Needle blank feeding apparatus

Abstract: A needle machining apparatus (10) which presents a stock needle to a device (12) for boring a hole in the needle. The apparatus also includes a needle feeding apparatus (14) which provides high speed feeding of blank needles for the needle machining apparatus. A method for high speed feeding of needles for subsequent laser drilling is also disclosed.

Description: The present invention relates to a needle machining apparatus which presents a stock needle to a device for boring a hole in the needle for subsequently securing a suture, thereto. The present invention is applicable to a high speed needle feeding apparatus for continuously feeding needle blanks for subsequent laser drilling. The invention also relates to a method for creating a hole in each of a plurality of needle shanks. Surgical sutures are generally manufactured by first longitudinally drilling a hole through the end face of a blank stock needle, bending the needle to a desired curvature, inserting an appropriate suture into the hole and crimping or otherwise securing the suture material to the needle. Generally, there are numerous ways to drill or cut the hole in the end face. For example, the hole may be made by drill machining, electric discharge machining, laser beam machining, electron beam machining and the like. With the advent of microsurgical procedures, surgical sutures have become increasingly smaller in size, thus making it more complex and costly to manufacture the surgical needles. In particular, one aspect of surgical suture manufacturing which has become complex is drilling the hole in the needle. A common procedure for making a hole in a surgical needle utilizes laser or electron beam machining. In order to utilize these methods in a production environment, techniques have been developed to continuously present a blank needle before the bean for cutting. One such technique includes presenting the blank needle from a rotary spool which is sequentially rotated to present an end face in line with the focal plane of the laser or electron beam. However, one drawback to this technique is that the rotating spool must stop before the beam is impinged on the needle. In order to operate properly the spool must come to a rest at precisely the same position aligned with the focus point of the beam. If the needle in the rotating spool is not aligned with the focus point of the beam, even by an infinitesimal amount, the centrality of the hole would be off center, thereby reducing the accuracy of the production process and ultimately resulting in increased defective quantities of needles. Currently, rotary spool systems are unable to obtain the precise positioning required for laser or electron beam machining. This lack of precision is magnified as the speed in which the blank needle is presented increases. As a result, the reliability and accuracy of rotary spool feeding systems is unacceptable in a high volume production environment. Another technique utilized has been to bundle blank needles into a container, digitize an image of the needle faces in the bundle and move the laser or electron beam to focus sequentially on each needle before firing the beam. These types of beam machining devices also have drawbacks, such as the need to optically determine where each needle is and then move the beam to coincide with the longitudinal axis at the center of the needle. Such systems are complex and require additional steps in order to determine the precise position of each needle. As a result, the speed of producing sufficient quantities to satisfy production needs is decreased. Therefore, a need exists for a precise needle blank feeding system which can be reliably operated at high speeds and which does not require movement of the laser or electron beam. According to one aspect of the invention, there is provided an apparatus for presenting a needle shank to a device for boring a hole in the needle shank, which comprises: a frame; guide means secured to said frame for transferring a needle shank between a needle receiving position and a hole creating position; blocking means slidably secured to said frame for positioning the needle shank a predetermined distance from said hole creating device; pusher means slidably secured to said frame for sliding the needle shank to abut said blocking means, such that the needle shank is positioned from said hole creating device said predetermined distance; and jaw means slidably secured to said frame for maintaining the needle shank in said hole creating position. According to another aspect of the invention, there is provided a method for creating a hole in each of a plurality of needle shanks using an apparatus for presenting needle shanks to hole creating means, said apparatus having frame means, guide means secured to said frame means for transferring each needle shank between needle receiving and hole creating positions, blocking means slidably secured to said frame means for positioning each needle shank a predetermined distance from said hole creating means, pusher means movably secured to said frame means for moving each needle shank to abut said blocking means, such that each needle shank is positioned said predetermined distance from said hole creating means, and jaw means slidably secured to said frame means for maintaining the needle shank in said hole creating position, the