阅读说明：本技术 基于关节运动角度控制外科缝合和切割器械的马达速度 (Controlling motor speed of a surgical stapling and cutting instrument based on an articulation angle ) 是由 F·E·谢尔顿四世 D·C·耶茨 J·L·哈里斯 于 2018-05-21 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。所述外科器械包括被构造成能够控制端部执行器的运动的控制电路。如果所述端部执行器移动到预先确定的期望位置之外,则所述控制电路可激活所述马达的通电状态以将所述端部执行器移回到所述期望位置。当所述端部执行器处于所述期望位置时,所述控制电路可接合所述马达的断电状态并接合电磁锁。(The invention discloses a motorized surgical instrument. The surgical instrument includes a control circuit configured to control movement of the end effector. If the end effector moves outside of a predetermined desired position, the control circuit may activate the energization state of the motor to move the end effector back to the desired position. The control circuit may engage a de-energized state of the motor and engage an electromagnetic lock when the end effector is in the desired position.)

1. A surgical instrument, comprising:

a motor operable to translate an articulation member along a distance from a proximal position to a distal position, wherein the articulation member is translatable relative to an end effector a distance from a proximal position to a distal position, wherein the translation of the articulation member causes an articulation joint to articulate, and wherein the motor has an energized state and a de-energized state;

a control circuit coupled to the motor;

a position sensor coupled to the control circuit, the position sensor configured to detect a position of the articulation member along at least a portion of the distance; and is

Wherein the control circuitry is configured to be capable of:

identifying a predetermined desired position corresponding to the articulation position of the articulation member;

receiving a position input from the position sensor indicative of a current articulation position of the articulation member;

identifying the current articulation position corresponding to the articulation position of the articulation member;

determining a control action of the motor in response to a current articulation position of the articulation member that does not correspond to the desired position; and

controlling the motion of the articulation member when the current articulation position corresponds to the desired position, wherein controlling the motion of the articulation member comprises placing the motor in the powered-off state.

2. The surgical instrument of claim 1, wherein the control circuit is configured to maintain the current position of the articulation member by engaging an electromagnetic lock when the motor is in the powered off state.

3. The surgical instrument of claim 2, wherein the electromagnetic lock is generated by shorting the motor.

4. The surgical instrument of claim 1, wherein the motor comprises a Direct Current (DC) brushed motor.

5. The surgical instrument of claim 4, wherein the control circuit is configured to internally connect a lead to the Direct Current (DC) brushed motor when the motor is in the de-energized state.

6. The surgical instrument of claim 4, wherein the control circuit comprises a forward state, a reverse state, and a braking state.

7. The surgical instrument of claim 6, wherein the control circuit comprises a first switch, a second switch, a third switch, and a fourth switch, wherein when the control circuit is in the forward state, the second switch and the third switch are in a closed configuration and the first switch and the fourth switch are in an open configuration.

8. The surgical instrument of claim 7, wherein when the control circuit is in the braking state, the first and second switches are in an open configuration and the third and fourth switches are in a closed configuration.

9. The surgical instrument of claim 7, wherein when the control circuit is in the reverse state, the first switch and the fourth switch are in a closed configuration and the second switch and the third switch are in an open configuration.

10. A surgical instrument, comprising:

a motor configured to be coupled to a gear assembly of a rotatable shaft assembly, wherein the rotatable shaft assembly is configured to rotate about a longitudinal axis, wherein the rotatable shaft assembly comprises a rotational position sensor configured to measure the rotation of the rotatable shaft assembly about the longitudinal axis, wherein the motor is configured to apply a rotational force to rotate the gear assembly, wherein the rotation of the gear assembly rotates the rotatable shaft assembly about the longitudinal axis, and wherein the motor has an energized state and a de-energized state;

a control circuit coupled to the motor, wherein the control circuit is configured to:

monitoring a rotational position of the rotatable shaft assembly based on a signal from the rotational position sensor;

identifying a predetermined desired position corresponding to the rotational position of the rotatable shaft assembly;

receiving a rotational input from the rotational position sensor indicative of a current rotational position of the rotatable shaft assembly;

determining a control action of the motor in response to a current rotational position of the rotatable shaft assembly that does not correspond to the desired position; and

controlling the rotation of the rotatable shaft assembly when the current rotational position corresponds to the desired position, wherein controlling the rotation of the rotatable shaft assembly comprises placing the motor in the de-energized state.

11. The surgical instrument of claim 10, wherein the control circuit is configured to maintain the current position of the rotatable shaft assembly by engaging an electromagnetic lock when the motor is in the de-energized state.

12. The surgical instrument of claim 11, wherein the electromagnetic lock is generated by shorting the motor.

13. The surgical instrument of claim 10, wherein the motor comprises a Direct Current (DC) brushed motor.

14. The surgical instrument of claim 13, wherein the control circuit is configured to internally connect a lead to the Direct Current (DC) brushed motor when the motor is in the de-energized state.

15. A surgical instrument, comprising:

a longitudinal shaft assembly, the longitudinal shaft assembly comprising:

a rotatable shaft portion including a longitudinal axis and a drive gear,

wherein the rotatable shaft portion is configured to rotate about the longitudinal axis; and

an articulation joint comprising an articulation gear;

a drive assembly, the drive assembly comprising:

a motor including a drive output;

a control circuit configured to be capable of controlling the motor; and

a drive member operatively connected to the drive output,

wherein when the control circuit is in a rotated state, the drive member is operatively connected to the drive gear of the rotatable shaft portion, and wherein when the control circuit is in an articulated state, the drive member is operatively connected to the articulation gear of the articulation joint; and

a power source;

wherein the motor has an energized state and a de-energized state, wherein the control circuit provides the power source to the motor in a series circuit configuration when the motor is in the energized state, wherein the control circuit disconnects the power source from the motor when the motor is in the de-energized state, and wherein an electromagnetic lock is engaged when the motor is in the de-energized state.

16. The surgical instrument of claim 15, wherein, when the control circuit is in the rotated state, the control circuit is configured to:

monitoring a rotational position of the rotatable shaft portion based on a signal from a rotational position sensor;

identifying a predetermined desired position corresponding to a rotational position of the rotatable shaft portion;

receiving a rotational input from the rotational position sensor indicating a current rotational position of the rotatable shaft portion;

determining a control action of the motor in response to a current rotational position of the rotatable shaft portion that does not correspond to the desired position;

controlling the rotation of the rotatable shaft portion when the current rotational position corresponds to the desired position, wherein controlling the rotation of the rotatable shaft portion comprises placing the motor in the powered-off state.

17. The surgical instrument of claim 16, wherein the control circuit is configured to maintain the current position of the rotatable shaft portion by engaging an electromagnetic lock when the motor is in the powered off state.

18. The surgical instrument of claim 15, wherein, when the control circuit is in the articulation state, the control circuit is configured to:

monitoring an articulation position of the articulation joint based on a signal from an articulation position sensor;

identifying a predetermined desired position corresponding to an articulation position of the articulation joint;

receiving a position input from the articulation position sensor indicative of a current articulation position of the articulation joint;

determining a control action of the motor in response to a current articulation position of the articulation joint that does not correspond to a desired position;

controlling the articulation of the articulation joint when the current articulation position corresponds to the desired position, wherein controlling the articulation of the articulation joint comprises placing the motor in the powered-off state.

19. The surgical instrument of claim 18, wherein the control circuit is configured to maintain the current position of the rotatable shaft assembly by engaging an electromagnetic lock when the motor is in the de-energized state.

20. The surgical instrument of claim 18, wherein the motor comprises a DC brushed motor, and wherein the power source comprises a battery.

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 powered surgical stapling and cutting instruments, it may be useful to control the speed of the cutting member or to control the articulation speed of the end effector. The velocity of the displacement member may be determined by measuring the elapsed time at predetermined position intervals of the displacement member or measuring the position of the displacement member at predetermined time intervals. Such control may be open loop or closed loop. Such measurements may be used to assess tissue conditions, such as tissue thickness, and 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 a default articulation speed at one or more regions within the scanning range of the end effector.

During use of the powered surgical stapling and severing instrument, the end effector may undesirably articulate or further articulate. Thus, when the end effector is not being articulated but the end effector jaws are open to synchronize the motor with the articulation member, it may be desirable to provide a holding load to create a dynamic brake for holding.

Disclosure of Invention

In one aspect, a surgical instrument is provided. The surgical instrument can include an end effector, an articulation joint, and an articulation member. The articulation member is configured to translate a distance from a proximal position to a distal position relative to the end effector, wherein translation of the articulation member causes the articulation joint to articulate. The surgical instrument can further include a motor operable to translate the articulation member along a distance from the proximal position to the distal position. The motor may include an energized state and a de-energized state. The surgical instrument may further comprise: a control circuit coupled to the motor and a position sensor coupled to the control circuit. The position sensor may be configured to detect a position of the articulation member along at least a portion of the distance. The control circuit may be configured to receive a position input from the position sensor indicative of an articulation position of the articulation member. The control circuit may also identify a predetermined desired position corresponding to the articulation position of the articulation member. The control circuit may also determine a control action of the motor in response to a current position of the articulation member that does not correspond to the desired position. The control circuit may control movement of the articulation member when the current position corresponds to the desired position, wherein controlling movement of the articulation member includes placing the motor in a de-energized state.

In another aspect, a surgical instrument can include an end effector and a rotatable shaft assembly. The rotatable shaft assembly may be configured to rotate about the longitudinal axis. The rotatable shaft assembly may include a rotational position sensor and a gear assembly. The rotational position sensor may be configured to monitor rotation of the rotatable shaft assembly about the longitudinal axis. The surgical instrument may further include a motor operatively connected to the gear assembly of the rotatable shaft assembly. The motor may be configured to apply a rotational force to rotate the gear assembly. Rotation of the gear assembly rotates the rotatable shaft assembly about the longitudinal axis. The surgical instrument may also include a control circuit coupled to the motor. The control circuit may be configured to monitor a rotational position of the rotatable shaft assembly based on a signal from the rotational position sensor. The control circuit may also identify a predetermined desired position corresponding to a rotational position of the rotatable shaft assembly. The control circuit may also determine a control action of the motor in response to a current position of the rotatable shaft assembly that does not correspond to the desired position. The control circuit may also control rotation of the rotatable shaft assembly when the current position corresponds to the desired position, wherein controlling rotation of the rotatable shaft assembly may include placing the motor in a de-energized state.

In another aspect, a surgical instrument can include a longitudinal shaft assembly. The longitudinal shaft assembly may include a rotatable shaft portion extending along a longitudinal axis. The longitudinal shaft assembly may also include a drive gear and an articulation joint. The drive gear may be configured to rotate the rotatable shaft portion about the longitudinal axis. The articulation joint may include an articulation gear. The surgical instrument may also include a drive assembly. The drive assembly may include a motor, a control circuit, and a drive member. The motor may include a drive output. The control circuit may be configured to control the motor. The drive member may be operatively connected to the drive output. The drive member is operatively connected to the drive gear of the rotatable shaft portion when the control circuit is in a rotated state. The drive member is operatively connected to the articulation gear of the articulation joint when the control circuit is in the articulated state. The surgical instrument may also include a power source. The motor may include an energized state and a de-energized state. The control circuit provides a power source to the motor in a series circuit configuration when the motor is in the energized state. When the control circuit is in the power-off state, the control circuit disconnects the power source from the motor.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

Drawings

The novel features believed characteristic of the aspects described herein are set forth with particularity in the appended claims. These aspects, however, both as to organization and method of operation, may best be 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 drawing sheets in accordance with an 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 in accordance with an aspect of the present disclosure.

