WO2024173660A2

WO2024173660A2 - Surgical system including a battery and control module

Info

Publication number: WO2024173660A2
Application number: PCT/US2024/015957
Authority: WO
Inventors: Conor MAC AN TUILE; Thomas Stritch; Matteo NICOLASI; Daniela BURIN; Krishanu CHOUDHURY; Vineet Mittal; Dustin James PAYNE; Cian MARTIN; Arthur Carlos PALLAR DA SILVA; Amanda FERRANTE; Ellis ARCHULETA; Daniel Jay HUIZENGA; Kana MORIYAMA
Original assignee: Stryker Corporation
Priority date: 2023-02-15
Filing date: 2024-02-15
Publication date: 2024-08-22
Also published as: WO2024173660A3

Abstract

A powered surgical tool including a handpiece including a motor and a battery and control module. The battery and control module includes a device housing having a recess for removably receiving the handpiece, the device housing defining a void space. A rechargeable battery module is disposed in the void space. A controller is configured to regulate power drawn from the rechargeable battery module based on user input.

Description

SURGICAL SYSTEM INCLUDING A BATTERY AND CONTROL MODULE

BACKGROUND

[0001] Modular handheld powered surgical tools are ubiquitous in the modem surgical theatre. Exemplary powered surgical tools include burs, drills, saws, and shavers. Modular handheld powered surgical tools typically include a handpiece component including a motor that is sized sufficiently to meet the demands of the surgical procedure, for example, resecting cortical bone and other hardened anatomical structures. Modular handheld powered surgical tools also typically include a device housing configured to couple with and power the motor of the handpiece component. As uses of modular handheld powered surgical tools continue to develop, it is important for modular handheld powered surgical tools to include device housings that are able to accommodate and identify a wide variety of devices.

[0002] Therefore, there is a need in the art for a handheld powered surgical tool that is able to identify and provide power to a variety of devices.

SUMMARY

[0003] In a first aspect, a powered surgical tool is provided. The powered surgical tool comprising: a handpiece including a motor and a tool coupler, the handpiece defining at least one of a rail and a slot, and the handpiece further defining a receiver surface; and a battery and control module including: a device housing including the other of the rail and the slot, the rail and slot configured such that the rail is slidable within the slot to allow coupling between the handpiece and the battery and control module, the device housing further defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a state of the motor; and at least three conductive terminals that extend through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece.

[0004] In a second aspect, a powered surgical tool is provided. The powered surgical tool comprising: a handpiece including a motor and a tool coupler, wherein the handpiece defines a cannulation; and a battery and control module including: a device housing defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a state of the motor; and at least three conductive terminals that extends through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece, wherein the battery and control module is free from cannulation.

[0005] In a third aspect, a surgical handpiece for coupling to a battery and control module is provided. The surgical handpiece comprising: a housing; a tool coupler; an electric motor disposed within the housing; a rotor defining an axis, the rotor being coupled to the electric motor and the tool coupler; a rigid circuit board including a controller, the rigid circuit board being disposed within the housing and oriented perpendicular to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the rigid circuit board.

[0006] In a fourth aspect, surgical handpiece for coupling to a battery and control module is provided. The surgical handpiece comprising: a housing; a tool coupler; an electric motor disposed within the housing; a rotor defining an axis, the rotor being coupled to the electric motor and the tool coupler; a circuit board including a controller, the circuit board disposed within the housing, the circuit board including a rigid portion and a flexible portion, the rigid portion defining an axis that is oriented parallel to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the flexible portion of the circuit board.

[0007] In a fifth aspect, a powered surgical tool is provided. The powered surgical tool comprising: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a first printed circuit board disposed in the void space and being rigid; a second printed circuit board disposed in the void space and being rigid, the second printed circuit board being coupled to the first printed circuit board, the second printed circuit board and the first printed circuit board being arranged in a stacked configuration, a plurality of motor control sensors connected to the second printed circuit board; and a controller configured to regulate power drawn from the rechargeable battery module based on user input, the controller being mounted to one of the first printed circuit board and the second printed circuit board.

[0008] In a sixth aspect, a powered surgical tool is provided. The powered surgical tool comprising: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly disposed in the void space, the printed circuit board assembly including a rigid portion; a plurality of motor control sensors disposed on the rigid portion of the printed circuit board assembly; and a controller configured to regulate power drawn from the rechargeable battery module based on user input, the controller being mounted to the printed circuit board assembly. [0009] In a seventh aspect, a powered surgical tool is provided. The powered surgical tool comprising: a handpiece including a motor, the motor including a plurality of magnets; and a control module including: a device housing for removably receiving the handpiece, the device housing defining a void space; a first terminal; a sensor configured to provide a sensor signal, the sensor being positioned to sense at least one of the plurality of magnets when the handpiece is received; and a controller configured to regulate power supplied to the first terminal based on the sensor signal.

[0010] In an eighth aspect, a powered surgical tool having a pencil-grip configuration is provided. The powered surgical tool comprising: a plastic housing defining an integral mounting base, the integral mounting base defining a first and second aperture, a first pin and a second pin extending through the first and second apertures respectively, with the first pin defining a pivot axis and pivot surface, the first pin and the second pin defining a press-fit engagement with one another; and a lever pivotably coupled to the pivot surface of the first pin.

[0011] In a ninth aspect, a powered surgical tool is provided. The powered surgical tool comprises: a housing defining a void; a circuit board disposed in the void of the housing for regulating operation of an electric motor; a rechargeable battery module disposed within the void; at least three motor pins spaced apart from one another to define an array of motor pins that extends through the housing and out of the void for establishing an electrical connection between the circuit board and the electric motor, wherein a hermetically-sealed housing-terminal interface is defined by the housing and the at least three motor pins; a routing feature disposed about the at least three motor pins, the routing feature defining a plurality of channels; and at least three wires, each of the three wires including a wire terminal connected to a first wire end of the at least three wires and the other end of the wire connected to the circuit board, each of wire terminals including a first end portion and a second end portion opposite the first end portion, the first end portion connected to one of the at least three wires, and the second end portion shaped to electrically engage one of the motor pins, each the wire terminals positioned within one of the channels of the routing feature.

[0012] In a tenth aspect, a powered surgical tool is provided. The powered surgical tool comprises: a handpiece including a motor; a module housing configured to couple with one of the handpiece and a charging module, wherein each of the handpiece and the charging module are configured to generate a magnetic field; and a printed circuit board assembly including a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.

[0013] In a eleventh aspect, a system for identifying a device coupled with a powered surgical tool is provided. The system comprises: a handpiece configured to generate a magnetic field; a charging module configured to generate a magnetic field; and a powered surgical tool comprising: a module housing configured to couple with one of the handpiece and the charging module; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.

[0014] In a twelfth aspect, a powered surgical tool is provided. The powered surgical tool comprises: a first handpiece including a motor; a second handpiece including a motor; a module housing configured to couple with one of the first handpiece and the second handpiece, wherein each of the handpiece and the charging module are configured to generate a magnetic field; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.

[0015] In a thirteenth aspect, a system for identifying a device coupled with a powered surgical tool is provided. The system comprises: a handpiece configured to generate a magnetic field; a charging module coupled to a charging adapter, the charging adapter being configured to generate a magnetic field; and a powered surgical tool comprising: a module housing configured to couple with one of the handpiece and the charging module; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging adapter based on the magnetic field sensed by the analog hall effect sensor.

[0016] In a fourteenth aspect, a surgical handpiece for coupling to a battery and control module is provided. The surgical handpiece comprises: a housing; an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft being, at a first end, coupled to the electric motor and, at a second end, configured to be coupled to a surgical tool, wherein the output shaft defines a lumen centered upon the longitudinal axis of the output shaft; a cannula disposed partially within the lumen and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing and configured to prevent a liquid from entering an interior of the surgical handpiece, wherein the cannula passes through the sealing plug; a seal disposed around an outside of the cannula; and a plurality of terminals extending through the sealing plug.

[0017] In a fifteenth aspect, a powered surgical tool is provided. The powered surgical tool comprises: a surgical handpiece, including: a housing; an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft being, at a first end, coupled to the electric motor and, at a second end, configured to be attached to a surgical tool, wherein the output shaft defines a lumen centered upon the longitudinal axis of the output shaft; a cannula disposed partially within the lumen and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing, wherein the cannula passes through the sealing plug; a seal disposed around an outside of the cannula. The powered surgical tool further comprises: a plurality of terminals extending through the sealing plug and a battery and control module including a module lumen configured to receive the surgical handpiece.

[0018] In a sixteenth aspect, a charging system for charging a rechargeable battery module of a powered surgical tool, the powered surgical tool including a module housing configured to receive a handpiece is provided. The charging system comprising: a charger comprising a recess; and an adapter comprising: a charger protrusion configured to be received by the recess, wherein the recess includes a surface facing a first direction; and a module protrusion configured to be received by the module housing to allow the charger to provide power to the rechargeable battery module via the adapter, wherein the module protrusion extends in a direction different than the first direction.

[0019] In a seventeenth aspect, a charging system for charging a rechargeable battery module of a first powered surgical tool of a pencil grip type and a rechargeable battery module of a second powered surgical tool of a pistol grip type, wherein the first and second powered surgical tools each include a module housing configured to receive a handpiece is provided. The charging system comprising: a charger including a recess; and an adapter including: a charger protrusion configured to be received by the recess; and a module protrusion configured to be received by: the module housing of the first powered surgical tool to allow the charger to provide power to the rechargeable battery module of the first powered surgical tool via the adapter; and the module housing of the second powered surgical tool to allow the charger to provide power to the rechargeable battery module of the second powered surgical tool via the adapter.

[0020] In an eighteenth aspect, a charging system is provided. The charging system comprising: a charger including a recess; an adapter including: a charger protrusion configured to be received by the recess; a module protrusion; and a magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; a first powered surgical tool including: a first module housing configured to receive the module protrusion, the first module housing including a first end and a second end; a first hall sensor located a first distance from the first end of the module housing; and a first controller configured to transition from a sleep state to an active state based on the first hall sensor sensing a magnetic field, wherein the first controller is configured to communicate with the charger when the first controller is in the active state; and a second powered surgical tool including: a second module housing configured to receive the module protrusion, the second module housing including a first end and a second end; a second hall sensor located a second distance from the first end of the second module housing, the second distance being different from the first distance; and a second controller configured to transition from a sleep state to an active state based on the second hall sensor sensing a magnetic field, wherein the second controller is configured to communicate with the charger when the second controller is in the active state.

[0021] In a nineteenth aspect, a charging system is provided. The charging system comprising: a charger; a battery configured to receive power from the charger in response to contacting the charger; an adapter including: a charger protrusion configured to contact the charger; a module protrusion; and a magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; and a powered surgical tool including: a module housing configured to receive the module protrusion; a hall sensor; and a controller configured to transition from a sleep state to an active state based on the hall sensor sensing a magnetic field, wherein the controller is configured to communicate with the charger when the controller is in the active state.

[0022] In a twentieth aspect, a powered surgical tool is provided. The powered surgical tool includes a battery and control module. The battery and control module includes a sealed housing assembly including a printed circuit board including at least one trigger sensor, a plurality of housings sealingly joined together and configured to encase the printed circuit board and the at least one trigger sensor therewithin, and at least one trigger lumen configured to receive a trigger, wherein the at least one trigger sensor is disposed proximate to the at least one trigger lumen. The powered surgical tool further includes at least one trigger installed to the battery and control module within the at least one trigger lumen, the at least one trigger including a stem portion configured to be engaged with the at least one trigger lumen, wherein the stem portion includes at least one magnet configured to interact with the at least one trigger sensor.

[0023] In an twenty-first aspect, a method of operating a powered surgical tool is provided. The method includes the step of providing a battery and control module including a sealed housing assembly, the housing assembly encapsulating a printed circuit board that includes at least one trigger sensor and at least one trigger lumen configured to receive a trigger. The method further includes the step of installing at least one trigger into the trigger lumen, the trigger including a stem portion with at least one magnet configured to interact with the trigger sensor without compromising the seal of the sealed housing assembly.

[0024] In a twenty-second aspect, a method of repairing a powered surgical tool is provided. The method includes the step of providing a battery and control module including a sealed housing assembly, the housing assembly encapsulating a printed circuit board that includes at least one trigger sensor, the battery and control module further including a trigger with a magnet.

The method further includes the step of removing the trigger from the battery and control module without compromising the seal of the sealed housing assembly.

[0025] In some implementations, the handpiece defines a cannula, and wherein the device housing is free from cannulation. In some implementations, the surgical handpiece defines a longitudinal axis, and the surgical handpiece defines a cannula surrounding the longitudinal axis.

In some implementations, the rigid circuit board defines an aperture, the aperture surrounding the cannula. In some implementations, the aperture and the cannula are coaxial. In some implementations, the battery and control module include a safety vent. In some implementations, the battery and control module further comprises a plurality of support ribs and a board mount, the board mount including a plurality of wings for engaging the support ribs. In some implementations, the device housing defines a mounting post, and the third printed circuit board abuts the mounting post such that an axial position of the third printed circuit board is controlled within the battery and control module. In some implementations, the battery and control module further comprises a board mount, the board mount includes one of a set of notches or a set of protrusions, and the device housing defines the other of the set of notches or the set of protrusions, wherein set of protrusions engages the set of notches to prevent the board mount from moving relative to the device housing in a plurality of degrees of freedom. In some implementations, the battery and control module further comprises board mount, wherein the board mount includes one of a set of notches or a set of protrusions, and the device housing defines the other of the set of notches or the set of protrusions, wherein set of protrusions engages the set of notches to prevent the rigid portion of the printed circuit board assembly from moving relative to the device housing in two or more degrees of freedom. In some implementations, the set of notches and/or set of protrusions are positioned in an arcuate arrangement relative to one another. In some implementations, the board mount includes the set of protrusions, and each of the set of protrusions define a receptacle for securing one of the plurality of motor control sensors. In some implementations, the board mount comprises a body portion and a flange, the flange defining a bore for insertion of a fastener, the flange extending perpendicularly from the body portion. In some implementations, the battery and control module further comprises a plurality of spacers, the plurality of spacers disposed between the first printed circuit board and the second printed circuit board. In some implementations, each of the plurality of spacers define a bore, wherein the battery and control module comprises a plurality of fasteners arranged to extend through the first printed circuit board, the bore of at least one of the plurality of spacers, and the second printed circuit board. In some implementations, the board mount defines a plurality of mount bores, each of the plurality of mount bores include a threaded insert. In some implementations, the battery and control module comprises a latch assembly including a locking member and a biasing member, the biasing member positioned to urge the locking member towards the receiver surface.

[0026] In some implementations, the motor is an electric motor. In some implementations, the motor sensor is further defined as a hall-effect sensor. In some implementations, the motor includes a plurality of magnets and wherein the device housing includes the set of notches, the notches defining a series of notch peaks and notch valleys, wherein an innermost surface of the notch peak is farther from magnets of the motor than an innermost surface of the notch valleys. In some implementations, the sensor is further defined as a first set of sensors, the first set of sensors being aligned axially with at least a portion of one of the plurality of magnets when the handpiece is received in the control module. In some implementations, the first set of sensors are digital hall effect sensors. In some implementations, the powered surgical tool further comprises a second set of sensors, wherein the second set of sensors are analog hall effect sensors. In some implementations, the controller is configured to energize the first terminal based the first set of sensors, and wherein the controller is configured to commutate the motor based on the second set of sensors. In some implementations, each sensor is the first set of sensors is aligned with one another. In some implementations, each sensor in the second set of sensors is aligned with one another. In some implementations, the first set of sensors is axially offset from the second set of sensors. In some implementations, the motor includes a motor rotor, a lamination stack surrounding the rotor of the motor, and a plurality of magnets surrounding the rotor, wherein a portion of the plurality of magnets extend axially beyond the lamination stack.

[0027] In some implementations, the controller is configured to transition between a sleep state and an active state, wherein the powered surgical tool is configured to cause the controller to transition from the sleep state to the active state based on the sensor signal. In some implementations, the powered surgical tool further comprises a second terminal, the second terminal being energized while the controller is in the sleep state and the active state. In some implementations, the controller is in the sleep state, the powered surgical tool has current draw less than 5 mA.

[0028] In some implementations, the battery and control module further comprises a third printed circuit board, the third printed circuit board connected to one of the first and the second printed circuit boards via a conductor, wherein the third printed circuit board comprises at least three conductive terminals that extends at least partially through the device housing for establishing an electrical connection between the third printed circuit board and the handpiece. In some implementations, the handpiece includes a memory device electrically connected to at least one of the plurality of terminals. In some implementations, the handpiece includes a memory device electrically connected to at least one of the at least three of conductive terminals. In some implementations, the at least three conductive terminals are soldered to the third printed circuit board. In some implementations, the conductor is further defined as a flexible circuit. In some implementations, the first printed circuit board has greater surface area than the second circuit board. In some implementations, the first printed circuit board is farther from the motor than the second circuit board when the handpiece is coupled to the battery and control module. In some implementations, the first printed circuit board and the second printed circuit board are interconnected with a board header. In some implementations, the second printed circuit board includes two major sides, wherein the board mount contacts only one of the two major sides. In some implementations, the second printed circuit board includes at least four minor sides, wherein the board mount contacts two or fewer minor sides of the second printed circuit board. In some implementations, the second printed circuit board includes at least four minor sides, wherein the board mount contacts no minor sides of the second printed circuit board. In some implementations, the third printed circuit board includes a light source, and the device housing includes a light guide aligned with the light source. In some implementations, the handpiece includes a memory device and a data terminal, the data terminal in electrical communication with the memory device, and wherein the data terminal is configured to connect with the second terminal of the control module when the handpiece is received in the recess.

[0029] In some implementations, a distal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module. In some implementations, a portion of a proximal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module. [0030] In some implementations, the plastic housing defines a first recess, the first recess adjacent the first aperture, with the first recess including a first flat surface, with the first pin including a head and a shaft extending from the head, with the head including a second flat surface, the first pin positioned within the first aperture such that the second flat surface of the head engages the first flat surface of the first recess. In some implementations, the plastic housing defines a channel, wherein the lever is pivotable about the first pin between a first fully depressed position and a second non-depressed position, and wherein the lever is at least partially disposed within the channel in both the first fully depressed position and the second non-depressed position.

In some implementations, at least one motor pin of the at least three motor pins define a longitudinal axis and the circuit board defines a longitudinal axis, wherein the longitudinal axis of the at least one motor pin is parallel to the longitudinal axis of the circuit board. In some implementations, at least three motor pins is further defined as at least six motor pins, and where the at least three wires is further defined as at least six wires. In some implementations, the at least six motor pins are positioned equidistant from a center of the array.

[0031] In some implementations the powered surgical tool further comprises: a handpiece including a motor; and wherein the plastic housing defines a recess for removably receiving the handpiece, the plastic housing defining a void space; a printed circuit board disposed in the void space; a rechargeable battery module disposed in the void space; the lever configured to receive an input from a user to cause power to be drawn from the rechargeable battery module and supplied to the motor, wherein the powered surgical tool has a pencil grip configuration; and wherein the plastic housing comprises a controller configured to regulate power drawn from the rechargeable battery module based on movement of the lever. In some implementations, the powered surgical tool further comprises a handswitch sensor configured to output a handswitch sensor signal based on a position of the lever, wherein the controller is configured to receive the handswitch sensor signal and regulate power drawn from the rechargeable battery module based on the handswitch sensor signal. In some implementations, the handswitch sensor is further defined as a first handswitch sensor and the handswitch sensor signal is further defined as a first handswitch sensor signal, the powered surgical tool further comprising a second handswitch sensor being configured to output a second handswitch sensor signal based on a position of the lever, wherein the controller is configured to receive the second handswitch sensor signal and regulate power drawn from the rechargeable battery module based on the first handswitch sensor signal and the second handswitch sensor signal. In some implementations, the first handswitch sensor and the second handswitch sensor are each mounted to opposing surfaces of the printed circuit board, the controller being disposed on the printed circuit board. In some implementations, the lever includes a run- safe switch slidably mounted to the lever, a magnet being mounted to the run- safe switch, a lever extension movably coupled to the lever, wherein the handswitch sensor is a

Hall effect sensor.

[0032] in some implementations, the powered surgical tool further including a torsion spring including a coil, a first leg, and a second leg, with the first leg and the second legs extending from opposite ends of the coil, with the coil surrounding the first pin.

