Methods and systems for detecting staple cartridge misfire or failure

Patent metadata

Field	Value
Publication number	US-9393017-B2
Application number	US-201213472431-A
Country	US
Kind code	B2
Filing date	May 15, 2012
Priority date	Feb 15, 2011
Publication date	Jul 19, 2016
Grant date	Jul 19, 2016

Abstract

Systems and methods are provided for detecting misfire of a surgical staple cartridge and for indicating such misfire to a user on a user interface. An actuation force applied to a staple cartridge is measured and compared to a threshold actuation force. In response to the comparison, a controller determines if there has been a misfire of the surgical staple cartridge. A determination that misfire has occurred is made when the measured actuation force is greater than a maximum threshold force or less than a minimum threshold force, and under such circumstances, the controller terminates the staple firing sequence.

First claim

What is claimed is:

1. A method of controlling a surgical stapler system, the method comprising:
monitoring a drive parameter of an actuator operatively coupled to transmit an actuation force to jaws of a surgical stapler end effector, the jaws being configured to move toward one another over a clamping range of motion to perform a clamping procedure, wherein the monitoring occurs while the actuator is transmitting the actuation force to move the jaws over at least part of the clamping range of motion;
comparing the monitored drive parameter to a preset threshold value; and
controlling a continued transmission of the actuation force based on the comparison.

2. The method of claim 1 , wherein controlling the continued transmission of the actuation force comprises terminating transmission of the actuation force if the monitored drive parameter is less than the preset value.

3. The method of claim 2 , further comprising providing an indication of clamping failure on a user interface if the monitored drive parameter is less than a preset value.

4. The method of claim 2 , wherein:
the actuator is a motor, and
monitoring the drive parameter comprises monitoring a rotational force output by the motor.

5. The method of claim 1 , further comprising controlling actuation of a cutting blade or staple firing mechanism of the surgical stapler end effector based on the comparison.

6. The method of claim 1 , wherein:
comparing the monitored drive parameter comprises comparing the monitored drive parameter to a preset minimum threshold value and a preset maximum threshold value, and
controlling a continued transmission of the actuation force comprises permitting continued transmission of the actuation force when the monitored drive parameter is within a range defined from the preset minimum threshold value to the preset maximum threshold value.

7. The method of claim 1 , further comprising:
monitoring a second drive parameter of the or another actuator during transmission of a subsequent actuation force applied to the surgical stapler end effector to actuate a staple firing procedure;
comparing the second drive parameter to a second preset value; and
controlling a continued transmission of the subsequent actuation force based on the comparison.

8. The method of claim 7 , wherein controlling the continued transmission of the subsequent actuation force comprises terminating transmission of the subsequent actuation force if the second drive parameter is less than the preset value.

9. The method of claim 1 , wherein monitoring the drive parameter of the actuator comprises sensing an output of the actuator, the output causing transmission of the actuation force to the jaws to begin a clamping procedure.

10. The system of claim 1 , wherein the measured actuation force being greater than the maximum threshold actuation force is indicative of jamming within the system.

11. A method of controlling a staple firing procedure in a surgical stapler system, the method comprising:
monitoring a drive parameter of an actuator operatively coupled to transmit an actuation force to jaws of a surgical stapler end effector, the jaws being configured to move toward one another over a clamping range of motion to perform a clamping procedure, wherein the monitoring occurs while the actuator is transmitting the actuation force to move the jaws over at least part of the clamping range of motion
comparing the monitored drive parameter to a preset value; and
controlling a staple firing procedure based on the comparison.

12. The method of claim 11 , wherein:
monitoring the drive parameter comprises measuring the actuation force applied to the jaws of the surgical stapler end effector.

13. The method of claim 11 , wherein controlling the staple firing procedure comprises terminating the staple firing procedure if the monitored drive parameter is less than the preset value.

14. The method of claim 13 , further comprising providing an indication of staple firing failure on a user interface if the monitored drive parameter is less than the preset value.

15. The method of claim 13 , further comprising controlling actuation of a cutting blade of the surgical stapler end effector based on the comparison.

16. The method of claim 11 , wherein:
comparing the monitored drive parameter comprises comparing the monitored drive parameter to a preset minimum threshold value and a preset maximum threshold value, and
controlling the staple firing procedure comprises terminating the staple firing procedure if the monitored drive parameter is outside the range defined from the preset minimum threshold value to the preset maximum threshold value.

17. A surgical stapler system comprising:
an end effector comprising a portion that removably receives a staple cartridge;
a drive system configured to transmit an actuation force to the staple cartridge to actuate a staple firing procedure;
a sensor configured to measure the actuation force; and
a controller communicatively coupled to the sensor and the drive system, the controller being configured to:
receive a signal indicative of the measured actuation force, and
control continued transmission of the actuation force by the drive system based on a comparison of the measured actuation force to a range defined from a minimum threshold actuation force to a maximum threshold actuation force.

18. The system of claim 17 , wherein the controller is configured to terminate continued transmission of the actuation force if the measured actuation force falls outside the defined range.

19. The system of claim 18 , wherein the controller is further communicatively coupled to a user interface and is configured to control the user interface to provide an indication of a staple firing procedure failure if the measured actuation force is outside the defined range.

20. The method of claim 19 , an indication of staple firing procedure failure is expressed as a percentile range based on the comparison of the measured actuation force to the defined range.

21. The method of claim 18 , further comprising:
transmitting an initial clamping actuation force applied to the staple cartridge after terminating the continued transmission of the actuation force to actuate the staple firing procedure.

22. The system of claim 17 , wherein the staple cartridge comprises a staple deployment element and a surgical blade.

23. The system of claim 22 , wherein the controller is configured to stop deployment of the surgical blade if the measured actuation force falls outside the defined range.

24. The system of claim 17 , further comprising a plurality of staples in the staple cartridge, wherein the controller is further configured to:
permit the drive system to continue transmission of the actuation force to deploy the staples if the measured actuation force falls within the defined range.

Assignees

• Flanagan Patrick
• Weir David
• Intuitive Surgical Operations

Inventors

• Flanagan Patrick
• Weir David

Classifications

• A61B2017/00115

  with audible or visual output · CPC title

• A61B2017/07214

  Stapler heads · CPC title

• A61B17/07207 Primary

  the staples being applied sequentially · CPC title

• A61B17/072

  for applying a row of staples in a single action, e.g. the staples being applied simultaneously · CPC title

• A61B17/068

  Surgical staplers {, e.g. containing multiple staples or clamps}({staplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105;} for performing anastomosis A61B17/115; {staplers in general B25C5/00}) · CPC title