Fig. 8 illustrates a combinational logic circuit configured to control aspects of the surgical instrument of fig. 1 in accordance with an aspect of the present disclosure.

Fig. 9 illustrates a sequential logic circuit configured to control aspects of the surgical instrument of fig. 1 in accordance with an aspect of the present disclosure.

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

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

FIG. 12 is a schematic view 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 the end effector of the surgical instrument of FIG. 1 illustrating the firing member travel relative to tissue clamped 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 partial perspective view of a portion of an end effector of a surgical instrument showing an elongate shaft assembly in an unarticulated orientation, a portion of which has been omitted for clarity, according to one aspect of the present disclosure.

FIG. 17 is another perspective view of the end effector of FIG. 16 showing the elongate shaft assembly in an unarticulated orientation, according to one aspect of the present disclosure.

Fig. 18 is an exploded assembly perspective view of the end effector of fig. 16, illustrating elongate shaft assembly aspects, according to one aspect of the present disclosure.

FIG. 19 is a top view of the end effector of FIG. 16 showing the elongate shaft assembly in an unarticulated orientation, according to one aspect of the present disclosure.

FIG. 20 is another top view of the end effector of FIG. 16 showing the elongate shaft assembly in a first articulation orientation in accordance with an aspect of the present disclosure.

FIG. 21 is another top view of the end effector of FIG. 16 showing the elongate shaft assembly in a second articulation orientation in accordance with an aspect of the present disclosure.

Fig. 22 depicts an example of an articulation mechanism for articulating an end effector of a surgical instrument according to one aspect of the present disclosure.

FIG. 23 is a graph of firing bar angle and motor duty cycle as a function of articulation angle of the end effector, according to one aspect of the present disclosure.

Fig. 24 is a graph of motor duty cycle as a function of shaft rotation of a surgical instrument according to one aspect of the present disclosure.

Fig. 25 is a circuit diagram illustrating a circuit configuration of a motor system of a surgical instrument according to one aspect of the present disclosure.

Fig. 26 depicts an example of an articulation mechanism for articulating an end effector of a surgical instrument according to one aspect of the present disclosure.

FIG. 27 is a logic flow diagram depicting a process of representing a control program or logic configuration of a dynamic articulation control program in accordance with an aspect of the present disclosure.

FIG. 28 is a logic flow diagram depicting a process of representing a control program or logic configuration of a dynamic rotation control program in accordance with an aspect of the present disclosure.

Fig. 29 is a logic flow diagram depicting a process representing a control procedure or logic configuration of a passive articulation control procedure in accordance with an aspect of the present disclosure.

Fig. 30 is a logic flow diagram depicting a process of control procedure or logic configuration representing a passive rotation control procedure in accordance with an aspect of the present disclosure.

Description

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

attorney docket number END8191USNP/170054, filed 2017, 20/6, and entitled "control MOTOR vehicle OF a SURGICAL STAPLING AND CUTTING instracting basic system OF artics, et al.

Attorney docket number END8192USNP/170055, filed 2017, 20/6, and entitled "SURGILINDERRUMENT WITH VARIABLE DURATION TRIGGER ARRANGEMENT", by the inventors of Frederick e.shelton, IV et al.

Attorney docket number END8193USNP/170056 filed on 20/6/2017, inventor Frederick e.shelton, IV et al, and entitled "SYSTEMSAND METHODS FOR CONTROLLING DISPLACEMENT MEMBER MOTION OF A SURGICAL STAPLINGAND CUTTING INSTRUMENT".

Attorney docket number END8194USNP/170057, filed 2017, 20/6, and entitled "SYSTEMSAND METHODS FOR CONTROLLING MOTOR VELOCITY OF A SURGICAL STAPLING AND cutting into concrete available and open END EFFECTOR", inventor, IV et al.

Attorney docket number END8195USNP/170058, filed 2017, 20/6, and entitled "SYSTEMSAND METHODS FOR CONTROLLING MOTOR VELOCITY OF A SURGICAL STAPLING AND cutting in lung cancer", by inventors Frederick e.shelton, IV et al.

Attorney docket number END8196USNP/170059, entitled "SURGILINSTRUNT HAVING CONTROL ARTICULATION VELOCITY", filed 2017, 20/6.IV, by inventors Frederick E.Shelton, IV et al.

Attorney docket number END8197USNP/170060, filed 2017, 20/6, AND entitled "SYSTEMSAND METHODS FOR CONTROLLING VELOCITY OF A DISPLACEMENT MEMBER OF a surgicat application AND customization instumment", inventors Frederick e.shelton, IV et al.

Attorney docket number END8198USNP/170061, filed 2017, 20 months and 6, inventor Frederick e.shelton, IV et al, and entitled "SYSTEMSAND METHODS FOR CONTROLLING DISPLACEMENT MEMBER VELOCITY FOR A SURGICALINSTRUMENT".

Attorney docket number END8199 USNP/062170m, entitled "tecniques FOR ADAPTIVE CONTROL OF MOTOR vehicle OF a basic station and tuning admission", filed 20/6 months in 2017, inventors Frederick e.shelton, IV et al.

Attorney docket number END8275USNP/170185M, filed 2017, month 6, 20, entitled "tecniquesford CLOSED LOOP CONTROL OF MOTOR vehicle OF a SURGICAL STAPLING AND cutting in.

Attorney docket number END8268USNP/170186, filed 2017, month 6, and day 20, entitled "CLOSED loop feedback CONTROL OF MOTOR vehicle OF a MOTOR vehicle BASED ON a basic STAPLING AND cutting in vehicle measurement systems.

Attorney docket number END8276USNP/170187, filed 2017 ON 20/6, and entitled "CLOSED loop CONTROL OF MOTOR vehicle OF a MOTOR vehicle OF CLOSED TIME coverage STAPLING AND cut in transmission TIME OVER A SPECIFIED DISPLACEMENT DISTANCE, by Jason l harris et al.

20/6/2017, Frederick E.Shelton, IV et al and attorney docket number END8266USNP/170188 entitled "CLOSED LOOP FEEDBACKCONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING NSTRUMENT BASED ON MEASURED DISPLACEMENT DISTANCE TRAVELED OVER A SPECIFIEDTIME INTERVAL.

20 days 6.2017, Frederick E.Shelton, IV et al and entitled "CLOSED LOOP FEEDBACK CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING TRANSISTRATING BASED ON MEASURED TIME OVER A SPECIFIED NUMBER OF SHAFT ROTATONS" att docket NUMBER END8267 USNP/170189.

Attorney docket number END8269USNP/170190 entitled "SYSTEMS and methods FOR vehicle FOR a SURGICAL instument" filed in 2017 on 20/6 months, by Jason l harris et al.

Attorney docket number END8270USNP/170191, filed 2017, 20/6, by Jason l.harris et al, entitled "SYSTEMS and methods FOR CONTROLLING MOTOR SPEED associated with USER INPUT FOR a SURGICALINSTRUMENT".

20 days 6.2017, Frederick E.Shelton, IV et al and attorney docket number END8271USNP/170192 entitled "CLOSED LOOP FEEDBACK CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING TRANSISTRATING BASED ON SYSTEM CONDITIONS".

Attorney docket number END8274USDP/170193D entitled "GRAPHICAL USERINTERFACE FOR A DISPLAY OR PORTION THEREOF" filed 2017, 20/6 months, by Jason l.

Attorney docket number END8273USDP/170194D entitled "GRAPHICAL USERINTERFACE FOR A DISPLAY OR PORTION THEREOF" filed 2017, 20/6 months, by Jason l.

Attorney docket number END8272USDP/170195D filed 2017, 6, 20, D, by inventors Frederick e.shelton, IV et al, and entitled "GRAPHICAL USER INTERFACE FOR A DISPLAY OR PORTION THEREOF".

Certain aspects are shown and described to provide an understanding of the structure, function, manufacture, and use of the disclosed apparatus and methods. Features illustrated 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, wherein "proximal" refers to a portion closer to the clinician and "distal" refers to a portion located further 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.

Example 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 made in the tissue. The working portion or end effector portion of the instrument may be inserted directly into the body or may be inserted through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument may be advanced.

Fig. 1-4 illustrate 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 including a handle assembly 14 configured to be grasped, manipulated and actuated by a clinician. The housing 12 is configured to be operatively attached to an interchangeable shaft assembly 200 having an end effector 300 operatively coupled thereto that is configured to perform one or more surgical tasks or procedures. In accordance with the present disclosure, various forms of interchangeable shaft assemblies may be effectively employed in connection with robotically controlled surgical systems. The term "housing" may also 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 usable 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 operatively 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 STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," 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 that includes 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 an interchangeable shaft assembly that includes an end effector that is adapted to support different sizes and types of staple cartridges, having different shaft lengths, sizes, and types. The housing 12 can be used with a variety of interchangeable shaft assemblies, including assemblies configured to apply other motions and forms of energy, such as Radio Frequency (RF) energy, ultrasonic energy, and/or motion, to end effector configurations suitable for use in connection with a variety of 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 that are interconnected by screws, snap features, adhesives, and 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 generate and apply control motions to corresponding portions of the interchangeable shaft assembly operatively attached thereto. The display may be disposed 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 operatively supports a "first" or closure drive system 30 that can 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 to enable the closure trigger 32 to be manipulated by a clinician. The closure trigger 32 may pivot from an activated 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 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 brushed DC motor having a maximum rotational speed of about 25,000 RPM. In other constructions, the motor may include 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, which may include a removable power pack 92. The removable power pack 92 may include a proximal housing portion 94 configured to attach to a distal housing portion 96. The proximal housing portion 94 and the distal housing portion 96 are configured to operably 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 for removable operative attachment to a control circuit board 100 that is also 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 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 a rack of drive teeth 122 formed thereon for 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 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 is moving.

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

Turning again to fig. 1, the interchangeable shaft assembly 200 includes an end effector 300 that includes an elongate channel 302 configured to operably 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 construction and operation of the end effector 300 and ARTICULATION joint 270 is set forth in U.S. patent application publication 2014/0263541 entitled "ARTICULATABLE SURGICAL INSTRUMENTC PRIMING 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 that can be used to close and/or open the anvil 306 of the end effector 300.

Turning again 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 reference 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 in accordance with an aspect of the present disclosure. The interchangeable shaft assembly 200 can include a firing member 220 that is 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" or "second shaft assembly". The intermediate firing shaft 222 can include a longitudinal slot 223 in a distal end 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. The sliding joint 286 can 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 may be advanced distally until the proximal side wall of the longitudinal slot 223 comes into contact with 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 slidably supports an articulation driver 230.

The interchangeable shaft assembly 200 can include a 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 accordingly, 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 transferred 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 can be configured to conduct electrical power to and/or from end effector 300 and/or transmit and/or receive signals to and/or 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 comprise a first face and the distal connector flange 601 can comprise a second face, wherein the second face is 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 face 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 configuration allows for relative rotation between the proximal connector flange 604 and the distal connector flange 601 while maintaining electrical contact therebetween. For example, the proximal connector flange 604 may include an electrical connector 606 that 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 chassis 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. An aperture 199 can be defined in the elongate channel 302 to receive a pin 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 translate longitudinally 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 thereof. The distal protruding end of the firing bar 172 may be attached to the I-beam 178 which helps space the anvil 306 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 can include a sharp cutting edge 182 that can be used to sever tissue as the I-beam 178 is advanced distally through the firing bar 172. In operation, the I-beam 178 can fire the surgical staple cartridge 304. The surgical staple cartridge 304 can comprise a molded cartridge body 194 that holds a plurality of staples 191 disposed on staple drivers 192 located in respective upwardly opening 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 edge 182 of the I-beam 178 severs 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 a middle pin 184 and a bottom base 186 to engage various 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 shown in FIG. 4, wherein the bottom base 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 the 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 trapped 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 the two stapled and severed tissue portions.