[0033] In some implementations, the routing feature defines a rim, the rim defining the plurality of channels, and the rim surrounding the at least three motor pins. In some implementations, the first end portion of the wire terminal is disposed inside the rim and the second end portion of the wire terminal is disposed outside the rim. In some implementations, the wire terminal defines a bend of at least 70 degrees, and wherein the first end portion of the wire terminal is separated from the second end portion of the wire terminal by the bend. In some implementations, the plurality of channels includes a first channel and a second channel, wherein the first channel has a first depth and the second channel includes a second depth, the first depth being different from the second depth. In some implementations, the first end portion of the at least one of the wire terminals defining a plurality of arms, the arms crimped to engage the first wire end. In some implementations, the second end portion of the wire terminals defining a cylindrical void, the cylindrical void being disposed about the motor pins.

[0034] In some implementations, the control module is further defined as a battery and control module, wherein the battery and control module further comprises a rechargeable battery module. In some implementations, the powered surgical tool comprises a rechargeable battery module, wherein the digital hall effect sensor is configured to receive power from the rechargeable battery module in the sleep state, and wherein the analog hall effect sensor is configured to receive power from the rechargeable battery in the active state. In some implementations, the analog hall effect sensor receives a greater amount of power from the rechargeable battery in the active state than the digital hall effect sensor in the sleep state.

[0035] In some implementations, the controller is configured to: communicate with the handpiece using a first communication protocol in response to determining that the module housing has been coupled with the handpiece; and communicate with the charging module using a second communication protocol in response to determining that the module housing has been coupled with the charging module. In some implementations, the controller is configured to communicate using the first communication protocol by communicating at a first transmission speed, and wherein the controller is configured to communicate using the second communication protocol by communicating at a second transmission speed. In some implementations, the controller is configured to communicate using the first communication protocol by communicating using full duplex transmission, and wherein the controller is configured to communicate using the second communication protocol by communicating using half duplex transmission.

[0036] In some implementations, the controller is configured to transmit a communication signal to the handpiece based on determining that the module housing has been coupled with the handpiece. In some implementations, the controller is configured to transmit a communication signal to the charging module based on determining that the module housing has been coupled with the charging module. In some implementations, the controller is configured to receive a communication signal from the programming fixture based on determining that the module housing has been coupled with the programming fixture.

[0037] In some implementations, the module housing is further configured to couple with a programming fixture, wherein the programming fixture is configured to generate a magnetic field, and wherein the controller is configured to determine whether the module housing has coupled with programming fixture based on the magnetic field sensed by the analog hall effect sensor.

[0038] In some implementations, the analog hall effect sensor is further defined as a first analog hall effect sensor, wherein the printed circuit board assembly further includes a second analog hall effect sensor, and a third analog hall effect sensor. In some implementations, the handpiece further includes a motor including a first rotor magnet and a second rotor magnet each being configured to generate a magnetic field to cause rotation of the motor; the first analog hall effect sensor, the second analog hall effect sensor, and the third analog hall effect sensor are each configured to sense the magnetic fields generated by the first rotor magnet and the second rotor magnet; the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing the magnetic fields generated by the first rotor magnet and the second rotor magnet; and the controller is configured to determine that the module housing has coupled with the handpiece based on the first analog hall effect sensor, the second analog hall effect sensor, and the third analog hall effect sensor sensing the magnetic fields generated by the first rotor magnet and the second rotor magnet.

[0039] In some implementations, the system further comprises a programming fixture including a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; the analog hall effect sensor is configured to sense a magnetic field by sensing a magnitude of the magnetic field; and a position of the magnet of the programming fixture and a position of the magnet of the charging module are selected such that the magnitude of the first magnetic field sensed by the analog hall effect sensor is different than the magnitude of the second magnetic field sensed by the analog hall effect sensor.

[0040] In some implementations, the system further comprises a programming fixture including a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; the analog hall effect sensor is configured to sense a magnetic field by sensing a polarity of the magnetic field; and a polarity of the magnet of the programming fixture and a polarity of the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the analog hall effect sensor is different than the polarity of the second magnetic field sensed by the analog hall effect sensor. In some implementations, the system further comprises a programming fixture including a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; the analog hall effect sensor is configured to sense a magnetic field by sensing a polarity of the magnetic field; and a polarity of the magnet of the programming fixture and a polarity of the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the analog hall effect sensor is different than the polarity of the second magnetic field sensed by the analog hall effect sensor.

[0041] In some implementations, the charger includes two recesses, and wherein the adapter includes two charger protrusions configured to engage the two recesses. In some implementations, the adapter includes two module protrusions. In some implementations, each recess includes a width; each of the module protrusions includes a width; and a sum of the widths of the module protrusions is less than the width of a recess. In some implementations, the two charger protrusions of the adapter are disposed along a first direction, and wherein the two module protrusions are disposed along a second direction different than the first direction.

[0042] In some implementations, the module protrusion includes: a first latch configured to engage an interface of the module housing of the first powered surgical tool; and a second latch configured to engage an interface of the module housing of the second powered surgical tool. In some implementations, the module protrusion includes a first portion shaped to be received by the module housing of the first powered surgical tool; and a second portion shaped to be received by the module housing of the second powered surgical tool. In some implementations, the module housing of the first powered surgical tool includes a first radius; the module housing of the second powered surgical tool includes a second radius different than the first radius; the first portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the first powered surgical tool; and the second portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the second powered surgical tool. In some implementations, the module protrusion includes: a first latch disposed on the first portion, the first latch being configured to engage an interface of the module housing of the first powered surgical tool; and a second latch disposed on the second portion, the second latch being configured to engage an interface of the module housing of the second powered surgical tool.

[0043] In some implementations, the first hall sensor is configured to sense the magnetic field generated by the magnet in response to the first module housing receiving the module protrusion. In some implementations, the second hall sensor is configured to sense the magnetic field generated by the magnet in response to the second module housing receiving the module protrusion.

[0044] In some implementations, the controller is configured to communicate using a first communication protocol, and wherein the charger is configured to communicate using a second communication protocol, and wherein the adapter is configured to translate one of the first communication protocol and the second communication protocol into the other one of the second communication protocol and the first communication protocol such that the controller is configured to communicate with the charger via the adapter. In some implementations, the charger includes a charger power terminal and a charger communication terminal, wherein the charger protrusion includes an adapter communication contact configured to contact the charger communication terminal and an adapter power contact configured to contact the charger power terminal, wherein the module protrusion includes a first adapter communication terminal and a second adapter communication terminal in communication with the adapter communication contact, and wherein the first and second adapter communication terminals are shorted to one another to such that the controller is configured to communicate with the charger via the adapter.

In some implementations, the controller is configured to communicate using the first communication protocol by communicating using full duplex transmission, and wherein the charger is configured to communicate using the second communication protocol by communicating using half duplex transmission; and wherein the adapter is configured to translate the second communication protocol into the first communication protocol by translating a half duplex transmission into a full duplex transmission.

[0045] In some implementations, the second distal end includes a tool coupler. In some implementations, the lumen centered upon the longitudinal axis of the output shaft is a first lumen; wherein the seal includes a cylinder shape with a second lumen; and wherein the cannula is disposed within the second lumen. In some implementations, the seal includes a first sealing surface upon an end surface of the cylinder shape, wherein the end surface abuts a mating surface upon the sealing plug. In some implementations, the seal includes a second sealing surface including an annular ring-shaped surface upon an inner diameter of the seal, the annular ringshaped surface abutting an outer surface of the cannula. In some implementations, the sealing plug comprises a polymer. In some implementations, the housing includes an internal structure insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece; and wherein the sealing plug is press-fit within the inner diameter of the internal structure insert. In some implementations, the surgical handpiece further comprises a socket stopper disposed around an outside of the internal structure insert and the sealing plug, wherein the socket stopper is configured to retain the sealing plug within the inner diameter of the internal structure insert. In some implementations, the seal is disposed in contact with the cannula flange.

[0046] In some implementations, the battery and control module further includes a cannula access point configured to enable external access to the cannula within the first proximal end of the surgical handpiece. In some implementations, the second distal end includes a tool coupler. In some implementations, the seal includes a cylinder shape with a hollow center; and wherein the cannula is disposed within the hollow center of the seal. In some implementations, the seal includes a first sealing surface upon an end surface of the cylinder shape abutting a mating surface upon the sealing plug; and wherein the seal includes a second sealing surface including an annular ring upon an inner diameter of the seal abutting an outer surface of the cannula. In some implementations, the battery and control module defines a pistol grip.

[0047] In some implementations, the at least one trigger lumen includes a trigger vent cutout formed in a wall of the at least one trigger lumen, the trigger vent cutout is formed in a surface of the wall without compromising a seal of the sealed housing assembly, and the trigger vent cutout is configured to enable air to be released from behind the at least one trigger when the at least one trigger is depressed or installed. In some implementations, the at least one trigger is retained in the at least one trigger lumen with a screw and a front plate, and the screw and the front plate enable the at least one trigger to be replaced without compromising a seal of the sealed housing assembly. In some implementations, the sealed housing assembly includes two trigger lumens, and the powered surgical tool further includes two triggers. In some implementations, the sealed housing assembly further includes a battery including at least one battery cell. In some implementations, the sealed housing assembly further includes a handpiece lumen configured to receive a handpiece including a modular motor configured to provide energy to a surgical end effector. In some implementations, the at least one trigger sensor is configured to detect the at least one magnet through one of the plurality of housings. In some implementations, the plurality of housings sealingly joined together are welded together with one of a vibration welding process or a laser-process.

[0048] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

[0050] FIG. 1 is a perspective view of a first implementation of the powered surgical tool shown with the battery and control module spaced from the surgical handpiece, according to the teachings of the present disclosure.

[0051] FIG. 2 is a perspective view of the control module of FIG. 1.

[0052] FIG. 3 is a side view of the control module of FIG. 2.

[0053] FIG. 4 is an exploded view of the control module of FIG. 2.

[0054] FIG. 5 is a perspective view of a printed circuit board assembly of FIG. 4.

[0055] FIG. 6 is a top view of the printed circuit board assembly of FIG. 5.

[0056] FIG. 7 is a front view of the printed circuit board assembly of FIG. 5.

[0057] FIG. 8 is an exploded view of the printed circuit board assembly of FIG. 5.

[0058] FIG. 9 depicts a rear perspective view of a front portion of the control module

FIG. 2, according to the teachings of the present disclosure.

[0059] FIG. 10 depicts a cross-sectional view of the control module of FIG. 3.

[0060] FIG. 11 depicts a perspective view of a printed circuit board and wiring assembly of the control module of FIG. 4.

[0061] FIG. 12 depicts a perspective view of the wiring assembly of FIG. 11. [0062] FIG. 13 depicts a rear view of the wiring assembly of FIG. 12 without the wiring shown.

[0063] FIG. 14 depicts a perspective view of a second implementation of the powered surgical tool with a second handpiece coupled with the battery and control module.

[0064] FIG. 15 depicts a cross sectional view of battery and control module of FIG. 14.

[0065] FIG. 16 depicts a first perspective view of a printed circuit board assembly of the battery and control module of FIG. 14.

[0066] FIG. 17 depicts a second perspective view of a printed circuit board assembly of the battery and control module of FIG. 14.

[0067] FIG. 18 A depicts an exploded view of a first instance of the printed circuit board assembly of FIG. 16.

[0068] FIG. 18B depicts an exploded view of a second instance of the printed circuit board assembly of FIG. 16.

[0069] FIG. 19 depicts a rear perspective view of a portion of the printed circuit board assembly of FIG. 16 adjacent to a portion of the battery and control module of FIG 14.

[0070] FIG. 20 depicts the rear perspective view of the battery and control module of

FIG. 14 with the printed circuit board assembly of FIG. 16 removed.

[0071] FIG. 21 depicts a cross section view of a base portion of a first implementation of the powered surgical tool of FIG. 2, according to the teachings of the present disclosure.

[0072] FIG. 22 depicts a cross section view of battery and control module of FIG. 1.

[0073] FIG. 23 depicts a perspective view of a third implementation of the powered surgical tool with a third handpiece coupled with the battery and control module. [0074] FIG. 24 depicts a rear perspective view of the third implementation of the powered surgical tool shown in FIG. 23.

[0075] FIG. 25 depicts a front perspective view of the third implementation of the powered surgical tool shown in FIG. 23 with the third handpiece removed.

[0076] FIG. 26 depicts a rear perspective view of third handpiece of FIG. 23.

[0077] FIG. 27 depicts a perspective view a portion of interior of the third handpiece of FIG. 26.

[0078] FIG. 28 depicts a perspective view of the exterior of the third handpiece of FIG.

26.

[0079] FIG. 29 depicts a cross section view of the third handpiece of FIG. 26.

[0080] FIG. 30 depicts a cross-section of a fourth handpiece.

[0081] FIG. 31 depicts a perspective view of the fourth handpiece of FIG. 30.

[0082] FIG. 32 depicts a perspective view a portion of interior of a fifth handpiece.

[0083] FIG. 33 depicts a cross section view of the fifth handpiece of FIG. 32.

[0084] FIG. 34 is a perspective view of a first implementation of a pin of the battery and control module of FIG. 1.

[0085] FIG. 35 is a perspective view of a second implementation of a pin of the battery and control module of FIG. 1.

[0086] FIG. 36 is a perspective view of a charging module and a charging adapter, wherein the charging module is coupled with the battery and control module FIG. 1 and with the battery and control module of FIG. 14 via the charging adapter.

[0087] FIG. 37 is a perspective view of the charging module and charging adapter of

FIG. 36, wherein the charging adapter is not received by the charging module. [0088] FIG. 38 is a perspective view of a module protrusion of the charging adapter of

FIG. 36.

[0089] FIG. 39 is an exploded view of the charging adapter of FIG. 36.

[0090] FIG. 40 is a bottom view of the charging adapter of FIG. 36.

[0091] FIG. 41 is a schematic view of the battery and control module FIG. 1, the battery and control module of FIG. 14, the charging adapter of FIG. 36, and the charging module of FIG.

36.

[0092] FIG. 42 is a perspective view of a programming fixture.

[0093] FIG. 43 is a front view of the programming fixture of FIG. 42.

[0094] FIG. 44 is a schematic view of a system for identifying a device coupled with a powered surgical tool.

[0095] FIG. 45 is a state diagram illustrating an operation of the system for identifying a device coupled with a powered surgical tool shown in FIG. 1.

[0096] FIG. 46 is a graph illustrating sensed readings of analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS . 14 or 23 when the battery and control module is not coupled with a device.

[0097] FIG. 47 is a graph illustrating sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with a handpiece.

[0098] FIG. 48 is a graph illustrating ideal sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with a handpiece. [0099] FIG. 49 is a graph illustrating sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with the charging module of FIG. 36.

[00100] FIG. 50 is a graph illustrating sensed readings of the analog hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIGS. 14 or 23 when the battery and control module is coupled with the programming fixture of FIGS. 42 and 43.

[00101] FIG. 51 schematically illustrates an exemplary battery and control module in a front perspective view.

[00102] FIG. 52 schematically illustrates the battery and control module of FIG. 51 in a rear perspective view.

[00103] FIG. 53 schematically illustrates in side view an attachment or surgical handpiece configured for attachment to the battery and control module of FIG. 51 .

[00104] FIG. 54 schematically illustrates in cross sectional view the surgical handpiece of FIG. 53, including a sealing plug and a seal, in combination, configured to seal an interior of the surgical handpiece and prevent liquid from entering the interior.

[00105] FIG. 55 shows an implementation of a powered surgical tool in which a device housing of a battery and control module is designed to provide improved ergonomics and usability.

[00106] FIG. 56 illustrates in side perspective view internal components of the battery and control module including a pair of trigger sensors corresponding to the triggers of FIG. 55.

[00107] FIG. 57 illustrates in rear perspective view a front housing configured to be assembled, welded, laser-process attached, or otherwise affixed to a handle portion of the mid housing of FIG. 56. [00108] FIG. 58 illustrates in side perspective view a sealed housing assembly including the front housing welded, laser-process attached, adhered, fastened, or otherwise attached to the mid housing in a sealing manner.

[00109] FIG. 59 illustrates in side perspective view the sealed housing assembly of FIG.

58 with the triggers installed thereto.

[00110] FIG. 60 illustrates the sealed housing assembly and the triggers of FIG. 59 in a disassembled state.

[00111] FIG. 61 illustrates in side cross-sectional view a portion of the sealed housing assembly and the triggers.

[00112] FIG. 62 illustrates in front cross-sectional view a portion of the sealed housing assembly and the triggers.

[00113] FIG. 63 illustrates in front perspective view a portion of the sealed housing assembly including a plurality of trigger vent cutouts.

[00114] FIG. 64 illustrates in front cross-sectional view a portion of the sealed housing assembly including the stem portions and the respective trigger vent cutouts.

[00115] FIG. 65 is a flowchart illustrating an example of a method for operating a powered surgical tool.

[00116] FIG. 66 is a flowchart illustrating an example of a method for repairing a powered surgical tool.

DETAILED DESCRIPTION

[00117] FIG. 1 shows an implementations of a powered surgical tool 20 in which a device housing 22 of a battery and control module 21 is designed to provide improved ergonomics and usability. The powered surgical tool 20 includes a handpiece 24 configured to be removably coupled with the battery and control module 21. The handpiece 24 may include a motor and a drivetrain (not identified), and also includes additional subcomponents such as electrical sockets, a gearbox, and geometries to removably receive a cutting accessory including a head. Other than certain features of the handpiece 24 to be described in further detail, the handpiece 24 may take a form disclosed in commonly-owned International Publication No. WO 2013/177423, published

November 28, 2013, the entire contents of which are hereby incorporated by reference.

[00118] The cutting accessory assembly may be unique to complementary versions of the motor and the drivetrain so as to provide a set of handpieces configured to be selectively and interchangeably coupled with the battery and control module 21. With additional reference to FIG.

1, the powered surgical tool 20 is shown with a coupler 26 for attaching to the cutting accessory, such as a sagittal saw blade. The medical professional may use the sagittal saw blade for cutting bones, for example small bones of a hand or foot of a patient, ligaments or other tissue. Any device or accessory which is applied to the surgical site, whether it be a sagittal saw blade or drill bit, may generally be referred to as an energy applicator throughout. In other embodiments, the powered surgical tool 20 may be a rotary drill, reamer, wire driver, oscillating or reciprocating saw, ultrasonic device or photonic device. Likewise, the energy applicator may be a drill bit, bur, saw, reamer, grinding disc, ultrasonic cutting or catheterization tip, laser, etc. The type of tool used is not intended to limit the present invention. The motor may be a universal motor which may interchangeably receive more than one cutting accessory as described below. It is further appreciated that the set of handpieces may be interchangeably coupled with the battery and control module 21 providing for a pencil grip configuration (FIGS. 1-13), and the battery and control modules 221, 421 providing for apistol grip configuration (FIGS. 14-23 and 23-25). The powered surgical tool 20 of the present disclosure may be particularly well suited for orthopedic procedures involving the arm, hand, leg, foot, mandible, and skull, but other small bone orthopedic and soft tissues procedures are contemplated. FIG. 2 shows the battery and control module 21 with the handpiece removed. FIG. 3 shows a side view of the battery and control module 21.

[00119] Referring to FIGS. 4 and 5, the battery and control module 21 includes at least one battery 28, and a main controller 31 that is coupled to a printed circuit board assembly 33 as will be discussed in greater detail below. The main controller 31 is in communication with the battery 28, which may be part of a battery assembly 30, a motor control sensor 32, and a handswitch sensor 34, and further configured to be arranged in communication with the motor when the handpiece 24 is removably coupled with the battery and control module 21. The main controller 31 may also be in communication with memory device 95 (shown in FIG. 8). The battery and control module 21 may include a handswitch assembly 36 optionally coupled to the device housing 22 and configured to receive an input from a user to operate the powered surgical tool 20.

For example, the handswitch assembly 36 may be spring-loaded and include a handswitch magnet such that, when the handswitch assembly 36 is actuated, the handswitch magnet is moved towards a handswitch sensor 34. While the example is provided that the handswitch assembly 36 is coupled to the battery and control module 21, the handswitch assembly 36 may be detachable and attached to any portion of the battery and control module 21 and/or handpiece 24. Further, the handswitch assembly 36 may be part or attached to the handpiece 24.

[00120] The main controller 31 receives a signal from the handswitch sensor 34, and causes power to be drawn from at least one battery cell 28 to be supplied to the motor. The main controller 31 is configured to determine a rotational position of the rotor of the motor, and control the motor based on the rotary position of the rotor as sensed by the motor control sensor 32. In alternative implementations, one or more handswitch sensors 34 may not be included and the motor may be controlled through other means. An operating speed of the powered surgical tool 20 may be increased incrementally as the handswitch assembly 36 is actuated between a default position and fully engaged position. Additional features of the main controller 31, the handswitch assembly 36, and other electronic subcomponents of the powered surgical tool 20 may be disclosed in the aforementioned International Publication No. WO 2013/177423. The main controller 31 may be configured to regulate power drawn from the rechargeable module based on movement of the lever 66.

[00121] The main controller 31 may also receive a signal from a handswitch sensor 34.

