 178 can engage a groove extending along the bottom surface of the elongate channel 302 along the length of the slot 189, the middle pin 184 can engage the top surface of the cartridge tray 196 along the length of the longitudinal slot 197, and the upper pin 180 can engage the anvil 306. The I-beam 178 can sever or limit relative movement between the anvil 306 and the surgical staple cartridge 304 as the firing bar 172 is advanced distally to fire the staples from the surgical staple cartridge 304 and/or incise tissue captured between the anvil 306 and the surgical staple cartridge 304. The firing bar 172 and the I-beam 178 may be retracted proximally, thereby allowing the anvil 306 to be opened to release two stapled and severed tissue sections (not shown).

Fig. 5A-5B are block diagrams of control circuitry 700 of the surgical instrument 10 of fig. 1 spanning two drawn sheets according to one aspect of the present disclosure. Referring primarily to fig. 5A-5B, the handle assembly 702 can include a motor 714, the motor 714 can be controlled by a motor driver 715, and can be used by a firing system of the surgical instrument 10. In various forms, the motor 714 may be a direct current brushed driving motor having a maximum rotational speed of about 25,000 RPM. In other arrangements, the motor 714 may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor driver 715 may include, for example, an H-bridge driver including a Field Effect Transistor (FET) 719. The motor 714 may be powered by a power assembly 706, which power assembly 706 is releasably mounted to the handle assembly 200 for supplying control power to the surgical instrument 10. The power assembly 706 may include a battery that may include a plurality of battery cells connected in series that may be used as a power source to power the surgical instrument 10. In some cases, the battery cells of power assembly 706 may be replaceable and/or rechargeable. In at least one example, the battery cell may be a lithium ion battery that is detachably coupleable to the power assembly 706.

Shaft assembly 704 can include a shaft assembly controller 722 that can communicate with a safety controller and power management controller 716 through an interface when shaft assembly 704 and power assembly 706 are coupled to handle assembly 702. For example, the interface can include a first interface portion 725 and a second interface portion 727, wherein the first interface portion 725 can include one or more electrical connectors for coupling engagement with corresponding shaft assembly electrical connectors and the second interface portion 727 can include one or more electrical connectors for coupling engagement with corresponding power assembly electrical connectors, thereby allowing electrical communication between the shaft assembly controller 722 and the power management controller 716 when the shaft assembly 704 and the power assembly 706 are coupled to the handle assembly 702. One or more communication signals may be transmitted over the interface to communicate one or more of the power requirements of the attached interchangeable shaft assembly 704 to the power management controller 716. In response, the power management controller may modulate the power output of the battery of power assembly 706 according to the power requirements of attached shaft assembly 704, as described in more detail below. These connectors may include switches that may be activated after the handle assembly 702 is mechanically coupled to the shaft assembly 704 and/or power assembly 706 to allow electrical communication between the shaft assembly controller 722 and the power management controller 716.

For example, the interface may facilitate the transmission of one or more communication signals between the power management controller 716 and the shaft assembly controller 722 by routing such communication signals through the main controller 717 located in the handle assembly 702. In other instances, when shaft assembly 704 and power assembly 706 are coupled to handle assembly 702, the interface may facilitate directing a communication line between power management controller 716 and shaft assembly controller 722 through handle assembly 702.

The main controller 717 may be any single-core or multi-core processor, such as those known under the trade name ARM Cortex, supplied by Texas Instruments. In one aspect, master controller 717 can be, for example, an LM4F230H5QR ARM Cortex-M4F processor core available from Texas instruments, which includes: 256KB of on-chip memory of single cycle flash memory or other non-volatile memory (up to 40MHz), prefetch buffer for performance improvement over 40MHz, 32KB of single cycle Serial Random Access Memory (SRAM), load with

Internal Read Only Memory (ROM) for software, Electrically Erasable Programmable Read Only Memory (EEPROM) for 2KB, one or more Pulse Width Modulation (PWM) modules, one or more Quadrature Encoder Input (QEI) analog, one or more 12-bit analog-to-digital converters (ADCs) with 12 analog input channels, the details of which can be seen in the product data sheet.

The safety controller may be a safety controller platform comprising two controller-based families such as TMS570 and RM4x, also known under the trade name Hercules ARM Cortex R4 supplied by Texas Instruments. The safety controller may be configured for specific use with IEC 61508 and ISO 26262 safety critical applications, among others, to provide advanced integrated safety features while delivering scalable performance, connectivity, and memory options.

The power component 706 may include a power management circuit that may include a power management controller 716, a power modulator 738, and a current sensing circuit 736. The power management circuitry may be configured to adjust the power output of the battery based on the power requirements of shaft assembly 704 when shaft assembly 704 and power assembly 706 are coupled to handle assembly 702. The power management controller 716 may be programmed to control the power modulator 738 to modulate the power output of the power component 706, and the current sensing circuit 736 may be employed to monitor the power output of the power component 706 to provide feedback to the power management controller 716 regarding the power output of the battery such that the power management controller 716 may adjust the power output of the power component 706 to maintain a desired output. Power management controller 716 and/or shaft assembly controller 722 may each include one or more processors and/or memory units that may store a plurality of software modules.

The surgical instrument 10 (fig. 1-4) may include an output device 742, and the output device 742 may include a device for providing sensory feedback to a user. Such devices may include, for example, visual feedback devices (e.g., LCD display screens, LED indicators), audio feedback devices (e.g., speakers, buzzers), or tactile feedback devices (e.g., haptic actuators). In some cases, the output device 742 can include a display 743, which display 743 can be included in the handle assembly 702. The shaft assembly controller 722 and/or the power management controller 716 can provide feedback to a user of the surgical instrument 10 via an output device 742. The interface may be configured to connect the shaft assembly controller 722 and/or the power management controller 716 to an output device 742. Alternatively, the output device 742 may be integrated with the power component 706. In such instances, when the shaft assembly 704 is coupled to the handle assembly 702, communication between the output device 742 and the shaft assembly controller 722 may be achieved through an interface.

The control circuit 700 includes a circuit segment configured to control the operation of the powered surgical instrument 10. The safety controller section (section 1) includes a safety controller and a main controller 717 section (section 2). The safety and/or main controller 717 is configured to be able to interact with one or more additional circuit segments such as an acceleration segment, a display segment, a shaft segment, an encoder segment, a motor segment, and a power segment. Each of the circuit segments may be coupled to a safety controller and/or a main controller 717. The main controller 717 is also coupled to flash memory. The main controller 717 also includes a serial communication interface. The main controller 717 includes a plurality of inputs coupled to, for example, one or more circuit segments, a battery, and/or a plurality of switches. The segmented circuit may be implemented by any suitable circuit, such as a Printed Circuit Board Assembly (PCBA) within powered surgical instrument 10. It is to be understood that the term "processor" as used herein includes any microprocessor, processor, microcontroller, controller or other basic computing device that combines the functions of a computer's Central Processing Unit (CPU) onto one integrated circuit or at most a few integrated circuits. The main controller 717 is a multipurpose programmable device that receives digital data as input, processes the input according to instructions stored in its memory, and then provides the result as output. Because the processor has internal memory, it is an example of sequential digital logic. The control circuit 700 may be configured to enable one or more of the processes described herein.

The acceleration segment (segment 3) includes an accelerometer. The accelerometer is configured to detect movement or acceleration of the powered surgical instrument 10. Inputs from the accelerometer can be used to transition to and from sleep mode, identify the orientation of the powered surgical instrument, and/or identify when the surgical instrument has been dropped. In some examples, the acceleration segment is coupled to a safety controller and/or a main controller 717.

The display segment (segment 4) includes a display connector coupled to a main controller 717. The display connector couples the main controller 717 to the display through one or more integrated circuit drivers for the display. The integrated circuit driver of the display may be integrated with the display and/or may be located separately from the display. The display may include any suitable display, such as, for example, an Organic Light Emitting Diode (OLED) display, a Liquid Crystal Display (LCD), and/or any other suitable display. In some examples, the display segment is coupled to a safety controller.

The shaft segment (segment 5) includes controls for an interchangeable shaft assembly 200 (fig. 1 and 3) coupled to the surgical instrument 10 (fig. 1-4) and/or one or more controls for an end effector 300 coupled to the interchangeable shaft assembly 200. The shaft section includes a shaft connector configured to couple the main controller 717 to the shaft PCBA. The shaft PCBA includes a low power microcontroller having a Ferroelectric Random Access Memory (FRAM), an articulation switch, a shaft release hall effect switch, and a shaft PCBA EEPROM. The shaft PCBA EEPROM includes one or more parameters, routines and/or programs that are specific to the interchangeable shaft assembly 200 and/or the shaft PCBA. The shaft PCBA may be coupled to the interchangeable shaft assembly 200 and/or integrated with the surgical instrument 10. In some examples, the shaft segment includes a second shaft EEPROM. The second shaft EEPROM includes a plurality of algorithms, routines, parameters, and/or other data corresponding to one or more shaft assemblies 200 and/or end effectors 300 that may interface with the powered surgical instrument 10.

The position encoder section (section 6) comprises one or more magnetic angular rotary position encoders. The one or more magnetic angular rotary position encoders are configured to identify the rotational position of the motor 714, interchangeable shaft assembly 200 (fig. 1 and 3), and/or end effector 300 of the surgical instrument 10 (fig. 1-4). In some examples, a magnetic angular rotational position encoder may be coupled to the safety controller and/or the main controller 717.

The motor circuit section (section 7) includes a motor 714 configured to control movement of the powered surgical instrument 10 (fig. 1-4). The motor 714 is coupled to a main microcontroller 717 through an H-bridge driver including one or more H-bridge Field Effect Transistors (FETs) and a motor controller. The H-bridge driver is also coupled to a safety controller. A motor current sensor is coupled in series with the motor for measuring a current draw of the motor. The motor current sensor is in signal communication with the main controller 717 and/or the safety controller. In some examples, the motor 714 is coupled to a motor electromagnetic interference (EMI) filter.