Fig. 5A-5B are block diagrams of control circuitry 700 of the surgical instrument 10 of fig. 1 spanning two drawings in accordance with an aspect of the present disclosure. Referring primarily to fig. 5A-5B, the handle assembly 702 can include a motor 714 that can be controlled by a motor driver 715 and can be used by the firing system of the surgical instrument 10. In various forms, the motor 714 may be a DC brushed driving motor having a maximum rotational speed of about 25,000 RPM. In other constructions, 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 the power assembly 706, which is releasably mounted to the handle assembly 200 for providing 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 module 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 safety 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 can include one or more electrical connectors for coupling engagement with corresponding shaft assembly electrical connectors and the second interface portion can include one or more electrical connectors for coupling engagement with corresponding power assembly electrical connectors, thereby allowing electrical communication between shaft assembly controller 722 and power management controller 716 when shaft assembly 704 and power assembly 706 are coupled to handle assembly 702. One or more communication signals may be transmitted over the interface to communicate one or more power requirements of the attached interchangeable shaft assembly 704 to the power management controller 716. In response, the power management controller may adjust the power output of the battery of power assembly 706 as a function of the power requirements of attachment shaft assembly 704, as described in more detail below. The connector may include switches that may be activated after the handle assembly 702 is mechanically coupled to the shaft assembly 704 and/or the power assembly 706 to allow electrical communication between the shaft assembly controller 722 and the power management controller 716.

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

The main controller 717 may be any single-core or multi-core processor, such as those provided by Texas Instruments under the trade name ARM Cortex. 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 single cycle flash or other non-volatile memory (up to 40MHZ) on-chip memory, prefetch buffers to improve performance by over 40MHz, 32KB of single cycle Serial Random Access Memory (SRAM), Stellaris loaded

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, also produced by Texas Instruments. The safety controller may be configured specifically for IEC 61508 and ISO 26262 safety critical applications, etc., 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. When shaft assembly 704 and power assembly 706 are coupled to handle assembly 702, the power management circuitry may be configured to adjust the power output of the battery based on the power requirements of shaft assembly 704. The power management controller 716 may be programmed to control the power modulator 738 to adjust the power output of the power component 706, and the current sensing circuit 736 may be used 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, which 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 that 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 integral with the power component 706. In such instances, communication between the output device 742 and the shaft assembly controller 722 may be achieved through an interface when the shaft assembly 704 is coupled to the handle assembly 702.

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 controller and/or the 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 input devices 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 the 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 circuitry 700 may be configured to implement 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 may be used, for example, 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 integral with the display and/or may be located separately from the display. The display may include any suitable display, such as 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 coupling to the interchangeable shaft assembly 200 (fig. 1 and 3) of the surgical instrument 10 (fig. 1-4) and/or one or more controls for coupling to the end effector 300 of 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 integrally formed 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 rotational 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 the main microcontroller processor 717 through an H-bridge driver and motor controller comprising one or more H-bridge Field Effect Transistors (FETs). The H-bridge driver is also coupled to the 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 be capable of providing 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 of 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 to be able to 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. The switch may be configured to control operation of the segmented circuit surgical instrument 10 (fig. 1-4) and/or to indicate a status of the surgical instrument 10. An emergency door switch and hall effect switch for an emergency are configured to indicate the status of the emergency door. A plurality of articulation switches, such as 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 the plurality of switches. For example, the switch may be a limit switch that is operated by movement 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 others. 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 others. Also, 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 others.

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, which 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 regulate 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 adjust the power output of the power component 706, and the current sensing circuit 736 may be used 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 so 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 that is coupled to a non-volatile memory 721 and a shaft assembly connector 728 to electrically couple 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 that provides 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 that 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 727 may be configured to enable connection of the shaft assembly controller 722 and/or the power management controller 716 to the output device 742. The output device 742 may be integral 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 shows 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 enable the 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 a surgical instrument 10 (fig. 1-4) according to 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 include a finite state machine including combinational logic 812 configured to receive data associated with the surgical instrument 10 at an input 814, process the data through the combinational 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. Sequential logic circuitry 820 or combinational logic circuitry 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. At least one memory circuit 820 may store the 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 from the inputs 826, process the data through the combinational logic circuit 822 and provide the outputs 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. An 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, including computer program instructions adapted to be executed by a general-purpose processor or a special-purpose processor.

Fig. 10 is a schematic diagram of an absolute positioning system 1100 of the surgical instrument 10 (fig. 1-4) according to one aspect of the present disclosure, wherein the absolute positioning system 1100 includes a controlled motor drive circuit configuration that includes a sensor configuration 1102. The position sensor 1102 for the absolute positioning system 1100 provides a unique position signal corresponding to the position of the displacement member 1111. Referring briefly to fig. 2-4, in one aspect, displacement member 1111 represents a longitudinally movable drive member 120 (fig. 2) including a rack of drive teeth 122 for meshing with a corresponding drive gear 86 of gear reducer assembly 84. In other aspects, the displacement member 1111 represents a firing member 220 (fig. 3) that 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 as a rack including drive teeth. 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 linear displacement of I-beam 178 by tracking the linear displacement of longitudinally movable drive member 120. In various other aspects, displacement member 1111 may be coupled to any sensor suitable for measuring linear displacement. Thus, the longitudinally movable drive member 120, the firing member 220, the firing bar 172, or the I-beam 178, or a combination thereof, may be coupled to any suitable linear displacement sensor. The linear displacement sensor may comprise a contact displacement sensor or a non-contact displacement sensor. The linear 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 mounted on the displacement member 1111 in meshing engagement with the set or rack of drive teeth. The sensor element 1126 may be operatively 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 transmission and sensor 1118 configuration may be coupled to a linear actuator via a rack and pinion configuration, or to a rotary actuator via a spur gear or other connection. A power source 1129 powers 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 including a rack of drive teeth 122 formed thereon for meshing engagement with a corresponding drive gear 86 of gear reducer assembly 84. The displacement member 1111 represents a longitudinally movable firing member 220, a firing bar 172, an I-beam 178, or a combination thereof.

A single rotation of sensor element 1126 associated with position sensor 1112 equates to a longitudinal linear displacement d1 of displacement member 1111, where d1 is the longitudinal linear 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 that causes position sensor 1112 to complete only 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 1122 a-1122 n (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 switches 1122 a-1122 n is fed back to controller 1104, which applies logic to determine a unique position signal corresponding to the longitudinal linear displacement d1+ d2+ … dn of movable member 1111. The output 1124 of the position sensor 1112 is provided to the controller 1104. The position sensor 1112 of the sensor configuration 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.

Thus, absolute positioning system 1100 provides the absolute position of displacement member 1111 upon instrument power-up, and does not retract or advance displacement member 1111 to a reset (clear or home) position as may be required by conventional rotary encoders, which 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 tool and the speed and position of the articulation system. In one aspect, the controller 1104 includes a processor 1108 and a memory 1106. Electric motor 1120 may be a brushed dc motor having a gear box and mechanical connection 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. A more detailed description of the absolute positioning system 1100 is described in U.S. patent application 15/130,590, entitled "SYSTEMS AND METHOD FOR CONTROLLING A SURGICAL STAPLING AND CUTTING NSTRUMENT," 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, 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 (such as a weighted average and a theoretical control loop) that drives the calculated response toward the measured response. The calculated response of the physical system takes into account characteristics such as mass, inertia, viscous friction, inductive resistance, etc. 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 drive 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 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 the absolute positioning system 1100.

Having described the general architecture for performing aspects of the absolute positioning system 1100 with respect to the sensor configuration 1102, the present disclosure now turns to fig. 11 and 12 to obtain a description of one aspect of the sensor configuration 1102 of the absolute positioning system 1100. FIG. 11 is an exploded perspective view of a sensor configuration 1102 of an absolute positioning system 1100 showing the relative alignment of elements of a circuit 1205 and the sensor configuration 1102, according to one aspect. The sensor configuration 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 the displacement member 1111, and a gear assembly 1206 that provides a gear reduction. Referring briefly to fig. 2, displacement member 1111 may represent a 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, structural elements such as a bracket 1216 are 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 disposed adjacent 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 revolution.

The sensor configuration 1102 may include any number of magnetic sensing elements, such as, for example, magnetic sensors that are classified according to whether they measure the total 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. Third gear 1212 is in meshing engagement with displacement member 1111 (or 120 shown in fig. 2) and rotates in a first direction when displacement member 1111 is advanced in distal direction D and rotates in a second direction when displacement member 1111 is retracted in 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 and is precisely aligned with an underlying magnet 1202 rotating within a magnet holder 1204, which defines an aperture 1220 adapted to contain the position sensor 1200. 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 schematic diagram of a position sensor 1200 of an absolute positioning system 1100 including a magnetic rotary absolute positioning system according to one 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 located in a region 1230 of the position sensor 1200 on the magnet 1202 (fig. 15 and 16). A high resolution ADC 1232 and an intelligent power management controller 1238 are also provided on the chip. CORDIC processor 1236 (for Coordinate Rotation digital computer (CORDIC)), also known as the bitwise and Volder algorithms, is provided to perform simple and efficient algorithms to compute hyperbolic and trigonometric functions, requiring only addition, subtraction, bit shifting and table lookup operations. 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 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 here for convenience, but it generally produces a voltage difference (hall voltage) across the conductor that is transverse to the current in the conductor and a magnetic field that is 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 AS a function of the angle of the magnet 1202 after 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, such as upon power up or upon request by the controller 1104, the controller 1104 is provided with a value of the angle that indicates the position of the magnet 1202 over one rotation.

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 supply 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. The completion of this cycle is represented as the 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 (600 μ s) after each power-up sequence. AS soon AS the measurement of an angle is completed, the AS5055 position sensor 1200 is suspended to a power-down state. On-chip filtering of 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 4 samples reduces 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 clamped 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 the 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 the 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. The I-beam 2514 is shown at one exemplary position at a stroke start position 2527. The I-beam 2514 firing member stroke chart 2529 shows 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, 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 rise. 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 smoothed in the third region 2521. With the fourth firing stroke region 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. Moreover, cutting edge 2509 and wedge slide 2513 can reach the end of tissue 2526 in 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, different regions may begin at different locations along the end effector longitudinal axis 2515, e.g., based on tissue positioning between the anvil 2516 and the staple cartridge 2518.

As described above, referring now to fig. 10-13, the electric motor 1122 located within the handle assembly of the surgical instrument 10 (fig. 1-4) can be used to advance and/or retract the firing system (including the I-beam 2514) of the shaft assembly relative to the end effector 2502 of the shaft assembly in order to staple and/or cut tissue captured within the end effector 2502. The I-beam 2514 can be advanced or retracted at a desired speed or within a desired speed range. 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 provided 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 provided 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 of the electric motor 1122 should be increased in order to increase the speed of the I-beam 2514 and/or decreased in order to decrease the speed of the I-beam 2514. U.S. Pat. No. 8,210,411 entitled "MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT," which is incorporated herein by reference in its entirety. U.S. patent 7,845,537 entitled "SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES," which is incorporated herein by reference in its entirety.