[00122] In certain instances, the handswitch sensor 34 is further defined as two handswitch sensors. Hence, the controller may be configured to receive signals from both sensors and regulate power drawn from the rechargeable battery module based on the both of the sensor signals. Both the first handswitch sensor and the second handswitch sensor 34 both mounted to the same surface of the printed circuit board 87 or on opposite sides of the printed circuit board

87. The lever 66 may thus be configured to receive an input from a user to cause power to be drawn from the rechargeable battery module and supplied to the motor of the handpiece.

[00123] Referring now to FIG. 1, the first implementation of the powered surgical tool

20 is shown. The device housing 22 defines a recess 40 sized to removably receive the handpiece

24. More particularly, the device housing 22 includes a front surface 42 defining an opening 44 that extends proximally to define the recess 40. The recess 40 may be at least substantially cylindrical to be contoured to a hub 46 of the handpiece 24. The hub 46 of the handpiece 24 is disposed within the recess 40 to establish communication between the motor of the handpiece 24 and the battery and control module 21. Several subcomponents of the device housing 22 may be disposed within or adjacent to the recess 40 to releasably secure the handpiece 24 to the device housing 22 and establish the communication between the motor and the main controller 31. The subcomponents may include one or more motor pins 48 (shown in FIG. 4), or other terminal configuration, that provide the connection for the battery and control module 21 to the handpiece

24. Such subcomponents may also include a latch and sensors as discussed in greater detail below.

Some of such subcomponents are disclosed in the aforementioned International Publication No.

WO 2013/177423, the contents which have previously been incorporated by reference. The tool

20 may also include a light guide 63 for directing light from one or more light sources on the printed circuit board assembly to the user.

[00124] It should be noted that, while the module housing 22 of the battery and control module 21 receives the handpiece 24 in the instance of FIG. 1, in other instances, the handpiece

24 may be configured to receive a component of the battery and control module 21. For example, the handpiece 24 may define a recess sized to removably receive the module housing 22 of the battery and control module 21.

[00125] The device housing 22 may further define a recess for positioning of a latch assembly 52. The latch assembly 52 may include a locking member 54 and a biasing member.

[00126] As discussed previously, the handswitch assembly 36 may be coupled to the device housing 22. With reference to FIG. 4, the device housing 22 may define a mounting base

56. The mounting base 56 may be integral with the device housing. Furthermore, the device housing 22 and the integral mounting base 56 may both be formed from a plastic material. The mounting base 56 may define apertures 58 adjacent to and on each side of the handswitch recess

50. The handswitch assembly 36 may be partially seated within the handswitch recess 50 or channel.

[00127] The handswitch assembly 36 may be adjustable in length relative to the device housing 22. The handswitch assembly 36 may further include a pressing pin 60 and a receiving pin 62. Each of the pins 60, 62 extend through one of the apertures 58. The pressing pin 60, during assembly, is pressed into a bore defined by the receiving pin 62. Once the pins are pressed into each other, the receiving pin defines a pivot axis 64 and the pivot surface. The pressing pin 60 and the receiving pin 62 thus define a press-fit engagement with one another. The handswitch assembly

36 further includes a lever 66 pivotably coupled to the pivot surface of the receiving pin 62. The lever 66 may define apertures to receive the receiving pin such that the lever 66 pivots about the receiving pin 62. As the plastic housing defines a channel, the lever 66 is pivotable about the receiving pin 62 between a first fully depressed position and a second non-depressed position, and wherein the lever 66 is at least partially disposed within the handswitch recess 50 or channel in both the first fully depressed position and the second non-depressed position.

[00128] Refening to FIGS. 3 and 4, in certain instances, the device housing 22 defines a recess 68. The recess 68 is positioned adjacent the aperture 58, with the recess 68 including a flat surface 70, with the receiving pin 62 optionally including a head 72 and a shaft 74 extending from the head 72. The head 72 including a flat pin surface 76, the receiving pin 62 positioned within the aperture 58 such that the flat pin surface 76 of the head 72 engages the flat surface 70 of the recess

68. It is contemplated that the pressing pin may include similar features with respect to the head and shaft and flat surfaces, and the other of the apertures 58 may include a similar recess with a similar flat surface. The engagement of the pin flat surface 76 and the flat surface 70 of the recess

68 contact one another to prevent rotation of the receiving pin relative to the device housing 22.

[00129] With continued reference to FIG. 4, the handswitch assembly 36 may further include a biasing member, such as a torsion spring 78. The torsion spring 78 includes a coil 80, and two legs 82, with the legs 82 extending from opposite ends of the coil 80. The coil 80 is positioned to surround the pivot surface of the receiving pin 62. [00130] The lever 66 may further comprise a run-safe switch 84 slidably mounted to the lever 66, a switch magnet being mounted to the run-safe switch, a lever extension movably coupled to the lever 66. When the run/safe switch 84 is in the “run” position and the user presses the lever that magnet moves up and down. The hall sensor voltage of the handswitch sensor changes in response to the magnet being closer or further away from it. That voltage change is what is used to control speed. When the run/safe switch is in “safe” position, the magnet is moved forward, it’s almost as if the magnet is out of range. Therefore, ensuring that even if the user presses the lever, the handswitch sensors will not see a meaningful voltage change. So, the handpiece will not run.

[00131] Referring to FIGS. 5-7, the printed circuit board assembly 33 may include a board mount 86 and a rigid printed circuit board 87. While a single printed circuit board is shown in these figures, it is contemplated that alternative configurations could split the electrical components, such as the motor control sensors and the microcontroller and MOSFETs in two or more circuits, including two or more rigid circuit boards or a combination of rigid circuit boards and flexible circuit boards. The board mount 86 may include a set of protrusions 88 shaped to align with a plurality of notches 90 defined by the device housing 22. The set of protrusions 88 engages the set of notches 90 to prevent the board mount 86 from moving relative to the device housing 22 in a plurality of degrees of freedom, such as at least two degrees of freedom. Each of the protrusions 88 may further define a receptacle 92 to fix position of the motor control sensor 32 relative to the board mount 86. The motor control sensors 32 may be inserted within the receptacles

92. One or more motor control sensors 32 may also be mounted on the surface of the printed circuit board 87 instead of being mounted in the receptacle of the board mount 86. The one or more or motor control sensors may be implemented as analog hall-effect sensors. [00132] Furthermore with reference to FIG. 8, the board mount 86 may be secured to the device housing 22 using a plurality of mount fasteners 96. The mount fasteners 96 may extend through the board mount 86 and engage apertures of the device housing 22 to fix the position of the printed circuit board assembly 33 in an additional degree of freedom.

[00133] With reference to FIG. 10, the set of protrusions 88 may be positioned about an arcuate arrangement relative one another. The set of protrusions 88 may engage the set of notches 90 on the device housing 22 such that relative movement between printed circuit board assembly 33 and the device housing 22 is prevented in a plurality of degrees of freedom.

[00134] Referring to FIG. 4, the printed circuit assembly 33 is further secured in its position with the device housing 22 by a plurality of mounting feet 94 are located on the opposite side of the rigid printed circuit board 87 from the set of protrusions 88. The plurality of mounting feet 94 are positioned to engage an internal surface of the device housing 22 when the printed circuit board assembly 33 is inserted into the device housing 22.

[00135] The contemplated board mount arrangement provides for several advantages.

For instance, by coupling the board mount to the printed circuit board including the motor control sensors, the position of the motor control sensors may be tightly controlled. In addition, by the board mount only engaging one major side of the circuit board, the circuit board can expand during thermal cycling without compromising the resiliency of the device. Furthermore, by the board mount only engaging the face of the smaller circuit board, the larger circuit board is provided with additional flexibility and thus is resistant to breakage imparted by torque during use of the powered surgical tool.

[00136] As will be described in greater detail below, the motor of the handpiece 24 includes a plurality of magnets. With further reference to FIGS. 6-8 and 10, the aforementioned set of notches 90 may define a series of notch peaks 97 and notch valleys 98, wherein an innermost surface of the notch peak 97 is farther from magnets of the motor of the handpiece than an innermost surface of the notch valleys 98 when the handpiece 24 is inserted into the device housing

22. In this manner, because the protrusions 88 of the board mount 86 include the motor control sensors 32 and because the protrusions 88 of the board mount 86 are aligned with the notch valleys

98, the motor control sensors 32 are closer to the magnets of the handpiece than if the motor control sensors were aligned with the notch peaks 97.

[00137] Referring to FIG. 4, the device housing 22 is formed to include a vent opening

100 for venting of the void space. For example, the void space may be vented during sterilization.

A cap 101 is coupled to the device housing 22 to cover the vent opening 100. A pressure relief valve 102 is at least partially inserted into the vent opening 100 for facilitating venting of the void space during sterilization. The cap 101 covers the pressure relief valve 102 and may protect the pressure relief valve 102, e.g. from being damaged/hit, by jets from washer during washing. The pressure relief valve 102 may be configured to open at a predetermined pressure. When the valve opens, the is clearance between the pressure relief valve 102 and the cap 101. The cap 101 may include one or more cuts adjacent or proximal to the position of the pressure relief valve 102. The cuts allow the gas/air to be released.

[00138] Referring now to FIGS. 9-13, the battery and control module 21 includes at least three motor pins 48 spaced apart from one another to define an array of motor pins 48 that extends through the housing and out of the void for establishing an electrical connection between the circuit board and the electric motor of the handpiece 24. It is contemplated that the battery and control module 21 includes at least six motor pins 48, with a plurality of the motor pins 48 being positioned equidistant from a center of the array. A hermetically-sealed housing-terminal interface is defined by the device housing 22 and the at least three motor pins 48. The battery and control module 21 may further include a plurality of pin wires 104, such as at least three wires, with of the wires 104 including a wire terminal 106 connected to a first wire end of the at least three pin wires

104 and the other end of the pin wire 104 connected to the rigid printed circuit board 87 via suitable connection methods, such as board-wire terminals.

[00139] Each of the wire terminals 106 including a first end portion 108 and a second end portion 110 opposite the first end portion, the first end portion 108 connected to one of the at least three wires 104, and the second end portion 110 shaped to electrically engage one of the motor pins 48. More particularly, the first end portion 108 of the wire terminals 106 may define a plurality of arms 118, the arms 118 crimped to engage the first wire end. The second end portion

110 of the wire terminals 106 may define a cylindrical void 120, the cylindrical void 120 sized to being disposed about the motor pins 48. The second end portion 110 may be soldered to the motor pins 48.

[00140] The battery and control module 21 further includes a routing feature 112 disposed within the void of the housing and disposed about the at least three motor pins 48, the routing feature 112 defining a plurality of channels 114. The routing feature 112 may be integral with the device housing 22 or may be a separate component that is affixed to the device housing

22. Each of the wire terminals 106 are positioned within one of the channels 114 of the routing feature 112. The plurality of channels 114 may include a first channel 114 and a second channel

114’. The plurality of channels 114 to secure the different radial positions of the wire terminals

106 about the routing feature 112. The first channel 114 has a first depth and the second channel

114’ includes a second depth, the first depth being different from the second depth. This allows the pin wires 104 and their respective wire terminals 106 to be offset from another, in this case, axially offset. The described implementation provides compact routing of the pin wires 104 in the axial direction which contributes to a smaller device housing 22. Furthermore, the implementation ensures that the wires are routed in a manner that minimizes stress across wire bends to ensure maximum reliability of the battery and control module.

[00141] In some cases, the routing feature 112 includes a rim 116 disposed about the circumference of the routing feature 112 and surrounding the motor pins 48. The rim 116 may define the plurality of channels 114. In instances where the routing feature 112 includes the rim

116, the first end portion 108 of each wire terminal 106 is disposed inside the rim 116 and the second end portion 110 of the wire terminal 106 is disposed outside the rim 116. The wire terminal

106 defines a bend of at least 70 degrees, and wherein the first end portion 108 of the wire terminal

106 is separated from the second end portion 110 of the wire terminal 106 by the bend.

[00142] As can be seen in FIG. 9, wherein at least one motor pin 48 of the at least three motor pins 48 define a longitudinal axis and the circuit board 87 defines a longitudinal axis, wherein the longitudinal axis of the at least one motor pin 48 is parallel to the longitudinal axis of the circuit board 87.

[00143] With reference to FIG. 22, a cross-section of the powered surgical tool 20 is provided. As can be seen, the handpiece 24 is fully inserted into the battery and control module

21. The handpiece 24 includes a motor 122, such as a brushless motor. The handpiece 24 may be configured to generate a magnetic field. For example, the motor 122 may include a plurality of motor magnets 124 surrounding a motor shaft 126 or a rotor. For instance, the motor 122 may include a first rotor magnet 123 and a second rotor magnet 125 forming a rotor magnet pair 123,

125. The first rotor magnet pair 123 and the second rotor magnet pair 125 may be configured to generate a magnetic field to cause rotation of the motor 122. The motor 122 includes a lamination element 128 or stack that surrounds a portion of the motor magnets 124. A portion of the plurality of motor magnets 124 extend axially beyond the lamination element 128. This extension of the plurality of magnets beyond the lamination element 128 allows for the magnetic field of the plurality of motor magnets 124 to be detected.

[00144] In other instances, the motor 122 may include any suitable number of rotor magnets for forming any suitable number of corresponding rotor magnet pairs. For example, in instances where the motor 122 is a three-phase motor, the motor 122 may include six rotor magnets forming three rotor magnet pairs. In such instances, the rotor magnets may be disposed at any location along the motor 122, such as equidistantly along the motor 122. In an instance where the motor 122 includes three rotor magnet pairs, the rotor magnet pairs may be disposed such that a first magnet of a rotor magnet pair is disposed 120 degrees from a first magnet of each of the other rotor magnet pairs.

[00145] The motor 122 may further include a handpiece circuit 130 that optionally includes a memory device and a data terminal, the data terminal in communication with the handpiece circuit 130 and memory device. The data terminal is configured to connect with a data pin 48’ of the battery and control module 21 when the handpiece 24 is received in the recess 40.

Thus, the data terminal 133 in electrical communication with the memory device. It is contemplated that the term memory device may be substituted with a microcontroller that includes onboard memory storage. Alternatively, the handpiece circuit may include a separate processor and a dedicated memory device in communication with the separate processor.

[00146] As described with reference to FIGS. 5-6 and 22, the battery and control module

21 may include one or more motor control sensors 32 which may define a set of motor control sensors 32. For example, the motor control sensor 32 of the battery and control module 21, shown in FIGS. 5-6 and 22, may be one or more analog hall effect sensors 32 that are coupled to the control module controller 31 and are configured to sense a magnetic field. In the instance of FIG.

22, the battery and control module 21 includes a first, second, and third analog hall effect sensor

32(1), 32(2), 32(3). The one or more motor control sensors 32 may be coupled to the printed circuit board assembly 33 by being mounted to a surface of the rigid printed circuit board 87, as shown in FIG. 5.

[00147] Additionally, as shown in FIGS. 5-6 and 22, the battery and control module 21 may further include one or more wake-up sensors 134 which may define a set of wake-up sensors

134. The set of wake-up sensors 134 may be defined as at least three wake-up sensors 134. The one or more wake-up sensors 134 may be positioned distally of the motor control sensors 32 on the rigid printed circuit board 87 and may be fixed on the board mount 86 in a manner similar to as described with respect to the motor control sensors 32. Additionally, or alternatively, the one or more wake-up sensors 134 may be mounted directly to the surface of the printed circuit board

87. The set of three or more wake-up sensors may be positioned to partially surround the handpiece

24 when the handpiece 24 is inserted in the battery and control module 21 such that the three or more wake-up sensors radially surround the plurality of motor magnets 124. This arrangement of three or more wake-up sensors 134 provide for enhanced accuracy as it accounts for the possibility that one or more of the wake-up sensors 134 may be aligned with a gap between the plurality of motor magnets. Three wake-up sensors 134 essentially guarantees that at least one of the wakeup sensors will detect a strong magnetic field no matter the rotation of the motor 122.

[00148] As will be described in greater detail below, the battery and control module 21 may be configured to couple with the handpiece 24, a charging module 1100 (shown in FIGS. 36-

37), or a programming fixture 1200 (shown in FIGS. 42 and 43). In such instances, the one or more wake-up sensors 134 may be positioned to partially surround the handpiece 24, a component of the charging module 1100, or a component of the programming fixture 1200 when one of the handpiece 24, the charging module 1100, or the programming fixture 1200 is coupled with the battery and control module 21. This arrangement of the one or more wake-up sensors 134 provides for enhanced accuracy by ensuring that the one or more wake-up sensors 134 sense a magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled with the module housing 22, a magnetic field generated by a charger module magnet M (shown in FIG. 37) when the charging module 1100 is coupled with the module housing 22, or a magnetic field generated by the programming fixture magnet 1204 (shown in FIGS. 42 and 43) when the programming fixture 1200 is coupled with the module housing 22. In one such example, the wakeup sensors 134 may be positioned to surround the plurality of motor magnets 124 when the handpiece 24 is coupled with the battery and control module 21.

[00149] The set of motor control sensors 32 may be aligned with one another in a direction perpendicular to the axis of the motor 122. Similarly, the set of wake-up sensors 134 may be aligned with one another in a direction perpendicular to the to the axis of the motor 122. The set of wake-up sensors 134 may be arranged parallel to the set of motor control sensors 32.

[00150] The control module controller 31 may include any suitable number of motor control sensors 32 for sensing the magnetic field generated by the motor 122. As previously stated, the motor 122 may any suitable number of rotor magnets for forming any suitable number of corresponding rotor magnet pairs. For example, in instances where the motor 122 is a three-phase motor, the motor 122 may include six rotor magnets forming three rotor magnet pairs. In such an instance, the control module controller 31 may include three motor control sensors 32 for sensing the magnetic field generated by each of the rotor magnet pairs. [00151] The control module controller 31 may include any suitable number of wake-up sensors 134. For example, the control module controller 31 may include a set of three or more wake-up sensors 134. The control module controller 31 may include any suitable number of wake- up sensors 134 to account for the possibility that one or more of the digital hall effect sensors 134 are not aligned with the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204.

[00152] As will described in greater detail below, the one or more wake-up sensors 134 may be configured to provide a sensor signal indicative of presence of the handpiece 24 being fully received in the battery and control module 21. With further reference to FIG. 22, it is contemplated that the wake-up sensor 134 is aligned axially with at least a portion of one of the plurality of motor magnets 124 when the handpiece 24 is received in the recess 40. More particularly, the one or more wake-up sensors 134 may be aligned with the portion of the plurality of motor magnets 124 that extend beyond the lamination element 128.

[00153] As will be explained in greater detail below, the main controller 31 may be configured to regulate power supplied to the one or more motor pins 48 of the battery and control module 21 based on the sensor signal provided by the wake-up sensor 134. More specifically, the main controller 31 may provide power to one or more motor pins 48 based on the sensor signal provided by the wake-up sensor 134. In such an implementation, the main controller 31 is configured to energize one or more motor terminals based on the output of the one or more wake- up sensors 134 and the main controller 31 is configured to commutate the motor 122 based on the one or more motor control sensors 32.

[00154] However, it is also contemplated that the wake-up sensors 134 could be omitted and the main controller 31 may be configured to regulate power supplied to the one or more motor pins 48 based on the sensor signal provided by the motor control sensors 32. In this case, the main controller 31 would both commutate the motor 122 based on the output of the motor control sensors

32 and wake-up the battery and control module 21 based on the output of the motor control sensors

32.

[00155] The one or more wake-up sensors 134 may be implemented as digital hall effect sensors and the one or more motor control sensors 32 may be implemented as analog hall effect sensors. Herein, the wake-up sensors 134 may be referred to as digital hall effect sensors 134 and the motor control sensors 32 may be referred to as analog hall effect sensors 32. Digital hall effect sensors are ideal for wake-up functions as they have a lower current draw (less than 5 uA each) than the analog hall effect sensors (greater than 5 mA each). Analog hall effect sensors are ideal for the motor control function as they possess a higher acquisition rate than the digital hall effect sensors.

[00156] By regulating power, the main controller 31 may be implemented to transition or switch between a sleep state and an active state based on the sensor signal from the wake-up sensors 134.

[00157] In the sleep state, the main controller 31 may stop performing certain functions, such as powering the motor 122 of the handpiece 24. In certain implementations, the controller 31 may also stop powering the motor control sensors 32 when in the sleep state. The main controller

31 may still drain some energy from the battery assembly 30 while in the sleep state such that the main controller 31 remains able to power the wake-up sensors 134. The main controller 31 may also still power one or more of the motor pins 48 while in the sleep state, specifically referred to as a data pin 48’. The data pin 48’ may be energized while the main controller 31 is in the sleep state. The data pin 48’ may also be energized while in the active state. While the main controller 31 is in the sleep state, the powered surgical tool has current draw less than 5 mA from the battery assembly 30.