The motor controller controls the first motor flag and the second motor flag to indicate the state and position of the motor 714 to the main controller 717. The main controller 717 provides a Pulse Width Modulation (PWM) high signal, a PWM low signal, a direction signal, a synchronization signal, and a motor reset signal to the motor controller through the buffer. The power segment is configured to provide a segment voltage to each of the circuit segments.

The power section (section 8) includes a battery coupled to a safety controller, a main controller 717 and additional circuit sections. The battery is coupled to the segmented circuit by a battery connector and a current sensor. The current sensor is configured to be able to measure the total current consumption of the segmented circuit. In some examples, the one or more voltage converters are configured to be capable of providing a predetermined voltage value to the one or more circuit segments. For example, in some examples, the segmented circuit may include a 3.3V voltage converter and/or a 5V voltage converter. The boost converter is configured to be able to provide a boost voltage up to a predetermined amount, such as up to 13V. The boost converter is configured to be able to provide additional voltage and/or current during power intensive operations and prevent a reduced voltage condition or a low power condition.

A plurality of switches are coupled to the safety controller and/or the main controller 717. These switches may be configured to control the operation of the surgical instrument 10 (fig. 1-4), the segmented circuit, and/or indicate the status of the surgical instrument 10. An emergency assistance door switch and a hall effect switch for emergency assistance are configured to be able to indicate a status of the emergency assistance door. A plurality of articulation switches, such as, for example, a left articulation switch, a left right articulation switch, a left center articulation switch, a right left articulation switch, a right articulation switch, and a right center articulation switch, are configured to control articulation of the interchangeable shaft assembly 200 (fig. 1 and 3) and/or the end effector 300 (fig. 1 and 4). The left hand and right hand commutation switches are coupled to a main controller 717. The left switches (including a left articulation switch, a left right articulation switch, a left center articulation switch, and a left reversing switch) are coupled to the main controller 717 through a left flex connector. The right switches (including the right left articulation switch, the right articulation switch, the right center articulation switch, and the right reversing switch) are coupled to the master controller 717 through a right flex connector. The cocking switch, clamp release switch, and shaft engagement switch are linked to the main controller 717.

Any suitable mechanical, electromechanical or solid state switch may be used in any combination to implement these multiple switches. For example, the switch may be a limit switch that is operated by the action of a component associated with the surgical instrument 10 (fig. 1-4) or the presence of some object. Such switches may be used to control various functions associated with the surgical instrument 10. Limit switches are electromechanical devices consisting of an actuator mechanically connected to a set of contacts. When an object comes into contact with the actuator, the device operates the contacts to make or break the electrical connection. The limit switch is durable, simple and convenient to install, reliable in operation and suitable for various applications and environments. The limit switches can determine the presence or absence, the passage, the location, and the end of travel of the object. In other implementations, the switches may be solid state switches that operate under the influence of a magnetic field, such as hall effect devices, Magnetoresistive (MR) devices, Giant Magnetoresistive (GMR) devices, magnetometers, and the like. In other implementations, the switch may be a solid state switch that operates under the influence of light, such as an optical sensor, an infrared sensor, an ultraviolet sensor, and so forth. Likewise, the switches may be solid state devices such as transistors (e.g., FETs, junction FETs, metal oxide semiconductor FETs (mosfets), bipolar transistors, etc.). Other switches may include wireless switches, ultrasonic switches, accelerometers, inertial sensors, and the like.

Fig. 6 is another block diagram of the control circuit 700 of the surgical instrument of fig. 1 illustrating the interface between the handle assembly 702 and the power assembly 706, and between the handle assembly 702 and the interchangeable shaft assembly 704, according to one aspect of the present disclosure. The handle assembly 702 may include a main controller 717, a shaft assembly connector 726, and a power assembly connector 730. The power component 706 may include a power component connector 732, a power management circuit 734, the power management circuit 734 may include a power management controller 716, a power modulator 738, and a current sensing circuit 736. The shaft assembly connectors 730, 732 form an interface 727. Power management circuit 734 may be configured to modulate the power output of battery 707 based on the power requirements of interchangeable shaft assembly 704 when interchangeable shaft assembly 704 and power assembly 706 are coupled to handle assembly 702. The power management controller 716 may be programmed to control the power modulator 738 to modulate the power output of the power component 706, and the current sensing circuit 736 may be employed to monitor the power output of the power component 706 to provide feedback to the power management controller 716 regarding the power output of the battery 707, such that the power management controller 716 may adjust the power output of the power component 706 to maintain a desired output. The shaft assembly 704 includes a shaft processor 719 coupled to a non-volatile memory 721 and a shaft assembly connector 728 for electrically coupling the shaft assembly 704 to the handle assembly 702. The shaft assembly connectors 726, 728 form an interface 725. The main controller 717, the axis processor 719, and/or the power management controller 716 may be configured to enable one or more of the processes described herein.

The surgical instrument 10 (fig. 1-4) may include an output device 742 for providing sensory feedback to the user. Such devices may include visual feedback devices (e.g., LCD display screens, LED indicators), audible feedback devices (e.g., speakers, buzzers), or tactile feedback devices (e.g., haptic actuators). In some cases, the output device 742 can include a display 743, which display 743 can be included in the handle assembly 702. The shaft assembly controller 722 and/or the power management controller 716 can provide feedback to a user of the surgical instrument 10 via an output device 742. Interface 727 may be configured to connect shaft assembly controller 722 and/or power management controller 716 to output device 742. The output device 742 may be integrated with the power component 706. When the interchangeable shaft assembly 704 is coupled to the handle assembly 702, communication between the output device 742 and the shaft assembly controller 722 can be accomplished through the interface 725. Having described the control circuit 700 (fig. 5A-5B and 6) for controlling the operation of the surgical instrument 10 (fig. 1-4), the present disclosure now turns to various configurations of the surgical instrument 10 (fig. 1-4) and the control circuit 700.

Fig. 7 illustrates a control circuit 800 configured to control aspects of the surgical instrument 10 (fig. 1-4) according to one aspect of the present disclosure. The control circuitry 800 may be configured to implement various processes described herein. The control circuit 800 may include a controller including one or more processors 802 (e.g., microprocessors, microcontrollers) coupled to at least one memory circuit 804. The memory circuit 804 stores machine-executable instructions that, when executed by the processor 802, cause the processor 802 to execute machine instructions to implement the various processes described herein. The processor 802 may be any of a variety of single-core or multi-core processors known in the art. The memory circuit 804 may include volatile storage media and non-volatile storage media. The processor 802 may include an instruction processing unit 806 and an arithmetic unit 808. The instruction processing unit may be configured to be able to receive instructions from the memory circuit 804.

Fig. 8 illustrates a combinational logic circuit 810 configured to control aspects of the surgical instrument 10 (fig. 1-4) in accordance with an aspect of the present disclosure. The combinational logic circuit 810 may be configured to enable the various processes described herein. The circuit 810 may comprise a finite state machine including combinatorial logic circuitry 812 configured to receive data associated with the surgical instrument 10 at an input 814, process the data through the combinatorial logic 812, and provide an output 816.

Fig. 9 illustrates a sequential logic circuit 820 configured to control aspects of the surgical instrument 10 (fig. 1-4) according to one aspect of the present disclosure. The sequential logic circuit 820 or the combinational logic circuit 822 may be configured to enable the various processes described herein. Circuitry 820 may include a finite state machine. The sequential logic circuit 820 may comprise, for example, a combinational logic circuit 822, at least one memory circuit 824, and a clock 829. The at least one memory circuit 820 may store a current state of the finite state machine. In some cases, sequential logic 820 may be synchronous or asynchronous. The combinational logic circuit 822 is configured to receive data associated with the surgical instrument 10 at an input 826, process the data through the combinational logic circuit 822 and provide an output 828. In other aspects, the circuitry may comprise a combination of the processor 802 and a finite state machine to implement the various processes herein. In other aspects, the finite state machine may comprise a combination of combinational logic circuit 810 and sequential logic circuit 820.

Aspects may be implemented as an article of manufacture. The article of manufacture may comprise a computer-readable storage medium arranged to store logic, instructions, and/or data for performing various operations of one or more aspects. For example, an article of manufacture may comprise a magnetic disk, optical disk, flash memory, or firmware containing computer program instructions adapted for execution by a general purpose or special purpose processor.

Fig. 10 is a diagram of an absolute positioning system 1100 of the surgical instrument 10 (fig. 1-4) according to one aspect of the present disclosure, where the absolute positioning system 1100 includes a controlled motor drive circuit arrangement having a sensor arrangement 1102. The sensor arrangement 1102 for the absolute positioning system 1100 provides a unique position signal corresponding to the position of the displacement member 1111. Turning briefly to fig. 2-4, in one aspect, displacement member 1111 represents a longitudinally movable drive member 120 (fig. 2), the longitudinally movable drive member 120 including a rack of drive teeth 122 for meshing engagement with a corresponding drive gear 86 of gear reducer assembly 84. In other aspects, the displacement member 1111 represents the firing member 220 (fig. 3), and the firing member 220 can be adapted and configured to include a rack of drive teeth. In yet another aspect, the displacement member 1111 represents the firing bar 172 (FIG. 4) or the I-beam 178 (FIG. 4), each of which may be adapted and configured to include the drive teeth of a rack. Accordingly, as used herein, the term displacement member is used to generally refer to any movable member of the surgical instrument 10 such as the drive member 120, the firing member 220, the firing bar 172, the I-beam 178, or any element that may be displaced. In one aspect, the longitudinally movable drive member 120 is coupled to the firing member 220, the firing bar 172, and the I-beam 178. Thus, absolute positioning system 1100 may actually track the displacement of I-beam 178 by tracking the displacement of longitudinally movable drive member 120. In various other aspects, displacement member 1111 may be coupled to any sensor suitable for measuring displacement. Thus, the longitudinally movable drive member 120, firing member 220, firing bar 172, or I-beam 178, or combinations thereof, may be coupled to any suitable displacement sensor. The displacement sensor may comprise a contact displacement sensor or a non-contact displacement sensor. The displacement sensor may comprise a Linear Variable Differential Transformer (LVDT), a Differential Variable Reluctance Transducer (DVRT), a sliding potentiometer, a magnetic sensing system comprising a movable magnet and a series of linearly arranged hall effect sensors, a magnetic sensing system comprising a fixed magnet and a series of movable linearly arranged hall effect sensors, an optical sensing system comprising a movable light source and a series of linearly arranged photodiodes or photodetectors, an optical sensing system comprising a fixed light source and a series of movable linearly arranged photodiodes or photodetectors, or any combination thereof.