Various techniques may be used to determine the force acting on the I-beam 2514. The force of the I-beam 2514 may be determined by measuring the current of the motor 2504, wherein the motor 2504 current is based on the load experienced by the I-beam 2514 as it is advanced distally. The force of the I-beam 2514 can be determined by positioning a strain gauge 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 monitored over a predetermined elapsed time period T ₁The actual position of the I-beam 2514, which is then moved at the desired speed based on the current set-speed of the motor 2504, and for a time period T ₁The end time is determined by comparing the actual position of the I-beam 2514 to the expected position of the I-beam 2514 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 is proportional to the force on the I-beam 2514 from the nominal force. Such technology is 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 can comprise an anvil 2516, an I-beam 2514 (including a sharp 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 liner 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 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 depicted in fig. 5A and 5B) may be programmed to control the translation of a displacement member 1111 (such as the I-beam 2514), as described in connection with 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 a 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 the 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 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 an actuator 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 can 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 instructed 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 and time, tissue compression and time, and anvil strain and 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 a 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 an impedance of a section of tissue located between the anvil 2516 and the staple cartridge 2518 that is indicative of the thickness and/or integrity of the tissue located 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 tissue compression experienced by a section of tissue trapped 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 the processor during the clamping operation, as described in fig. 5A-5B. The control circuit 2510 receives real-time sample measurements to provide and analyze time-based information and evaluates the closing force applied to the anvil 2516 in real time.

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, for example. 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 gear box and mechanical connection 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 aspects of the surgical instrument 2500 in detail, it should be noted that the applicability or use of the exemplary aspects is not limited to the details of construction and the arrangement of components set forth in the accompanying drawings and description. The illustrative aspects may be implemented alone, in combination with 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 embodiments 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 example aspects are directed to a surgical instrument 2500 that includes a surgical stapling and severing implement end effector 2502 having a motor drive. 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 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. As the displacement member is translated distally, the I-beam 2514 with the cutting element positioned at the distal end can cut tissue between the staple cartridge 2518 and the anvil 2516.

In various examples, the surgical instrument 2500 can include a control circuit 2510 programmed to control distal translation of a displacement member (such as an I-beam 2514) 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 elapsed time 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 axes. Horizontal axis 2584 indicates elapsed time. The vertical axis 2582 represents 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 the firing signal and begin at t ₀An initial motor setting is provided. The open loop portion of the firing member stroke may be at t ₀And t ₁An initial period of time elapsed 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 the open-loop part of the displacement member stroke, e.g. at t ₀And t ₁During the initial time period in between, the I-beam 2514 may traverse from the stroke start position 2586 to the position 2594. The control circuit 2510 can determine that the position 2594 corresponds to a firing control procedure that advances the I-beam 2514 at a selected constant rate (Vslow), at t, from the slope of the example 2592 ₁Followed by (e.g., in the closed loop portion) an indication. The control circuit 2510 can drive the I-beam 2514 to the velocity vshaar to maintain vshaar 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 routine that advances the displacement member at a selected constant rate (veast). 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. And alsoIn some examples, thinner tissue (e.g., a larger portion of the displacement member stroke traversed during the initial time period) may correspond to a higher displacement member velocity after the initial time period.

Fig. 16-21 illustrate the end effector 2300 of the surgical instrument 2010, showing how the end effector 2300 may be articulated relative to the elongate shaft assembly 2200 about an articulation joint 2270, according to one aspect of the present disclosure. FIG. 16 is a partial perspective view of a portion of the end effector 2300 showing the elongate shaft assembly 2200 in a non-articulated orientation with portions thereof omitted for clarity. FIG. 17 is a perspective view of the end effector 2300 of FIG. 16, showing the elongate shaft assembly 2200 in an unarticulated orientation. FIG. 18 is an exploded assembly perspective view of the end effector 2300 of FIG. 16, showing an elongate shaft assembly 2200. FIG. 19 is a top view of the end effector 2300 of FIG. 16, showing the elongate shaft assembly 2200 in a non-articulating orientation. FIG. 20 is a top view of the end effector 2300 of FIG. 16, showing the elongate shaft assembly 2200 in a first articulation orientation. FIG. 21 is a top view of the end effector 2300 of FIG. 16, showing the elongate shaft assembly 2200 in a second articulation orientation.

Referring now to fig. 16-21, the end effector 2300 is adapted to cut and staple tissue and includes a first jaw in the form of an elongate channel 2302 configured to operably support a surgical staple cartridge 2304 therein. The end effector 2300 also includes a second jaw in the form of an anvil 2310 that is supported on the elongate channel 2302 for movement relative thereto. The elongate shaft assembly 2200 includes an articulation system 2800 that employs an articulation lock 2810. The articulation lock 2810 can be configured and operated to selectively lock the surgical end effector 2300 in various articulation positions. Such a configuration enables the surgical end effector 2300 to rotate or articulate relative to the shaft closure sleeve 260 when the articulation lock 2810 is in its unlocked state. Referring specifically to fig. 18, the elongate shaft assembly 2200 includes a spine 210 configured to: (1) slidably supporting the firing member 220 therein, and (2) slidably supporting a closure sleeve 260 (fig. 16) extending around the spine 210. The shaft closure sleeve 260 is attached to an end effector closure sleeve 272 that is pivotally attached to the closure sleeve 260 by a dual pivot closure sleeve assembly 271.

The spine 210 also slidably supports a proximal articulation driver 230. Proximal articulation driver 230 has a distal end 231 configured to operatively engage articulation lock 2810. The articulation lock 2810 also includes a shaft frame 2812 that attaches to the spine 210 in the various ways disclosed herein. The shaft frame 2812 is configured to movably support the proximal portion 2821 of the distal articulation driver 2820 therein. A distal articulation driver 2820 is movably supported within the elongate shaft assembly 2200 for selective longitudinal travel in the distal direction DD and the proximal direction PD along an articulation actuation axis AAA that is laterally offset from and parallel to the shaft axis SA-SA in response to articulation control motions applied thereto.

In fig. 17 and 18, the shaft frame 2812 includes a distal end portion 2814 having a pivot pin 2818 formed thereon. The pivot pin 2818 is adapted to be pivotally received within a pivot hole 2397 formed in a pivot base portion 2395 of the end effector mounting assembly 2390. The end effector mounting assembly 2390 is attached to the proximal end 2303 of the elongate channel 2302 by a spring pin 2393 or equivalent. The pivot pin 2818 defines an articulation axis BB transverse to the shaft axis SA-SA to facilitate pivotal travel (i.e., articulation) of the end effector 2300 about the articulation axis BB relative to the shaft frame 2812.

As shown in fig. 18, a connection pin 2825 is formed on the distal end 2823 of the distal articulation link 2820 and is configured to be received within the aperture 2904 in the proximal end 2902 of the cross-link 2900. Cross-connect 2900 extends transversely across shaft axis SA-SA and includes a distal end portion 2906. A distal attachment aperture 2908 is disposed through the distal end portion 2906 of the cross-link 2900 and is configured to pivotally receive therein a base pin 2398 that extends from the bottom of a pivot base 2395 of an end effector mounting assembly 2390. The base pin 2395 defines a link axis LA that is parallel to the articulation axis B-B. Fig. 17 and 20 illustrate the surgical end effector 2300 in an unarticulated position. The end effector axis EA defined by the elongate channel 2302 is aligned with the shaft axis SA-SA. The term "aligned with …" may mean "coaxially aligned" with or parallel to the shaft axis SA-SA. Movement of the distal articulation driver 2820 in the proximal direction PD will cause the cross-connect 2900 to pull the surgical end effector 2300 in the clockwise CW direction about the articulation axis B-B, as shown in fig. 19. Movement of the distal articulation driver 2820 in the distal direction DD will cause the cross-link 2900 to move the surgical end effector 2300 in a counterclockwise CCW direction about the articulation axis B-B, as shown in fig. 21. As shown in fig. 21, cross-link 2900 has a curved shape that allows cross-link 2900 to bend about articulation pin 2818 as surgical end effector 2300 is articulated in that direction. The articulation angle 2700 between the end effector axis EA and the shaft axis SA-SA is about sixty-five degrees (65 °) when the surgical end effector 2300 is in the fully articulated position on either side of the shaft axis SA-SA. Thus, the range of articulation on either of the shaft axes is one degree (1 °) to sixty-five degrees (65 °).

FIG. 19 illustrates the articulation joint 2270 in a vertical position, i.e., at a zero angle θ with respect to the longitudinal direction, shown as shaft axis SA, according to one aspect ₀. FIG. 20 illustrates the articulation joint 2270 of FIG. 19 at a first angle θ defined between the shaft axis SA and the end effector axis EA, according to one aspect ₁Articulation is performed in one direction. FIG. 21 illustrates the articulation joint 2270 of FIG. 19 at a second angle θ defined between the shaft axis SA and the end effector axis EA ₂Articulation is performed in the other direction.

The surgical end effector 2300 of fig. 16-21 includes a surgical cutting and stapling device that employs a firing member 220 of the various types and configurations described herein. However, the surgical end effector 2300 may comprise other forms of surgical end effectors that do not cut and/or staple tissue. The intermediate support member 2950 is pivotally and slidably supported relative to the spine 210. In FIG. 18, the intermediate support member 2950 includes a slot 2952 adapted to receive a pin 2954 therein, the pin protruding from the spine 210. This enables the intermediate support member 2950 to pivot and translate relative to the pin 2954 as the surgical end effector 2300 is articulated. A pivot pin 2958 projects from the underside of the intermediate support member 2950 to be pivotally received within a corresponding pivot hole 2399 provided in the base portion 2395 of the end effector mounting assembly 2390. The intermediate support member 2950 also includes a slot 2960 for receiving the firing member 220 therethrough. The intermediate support member 2950 serves to provide lateral support to the firing member 220 as it flexes to accommodate articulation of the surgical end effector 2300.

The surgical instrument can additionally be configured to determine the angle of orientation of the end effector 2300. In various aspects, the position sensors 1112 of the sensor arrangement 1102 can include, for example, one or more magnetic sensors, analog rotation sensors (e.g., potentiometers), analog hall effect sensor arrays that output unique combinations of position signals or values, and the like. In one aspect, the articulation joint 2270 of the aspect illustrated in fig. 16-21 can additionally include an articulation sensor configuration configured to determine the angular position, i.e., the articulation angle, of the end effector 2300 and provide a unique position signal corresponding thereto.

The articulation sensor configuration may be similar to the sensor configuration 1102 described above and shown in fig. 10-12. In this regard, the articulation sensor configuration may include a position sensor and a magnet operatively coupled to the articulation joint 2270 such that it rotates in unison with the rotation of the articulation joint 2270. The magnet may be coupled to the pivot pin 2818, for example. The position sensor includes one or more magnetic sensing elements, such as hall effect sensors, and is disposed adjacent the magnet, within or near the articulation joint 2270. Thus, as the magnet rotates, the magnetic sensing element of the position sensor determines the absolute angular position of the magnet. When the magnet is coupled to the articulation joint 2270, the angular position of the magnet relative to the position sensor corresponds to the angular position of the end effector 2300. Thus, the articulation sensor configuration can determine the angular position of the end effector as the end effector is articulated.