[00158] As mentioned above, in an alternative implementation, the main controller 31 is configured to cause the main controller 31 to transition from the sleep state to the active state based on the sensor signal of the wake-up sensor in one implementation.

[00159] A switching module 159 including a plurality of MOSFETs 159 may also be coupled to the printed circuit board 87. Although the disclosure contemplates MOSFETs as the switching components that are coupled to the printed circuit board 87, other suitable transistors or switching components may be used. The switching module 159 may be used in controlling the direction of operation of the motor of the handpiece 24, for example, in a forward direction or in a reverse direction.

[00160] FIGS. 14—21 depict another implementation of the powered surgical tool 220 shown in a pistol configuration. A battery and control module 221 of the pistol configuration includes a barrel 200 and a handle 201. The handle 201 extends downwardly from the barrel 200.

The handpiece 224 may be inserted to a recess 240 of the barrel 200. Four battery cells 228 are disposed in the handle 201 which may be surrounded by an insulation layer to form a battery assembly 230. Battery and control module 221 may have has two triggers 202, 203 or switches that are spring-loaded. Both triggers 202, 203 extend forward from the distally directed portion of the handle 201. The practitioner may actuate triggers 202, 203 to control the operation of the tool unit. The triggers 202, 203 may each include a magnet which gets moved when the triggers 202,

203 are actuated by the user as discussed in greater detail below. The battery and control module

221 may include a pressure relief valve and a cap that function substantially similar to the pressure relief valve and cap discussed with respect to the pencil configuration. [00161] Similar to the battery control module 21, the battery and control module 221 includes at least one battery 28 in a battery assembly 230, and a main controller 231 that is coupled to a printed circuit board assembly 233 as will be discussed in greater detail below. The main controller 231 is in communication with the battery 228, which may be part of a battery assembly

230, a motor control sensor 232, and trigger sensors 235, and further configured to be arranged in communication with the handpiece when the handpiece 224 is removably coupled with the battery and control module 221. The main controller 231 may also be in communication with memory device 295 on the board assembly, and both may be positioned on the first printed circuit board

249.

[00162] The main controller 231 may receive a signal from the trigger sensor 235, and the main controller 231 may provide for power to be drawn from at least one battery cell 228 to be supplied to the motor of the handpiece 224. During operation, the main controller 231 is configured to determine a rotational position of the motor, and control the motor based on the rotary position of the motor as sensed by the one or more motor control sensors 232. The device housing 222 of the battery and control module 221 defines a recess 240 sized to removably receive the handpiece 224. More particularly, the device housing 222 includes a front surface 242 defining an opening 244 that extends proximally to define the recess 240. The recess 240 may be at least substantially cylindrical to be contoured to the handpiece 224. Alternatively, the recess may be shaped in other ways, such as that which is described with expect to battery and control module

421.

[00163] With reference to FIGS. 15-18, a first printed circuit board 249, a second printed circuit board 251, and a fourth printed circuit board 255 may be disposed in the barrel 200 while a third printed circuit board 253 is disposed in the handle 201. As depicted, the first printed circuit board 249 is interconnected with the second printed circuit board 251 by a board header 257, the first printed circuit board 249 is connected to the third printed circuit board 25 by a flexible circuit, and the first printed circuit board 249 is connected to the fourth printed circuit board 255 by a flexible circuit.

[00164] A plurality of motor control sensors 232 may be coupled to the second printed circuit board 251. The motor control sensors 232 may be Hall-effect sensors and may be similar to the previously described motor control sensors 32. A switching module 259 including a plurality of MOSFETs 270 may also be coupled to the second printed circuit board 251. Although the disclosure contemplates MOSFETs as the switching components that are coupled to the second printed circuit board 251, other suitable transistors or switching components may be used. The switching module 259 may be used in controlling the direction of operation of the motor of the handpiece 224, for example, in a forward direction or in a reverse direction.

[00165] The fourth printed circuit board 255 may include a plurality of motor pins 248.

The plurality of motor pins 248 may be soldered to the fourth printed circuit board 255. One or more of the motor pins 248 may be connected to the switching module 259. The fourth printed circuit board 255 may also include one or more light sources 261, such as LEDs. The light source(s) 261 may be controlled by the main controller 231 The battery and control module 221 may include a light guide 263 aligned with the one or more light sources 261 of the third printed circuit board. The motor pins 248 may have form factors other than a pin, and may be more generally referred to as motor terminals.

[00166] The trigger sensors 235 may be disposed on the third printed circuit board 253.

The trigger sensors 235 may be Hall-effect sensors and may be similar to the previously described handswitch sensors 34. The third printed circuit board 253 is disposed inside the handle 201. In particular, the third printed circuit board 253 is disposed in close proximity to the triggers 202, 203 so that the plurality of trigger sensors 235 may sense a state of the triggers 202, 203, such as when the triggers 202, 203 have been actuated by the user.

[00167] The first printed circuit board 249 and the second printed circuit board 251 may each be rigid boards, with the second printed circuit board 251 and the first printed circuit board

249 being arranged in a stacked configuration, a plurality of motor control sensors 232 connected to the second printed circuit board 251. The main controller 231 may be mounted to the second printed circuit board 251. The second printed circuit board 251 may also include a plurality of wake-up sensors 334, which function as described with respect to battery and control module 21.

The first printed circuit board 249 has greater surface area than the second printed circuit board

251. The first printed circuit boaid 249 is also farther from handpiece and the motor than the second printed circuit board 251 when the handpiece 224 is coupled with the battery and control module

221.

[00168] Referring to FIG. 19, the device housing 222 may include one or more mounting posts 265 to facilitate positioning of the third printed circuit board 253 within the device housing

222. The third printed circuit board 253 abuts the mounting post 256 such that an axial position of the third printed circuit board 253 is controlled within the battery and control module 221. The axial positioning of the third printed circuit board 253 is important as it includes a plurality of light sources and these light sources need to be aligned with the light guide 263. The board mount 286 indirectly ensures alignment of the third printed circuit board in the housing by locking all degrees of freedom of the first and second printed circuit boards. The fasteners that engage the third printed circuit board only fix one degree of freedom. [00169] The device housing 222 may further include a plurality of support ribs 267 and the tool may further include a board mount 286. The board mount 286 may include a plurality of wings 269 for engaging the support ribs 267.

[00170] Referring to FIGS 16 and 17, the second printed circuit board 251 includes two major sides 271, wherein the board mount 286 contacts only one of the two major sides 271. The second printed circuit board 251 includes at least four minor sides 273, wherein the board mount

286 contacts two or fewer minor sides 273. In some configurations, the second printed circuit board 251 includes at least four minor sides 273, wherein the board mount 286 contacts no minor sides 273. This configuration may be advantageous in that the printed circuit board 87 may expand during exposure to elevated temperatures in the latitudinal direction without being constrained by the board mount.

[00171] The board mount 286 comprises a body portion 275 and a flange 277, the flange

277 defining a bore for insertion of a fastener, the flange 277 extending perpendicularly from the body portion 275. The flange 277 is configured to partially secure the position of the fourth printed circuit board 255. Together, the flange 277 and the mounting posts 265 fix the position of the fourth printed circuit board 255.

[00172] The battery and control module 221 further comprises a plurality of spacers

279, the plurality of spacers 279 disposed between the first printed circuit board 249 and the second printed circuit board 251. Each of the plurality of spacers 279 define a bore, and a plurality of board fasteners 281 are arranged to extend through the second printed circuit board 251, the bore of at least one of the plurality of spacers 279, and the first printed circuit board 249. The board mount 286 may define a plurality of mount bores, each of the plurality of mount bores include a threaded insert 283. [00173] Similar to the battery and control module 21, battery and control module 221 may include a set of protrusions 288, and the device housing defines the other of the set of notches

290, wherein set of protrusions 288 engages the set of notches 290 to prevent the board mount 286 from moving relative to the device housing 222 in a plurality of degrees of freedom. The set of notches 290 and/or set of protrusions 288 are positioned in an arcuate arrangement relative to one another. Each of the set of protrusions 288 define a receptacle 292 for securing one of the plurality of motor control sensors 232. As described above with respect to notches 90, the notches 290 defining a series of notch peaks 297 and notch valleys 298, wherein an innermost surface of the notch peak 297 is farther from magnets of the motor than an innermost surface of the notch valleys

298.

[00174] The first printed circuit board 249 may be longer and wider than the second printed circuit board 251 and thus, has a larger surface area than the second printed circuit board

251. For example, the surface area of the first printed circuit board 249 may be at least 30, 40, or

50 % more than the second printed circuit board 251. The first printed circuit board 249 and the second printed circuit board 251 are arranged in a stacked configuration which helps to minimize the footprint of the powered surgical tool 220, in particular, a small footprint of the battery and control module. The first printed circuit board 249 may have a first longitudinal axis and the second printed circuit board 251 may have a second longitudinal axis, with the first and second longitudinal axes being in alignment. The first and second printed circuit board 249, 251 may each have rigid back layers and are thus rigid printed circuit boards.

[00175] Since the first printed circuit board 249 is longer than the second printed circuit board 251, a distal end of the first printed circuit board 249 extends beyond a distal end of the second printed circuit board 251. Furthermore, the second printed circuit board 251 may be positioned such that it does not extend beyond the first printed circuit board 249 in any direction beyond being spaced apart from the first circuit board as described above.

[00176] FIGS. 23-25 depict another implementation of the powered surgical tool 420 shown in an open-top pistol configuration. A battery and control module 421 of the pistol configuration includes a receiver surface 404 and a handle 401. The handle 401 extends downwardly from the receiver surface 404. The handpiece 424 may be inserted to a receiver surface 404. The battery and control module 421 may include any of the features described with respect to battery and control modules 21 and 221. However, the battery and control module 421 provides for an open-top configuration with respect to the handpiece 424 that provides for certain ergonomic and construction advantages.

[00177] Refening to FIGS. 25 and 26, the handpiece 424 may include a rail 405 and the

404 of the battery and control module 421 defines a slot 406. The rail 405 and the slot 406 being configured such that the rail is slidable within the slot 406 to allow coupling between the handpiece

424 and the battery and control module 421. The opposite arrangement is also contemplated with the slot defined by the handpiece and the rail defined by the battery and control module, as are other arrangements beyond the slot-rail arrangement. The battery and control module 421 may further include a latch assembly with a locking member in a construction similar to as described above with respect to battery and control module 21. The handpiece 424 may include a receiver surface 404 similar to the handpiece 24.

[00178] As described above with respect to battery and control module 21, the battery and control module 421 may feature a device housing 422 the defines a void space that receives a rechargeable battery module disposed in that void space. The battery and control module 21 may further include a printed circuit board including a controller configured to regulate power drawn from the rechargeable battery module based on user input. The printed circuit board may further include a motor sensor configured to output a motor sensor signal representative of a state of the motor of the handpiece 424.

[00179] The battery and control module 421 may further include motor pins 448 at that extend through the device housing for establishing an electrical connection between the printed circuit board and the motor of the handpiece 424. As described above, the motor pins 448 can take other form factors, such as other shapes of electrical terminals. The battery and control module

421 may include a safety vent as described above with respect to battery and control module 21.

The battery and control module 421 may also include one or more motor control sensors as described above with respect to battery and control module 221, which may be implemented as hall-effect sensors.

[00180] As will be described in greater detail below, the handpiece 424 may take the form of a pin or wire driver that defines a cannula 408. This cannula 408 allows fixation pins and fixation wires to be pass through the proximal end of the handpiece 424, extending through the body of the handpiece, and extend out through the distal end of the handpiece. The handpiece 424 may include the features of U.S. Patent Pub. 20210220035, which is hereby incorporated by reference in its entirety. The battery and control module 421 may be free from cannulation, let allow a wire or pin to enter the proximal end of the handpiece. 424. The proximal end of the battery and control module 421 may be shaped to allow the wire or pin to enter the handpiece 424 from the proximal end of the tool 420. For example, the control module 421 may define a groove 410 to accommodate the wire or pin as the wire or pin enters the proximal end of the handpiece 424.

Because the battery and control module is free of cannulation, the battery and control module 421 may be free of additional welding locations in the device housing 422 to defined such cannulation. The avoidance of these additional welding location simplifies the design of the battery and control module 421, and eliminates a location of possible ingress of sterilants during the sterilization process.

[00181] Referring to FIG. 24, the powered surgical tool 420 may be constructed such that a distal end face 411 of the handpiece is exposed when the handpiece 424 is coupled with the battery and control module 421. In addition, a portion of the proximal end face 412 of the handpiece 424 is exposed when the handpiece 424 is coupled with the battery and control module

421. Because the distal end face of the handpiece 424 and/or the proximal end face is exposed, the battery and control module 421 may be relatively smaller as the battery and control module

421 no longer features plastic that surrounds the handpiece 424 in a circumferential arrangement.

Furthermore, by coupling the handpiece 424 to the battery and control module 421 using the slot and rail arrangement, the battery and control module 421 no longer features a cylindrical profile that leads to a relatively larger device. . This in turn also allows for the diameter of the motor to increase without becoming too large for the user. The increased diameter allows for a reduced length of the motor, thus reducing the size of the tool.

[00182] Referring to FIGS. 26-29, the handpiece 424 features a motor 522 featuring motor magnets 524 and a motor shaft 526. The motor 522 may include a lamination element 228 surrounding the motor shaft 526. The handpiece 424 may further include a handpiece circuit 530, such as a rigid circuit board that includes a handpiece memory 532 and conductive terminals to receive the motor pins, one of which being a data terminal 533. The motor shaft 526 may define a cannula 536. The handpiece 424 may further include a gearbox 538 for altering an output parameter of the motor shaft output to the tool coupler, such as the speed, torque or direction of the output to the tool coupler. The surgical handpiece 424 may define an axis and the cannula 536 may surround the axis.

[00183] Referring to FIG. 29, the motor shaft 526 or rotor may define an axis. The rigid circuit board 530 may be defined as a rigid circuit board including a controller. The rigid circuit board 530 may be oriented perpendicular to the axis of the rotor. The rigid circuit board 530 may also be cannulated via cannulation aperture 540. The cannulation aperture 540 may be coaxial with the cannula 536 The plurality of terminals, including data terminal 533, may be soldered to the rigid circuit board, and may be shaped to engage the motor pins 448 when the handpiece 424 is coupled with the battery and control module 421. This arrangement of the rigid circuit board 530 may lead to a relatively shorter handpiece 424, which allows the tool 420 to be relatively shorter and more compact than designs where the circuit board is oriented parallel to the axis of the motor shaft.

[00184] Referring to FIGS. 30 and 31, an alternative handpiece 624 is described. The handpiece 624 features a motor 722 featuring motor magnets 724 and a motor shaft 726. The motor

722 may include a lamination element 728 surrounding the motor shaft 726. The handpiece 624 may further include a handpiece circuit 730 that includes a handpiece memory 732 and conductive terminals to receive the motor pins, one of which being a data terminal 733. The other motor pins may function as power terminals, and may operate at higher voltages than the data terminal. The handpiece 624 may further include a gearbox 738 for altering an output parameter of the motor shaft output to the tool coupler, such as the speed, torque or direction of the output to the tool coupler.

[00185] The handpiece circuit 730 may be defined as a rigid circuit board including a controller. The controller may be integrated with the memory device 732, and is not shown separately. The handpiece circuit 730 may be oriented perpendicular to the axis of the motor shaft

726. The plurality of terminals, including data terminal 733, may be soldered to the rigid circuit board, and may be shaped to engage the motor pins 248 when the handpiece 624 is coupled with the battery and control module 221. This arrangement of the handpiece circuit 730 may lead to a relatively shorter handpiece 624, which allows the tool 220 to be relatively shorter and more compact. This handpiece may also be coupled with other control modules, such as control module

21 or control module 421.

[00186] Referring to FIGS. 32 and 33, an alternative handpiece 824 is described. The handpiece 824 features a motor 822 featuring motor magnets 924 and a motor shaft 926. The motor

922 may include a lamination element 928 surrounding the motor shaft 926. The handpiece 824 may further include a handpiece circuit 930 that includes a handpiece memory 932 and conductive terminals to receive the motor pins, one of which being a data terminal 933. The handpiece 824 may further include a gearbox 938 for altering an output parameter of the motor shaft output to the tool coupler 826, such as the speed, torque or direction of the output to the tool coupler 826.

[00187] The handpiece circuit 930 may be defined as a flex-rigid board that includes a flexible portion 942 and a rigid portion 944. The rigid portion 944 may be oriented parallel to the axis of the motor shaft 926. The plurality of terminals, including data terminal 933, may be soldered to the flexible portion 942, and may be shaped to engage the motor pins 248 when the handpiece 824 is coupled with the battery and control module 221. This particular arrangement of the rigid portion and the flexible portion advantageously provides for a compact design, while also providing room for the electrical components of in the handpiece, including, but not limited to the controller and memory device of the handpiece. The controller and memory device may be integrated into a single unit. In either case, these electrical components may be onboard the rigid portion of the circuit board. It is also contemplated that this handpiece may be configured to operate with battery and control module 421, as all described handpieces in this disclosure are.

[00188] The pins 48 of the battery and control module 21 may establish an electrical connection between the control module controller 31 and a device coupled with the battery and control module 21. Two instances of an example pin 48 are shown in FIGS. 34 and 35.

[00189] A first instance of a pin 48 for establishing an electrical connection between the control module controller 31 and a device coupled with the battery and control module 21 is shown in FIG. 34. As shown, the pin 48 includes a first end 1050 and a second end 1052. Either the first or second end 1050, 1052 may be configured to electrically connect with the control module controller 31 and either the first or second end 1050, 1052 may be configured to electrically connect with electrical components of a device coupled with the battery and control module 21, such as the handpiece 24. Additionally, because the pin 48 of FIG. 34 is geometrically symmetrical, the pin 48 is unable to be loaded into an injection mold incorrectly when the pin 48 is injection molded to the module housing 22 of the battery and control module 21. Furthermore, the pin 48 includes abutments 1054 defining a groove 1056. The abutments 1054 interact with the module housing 22 to provide a seal configured to prevent steam and liquid from entering into the battery and control module 21. During the process of injection molding the pins 48 to the module housing 22, plastic flows into the groove 1056 to affix the pins 1048 to the module housing 22.

The abutments 1054 are also configured to aid in securing the pin 48 to the battery and control module 21 once the pin 48 is injection molded to the battery and control module 21.

[00190] A second instance of a pin 48 for establishing an electrical connection between the control module controller 31 and a device coupled with the battery and control module 21 is shown in FIG. 35. As shown, the pin 48 includes a first end 1058 and a second end 1060. The first end 1058 may be configured to electrically connect with the control module controller 31 and the second end 1060 may be configured to electrically connect with electrical components of a device coupled with the battery and control module 21, such as the handpiece 24. Additionally, the pin 48 includes a half groove 1062 defined by an abutment 1064. The half groove 1062 is configured to receive an O-ring such that the O-ring is proximate to the abutment 1064. The Oring is configured to be sandwiched between against the abutment 64 and the module housing 22 of the battery and control module 21 to provide a seal configured to prevent steam and liquid from entering into the battery and control module 21. Furthermore, the pin 48 includes a barb 1065 configured to aid in securing the pin 48 to the battery and control module 21, while providing a seal configured to prevent steam and liquid from entering into the battery and control module 21.

[00191] Various aspects of the powered surgical tool, including various aspects of the surgical handpiece and various aspects of the battery and control module, are described in

PCT/IB2022/057637, which is hereby incorporated by reference in its entirety. Thus, any of the described features of the battery and control module or surgical handpiece described therein are expressly contemplated in conjunction with one or more features described in the subject application.

[00192] The module housing 22 of the battery and control module 21 may be configured to be received by a charging module 1100. In the instance of FIG. 36, the charging module 1100 includes a charging adapter 1102, and the module housing 22 of the battery and control module 21 couples with the charging module 1100 via a charging adapter 1102. As shown in FIG. 36, the recess 40 of the module housing 22 receives the charging adapter 1102 and, as indicated by the dotted arrow, the rechargeable battery module 28 receives charging power from the charging module 1100. [00193] The charging module 1100 is further shown in FIG. 37. As shown in FIG. 37, the charging module 1100 may include a recess 1104. The charging module 1100 may be configured to provide charging power to devices received by the recess 1104. For example, a rechargeable battery may be received by the recess 1104 and the rechargeable battery may be configured to receive charging power from the charging module 1100 in response to the rechargeable battery contacting the charging module 1100. The charging module 1100 may include any suitable number of recesses 1104 arranged in any suitable manner. For example, in

FIG. 37, the charging module 1100 includes six recesses 1104. The six recesses 1104 are arranged in a two-row by three-column configuration with each row including three recesses 1104 arranged along a direction of a first charger axis AX1 and with each column including two recesses 1104 arranged along a direction of a second charger axis AX2 perpendicular to the first charger axis

AX1.

