To support code generation with our target processor, we worked with a third-party software development group to develop a software framework that performs low-level tasks to initialize the board’s interrupts and peripherals. We also performed what-if analysis to determine a lower limit for sensor resolution that would still enable the design to meet its submillimeter tolerances for positioning. We designed filters to eliminate the problem, and verified the fix via simulation-all before the hardware was ready. Our simulations revealed errors in our digital signal processing algorithm. For example, we used specifications from the sensor datasheet to update our submodel of the sensor. While waiting for the board with these components to be assembled, we modified our Simulink controller model to reflect the changes. To prepare for production using less expensive components, we began designing a second prototype using hardware comparable to the type that will be used in production, including a more modestly powered Cortex-M4 processor and a single, lower-resolution sensor. Our first prototype was designed with a relatively high-powered processor and multiple high-resolution sensors. Using this approach we were able to create a prototype that surgeons found comfortable, stable, and intuitive while refining system requirements in preparation for moving into production. We used MATLAB ® and Simulink ® to model and simulate the stapler’s motor and controls, and then generated code for ontarget rapid prototyping using Embedded Coder ®. Using this workflow, we designed and built a prototype for a next-generation endoscopic surgical stapler in just three months. At Ethicon Endo-Surgery, Inc, we have adopted a rapid prototyping workflow based on Model-Based Design that enables us to implement and test new design refinements in minutes and reduce overall development time by months. Each design modification can take weeks to implement, making traditional design workflows unfeasible. It takes many design iterations to perfect the control and feel of a laparoscopic device. For laparoscopic surgeons, who perform procedures through 5-to-15-millimeter incisions, such instruments are critical. Instruments that have intuitive controls and feel right in the hands are key requirements for all surgeons.
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