In another aspect, the surgical instrument is configured to determine the angle at which the end effector 2300 is positioned in an indirect manner by monitoring the absolute position of the articulation driver 230 (fig. 3). Since the position of the articulation driver 230 corresponds to the angle at which the end effector 2300 is oriented in a known manner, the absolute position of the articulation driver 230 can be tracked and then converted to the angular position of the end effector 2300. In this regard, the surgical instrument includes an articulation sensor arrangement configured to determine the absolute linear position of the articulation driver 230 and provide a unique position signal corresponding thereto. In some aspects, the articulation sensor configuration or a controller operatively coupled thereto is additionally configured to translate or calculate the angular position of the end effector 2300 from the unique position signal.

In this regard, the articulation sensor configuration may likewise be similar to the sensor configuration 1102 described above and shown in fig. 10-12. In one aspect similar to that shown in fig. 10 with respect to displacement member 1111, the articulation sensor configuration includes a position sensor and a magnet that rotates once per full stroke of the longitudinally movable articulation driver 230. The position sensor includes one or more magnetic sensing elements, such as hall effect sensors, and is disposed adjacent to the magnet. Thus, as the magnet rotates, the magnetic sensing element of the position sensor determines the absolute angular position of the magnet through one revolution.

In one aspect, a single rotation of the sensor element associated with the position sensor is equivalent to the longitudinal linear displacement d1 of the longitudinally movable articulation driver 230. In other words, d1 is the longitudinal linear distance that the longitudinally movable articulation driver 230 moves from point "a" to point "b" after a single rotation of the sensor element coupled to the longitudinally movable articulation driver 230. The articulation sensor configuration may be coupled via a gear reduction that allows the position sensor to complete only one rotation for the full stroke of the longitudinally movable articulation driver 230. In other words, d1 may be equal to the full stroke of articulation driver 230. The position sensor is configured to be able to subsequently transmit a unique position signal corresponding to the absolute position of the articulation driver 230 to the controller 1104, such as in those aspects shown in fig. 10. Upon receipt of the unique position signal, the controller 1104 is then configured to execute logic to determine the angular position of the end effector corresponding to the linear position of the articulation driver 230 by, for example, querying a lookup table that returns pre-calculated angular position values for the end effector 2300, algorithmically calculating the angular position of the end effector 2300, using the linear position of the articulation driver 230 as an input, or performing any other such method known in the art.

In various aspects, any number of magnetic sensing elements may be employed in the articulation sensor configuration, such as magnetic sensors that are categorized according to whether they measure the entire magnetic field or vector components of the magnetic field. The number of magnetic sensing elements utilized corresponds to the desired resolution sensed by the articulation sensor configuration. In other words, the greater the number of magnetic sensing elements used, the more subtle the degree of articulation that can be sensed by the articulation sensor configuration. 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.

In one aspect, the position sensors of various aspects of the articulation sensor configuration may be implemented in a manner similar to the positioning system shown in FIG. 12 for tracking the position of displacement member 1111. In one such aspect, the articulation sensor configuration may be implemented AS an AS5055EQFT monolithic magnetic rotational position sensor, available from australia Microsystems, AG. The position sensor interfaces with the controller to provide an absolute positioning system for directly or indirectly determining the absolute angular position of the end effector 2300. The position sensor is a low voltage and low power component and includes four hall effect elements 1228A, 1228B, 1228C, 1228D located in a region 1230 of the position sensor 1200 on the magnet 1202 (fig. 11). 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 (Coordinate Rotation Digital Computer)), also known as the bitwise and Volder algorithms, is provided to perform simple and efficient algorithms to compute hyperbolic and trigonometric functions, requiring only addition, subtraction, bit shifting and table lookup operations. 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 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.

Referring to fig. 1-4 and 10-21, the absolute position feedback signal/value from absolute positioning system 1100 may be used to determine the position of articulation joint 2270 and the position of I-beam 178 (fig. 4). In one aspect, the articulation angle θ may be determined fairly accurately based on the drive member 120 of the surgical instrument 10. As described above, the motion of the longitudinally movable drive member 120 (fig. 2) may be tracked by the absolute positioning system 1100, wherein the absolute positioning system 1100 may actually track the motion of the articulation system through the drive member 120 when the articulation driver is operatively coupled to the firing member 220 (fig. 3) through, for example, the clutch assembly 400 (fig. 3). As a result of tracking the motion of the articulation system, the controller of the surgical instrument may track the articulation angle θ of the end effector 2300 (such as the end effector 2300). In various circumstances, as a result, the articulation angle θ may be determined from the longitudinal displacement DL of the drive member 120. Since the longitudinal displacement DL of the drive member 120 can be accurately determined based on the absolute position signal/value provided by the absolute positioning system 1100, the articulation angle θ can be determined from the longitudinal displacement DL.

In another aspect, the articulation angle θ may be determined by positioning a sensor on the articulation joint 2270. The sensor may be configured to sense rotation of the articulation joint 2270 using an absolute positioning system 1100 adapted to measure absolute rotation of the articulation joint 2270. For example, the sensor configuration 1102 includes a position sensor 1200, a magnet 1202, and a magnet holder 1204 adapted to sense rotation of an articulation joint 2270. The position sensor 1200 includes one or more magnetic sensing elements (such as hall elements) and is disposed adjacent to the magnet 1202. The position sensor 1200 depicted in figure 12 may be adapted to measure the angle of rotation of the articulation joint 2270. Thus, as the magnet 1202 rotates, the magnetic sensing element of the position sensor 1200 determines the absolute angular position of the magnet 1202 located on the articulation joint 2270. This information is provided to the microcontroller 1104 to calculate the articulation angle of the articulation joint 2270. Accordingly, the articulation angle of the end effector 2300 may be determined by an absolute positioning system 1100 adapted to measure the absolute rotation of the articulation joint 2270.

In one aspect, the firing rate or speed of the I-beam 178 can be varied depending on the articulation angle of the end effector 2300 to reduce the firing force on the firing drive system 80, particularly the firing force of the I-beam 178, as well as the firing forces of other components of the firing drive system 80 discussed herein. To accommodate the variable firing force of the I-beam 178 as a function of the articulation angle of the end effector 2300, a variable motor control voltage may be applied to the motor 82 to control the speed of the motor 82. The speed of the motor 82 may be controlled by comparing the firing force of the I-beam 178 to a different maximum threshold based on the articulation angle of the end effector 2300. For example, the speed of the electric motor 82 may be varied by adjusting the voltage, current, Pulse Width Modulation (PWM), or duty cycle (0-100%) applied to the motor 82.

Various aspects described herein relate to a surgical instrument including a distally positioned, rotatable, and articulatable jaw assembly. The jaw assembly may be used in place of or in addition to the shaft articulation. For example, the jaw assembly may be used to grasp, staple, and cut tissue.

Referring to fig. 13 and 14, in one aspect, a surgical instrument 2500 can comprise: an end effector 2502 including a staple cartridge 2518 and an anvil 2516 at distal ends; and an I-beam 2514 including a cutting edge 2509 for severing tissue. The jaw assembly may be articulatable and pivotable about a longitudinal axis of the instrument shaft. The jaw assembly may pivot about a wrist pivot axis from a first position in which the jaw assembly is substantially parallel to staple cartridge 2518 to a second position in which the jaw assembly is substantially non-parallel to staple cartridge 2518. Additionally, the jaw assembly may include first and second jaw members that are pivotable about a second axis or jaw pivot axis. The jaw pivot axis may be substantially perpendicular to the wrist pivot axis. In some aspects, the jaw pivot axis itself may pivot as the jaw assembly pivots about the wrist pivot axis. The first and second jaw members may be pivotable relative to each other about a jaw pivot axis such that the first and second jaw members may be "opened" and "closed". Additionally, in some aspects, the first and second jaw members can also pivot together about a jaw pivot axis such that the orientation of the first and second jaw members can be changed.

In one aspect, surgical instrument 2500 can comprise an end effector 2502, an articulation joint, and an articulation member. The articulation member is configured to translate a distance from a proximal position to a distal position relative to the end effector 2502, wherein translation of the articulation member causes the articulation joint to articulate. Surgical instrument 2500 can include a motor 2504 operable to translate an articulation member along a distance from a proximal position to a distal position. Motor 2504 may have an on state, an off state, and a hold state. The surgical instrument 2500 may also include: a control circuit 2510 coupled to the motor 2504 and a position sensor 2534 coupled to the control circuit 2510. The position sensor 2534 may be configured to detect the position of the articulation member along at least a portion of the distance. The control circuit 2510 can be configured to receive a position input from the position sensor 2534 indicative of an articulation position of the articulation member. The control circuit 2510 can identify a predetermined threshold value corresponding to the articulation position of the articulation member. When motor 2504 is in a powered off state, control circuitry 2510 can determine a control action for motor 2504 in response to movement of the articulation member exceeding a predetermined threshold. Control circuit 2510 can control the movement of the articulation member, where controlling the movement of the articulation member includes engaging motor 2504 to a holding state.

One or more of the following features may be included. The control circuit 2510 can be configured to maintain the articulation position in response to movement of the articulation member exceeding a predetermined threshold. In holding the articulation position, the control circuit may provide Pulse Width Modulation (PWM) of current (e.g., motor drive signal 2514) to motor 2504 to resist movement of the articulation member in the holding state. The motor 2504 may comprise a DC brushed motor. Control circuit 2510 can be configured to connect the leads internally to the DC brushed motor when motor 2504 is in a hold state. The control circuit 2510 may include a forward state, a coast state, and a brake state. When the control circuit 2510 is in the forward state, the DC motor is in the energized state. When the control circuit 2510 is in the coast state, the DC motor is in a power-off state. When the control circuit 2510 is in the braking state, the DC motor is in the holding state. The control circuit 2510 may include a first switch, a second switch, a third switch, and a fourth switch. When the control circuit 2510 is in the forward state, the second and third switches are in a closed configuration and the first and fourth switches are in an open configuration. When the control circuit is in the braking state, the first switch and the second switch are in a closed configuration, and the third switch and the fourth switch are in an open configuration. When the control circuit 2510 is in the coast state, the first, second, third and fourth switches are all in an open configuration.

In one aspect, the surgical instrument 2500 can comprise an end effector 2502 and a rotatable shaft assembly. The rotatable shaft assembly may include a longitudinal axis, a rotational position sensor 2534, and a gear assembly. The rotational position sensor 2534 may be configured to measure rotation of the rotatable shaft assembly about the longitudinal axis. The surgical instrument 2500 can include a motor 2504 operatively connected to the gear assembly of the rotatable shaft assembly. The motor 2504 can be configured to apply a rotational force to rotate the gear assembly. Rotation of the gear assembly rotates the rotatable shaft assembly about the longitudinal axis. The surgical instrument 2500 may also include a control circuit 2510 coupled to the motor 2504. The control circuit 2510 can be configured to monitor the rotational position of the rotatable shaft assembly based on a signal from the rotational position sensor 2534. The control circuit 2510 can also identify a predetermined threshold value corresponding to the rotational position of the rotatable shaft assembly. The control circuit 2510 can also determine a control action for the motor 2504 in response to the rotational movement of the rotatable shaft assembly exceeding a predetermined threshold. The control circuit 2510 can control rotation of the rotatable shaft assembly, wherein controlling rotation of the rotatable shaft assembly can include resisting rotation of the rotatable shaft assembly about the longitudinal axis.

One or more of the following features may be included. The control circuit may be configured to maintain the rotational position of the rotatable shaft assembly in response to rotation of the rotatable shaft assembly about the longitudinal axis exceeding a predetermined threshold. Maintaining the rotational position may include PWM providing current to the motor 2504 to resist rotation of the rotatable shaft assembly. The motor 2504 may comprise a DC brushed motor. The control circuit 2510 can be configured to connect the leads internally to the DC brushed motor when the motor 2504 resists rotation of the rotatable shaft assembly beyond a predetermined threshold.

