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EP-4739226-A1 - POWERED SURGICAL IMPACTOR

EP4739226A1EP 4739226 A1EP4739226 A1EP 4739226A1EP-4739226-A1

Abstract

A powered surgical impactor is provided. The powered surgical impactor includes a housing, a stator disposed within the housing, a plurality of coils arranged about the stator and being configured to be energized to generate a magnetic field, an armature disposed within the stator and configured for movement within the stator in response to the plurality of coils being energized. The powered surgical impactor includes a hammer coupled to the armature. The powered surgical impactor includes a controller configured to measure a voltage of a first coil and a second coil of a pair of coils of the plurality of coils, determine a back EMF signal based on the voltage of the first coil and the voltage of the second coil, and determine a motion parameter of the armature based on the back EMF signal.

Inventors

  • BELAGALI, KRISHNAMURTHY
  • GUTHRIE, Warren, Edwin
  • EMENS, Eric, J.
  • VIDETICH, John, Gregory
  • LATHAM, Jeremy

Assignees

  • Stryker Corporation

Dates

Publication Date
20260513
Application Date
20240708

Claims (20)

  1. CLAIMS What is claimed is: 1. A powered surgical impactor comprising: a housing defining a longitudinal axis; a stator disposed within the housing and extending along the longitudinal axis between a proximal stator end and a distal stator end; a plurality of coils arranged about the stator and configured to be energized to generate a magnetic field; an armature disposed within the stator and extending along the longitudinal axis between a proximal armature end and a distal armature end, wherein the armature is configured for movement relative to the stator along the longitudinal axis in a distal direction and a proximal direction between a plurality of armature positions in response to the plurality of coils being energized, the plurality of armature positions including: a proximal armature position where movement of the armature relative to the stator is delimited in the proximal direction, and a distal armature position where movement of the armature relative to the stator is delimited in the distal direction; and a hammer coupled to the distal armature end of the armature for movement with the armature in response to the plurality of coils being energized, wherein the hammer defines a hollow region delimited by a proximal impact face and a distal impact face, wherein a portion of the hammer that defines the hollow region is at least partially arranged within the stator when the armature is in the proximal armature position; and an anvil assembly including: a shaft supported by the housing for translation along the longitudinal axis in the distal direction and the proximal direction, the shaft extending between a distal shaft end arranged to support a tool and a proximal shaft end; and an anvil supported by the proximal shaft end of the shaft and disposed within the hollow region of the hammer, the anvil including a distal strike face and a proximal strike face, wherein the proximal strike face of the anvil is arranged to be impacted by the proximal impact face of the hammer as the armature moves in the distal direction to urge the shaft and the tool in the distal direction, and wherein the distal strike face of the anvil Attorney Docket No. INST2471PCT/060210.04135 is arranged to be impacted by the distal impact face of the hammer as the armature moves in the proximal direction to urge the shaft and the tool in the proximal direction.
  2. 2. The powered surgical impactor of claim 1, wherein the stator defines a stator length between the proximal stator end and the distal stator end, and wherein the armature defines an armature length, less than the stator length of the stator, between the proximal armature end and the distal armature end.
  3. 3. The powered surgical impactor of claim 2, wherein the plurality of coils is arranged about the stator length of the stator.
  4. 4. The powered surgical impactor of claim 2, wherein the proximal armature end is aligned with the proximal stator end when the armature is in the proximal armature position.
  5. 5. The powered surgical impactor of claim 2, wherein the distal armature end is aligned with the distal stator end when the armature is in the distal armature position.
  6. 6. The powered surgical impactor of claim 1, wherein a distal portion of the housing defines a constraining void delimited by a distal constraining face and a proximal constraining face; and wherein the anvil assembly further comprises a constraining member disposed within the constraining void and coupled to the shaft such that the constraining member is configured to abut the distal constraining face to delimit motion of the shaft in the distal direction and to abut the proximal constraining face to delimit motion of the shaft in the proximal direction.
  7. 7. The powered surgical impactor of claim 6, further comprising a shaft biasing member interposed between the proximal constraining face and the constraining member to bias the shaft in the distal direction.
  8. 8. The powered surgical impactor of claim 1, further comprising a controller configured to: Attorney Docket No. INST2471PCT/060210.04135 measure a voltage of a first coil and a second coil of a pair of coils of the plurality of coils; determine a back EMF signal based on the voltage of the first coil and the voltage of the second coil; and determine a motion parameter of the armature based on the back EMF signal.