[00194] The charging adapter 1102 is configured alter the form factor of the charging module 1100. For example, the charging adapter 1102 is configured to be received by the charging module 1100 and coupled with devices not shaped to be received by the recess 1104, allowing the charging module 1100 to provide charging power to such devices. For example, referring to FIG.

36, the powered surgical tool 20 is not shaped to be received by the recess 1104. The charging adapter 1102 is configured to be received by the charging module 1100 and coupled with the module housing 22 such that the charging module 1100 may provide charging power to the rechargeable battery module 28 of the powered surgical tool 20 via the charging adapter 1102.

Specifically, as shown in FIG. 37, the charging adapter 1102 includes a charger protrusion 1108 configured to be received by the recess 1104 of the charging module 1100 and a module protrusion

1110 configured to be received by a module housing 22 of a battery and control module 21. The module protrusion 1110 is received by the module housing 22 to allow the charging module 1100 to provide power to the rechargeable battery module 28 via the charging adapter 1102.

[00195] Additionally, the charging adapter 1102 alters a form factor of the charging module 1100 such that devices coupled with the charging adapter 1102 extend along a direction of the module protrusions 1110. For example, as shown in FIG. 37, the recesses 1104 include a surface 1106 facing a surface direction D1. In instances where the charging adapter 1102 is not received by the charging module 1100, devices received by the recesses 1104 of the charging module 1100 extend along the surface direction D1. As shown in FIG. 37, the module protrusions

1110 extend along a protrusion direction D2 different than the surface direction D1. In instances where the charging adapter 1102 is received by the charging module 1100, devices coupled with charging adapter 1102 via the module protrusions 1110 extend along the protrusion direction D2.

In this way, in instances where multiple devices are coupled with charging adapter 1102 via the module protrusions 1110, the multiple devices may be aligned for ease of access by a user.

[00196] The charging adapter 1102 may be configured to couple with any implementation of the powered surgical tool described herein. For example, the charging adapter

1102 in FIG. 36 is coupled with a powered surgical tool of a pencil grip type, powered surgical tool 20, as well as a powered surgical tool of a pistol grip type, powered surgical tool 220.

Specifically, the charging adapter 1102 is configured to couple with the module housing 22 of the battery and control module 21 and with the module housing 222 of the battery and control module

221. In each implementation, the module housing 22, 222 of the corresponding battery and control module 21, 221 couples with the charging module 1100 via the charging adapter 1102 and the corresponding rechargeable battery module 28, 228 receives charging power from the charging module 1100. In other instances, the charging module 1100 may be configured to couple with any other implementation of the powered surgical tool, such as powered surgical tool 420.

[00197] The charging adapter 1102 may include components that allow the charging adapter 1102 to couple with various implementations of the powered surgical tool. Referring to

FIG. 38, the module protrusion 1110 may include a first portion 1112 shaped to be received by the module housing 22 of the powered surgical tool 20, and a second portion 1114 shaped to be received by the module housing 222 of the powered surgical tool 220. Referring to FIG. 36, the first portion 1112 is shown receiving the module housing 22 of the powered surgical tool 20 and the second portion 1114 is shown receiving the module housing 222 of the powered surgical tool

220. The recess 40 of the module housing 22 (shown in FIG. 1) may include a first radius and the recess 240 of the module housing 222 (shown in FIG. 15) may include a second radius different than the first radius. The first portion 1112 may include a cylindrical shape sized to be received by the recess 40 of the module housing 22 and the second portion 1114 may include a cylindrical shape sized to be received by the recess 240 of the module housing 222.

[00198] The charging adapter 1102 may also include components to ensure proper reception of the module protrusion 1110 by various implementations of the powered surgical tool.

[00199] Referring to FIG. 38, the charging adapter 1102 may include an alignment feature 1116 configured to ensure that the module protrusion 1110 is properly received by the module housing 22, and an alignment feature 1116’ configured to ensure that the protrusion 1104 is properly received by the module housing 222. During reception of the module protrusion 1110 by a module housing 22, 222, the corresponding alignment feature 1116, 1116’ is configured to engage the module housing 22, 222 prior to pins 48, 248 of the battery and control module 21, 221 electrically connecting to the charging adapter 1102. In this way, the alignment features 1116, 1116’ protect the pins 48 by ensuring that the pins 48 of the battery and control module 21 are received by the pin receptacles 1112 of the charging adapter 1102. Additionally, the alignment features 1116, 1116’ may be configured to ensure that the module housing 22, 222 is prevented from rotating after receiving the module protrusion 1110. Alternatively, the charging adapter 1102 may include additional features configured to prevent a module housing 22, 222 from rotating after receiving the module protrusion 1110.

[00200] The charging adapter 1102 may also include a latch L1 configured to configured to engage an interface of the module housing 22 of the powered surgical tool 20 to ensure that the module protrusion 1110 is secured to the module housing 22 after the module housing 22 receives the module protrusion 1110. The charging adapter 1102 may also include a latch L2 configured to engage an interface of the module housing 222 of the powered surgical tool 220 to ensure that the module protrusion 1110 is secured to the module housing 222 after the module housing 222 receives the module protrusion 1110.

[00201] The charging adapter 1102 may be configured to generate a magnetic field. For example, in the instance of FIG. 38, the charging adapter 1102 includes a magnet M disposed on the module protrusion 1110 configured to generate a magnetic field. In the instance of FIG. 38, the magnet M is located proximate to the latch L1. However, in other instances, the magnet M may be disposed on any other suitable location of the charging adapter 1102 or charging module

1100. As shown in FIG. 41, the wake-up sensors 134 of the battery and control module 21 may be configured to sense the magnetic field generated by the magnet M in response to the module housing 22 receiving the module protrusion 1110; and the wake-up sensors 334 of the battery and control module 221 may be configured to sense the magnetic field generated by the magnet M in response to the module housing 222 receiving the module protrusion 1110. The controller 31, 231 may be configured to transition from a sleep state to an active state based on the wake-up sensors

134, 334 sensing the magnetic field generated by the magnet M, wherein the controller 31, 231 is configured to communicate with the charger when the controller is in the active state.

[00202] Referring to FIG. 39, each charger protrusion 1108 of the charging adapter 1102 may include adapter contacts 1119. As shown in FIG. 40, the adapter contacts 1119 include an adapter ground contact 1120, an adapter communication contact 1122, and an adapter power contact 1124. Each recess 1104 of the charging module 1100 may include a charger ground terminal 1126, a charger communication terminal 1128, and a charger power terminal 1130, as shown in FIG. 41. In instances where the charger protrusions 1108 are received by the recesses

1104, the adapter ground contact 1120 contacts the charger ground terminal 1126, the adapter communication contact 1112 contacts the charger communication terminal 1128, and the adapter power contact 1124 contacts the charger power terminal 1130.

[00203] Referring to FIG. 40, each module protrusion 1110 of the charging adapter 1102 include adapter terminals 1121. Specifically, the adapter terminals 1121 include an adapter ground terminal 1132, a first adapter communication terminal 1134, a second adapter communication terminal 1136, and an adapter power terminal 1138. In instances where the module protrusions

1110 of the charging adapter 1102 are received by a module housing 22, 222 of a battery and control module 21, 221, the adapter terminals 1121 contact the pins 48, 48’ such that the charging adapter 1102 may facilitate communication between the charging module 1100 and the battery and control module 21 , 221 , and such that the charging module 1100 may provide charging power to the rechargeable battery of the battery and control module 21, 221.

[00204] It should be noted that, while the module housings 22, 222 of the battery and control modules 21, 221 are shown as receiving the module protrusion 1100 of the charging adapter 1102 in the instance of FIG. 37, in other instances, the charging adapter 1102 may instead be configured to receive a component of the battery and control modules 21, 221. For example, the charging adapter 1102 may define a recess sized to removably receive the module housing 22, 222 of a battery and control module 21, 221.

[00205] The charging adapter 1102 and components of the charging adapter 1102 may include any suitable structure and any suitable dimensions. Refening to FIG. 37, the charging adapter 1102 includes two charger protrusions 1108 arranged along the direction of the first charger axis AX1 such that, when the charging adapter 1102 is received by the charging module

1100, the charging adapter 1102 is received by two recesses 1104 of the charging module 1100 and occupies a single column of recesses 1104. Additionally, the charging adapter 1102 may include two module protrusions 1110 arranged along the direction of the second charger axis AX2.

Each module protrusion 1110 may include a width w_a along the second charger axis AX2 such that a sum of the widths w_a is less than a width w_c of a recess 1104 along the second charger axis

AX2. In this way, while the charging adapter 1102 is received by two recesses 1104 of the charging module 1100 and occupies a single column of recesses 1104, the charging module 1100 is able to provide charging power to two powered surgical tools coupled with the module protrusions 1110 of the charging adapter 1102. As such, the charging adapter 1102 preserves the ability of the charging module 1100 to provide charging power to a number of devices corresponding to a number of recesses 1104.

[00206] The charging adapter 1102 may include any suitable number of charger protrusions 1108 and module protrusions 1110. For example, in FIG. 37, the charging adapter

1102 includes a first and second charger protrusion 1108(1), 1108(2) and a first and second module protrusion 1110(1), 1110(2). The first and second charger protrusions 1108(1), 1108(2) are configured to be received by a first and second recess 1104(1), 1104(2) of the charging module

1100, as indicated by the arrows in FIG. 37. Each of the first and second module protrusions

1110(1), 1110(2) may be received by a module housing 22 of a battery and control module 21.

For example, in FIG. 36, the module protrusions 1110 are shown being received by the module housings 22, 222 of the battery and control modules 21, 221.

[00207] Any suitable number of charging adapters 1102 may be received by the charging module 1100. For example, the charging module 1100 of FIGS.36 and 37 include six recesses 1104 arranged in a two-by-three grid and each charging adapter 1102 includes two charger protrusions 1108 configured to be received by two recesses 1104 along the direction of the first charger axis AX1. As follows, the charging module 1100 of FIGS. 36 and 37 is configured to receive three charging modules 1102(1), 1102(2), 1102(3). In other instances, the charging module

1100 may include a different arrangement or different number of recesses 1104.

[00208] The module housing 22 of the battery and control module 21 may be configured to couple with a programming fixture 1200 shown in FIGS. 42 and 43. For example, the recess

40 of the module housing 22 may receive the programming fixture 1200. Once the module housing

22 of the battery and control module 21 is received by the programming fixture 1200, a computing system coupled with the programming fixture 1200 may update, repair, or run diagnostics on the control module controller 31 of the battery and control module 21.

[00209] The programming fixture 1200 may be configured to couple with any implementation of the battery and control module 21. For example, the module housing 222 of the battery and control module 221 may also be configured to couple with the programming fixture

1200. [00210] Additionally, while the module housing 22 of the battery and control module

21 is configured to receive the programming fixture 1200 in the instance of FIGS. 42 and 43, in other instances, the programming fixture 1200 may be configured to receive a component of the battery and control module 21. For example, the programming fixture 1200 may define a recess sized to removably receive the module housing 22 of the battery and control module 21.

[00211] Various features of the programming fixture 1200 are shown in FIGS. 42 and

43. In the instance of FIGS. 42 and 43, the programming fixture 1200 includes an alignment feature 1202 configured to ensure that the programming fixture 1200 is properly received by the battery and control module 21, and an alignment feature 1202’ configured to ensure that the programming fixture 1200 is properly received by the battery and control module 221.

Additionally, the alignment features 1202, 1202’ may be configured to ensure that the battery and control modules 21, 221 are prevented from rotating after receiving the programming fixture 1200.

The alignment features 1202, 1202’ are configured to engage the module housings 22, 222 prior to pins 48 of the battery and control module 21 electrically connecting to the programming fixture

1200 when the module housings 22, 222 receive the programming fixture 1200. In this way, the alignment features 1202, 1202’ protect the pins 48 by ensuring that the pins 48 of the battery and control module 21 are received by the pin receptacles 1206 of the programming fixture 1200.

[00212] The programming fixture 1200 may be configured to generate a magnetic field.

For example, in the instance of FIGS. 42 and 43, the programming fixture 1200 includes a magnet

1204 configured to generate a magnetic field. The magnet 1204 may be located at any suitable location of the programming fixture 1200.

[00213] FIG. 44 illustrates a system 10 for identifying a device coupled with a powered surgical tool 20. As shown, the powered surgical tool 20 includes a battery and control module 21. Additionally, the battery and control module 21 includes a module housing 22, which is configured to couple with a handpiece 24 (shown in FIG. 2), a charging module 1100 (shown in

FIG. 36), and a programming fixture 1200 (shown in FIGS. 42 and 43). As shown in FIG. 44, the handpiece 100 includes a motor 122 including a first rotor magnet 123 and a second rotor magnet

125 forming a rotor magnet pair 123, 125, the charging module 1100 includes a magnet M, and the programming fixture 1200 includes a magnet 1204. The battery and control module 21 includes a control module controller 31 configured to determine whether the module housing 22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204.

[00214] It should be noted that, while FIG. 44 illustrates the system 10 as including the battery control module 21, the system 10 may include any implementation of the battery and control module described herein. For example, the system 10 may include the pencil grip configuration of the battery and control module 21 of FIGS. 1-13 and the pistol grip configuration of the battery and control modules 221, 421 of FIGS. 14-23 and 23-35. As follows, the pencil grip configuration of the battery and control module 21 of FIGS. 1-13 and the pistol grip configuration of the battery and control modules 221, 421 of FIGS. 14-23 and 23-35 may be coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200.

[00215] The control module controller 31 may sense a magnetic field generated proximate the battery and control module 21. The analog hall effect sensors 32 shown in FIGS.

5-6 and 22 may be configured to sense a magnetic field generated by the rotor magnet pair 123,

125 of the motor 122. The analog hall effect sensors 32 may also be configured to sense a magnetic field generated by the magnet M of the charging adapter 1102 (shown in FIG. 37) and the magnet 1204 (shown in FIGS. 42 and 43) of the programming fixture 1200. The analog hall effect sensors

32 may sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece

24 is coupled with the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled with the module housing 22, or magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is coupled with the module housing 22.

[00216] The control module controller 31 may also include one or more digital hall effect sensors 134, shown in FIGS. 5-6 and 22, that are coupled to the control module controller

31 and are configured to sense a magnetic field. The digital hall effect sensors 134 may be coupled to the printed circuit board assembly 33 by being mounted to a surface of the rigid printed circuit board 87, as shown in FIG. 5. The digital hall effect sensors 134 may be configured to sense a magnetic field generated by the rotor magnet pair 123, 125 of the motor 122. The digital hall effect sensors 134 may also be configured to sense a magnetic field generated by the magnet M of the charging adapter 1102 (shown in FIG. 37) and the magnet 1204 (shown in FIGS. 42 and 43) of the programming fixture 1200.

[00217] The digital hall effect sensors 134 may sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled with the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled with the module housing 22, or magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is coupled with the module housing 22.

[00218] As previously stated, the control module controller 31 is configured to determine whether the module housing 22 has coupled with the handpiece 24, the charging module

1100, or the programming fixture 1200 based on the digital hall effect sensors 134 sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204. However, prior to determining whether the module housing

22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture

1200, the control module controller 31 is configured to operate in a sleep state and transition from the sleep state to an active state.

[00219] It should be noted that the main controller 231 of the battery and control module

221 may be similarly configured to determine whether the module housing 222 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on the digital hall effect sensors 334 sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204. Descriptions herein of the main controller 31 should be understood to apply to the main controller 231.

[00220] Referring to FIG. 45, in the sleep state, the digital hall effect sensors 134 are active and the analog hall effect sensors 32 are inactive. In other words, during the sleep state, the digital hall effect sensors 134 are configured to sense a magnetic field, such as the magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204, while the analog hall effect sensors 32 are unable to sense a magnetic field.

In the sleep state, the digital hall effect sensors 134 are configured to receive power from the rechargeable battery module 28, while the analog hall effect sensors 32 do not receive power from the rechargeable battery module 28.

[00221] As shown in FIG. 45, once the digital hall effect sensors 134 sense a magnetic field, the control module controller 31 transitions to an active state. For example, the digital hall effect sensors 134 may sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled with the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled with the module housing

22, or magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is coupled with the module housing 22. Therefore, once one of the handpiece 24, the charging module 1100, or the programming fixture 1200 is coupled with the module housing 22, the control module controller 31 transitions to the active state.

[00222] In the active state, the analog hall effect sensors 32 are configured to sense a magnetic field and receive power from the rechargeable battery module 28. In some instances, the digital hall effect sensors 134 are inactive during the active state and do not receive power from the rechargeable battery module 28. In alternative instances, the digital hall effect sensors 134 are also active during the active state and receive power from the rechargeable battery module 28.

[00223] In this way, the digital hall effect sensors 134 function as wake-up sensors. In some instances, the analog hall effect sensors 32 receive a greater amount of power from the rechargeable battery module 28 in the active state than the digital hall effect sensors 134 receive in the sleep state. Advantageously, power provided to the sensors 134, 32 is conserved as the analog hall effect sensors 32 are inactive during the sleep state and do not receive power.

Furthermore, by detecting the presence of a magnetic field with the digital hall effect sensors 134, as opposed to the analog hall effect sensors 32, the control module controller 31 is able to detect whether the handpiece 24, the charging module 1100, or the programming fixture 1200 is coupled with the battery and control module 21 while minimizing power provided by the rechargeable battery module 28. The digital hall effect sensors 134 are ideal for detecting magnetic fields during the sleep state as they have a lower current draw (less than 5 uA each) than the analog hall effect sensors (greater than 5 mA each). Additionally, the analog hall effect sensors are ideal for the motor control function as they possess a higher acquisition rate than the digital hall effect sensors. [00224] During the active state, one of the handpiece 24, the charging module 1100, or the programming fixture 1200 is coupled with the module housing 22. The control module controller 31 may then be configured to determine whether the module housing 22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensing a magnetic field generated by the rotor magnet pair 123, 125, the charger module magnet

M, or the programming fixture magnet 1204. The control module controller 31 may determine whether the module housing 22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3), where the sensed readings SR1,

SR2, SR3 correspond to a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3).

[00225] FIG. 46 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the sleep state. As shown, the first, second, and third analog hall effect sensor

32(1), 32(2), 32(3) merely provide an offset voltage of the body and control module 21, as none of the handpiece 24, the charging module 1100, or the programming fixture 1200 are coupled with the module housing 22 and the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) do not sense a magnetic field generated by the handpiece 24, the charging module 1100, or the programming fixture 1200.

[00226] FIG. 47 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the active state, and while the handpiece 24 is coupled with the module housing

22. In the instance of FIG. 47, the handpiece 24 includes three rotor magnet pairs, the three rotor magnet pairs causing the motor 122 to rotate. FIG. 48 illustrates an ideal representation of the example sensed readings SR1, SR2, SR3. As shown, the sensed readings SR1, SR2, SR3 are sinusoidal and have a phase difference of 120 degrees, corresponding to a location of the rotor magnet pairs on the motor 122. Accordingly, a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) varies in a sinusoidal manner when the handpiece 24 is coupled with the module housing 22.

[00227] FIG. 49 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the active state, and while the charging module 1100 is coupled with the module housing 22. In the instance of FIG. 49, the first, second, and third analog hall effect sensor 32(1),

32(2), 32(3) sense the magnet M of the charging module 1100. However, as the charging module

1100 does not rotate while coupled with the module housing 22, the magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) is a relatively constant value when the charging module 1100 is coupled with the module housing 22.

[00228] FIG. 50 illustrates example sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) while the control module controller 31 is in the active state, and while the programming fixture 1200 is coupled with the module housing 22. In the instance of FIG. 50, the first, second, and third analog hall effect sensor

32(1), 32(2), 32(3) sense the magnet 1204 of the programming fixture 1200. However, as the programming fixture 1200 does not rotate while coupled with the module housing 22, the magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor

32(1), 32(2), 32(3) is a relatively constant value when the programming fixture 1200 is coupled with the module housing 22. [00229] The control module controller 31 may determine whether the module housing

22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensed readings SR1, SR2, SR3 provided by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3). For example, in instances where a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) varies in a sinusoidal manner, the control module controller 31 may determine that the handpiece 24 is coupled with the module housing 22. In instances where a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) is relatively constant, the control module controller 31 may determine that either the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22.

[00230] As a magnitude of the magnetic field sensed by the first, second, and third analog hall effect sensor 32(1), 32(2), 32(3) is relatively constant in instances where the charging module 1100 is coupled with the module housing 22 and in instances where the charging module

1100 is coupled with the module housing 22, the control module controller 31 may use a variety of methods to determine whether the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22. For example, the control module controller 31 may determine that the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22 by comparing the constant values of the sensed readings SR1, SR2, SR3. In instances where the first sensed reading SR1 is greater than the third sensed reading SR3, such as in the instance of FIG. 49, the control module controller 31 may determine that the charging module 1100 is coupled with the module housing 22. In instances where the first sensed reading SR1 is less than the third sensed reading SR3, such as in the instance of FIG. 50, the control module controller 31 may determine that the programming fixture 1200 is coupled with the module housing 22.