In one aspect, surgical instrument 2500 can comprise a longitudinal shaft assembly. The longitudinal shaft assembly may include a rotatable shaft portion including a longitudinal axis and a drive gear and an articulation joint. The drive gear may be configured to rotate about a longitudinal axis. The articulation joint may include an articulation gear. The surgical instrument 2500 may also include a drive assembly. The drive assembly may include a motor 2504, control circuitry 2510, and a drive member. The motor 2504 may include a drive output. The control circuit 2510 can be configured to control the motor 2504. The drive member may be operatively connected to the drive output. When the control circuit 2510 is in a rotating state, the drive member is operatively connected to the drive gear of the rotatable shaft portion. When the control circuit 2510 is in the articulation state, the drive member is operatively connected to the articulation gear of the articulation joint. The surgical instrument 2500 may also include an energy source 2512. The control circuit 2510 may include a power-on state, a power-off state, and a dynamic braking state. When the control circuit 2510 is in the energized state, the control circuit 2510 supplies an energy source 2512 to the motor 2504 in a series circuit configuration. When the control circuit 2510 is in a power-off state, the control circuit 2510 disconnects the energy source 2512 from the motor 2504. When the control circuit 2510 is in the dynamic braking state, the control circuit 2510 places the energy source 2512 and the motor 2504 in a parallel circuit state.

One or more of the following features may be included. When the control circuit 2510 is in the rotational state and the dynamic braking state, the control circuit 2510 may be configured to monitor the rotational position of the rotatable shaft portion based on a signal from the rotational position sensor 2534. The control circuit 2510 may identify a predetermined threshold value corresponding to the rotational position of the rotatable shaft portion. The control circuit 2510 can determine a control action for the motor 2504 in response to the rotational movement of the rotatable shaft portion exceeding a predetermined threshold. The control circuit 2510 can control rotation of the rotatable shaft portion, wherein controlling rotation of the rotatable shaft portion comprises resisting rotation of the rotatable shaft portion about the longitudinal axis. When the control circuit 2510 is in the articulation state and the dynamic braking state, the control circuit may be configured to monitor the articulation position of the articulation joint based on a signal from the articulation position sensor 2534. The control circuit 2510 can identify a predetermined threshold value corresponding to the articulation position of the articulation joint. The control circuit 2510 can determine a control action for the motor 2504 in response to the articulation of the articulation joint exceeding a predetermined threshold. The control circuit 2510 can control articulation of the articulation joint, where controlling articulation of the articulation joint includes resisting articulation of the articulation joint. The motor 2504 may comprise a DC brushed motor and the energy source 2512 may comprise a battery.

In one aspect, surgical instrument 2500 can comprise an end effector 2502, an articulation joint, and an articulation member. The articulation member is configured to translate a distance from a proximal position to a distal position relative to the end effector 2502, wherein translation of the articulation member causes the articulation joint to articulate. Surgical instrument 2500 can include a motor 2504 operable to translate an articulation member along a distance from a proximal position to a distal position. Motor 2504 may include an energized state and a de-energized state. The surgical instrument 2500 may also include: a control circuit 2510 coupled to the motor 2504 and a position sensor 2534 coupled to the control circuit 2510. A user may wish to articulate the end effector 2502 to a predetermined desired position. To articulate the end effector 2502 to a desired position, the control circuit 2510 can place the motor 2504 in an energized state. The position sensor 2534 may be configured to be able to detect a current position of the articulation member along at least a portion of the distance. The control circuit 2510 can be configured to receive a position input from the position sensor 2534 indicative of the current articulation position of the articulation member. The control circuit 2510 can identify a current articulation position that corresponds to the articulation position of the articulation member. The control circuit 2510 can determine a control action for the motor 2504 in response to a current position that does not correspond to a desired position. When the current position corresponds to the desired position, the control circuit 2510 can control the movement of the articulation member, wherein controlling the movement of the articulation member includes placing the motor 2504 in a de-energized state.

One or more of the following features may be included. The control circuit 2510 can be configured to maintain the articulation position in response to a current position of the articulation member corresponding to a desired articulation position. The control circuit may engage the electromagnetic lock while maintaining the articulated position. When the motor 2504 is placed in a power-off state, an electromagnetic lock may be created by shorting the motor. The motor 2504 may comprise a DC brushed motor. The control circuit 2510 can be configured to internally connect the leads to the DC brushed motor when the motor 2504 is de-energized to resist articulation of the end effector 2502 beyond a desired position. Internally connecting the leads to the DC brushed motor creates an internal reluctance within the motor 2504. When the end effector 2502 is in operation, the internal reluctance prevents any inadvertent back-driving of the motor 2504 by externally applied forces. Shorting the contacts of the motor 2504 creates a brake that holds the end effector 2502 in its current position because the mechanical back drive is combined with the natural resistance of the motor 2504 (coil short) to passively maintain the current articulation position.

In one aspect, the surgical instrument 2500 can comprise an end effector 2502 and a rotatable shaft assembly. The rotatable shaft assembly may be configured to rotate about the longitudinal axis. The rotatable shaft assembly may include a rotational position sensor 2534 and a gear assembly. The rotational position sensor 2534 can be configured to monitor rotation of the rotatable shaft assembly about the longitudinal axis. The surgical instrument 2500 can include a motor 2504 operatively connected to the gear assembly of the rotatable shaft assembly. The motor 2504 can be configured to apply a rotational force to rotate the gear assembly. Rotation of the gear assembly rotates the rotatable shaft assembly about the longitudinal axis. The surgical instrument 2500 may also include a control circuit 2510 coupled to the motor 2504. The control circuit 2510 can be configured to monitor the rotational position of the rotatable shaft assembly based on a signal from the rotational position sensor 2534. The control circuit 2510 can also identify a predetermined desired position corresponding to a rotational position of the rotatable shaft assembly. The control circuit 2510 can be configured to receive a position input from the position sensor 2534 indicative of a current rotational position of the rotatable shaft assembly. The control circuit 2510 can identify a current rotational position corresponding to the rotational position of the rotatable shaft assembly. The control circuit 2510 can determine a control action for the motor 2504 in response to a current position that does not correspond to a desired position. When the current position corresponds to the desired position, the control circuit 2510 can control movement of the rotatable shaft assembly, wherein controlling movement of the rotatable shaft assembly includes placing the motor 2504 in a de-energized state.

One or more of the following features may be included. The control circuit 2510 can be configured to maintain the rotational position in response to a current position of the rotatable shaft assembly corresponding to a desired rotational position. The control circuit may engage the electromagnetic lock while maintaining the rotational position. When the motor 2504 is placed in a power-off state, an electromagnetic lock may be created by shorting the motor. The motor 2504 may comprise a DC brushed motor. The control circuit 2510 can be configured to internally connect the leads to the DC brushed motor when the motor 2504 is de-energized to resist articulation of the end effector 2502 beyond a desired position. Internally connecting the leads to the DC brushed motor creates an internal reluctance within the motor 2504. The internal reluctance prevents any accidental back-driving of the motor 2504 by externally applied forces when the surgical instrument 2500 is in operation. Shorting the contacts of motor 2504 creates a brake that holds the shaft assembly in its current position because the mechanical back drive is combined with the natural resistance (coil short) of motor 2504 to passively maintain the current rotational position.

In one aspect, surgical instrument 2500 can comprise a longitudinal shaft assembly. The longitudinal shaft assembly may include a rotatable shaft portion extending along a longitudinal axis. The longitudinal shaft assembly may also include a drive gear and an articulation joint. The drive gear may be configured to rotate the rotatable shaft portion about the longitudinal axis. The articulation joint may include an articulation gear. The surgical instrument 2500 may also include a drive assembly. The drive assembly may include a motor 2504, control circuitry 2510, and a drive member. The motor 2504 may include a drive output. The control circuit 2510 can be configured to control the motor 2504. The drive member may be operatively connected to the drive output. When the control circuit 2510 is in a rotating state, the drive member is operatively connected to the drive gear of the rotatable shaft portion. When the control circuit 2510 is in the articulation state, the drive member is operatively connected to the articulation gear of the articulation joint. The surgical instrument 2500 may also include an energy source 2512. Motor 2504 may include an energized state and a de-energized state. When the motor 2504 is in the energized state, the control circuit 2510 supplies the motor 2504 with the energy source 2512 in a series circuit configuration. When the motor 2504 is in the powered-off state, the control circuit 2510 disconnects the energy source 2512 from the motor 2504.

One or more of the following features may be included. When the control circuit 2510 is in the rotated state and the motor 2504 is in the energized state, the control circuit 2510 may be configured to monitor the current rotational position of the rotatable shaft portion based on signals from the rotational position sensor 2534. The control circuit 2510 can identify a predetermined desired position corresponding to the rotational position of the rotatable shaft portion. The control circuitry 2510 can determine a control action for the motor 2504 in response to a current position of the rotatable shaft portion that does not correspond to a desired position. The control circuit 2510 can control rotation of the rotatable shaft portion when the current position corresponds to the desired position, wherein controlling rotation of the rotatable shaft portion includes placing the motor in a power-off state. When the control circuit 2510 is in the articulation state and the motor is in the energized state, the control circuit may be configured to monitor the current articulation position of the articulation joint based on a signal from the articulation position sensor 2534. The control circuit 2510 can identify a predetermined desired position corresponding to the articulation position of the articulation joint. The control circuit 2510 can determine a control action for the motor 2504 in response to a current position that does not correspond to a desired position. When the current position corresponds to the desired position, the control circuit 2510 can control articulation of the articulation joint, where controlling articulation of the articulation joint includes placing the motor in a powered off state. The control circuit 2510 can be configured to maintain a rotational or articulation position in response to a current position of the rotatable shaft assembly or articulation member corresponding to a desired rotational or articulation position. The control circuit may engage the electromagnetic lock while maintaining the desired position. When the motor 2504 is placed in a power-off state, an electromagnetic lock may be created by shorting the motor. The motor 2504 may comprise a DC brushed motor. The control circuit 2510 can be configured to internally connect the leads to the DC brushed motor when the motor 2504 is in a de-energized state to resist movement of the rotatable shaft assembly or end effector 2502 beyond a desired position. Internally connecting the leads to the DC brushed motor creates an internal reluctance within the motor 2504. The internal reluctance prevents any accidental back-driving of the motor 2504 by externally applied forces when the surgical instrument 2500 is in operation. Shorting the contacts of the motor 2504 creates a brake that holds the shaft assembly and end effector 2502 in their current position because the mechanical back drive is combined with the natural resistance of the motor 2504 (coil short) to passively maintain the current rotational/articulation position.

In various aspects, the surgical instrument 2500 can comprise a single motor 2504 and a clutch or gear assembly. The single motor 2504 can be configured to articulate the end effector 2502, rotate a shaft of the surgical instrument 2500, and translate a firing member of the surgical instrument 2500. A gear or clutch system allows motor 2504 to transfer its power to the various functions of surgical instrument 2500. In one aspect, motor 2504 and clutch assembly can be configured to simultaneously engage the functions of multiple surgical instruments 2500. This allows, for example, the surgical instrument 2500 to maintain a dynamic hold or resistance state with respect to articulation or rotation of the end effector 2502 and shaft while allowing firing of the firing member. In another aspect, the surgical instrument 2500 can comprise separate motors 2504 for articulation of the end effector 2502, rotation of the shaft, and firing of the end effector 2502.