  9. 9. The powered surgical impactor of claim 8, wherein the armature includes a magnet configured to generate a magnetic field.
  10. 10. The powered surgical impactor of claim 9, further comprising a battery electrically connected to the plurality of coils, the battery being configured to provide an electrical current to the plurality of coils to energize the plurality of coils such that the plurality of coils generate a magnetic field.
  11. 11. The powered surgical impactor of claim 10, wherein the magnetic field generated by the plurality of coils interacts with the magnetic field generated by the magnet of the armature to move the armature within the stator between the proximal stator end and the distal stator end.
  12. 12. The powered surgical impactor of claim 10, wherein the magnet of the armature is adjacent to one of the first coil and the second coil, and wherein, to determine the back EMF signal, the controller is configured to subtract the measured voltage of the other one of the first coil and the second coil from the measured voltage of the one of the first coil and the second coil.
  13. 13. The powered surgical impactor of claim 10, wherein voltage of the first coil includes the back EMF signal, and wherein the back EMF signal is generated in response to the magnet of the armature being adjacent to the first coil.
  14. 14. The powered surgical impactor of claim 10, wherein the pair of coils is further defined as a first pair of coils, and wherein the plurality of coils includes a second pair of coils, the first pair of coils being electrically connected in series, the second pair of coils being Attorney Docket No. INST2471PCT/060210.04135 electrically connected in series, and the first pair of coils being electrically connected in parallel with the second pair of coils.
  15. 15. The powered surgical impactor of claim 14, further comprising a battery electrically connected to the plurality of coils, the battery being configured to: provide an electrical current to the first pair of coils such that the first coil of the first pair of coils generates a first magnetic field and the second coil of the first pair of coils generates a second magnetic field; and provide an electrical current to second pair of coils such that a first coil of the second pair of coils generates a third magnetic field and the second coil of the second pair of coils generates a fourth magnetic field.
  16. 16. The powered surgical impactor of claim 14, wherein the back EMF signal is further defined as a first back EMF signal, and wherein the controller is configured to: measure a voltage of a first coil and a second coil of the second pair of coils; determine a second back EMF signal based on the voltage of the first coil of the second pair of coils and the voltage of the second coil of the second pair of coils; and determine the motion parameter of the armature based on the first back EMF signal and the second back EMF signal.
  17. 17. The powered surgical impactor of claim 16, wherein the battery is electrically connected to the controller, and wherein the controller is configured to control the battery to provide an electrical current to the one of the first pair of coils and the second pair of coils based on the determined motion parameter of the armature.
  18. 18. The powered surgical impactor of claim 10, wherein the pair of coils is further defined as a first pair of coils, and wherein the plurality of coils includes a second, third, and fourth pair of coils, the first pair of coils being electrically connected in series, the second pair of coils being electrically connected in series, the third pair of coils being electrically connected in series, the fourth pair of coils being electrically connected in series, and the first, second, third, and fourth pair of coils being electrically connected in parallel with one another. Attorney Docket No. INST2471PCT/060210.04135
  19. 19. The powered surgical impactor of claim 18, further comprising a battery electrically connected to the plurality of coils, the battery being configured to: provide an electrical current to the first pair of coils such that the first coil of the first pair of coils generates a first magnetic field and the second coil of the first pair of coils generates a second magnetic field; provide an electrical current to second pair of coils such that a first coil of the second pair of coils generates a third magnetic field and the second coil of the second pair of coils generates a fourth magnetic field; provide an electrical current to the third pair of coils such that the first coil of the third pair of coils generates a fifth magnetic field and the second coil of the third pair of coils generates a sixth magnetic field; and provide an electrical current to the fourth pair of coils such that the first coil of the fourth pair of coils generates a seventh magnetic field and the second coil of the fourth pair of coils generates an eighth magnetic field.
  20. 20. The powered surgical impactor of claim 19, wherein the back EMF signal is further defined as a first back EMF signal, and wherein the controller is configured to: measure a voltage of a first coil and a second coil of the second pair of coils; determine a second back EMF signal based on the voltage of the first coil of the second pair of coils and the voltage of the second coil of the second pair of coils; and determine the motion parameter of the armature based on the first back EMF signal and the second back EMF signal.