The electric motor 1120 may include a rotatable shaft 1116 operatively interfacing with a gear assembly 1114, the gear assembly 1114 being mounted in meshing engagement with drive teeth of a set or rack on the displacement member 1111. The sensor element 1126 is operably coupled to the gear assembly 1114 such that a single rotation of the sensor element 1126 corresponds to some linear longitudinal translation of the displacement member 1111. The arrangement of the transmission and sensor 1118 may be connected to a linear actuator via a rack and pinion arrangement, or to a rotary actuator via a spur gear or other connection. A power source 1129 provides power to the absolute positioning system 1100 and an output indicator 1128 may display the output of the absolute positioning system 1100. In fig. 2, displacement member 1111 represents a longitudinally movable drive member 120, the longitudinally movable drive member 120 including a rack of drive teeth 122 formed thereon for meshing engagement with a corresponding drive gear 86 of gear reducer assembly 84. Displacement member 1111 represents a longitudinally movable firing member 220, firing bar 172, I-beam 178, or a combination thereof.

A single rotation of sensor element 1126 associated with position sensor 1112 equates to a longitudinal displacement d1 of displacement member 1111, where d1 is the longitudinal distance that displacement member 1111 moves from point "a" to point "b" after a single rotation of sensor element 1126 coupled to displacement member 1111. Sensor arrangement 1102 may be connected via a gear reduction, which causes position sensor 1112 to complete one or more rotations for the full stroke of displacement member 1111. Position sensor 1112 may complete multiple rotations for the full stroke of displacement member 1111.

A series of switches 1122a-1122n (where n is an integer greater than one) may be employed alone or in conjunction with gear reduction to provide unique position signals for more than one rotation of position sensor 1112. The state of the switches 1122a-1122n is fed back to the controller 1104, which the controller 1104 applies logic to determine a unique position signal corresponding to the longitudinal displacement d1+ d2+ … dn of the displacement member 1111. The output 1124 of the position sensor 1112 is provided to the controller 1104. The position sensor 1112 of the sensor arrangement 1102 can include a magnetic sensor, an analog rotation sensor (e.g., a potentiometer), an array of analog hall effect elements that output a unique combination of position signals or values.

Absolute positioning system 1100 provides the absolute position of displacement member 1111 upon instrument power-up without retracting or advancing displacement member 1111 to a reset (clear or home) position as may be required by conventional rotary encoders that simply count the number of forward or backward steps taken by motor 1120 to infer the position of the device actuator, drive rod, knife, etc.

The controller 1104 may be programmed to perform various functions, such as precise control of the speed and position of the knife and articulation system. In one aspect, the controller 1104 includes a processor 1108 and a memory 1106. The electric motor 1120 may be a brushed dc motor having a gearbox and mechanical linkage to an articulation or knife system. In one aspect, the motor drive 1110 can be a3941 available from Allegro Microsystems, inc. Other motor drives can be readily substituted for use in absolute positioning system 1100. More detailed description of the absolute positioning system 1100 is described in U.S. patent application 15/130,590 entitled SYSTEMS AND METHODS FOR CONTROLLING a motor vehicle, incorporated STAPLING AND cutting, filed on 15.4.2016, the entire disclosure of which is incorporated herein by reference.

The controller 1104 may be programmed to provide precise control of the speed and position of the displacement member 1111 and the articulation system. The controller 1104 can be configured to calculate a response in software of the controller 1104. The calculated response is compared to the measured response of the actual system to obtain an "observed" response, which is used for the actual feedback decision. The observed response is a favorable tuning value that equalizes the smooth continuous nature of the simulated response with the measured response, which can sense external influences on the system.

The absolute positioning system 1100 may include and/or be programmed to implement feedback controllers such as PID, state feedback, and adaptive controllers. The power source 1129 converts the signal from the feedback controller into a physical input, in this case a voltage, to the system. Other examples include Pulse Width Modulation (PWM) of voltage, current, and force. In addition to the position measured by position sensor 1112, one or more other sensors 1118 may be provided to measure physical parameters of the physical system. In a digital signal processing system, the absolute positioning system 1100 is coupled to a digital data acquisition system, wherein the output of the absolute positioning system 1100 will have a limited resolution and sampling frequency. The absolute positioning system 1100 may include comparison and combination circuitry to combine the calculated response with the measured response using an algorithm that drives the calculated response toward the measured response, such as a weighted average and a theoretical control loop. The calculated response of the physical system takes into account characteristics such as mass, inertia, viscous friction, inductive resistance to predict the state and output of the physical system by knowing the inputs. The controller 1104 may be the control circuit 700 (fig. 5A-5B).

The motor driver 1110 may be a3941 available from Allegro Microsystems, inc. The a3941 driver 1110 is a full-bridge controller for use with an external N-channel power Metal Oxide Semiconductor Field Effect Transistor (MOSFET) specifically designed for inductive loads, such as brushed dc motors. Driver 1110 includes a unique charge pump voltage regulator that provides full (>10V) gate drive for battery voltages as low as 7V and allows a3941 to operate with a reduced gate drive as low as 5.5V. A bootstrap capacitor may be employed to provide the aforementioned battery supply voltage required for the N-channel MOSFET. The internal charge pump of the high-side drive allows for direct current (100% duty cycle) operation. The full bridge may be driven in fast decay mode or slow decay mode using diodes or synchronous rectification. In slow decay mode, current recirculation can pass through either the high-side or low-side FETs. The power FET is protected from breakdown by a resistor adjustable dead time. The overall diagnostics indicate undervoltage, overheating, and power bridge faults, and may be configured to protect the power MOSFETs in most short circuit situations. Other motor drives can be readily substituted for use in absolute positioning system 1100.

Having described a general architecture for implementing various aspects of the absolute positioning system 1100 with respect to the sensor arrangement 1102, the present disclosure now turns to fig. 11 and 12 to describe one aspect of the sensor arrangement 1102 of the absolute positioning system 1100. FIG. 11 is an exploded perspective view of a sensor arrangement 1102 of an absolute positioning system 1100 showing the relative alignment of elements of the sensor arrangement 1102 and a circuit 1205, according to one aspect. The sensor arrangement 1102 of the absolute positioning system 1100 includes a position sensor 1200, a magnet 1202 sensor element, a magnet holder 1204 that rotates once per full stroke of each displacement member 1111, and a gear assembly 1206 that provides a gear reduction. Referring momentarily to fig. 2, displacement member 1111 may represent a longitudinally movable drive member 120, the longitudinally movable drive member 120 including a rack of drive teeth 122 for meshing engagement with a corresponding drive gear 86 of gear reducer assembly 84. Returning to fig. 11, a structural element such as a bracket 1216 is provided to support the gear assembly 1206, magnet holder 1204, and magnet 1202. The position sensor 1200 includes a magnetic sensing element, such as a hall element, and is placed in proximity to the magnet 1202. As the magnet 1202 rotates, the magnetic sensing element of the position sensor 1200 determines the absolute angular position of the magnet 1202 over one rotation.

The sensor arrangement 1102 may include any number of magnetic sensing elements, such as magnetic sensors that are classified, for example, according to whether they measure the entire magnetic field or vector components of the magnetic field. The techniques for producing the two types of magnetic sensors described above encompass a number of aspects of physics and electronics. Technologies for magnetic field sensing include detection coils, flux gates, optical pumps, nuclear spins, superconducting quantum interferometers (SQUIDs), hall effects, anisotropic magnetoresistance, giant magnetoresistance, magnetic tunnel junctions, giant magnetoimpedances, magnetostrictive/piezoelectric composites, magnetodiodes, magnetotransistors, optical fibers, magneto-optical, and magnetic sensors based on micro-electromechanical systems, among others.

The gear assembly includes a first gear 1208 and a second gear 1210 that are in meshing engagement to provide a 3:1 gear ratio connection. Third gear 1212 rotates about shaft 1214. The third gear 1212 is in meshing engagement with the displacement member 1111 (or 120 as shown in fig. 2) and rotates in a first direction when the displacement member 1111 is advanced in the distal direction D and rotates in a second direction when the displacement drive member 1111 is retracted in the proximal direction P. The second gear 1210 also rotates about the axis 1214, and thus, rotation of the second gear 1210 about the axis 1214 corresponds to longitudinal translation of the displacement member 1111. Thus, one full stroke of displacement member 1111 in the distal direction D or the proximal direction P corresponds to three rotations of second gear 1210 and a single rotation of first gear 1208. Since magnet holder 1204 is coupled to first gear 1208, magnet holder 1204 makes one full rotation with each full stroke of displacement member 1111.