[00231] A position of the magnets 310, 404 may be selected to allow the control module controller 31 to determine whether the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22. For example, a position of the magnet 1204 of the programming fixture 1200 and a position of the magnet M of the charging module 1100 may be selected such that the magnitude of the magnetic field generated by the magnet 1204 and sensed by the analog hall effect sensors 32 is different than the magnitude of the magnetic field generated by the magnet M and sensed by the analog hall effect sensors 32. For example, the magnet 1204 may be placed in a location about the programming fixture 1200 and the magnet M may be placed in a location about the protrusion 1104 such that the magnet 1204 aligns with the first analog hall effect sensor 32(1) when the programming fixture 1200 is coupled with the module housing 22 and the magnet M aligns with the third analog hall effect sensor 32(3) when the charging module

1100 is coupled with the module housing 22.

[00232] A polarity of the magnets M, 1204 may be selected to allow the control module controller 31 to determine whether the charging module 1100 or the programming fixture 1200 is coupled with the module housing 22. For example, a polarity of the magnet 1204 of the programming fixture 1200 and a polarity of the magnet M of the charging module 1100 may be selected such that the magnitude of the magnetic field generated by the magnet 1204 and sensed by the analog hall effect sensors 32 is different than the magnitude of the magnetic field generated by the magnet M and sensed by the analog hall effect sensors 32. For example, the magnets 404,

310 may be polarized such that the first analog hall effect sensor 32(1) senses a magnetic field of a positive polarity when the programming fixture 1200 is coupled with the module housing 22 and the first analog hall effect sensor 32(1) senses a magnetic field of a negative polarity when the charging module 1100 is coupled with the module housing 22.

[00233] The control module controller 31 may determine whether the module housing

22 has coupled with the handpiece 24, the charging module 1100, or the programming fixture 1200 in order to properly communicate with the handpiece 24, the charging module 1100, or the programming fixture 1200. For example, one or more of the handpiece 24, the charging module

1100, and the programming fixture 1200 may be configured to communicate with the control module controller 31 using a different communication protocol, and communication may be initiated using a different method.

[00234] In one example, the control module controller 31 may be configured to communicate with the handpiece 24, the charging module 1100, or the programming fixture 1200 using different communication protocols. In one such instance, the control module controller 31 may be configured to communicate with the handpiece 24 using a first communication protocol in response to determining that the module housing 22 has been coupled with the handpiece 24, and the control module controller 31 may be configured to communicate with the charging module

1100 using a second communication protocol in response to determining that the module housing

22 has been coupled with the charging module 1100.

[00235] The control module controller 31 may be configured to communicate using the first and second communication protocol by communicating at different transmission speed. For example, the control module controller 31 may be configured to communicate using the first communication protocol by communicating at a first transmission speed, and the control module controller 31 may be configured to communicate using the second communication protocol by communicating at a second transmission speed. In one such example, the control module controller 31 may be configured to communicate at different Baud rates. For instance, the control module controller 31 may be configured to communicate using the first communication protocol by communicating at 460kBaud, while being configured to communicate using the second communication protocol by communicating at 19.2kBaud. It should be noted that the control module controller 31 may be configured to communicate with the handpiece 24, the charging module 1100, and the programming fixture 1200 using any suitable Baud rate.

[00236] The control module controller 31 may be configured to communicate using the first and second communication protocol by communicating using different transmission modes.

For example, the control module controller 31 may be configured to communicate using the first communication protocol by communicating using full duplex transmission, and the control module controller 31 may be configured to communicate using the second communication protocol by communicating using half duplex transmission. It should be noted that the control module controller 31 may be configured to communicate with the handpiece 24, the charging module 1100, and the programming fixture 1200 using any suitable transmission mode, such as full duplex transmission, half duplex transmission, and/or simplex transmission.

[00237] In one instance, the charging adapter 1102 may be configured to translate the communication protocol used by the charging module 1100 into the communication protocol used by the control module controller 31 such that the control module controller 31 may be configured to communicate with the charging module 1100 via the adapter 1102. In another instance, the charging adapter 1102 may be configured to translate the communication protocol used by the control module controller 31 into the communication protocol used by the charging device 1100 such that the control module controller 31 may be configured to communicate with the charging module 1100 via the adapter 1102. Referring to FIG. 41, the first and second adapter communication terminals 1134, 1136 are shorted to one another within the charging adapter 1102 to allow translation of the communication protocol used by the charging module 1100 and/or the communication protocol used by the control module controller 31. For example, in an instance where the controller is configured to communicate using a first communication protocol by communicating using full duplex transmission and the charging module 1100 is configured to communicate using a second communication protocol by communicating using half duplex transmission; the charging adapter 1102 may be configured to translate the second communication protocol into the first communication protocol by translating a half duplex transmission into a full duplex transmission.

[00238] In another example, communication between the control module controller 31 and the handpiece 24, charging module 1100, or programming fixture 1200 coupled with the module housing 22 may be initiated by either the control module controller 31 or by the handpiece

24, charging module 1100, or programming fixture 1200 coupled with the module housing 22. In one such instance, the control module controller 31 may be configured to initiate communication between the control module controller 31 and the charging module 1100 and the programming fixture 1200 may be configured to initiate communication between the control module controller

31 and the programming fixture 1200. Specifically, the control module controller 31 may initiate communication by transmitting a communication signal to the charging module 1100 based on determining that the module housing 22 has been coupled with the charging module 1100, and the control module controller 31 may be configured to receive a communication signal from the programming fixture 1200 based on determining that the module housing 22 has been coupled with the programming fixture 1200. [00239] Referring back to FIG. 44, once the analog hall effect sensors 32 no longer detect the magnetic field generated by the handpiece 24, charging module 1100, or programming fixture 1200, the control module controller 31 may return to the sleep mode. For example, the analog hall effect sensors 32 may no longer detect the magnetic field generated by the handpiece

24, charging module 1100, or programming fixture 1200 when the handpiece 24, charging module

1100, or programming fixture 1200 are no longer coupled with the module housing 22. In instances where the digital hall effect sensors 134 are active during the active state, the control module controller 31 may return to the sleep mode once the digital hall effect sensors 134 no longer detect the magnetic field generated by the handpiece 24, charging module 1100, or programming fixture 1200.

[00240] Powered surgical tools may include a motor or a motor body configured for receiving power, for example, including electrical power or pressurized air, and transforming that power into an output torque which is transmitted through an output shaft. In one implementation, the powered surgical tool may further include a cannula or may be cannulated.

[00241] In one implementation, the output shaft of the motor may include a lumen or include a hollow center, for example extending through a center line of the output shaft. The lumen may include a first opening on one end of the output shaft and may include a second opening on the second end of the output shaft. The cannula may include a tube at least partially contained within the lumen extending down the center line of the output shaft. The cannula may be open at both ends, for example, to permit passage of a device through the cannula. In this disclosure, a distal portion or direction of a device or component refers to a direction towards the patient.

Similarly, a proximal portion or direction of a device or component refers to a direction away from the patient. [00242] The motor may include electronic components, such as electric magnets in the rotor and the stator, wires electrically connecting portions of the motor to other portions of the motor or to terminals extending out of the motor,

[00243] A powered surgical tool is provided including a motor including a cannula disposed therewithin, wherein the powered surgical tool further includes a housing, a sealing plug, and a shaft seal, wherein the sealing plug and the shaft seal are configured to prevent liquids utilized in an autoclave process from entering an interior of the powered surgical tool while enabling the cannula to allow passage of surgical devices, such as k-wires or pins through the cannula..

[00244] In one implementation, an attachment to a powered surgical tool may be described as a surgical handpiece or a handpiece.

[00245] In one implementation, a pistol grip (or a wand or a tool handle) may include a battery and a control module and may be described as a battery and control module (BMC) as described throughout this disclosure.

[00246] FIG. 51 shows an exemplary battery and control module 1300 configured as a pistol grip in a front perspective view. The battery and control module 1300 includes a module lumen 1301 or hollow cavity portion configured to receive a surgical handpiece or attachment.

The module lumen 1301 may be described as a module lumen. FIG. 52 shows the battery and control module 1300 of FIG. 51 in a rear perspective view. The battery and control module 1300 includes a cannula access point 1302 configured to enable external access to a cannula disposed within the surgical handpiece which may be loaded into the module lumen 1301 of FIG. 51.

[00247] FIG. 53 shows a surgical handpiece 1310 configured to be disposed within the module lumen 1301 of the battery and control module 1300 of FIG. 51. The surgical handpiece 1310 includes a housing 1320 configured to contain and physically protect components contained therewithin and features 1312 for making physical connections to the battery and control module

1300 at one end and a surgical endpiece attachment at the second end. The second end may include a tool coupler or may be configured for attachment to a tool coupler. A sealing plug 1360 is illustrated sealing an end of the surgical handpiece 1310. A cannula lumen 1344 is illustrated exposed to the end of the surgical handpiece 1310. A powered surgical tool may be described as including the battery and control module 1300 including the module lumen 1301 of FIG. 51 with the surgical handpiece 10 of FIG. 53 inserted within the module lumen 1301.

[00248] FIG. 54 shows in cross-section the surgical handpiece 1310 of FIG. 53. The surgical handpiece 1310 is illustrated including the housing 1320, an internal structure insert 1322, a circuit board 1350, a motor 1330, a cannula 1340, and terminals 1352, 1353 projected into the surgical handpiece 1310. The internal structure insert 1322 may be metallic, plastic, or some other similar material and holds a number of illustrated components in place relative to the housing

1320. The internal structure insert 1322 may be considered a part of the housing 1320. The internal structure insert 1322 may be configured to provide distinct locations and act as a locating fixture for the circuit board 1350, the cannula 1340, the output shaft 1332 and other portions of the illustrated surgical handpiece 1310. The internal structure insert 1322 includes an inner diameter at a first proximal end of the surgical handpiece 1310. The terminals 1352, 1353 electronically connect the circuit board 1350 to outside electronic components, such as a connector within the battery and control module 1300 of FIG. 51. Electrical power may be supplied to the circuit board 1350 and the motor 1330 through the terminals 1352, 1353.

[00249] The motor 1330 includes an output shaft 1332 which is mechanically connected to a motor rotor structure 1336 and is configured to provide an output torque from the motor 1330. The motor further includes connector board 1338 including exemplary layers of copper configured to provide electrical connections to portions of the motor 1330. The output shaft 1332 is hollow and includes a lumen 1334 into which the cannula 1340 is disposed. The cannula includes a cannula lumen 1344 at a first proximal end and a second end 1342 which may extend outwardly from a front or a distal end of the surgical handpiece 1310. The cannula 1340 further includes a cannula flange 1346 which aids in positioning the cannula 1340 and interacting with sealing components of the surgical handpiece, sealing plug 1360 and seal 1370.

[00250] Components of the surgical handpiece 1310 internal to the surgical handpiece

1310 may be sensitive or may experience increased wear if exposed to high temperatures and/or liquid during a sterilization or cleaning process. The sealing plug 1360 and the seal 1370 are configured to prevent liquid from entering the interior of the surgical handpiece 1310. The sealing plug 1360 may be constructed with plastic or a rigid polymer. The sealing plug 1360 may be press fit within the inner diameter of the internal structure insert 1322, with friction and compression between a sidewall 1362 of the sealing plug 1360 retaining the sealing plug 1360 within the surgical handpiece 1310. The sealing plug 1360 may include terminal pass-through points 1364 configured to enable terminals 1352, 1353 to enter the internal portion of the surgical handpiece

1310 while maintaining a seal of the surgical handpiece 1310.

[00251] The cannula 1340 passes through the sealing plug 1360. The seal 1370 is provided to enable the cannula 1340 to seal against the sealing plug 1360. The seal 1370 is illustrated including a cylinder shape exterior and including a hollow center or a seal lumen configured to receive the cannula 1340 in the hollow center. The cylinder shape of the rubberized seal 1370 may include a same longitudinal axis as the cannula 1340. A first sealing surface 1372 is provided upon an end surface of the cylinder shape of the seal 1370, resulting in a seal between the seal 1370 against an opposite face or mating surface of the sealing plug 1360. A second sealing surface 1374 is provided as an annular ring-shaped surface upon an inner diameter of the seal 1370 configured to seal to an outer radial surface of the cannula 1340. The seal 1370 may be disposed in contact with the cannula flange 1346.

[00252] A tool coupler may be attached to the output shaft 1332.

[00253] A socket stopper 1380 is disposed around an outside of the internal structure insert 1322 and the sealing plug 1360. The socket stopper 1380 may be configured to retain the sealing plug 1360 within the inner diameter of the internal structure insert 1322 if the press-fitting between the sealing plug 1360 and the internal structure insert 1322 does not hold or loosens.

[00254] FIG. 55 shows an implementation of a powered surgical tool 1400 in which a device housing 1420 of a battery and control module 1410 is designed to provide improved ergonomics and usability. The powered surgical tool 1400 additionally includes a handpiece configured to be removably coupled with the battery and control module 1410 within a handpiece lumen 1430. The battery and control module 1410 may include a battery 1415 contained therewithin and may further contain a circuit board configured for providing functionality of the powered surgical tool 1400, such as selectively supplying power from the battery 1415 to a handpiece or unit installed to the handpiece lumen 1430. The battery 1415 may include one battery cell or a plurality of battery cells. The handpiece may include a modular motor and a drivetrain

(not identified) and may include additional subcomponents such as electrical sockets, a gearbox, and geometries to removably receive a cutting accessory including a head. The handpiece may include the modular motor and may be configured to provide energy to a surgical end effector, such as a burr, a saw, a drill, or other similar device. Other than certain features of the handpiece to be described in further detail, the handpiece may take a form disclosed in commonly-owned International Publication No. WO 2013/177423, published November 28, 2013, the entire contents of which have previously been incorporated by reference herein.

[00255] The cutting accessory assembly may be unique to complementary versions of the motor and the drivetrain so as to provide a set of handpieces configured to be selectively and interchangeably coupled with the battery and control module 1410. Any device or accessory which is applied to the surgical site, whether it be a sagittal saw blade or drill bit, may generally be referred to as an energy applicator throughout. In other implementations, the powered surgical tool

1400 may be a rotary drill, reamer, wire driver, oscillating or reciprocating saw, ultrasonic device, or photonic device. Likewise, the energy applicator may be a drill bit, bur, saw, reamer, grinding disc, ultrasonic cutting or catheterization tip, laser, etc. The type of tool used is not intended to limit the present invention. The motor may be a universal motor which may interchangeably receive more than one cutting accessory as described below. The powered surgical tool 1400 of the present disclosure may be particularly well suited for orthopedic procedures involving the arm, hand, leg, foot, mandible, and skull, but other small bone orthopedic and soft tissue procedures are contemplated.

[00256] The battery and control module 1410 includes at least one battery and a main controller that is coupled to a printed circuit board assembly as will be discussed in greater detail below. The main controller is in communication with the battery, which may be part of a battery assembly, a motor control sensor, and a handswitch sensor, and further configured to be arranged in communication with the motor when the handpiece is removably coupled with the battery and control module 1410. The main controller may also be in communication with a memory device.

The battery and control module 1410 may include a handswitch assembly optionally coupled to the device housing 1420 and configured to receive an input from a user to operate the powered surgical tool 1400. For example, the handswitch assembly may be spring-loaded and include a handswitch magnet such that, when the handswitch assembly is actuated, the handswitch magnet is moved towards a handswitch sensor. While the example is provided that the handswitch assembly is coupled to the battery and control module 1410, the handswitch assembly may be detachable and attached to any portion of the battery and control module 1410 and/or handpiece.

Further, the handswitch assembly may be part of or attached to the handpiece.

[00257] The battery and control module 1410 includes a barrel 1440 and a handle 1450.

The handle 1450 extends downwardly from the barrel 1440. The battery and control module

1410 may have two triggers 1460, 1470 or switches that are spring-loaded and installed externally upon or to the battery and control module 1410. Both triggers 1460, 1470 extend forward from the distally directed portion of the handle 1450. The practitioner may actuate the triggers 1460, 1470 to control the operation of the tool unit. The triggers 1460, 1470 may each include a magnet which gets moved when the triggers 1460, 1470 are actuated by the user as discussed in greater detail below. The battery and control module 1410 may include a pressure relief valve and a cap.

[00258] FIG. 56 illustrates in side perspective view internal components of the battery and control module 1410 including a pair of trigger sensors 1520, 1530 corresponding to the triggers 1460, 1470 of FIG. 55. The trigger sensors 1520, 1530 may be configured to monitor or detect presence of or proximity to a magnetic field created by a permanent magnet, which may be detected through a housing wall. A mid housing 1500 of the device housing 1420 of FIG. 55 is illustrated. The trigger sensors 1520, 1530 may be disposed on or included in a printed circuit board 1510. The trigger sensors 1520, 1530 may be Hall-effect sensors. The printed circuit board

1510 is disposed inside the handle 1450. In particular, the printed circuit board 1510 is disposed in close proximity to the triggers 1460, 1470 so that the plurality of trigger sensors 1520, 1530 may sense a state of the triggers 1460, 1470, such as when the triggers 1460, 1470 have been actuated by the user.

[00259] A plurality of motor control sensors may be coupled to another or a second printed circuit board coupled with the battery and control module 1410. The motor control sensors may be Hall-effect. A switching module including a plurality of metal-oxide semiconductor field- effect transistors (MOSFETs) may also be coupled to the second printed circuit board. Although the disclosure contemplates MOSFETs as the switching components that are coupled to the second printed circuit board, other suitable transistors or switching components may be used. The switching module may be used in controlling the direction of operation of the motor of the handpiece, for example, in a forward direction or in a reverse direction.

[00260] FIG. 57 illustrates in rear perspective view a front housing 1600 configured to be assembled, welded, laser-process attached, or otherwise affixed to a handle portion of the mid housing 1500 of FIG. 56. The front housing 1600 is illustrated including structures 1620, 1630 configured for containing portions of the triggers 1460, 1470 of FIG. 55 and springs and other hardware configured for aligning and enabling actuation of the triggers 1460, 1470. Additionally, a pocket 1640 or cutout region is illustrated configured for containing the trigger sensors 1520,

1530 of FIG. 56 and enabling the trigger sensors 1520, 1530 to be in proximity to the triggers

1460, 1470. The pocket 1640 may include space in which the trigger sensors 1520, 1530 may be disposed, while a wall of the front housing 1600 is disposed between the trigger sensors 1520,

1530 and the triggers 1460, 1470, such that the battery and control module 1410 may be sealed to prevent liquids from entering the interior of the battery and control module 1410 while enabling signal interaction between the triggers 1460, 1470 and the corresponding trigger sensors 1520,

1530. The front housing 1600 may be intact without any through-holes in the area of the structures 1620, 1630 and the pocket 1640. Magnetic interaction between the triggers 1460, 1470, and the corresponding trigger sensors 1520, 1530 enables recognition or signal generation corresponding to depression of the triggers 1460, 1470 while maintaining a sealed housing between the triggers

1460, 1470 and the trigger sensors 1520, 1530.

[00261] Refening to FIGS. 55-57, one may assemble the printed circuit board 1510 with triggers sensors 1520, 1530 on the mid housing 1500 and weld, laser-process attach, or otherwise affix the front housing 1600 including the pocket 225 to accommodate the trigger sensors 1520,

1530, resulting in the battery and control module 1410 being sealed prior to assembly of the triggers 1460, 1470 to the battery and control module 1410. It will be appreciated that the triggers

1460, 1470 may be later replaced or refurbished without breaking the seal of the battery and control module 1410.

[00262] FIG. 58 illustrates in side perspective view a sealed housing assembly 1610 including the front housing 1600 welded, laser-process attached, adhered, fastened, or otherwise attached to the mid housing 1500 in a sealing manner. The sealed housing assembly 1610 may include a plurality of housings sealingly joined together and configured to encase components therewith. Wherein housings of the disclosed battery and control module 1410 may be constructed with polymers, welding may refer to a joining process such as a vibration welding process wherein contacting surfaces of the housings are heated locally and joined. The sealed housing assembly

1610 of the battery and control module 1410 enables the sealed housing assembly 1610 to be sterilized, for example, according to an autoclave process, without the heated liquids of the sterilization process entering the sealed housing assembly 1610 and coming into contact with components therein, such as circuit boards and the battery 1415. [00263] FIG. 59 illustrates in side perspective view the sealed housing assembly 1610 of FIG. 58 with the triggers 1460, 1470 installed thereto. The trigger 1460 is illustrated in an at least partially not-depressed state and the trigger 1470 is illustrated in an at least partially depressed state.