Several aspects will now be mentioned in detail, including aspects showing an exemplary implementation of a manual and robotic surgical instrument 2500 having an end effector 2502 that includes a sealing and cutting element. Wherever practicable similar or like reference numbers may be used in the figures and may indicate similar or like functionality. The figures depict exemplary aspects of the disclosed surgical instrument and/or method of use for purposes of illustration only. Alternative exemplary aspects of the structures and methods illustrated herein may be employed without departing from the scope of the present disclosure.

Fig. 22 depicts an example of an articulation mechanism 3000 for articulating an end effector of a surgical instrument according to one aspect of the present disclosure. Referring also to fig. 14, the articulation mechanism 3000 includes an articulation joint 3006 that allows the distal arm 3014 of the surgical instrument 2500 to articulate or pivot relative to the proximal arm 3016 of the surgical instrument 2500. The articulation joint 3006 may be articulated by actuating the articulation rod/member 3008. The articulation rod/member 3008 may have a degree of displacement 3012. In one aspect, the total degree of displacement may be 0.304 ". However, in other aspects, the degree of displacement 3012 can be greater or less. The articulation rod/member 3008 may be operatively coupled to a motor 2504 or actuator controlled by the control circuit 2510. In controlling the desired articulation of the distal arm 3014 of the surgical instrument 2500 relative to the proximal arm 3016, the surgical instrument 2500 may include a sensor 2534 to detect articulation. In one aspect, the distal arm sensor may detect an articulation angle of the distal arm 3014 relative to the proximal arm 3016 of the surgical instrument 2500. The distal arm sensor may communicate the position of the distal arm 3014 relative to the proximal arm 3016 of the surgical instrument 2500 to the control circuitry 2510 via various communication means (e.g., wired or wireless means). Additionally or alternatively, the surgical instrument 2500 can include an articulation joint sensor 2534 that detects the articulation position of the distal arm 3014 relative to the proximal arm 3016 and communicates it to the control circuit 2510. Additionally or alternatively, the surgical instrument 2500 may include an articulation rod sensor that measures and detects displacement of the articulation member 3008, as discussed with reference to fig. 16-21. The displacement measured by the articulation sensor 2534 may be related to the articulation displacement of the distal arm 3014 and communicated to the control circuit 2510.

In operation, the articulation mechanism 3000 of the surgical instrument 2500 may be articulated by a technician to allow the end effector 2502 of the surgical instrument 2500 to reach a desired location within a patient's body. Once the desired articulation is achieved, motor 2504 may be deactivated and placed in a powered-off state by control circuit 2510 to allow articulation mechanism 3000 to maintain its articulated position. During surgery, external resistance or force 3002 may act on the end effector or distal arm 3014 of the surgical instrument. When the motor is in the de-energized state, the control circuit 2510 can energize the electromagnetic lock to maintain the end effector 2502 in its current articulation position. To create an electromagnetic lock, the control circuit 2510 can be configured to internally connect the wire to the motor 2504 when the motor 2504 is in a de-energized state to resist articulation of the end effector 2502 beyond a current position. Internally connecting the leads to motor 2504 creates an internal reluctance within motor 2504. The internal reluctance prevents any inadvertent back-driving of the motor 2504 by externally applied forces 3010a-d when the end effector 2502 is in operation. Shorting the contacts of the motor 2504 creates a brake that holds the end effector 2502 in its current position because the mechanical back drive is combined with the natural resistance of the motor 2504 (coil short) to passively maintain the current articulation position. While the motor is in the de-energized state, the control circuit 2510 can continue to monitor the articulation angle 3004 of the end effector 2502 and distal arm 3014 via the various sensors described above. If the change in the articulation angle 3004 no longer corresponds to the desired position, the control circuit 2510 can activate the energized state of the motor 2504 to articulate the end effector 2502 back to the desired position. By activating the energized state of motor 2504, the electromagnetic lock is disabled. When the end effector 2502 is repositioned to the desired position, the control circuit 2510 can again activate the de-energized state of the motor 2504, thereby energizing the electromagnetic lock to prevent further movement.

FIG. 23 illustrates a graph 3100 showing firing bar angle and motor duty cycle as a function of articulation angle of an end effector, according to one aspect of the present disclosure. The top graph 3130 depicts the firing bar displacement (δ) along the vertical axis 3122 as a function of the articulation angle in degrees (°) along the horizontal axis 3120. Referring also to fig. 14, when the articulation bar/member 3008 is within a predetermined range of displacement 3108, the control circuit 2510 triggers a deactivated state of the motor 2504. The predetermined displacement range 3108 of the articulation rod 3008 corresponds to an allowable range of articulation angles 3102 for articulation of the distal arm 3014. When the predetermined range 3108 and/or allowed range 3102 are exceeded, the control circuit 2510 activates a resistive holding mode of the motor 2504 to resist or counteract the force applied to the distal arm 3014 and hold the distal arm 3014 and articulation rod 3018 within the predetermined/allowed ranges 3108, 3102.

The bottom graph 3132 in fig. 23 depicts the motor duty cycle (%) along the vertical axis 3126 as a function of the articulation angle in degrees (°) along the horizontal axis 3120. The degree of articulation angle of the distal arm 3104 gradually deviates from a predetermined threshold of articulation angle 3102 due to externally applied forces, so the motor 2504 applies force to resist undesired articulation for an extended duration. In other words, the motor duty cycle increases as the articulation angle gradually deviates from the predetermined threshold 3102. For example, the bottom graph 3132 in fig. 23 represents the end effector 2502 having the desired articulation angle of-60 °. The allowable range 3102 of articulation angles extends to-55. The motor duty cycle is minimized when the end effector 2502 is articulated to a degree that falls within the allowed range 3102. However, when the articulation angle exceeds the boundary of the allowable range 3102, the control circuit 2510 begins to respond in a more aggressive manner by activating the resistive holding mode of the motor 2504, thereby increasing the motor duty cycle. In addition to increasing the motor duty cycle, articulating the end effector 2502 to a degree that is outside of the allowable range 3102 may increase the drive force or torque of the motor 2504. The shaded region 3112 indicates the initial constraints required by the motor 2504 when the articulation angle begins to exceed the boundaries of the allowed range 3102. The shaded region 3110 indicates the progressive constraint required by the motor 2504 as the articulation angle continues to exceed the boundary of the allowed range 3102. In one aspect, the energy applied to the motor 2504 to oppose the externally applied force does not cause further articulation and/or movement of the end effector 2502, but prevents any additional undesired movement outside of the predetermined range 3102. In other aspects of the disclosure, energy applied to the motor 2504 to oppose the externally applied force may articulate or rotate the end effector 2502 back to a previously set position.

Fig. 24 illustrates a graph 3200 of motor duty cycle as a function of shaft rotation, in accordance with an aspect of the present disclosure. Graph 3200 depicts the motor duty cycle along the vertical axis 3222 as a function of shaft rotation angle (°) along the horizontal axis 3220. Referring also to fig. 14, control circuit 2510 allows for an initial rotation threshold 3202 before activating the hold feature of motor 2504. In one aspect, the retention feature includes a current modulation proportional to a resistance required to restrict or limit shaft rotation. As the required motor resistance 3208 increases with displacement of shaft rotation, the current 3204 may increase. Thus, the motor resistance may be increased in a step 3206 fashion. Alternatively, the lead wires may be internally connected to the motor 2504 whenever the motor 2504 is in a powered off state. This creates an internal reluctance within the motor 2504 to prevent any accidental back-drive of the motor by externally applied forces. The mechanical back drive is combined with the natural resistance of the motor (coil short circuit) to passively maintain rotation.

In one aspect, the DC motor of the surgical instrument 2500 can be internally connected with the lead when in a powered down state. The internal connection of the DC motor leads can result in internal magnetic reluctance within the motor to prevent accidental back-driving of the motor 2504 by externally applied forces applied to the end effector 2502. Dynamic and regenerative braking can be achieved using PWM DC motors, brushed, brushless, and/or stepper motors to maintain a desired position of the articulated portion of the end effector 2502. Additionally or alternatively, various dynamic braking mechanisms may be combined with mechanical locks to maintain a desired articulation or rotational position of the end effector. Additionally or alternatively, the natural resistance (coil short) of the motor 2504 may be combined with a mechanical brake or lock as a passive method to perform the station holding function of the articulation or rotation system.

Fig. 25 shows a control circuit 3300 in accordance with aspects discussed above and in accordance with an aspect of the present disclosure. Circuit 3300 includes a power source 3306, a motor 3308, and a plurality of switches 3301, 3302, 3303, 3304. The circuit may also include an alternative switch 3305. Switches 3301-3305 each allow circuit 3300 to be configured to operate motor 3308 in a forward mode, a reverse mode, and a resistive or braking mode. When circuit 3300 is in the forward mode, switches 3301, 3304, and 3305 may be in an open state, while switches 3302 and 3303 may be in a closed state. The forward mode allows motor 3308 and power source 3306 to operate in a series configuration, with motor 3308 operating in the forward direction. When circuit 3300 is in the reverse mode, switches 3302, 3303, and 3305 may be in an open state, while switches 3301 and 3304 may be in a closed state. The reverse mode allows the motor 3308 and power source 3306 to operate in a series configuration, with the motor 3308 operating in the reverse direction. Table 1 below shows various circuit 3300 configurations discussed herein.

1	2	3	4
					0	1	1	0	Forward direction
1	0	0	1	Reverse direction
					0	0	1	1	Brake (static holding load)
0	0	0	0	Alternative switch 3305

TABLE 1 various circuit configurations. 1 is closed; open 0 ═ open.

In one aspect, the braking mode may use a static holding load to resist external forces on articulation or rotation of the distal portion of the surgical instrument. When circuit 3300 is in a braking mode providing a static holding load, switches 3301, 3302, and 3305 may be in an open state, while switches 3303 and 3304 may be in a closed state. This braking mode allows the motor 3308 and power source 3306 to operate in a static configuration, where the circuit configuration produces a static hold. In another aspect, the braking mode may use a static holding load to resist external forces on articulation or rotation of the distal portion of the surgical instrument. When circuit 3300 is in a braking mode providing a static holding load, switches 3301, 3302, 3303, 3304 may be in an open state, while switch 3305 may be in a closed state. This braking mode allows motor 3308 to be isolated from power source 3306. In this braking mode, the motor 3308 is in a closed loop configuration isolated from the power source, where the circuit configuration produces a static hold.

Fig. 26 illustrates a rotatable and articulatable shaft 3400 of a surgical instrument according to an aspect of the present disclosure. Referring also to fig. 25, shaft assembly 3400 includes a distal end effector portion 3416, a proximal portion 3420, and an articulation mechanism 3406 connecting distal end effector portion 3416 and proximal portion 3420. The proximal portion 3420 defines a longitudinal axis 3422. The proximal portion 3420 is configured to rotate about a longitudinal axis 3422. The output of the motor 3308 of the surgical instrument is configured to rotate the rotary drive shaft 3408. The rotary drive shaft includes a drive gear 3424 that is operatively engaged with driven gear 3418 of proximal portion 3420. As discussed with reference to fig. 14, the control circuitry 2510 can be connected to a rotation sensor 2534 that detects rotation of the shaft assembly 3400. However, when the external force 3402 causes the shaft assembly 3400 to rotate beyond a desired position, the control circuitry 2510 can activate an energized state on the motors 3308(2504), as discussed above with reference to fig. 22-25. When the control circuitry 2510 is energized, the motor 3308(2504) may apply a force 3410 to resist the external rotational force 3402 and/or to rotate the shaft assembly 3400 to a desired position. The force 3410 exerted by motors 3308(2504) may include passive or active resistance, as discussed above with reference to fig. 22-25.