The position sensor 1200 is supported by a position sensor holder 1218 that defines a bore 1220 adapted to contain the position sensor 1200, in precise alignment with an underlying magnet 1202 that rotates within a magnet holder 1204. The clamp is coupled to bracket 1216 and circuit 1205 and remains stationary as magnet 1202 rotates with magnet holder 1204. A hub 1222 is provided to mate with the first gear 1208 and the magnet holder 1204. Also shown are a second gear 1210 and a third gear 1212 coupled to the shaft 1214.

Fig. 12 is a diagram of a position sensor 1200 including a magnetic rotary absolute positioning system for an absolute positioning system 1100 according to an aspect of the present disclosure. The position sensor 1200 may be implemented AS an AS5055EQFT monolithic magnetic rotary position sensor available from australia Microsystems, AG. The position sensor 1200 interfaces with a controller 1104 to provide an absolute positioning system 1100. The position sensor 1200 is a low voltage and low power component and includes four hall effect elements 1228A, 1228B, 1228C, 1228D in a region 1230 of the position sensor 1200 located above the magnet 1202 (fig. 15 and 16). A high resolution ADC 1232 and a smart power management controller 1238 are also provided on the chip. CORDIC processor 1236 (for Coordinate Rotation DIgital Computer), also known as the bitwise and Volder algorithms, is provided to implement simple and efficient algorithms that require only addition, subtraction, bit shift and table lookup operations to compute hyperbolic and trigonometric functions. The angular position, alarm bits, and magnetic field information are transmitted to the controller 1104 over a standard serial communication interface, such as SPI interface 1234. The position sensor 1200 provides 12-bit or 14-bit resolution. The position sensor 1200 may be an AS5055 chip provided in a small QFN 16-pin 4 × 4 × 0.85mm package.

The hall effect elements 1228A, 1228B, 1228C, 1228D are located directly above the rotating magnet 1202 (fig. 11). The hall effect is a well-known effect and will not be described in detail herein for convenience, however, the hall effect typically produces a voltage difference (hall voltage) across a conductor that is transverse to the current in an electrical conductor and a magnetic field perpendicular to the current. The hall coefficient is defined as the ratio of the induced electric field to the product of the current density and the applied magnetic field. It is a property of the material from which the conductor is made, as its value depends on the type, number and properties of the charge carriers that make up the current. In the AS5055 position sensor 1200, the hall effect elements 1228A, 1228B, 1228C, 1228D can generate a voltage signal that indicates the absolute position of the magnet 1202 in terms of the angle through which the magnet 1202 has undergone a single rotation. This value of the angle, which is a unique position signal, is calculated by CORDIC processor 1236 and stored on board the AS5055 position sensor 1200 in a register or memory. In various techniques, the controller 1104 is provided with a value of the angle indicating the position of the magnet 1202 over one rotation, such as at power up or upon request by the controller 1104.

The AS5055 position sensor 1200 requires only a few external components to be operable when connected to the controller 1104. A simple application using a single power source requires six wires: two wires are used for power and four wires 1240 are used for SPI interface 1234 with controller 1104. A seventh connection may be added to send an interrupt to the controller 1104 to inform that a new valid angle can be read. Upon power up, the AS5055 position sensor 1200 performs a full power up sequence, including an angle measurement. Completion of this cycle is indicated as INT output 1242 and the angle value is stored in an internal register. Once this output is set, the AS5055 position sensor 1200 pauses into the sleep mode. The controller 1104 can respond to an INT request at INT output 1242 by reading the angle value from AS5055 position sensor 1200 through SPI interface 1234. Once the controller 1104 reads the angle value, the INT output 1242 is cleared again. Sending a "read angle" command by controller 1104 to position sensor 1200 through SPI interface 1234 also automatically powers up the chip and initiates another angle measurement. As soon as the controller 1104 completes reading the angle value, the INT output 1242 is cleared and the new result is stored in the angle register. Completion of the angle measurement is again indicated by setting the INT output 1242 and the corresponding flags in the status register.

Due to the measurement principle of the AS5055 position sensor 1200, only a single angular measurement is performed in a very short time (about 600 μ β) after each power-up sequence. AS soon AS the measurement of one angle is completed, the AS5055 position sensor 1200 is suspended to the power-down state. On-chip filtering of the angle values according to digital averaging is not performed, as this would require more than one angle measurement and thus longer power-up time, which is undesirable in low power applications. Angular jitter may be reduced by averaging the number of angular samples in the controller 1104. For example, averaging four samples may reduce jitter by 6dB (50%).

Fig. 13 is a cross-sectional view of the end effector 2502 of the surgical instrument 10 (fig. 1-4) illustrating the firing stroke of the I-beam 2514 relative to tissue 2526 grasped within the end effector 2502 according to one aspect of the present disclosure. The end effector 2502 is configured to operate with the surgical instrument 10 illustrated in fig. 1-4. The end effector 2502 includes an anvil 2516 and an elongate channel 2503, with a staple cartridge 2518 positioned in the elongate channel 2503. The firing rod 2520 is configured to translate distally and proximally along a longitudinal axis 2515 of the end effector 2502. When the end effector 2502 is not articulated, the end effector 2502 is in-line with the axis of the instrument. An I-beam 2514 including a cutting edge 2509 is shown at a distal portion of the firing bar 2520. A wedge sled 2513 is positioned in the staple cartridge 2518. As the I-beam 2514 translates distally, the cutting edge 2509 contacts and can cut tissue 2526 positioned between the anvil 2516 and the staple cartridge 2518. Also, the I-beam 2514 contacts the wedge sled 2513 and pushes it distally, causing the wedge sled 2513 to contact the staple driver 2511. The staple drivers 2511 can be driven upward into the staples 2505 such that the staples 2505 are advanced through the tissue and into pockets 2507 defined in the anvil 2516, which form the staples 2505.

An exemplary I-beam 2514 firing stroke is illustrated by a chart 2529 aligned with the end effector 2502. Alignment of exemplary tissue 2526 with the end effector 2502 is also shown. The firing member stroke may include a stroke start position 2527 and a stroke end position 2528. During the I-beam 2514 firing stroke, the I-beam 2514 can be advanced distally from a start of stroke position 2527 to an end of stroke position 2528. An I-beam 2514 is shown at one exemplary location of the stroke start location 2527. The I-beam 2514 firing stroke chart 2529 illustrates five firing member stroke zones 2517, 2519, 2521, 2523, 2525. In the first stroke zone 2517, the I-beam 2514 may begin to advance distally. In the first stroke zone 2517, the I-beam 2514 may contact the wedge sled 2513 and begin to move distally. However, while in the first region, the cutting edge 2509 may not contact the tissue and the wedge sled 2513 may not contact the staple drivers 2511. After the static friction force is overcome, the force driving the I-beam 2514 in the first region 2517 may be substantially constant.

In the second firing member stroke zone 2519, the cutting edge 2509 can begin to contact and cut tissue 2526. Also, the wedge sled 2513 can begin to contact the staple drivers 2511 to drive the staples 2505. The force driving the I-beam 2514 may begin to increase. As shown, due to the manner in which the anvil 2516 pivots relative to the staple cartridge 2518, tissue initially encountered may be compressed and/or thinned. In the third firing member stroke region 2521, the cutting edge 2509 can continuously contact and cut tissue 2526, and the wedge sled 2513 can repeatedly contact the staple drivers 2511. The force driving the I-beam 2514 may be stabilized in the third region 2521. With the fourth firing stroke area 2523, the force driving the I-beam 2514 may begin to fall. For example, tissue in the portion of the end effector 2502 corresponding to the fourth firing region 2523 may be compressed less than tissue closer to the pivot point of the anvil 2516, requiring less cutting force. Also, the cutting edge 2509 and wedge slide 2513 can reach the end of the tissue 2526 in a fourth region 2523. When the I-beam 2514 reaches the fifth region 2525, the tissue 2526 may be severed completely. The wedge sled 2513 can contact one or more staple drivers 2511 at or near the end of the tissue. The force urging the I-beam 2514 through the fifth region 2525 may be reduced, and in some examples, may be similar to the force driving the I-beam 2514 in the first region 2517. At the end of the firing member stroke, the I-beam 2514 can reach an end of stroke position 2528. The positioning of the firing member travel regions 2517, 2519, 2521, 2523, 2525 in fig. 18 is but one example. In some examples, the different zones may begin at different locations along the end effector longitudinal axis 2515, e.g., based on the positioning of tissue between the anvil 2516 and the staple cartridge 2518.

As discussed above, and referring now to fig. 10-13, a firing system of the shaft assembly (including the I-beam 2514) can be advanced and/or retracted relative to the end effector 2502 of the shaft assembly using the electric motor 1122 positioned within the handle assembly of the surgical instrument 10 (fig. 1-4) in order to staple and/or incise tissue captured within the end effector 2502. The I-beam 2514 can be advanced or retracted at a desired speed or within a range of desired speeds. The controller 1104 may be configured to control the speed of the I-beam 2514. The controller 1104 may be configured to be able to predict the speed of the I-beam 2514 based on, for example, various parameters of the power supplied to the electric motor 1122 (such as voltage and/or current) and/or other operating parameters or external influences of the electric motor 1122. The controller 1104 may be configured to predict a current speed of the I-beam 2514 based on previous values of current and/or voltage supplied to the electric motor 1122 and/or previous states of the system (e.g., speed, acceleration, and/or position). The controller 1104 may be configured to sense the velocity of the I-beam 2514 using an absolute positioning sensor system as described herein. The controller may be configured to be able to compare the predicted speed of the I-beam 2514 to the sensed speed of the I-beam 2514 to determine if the power to the electric motor 1122 should be increased in order to increase the speed of the I-beam 2514 and/or if the power to the electric motor 1122 should be decreased in order to decrease the speed of the I-beam 2514. U.S. patent No. 8,210,411 entitled "MOTOR-driver basic catalyst" is incorporated herein by reference in its entirety. U.S. patent No. 7,845,537 entitled "SURGICAL LINESTRUCTION HAVING RECORDING CAPABILITIES," which is incorporated herein by reference in its entirety.