Description

POWERED SURGICAL IMPACTOR RELATED APPLICATIONS [0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/525,393, filed Jul. 7, 2023, U.S. Provisional Patent Application No. 63/525,396, filed Jul. 7, 2023, U.S. Provisional Patent Application No. 63/525,405, filed Jul. 7, 2023, and U.S. Provisional Patent Application No. 63/525,410, filed Jul. 7, 2023, each of which is hereby incorporated by reference in its entirety. FIELD OF THE INVENTION [0002] The invention is related generally to a surgical instrument. More particularly, the invention is related to a powered surgical impactor having a stator and an armature disposed within the stator. BACKGROUND [0003] The installation of prosthetics such as hip implants is crucial for patients. Manually impacted tools play a vital role in the surgical insertion of such prostheses. For example, manually impacted tools may be used for broaching voids where a prosthesis is to be inserted. Furthermore, manually impacted tools may be used for impacting the prosthesis into the anatomy such that the prosthesis is press-fit in the anatomy. However, manually impacted tools may pose challenges that can hinder optimal outcomes. There are a number of challenges associated with manually impacting prostheses into a patient. Manually impacted tools rely on surgeon skill, leading to inconsistent force application. Additionally, manually impacted tools contribute to surgeon fatigue, such as during physically demanding hip implant surgeries. Furthermore, manually impacted tools lack real-time feedback and monitoring capabilities, hindering evaluation of implant fixation quality and necessitating adjustments. [0004] Therefore, there is a need in the art for a powered surgical impactor for impacting a tool into a patient that addresses one or more of the challenges above. SUMMARY [0005] A first aspect of the disclosure is directed to a powered surgical impactor. The powered surgical impactor comprising: a housing defining a longitudinal axis; a stator disposed 1 Attorney Docket No. INST2471PCT/060210.04135 within the housing and extending along the longitudinal axis between a proximal stator end and a distal stator end; a plurality of coils arranged about the stator and being configured to be energized to generate a magnetic field; an armature disposed within the stator and extending along the longitudinal axis between a proximal armature end and a distal armature end, the armature configured for movement within the stator between the proximal stator end and the distal stator end in response to the plurality of coils being energized; a hammer coupled to the armature; and a controller configured to: measure a voltage of a first coil and a second coil of a pair of coils of the plurality of coils; determine a back EMF signal based on the voltage of the first coil and the voltage of the second coil; and determine a motion parameter of the armature based on the back EMF signal. [0006] A second aspect of the disclosure is directed to a method of operating the powered surgical impactor of the first aspect. [0007] A third aspect of the disclosure is directed to a method of controlling a surgical impactor including a stator and an armature disposed within the stator, the stator including a first coil and a second coil, the second coil being spaced apart from the first coil, and the armature including a plurality of magnets, the armature being movable between a first position and a second position, the first position being spaced from the second position, and wherein a hammer is coupled to the armature, the method comprising determining a first electrical parameter of a first coil while the armature is in the first position; determining a second electrical parameter of a second coil while the armature is in the first position; determining an electromagnetic factor based on the first and second electrical parameters; and determining a motion parameter of the armature in the stator based on the electromagnetic factor. [0008] A fourth aspect of the disclosure is directed to a powered surgical impactor comprising: a housing defining a longitudinal axis; a stator disposed within the housing and extending along the longitudinal axis between a proximal stator end and a distal stator end, the stator including a plurality of coils arranged about the longitudinal axis and being configured to be energized to generate a magnetic field, the plurality of coils including a first coil and a second coil; an armature disposed within the stator and extending along the longitudinal axis between a proximal armature end and a distal armature end, the armature including a plurality of magnets and the armature is configured for movement within the stator between the proximal stator end and the distal stator end in response to the plurality of coils being energized; and a controller 2 Attorney Docket No. INST2471PCT/060210.04135 configured to: measure electrical parameters