System and method for non-contact electronic articulation sensing

1. A surgical instrument, comprising:

a handle portion;

a body portion extending distally from the handle portion and defining a first longitudinal axis;

an articulating tool assembly configured to eject at least one fastener and defining a second longitudinal axis, the articulating tool assembly disposed at a distal end of the body portion and being movable from a first position in which the second longitudinal axis is substantially aligned with the first longitudinal axis to at least a second position in which the second longitudinal axis is disposed at an angle with respect to the first longitudinal axis; and

an articulation mechanism configured to articulate the articulating tool assembly, the articulation mechanism including:

an articulation knob mechanically engaged to the articulation tool assembly, wherein rotational motion of the articulation knob is translated into articulation movement of the articulation tool assembly; and

an articulation sensor assembly having an optical encoder sensor including a rotary encoder circumferentially disposed about the articulation knob, the optical encoder sensor further including a photo emitter and a photo receiver disposed on opposite sides of the rotary encoder, the optical encoder sensor configured to detect movement of the articulation knob and to transmit a sensor signal indicative of the movement of the articulation knob to a microcontroller which is configured to determine an articulation angle of the articulation tool assembly.

2. The surgical instrument according to claim 1 , wherein the articulation mechanism further includes:

a housing block configured to receive an articulation spindle rotatably housed therein; and

an articulation link operatively coupled to the articulation spindle; wherein

the articulation knob is coupled to the articulation spindle, such that rotational motion of the articulation knob is translated into axial motion of the articulation link thereby articulating the articulating tool assembly.

3. A surgical instrument according to claim 2 , wherein the articulation sensor assembly includes a photo sensor that is disposed in spaced relation to the articulation link, the photo sensor is configured to illuminate the articulation link and to measure a light reflected from the articulation link and transmit the sensor signal corresponding to the measured reflected light to the microcontroller that is configured to determine the articulation angle as a function of a displacement of the articulation link based on the measured reflected light.

4. A surgical instrument according to claim 3 , wherein the articulation link includes a marker at a location that corresponds with an unarticulated position of the articulating surgical tool assembly when the marker is disposed over the optical sensor.

5. A surgical instrument according to claim 2 , wherein the articulation sensor assembly includes a magnet coupled to the articulation knob and a magnetic sensor coupled to the housing block configured to measure a magnetic field of the magnet and transmit the sensor signal corresponding to the measured magnetic field to the microcontroller that is configured to determine the articulation angle as a function of a displacement of the articulation knob based on the measured magnetic field.

6. A surgical instrument according to claim 2 , wherein the articulation sensor assembly includes a sensor switch coupled to the housing block configured to interface with a protrusion coupled to the articulation knob, such that the protrusion actuates the sensor switch when the articulation knob is centered and the sensor switch transmits the sensor signal to the microcontroller that is configured to determine whether the articulating tool assembly is in the first position.

7. A surgical instrument according to claim 2 , wherein the articulation sensor assembly includes a potentiometer electrically coupled to a contact that is coupled to at least one of the articulation link and the articulation spindle, wherein the potentiometer is configured to measure the sensor signal reflective at least one of a rotation of the articulation spindle and a displacement of the articulation link and to transmit the sensor signal to the microcontroller configured to determine the articulation angle as a function of the sensor signal.

8. The surgical instrument according to claim 2 , wherein the optical encoder sensor is coupled to at least one of the articulation link or the articulation spindle and is configured to measure the sensor signal reflective of at least one of a rotation of the articulation spindle or a displacement of the articulation link and to transmit the sensor signal to the microcontroller configured to determine the articulation angle as a function of the sensor signal.