The force acting on the I-beam 2514 may be determined using various techniques. The force of the I-beam 2514 may be determined by measuring the current of the motor 2504, wherein the current of the motor 2504 is based on the load experienced by the I-beam 2514 as it advances distally. The force of the I-beam 2514 can be determined by positioning strain gauges on the drive member 120 (fig. 2), the firing member 220 (fig. 2), the I-beam 2514 (I-beam 178, fig. 20), the firing bar 172 (fig. 2), and/or on the proximal end of the cutting edge 2509. The force of the I-beam 2514 may be determined by: during a predetermined lapse period T ₁Thereafter, based on the current set-speed of the motor 2504, the actual position of the I-beam 2514 moving at the desired speed is monitored and during a time period T ₁At the end, the actual position of the I-beam 2514 relative to the expected speed of the I-beam 2514 is compared based on the current set speed of the motor 2504. Thus, if the actual position of the I-beam 2514 is less than the expected position of the I-beam 2514, the force on the I-beam 2514 is greater than the nominal force. Conversely, if the actual position of the I-beam 2514 is greater than the expected position of the I-beam 2514, the force on the I-beam 2514 is less than the nominal force. The difference between the actual position and the expected position of the I-beam 2514 and the force on the I-beam 2514 from the nominal force are proportional. Such techniques are described in attorney docket number END8195USNP, which is incorporated by reference herein in its entirety.

Fig. 14 illustrates a block diagram of a surgical instrument 2500 programmed to control distal translation of a displacement member according to one aspect of the present disclosure. In one aspect, the surgical instrument 2500 is programmed to control distal translation of a displacement member 1111, such as an I-beam 2514. The surgical instrument 2500 includes an end effector 2502, which end effector 2502 can include an anvil 2516, an I-beam 2514 (including a sharpened cutting edge 2509), and a removable staple cartridge 2518. The end effector 2502, anvil 2516, I-beam 2514, and staple cartridge 2518 may be configured as described herein, for example, with reference to fig. 1-13.

The position, movement, displacement, and/or translation of the linear displacement member 1111, such as the I-beam 2514, may be measured by the absolute positioning system 1100, the sensor arrangement 1102, and the position sensor 1200 as shown in fig. 10-12, and the position sensor 1200 is represented in fig. 14 as the position sensor 2534. Since the I-beam 2514 is coupled to the longitudinally movable drive member 120, the position of the I-beam 2514 can be determined by measuring the position of the longitudinally movable drive member 120 using the position sensor 2534. Thus, in the following description, the position, displacement, and/or translation of the I-beam 2514 may be achieved by a position sensor 2534 as described herein. The control circuit 2510, such as the control circuit 700 described in fig. 5A and 5B, may be programmed to control the translation of a displacement member 1111, such as an I-beam 2514, as described with respect to fig. 10-12. In some examples, the control circuitry 2510 can include one or more microcontrollers, microprocessors, or other suitable processors for executing instructions that cause the one or more processors to control the displacement member (e.g., the I-beam 2514) in the manner described. In one aspect, the timer/counter circuit 2531 provides an output signal, such as an elapsed time or a digital count, to the control circuit 2510 to correlate the position of the I-beam 2514 as determined by the position sensor 2534 with the output of the timer/counter circuit 2531, such that the control circuit 2510 can determine the position of the I-beam 2514 at a particular time (t) relative to a starting position. The timer/counter circuit 2531 may be configured to be able to measure elapsed time, count external events, or time external events.

The control circuit 2510 can generate a motor set point signal 2522. The motor set point signal 2522 may be provided to the motor controller 2508. The motor controller 2508 can include one or more circuits configured to provide motor drive signals 2524 to the motor 2504 to drive the motor 2504, as described herein. In some examples, motor 2504 may be a brushed dc electric motor, such as motors 82, 714, 1120 shown in fig. 1, 5B, 10. For example, the speed of motor 2504 may be proportional to motor drive signal 2524. In some examples, the motor 2504 can be a brushless Direct Current (DC) electric motor, and the motor drive signals 2524 can include Pulse Width Modulated (PWM) signals provided to one or more stator windings of the motor 2504. Also, in some examples, the motor controller 2508 may be omitted, and the control circuit 2510 may directly generate the motor drive signal 2524.

Motor 2504 may receive power from energy source 2512. The energy source 2512 may be or may include a battery, a super capacitor, or any other suitable energy source 2512. The motor 2504 may be mechanically coupled to the I-beam 2514 via a transmission 2506. The transmission 2506 may include one or more gears or other linkage components to couple the motor 2504 to the I-beam 2514. The position sensor 2534 may sense the position of the I-beam 2514. The position sensor 2534 may be or include any type of sensor capable of generating position data indicative of the position of the I-beam 2514. In some examples, the position sensor 2534 may comprise an encoder configured to provide a series of pulses to the control circuit 2510 as the I-beam 2514 translates distally and proximally. The control circuit 2510 may track pulses to determine the position of the I-beam 2514. Other suitable position sensors may be used, including, for example, proximity sensors. Other types of position sensors may provide other signals indicative of the movement of the I-beam 2514. Also, in some examples, position sensor 2534 may be omitted. In the case where the motor 2504 is a stepper motor, the control circuit 2510 can track the position of the I-beam 2514 by aggregating the number and direction of steps that the motor 2504 has been commanded to perform. The position sensor 2534 can be located in the end effector 2502 or at any other portion of the instrument.

The control circuitry 2510 can communicate with one or more sensors 2538. The sensors 2538 can be positioned on the end effector 2502 and adapted to operate with the surgical instrument 2500 to measure various derivative parameters, such as gap distance versus time, tissue compression versus time, and anvil strain versus time. The sensors 2538 can include, for example, magnetic sensors, magnetic field sensors, strain gauges, pressure sensors, force sensors, inductive sensors (such as eddy current sensors), resistive sensors, capacitive sensors, optical sensors, and/or any other suitable sensors for measuring one or more parameters of the end effector 2502. The sensor 2538 may include one or more sensors.

The one or more sensors 2538 can comprise a strain gauge, such as a micro-strain gauge, configured to measure the magnitude of strain in the anvil 2516 during a clamped condition. The strain gauge provides an electrical signal whose magnitude varies with the magnitude of the strain. The sensor 2538 can comprise a pressure sensor configured to detect pressure generated by the presence of compressed tissue between the anvil 2516 and the staple cartridge 2518. The sensor 2538 can be configured to detect the impedance of a section of tissue positioned between the anvil 2516 and the staple cartridge 2518, which is indicative of the thickness and/or degree of filling of the tissue positioned therebetween.

The sensor 2538 can be configured to measure the force exerted by the closure drive system 30 on the anvil 2516. For example, one or more sensors 2538 can be positioned at the point of interaction between the closure tube 260 (FIG. 3) and the anvil 2516 to detect the closing force applied to the anvil 2516 by the closure tube 260. The force exerted on the anvil 2516 may be indicative of the compression of tissue experienced by a section of tissue captured between the anvil 2516 and the staple cartridge 2518. One or more sensors 2538 can be positioned at various interaction points along the closure drive system 30 (FIG. 2) to detect the closure force applied to the anvil 2516 by the closure drive system 30. One or more sensors 2538 may be sampled in real time by a processor as described in fig. 5A-5B during a gripping operation. The control circuit 2510 receives real-time sample measurements to provide, analyze, and evaluate in real-time the closing force applied to the anvil 2516.

A current sensor 2536 may be employed to measure the current drawn by the motor 2504. The force required to advance the I-beam 2514 corresponds to the current drawn by the motor 2504. The force is converted to a digital signal and provided to the control circuit 2510.

Using the physical characteristics of the instrument disclosed herein in connection with fig. 1-14, and with reference to fig. 14, the control circuit 2510 can be configured to be capable of simulating the response of the actual system of the instrument in the software of the controller. The displacement member may be actuated to move the I-beam 2514 in the end effector 2502 at or near a target speed. The surgical instrument 2500 may include a feedback controller, which may be one of any feedback controller including, but not limited to, for example, a PID, status feedback, LQR, and/or adaptive controller. Surgical instrument 2500 may include a power source to, for example, convert signals from a feedback controller into physical inputs, such as a housing voltage, a Pulse Width Modulated (PWM) voltage, a frequency modulated voltage, a current, a torque, and/or a force.

The actual drive system of the surgical instrument 2500 is configured to drive the displacement member, cutting member, or I-beam 2514 through a brushed DC motor having a gearbox and mechanical link to an articulation and/or knife system. Another example is an electric motor 2504 that operates a displacement member and articulation driver, e.g., an interchangeable shaft assembly. External influences are unmeasured, unpredictable effects of things such as tissue, surrounding body and friction on the physical system. Such external influences may be referred to as drag forces acting against the electric motor 2504. External influences such as drag forces may cause the operation of the physical system to deviate from the desired operation of the physical system.

Before explaining the various aspects of the surgical instrument 2500 in detail, it should be noted that the applications or uses of the exemplary aspects are not limited to the details of the construction and arrangement of parts illustrated in the accompanying drawings and description. The illustrative aspects may be implemented or incorporated in other aspects, variations and modifications, and may be practiced or carried out in various ways. Furthermore, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative aspects for the convenience of the reader and are not for the purpose of limiting the invention. Moreover, it is to be understood that expressions of one or more of the following described aspects, and/or examples may be combined with any one or more of the other below described aspects, and/or examples.