[00264] FIG. 60 illustrates the sealed housing assembly 1610 and the triggers 1460,

1470 of FIG. 59 in a disassembled state. Trigger hardware components 1700 are illustrated including springs, a trigger lock translating plate, and alignment hardware configured for enabling assembly and selective actuation of the triggers 1460, 1470. The trigger hardware components

1700 may include a front plate 1710 and a screw 1720 configured for installation and removal, permitting one to easily install and later replace the triggers 1460, 1470. The triggers 1460, 1470 may be retained in place by the front plate 1710 and the screw 1720. Each of the triggers 1460,

1470 are illustrated including round or cylindrical stem portions 1462, 1472. The sealed housing assembly 1610 is illustrated including a pair of trigger lumens 1612, 1614 configured respectively for receiving the stem portions 1462, 1472. The stem portions 1462, 1472 may be described as being configured to be engaged with the trigger lumens 1612, 1614.

[00265] FIG. 61 illustrates in side cross-sectional view a portion of the sealed housing assembly 1610 and the triggers 1460, 1470. The circuit board 1510 is additionally illustrated. The triggers may each include magnets 1730, 1732 useful for providing control signals to the trigger sensors 1520, 1530 of FIG. 56.

[00266] FIG. 62 illustrates in front cross-sectional view a portion of the sealed housing assembly 1610 and the trigger 1470. The trigger 1470 is illustrated including magnet 1730. The corresponding trigger sensor 1530 of FIG. 56 is additionally illustrated. Additionally, a screw boss feature 1618 is illustrated configured for receiving the screw 1720 of FIG. 60. [00267] The triggers 1460, 1470 may be selectively depressed for actuation of the surgical tool 1400 of FIG. 55. The triggers 1460, 1470 of FIG. 60 may include stem portions 1462,

1472 configured to be installed to corresponding trigger lumens 1612, 1614. In some examples, air trapped between the triggers 1460, 1470 and the walls of the trigger lumens 1612, 1614 may inhibit free movement of the triggers 1460, 1470 relative to the sealed housing assembly 1610.

[00268] FIG. 63 illustrates in front perspective view a portion of the sealed housing assembly 1610 including a plurality of trigger vent cutouts 1660, 1670. Each of the trigger vent cutouts 1660, 1670 may include a channel formed in a wall of the sealed housing assembly 1610 configured to release air from behind each of the triggers 1460, 1470 of FIG. 60 as each are installed or depressed. The trigger vent cutouts 1660, 1670 enable air to be released from behind each of the triggers 1460, 1470 while maintaining the sealed housing assembly 1610 as a sealed unit.

[00269] FIG. 64 illustrates in front cross-sectional view a portion of the sealed housing assembly 1610 including the stem portions 1462, 1472 and the respective trigger vent cutouts

1660, 1670. The stem portions 1462, 1472 may fit tightly with the surfaces of the respective trigger lumens 1612, 1614, while the trigger vent cutouts 260A, 260B provide paths for air to flow from behind the triggers 1460, 1470 of FIG. 60.

[00270] FIG. 65 is a flowchart illustrating a method 1800 for operating a powered surgical tool. The method 1800 is provided utilizing the battery and control module 1410 of FIG.

55, although other examples of surgical tools may be utilized in accordance with the method 1800.

The method 1800 starts at step 1802. At step 1804, the method 1800 includes providing a battery and control module 1410 including a sealed housing assembly 1610. The sealed housing assembly

1610 encapsulates a printed circuit board 1510 that includes at least one trigger sensor 1520 and includes at least one trigger lumen 1612 configured to receive a trigger 1460. At step 1806, the method 1800 continues, including installing at least one trigger 1460 into the trigger lumen 1612, the trigger 1460 including a stem portion 1462 with at least one magnet 1530 configured to interact with the trigger sensor 1520 without compromising the seal of the sealed housing assembly 1610.

At step 1808, the method 1800 ends. A number of additional and/or alternative method steps are envisioned, and the method 1800 is not intended to be limited to the examples provided herein.

[00271] FIG. 66 is a flowchart illustrating a method 1900 for repairing a powered surgical tool. The method 1900 is provided utilizing the battery and control module 1410 of FIG.

55, although other examples of surgical tools may be utilized in accordance with the method 1900.

The method 1900 starts at step 1902. At step 1904, the method 1900 includes providing a battery and control module 1410 including a sealed housing assembly 1610. The sealed housing assembly

1610 encapsulates a printed circuit board 1510 that includes at least one trigger sensor 1520. The battery and control module 1410 includes at least one trigger 1460 including a magnet 1530. At step 1906, the method 1900 continues, including removing the trigger 1460 from the battery and control module 1410 without compromising the seal of the sealed housing assembly 1610. At step

1908, the method 1900 ends. A number of additional and/or alternative method steps are envisioned, and the method 1900 is not intended to be limited to the examples provided herein.

[00272] The broad teachings of the disclosure can be implemented in a variety of forms.

Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following interconnected with a board header claims. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the examples is described above as having certain features, any one or more of those features described with respect to any example of the disclosure can be implemented in and/or combined with features of any of the other examples, even if that combination is not explicitly described. In other words, the described examples are not mutually exclusive, and permutations of one or more examples with one another remain within the scope of this disclosure.

[00273] Spatial and functional relationships between elements (for example, between controllers, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “engaged,” “coupled,” 'adjacent,” “next to,” “on top of,” “above,”

“below,” and “disposed.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship can be a direct relationship where no other intervening elements are present between the first and second elements, but can also be an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements.

[00274] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.” The term subset does not necessarily require a proper subset. In other words, a first subset of a first set may be coextensive with (equal to) the first set.

[00275] In the figures, the direction of an arrow, as indicated by the arrowhead, generally demonstrates the flow of information (such as data or instructions) that is of interest to the illustration. For example, when element A and element B exchange a variety of information but information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send requests for, or receipt acknowledgements of, the information to element A.

[00276] In this application, including the definitions below, the term “controller” or

“module” may be replaced with the term “circuit.” The term “controller” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a programmable system on a chip

(PSoC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array

(FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit

(shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

[00277] The controller may include one or more interface circuits with one or more transceivers. In some examples, the interface circuit(s) may implement wired or wireless interfaces that connect to a local area network (LAN) or a wireless personal area network (WPAN). Examples of a LAN are Institute of Electrical and Electronics Engineers (IEEE) Standard 802.11-2016 (also known as the WIFI wireless networking standard) and IEEE Standard 802.3-2015 (also known as the ETHERNET wired networking standard). Examples of a WPAN arc the BLUETOOTH wireless networking standard from the Bluetooth Special Interest Group and IEEE Standard

802.15.4.

[00278] The controller may communicate with other controllers using the interface circuit(s). Although the controller may be depicted in the present disclosure as logically communicating directly with other controllers, in various implementations the controller may actually communicate via a communications system. The communications system may include physical and/or virtual networking equipment such as hubs, switches, routers, gateways and transceivers. In some implementations, the communications system connects to or traverses a wide area network (WAN) such as the Internet. For example, the communications system may include multiple LANs connected to each other over the Internet or point-to-point leased lines using technologies including Multiprotocol Label Switching (MPLS) and virtual private networks

(VPNs).

[00279] In various implementations, the functionality of the controller may be distributed among multiple controllers that are connected via the communications system. For example, multiple controllers may implement the same functionality distributed by a load balancing system. In a further example, the functionality of the controller may be split between a server (also known as remote, or cloud) controller and a client (or user) controller.

[00280] Some or all hardware features of a controller may be defined using a language for hardware description, such as IEEE Standard 1364-2005 (commonly called “Verilog”) and

IEEE Standard 1076-2008 (commonly called “VHDL”). The hardware description language may be used to manufacture and/or program a hardware circuit. In some implementations, some or all features of a controller may be defined by a language, such as IEEE 1666-2005 (commonly called

“SystemC”), that encompasses both code, as described below, and hardware description.

[00281] The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, data structures, and/or objects.

The term shared processor circuit encompasses a single processor circuit that executes some or all code from multiple controllers. The term group processor circuit encompasses a processor circuit that, in combination with additional processor circuits, executes some or all code from one or more controllers. References to multiple processor circuits encompass multiple processor circuits on discrete dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term shared memory circuit encompasses a single memory circuit that stores some or all code from multiple controllers. The term group memory circuit encompasses a memory circuit that, in combination with additional memories, stores some or all code from one or more controllers.

[00282] The term memory circuit is a subset of the term computer-readable medium.

The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray

Disc).

[00283] The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks and flowchart elements described above may serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer. [00284] The computer programs include processor-executable instructions that are stored on at least one non-transitory computer-readable medium. The computer programs may also include or rely on stored data. The computer programs may encompass a basic input/output system

(BIOS) that interacts with hardware of the special purpose computer, device drivers that interact with particular devices of the special purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[00285] The computer programs may include: (i) descriptive text to be parsed, such as

HTML (hypertext markup language), XML (extensible markup language), or JSON (JavaScript

Object Notation), (ii) assembly code, (iii) object code generated from source code by a compiler,

(iv) source code for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. As examples only, source code may be written using syntax from languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran,

Perl, Pascal, Curl, OCaml, JavaScript®, HTML5 (Hypertext Markup Language 5th revision), Ada,

ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang,

Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

Claims

What is claimed is:

1. A powered surgical tool comprising: a handpiece including a motor and a tool coupler, the handpiece defining at least one of a rail and a slot, and the handpiece further defining a receiver surface; and a battery and control module including: a device housing including the other of the rail and the slot, the rail and slot configured such that the rail is slidable within the slot to allow coupling between the handpiece and the battery and control module, the device housing further defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a state of the motor; and at least three conductive terminals that extend through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece.

2. The powered surgical tool of claim 1, wherein the handpiece defines a cannula, and wherein the device housing is free from cannulation.

3. The powered surgical tool of any preceding claim, wherein the battery and control module include a safety vent.

4. The powered surgical tool of any preceding claim, wherein the motor is an electric motor.

5. The powered surgical tool of any preceding claim, the motor sensor is further defined as a hall-effect sensor.

6. The powered surgical tool of any preceding claim, wherein the handpiece includes a memory device electrically connected to at least one of the at least three of conductive terminals.

7. The powered surgical tool of any preceding claim, wherein a distal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

8. The powered surgical tool of any preceding claim, wherein a portion of a proximal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

9. The powered surgical tool of any preceding claim, wherein the battery and control module comprises a latch assembly including a locking member and a biasing member, the biasing member positioned to urge the locking member towards the receiver surface.

10. A powered surgical tool comprising: a handpiece including a motor and a tool coupler, wherein the handpiece defines a cannulation; and a battery and control module including: a device housing defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a state of the motor; and at least three conductive terminals that extends through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece, wherein the battery and control module is free from cannulation.

11. The powered surgical tool of claim 10, wherein the battery and control module include a safety vent.

12. The powered surgical tool of any one of claims 10 and 11, wherein the motor is an electric motor.

13. The powered surgical tool of any one of claims 10-12, the motor sensor is further defined as a hall-effect sensor.

14. The powered surgical tool of any one of claims 10-13, wherein the handpiece includes a memory device electrically connected to at least one of the at least three conductive terminals.

15. The powered surgical tool of any one of claims 10-14, wherein a distal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

16. The powered surgical tool of claim 15, wherein a portion of a proximal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

17. A surgical handpiece for coupling to a battery and control module, the surgical handpiece comprising: a housing; a tool coupler; an electric motor disposed within the housing; a rotor defining an axis, the rotor being coupled to the electric motor and the tool coupler; a rigid circuit board including a controller, the rigid circuit board being disposed within the housing and oriented perpendicular to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the rigid circuit board.

18. The surgical handpiece of claim 17, wherein the handpiece includes a memory device electrically connected to at least one of the plurality of terminals.

19. The surgical handpiece of any one of claims 17 and 18, wherein the surgical handpiece defines a longitudinal axis, and the surgical handpiece defines a cannula surrounding the longitudinal axis.

20. The surgical handpiece of claim 19, wherein the rigid circuit board defines an aperture, the aperture surrounding the cannula.

21. The surgical handpiece of claim 20, wherein the aperture and the cannula are coaxial.

22. A surgical handpiece for coupling to a battery and control module, the surgical handpiece comprising: a housing; a tool coupler; an electric motor disposed within the housing; a rotor defining an axis, the rotor being coupled to the electric motor and the tool coupler; a circuit board including a controller, the circuit board disposed within the housing, the circuit board including a rigid portion and a flexible portion, the rigid portion defining an axis that is oriented parallel to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the flexible portion of the circuit board.

23. The surgical handpiece of claim 22, wherein the handpiece includes a memory device electrically connected to at least one of the plurality of terminals.

24. A powered surgical tool comprising: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a first printed circuit board disposed in the void space and being rigid; a second printed circuit board disposed in the void space and being rigid, the second printed circuit board being coupled to the first printed circuit board, the second printed circuit board and the first printed circuit board being arranged in a stacked configuration, a plurality of motor control sensors connected to the second printed circuit board; and a controller configured to regulate power drawn from the rechargeable battery module based on user input, the controller being mounted to one of the first printed circuit board and the second printed circuit board.

25. The powered surgical tool of claim 24, wherein the battery and control module further comprises a third printed circuit board, the third printed circuit board connected to one of the first and the second printed circuit boards via a conductor, wherein the third printed circuit board comprises at least three conductive terminals that extends at least partially through the device housing for establishing an electrical connection between the third printed circuit board and the handpiece.

26. The powered surgical tool of claim 25, wherein the device housing defines a mounting post, and the third printed circuit board abuts the mounting post such that an axial position of the third printed circuit board is controlled within the battery and control module.

27. The powered surgical tool of claim 26, wherein the at least three conductive terminals are soldered to the third printed circuit board.

28. The powered surgical tool of any one of claims 24-27, wherein the conductor is further defined as a flexible circuit.

29. The powered surgical tool of any one of claims 24-28, wherein the battery and control module further comprises a plurality of support ribs and a board mount, the board mount including a plurality of wings for engaging the support ribs.

30. The powered surgical tool of any one of claims 24-29, wherein the battery and control module further comprises a board mount, the board mount includes one of a set of notches or a set of protrusions, and the device housing defines the other of the set of notches or the set of protrusions, wherein set of protrusions engages the set of notches to prevent the board mount from moving relative to the device housing in a plurality of degrees of freedom.

31. The powered surgical tool of claim 30, wherein one of the set of notches and/or set of protrusions are positioned in an arcuate arrangement relative to one another.

32. The powered surgical tool of any one of claims 24-31, wherein the board mount includes the set of protrusions, and each of the set of protrusions define a receptacle for securing one of the plurality of motor control sensors.

33. The powered surgical tool of claim 30, wherein the motor includes a plurality of magnets and wherein the device housing includes the set of notches, the notches defining a series of notch peaks and notch valleys, wherein an innermost surface of the notch peak is farther from magnets of the motor than an innermost surface of the notch valleys.

34. The powered surgical tool of any one of claims 24-33, wherein the first printed circuit board has greater surface area than the second circuit board.

35. The powered surgical tool of any one of claims 24-34, wherein the first printed circuit board is farther from the motor than the second circuit board when the handpiece is coupled to the battery and control module.

36. The powered surgical tool of any one of claims 24-35, wherein the first printed circuit board and the second printed circuit board are interconnected with a board header.

37. The powered surgical tool of any one of claims 24-36, wherein the second printed circuit board includes two major sides, wherein the board mount contacts only one of the two major sides.

38. The powered surgical tool of claim 37, wherein the second printed circuit board includes at least four minor sides, wherein the board mount contacts two or fewer minor sides of the second printed circuit board.

39. The powered surgical tool of claim 37, wherein the second printed circuit board includes at least four minor sides, wherein the board mount contacts no minor sides of the second printed circuit board.

40. The powered surgical tool of claim 37, wherein the board mount comprises a body portion and a flange, the flange defining a bore for insertion of a fastener, the flange extending perpendicularly from the body portion.

41. The powered surgical tool of claim 40, wherein the battery and control module further comprises a plurality of spacers, the plurality of spacers disposed between the first printed circuit board and the second printed circuit board.

42. The powered surgical tool of claim 41, wherein each of the plurality of spacers define a bore, wherein the battery and control module comprises a plurality of fasteners arranged to extend through the first printed circuit board, the bore of at least one of the plurality of spacers, and the second printed circuit board.

43. The powered surgical tool of claim 42, wherein the board mount defines a plurality of mount bores, each of the plurality of mount bores include a threaded insert.

44. The powered surgical tool of any one of claims 24-43, wherein the third printed circuit board includes a light source, and the device housing includes a light guide aligned with the light source.

45. A powered surgical tool comprising: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly disposed in the void space, the printed circuit board assembly including a rigid portion; a plurality of motor control sensors disposed on the rigid portion of the printed circuit board assembly; and a controller configured to regulate power drawn from the rechargeable battery module based on user input, the controller being mounted to the printed circuit board assembly.

46. The powered surgical tool of claim 45, wherein the battery and control module further comprises board mount, wherein the board mount includes one of a set of notches or a set of protrusions, and the device housing defines the other of the set of notches or the set of protrusions, wherein set of protrusions engages the set of notches to prevent the rigid portion of the printed circuit board assembly from moving relative to the device housing in two or more degrees of freedom.

47. The powered surgical tool of claim 46, wherein one of the set of notches and/or the set of protrusions are positioned in an arcuate arrangement relative to one another.

48. The powered surgical tool of claim 46, wherein the board mount includes the set of protrusions, and each of the set of protrusions define a receptacle for securing one of the plurality of motor control sensors.

49. The powered surgical tool of claim 47, wherein the motor includes a plurality of magnets, wherein the device housing includes the set of notches, the notches defining a series of notch peaks and notch valleys, wherein an innermost surface of the notch peak is farther from the plurality of magnets of the motor than an innermost surface of the notch valleys.

50. A powered surgical tool comprising: a handpiece including a motor, the motor including a plurality of magnets; and a control module including: a device housing for removably receiving the handpiece, the device housing defining a void space; a first terminal; a sensor configured to provide a sensor signal, the sensor being positioned to sense at least one of the plurality of magnets when the handpiece is received; and a controller configured to regulate power supplied to the first terminal based on the sensor signal.

51. The powered surgical tool of claim 50, wherein the sensor is further defined as a first set of sensors, the first set of sensors being aligned axially with at least a portion of one of the plurality of magnets when the handpiece is received in the control module.

52. The powered surgical tool of any one of claims 50 and 51, where the first set of sensors are digital hall effect sensors.

53. The powered surgical tool of any one of claims 50-52, further comprising a second set of sensors, wherein the second set of sensors are analog hall effect sensors.

54. The powered surgical tool of claim 53, wherein the controller is configured to energize the first terminal based the first set of sensors, and wherein the controller is configured to commutate the motor based on the second set of sensors.

55. The powered surgical tool of claim 53, wherein each sensor is the first set of sensors is aligned with one another.

56. The powered surgical tool of claim 53, wherein each sensor in the second set of sensors is aligned with one another.

57. The powered surgical tool of claim 56, wherein the first set of sensors is axially offset from the second set of sensors.

58. The powered surgical tool of claim 56, wherein the controller is configured to transition between a sleep state and an active state, wherein the powered surgical tool is configured to cause the controller to transition from the sleep state to the active state based on the sensor signal.

59. The powered surgical tool of claim 58, further comprising a second terminal, the second terminal being energized while the controller is in the sleep state and the active state.

60. The powered surgical tool of claim 59, wherein the handpiece includes a memory device and a data terminal, the data terminal in electrical communication with the memory device, and wherein the data terminal is configured to connect with the second terminal of the control module when the handpiece is received in the recess.

61. The powered surgical tool of claim 59, wherein while the controller is in the sleep state, the powered surgical tool has current draw less than 5 mA.

62. The powered surgical tool of any one of claims 50-61, wherein the motor includes a motor rotor, a lamination stack surrounding the rotor of the motor, and a plurality of magnets surrounding the rotor, wherein a portion of the plurality of magnets extend axially beyond the lamination stack.

63. The powered surgical tool of any one of claims 50-62, wherein the control module is further defined as a battery and control module, wherein the battery and control module further comprises a rechargeable battery module.

64. A powered surgical tool having a pencil-grip configuration, the powered surgical tool comprising: a plastic housing defining an integral mounting base, the integral mounting base defining a first and second aperture, a first pin and a second pin extending through the first and second apertures respectively, with the first pin defining a pivot axis and pivot surface, the first pin and the second pin defining a press-fit engagement with one another; and a lever pivotably coupled to the pivot surface of the first pin.

