Surgical stapler having a powered handle
A powered handle for a surgical stapler can have a drive system including an electric motor. The powered handle can include a manual articulation mechanism to articulate a jaw assembly coupled to a reload shaft connected to the handle. The manual articulation mechanism can include a ball screw mechanism that translates an articulation member responsive to rotation of an articulation knob. The articulation mechanism includes a release function that allows the jaw assembly to return to a longitudinally centered orientation. The powered handle includes a battery pack serving as a power supply for the drive system. A control system can control actuation of the motor based on user inputs and operating parameters of the stapler. The powered handle can include a manual return mechanism.
1. A handle assembly for a surgical stapler, the handle assembly comprising:
a handle body comprising a stationary handle and a trigger pivotably coupled to the handle body;
an electric motor disposed within the handle body, the motor comprising an output shaft;
an actuation shaft slidable within the handle body along a longitudinal axis;
a motor gear coupled to the output shaft of the motor;
an auxiliary gear in driven engagement with the motor gear and operatively engaged with the actuation shaft;
a crown gear mounted in the handle in meshed engagement with the motor gear;
a potentiometer coupled to the crown gear; and
a control system electrically coupled to the trigger, the electric motor, and the potentiometer, the control system configured to control the speed and torque of the electric motor.
2. The handle assembly of claim 1 , wherein the control system is configured to measure a longitudinal position of the actuation shaft.
3. The handle assembly of claim 2 , wherein the control system measures changes of resistance at the potentiometer to determine a position of the actuation shaft.
4. The handle assembly of claim 1 , further comprising a circuit board, and wherein the potentiometer and the control system are mounted on the circuit board.
5. The handle assembly of claim 1 , wherein the actuation shaft comprises a rack extending longitudinally thereon and wherein the auxiliary gear is in meshed engagement with the rack.
6. The handle assembly of claim 5 , further comprising a guide member through which the actuation shaft slides, and wherein the auxiliary gear is supported in the guide member.
7. The handle assembly of claim 1 , further comprising a manual return system selectively operable to disengage the auxiliary gear from the actuation shaft and return the actuation shaft proximally within the handle body.
8. The handle assembly of claim 1 , further comprising a manual articulation mechanism.
9. The handle assembly of claim 8 , wherein the manual articulation mechanism comprises a manually actuated articulation knob positioned at a proximal end of the handle body and rotatable about the longitudinal axis; and a ball screw operatively coupled to the articulation knob and longitudinally movable by rotation of the articulation knob.
10. A handle assembly for a surgical stapler, the handle assembly comprising:
a handle body comprising a stationary handle and a trigger pivotably coupled to the handle body;
an electric motor disposed within the handle body, the motor comprising an output shaft;
an actuation shaft slidable within the handle body along a longitudinal axis;
a motor gear coupled to the output shaft of the motor;
an auxiliary gear in driven engagement with the motor gear and operatively engaged with the actuation shaft;
a position sensor operably coupled to the motor gear to determine a longitudinal position of the actuation shaft;
a control system electrically coupled to the trigger, the electric motor, and the position sensor, the control system configured to control the speed and torque of the electric motor; and
a manual return mechanism selectively operable to disengage the auxiliary gear from the actuation shaft and retract the actuation shaft proximally.
11. The handle assembly of claim 10 , wherein the actuation shaft is rotatable about the longitudinal axis by the manual return mechanism from a first orientation in which the auxiliary gear is operatively engaged with the actuation shaft to a second orientation in which the auxiliary gear is disengaged from the actuation shaft.
12. The handle assembly of claim 10 , wherein the position sensor comprises a potentiometer.
13. A handle assembly for a surgical stapler, the handle assembly comprising:
a handle body comprising a stationary handle and a trigger pivotably coupled to the handle body;
a powered drive system disposed within the handle body;
an actuation shaft slidable within the handle body along a longitudinal axis by actuation of the drive system;
a position sensor operably coupled to the motor gear to determine a longitudinal position of the actuation shaft;
a control system electrically coupled to the trigger, the drive system, and the position sensor;
a manual return mechanism selectively operable to disengage the drive system from the actuation shaft and retract the actuation shaft proximally; and
a manual articulation mechanism.
14. The handle assembly of claim 13 , wherein the manual articulation mechanism comprises a manually actuated articulation knob positioned at a proximal end of the handle body and rotatable about the longitudinal axis; and a ball screw operatively coupled to the articulation knob and longitudinally movable by rotation of the articulation knob.
15. The handle assembly of claim 13 , wherein the manual return mechanism comprises a shaft rotation mechanism configured to rotate the actuation shaft about the longitudinal axis from a first orientation in which the drive system is operatively engaged with the actuation shaft to a second orientation in which the drive system is disengaged from the actuation shaft.