method comprising: sequentially advancing a plurality of needle shanks at a rate between about 1 Hz and about 10 Hz into said hole creating position such that the longitudinal axis of each needle shank is in substantial alignment with a predetermined axis of said hole creating means to permit creating a hole along the longitudinal axis of each needle shank; and activating said hole creating means to create the hole in each needle shank. The features of the present invention will become more readily apparent and may be understood by referring to the following detailed description of an illustrative embodiment of the invention, taken in conjunction with the accompanying drawings, in which: Fig. 1 is a perspective view from the rear of the needle machining system of the present invention; Fig. 2 is a rear view of a needle feeding apparatus which forms part of the system of Fig. 1, illustrating the primary drive system and the adjustable base assembly; Fig. 3 is a perspective view of a needle shank machined by the needle machining system of Fig. 1; Fig. 4 is a top view, partially in cross-section, of the needle feeding apparatus taken along lines 4-4 of Fig. 2; Fig. 5 is a left side view of a portion of the adjustable base assembly taken along lines 5-5 of Fig. 2; Fig. 6 is a left side view, partially in cross-section, of the primary drive system taken along lines 6-6 of Fig. 2; Fig. 7 is a front view of a portion of the needle positioning system of the needle machining system of Fig. 1 taken along lines 7-7 of Fig. 6; Fig. 8 is a top view, partially in cross-section, of the needle positioning system taken along lines 8-8 of Fig. 7; Fig. 9 is a front view, partially in cross-section, of the needle positioning system taken along lines 9-9 of Fig. 8; Fig. 10 is a perspective view with parts separated, of the needle positioning system of Fig. 7, showing the jaw assembly, pusher assembly, guide assembly, and the blocking system; Fig. 11 is a front view of the needle positioning system taken along lines 11-11 of Fig. 8; Fig. 12 is a top plan view of the needle blank supply hopper assembly of Fig. 7, illustrating a portion of an anti-binding system; Fig. 12a is a cross-sectional view of the cycle wheel which forms part of the anti-binding system taken along lines 12A-12A of Fig. 12. Fig. 13 is a top view, partially in cross-section, of a portion of the needle detection system taken along lines 13-13 of Fig. 7; Fig. 14a is a front view, partially in cross section, of the needle positioning system of Fig. 7 and a portion of the supply hopper assembly of Fig. 12, illustrating a row of needle blanks in position prior to creation of the hole, and a needle blank being released after creation of the hole; Fig. 14b is a front view similar to Fig. 14a, illustrating the next needle blank in position in the needle carriage prior to transfer to the hole creation position; Fig. 14c is a front view similar to 14b, after the needle carriage has transferred the needle to one jaw in the hole creation position, prior to creation of the hole; and Fig. 14d is a view similar to Fig. 14c, illustrating the needle blank in the hole creating position gripped by both needle gripping jaws after creation of the hole. Referring now in detail to the drawings, in which like reference numerals identify similar or identical elements throughout the several views, Fig. 1 illustrates a needle machining system 10 which includes a hole making device 12, a needle feeding apparatus 14, a control system 16 and an imaging system 18. The hole making device 12 preferably comprises a laser, however, it should be understood that the hole making device may include a wide variety of machinery, such as, drill machinery, electric discharge machining devices and electron beam machining devices. Referring to Figs. 1 through 6, the needle feeding apparatus 14 of system 10 includes frame 20, drive system 22, and needle positioning system 24. In the preferred embodiment, shown in Figs. 2 and 6, frame 20 has adjustable base assembly 26, vertical support 28 secured to base 36 by side walls 50 and 52, and operational platform 30 secured to vertical support 28. Adjustable base assembly 26 is provided to support the operational components of needle feeding apparatus 14 and to provide proper alignment and adjustment of the position of the needle prior to drilling or machining the hole. Frame 20 is movable by adjusting the position of adjustable base assembly 26 to ensure that the hole is centered in the face 35 of the needle 37 and extends linearly therein a predetermined depth, as shown in Fig. 3. The depth of the hole may vary depending on the type of suture to be inserted therein and the diameter, length and composition of the needle. Referring to Figs. 2 and 4, adjustable base assembly 26 includes base support members 32, base retainer 34 and base 36 which provide for adjustment of the needle in five axes. Base retainer 34 is secured to base supports 32, with vertical adjusting members 38, while base 36 is slidably secured to base retainer 34 with set screws 40. An example of the five axes adjustment of adjustable base assembly 26 lies within the three dimensional rectangular coordinate system. The base is adjustable in the positive and negative x direction, the positive and negative y direction, the positive and negative z direction or any combination thereof. In addition, rotational adjustment