65. The powered surgical tool of claim 64, wherein the plastic housing defines a first recess, the first recess adjacent the first aperture, with the first recess including a first flat surface, with the first pin including a head and a shaft extending from the head, with the head including a second flat surface, the first pin positioned within the first aperture such that the second flat surface of the head engages the first flat surface of the first recess.

66. The powered surgical tool of claim 65, further including a torsion spring including a coil, a first leg, and a second leg, with the first leg and the second legs extending from opposite ends of the coil, with the coil surrounding the first pin.

67. The powered surgical tool of claim 65, wherein the plastic housing defines a channel, wherein the lever is pivotable about the first pin between a first fully depressed position and a second non-depressed position, and wherein the lever is at least partially disposed within the channel in both the first fully depressed position and the second non-depressed position.

68. The powered surgical tool of claim 65, further comprising: a handpiece including a motor; and wherein the plastic housing defines a recess for removably receiving the handpiece, the plastic housing defining a void space; a printed circuit board disposed in the void space; a rechargeable battery module disposed in the void space; the lever configured to receive an input from a user to cause power to be drawn from the rechargeable battery module and supplied to the motor, wherein the powered surgical tool has a pencil grip configuration; and wherein the plastic housing comprises a controller configured to regulate power drawn from the rechargeable battery module based on movement of the lever.

69. The powered surgical tool of claim 68, further comprising a handswitch sensor configured to output a handswitch sensor signal based on a position of the lever, wherein the controller is configured to receive the handswitch sensor signal and regulate power drawn from the rechargeable battery module based on the handswitch sensor signal.

70. The powered surgical tool of claim 69, wherein the handswitch sensor is further defined as a first handswitch sensor and the handswitch sensor signal is further defined as a first handswitch sensor signal, the powered surgical tool further comprising a second handswitch sensor being configured to output a second handswitch sensor signal based on a position of the lever, wherein the controller is configured to receive the second handswitch sensor signal and regulate power drawn from the rechargeable battery module based on the first handswitch sensor signal and the second handswitch sensor signal.

71. The powered surgical tool of claim 70, wherein the first handswitch sensor and the second handswitch sensor are each mounted to opposing surfaces of the printed circuit board, the controller being disposed on the printed circuit board.

72. The powered surgical tool of claim 71, wherein the lever includes a run-safe switch slidably mounted to the lever, a magnet being mounted to the run-safe switch, a lever extension movably coupled to the lever, wherein the handswitch sensor is a Hall effect sensor.

73. A powered surgical tool comprising: a housing defining a void; a circuit board disposed in the void of the housing for regulating operation of an electric motor; a rechargeable battery module disposed within the void; at least three motor pins spaced apart from one another to define an array of motor pins that extends through the housing and out of the void for establishing an electrical connection between the circuit board and the electric motor, wherein a hermetically- sealed housing-terminal interface is defined by the housing and the at least three motor pins; a routing feature disposed about the at least three motor pins, the routing feature defining a plurality of channels; and at least three wires, each of the three wires including a wire terminal connected to a first wire end of the at least three wires and the other end of the wire connected to the circuit board, each of wire terminals including a first end portion and a second end portion opposite the first end portion, the first end portion connected to one of the at least three wires, and the second end portion shaped to electrically engage one of the motor pins, each the wire terminals positioned within one of the channels of the routing feature.

74. The powered surgical tool of claim 73, wherein at least one motor pin of the at least three motor pins define a longitudinal axis and the circuit board defines a longitudinal axis, wherein the longitudinal axis of the at least one motor pin is parallel to the longitudinal axis of the circuit board.

75. The powered surgical tool of claim 74, wherein the at least three motor pins is further defined as at least six motor pins, and where the at least three wires is further defined as at least six wires.

76. The powered surgical tool of claim 75, wherein the at least six motor pins are positioned equidistant from a center of the array.

77. The powered surgical tool of claim 76, wherein the routing feature defines a rim, the rim defining the plurality of channels, and the rim surrounding the at least three motor pins.

78. The powered surgical tool of claim 77, wherein the first end portion of the wire terminal is disposed inside the rim and the second end portion of the wire terminal is disposed outside the rim.

79. The powered surgical tool of claim 78, wherein the wire terminal defines a bend of at least 70 degrees, and wherein the first end portion of the wire terminal is separated from the second end portion of the wire terminal by the bend.

80. The powered surgical tool of claim 79, wherein the plurality of channels includes a first channel and a second channel, wherein the first channel has a first depth and the second channel includes a second depth, the first depth being different from the second depth.

81. The powered surgical tool of claim 79, wherein the first end portion of the at least one of the wire terminals defining a plurality of arms, the arms crimped to engage the first wire end.

82. The powered surgical tool of claim 81, wherein the second end portion of the wire terminals defining a cylindrical void, the cylindrical void being disposed about the motor pins.

83. A powered surgical tool comprising: a handpiece including a motor; a module housing configured to couple with one of the handpiece and a charging module, wherein each of the handpiece and the charging module are configured to generate a magnetic field; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.

84. The powered surgical tool of claim 83, wherein the module housing comprises a rechargeable battery module and wherein the controller is disposed within the module housing and, wherein the digital hall effect sensor is configured to receive power from the rechargeable battery module in the sleep state, and wherein the analog hall effect sensor is configured to receive power from the rechargeable battery in the active state.

85. The powered surgical tool of claim 84, wherein the analog hall effect sensor receives a greater amount of power from the rechargeable battery in the active state than the digital hall effect sensor in the sleep state.

86. The powered surgical tool of any one of claims 83-85, wherein the controller is configured to: communicate with the handpiece using a first communication protocol in response to determining that the module housing has been coupled with the handpiece; and communicate with the charging module using a second communication protocol in response to determining that the module housing has been coupled with the charging module.

87. The powered surgical tool of claim 86, wherein the controller is configured to communicate using the first communication protocol by communicating at a first transmission speed, and wherein the controller is configured to communicate using the second communication protocol by communicating at a second transmission speed.

88. The powered surgical tool of claim 86, wherein the controller is configured to communicate using the first communication protocol by communicating using full duplex transmission, and wherein the controller is configured to communicate using the second communication protocol by communicating using half duplex transmission.

89. The powered surgical tool of any one of claims 83-88, wherein the controller is configured to transmit a communication signal to the handpiece based on determining that the module housing has been coupled with the handpiece.

90. The powered surgical tool of any one of claims 83-89, wherein the controller is configured to transmit a communication signal to the charging module based on determining that the module housing has been coupled with the charging module.

91. The powered surgical tool of any one of claims 83-90, wherein the module housing is further configured to couple with a programming fixture, wherein the programming fixture is configured to generate a magnetic field, and wherein the controller is configured to determine whether the module housing has coupled with programming fixture based on the magnetic field sensed by the analog hall effect sensor.

92. The powered surgical tool of claim 91, wherein the controller is configured to receive a communication signal from the programming fixture based on determining that the module housing has been coupled with the programming fixture.

93. A system for identifying a device coupled with a powered surgical tool comprising: a handpiece configured to generate a magnetic field; a charging module configured to generate a magnetic field; and a powered surgical tool comprising: a module housing configured to couple with one of the handpiece and the charging module; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.

94. The system of claim 93, wherein the analog hall effect sensor is further defined as a first analog hall effect sensor, wherein the printed circuit board assembly further includes a second analog hall effect sensor, and a third analog hall effect sensor.

95. The system of claim 94, wherein: the handpiece further includes a motor including a first rotor magnet and a second rotor magnet each being configured to generate a magnetic field to cause rotation of the motor; the first analog hall effect sensor, the second analog hall effect sensor, and the third analog hall effect sensor are each configured to sense the magnetic fields generated by the first rotor magnet and the second rotor magnet; the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing the magnetic fields generated by the first rotor magnet and the second rotor magnet; and the controller is configured to determine that the module housing has coupled with the handpiece based on the first analog hall effect sensor, the second analog hall effect sensor, and the third analog hall effect sensor sensing the magnetic fields generated by the first rotor magnet and the second rotor magnet.

96. The system of claim 93 further comprising a programming fixture including a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; the analog hall effect sensor is configured to sense a magnetic field by sensing a magnitude of the magnetic field; and a position of the magnet of the programming fixture and a position of the magnet of the charging module are selected such that the magnitude of the first magnetic field sensed by the analog hall effect sensor is different than the magnitude of the second magnetic field sensed by the analog hall effect sensor.

97. The system of claim 93 further comprising a programming fixture including a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; the analog hall effect sensor is configured to sense a magnetic field by sensing a polarity of the magnetic field; and a polarity of the magnet of the programming fixture and a polarity of the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the analog hall effect sensor is different than the polarity of the second magnetic field sensed by the analog hall effect sensor.

98. A powered surgical tool comprising: a first handpiece including a motor; a second handpiece including a motor; a module housing configured to couple with one of the first handpiece and the second handpiece, wherein each of the handpiece and the second handpiece are configured to generate a magnetic field; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging module based on the magnetic field sensed by the analog hall effect sensor.

99. A system for identifying a device coupled with a powered surgical tool comprising: a handpiece configured to generate a magnetic field; a charging module coupled to a charging adapter, the charging adapter being configured to generate a magnetic field; and a powered surgical tool comprising: a module housing configured to couple with one of the handpiece and the charging module; and a printed circuit board assembly including: a digital hall effect sensor configured to sense a magnetic field; an analog hall effect sensor configured to sense a magnetic field; and a controller configured operate in: a sleep state, in which the digital hall effect sensor is active and the analog hall effect sensor is inactive; and an active state, in which the analog hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has coupled with one of the handpiece and the charging adapter based on the magnetic field sensed by the analog hall effect sensor.

100. A charging system for charging a rechargeable battery module of a powered surgical tool, the powered surgical tool including a module housing configured to receive a handpiece, the charging system comprising: a charger comprising a recess; and an adapter comprising: a charger protrusion configured to be received by the recess, wherein the recess includes a surface facing a first direction; and a module protrusion configured to be received by the module housing to allow the charger to provide power to the rechargeable battery module via the adapter, wherein the module protrusion extends in a direction different than the first direction.

101. The charging system of claim 100, wherein the charger includes two recesses, and wherein the adapter includes two charger protrusions configured to engage the two recesses.

102. The charging system of claim 101, wherein the adapter includes two module protrusions.

103. The charging system of claim 102, wherein: each recess includes a width; each of the module protrusions includes a width; and a sum of the widths of the module protrusions is less than the width of a recess.

104. The charging system of claim 103, wherein the two charger protrusions of the adapter are disposed along a first direction, and wherein the two module protrusions are disposed along a second direction different than the first direction.

105. A charging system for charging a rechargeable battery module of a first powered surgical tool of a pencil grip type and a rechargeable battery module of a second powered surgical tool of a pistol grip type, wherein the first and second powered surgical tools each include a module housing configured to receive a handpiece, the charging system comprising: a charger including a recess; and an adapter including: a charger protrusion configured to be received by the recess; and a module protrusion configured to be received by: the module housing of the first powered surgical tool to allow the charger to provide power to the rechargeable battery module of the first powered surgical tool via the adapter; and the module housing of the second powered surgical tool to allow the charger to provide power to the rechargeable battery module of the second powered surgical tool via the adapter.

106. The charging system of claim 105, wherein the module protrusion includes: a first latch configured to engage an interface of the module housing of the first powered surgical tool; and a second latch configured to engage an interface of the module housing of the second powered surgical tool.

107. The charging system of claim 106, wherein: the module protrusion includes a first portion shaped to be received by the module housing of the first powered surgical tool; and a second portion shaped to be received by the module housing of the second powered surgical tool.

108. The charging system of claim 107, wherein: the module housing of the first powered surgical tool includes a first radius; the module housing of the second powered surgical tool includes a second radius different than the first radius; the first portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the first powered surgical tool; and the second portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the second powered surgical tool.

109. The charging system of claim 107, wherein the module protrusion includes: a first latch disposed on the first portion, the first latch being configured to engage an interface of the module housing of the first powered surgical tool; and a second latch disposed on the second portion, the second latch being configured to engage an interface of the module housing of the second powered surgical tool.

110. A charging system comprising: a charger including a recess; an adapter including: a charger protrusion configured to be received by the recess; a module protrusion; and a magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; a first powered surgical tool including: a first module housing configured to receive the module protrusion, the first module housing including a first end and a second end; a first hall sensor located a first distance from the first end of the module housing; and a first controller configured to transition from a sleep state to an active state based on the first hall sensor sensing a magnetic field, wherein the first controller is configured to communicate with the charger when the first controller is in the active state; and a second powered surgical tool including: a second module housing configured to receive the module protrusion, the second module housing including a first end and a second end; a second hall sensor located a second distance from the first end of the second module housing, the second distance being different from the first distance; and a second controller configured to transition from a sleep state to an active state based on the second hall sensor sensing a magnetic field, wherein the second controller is configured to communicate with the charger when the second controller is in the active state.

111. The charging system of claim 110, wherein the first hall sensor is configured to sense the magnetic field generated by the magnet in response to the first module housing receiving the module protrusion.

112. The charging system of claim 111, wherein the second hall sensor is configured to sense the magnetic field generated by the magnet in response to the second module housing receiving the module protrusion.

113. A charging system comprising: a charger; a battery configured to receive power from the charger in response to contacting the charger; an adapter including: a charger protrusion configured to contact the charger; a module protrusion; and a magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; and a powered surgical tool including: a module housing configured to receive the module protrusion; a hall sensor; and a controller configured to transition from a sleep state to an active state based on the hall sensor sensing a magnetic field, wherein the controller is configured to communicate with the charger when the controller is in the active state.

114. The charging system of claim 113, wherein the controller is configured to communicate using a first communication protocol, and wherein the charger is configured to communicate using a second communication protocol, and wherein the adapter is configured to translate one of the first communication protocol and the second communication protocol into the other one of the second communication protocol and the first communication protocol such that the controller is configured to communicate with the charger via the adapter.

115. The charging system of claim 114, wherein the charger includes a charger power terminal and a charger communication terminal, wherein the charger protrusion includes an adapter communication contact configured to contact the charger communication terminal and an adapter power contact configured to contact the charger power terminal, wherein the module protrusion includes a first adapter communication terminal and a second adapter communication terminal in communication with the adapter communication contact, and wherein the first and second adapter communication terminals are shorted to one another to such that the controller is configured to communicate with the charger via the adapter.

116. The charging system of claim 115, wherein the controller is configured to communicate using the first communication protocol by communicating using full duplex transmission, and wherein the charger is configured to communicate using the second communication protocol by communicating using half duplex transmission; and wherein the adapter is configured to translate the second communication protocol into the first communication protocol by translating a half duplex transmission into a full duplex transmission.

117. A surgical handpiece for coupling to a battery and control module, the surgical handpiece comprising: a housing; an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft being, at a first end, coupled to the electric motor and, at a second end, configured to be coupled to a surgical tool, wherein the output shaft defines a lumen centered upon the longitudinal axis of the output shaft; a cannula disposed partially within the lumen and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing and configured to prevent a liquid from entering an interior of the surgical handpiece, wherein the cannula passes through the sealing plug; a seal disposed around an outside of the cannula; and a plurality of terminals extending through the sealing plug.

118. The surgical handpiece of claim 117, wherein the second distal end includes a tool coupler.

119. The surgical handpiece of any one of claims 117 and 118, wherein the lumen centered upon the longitudinal axis of the output shaft is a first lumen; wherein the seal includes a cylinder shape with a second lumen; and wherein the cannula is disposed within the second lumen.

120. The surgical handpiece of claim 119, wherein the seal includes a first sealing surface upon an end surface of the cylinder shape, wherein the end surface abuts a mating surface upon the sealing plug.

121. The surgical handpiece of claim 120, wherein the seal includes a second sealing surface including an annular ring-shaped surface upon an inner diameter of the seal, the annular ring-shaped surface abutting an outer surface of the cannula.

122. The surgical handpiece of any one of claims 117-121, wherein the sealing plug comprises a polymer.

123. The surgical handpiece of claim 122, wherein the housing includes an internal structure insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece; and wherein the sealing plug is press-fit within the inner diameter of the internal structure insert.

124. The surgical handpiece of claim 123, further comprising a socket stopper disposed around an outside of the internal structure insert and the sealing plug, wherein the socket stopper is configured to retain the sealing plug within the inner diameter of the internal structure insert.

125. The surgical handpiece of any one of claims 117-124 wherein the seal is disposed in contact with the cannula flange.

126. A powered surgical tool comprising: a surgical handpiece, including: a housing; an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft being, at a first end, coupled to the electric motor and, at a second end, configured to be attached to a surgical tool, wherein the output shaft defines a lumen centered upon the longitudinal axis of the output shaft; a cannula disposed partially within the lumen and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing, wherein the cannula passes through the sealing plug; a seal disposed around an outside of the cannula; and a plurality of terminals extending through the sealing plug; and a battery and control module including a recess configured to receive the surgical handpiece.

127. The powered surgical tool of claim 126, wherein the battery and control module further includes a cannula access point configured to enable external access to the cannula within the first proximal end of the surgical handpiece.

128. The powered surgical tool of any one of claims 126 and 127, wherein the second distal end includes a tool coupler.

129. The powered surgical tool of any one of claims 126-128, wherein the seal includes a cylinder shape with a hollow center; and wherein the cannula is disposed within the hollow center of the seal.

130. The powered surgical tool of claim 129, wherein the seal includes a first sealing surface upon an end surface of the cylinder shape abutting a mating surface upon the sealing plug; and wherein the seal includes a second sealing surface including an annular ring upon an inner diameter of the seal abutting an outer surface of the cannula.

131. The powered surgical tool of any one of claims 126-130, wherein the sealing plug comprises a polymer.

132. The powered surgical tool of claim 131, wherein the housing includes an internal structure insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece; and wherein the sealing plug is affixed with a press-fit within the inner diameter of the internal structure insert.

133. The powered surgical tool of claim 132, further comprising a socket stopper disposed around an outside of the internal structure insert and the sealing plug, wherein the socket stopper is configured to retain the sealing plug within the inner diameter of the internal structure insert.

134. The powered surgical tool of any one of claims 126-130, wherein the seal is disposed in contact with the cannula flange.

135. The powered surgical tool of any one of claims 126-134, wherein the battery and control module defines a pistol grip.

136. A powered surgical tool comprising: a battery and control module including: a sealed housing assembly including: a printed circuit board including at least one trigger sensor; a plurality of housings sealingly joined together and configured to encase the printed circuit board and the at least one trigger sensor therewithin; and at least one trigger lumen configured to receive a trigger, wherein the at least one trigger sensor is disposed proximate to the at least one trigger lumen; and at least one trigger installed to the battery and control module within the at least one trigger lumen, the at least one trigger including a stem portion configured to be engaged with the at least one trigger lumen, wherein the stem portion includes at least one magnet configured to interact with the at least one trigger sensor.

137. The powered surgical tool of claim 136, wherein the at least one trigger lumen includes a trigger vent cutout formed in a wall of the at least one trigger lumen; wherein the trigger vent cutout is formed in a surface of the wall without compromising a seal of the sealed housing assembly; and wherein the trigger vent cutout is configured to enable air to be released from behind the at least one trigger when the at least one trigger is depressed or installed.

138. The powered surgical tool of any one of claims 136 and 137, wherein the at least one trigger is retained in the at least one trigger lumen with a screw and a front plate; and wherein the screw and the front plate enable the at least one trigger to be replaced without compromising a seal of the sealed housing assembly.

139. The powered surgical tool of any one of claims 136-138, wherein the sealed housing assembly includes two trigger lumens; and further comprising two triggers.

140. The powered surgical tool of any one of claims 136-139, wherein the sealed housing assembly further includes a battery including at least one battery cell.

141. The powered surgical tool of any one of claims 136-140, wherein the sealed housing assembly further includes a handpiece lumen configured to receive a handpiece including a modular motor configured to provide energy to a surgical end effector.

142. The powered surgical tool of any one of claims 136-141, wherein the at least one trigger sensor is configured to detect the at least one magnet through one of the plurality of housings.

143. The powered surgical tool of any one of claims 136-142, wherein the plurality of housings sealingly joined together are welded together with one of a vibration welding process or a laser-process.

144. A method of operating a powered surgical tool comprising the steps of: providing a battery and control module including a sealed housing assembly, the housing assembly encapsulating a printed circuit board that includes at least one trigger sensor and at least one trigger lumen configured to receive a trigger; and installing at least one trigger into the trigger lumen, the trigger including a stem portion with at least one magnet configured to interact with the trigger sensor without compromising the seal of the sealed housing assembly.

145. A method of repairing a powered surgical tool comprising the steps of: providing a battery and control module including a sealed housing assembly, the housing assembly encapsulating a printed circuit board that includes at least one trigger sensor, the battery and control module further including a trigger with a magnet; and removing the trigger from the battery and control module without compromising the seal of the sealed housing assembly.