Modular battery powered handheld surgical instrument with variable motor control limits
A surgical instrument comprises a shaft assembly; a handle assembly; a battery assembly; a first driver configured to drive movement of at least a first component of the surgical instrument; a second driver configured to drive movement of at least a second component of the surgical instrument; a motor powered by the battery assembly and configured to selectively actuate the first driver or the second driver using an output of the motor; and a controller for the motor, configured to: perform a first limiting operation to the output of the motor when the motor actuates the first driver and a first limiting condition is met, and perform a second limiting operation to the output of the motor when the motor actuates the second driver and a second limiting condition is met.
1. A surgical instrument, comprising:
a shaft assembly comprising a shaft and an end effector coupled to a distal end of the shaft;
a handle assembly coupled to a proximal end of the shaft;
a battery assembly coupled to the handle assembly;
a first driver configured to drive movement of at least a first component of the surgical instrument;
a second driver configured to drive movement of at least a second component of the surgical instrument;
a motor powered by the battery assembly and configured to selectively actuate the first driver or the second driver using an output of the motor; and
a controller for the motor, configured to:
determine a first limiting condition based on an identity of the first driver, wherein the first limiting condition defines a first velocity profile to drive the output of the motor over a range of movement of the first component, wherein the first velocity profile comprises a first limited velocity region at one end of the range of movement of the first component, a second limited velocity region at the other end of the range of movement of the first component, and a first full velocity region between the first and second limited velocity regions, wherein the first full velocity region is defined by a portion of the range of movement of the first component, and wherein the range of movement of the first component is determined based on an identity of the first component;
perform a first limiting operation to the output of the motor when the motor actuates the first driver and the first limiting condition is met;
determine a second limiting condition based on an identity of the second driver, wherein the second limiting condition defines a second velocity profile to drive the output of the motor over a range of movement of the second component, wherein the second velocity profile comprises a third limited velocity region at one end of the range of movement of the second component, a fourth limited velocity region at the other end of the range of movement of the second component, and a second full velocity region between the third and fourth limited velocity regions, and wherein the second full velocity region is defined by a portion of the range of movement of the second component, wherein the range of movement of the second component is determined based on an identity of the second component; and
perform a second limiting operation to the output of the motor when the motor actuates the second driver and the second limiting condition is met.
2. The surgical instrument of claim 1 , wherein:
the end effector comprises a pair of jaws configured for pivotal movement between a closed position and an open position; and
the first driver is configured to drive the pivotal movement.
3. The surgical instrument of claim 1 , further comprising a transducer configured to output an ultrasonic energy, wherein:
the second driver is configured to apply a torque to the transducer.
4. The surgical instrument of claim 3 , wherein the second limiting condition is met when the torque applied to the transducer reaches a maximum torque.
5. The surgical instrument of claim 1 , wherein:
the shaft comprises an articulation joint, a first portion of the shaft comprising the proximal end, and a second portion of the shaft comprising the distal end, the first and second portions being coupled about the articulation joint;
the second portion of the shaft is configured for articulation movement about the articulation joint; and
the first driver is configured to drive the articulation movement.
6. The surgical instrument of claim 5 , wherein the second driver is configured to drive axial rotation of the second portion.
7. The surgical instrument of claim 1 , further comprising a blade, wherein:
the first or second driver is configured to advance the blade.
8. The surgical instrument of claim 1 , further comprising a third driver configured to drive movement of at least a third component of the surgical instrument, wherein:
the motor is configured to selectively actuate the first driver, the second driver or the third driver using the output of the motor; and
the controller for the motor is further configured to perform a third limiting operation to the output of the motor when the motor actuates the third driver and a third limiting condition is met.
9. The surgical instrument of claim 1 , wherein:
the first limiting condition is met when the output of the motor reaches a first maximum velocity; and
the second limiting condition is met when the output of the motor reaches a second maximum velocity.
10. The surgical instrument of claim 1 , wherein:
the first limiting condition is met when a current of the motor reaches a first maximum current; and
the second limiting condition is met when the current of the motor reaches a second maximum current.
11. The surgical instrument of claim 10 , wherein the first limiting operation controls the current of the motor to be substantially zero.
12. The surgical instrument of claim 10 , wherein the second limiting operation controls the current of the motor to substantially equal to the second maximum current.
13. The surgical instrument of claim 1 , wherein the controller adjusts the first and the second limiting conditions based on a determined type of a tissue to be treated by the surgical instrument.
14. A method for operating a surgical instrument, the surgical instrument comprising a shaft assembly comprising a shaft and an end effector coupled to a distal end of the shaft, and a handle assembly coupled to a proximal end of the shaft, the method comprising:
selectively actuating a first driver or a second driver using an output of a battery-powered motor;
driving, with the first driver, movement of at least a first component of the surgical instrument when the motor actuates the first driver;
determining a first limiting condition based on an identity of the first driver, wherein the first limiting condition defines a first velocity profile to drive the output of the motor over a range of movement of the first component, wherein the first velocity profile comprises a first limited velocity region at one end of the range of movement of the first component, a second limited velocity region at the other end of the range of movement of the first component, and a first full velocity region between the first and second limited velocity regions, wherein the first full velocity region is defined by a portion of the range of movement of the first component, wherein the range of movement of the first component is determined based on an identity of the first component;
performing a first limiting operation to the output of the motor when the motor actuates the first driver and the first limiting condition is met;
determining a second limiting condition based on an identity of the second driver, wherein the second limiting condition defines a second velocity profile of the output of the motor over a range of movement of a second component, wherein the second velocity profile comprises a third limited velocity region at one end of the range of movement of the second component, a fourth limited velocity region at the other end of the range of movement of the second component, and a second full velocity region between the third and fourth limited velocity regions, wherein the second full velocity region is defined by a portion of the range of movement of the second component, wherein the range of movement of the second component is determined based on an identity of the second component;
driving, with the second driver, movement of at least the second component of the surgical instrument when the motor actuates the second driver; and
performing a second limiting operation to the output of the motor when the motor actuates the second driver and the second limiting condition is met.
15. The method of claim 14 , wherein driving the movement of at least the first component of the surgical instrument comprises:
driving a pivotal movement of a pair of jaws of the end effector between a closed position and an open position.
16. The method of claim 14 , wherein driving the movement of at least the second component of the surgical instrument comprises:
applying a torque to a transducer configured to output an ultrasonic energy.
17. The method of claim 14 , wherein:
the first limiting condition is met when a current of the motor reaches a first maximum current; and
the second limiting condition is met when the current of the motor reaches a second maximum current.