is provided in the x-y plane and in the y-z plane. To illustrate and referring to Fig. 4, x-plane adjusting members 42 provide left to right adjustment of base 36, while y-plane adjusting members 44 provide back and forth adjustment of base 36. As shown in Fig. 5, vertical adjustment of base 36 is provided by vertical adjusting members 38. Rotational movement of base 36 is provided by properly adjusting y-plane adjusting members 44 for x-y plane rotation and/or vertical adjusting members 38 for y-z plane rotation. Preferably, the various adjusting members are screws which cause the corresponding motion as described. However, bolts, micrometers, and the like may be utilized as aligning members. It should be noted that the underlying principle in adjusting base 36 is to properly position the longitudinal axis of the needle within the focal plane or cutting axis of the laser, so that the hole is substantially centered within needle 37, as shown in Fig. 3. Gauges 48 may be provided to ensure that base 36 is symmetrically adjusted in each axis the same distance. To supplement the positioning of the needle in the hole creating position an imaging system 18 is provided to assist in the initial adjustment of the needle. As shown in Fig. 1, imaging system 18 generally includes video camera 54, lens assembly 56 and video monitor 58. In the preferred embodiment, lens assembly 56 is connected to focal lens 60 of laser 12 so that the focal plane of lens assembly 56 coincides with the focal plane of laser 12. Video camera 54 is connected to lens assembly 56 and electrically connected to video monitor 58. Cross-hairs 59 superimposed on the video image correspond to the focus point of laser 12. As a result, the displayed image on video monitor 58 includes needle face 35 and cross-hairs 59, as shown in Fig. 1. In this configuration, imaging system 18 allows an operator to observe the needle face 35 in the hole creating position and adjust the frame, as discussed above, to align the longitudinal axis of the needle with the center point of the intersecting cross-hairs. Drive system 22 will now be described with reference to Figs. 2, 6, 8 and 9. Preferably, drive system 22 includes; a) motor 62 secured to vertical support 28; b) primary drive shaft 64 rotatably secured to support 28 having primary drive wheel 66 secured thereto; c) clutch assembly 68 operatively connected to primary drive shaft 64; d) primary cam system 70 connected to primary drive shaft 64; e) secondary drive shaft 72 operatively connected to primary drive shaft 64; and f) secondary cam system 74 connected to secondary drive shaft 72. Referring to Fig. 2, motor 62 rotates primary drive wheel 66 via primary drive belt 76 connected between primary drive wheel 66 and motor drive wheel 67. Although primary drive belt 76 is utilized to transfer the rotational movement of motor 62 to primary drive shaft 64 any other known device may be used to transfer the rotational movement, such as gears, chain links and the like. The rate at which the motor rotates varies with the operational speed of needle machining system 10, which is regulated by control system 16. For example, if a laser is utilized to make the hole, the motor should rotate at a speed which allows maximum use of the laser while maintaining the accuracy of needle feeding apparatus 14. Thus, if the laser is programmed to fire at a rate of 4 Hertz (Hz), the motor must rotate so that 4 needles per second are positioned in the hole creating position. Similarly, if the laser is programmed to operate at 2 Hz, the motor must rotate so that 2 needles per second are positioned in the hole creating position. Referring to Fig. 6, clutch assembly 68 is provided to transfer rotational movement of primary drive wheel 66 to primary drive Shaft 64. The clutch assembly is shown in phantom in Fig. 2 for the purpose of clearly illustrating the primary drive shaft and its associated components, however, the clutch assembly is shown in detail in Fig. 6. Preferably, clutch assembly 68 includes solenoid 78, solenoid arm 80 and brake arm 82. However, other types of known clutch mechanisms are contemplated. To activate clutch assembly 68 solenoid 78 is energized, preferably from a 24 volt electrical signal from control system 16, which indicates that the laser is ready to activate. Energized solenoid 78 causes solenoid arm 80 to retract so as to disengage from brake arm 82. Release of brake arm 82 allows primary drive shaft 64 to rotate until solenoid 78 is deactivated. Deactivation of solenoid 78 causes solenoid arm 80 to protract and engage brake arm 82 so as to inhibit primary drive shaft 64 from rotating. Referring to Figs. 6 and 8, primary cam system 70 is secured to primary drive shaft 64 to translate the rotational movement of primary drive shaft 64 to the reciprocating movement of pusher system 84 and guide assembly 86. Primary cam system 70 includes upper primary cam 88, intermediate primary cam 90 and lower primary cam 92, where upper primary cam 88 and intermediate primary cam 90 reciprocate guide assembly 86 and lower primary cam 92 reciprocates pusher system 84. Secondary drive shaft 72 is rotatably secured to vertical support 28 and has secondary drive wheel 94 secured thereto. Secondary drive wheel 94 is operatively connected to intermediate drive wheel 96 on primary drive shaft 64, so as to transfer rotational movement of primary