Powered surgical instrument

Abstract

A method of operating a surgical instrument is disclosed. The surgical instrument includes an electronic system comprising an electric motor coupled to the end effector; a motor controller coupled to the motor; a parameter threshold detection module configured to monitor multiple parameter thresholds; a sensing module configured to sense tissue compression; a processor coupled to the parameter threshold detection module and the motor controller; and a memory coupled to the processor. The memory stores executable instructions that when executed by the processor cause the processor to monitor multiple levels of action thresholds and monitor speed of the motor and increment a drive unit of the motor, sense tissue compression, and provide rate and control feedback to the user of the surgical instrument.

1 - 20 . (canceled) 
     
     
         21 . A surgical instrument, comprising:
 a motor;   a motor controller configured to control the motor;   a processor coupled to the motor controller; and   a memory coupled to the processor, wherein the memory stores:
 a plurality of set parameters associated with the surgical instrument; 
 an ultimate threshold associated with each of the set parameters; and 
 a marginal threshold associated with each of the set parameters; 
   wherein the processor is configured to:
 monitor, by the processor, a parameter of the plurality of set parameters during use of the surgical instrument; 
 compare, by the processor, the monitored parameter to an ultimate threshold associated with the parameter; 
 adjust, by the motor controller, an operation of the motor based on a result of the comparison of the monitored parameter and the ultimate threshold; 
 compare, by the processor, the monitored parameter to a marginal threshold associated with the parameter; and 
 adjust, by the motor controller, an operation of the motor based on a result of the comparison of the monitored parameter and the marginal threshold. 
   
     
     
         22 . The surgical instrument of  claim 21 , wherein the processor is configured to compare the monitored parameter to the marginal threshold based on the monitored parameter not reaching or exceeding the ultimate threshold. 
     
     
         23 . The surgical instrument of  claim 21 , wherein the processor is configured to adjust a speed of the motor based on the monitored parameter reaching or exceeding the ultimate threshold. 
     
     
         24 . The surgical instrument of  claim 23 , wherein the processor is configured to adjust the speed of the motor to zero based on the monitored parameter reaching or exceeding the ultimate threshold. 
     
     
         25 . The surgical instrument of  claim 21 , wherein the processor is further configured to set, by the processor, a new marginal threshold for the parameter based on the monitored parameter reaching or exceeding the ultimate threshold. 
     
     
         26 . The surgical instrument of  claim 21 , wherein the processor is configured to set, by the processor, a linear progression function to the motor controller based on the monitored parameter reaching or exceeding the marginal threshold. 
     
     
         27 . The surgical instrument of  claim 21 , wherein the processor is configured to set, by the processor, a non-linear progression function to the motor controller based on the monitored parameter reaching or exceeding the marginal threshold. 
     
     
         28 . The surgical instrument of  claim 21 , wherein the parameter comprises a current draw of the motor. 
     
     
         29 . The surgical instrument of  claim 21 , wherein the parameter comprises a number of sterilization cycles of the surgical instrument. 
     
     
         30 . The surgical instrument of  claim 21 , wherein the surgical instrument further comprises a firing drive system, and wherein the parameter comprises a velocity of the firing drive system. 
     
     
         31 . The surgical instrument of  claim 21 , wherein the surgical instrument further comprises a firing drive system, and wherein the parameter comprises a firing force experienced by the firing drive system. 
     
     
         32 . A surgical instrument, comprising:
 a motor;   a motor controller configured to control the motor;   a processor coupled to the motor controller; and   a memory coupled to the processor;   wherein the processor is configured to:
 monitor, by the processor, a speed of the motor; 
 predict, by the processor, a future motor speed based on the speed of the motor increasing; 
 compare, by the processor, the predicted future motor speed to a threshold motor speed; and 
 adjust, by the motor controller, the speed of the motor based on a result of the comparison. 
   
     
     
         33 . The surgical instrument of  claim 32 , wherein the processor is configured to divert the speed of the motor away from an expected speed curve based on the result of the comparison. 
     
     
         34 . A surgical system, comprising:
 a motor;   a motor control circuit configured to control the motor;   a processing circuit coupled to the motor control circuit; and   a memory coupled to the processing circuit, wherein the memory stores:
 a plurality of set parameters associated with the surgical system; 
 an ultimate threshold associated with each of the set parameters; and 
 a marginal threshold associated with each of the set parameters; 
   wherein the processing circuit is configured to:
 monitor, by the processing circuit, a parameter of the plurality of set parameters during use of the surgical system; 
 compare, by the processing circuit, the monitored parameter to an ultimate threshold associated with the parameter; 
 adjust, by the motor control circuit, an operation of the motor based on a result of the comparison of the monitored parameter and the ultimate threshold; 
 compare, by the processing circuit, the monitored parameter to a marginal threshold associated with the parameter based on the monitored parameter not reaching or exceeding the ultimate threshold; and 
 adjust, by the motor control circuit, an operation of the motor based on a result of the comparison of the monitored parameter and the marginal threshold. 
   
     
     
         35 . The surgical system of  claim 34 , wherein the processing circuit is configured to set, by the processing circuit, a new marginal threshold for the parameter based on the monitored parameter reaching or exceeding the ultimate threshold. 
     
     
         36 . The surgical system of  claim 34 , wherein the processing circuit is configured to adjust a speed of the motor based on the monitored parameter reaching or exceeding the ultimate threshold. 
     
     
         37 . The surgical system of  claim 34 , wherein the parameter comprises a current draw of the motor of the surgical system. 
     
     
         38 . The surgical system of  claim 34 , wherein the parameter comprises a number of sterilization cycles of the surgical system. 
     
     
         39 . The surgical system of  claim 34 , further comprising a firing drive system, and wherein the parameter comprises a velocity of the firing drive system. 
     
     
         40 . The surgical system of  claim 34 , further comprising a firing drive system, and wherein the parameter comprises a firing force experienced by the firing drive system.