Various exemplary aspects are directed to a surgical instrument 2500 that includes an end effector 2502 having a motor-driven surgical stapling and cutting tool. For example, the motor 2504 can drive the displacement member distally and proximally along the longitudinal axis of the end effector 2502. The end effector 2502 can comprise a pivotable anvil 2516, and when it is configured for use, the staple cartridge 2518 is positioned opposite the anvil 2516. The clinician may grasp tissue between the anvil 2516 and the staple cartridge 2518 as described herein. When the instrument 2500 is ready to be used, the clinician may provide a firing signal, such as by depressing a trigger of the instrument 2500. In response to the firing signal, the motor 2504 can drive the displacement member distally along the longitudinal axis of the end effector 2502 from a proximal stroke start position to an end of stroke position distal to the stroke start position. An I-beam 2514 with a cutting element positioned at a distal end can cut tissue between the staple cartridge 2518 and the anvil 2516 as the displacement member is translated distally.

In various examples, the surgical instrument 2500 can include a control circuit 2510, the control circuit 2510 programmed to control distal translation of a displacement member, such as an I-beam 2514, for example, based on one or more tissue conditions. The control circuit 2510 can be programmed to sense a tissue condition, such as thickness, directly or indirectly, as described herein. The control circuit 2510 can be programmed to select a firing control program based on tissue conditions. The firing control routine may describe distal movement of the displacement member. Different firing control programs may be selected to better address different tissue conditions. For example, when thicker tissue is present, the control circuit 2510 can be programmed to translate the displacement member at a lower speed and/or at a lower power. When thinner tissue is present, the control circuit 2510 can be programmed to translate the displacement member at a higher speed and/or at a higher power.

In some examples, the control circuit 2510 can initially operate the motor 2504 in an open-loop configuration for a first open-loop portion of the stroke of the displacement member. Based on the response of the instrument 2500 during the open loop portion of the stroke, the control circuit 2510 can select a firing control program. The response of the instrument may include the translation distance of the displacement member during the open loop portion, the time elapsed during the open loop portion, the energy provided to motor 2504 during the open loop portion, the sum of the pulse widths of the motor drive signals, and the like. After the open loop portion, the control circuit 2510 can implement the selected firing control program for the second portion of the displacement member stroke. For example, during the closed-loop portion of the stroke, the control circuit 2510 can modulate the motor 2504 based on translation data that describes the position of the displacement member in a closed-loop manner to translate the displacement member at a constant speed.

Fig. 15 shows a graph 2580 plotting two exemplary displacement member strokes performed in accordance with an aspect of the present disclosure. Fig. 2580 includes two shafts. Horizontal axis 2584 indicates elapsed time. The vertical axis 2582 indicates the position of the I-beam 2514 between the start of travel position 2586 and the end of travel position 2588. On the horizontal axis 2584, the control circuit 2510 may receive a fire signal and begin at t ₀An initial motor setting is provided. The open loop portion of the displacement member stroke is possible at t ₀And t ₁An initial period of time elapsing in between.

A first example 2592 illustrates the response of the surgical instrument 2500 when thick tissue is positioned between the anvil 2516 and the staple cartridge 2518. During an open loop portion of firing member travel, e.g. at t ₀And t ₁During an initial period of time in between, the I-beam 2514 may traverse from the stroke start position 2586 to the position 2594. The control circuit 2510 may determine that position 2594 corresponds to ₁The selected constant speed (vshaow), as indicated by the ramp (e.g., in the closed loop portion) of the following example 2592, advances the firing control program of the I-beam 2514. The control circuit 2510 can drive the I-beam 2514 to the velocity vsow to maintain vsow by monitoring the position of the I-beam 2514 and modulating the motor setpoint 2522 and/or motor drive signal 2524. A second example 2590 illustrates the response of the surgical instrument 2500 when thin tissue is positioned between the anvil 2516 and the staple cartridge 2518.

At t ₀And t ₁During an initial period of time (e.g., open ring segment) in between, the I-beam 2514 may traverse from the stroke start position 2586 to the position 2596. The control circuitry may determine that position 2596 corresponds to a firing control program that advances the displacement member at a selected constant speed (Vfast). Because the tissue in example 2590 is thinner than the tissue in example 2592, it may provide less resistance to movement of the I-beam 2514. As a result, the I-beam 2514 may traverse a larger portion of the stroke during the initial time period. Also, in some examples, thinner tissue (e.g., a larger portion of displacement member travel traversed during the initial time period) may correspond to a higher displacement member velocity after the initial time period.

Fig. 16-22 illustrate various graphical representations and processes for determining an error between an orientation velocity of a displacement member and an actual velocity of the displacement member and adjusting the orientation velocity of the displacement member based on the error. In aspects shown in fig. 16-22, the displacement member is an I-beam 2514. However, in other aspects, the displacement member may be the drive member 120 (fig. 2), the firing member 220, 2509 (fig. 3, 13), the firing bar 172 (fig. 4), the I-beam 178, 2514 (fig. 4, 13, 14), or any combination thereof.

Turning now to fig. 16, a graph 8500 depicting velocity (v) of a displacement member as a function of displacement (δ) of the displacement member is shown, in accordance with an aspect of the present disclosure. In the aspect shown, the displacement (δ) of the I-beam 2514 is shown along a horizontal axis 8502, and the velocity (v) of the I-beam 2514 is shown along a vertical axis 8504. It should be appreciated that the speed of the motor 2504 may be shown along the vertical axis 8504 instead of the speed of the I-beam 2514. The function shown in dashed lines represents the directional velocity 8506 of the I-beam 2514, and the function shown in solid line form represents the actual velocity 8508 of the I-beam 2514. The directional speed 8506 is based on the motor setpoint 2522 speed applied by the control circuit 2510 to the motor control 2508 circuit. In response, the motor control 2508 applies a corresponding motor drive signal 2524 having a predetermined duty cycle to the motor 2504 to set the speed of the motor 2504 to achieve the directional speed 8506 of the I-beam 2514, as shown in FIG. 14. Directional velocity 8506 may also be referred to as a command velocity. The displacement of the I-beam 2514 is given by the directional velocity 8506, based on the motor setpoint 2522 velocity. However, due to external influences, the actual displacement of the I-beam 2514 is given by the actual velocity 8508. As can be determined from the graph 8500, there is a significant difference between the orientation velocity 8506 and the actual velocity 8508 of the I-beam 2514. The difference between directional velocity 8506 and actual velocity 8508 is referred to herein as a velocity error term, such as short term error (S), cumulative error (C), rate of change error (R), and overshoot number error (N). The short-term error S represents the distance of the actual velocity 8508 from the orientation velocity 8506 at the displacement δ 1. Shown as cross-hatched area (mm) over time ²The accumulated error C of/s) represents the error deviation between the actual velocity 8508 and the orientation velocity 8506 accumulated over time.The rate of change R given by the slope b/a represents the rate at which the actual velocity 8508 approaches the directional velocity 8506. Finally, the number of overshoots N represents the number of times the actual speed 8508 overshoots or undershoots the directional speed 8506.

Fig. 17 is a graph 8510 depicting velocity (v) of a displacement member as a function of displacement (δ) of the displacement member, in accordance with an aspect of the present disclosure. In the illustrated aspect, the displacement (δ) (mm) of the I-beam 2514 is shown along a horizontal axis 8512, and the velocity (v) (mm/s) of the I-beam 2514 is shown along a vertical axis 8514. The horizontal axis 8512 is scaled to represent, for example, the displacement of the I-beam 2514 over the length X of the staple cartridge 2518, such as a 10-60mm staple cartridge. In one aspect, for a 60mm staple cartridge 2518, the I-beam 2514 displacement is 60mm and the speed of the I-beam 2514 varies between 0 and 30 mm/s. The function shown in dashed form represents the directional velocity 8506 of the I-beam 2514, and the function shown in solid form represents the actual velocity 8508 of the I-beam 2514. As shown in the graph 8510, the displacement of the I-beam 2514 along the stroke of the staple cartridge 2518 is divided into three zones 8516, 8518, 8520. In the first region 8516(0 to δ) _2mm) At the beginning of the stroke (0mm), the control circuit 2510 sets the motor drive signal 2524 to the first duty cycle (DS 1). In the second region 8518 (delta) _2mmTo delta _3mm) In (1), the control circuit 2510 sets the motor drive signal 2524 to the second duty cycle (DS 2). In the third region 8520(δ) _3mmTo the end of the stroke), the control circuit 2510 sets the motor drive signal 2524 to the third duty cycle (DS 3). According to this aspect, the orientation speed 8506 is adjusted based on the position of the I-beam 2514 during the firing stroke. While the graph 8510 illustrates a firing stroke that is divided into three zones 8516, 8518, 8520, it should be understood that the firing stroke may be divided into additional zones or fewer zones. The surgical instrument 2500 includes a closed loop feedback system that adjusts or controls the duty cycle of the motor drive signal 2524 to adjust the velocity of the I-beam 2514 based on the magnitude of one or more of the error terms S, C, R and N, which is based on the difference between the orientation velocity 8506 and the actual velocity 8508 at specified time or distance increments as the I-beam 2514 traverses the staple cartridge 2518. In one aspect, the control system 2500 employs PID error control to discretize the travel of the I-beam 2504Time/distance position delta _nThe speed of the motor 2514 is controlled and the PID error is employed to control the constant speed of the I-beam 2514 between discrete time/displacement checks.