drive shaft 64 to secondary drive shaft 72. Typically, drive belt 98 which passes through vertical support 28, is employed to connect primary drive shaft 64 to secondary drive shaft 72. However, other known techniques may be utilized to transfer the rotational movement between the shafts, such as gears, chain links and the like. Referring to Figs. 8 and 9, secondary cam system 74 is secured to secondary drive shaft 72 to translate the rotational movement of secondary drive shaft 74 to the reciprocating movement of blocking system 100 and jaw assembly 102. Secondary cam system 74 includes upper secondary cam 104 and lower secondary cam 106, where upper secondary cam 104 reciprocates jaw assembly 102 and lower secondary cam 106 reciprocates blocking system 100. The needle positioning system 24 will now be described with reference to Figs. 6 through 11. In the preferred embodiment, shown in Fig. 10, needle positioning system 24 includes guide assembly 86, blocking system 100, pusher system 84 and jaw assembly 102, which are slidably secured to operational platform 30. Referring to Fig. 8, guide assembly 86 includes carriage 108 and guide member 110. Carriage 108 is slidably secured to guide track 112 and reciprocates between a needle receiving position and a hole creating position. Guide member 110 is slidably secured within guide track 112 at a point adjacent the hole creating position and in opposition to carriage 108. In the preferred embodiment, carriage 108 and guide member 110 are fabricated from an aluminum-bronze alloy. If necessary or desirable a lubricant may be added to carriage 108, guide member 110 and/or guide track 112 to provide lubrication for guide assembly 86. However, it is also contemplated that guide assembly 86 may be fabricated from materials, such as an oil or other lubricant impregnated material, which may be used in conjunction with a lubricating substance to assist the sliding motion. As noted above and referring to Figs. 6 and 8, reciprocating movement of carriage 108 is caused by primary cam system 70. Cooperation between upper primary cam 88 and carriage spring 114 causes carriage arm 116 to reciprocate. Reciprocating movement of carriage arm 116 causes carriage 108 to reciprocate between the needle receiving position and the hole creating position. Reciprocating movement of guide member 110 is also caused by primary cam system 70, however, guide member 110 is reciprocated between the hole creating position in opposition to carriage 108 and an open position in which guide member 110 is displaced from the hole creating position. To illustrate, cooperation between intermediate primary cam 90 and guide spring 118 causes guide arm 120 to reciprocate. Reciprocating movement of guide arm 120 causes guide member 110 to reciprocate between the hole creating position and the open position. The needle receiving position represented by the letter "A" in Fig. 9, is the plane along guide track 112 where a needle is supplied to carriage 108. The hole creating position on the other hand, is the plane along guide track 112 where the needle is positioned for subsequent drilling, as shown by the letter "B" in Fig. 9. Generally, the supplied needle is oriented so that the longitudinal axis of the needle is substantially perpendicular to the longitudinal axis of guide track 112 with one face of the needle positioned toward the laser. It should be noted, however, that the requirement for orientation of the longitudinal axis of the needle is such that the needle face coincides with the focus point or cutting point of the laser so that the hole created is centered on the front face of the needle and extends linearly into the needle, as shown in Fig. 3. Referring again to Figs. 6 and 8, pushing system 84 is provided to push the needle along its longitudinal axis in the hole creating position to a predetermined distance from laser 12. Pushing the needle toward laser 12 enables jaw assembly 102 to grasp the needle, while the predetermined distance between the needle and laser 12 ensures the precision of the depth and shape of the hole and, in some instances, prevents overheating and discoloration of the needle when drilling. As noted above, the pushing system 84 is activated by lower primary cam 92 of primary cam system 70. To illustrate, cooperation between lower primary cam 92 and wheel 93 against the biasing force of pusher spring 122 causes pusher pin 124 to vertically reciprocate. Reciprocating movement of pusher pin 124 causes pusher bar 126 to reciprocate between the hole creating position and an open position displaced from the hole creating position. Referring to Figs. 8 and 11, blocking system 100 is provided to prevent the needle from extending a predetermined distance beyond jaw assembly 102 and guide assembly 86 in the direction of the laser. As a result, pusher system 84 may push the needle toward the laser a maximum distance which abuts blocking system 100. In the preferred embodiment, the blocking system includes a shutter 128 positioned adjacent to jaw assembly 102 and slidably secured to operational platform 30. Cooperation between lower secondary cam 106 of secondary cam system 74 and shutter spring 130 causes shutter arm 132 to reciprocate. Reciprocating movement of shutter arm 132 causes shutter 128 to reciprocate along a path parallel to guide 112, between an intersecting position, where shutter 128 