Additionally or alternatively, the control circuit 2510 can resist undesired rotation or articulation of the end effector caused by external forces through the active PWM and current step resistances of the control circuit 2510 and the dynamic and passive resistances of the control circuit configuration. The control circuit 2510 can allow the end effector and shaft assembly to remain in a desired position during a surgical procedure.

The logic flow diagram illustrated in fig. 27 illustrates one example of a process 3430 that may be performed by surgical instrument 2500 (e.g., control circuitry 2510) to resist and control articulation of end effector 2502 caused by external forces. The control circuit 2510 can receive 3432 an initial articulation signal. Once the end effector 2502 is in the desired articulation position, an initial articulation signal may be received 3432 from the articulation sensor. For example, the clinician may place the end effector 2502 in a desired position, then clamp tissue between the anvil 2516 and the staple cartridge 2518, and then actuate the trigger 32 to begin the firing stroke. The trigger 32 may be configured to provide a firing signal to the control circuit 2510 upon actuation.

Once the end effector 2502 is placed in the desired position, the control circuit 2510, in response to the initial articulation signal, can determine 3434 an initial articulation position of the end effector 2502 from the articulation signal. After determining 3434 the initial position, the control circuit 2510 can identify 3436 predetermined thresholds for allowable displacement of the end effector 2502. For example, the surgical instrument 2500 may be converted from an articulation mode to a firing mode via the transmission 2506. While in the firing mode, the control circuit 2510 can monitor the articulation position of the end effector 2502.

The control circuit 2510 may receive 3438 the current articulation signal. Once the end effector 2502 is in the firing mode to monitor the position of the end effector 2502 during the firing mode, a current articulation signal may be received 3438 from the articulation sensor. A current articulation signal may be received 3438 from the articulation sensor. In response to the current articulation signal, the control circuit 2510 can determine 3440 a current articulation position of the end effector 2502 from the current articulation signal. The control circuit 2510 can compare 3442 the current articulation position of the end effector 2502 to the initial articulation position of the end effector 2502 and a predetermined threshold of allowable displacement. If the current position exceeds a predetermined threshold 3444, the control circuit 2510 controls 3450 the movement of the end effector 2502 by engaging 3452 the hold state of the motors 3308 (2504). For example, the control circuit 2510 can switch the transmission 2506 from the firing mode to the control mode when the control circuit compares 3442 the current position of the end effector 2502 to a predetermined threshold and the current position exceeds the predetermined threshold. When the control circuit 2510 switches to the control mode, the control circuit 2510 engages 3452 the holding state of the motors 3308(2504) to resist undesired movement of the end effector 2502. The holding conditions may include any of the holding conditions discussed above with respect to fig. 22-25. When the control circuit 2502 compares 3442 the current position of the end effector 2502 to the predetermined threshold and the current position is within 3446 of the predetermined threshold, the control circuit 2510 continues 3448 operation of the end effector function, e.g., continues to operate in the firing mode.

In another aspect, the surgical instrument 2500 can have a second motor. The prime motors 3308(2504) can be configured to operate the articulation of the end effector 2502. The second motor may be configured to operate the firing drive of the end effector 2502. When the surgical instrument includes two motors, control 3450 can be accomplished independently of the firing mode.

In another aspect, the surgical instrument 2500 may have a manual firing drive. In the case of a surgical instrument having a manual firing drive, the motors 3308(2504) may remain engaged with the articulation mechanism during the firing mode. The motors 3308(2504) can be configured to operate the articulation of the end effector 2502. When the surgical instrument includes a manual firing drive, the control 3450 can be accomplished independently of the firing mode.

The logic flow diagram illustrated in fig. 28 illustrates one example of a process 3460 that may be performed by the surgical instrument 2500 (e.g., the control circuitry 2510) to resist and control rotation of the shaft assembly 200 caused by external forces. The control circuit 2510 can receive an initial rotation signal 3462. Once the shaft assembly 200 is in the desired rotational position, an initial rotation signal can be received 3462 from the rotation sensor. For example, the clinician may place the shaft assembly 200 in a desired rotational position, then clamp tissue between the anvil 2516 and the staple cartridge 2518, and then actuate the trigger 32 to begin the firing stroke. The trigger 32 may be configured to provide a firing signal to the control circuit 2510 upon actuation.

Once the shaft assembly 200 is placed in the desired rotational position, the control circuit 2510, in response to the initial rotation signal, can determine 3464 an initial rotational position of the shaft assembly 200 from the rotation signal. After determining 3464 the initial rotational position, the control circuitry 2510 can identify 3466 a predetermined threshold of allowable displacement of the shaft assembly 200. For example, the surgical instrument 2500 can be converted from a rotary mode to a firing mode via the transmission 2506. While in the firing mode, the control circuit 2510 can monitor the rotational position of the shaft assembly 200.

The control circuit 2510 may receive 3468 the current rotation signal. Once the shaft assembly 200 is in the firing mode to monitor the position of the shaft assembly 200 during the firing mode, a current rotation signal may be received 3468 from the rotation sensor. A current rotation signal may be received 3468 from the rotation sensor. In response to the current rotation signal, the control circuitry 2510 can determine 3470 a current rotational position of the shaft assembly 200 from the current rotation signal. The control circuit 2510 can compare 3472 the current rotational position of the shaft assembly 200 to the initial rotational position of the shaft assembly 200 and a predetermined threshold of allowable rotational displacement. If the current rotational position of the shaft assembly 200 exceeds a predetermined threshold 3474, the control circuitry 2510 will control 3480 the rotation of the shaft assembly 200 by engaging the holding state of 3482 the motors 3308 (2504). For example, the control circuit 2510 can switch the transmission 2506 from the firing mode to the control mode when the control circuit compares 3472 the current position of the shaft assembly 200 to a predetermined threshold and the current position exceeds a boundary of the predetermined threshold. When the control circuit 2510 switches to the control mode, the control circuit 2510 engages 3482 the holding state of the motors 3308(2504) to resist undesired rotation of the shaft assembly 200. The holding condition can include any of the holding conditions discussed above with respect to fig. 22-25 and with respect to articulation of the end effector 2502. When the control circuit 2510 compares 3472 the current rotational position of the shaft assembly 200 to a predetermined threshold and the current rotational position is within 3476 the predetermined threshold, the control circuit 2510 continues 3478 operation of the end effector function, e.g., continues to operate in the firing mode.

The logic flow diagram illustrated in fig. 29 shows one example of a process 7000 that may be performed by surgical instrument 2500 (e.g., control circuitry 2510) to resist and control articulation of end effector 2502 by external forces. The control circuit 2510 can determine a desired articulation position of the end effector 7002. The control circuit 2510 can place the motor in an energized state to control movement of the end effector to the desired position 7004. Once the end effector 2502 is in the desired articulation position, an initial articulation position may be received from the articulation sensor. The control circuit 2510 can be configured to determine a desired articulation position of the end effector 7006. If the current position does not correspond to the desired position 7010, the control circuit 2510 can be configured to place the motor in an energized state to control movement of the end effector to the desired position 7004. Once the current position corresponds to the desired position 7008, the control circuitry 2510 can be configured to place the motor in the powered off state 7012. When the motor is in the de-energized state 7012, the control circuit 2510 can be configured to energize the electromagnetic lock to prevent movement of the end effector 7014.

The logic flow diagram illustrated in fig. 30 illustrates one example of a process 7100 that may be performed by the surgical instrument 2500 (e.g., the control circuitry 2510) to resist and control rotation of the shaft assembly by an external force. The control circuitry 2510 can determine a desired rotational position of the shaft assembly 7102. The control circuit 2510 can place the motor in an energized state to control movement of the shaft assembly to the desired position 7104. Once the shaft assembly is in the desired rotational position, an initial rotational position may be received from the rotational position sensor. The control circuit 2510 can be configured to determine 7106 a current rotational position of the shaft assembly. If the current position does not correspond to the desired position 7110, the control circuit 2510 can be configured to place the motor in an energized state to control movement of the shaft assembly to the desired position 7104. Once the current position corresponds to the desired position 7108, the control circuit 2510 can be configured to place the motor in the powered down state 7112. When the motor is in a de-energized state 7112, the control circuit 2510 can be configured to energize the electromagnetic lock to prevent the shaft assembly from moving 7114.

In another aspect, the surgical instrument 2500 can have a second motor. The prime motor 3308(2504) may be configured to operate the rotation of the shaft assembly 200. The second motor may be configured to operate the firing drive of the end effector 2502. When the surgical instrument includes two motors, control 3480 can be accomplished independently of the firing mode.

In another aspect, the surgical instrument 2500 may have a manual firing drive. In the case of a surgical instrument having a manual firing drive, the motor 3308(2504) may remain engaged with the transmission 2506 during the firing mode. Motor 3308(2504) may be configured to operate the rotation of shaft assembly 200. When the surgical instrument includes a manual firing drive, the control 3480 can be accomplished independently of the firing mode.

In another aspect, the control circuit 2510 of the surgical instrument 2500 can be configured to resist and control articulation of the articulation mechanism and resist and control rotation of the shaft assembly 200. The resistance and hold functions of the articulation control and the rotation control can be operated independently or in cooperation to control the overall spatial position of the end effector 2502.

The functions or processes 3430, 3460, 7000, 7100 described herein may be performed by any processing circuit described herein, such as the control circuit 700 described in connection with fig. 5-6, the circuits 800, 810, 820 described in fig. 7-9, the microcontroller 1104 described in connection with fig. 10 and 12, and/or the control circuit 2510 described in fig. 14.

Aspects of the powered surgical instrument may be practiced without the specific details disclosed herein. Certain aspects have been illustrated in block diagrams, rather than in detail. 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, 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 various types of "electronic circuitry". Thus, "electronic circuitry" includes electronic circuitry having at least one discrete electronic 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 processor configured by a computer program that implements, at least in part, the processes and/or devices described herein), electronic circuitry forming a memory device (e.g., forming random access memory), and/or electronic circuitry forming a communication device (e.g., a modem, a communication switch, or an optoelectronic device). These aspects may be implemented in analog or digital form, or a combination thereof.

The foregoing description has set forth various aspects of the devices and/or processes via the use of block diagrams, flowcharts, and/or examples, which 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 (PLDs), circuits, registers, and/or software components (e.g., programs, subroutines, logic), and/or a combination of hardware and software components, logic gates, or other integrated formats. Aspects disclosed herein may 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 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 the present 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 in 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 motor operable to translate an articulation member along a distance from a proximal position to a distal position, wherein the articulation member is translatable relative to an end effector a distance from a proximal position to a distal position, wherein translation of the articulation member causes an articulation joint to articulate, and wherein the motor has an energized state and a de-energized state; a control circuit coupled to the motor; a position sensor coupled to the control circuit, the position sensor configured to detect a position of the articulation member along at least a portion of the distance; and wherein the control circuitry is configured to be capable of: identifying a predetermined desired position corresponding to the articulation position of the articulation member; receiving a position input from the position sensor indicative of a current articulation position of the articulation member; identifying the current articulation position corresponding to the articulation position of the articulation member; determining a control action of the motor in response to a current articulation position of the articulation member that does not correspond to the desired position; and controlling movement of an articulation member when the current articulation position corresponds to a desired position, wherein controlling the movement of the articulation member comprises placing the motor in the powered-off state.