Referring to the first zone 8516, at the beginning of a stroke, the control circuit 2510 provides a motor setpoint 2522 to the motor control 2508, which motor control 2508 applies a motor drive signal 2524 having a first duty cycle (DS1) to the motor 2504 to set the directional speed 8506 of the I-beam 2514 to V ₂. As the I-beam 2514 advances distally, the position sensor 2534 and timer/counter 2531 circuitry track the position and time, respectively, of the I-beam 2514 to determine the actual position and actual speed 8508 of the I-beam 2514. When the position of the I-beam 2514 approaches δ ₁At that time, actual velocity 8508 begins a positive transition toward directional velocity 8506. As shown, actual speed 8508 lags orientation speed 8506S1, and orientation speed 8506 has been lagged by cumulative error C1 over a period of time. At delta ₁At this point, the rate of change of the actual speed 8508 is R1. When the I-beam 2514 is towards delta ₂As the distal advance progresses, the actual speed 8508 overshoots the directional speed 8506N1 ₁、N1 ₂…N1 _nAnd eventually stabilizes at directional velocity 8506.

Turning now to the second region 8518, at δ ₂Here, the control circuit 2510 provides a new motor setpoint 2522 to the motor control 2508, which motor control 2508 applies a new motor drive signal 2524 having a second duty cycle (DS2) to the motor 2504 to reduce the directional speed 8506 of the I-beam 2514 to V ₁. At delta ₂At this point, the actual velocity 8508 of the I-beam 2514 begins a negative transition to a lower orientation velocity 8506. As the I-beam 2514 advances distally, the actual speed 8508 lags the directional speed 8506S2 and the directional speed 8506 lags the cumulative error C2 for a period of time and the rate of change of the actual speed 8508 is R2. When the I-beam 2514 is towards delta ₂As it advances distally, the actual velocity 8508 undershoots the directional velocity 8506N2 ₁、N2 ₂…N2 _nAnd eventually stabilizes at directional velocity 8506.

Turning now to the third region 8520, at δ ₃Control circuit 2510 provides signals to motor control 2508For a new motor setpoint 2522, the motor control 2508 applies a new motor drive signal 2524 having a third duty cycle (DS3) to the motor 2504 to increase the directional speed 8506 of the I-beam 2514 to V ₃. At delta ₃At this point, the actual velocity 8508 of the I-beam 2514 begins a positive transition to a higher orientation velocity 8506. As the I-beam 2514 advances distally, the actual speed 8508 lags the directional speed 8506S3 ₁And retarding the orientation speed 8506 by the accumulated error C3 for a certain period of time ₁And the rate of change of the actual speed 8508 is R3 ₁. As the I-beam 2514 advances distally, the actual speed 8508 is at R3 ₂Approaches the orientation speed 8506, thereby reducing the hysteresis error to S3 for a certain period of time ₂And increases the accumulated error by C3 ₂. As the I-beam 2514 advances towards the end of the stroke, the actual speed 8508 overshoots the directional speed 8506N3 ₁、N3 ₂、N3 ₃…N3 _nAnd eventually stabilizes at directional velocity 8506.

In another aspect, the control system of the surgical instrument 2500 employs a PID control error to control the motor speed based on the magnitude of the PID error term S, C, R, N over the stroke of the I-beam 2514. The change in the orientation velocity 8506 may be based on a measured error between the actual velocity 8508 and the orientation velocity 8506 as the I-beam 2514 traverses the staple cartridge 2528. For example, in the velocity control system of surgical instrument 2500, an error term is generated between directional velocity 8506 and actual measured velocity 8508. The magnitude of these error terms can be used to set the new orientation velocity 8506. The error terms of interest may include, for example, short term errors, steady state errors, and cumulative errors. Different error terms may be used in different regions 8516, 8518, 8520 (e.g., ramp, intermediate, final). The error terms may be scaled up differently depending on their importance in the algorithm.

FIG. 18 is a graph 8530 of velocity (v) of a displacement member as a function of displacement (δ) of the displacement member depicting conditions for a threshold change in orientation velocity 8506-1, in accordance with an aspect of the present disclosure. In the illustrated aspect, the displacement (δ) (mm) of the I-beam 2514 is shown along the horizontal axis 8532, and the velocity (v) (mm/s) of the I-beam 2514 is shown along the vertical axis 8534. According to FIG. 18, in additionThe velocity control system of the surgical instrument 2500 may be configured to measure an error between the orientation velocity of the I-beam 2514 and the actual velocity 8508 of the I-beam 2514 and adjust the orientation velocity 8506 based on the magnitude of the error. As shown in fig. 18, at δ ₀Here, the directional velocity 8506-1 and the actual velocity 8508 are approximately the same. However, as the I-beam 2514 advances distally, the actual velocity deviates from the directional velocity 8506-1 due to external tissue effects. The speed control system of the surgical instrument 2500 measures the position and timing of the I-beam 2514 using the position sensor 2534 and the timer/counter 2531 to determine the position and actual speed 8508 of the I-beam 2514, and at each predetermined position, the speed control system determines an error between the orientation speed of the I-beam 2514 and the actual speed 8508 of the I-beam 2514 and compares the error to a threshold. E.g. at delta ₁Here, the control circuit 2510 takes a first error measurement and determines a lag S2 between the actual velocity 8508 and the directional velocity 8506-1 ₁Accumulated error C2 ₁And rate of change R2 ₁. Based on delta ₁The control circuit 2510 determines that the magnitude of the error is within the error threshold 8536 and maintains the current orientation velocity 8506-1. At delta ₂Here, the control circuit 2510 takes another error measurement and determines a lag S2 between the actual velocity 8508 and the directional velocity 8506-1 ₂Accumulated error C2 ₂And rate of change R2 ₂. Based on delta ₂The control circuit 2510 determines that the magnitude of the error exceeds the error threshold 8536 and reduces the orientation velocity to the new orientation velocity 8506-2. This process is repeated until the measurement error falls to a threshold 8536, and the orientation velocity may be adjusted back to the initial orientation velocity 8506-1 or the new orientation velocity 8506-n. It should be appreciated that multiple error thresholds may be employed at different I-beam 2514 displacement positions during the firing stroke.

In one aspect, a velocity error V between an actual velocity 8508 and an orientation velocity 8506 of a displacement member (e.g., an I-beam 2514) _DMCan be represented by equation 1:

where A, B and D are coefficients, and S is the short term error, C is the accumulated error, and R is the rate of change error. Referring to FIG. 18, if the sum of the errors is less than the error threshold Z, as shown in equation 2:

S2 ₁+C2 ₁+R2 ₁<z equation 2

The control circuit 2510 determines that the error is within the threshold Z and not within the directional velocity 8506. Thus, the orientation speed 8506-1 is maintained until the next predetermined position of the I-beam 2514. If the sum of the errors is greater than the error threshold Z, as shown in equation 3:

S2 ₂+C2 ₂+R2 ₂>z equation 3

The control circuit 2510 determines that the error is outside the threshold Z and adjusts the orientation velocity 8506 to a lower orientation velocity 8506-2.

Fig. 19 is a graph 8540 illustrating conditions for changing the directional velocity 8506 of a displacement member, according to an aspect of the present disclosure. In the aspect shown, the displacement of the I-beam 2514 is shown along a horizontal axis 8541, and the accumulated error (S + C + R) is shown along a vertical axis 8544. The error curve 8546 represents the cumulative error as a function of the displacement of the I-beam 2514. Various error thresholds-Y, -Z, 0, + Z, + Y are labeled along vertical axis 8544. As the error curve 8546 traverses the various error thresholds-Y, -Z, 0, + Z, + Y, the control circuit 2510 of the velocity control system of the surgical instrument 2500 transitions to a new orientation velocity at a different rate, or does not transition and maintain the current orientation velocity. A cumulative error of 0 along the horizontal axis 8542 represents a case where there is no difference between the orientation velocity and the actual velocity of the I-beam 2514. When the accumulated error is within the ± Z error threshold, the control circuit 2510 of the velocity control system does not adjust the directional velocity. If the accumulated error is between the Z threshold and the Y threshold or between the-Z threshold and the-Y threshold, the control circuit 2510 of the velocity control system transitions to the new directional velocity at a first transition rate indicated in curve 8540 as transition rate 1. If the accumulated error exceeds the Y error threshold, the control circuit 2510 transitions to the new directional speed at a second transition rate indicated in the plot 8540 as transition rate 2, where, for example, transition rate 2 is greater than transition rate 1.

Referring also to the graph 8540 in FIG. 19, the control circuit 2510 of the velocity control system of the surgical instrument 2500 is at δ ₀And delta ₁No action is taken during the initial displacement of the I-beam 2514 therebetween. Thus, at the initial displacement (δ) ₁-δ ₀) Meanwhile, as the actual velocity approaches the directional velocity, the accumulated error 8548 returns to zero and remains near zero until δ ₂Until now. At delta ₂Then, the accumulated error 8550 deviates from zero until at δ ₃Until the-Z threshold is exceeded. After the-Z threshold is exceeded, the control circuit 2510 adjusts the speed of the I-beam 2514 to the new orientation speed at a transformation rate of 1. Cumulative error 8552 eventually returns to zero and remains near zero until δ ₄Until now. At delta ₄And delta ₅In between, the accumulated error 8554 deviates from zero and exceeds the + Y error threshold, and at δ ₅At this point, the control circuit 2510 adjusts the speed of the I-beam 2514 to a new directional speed at a transformation rate 2 that is greater than transformation rate 1. After adjusting the directional velocity for slew rate 2, the accumulated error 8556 will return to zero. The different error terms (S, C, R) may be scaled up differently using algorithms based on their importance, and may be used in different regions (e.g., regions 8516, 8518, 8520 in fig. 17) (e.g., hill climbing, intermediate, final) (S, C, R).