intersects the focal or cutting plane of the laser, and a retracted position where shutter 128 no longer intersects the laser's focal or cutting plane. Referring to Figs. 8, 10 and 11, jaw assembly 102 includes a pair of jaws 134 and 136 which are preferably fabricated from carbide, to enable jaw assembly 102 to withstand arcing caused when the laser beam is impinged on the needle shank without deteriorating. Fixed jaw 134 is rigidly secured to operational platform 30 adjacent guide 112 so as to have fixed gripper 138 in communication with the plane of the hole creating position. Movable jaw 136 is slidably secured to operational platform 30 adjacent guide 112 so as to have movable gripper 140 slide into communication with the plane of the hole creating position in opposition to fixed gripper 138. As noted above, jaw assembly 102 is activated by upper secondary cam 104 of secondary cam system 74 and maintains the needle in the hole creating position until the hole has been created. To illustrate, cooperation between upper secondary cam 104 and jaw spring 142 causes jaw arm 144 to reciprocate. Reciprocating movement of jaw arm 144 causes movable jaw 136 to move between an open position which allows an existing needle between the jaws to fall through, and a closed position which grasps the new needle to be drilled. Turning to Figs. 6, 7 and 9, supply hopper 146 is provided to continuously supply blank needles to guide assembly 86. In the preferred embodiment, supply hopper 146 is secured to operational platform 30 adjacent the needle receiving position of guide assembly 86 and continuously supplies needles thereto. However, supply hopper 146 may be releasably secured to platform 30 such that supply hopper 146 can be replaced with a new full hopper assembly after the existing supply of needles has depleted. For example, supply hopper 146 may be secured to platform 30 by a track which receives flanges (not shown) positioned on supply hopper 146, to frictionally secure supply hopper 146 to platform 30. Another example for releasably securing supply hopper 146 to platform 30 may be to provide a snap-lock mechanism in which a first flange on supply hopper 146 snaps into a corresponding channel in platform 30, while a second flange on supply hopper 146 snaps into a corresponding channel in a spring loaded member secured to platform 30. The spring loaded member would allow an operator to release the supply hopper from the platform by simply retracting the spring loaded member so that the second flange is exposed, thus enabling the operator to tilt or pivot the supply hopper and disengage the first flange. Referring to Figs. 6, 7 and 12, supply hopper 146 is also provided with an anti-binding system which prevents needles within supply hopper 146 from binding at the point where the needles are supplied to guide assembly 86. Preferably, anti-binding system 148 includes cycle wheel 150, gear 152, drive means such as chain 154 and hopper motor 156. Cycle wheel 150 is rotatably secured within supply hopper 146 at a point adjacent to needle supply opening 158, thereby ensuring continuous and sequential gravity feeding of needles through needle supply opening 158, as shown in Figs. 12, 12a and 14a. Gear 152 is secured to cycle wheel 150 on the exterior of supply hopper 146 and is operatively connected to hopper motor 156 by drive chain 154. Hopper motor 156 continuously rotates cycle wheel 150 in a direction opposite the direction needles are supplied to guide assembly 86, i.e., a counter-clockwise direction, which prevents needles from building-up and binding at needle supply opening 158. Preferably, cycle wheel 150 is a twenty-four sided, about one-half inch diameter wheel which is fabricated from a polyurethane material to prevent the needles from binding at needle supply opening 158, as shown in Fig. 14a. Utilization of a polyurethane material also prevents excessive marring of the needle shank surface. However, cycle wheel 150 may be fabricated from other suitable materials such as rubber. To illustrate the dimensioning of cycle wheel 150, Fig. 12a shows cycle wheel 150 divided into four quadrants having six sides within each quadrant. As shown, the first quadrant begins with side below side 150d and ends with side 150a the sixth side. The second quadrant begins with the side to the left of side 150a and ends with side 150b, the twelfth side. The third quadrant begins with the side above side 150b and ends with side 150c, the eighteenth side. The fourth side begins with the side to the right of said 150c and ends with side 150d, the twenty fourth side. However, cycle wheel 150 may be in other known configurations which prevent binding of the needle at the needle supply opening. Referring again to Fig. 6, receiving hopper 160 may also be provided to receive the needles after the hole has been created therein. Receiving hopper 160 is releasably secured to frame 20 at a point aligned in communication with the hole creating position. Preferably, receiving hopper 160 is releasably secured to frame by positioning receiving hopper 160 on platform 161 secured to frame 20, so as to releasably maintain receiving hopper 160 in communication with the hole creating position. After a hole has been created in a needle, movable jaw 136 is moved to release the needle, which drops by gravity into receiving hopper 160. Referring again to Fig. 1, control system 16 is connected to laser 12 and needle feeding apparatus 14 and provides control signals thereto. Preferably, control system 16 is programmable which enables the operator to set the desired operational speed of needle feeding apparatus 14 and laser 12. An example of a suitable control system includes a GE-Fanuc 9030 Programmable Controller, a LCD display manufactured by Horner Electric and numerous control switches and indicators. In order to properly operate, the timing for activating laser 12 and needle feeding apparatus 14 should be synchronized so that the laser cannot activate until the needle is present in the hole creating position. To accomplish this, it is preferred that the operating frequency of the laser be provided by the control system. For example, if the desired operating speed of the system is 240 needles per minute (4 Hz) control system 16 will supply a 4 Hz signal to the laser. Control system also activates solenoid 78, shown in Fig. 6, so that the operation of needle feeding apparatus 14 is synchronized with the firing of the laser. As noted above, control system 16 also provides the variable voltage to motor 62, shown in Fig. 2. Referring to Figs. 2, 7 and 13, it is also preferred that needle detecting system 162 be provided to ensure that a needle is present in the hole creating position prior to activating the laser. When no needle is present, needle detecting system 162 inhibits the laser from activating so that the laser beam does not accidentally impinge the mechanical structure of needle feeding apparatus 14. Preferably, needle detecting system 162 includes photo proximity switch 164 and photo sensor 166 connected to proximity switch 164. When activated, proximity switch 164 sends a signal to control system 16 so as to inhibit the laser from activating if a needle is not present. Photo sensor 166 is secured to vertical support 28 by bracket 167 so that photo sensor 166 is positioned within close proximity to the hole creating position to detect a needle positioned in the hole creating position. An operation cycle of needle feeding apparatus 14 will be discussed with reference to Figs. 6 and 8. Initially, solenoid 78 retracts solenoid arm 80 which allows clutch assembly 68 to activate. Activation of clutch assembly 68 causes primary drive shaft 64 to rotate. Rotational movement of primary drive shaft 64 causes primary drive wheel 66 and primary cam system 70 to rotate. Rotational movement of intermediate drive wheel 96 rotates secondary drive shaft 72 and ultimately secondary cam system 74. The timing pattern of the actuation of the cam systems is as follows: upper secondary cam 104 of secondary cam system 74 initially causes jaw assembly 102 to open while upper primary cam 88 and intermediate primary cam 90 of primary cam system 70 causes guide assembly 86 to open. At this point any needle which may be in the hole creating position will be released and subsequently fall, shown in Fig. 14a, into the receiving hopper. Once jaw assembly 102 and guide assembly 86 have opened, lower primary cam 92 of primary cam system 70 causes pushing system 84 to retract from the hole creating position. Blocking system 100 then slides along platform 30 adjacent jaw assembly 102 to intersect the hole creating position in response to lower secondary cam 106. In the intersecting position, blocking system 100 prevents the needle from extending beyond guide assembly 86 and jaw assembly 102 a predetermined distance, as noted above. At this point, guide assembly 86, in response to upper and intermediate cams 88 and 90 respectively, moves to the needle receiving position, to receive a new needle from supply hopper 146, as shown in Fig. 14b. Guide assembly 86 continues to move with the needle engaged therein until the needle is positioned at least partially in the hole creating position, as shown in Fig. 14c. Pushing system 84 then advances towards jaw assembly 102 to push the needle to the desired distance from the laser drill, as noted above. In the preferred embodiment, pushing system 84 advances the needle to abut blocking system 100 so that the end face of the needle is positioned a predetermined distance from the laser, as noted above. Once the needle is completely positioned in the hole creating position, jaw assembly 102 closes, in response to upper secondary cam 104, so as to firmly maintain the needle in the hole creating position, as shown in Fig. 14d. Blocking system 100 retracts to allow the focus point of laser 12 to coincide with the center of the needle face 35. Once blocking system 100 retracts the cycle of loading the needle has ended and clutch assembly 68 disengages causing the cam assemblies to cease rotating. A cycle end switch activates and sends a signal to control system 16 indicating the cycle has ended and a needle is in position. Preferably, as shown in Fig. 2, cycle end switch 168 is a proximity switch which is activated when cycle pin 170 rotates past proximity switch 168. Upon receiving the cycle end signal, control system 16 then activates unless, as noted above, needle detecting system 162 fails to detect the presence of a needle. Activation of laser 12 causes a laser beam to strike the needle, thereby creating a hole in the needle, having a predetermined length along the longitudinal axis thereof, as noted above. The apparatus described above permits needle blanks to be precisely and accurately