Fig. 20 is a logic flow diagram of a process 8600 depicting a control procedure or logic configuration for controlling a velocity of a displacement member based on a measured error between a position of the displacement member and an actual velocity of the displacement member, according to one aspect of the present disclosure. Referring also to the speed control system of the surgical instrument 2500 shown in fig. 14, the control circuit 2510 utilizes a position sensor 2534 and a timer/counter 2531 circuit to determine 8602 the position of a displacement member, such as an I-beam 2514. The control circuit 2510 compares the position of the displacement member to one of a plurality of zones 8516, 8518, 8520, as discussed in connection with fig. 17. The regions 8516, 8518, 8520 may be stored in memory. The control circuitry 2510 determines 8604 which region 8516, 8518, 8520 the displacement member is located in based on the previously determined 8602 position of the displacement member. The control circuit 2510 then sets 8606 the motor setpoint 2522 speed, and the motor control 2508 sets the motor drive signal 2524 to set the motor 254 speed to achieve the desired directional velocity of the displacement member based on the zone. In one aspect, motor control 2508 sets motor drive signal 2524 to a duty cycle based on which zone 8516, 8518, 8520 the displacement member is located in. The control circuit 2510 determines 8608 the displacement member is at the end of the stroke. If the displacement member is not at the end of the stroke, the process 8600 continues along the "no" branch and a new position for the displacement member is determined 8602. The process 8600 continues until the displacement member reaches the end of the stroke and proceeds along the yes branch and ends 8610.

Fig. 21 is a logic flow diagram of a process 8600 depicting a control procedure or logic configuration for controlling a velocity of a displacement member based on a measured error between an orientation velocity of the displacement member and an actual velocity of the displacement member, according to one aspect of the present disclosure. Referring also to the speed control system of the surgical instrument 2500 shown in FIG. 14, the control circuit 2510 utilizes a position sensor 2534 and a timer/counter 2531 circuit to determine 8702 the position of a displacement member, such as an I-beam 2514. The control circuit 2510 then determines 8704 the actual velocity of the displacement member based on the position information received from the position sensor 2534 and timer/counter 2531 circuits. After determining 8704 the actual velocity of the displacement member, the control circuit 2510 compares 8706 the directional velocity of the displacement member with the actual velocity of the displacement member. Based on the comparison 8706, the control circuit 2510 determines 8708 an error between the directional velocity of the displacement member and the actual velocity of the displacement member and compares 8710 the error to an error threshold.

The error may be calculated based on equation 1 above. The control circuit 2510 determines 8712 whether the error is within an error threshold. If the error is within the error threshold (equation 2), the process 8700 continues along the "Yes" branch and the directional velocity is maintained 8714 at its current value. The control circuit 2510 then determines 8718 whether the displacement member is at the end of the stroke. If the displacement member is at the end of the stroke, the process 8700 continues along the YES branch and ends 8720. If the displacement member is not at the end of the stroke, the process 8700 continues along the "No" branch and a new position of the displacement member is determined 8702. The process 8700 continues until the displacement member reaches the end of the stroke.

If the error exceeds the error threshold (equation 3), the process 8700 continues along the "No" branch and the directional velocity is adjusted 8716 to a new value. The new orientation speed may be higher or lower than the current orientation speed of the displacement member. The control circuit 2510 then determines 8718 whether the displacement member is at the end of a stroke. If the displacement member is at the end of the stroke, the process 8700 continues along the YES branch and ends 8720. If the displacement member is not at the end of the stroke, the process 8700 continues along the "No" branch and a new position of the displacement member is determined 8702. The process 8700 continues until the displacement member reaches the end of the stroke.

Fig. 22 is a logic flow diagram of a process 8700 depicting a control routine of a logic configuration for controlling a velocity of a displacement member based on a measured error between an orientation velocity of the displacement member and an actual velocity of the displacement member, according to one aspect of the present disclosure. Referring also to the speed control system of the surgical instrument 2500 shown in fig. 14, the control circuit 2510 utilizes a position sensor 2534 and a timer/counter 2531 circuit to determine the position of a 8802 displacement member, such as the I-beam 2514. The control circuit 2510 then determines 8804 the actual speed of the displacement member based on the position information received from the position sensor 2534 and the timer/counter 2531 circuits. After determining 8804 the actual velocity of the displacement member, the control circuit 2510 compares 8806 the directional velocity of the displacement member to the actual velocity of the displacement member. Based on the comparison 8806, the control circuit 2510 determines an error between the directional velocity of the displacement member 8808 and the actual velocity of the displacement member and compares 8810 the error to a plurality of error thresholds. For example, in the example shown, the error is compared to two error thresholds, as described in connection with FIG. 19.

The control circuit 2510 determines 8812 whether the error is within the first error threshold (± Z) as described in fig. 19. If the error is within the first error threshold (± Z), the process continues along the yes branch and the control circuit 2510 maintains 8814 the directional velocity without any change in the transformation. The control circuit 2510 determines 8816 whether the displacement member is at the end of the stroke. If the displacement member is at the end of the stroke, the process 8800 continues along the yes branch and ends 8824. If the displacement member is not at the end of the stroke, the process 8800 continues along the no branch and the control circuit 2510 determines 8802 new positions of the displacement member and the process 8800 continues until the displacement member reaches the end of the stroke.

If the error is outside the first error threshold (+ -Z), the process 8800 continues along the NO branch and the control circuit 2510 determines 8818 whether the error exceeds the second error threshold (+ -Y). If the error does not exceed the second error threshold, the control circuit 2510 determines that the error is between the-Z and-Y error thresholds or between the + Z and + Y error thresholds and proceeds along the NO branch and the control circuit 2510 adjusts 8820 the directional velocity at the first rate of change. The control circuit 2510 determines the end of 8816 stroke and proceeds to determine a new position for the displacement member 8802. The process 8800 continues until the displacement member reaches the end of the stroke. If the error exceeds the second error threshold, the control circuit 2510 determines that the error exceeds the second error threshold (± Y) and proceeds along the yes branch, and the control circuit 2510 adjusts 8822 the directional velocity at a second rate of change that is higher than the first rate of change. In one aspect, the second rate of change is twice the first rate of change. It should be understood that the second rate of change may be greater than or less than the first rate of change. The control circuit 2510 determines the end of 8816 stroke and proceeds to determine a new position for the displacement member 8802. The process 8800 continues until the displacement member reaches the end of the stroke. It should be appreciated that additional error thresholds and corresponding rates of change may be implemented.

The functions or processes 8600, 8700, 8800 described herein can be performed by any of the processing circuits described herein, such as the control circuit 700 described with respect to fig. 5-6, the circuits 800, 810, 820 described in fig. 7-9, the microcontroller 1104 described with respect to fig. 10 and 12, and/or the control circuit 2510 described in fig. 14.

Aspects of the motorized surgical instrument may be practiced without specific details disclosed herein. Certain aspects have been shown as block diagrams rather than details. Portions of the present disclosure may be presented as instructions to operate on data stored in a computer memory. An algorithm is a self-consistent sequence of steps leading to a desired result, where "step" refers to the manipulation of physical quantities which may take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. These signals may be referred to as bits, values, elements, symbols, characters, terms, numbers. These and similar terms may be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.

In general, various aspects described herein, which may be implemented individually and/or collectively in various hardware, software, firmware, or any combination thereof, may be viewed as being comprised of multiple types of "electronic circuitry". Thus, "electronic circuitry" includes electronic circuitry having at least one discrete circuit, electronic circuitry having at least one integrated circuit, electronic circuitry having at least one application specific integrated circuit, electronic circuitry forming a general purpose computing device configured by a computer program (e.g., a general purpose computer, or a processor configured by a computer program that at least partially implements the methods and/or apparatus described herein), electronic circuitry forming memory means (e.g., forming random access memory), and/or electronic circuitry forming communication means (e.g., a modem, a communication switch, or an optoelectronic device). These aspects may be implemented in analog or digital or a combination thereof.

The foregoing description sets forth aspects of the devices and/or processes via the use of block diagrams, flowcharts, and/or examples that may include one or more functions and/or operations. Each function and/or operation within such block diagrams, flowcharts, or examples may be implemented, individually and/or collectively, by a wide variety of hardware, software, firmware, or virtually any combination thereof. In one aspect, portions of the subject matter described herein may be implemented via Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs), Digital Signal Processors (DSPs), programmable logic Devices (DSPs), circuits, registers, and/or software components (e.g., programs, subroutines, logic, and/or combinations of hardware and software components), logic gates, or other integrated formats. Some aspects disclosed herein, in whole or in part, can be equivalently implemented in integrated circuits, in whole or in part, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or as virtually any combination thereof, and designing the electronic circuitry and/or writing the code for the software and/or hardware would be well within the skill of one of skill in the art in light of this disclosure.

The mechanisms of the subject matter disclosed herein are capable of being distributed as a program product in a variety of forms, and exemplary aspects of the subject matter described herein apply regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include the following: recordable media such as floppy disks, hard disk drives, Compact Disks (CDs), Digital Video Disks (DVDs), digital tapes, computer memory, etc.; and a transmission-type medium such as a digital and/or analog communication medium (e.g., a fiber optic cable, a waveguide, a wired communications link, a wireless communication link (e.g., transmitter, receiver, transmission logic, reception logic), etc.).

The foregoing description of these aspects has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The aspects were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention and various aspects and with various modifications as are suited to the particular use contemplated. The claims as filed herewith are intended to define the full scope.

Various aspects of the subject matter described herein are set forth in the following numbered examples:

embodiment 1. a surgical instrument, comprising: a displacement member configured to translate over a plurality of predefined regions within the surgical instrument; a motor coupled to the displacement member to translate the displacement member; a control circuit coupled to the motor; a position sensor coupled to the control circuit, the position sensor configured to measure a position of the displacement member; and a timer circuit coupled to the control circuit, the timer/counter circuit configured to be capable of measuring elapsed time; wherein the control circuitry is configured to be capable of: determining a position of the displacement member; determining a region in which the displacement member is located; and setting an orientation speed of the displacement member based on the area in which the displacement member is located.

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Closed loop feedback control of motor speed of surgical stapling and cutting instrument based on magnitude of speed error measurement

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