positioned for end drilling. Advantageously, the apparatus sequentially advances and accurately positions needle blanks for end drilling at a very high repetition rate, which allows a high volume of needle blanks to be processed in a relatively short period. Indeed, the apparatus enables needle blanks to be sequentially positioned for end drilling at a repetition rate approaching the cycle time of the laser. In addition to production volume considerations, the high repetition rate is also important because a laser is most efficient and reliable when operated at a consistent pulse cycle. Thus, a laser produces the most consistent needle holes when operated substantially continuously at a normal cycle of between about 1 Hz, and 10 Hz., preferably about 4 Hz. Previously, it has not been possible to accurately feed and position needle blanks at such rapid speeds. The claims which follow include embodiments additional to those described in detail above.

Claims: An apparatus for presenting a needle shank to a device (12) for boring a hole in the needle shank (37), which comprises: a frame (20); guide means (86) secured to said frame (20) for transferring a needle shank between a needle receiving position and a hole creating position; blocking means (106) slidably secured to said frame (20) for positioning the needle shank (37) a predetermined distance from said hole creating device (12); pusher means (84) slidably secured to said frame (20) for sliding the needle shank (37) to abut said blocking means (100), such that the needle shank is positioned from said hole creating device (12) said predetermined distance; and jaw means (102) slidably secured to said frame (20) for maintaining the needle shank (37) in said hole creating position. The apparatus according to claim 1, further comprising means (22) for driving said guide means (86), said blocking means (100), said pusher means (84) and said jaw means (102) in a predetermined sequence. The apparatus according to claim 2, wherein said blocking means (100) is movable in response to said drive means (22) between a retracted position and a position intersecting said hole creating position. The apparatus according to claim 2 or 3, wherein said drive means (22) comprises: a motor (62); first drive shaft means (64) having first gear means (66) operatively connected to said motor (62) for rotating said first drive shaft means (64); second gear means (96) connected to said first drive (64) shaft means and operatively connected to third gear means (94) connected to second drive shaft means (72) for transmitting rotational movement from said first drive shaft means (64) to said second drive shaft means (72); first cam means (70) connected to said first drive shaft means (64) for reciprocating said pusher means (84) and said guide means (86); second cam means (74) secured to said second drive shaft means (72) for reciprocating said jaw means (102) and said blocking means (100); and clutch means (68) operatively connected to said first drive shaft means (64) for preventing said first and second cam means (70, 74) from rotating when said needle is in said hole creating position. The apparatus according to any of claims 2 to 4, wherein said guide means (86) comprises: a first member (110) slidably positioned on said frame (20) to facilitate positioning of the needle in said hole creating position, said first member (110) being operatively connected to said drive means (22) such that said first member (108) reciprocates between a first position in aligned communication with said hole creating position and a second open position; and a second member (108) slidably positioned on said frame (20) to facilitate positioning of the needle in said hole creating position, said second member (108) being operatively connected to said drive means (22) such that said second member (180) is movable between said needle receiving position and said hole creating position. An apparatus according to claim 1, wherein said guide means (86) is operatively connected to a first drive means (64) for transferring a needle shank between said needle receiving position and said hole creating position; said blocking means (100) is operatively connected to a second drive means (72) for positioning the needle shank said predetermined distance from said hole creating device (12); said pusher means (84) is operatively connected to said first drive means (64) for sliding the needle shank towards said blocking means (100) in response to a first drive means (64); and said jaw means (102) are operatively connected to said second drive means (72) for maintaining the needle shank (37) in said hole creating position in response to said second drive means (72). Apparatus according to claim 6, wherein said guide means comprises: a first member (110) slidably positioned on said frame to facilitate positioning of the needle in said hole creating position, said first member (110) being operatively connected to said first drive means (64) such that said first member reciprocates between a first position in aligned communication with said hole creating position and a second open position; and a second member (108) slidably positioned on said frame (20) to facilitate positioning of the needle in said hole creating position, said second member being operatively connected to said first drive means (64) such that said second member is movable between said needle receiving position and said hole creating position. The apparatus according to claim 6 or 7, wherein said first drive means comprises: a motor (62); first drive shaft means (64) operatively connected to said motor (62); first cam means (70) connected to said first drive shaft means (64) for reciprocating said pusher means (84) and said guide means (86); and clutch means (68) connected to said first drive shaft means (64) for preventing rotation of said first drive shaft means when the needle shank is in said hole creating position. Apparatus according to claim 8, further comprising cycle end switch means (168) for disengaging said clutch means (68) when the needle is positioned in said hole creating position. Apparatus according to any one of claims 6 to 9, wherein said second drive means comprises: second drive shaft means (72) operatively connected to said first drive shaft means (64) for transmitting rotational movement from said first drive shaft means (64) to said second drive shaft means (72); and second cam means (74) secured to said second drive shaft means (72) for reciprocating said jaw means and said blocking means. The apparatus according to any one of the preceding claims, further comprising: means (162) for verifying the presence of the needle shank in said hole creating position; and means for inhibiting (164) said hole creating device (12) from activating in response to an indication from said verifying means of the absence of a needle shank. The apparatus according to any one of the preceding claims, further comprising: needle supplying means (146) comprising means attached to said frame for supplying needle shanks to said guide means. The apparatus according to claim 12, with binding preventing means (148) such as a rotatable toothed wheel (150) positioned within said needle supplying means (146). Apparatus according to any one of the preceding claims, further comprising means (160) attached to said frame for receiving the needle shanks after boring of a hole in said needle shanks. Apparatus according to any one of the preceding claims, further comprising imaging means (18) for verifying alignment of the needle with a focal plane of said hole creating device, said imaging means (18) having a focal plane aligned with the focal plane of said hole creating device. Apparatus according to any one of the preceding claims, wherein the frame (20) includes means for adjusting the position of the axis of the needle shank within said hole creating position such that the hole created by said hole creating device extends linearly along the longitudinal axis of the needle shank. Apparatus according to claim 16, wherein the axis adjustment means provides five axes of adjustment of the needle. Apparatus according to any one of the preceding claims, wherein said jaw means (102) comprises: a fixed jaw member (134) secured to said frame and positioned in aligned communication with said hole creating position; and a movable jaw member (136) slidably secured to said frame such that said movable jaw member (136) reciprocates into aligned communication with said hole creating position in opposition to said fixed jaw member (134). Apparatus according to claim 2, further comprising: control means for controlling the operation of said needle positioning apparatus; and means (162) for verifying the presence of the needle shank in said hole creating position; means (164) for inhibiting the hole creating device from activating in response to an indication of the absence of a needle shank from said verifying means, said inhibiting means being electrically connected to said control means; and cycle end switch means (168) for disengaging said drive means when the needle is in said hole creating position. A method for creating a hole in each of a plurality of needle shanks using an apparatus for presenting needle shanks to hole creating means (12), said apparatus having frame means (20), guide means (86) secured to said frame means for transferring each needle shank (37) between needle receiving and hole creating positions, blocking means (100) slidably secured to said frame means (20) for positioning each needle shank a predetermined distance from said hole creating means (12), pusher means (84) movably secured to said frame means (20) for moving each needle shank to abut said blocking means (100), such that each needle shank is positioned said predetermined distance from said hole creating means (12), and jaw means (102) slidably secured to said frame means (20) for maintaining the needle shank in said hole creating position, the method comprising: sequentially advancing a plurality of needle shanks (37) at a rate between about 1 Hz and about 10 Hz into said hole creating position such that the longitudinal axis of each needle shank is in substantial alignment with a predetermined axis of said hole creating means (12) to permit creating a hole along the longitudinal axis of each needle shank; and activating said hole creating means (12) to create the hole in each needle shank (37). A method according to claim 20, wherein the plurality of needle shanks are sequentially fed at a rate of speed of 4 Hz.

Inventors: BUCHTER MARK S, PROTO GEORGE R, BUCHTER, MARK S., PROTO, GEORGE R.
Applicants: UNITED STATES SURGICAL CORP, UNITED STATES SURGICAL CORPORATION
Application year: 1993
Main classification: B23K26
IPC codes: B21G1, B23K26