Methods, systems, and devices for limiting torque in robotic surgical tools

• US 10,045,827 B2
• Filed: 08/16/2016
• Issued: 08/14/2018
• Est. Priority Date: 08/16/2016
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Shelton, IV, Frederick E., Harris, Jason L., Swayze, Jeffrey S., Vendely, Michael J.
• Primary Examiner(s): Masih, Karen
• Application Number:
  US15/237,661
• Publication Number:
  US 20180049816A1
• Time in Patent Office: 728 Days
• CPC Class Codes: A61B 2090/031 torque limiting
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/35 for telesurgery
• CPC Class Codes: A61B 90/03 Automatic limiting or abutting means, e.g. for safety
• CPC Class Codes: F16H 3/20 exclusively or essentially using gears that can be moved out of gear
• CPC Class Codes: F16H 3/22 with gears shiftable only axially
• CPC Class Codes: F16H 63/00 Control outputs from the control unit to change-speed- or reversing-gearings for conveying rotary motion or to other devices than the final output mechanism

Abstract

Various exemplary methods, systems, and devices for limiting torque in robotic surgical tools are provided. In general, a surgical tool can be configured to releasably and removably couple to a robotic surgical system. The robotic surgical system can include a motor configured to provide torque to the surgical tool to drive two different functions of the surgical tool. The surgical tool can include two torque limiting mechanisms, each associated with the motor, each associated with one of the functions, and each configured to limit an amount of the torque from the motor that drives the function associated therewith.

Claims

1. A surgical system, comprising:

a tool driver of a robotic surgical system, the tool driver being configured to releasably and replaceably couple to a surgical tool including an elongate shaft with an end effector at a distal end thereof, and the tool driver including a first motor, a first actuator configured to be driven by the first motor to actuate a first function of the end effector, a first torque limiting mechanism that sets a first torque threshold for the first actuator, a second actuator configured to be driven by the first motor to actuate a second function of the end effector, and a second torque limiting mechanism that sets a second torque threshold for the first actuator that is different from the first torque threshold.

2. The system of claim 1, wherein the first motor is configured to selectively shift between engagement with the first actuator to drive the first actuator without driving the second actuator and engagement with the second actuator to drive the second actuator without driving the first actuator.

3. The system of claim 1, wherein the first function is closing of the end effector at a first speed, and the second function is closing the end effector at a second speed that is greater than the first speed.

4. The system of claim 3, wherein the first torque threshold is greater than the second torque threshold.

5. The system of claim 1, wherein the tool driver includes a third torque limiting mechanism that sets a third torque threshold for the first actuator that is different from the first torque threshold, the first torque limiting mechanism but not the third torque limiting mechanism being configured to be engaged by the first actuator when the first actuator is being driven to rotate in a first direction, and the third torque limiting mechanism but not the first torque limiting mechanism being configured to be engaged by the first actuator when the first actuator is being driven in to rotate in a second direction that is opposite to the first direction.

6. The system of claim 5, wherein the tool driver includes a fourth torque limiting mechanism that sets a fifth torque threshold for the second actuator that is different from the second torque threshold, the second torque limiting mechanism but not the fourth torque limiting mechanism being configured to be engaged by the second actuator when the second actuator is being driven to rotate in the first direction, and the fourth torque limiting mechanism but not the second torque limiting mechanism being configured to be engaged by the second actuator when the second actuator is being driven in to rotate in the second direction that is opposite to the first direction.

7. The system of claim 1, wherein the first actuator has a first mating element, the first torque limiting mechanism has a second mating element, and engagement of the first mating element with the second mating element during the driving of the first actuator by the motor defines the first torque threshold;

and

the second actuator has a third mating element, the second torque limiting mechanism has a fourth mating element, and engagement of the third mating element with the fourth mating element during the driving of the second actuator by the motor defines the second torque threshold.

8. The system of claim 1, wherein the tool driver includes a first shaft having the first and second actuators and the first and second limiting mechanisms attached thereto along a longitudinal length thereof.

9. The system of claim 8, wherein the first motor is configured to rotate a second shaft having first and second drive disks attached thereto along a longitudinal length thereof, the first drive disk being operatively coupled to the first actuator such that rotation of the second shaft causes the first actuator to rotate, and the second drive disk being operatively coupled to the second actuator such that rotation of the second shaft causes the second actuator to rotate.

10. The system of claim 8, wherein the tool driver includes, a third actuator attached to the shaft along a longitudinal length thereof, a second motor configured to drive the third actuator to actuate a third function of the actuator, and a third torque limiting mechanism that sets a third torque threshold for the third actuator.

11. The system of claim 10, wherein the first function is closing of the end effector at a first speed, the second function is closing the end effector at a second speed that is greater than the first speed, and the third function is firing of the end effector.

12. The system of claim 1, wherein the first motor includes a single motor, and the tool driver includes one or more additional motors that are each configured to drive one or more additional actuators of the tool driver that each actuate a function of the end effector that is different from the first and second functions.

13. The system of claim 1, wherein the first and second actuators each include a rotatable gear.

14. A surgical system, comprising:

a surgical tool including an elongate shaft having an end effector at a distal end thereof; and

a tool driver of a robotic surgical system, the tool driver being configured to releasably couple to the surgical tool, the tool driver including a first actuator configured to be actuated to cause the end effector to perform a first function, a second actuator configured to be actuated to cause the end effector to perform a second function, a first motor configured to selectively actuate each of first and second actuators, a first torque limiting mechanism configured to limit an amount of torque applied by the motor to the first actuator, and a second torque limiting mechanism configured to limit an amount of torque applied by the motor to the second actuator.

15. The system of claim 14, wherein the first motor is configured to selectively shift between engagement with the first actuator to drive the first actuator without driving the second actuator and engagement with the second actuator to drive the second actuator without driving the first actuator.

16. The system of claim 14, wherein the first function is closing of the end effector at a first speed, and the second function is closing the end effector at a second speed that is greater than the first speed.

17. The system of claim 14, wherein the first motor includes a single motor, and the tool driver includes one or more additional motors that are each configured to drive one or more additional actuators of the tool driver that are each configured to be actuated to cause the end effector to perform a function of that is different from the first and second functions.

18. A surgical method, comprising:

advancing an end effector of a surgical tool into a body of a patient using a robotic surgical system, the surgical tool being releasably and replaceably coupled to the robotic surgical system;

actuating a single motor of the robotic surgical system to drive a first actuator of the robotic surgical system and thereby cause the end effector to execute a first function in the body of the patient, the motor having a maximum torque output, and an amount of torque applied by the motor to the first actuator being prevented from exceeding a first torque threshold that is less than the maximum torque output; and

actuating the single motor of the robotic surgical system to cause the end effector to execute a second function in the body of the patient that is different from the first function, an amount of torque applied by the motor to the second actuator being prevented from exceeding a second torque threshold that is less than the maximum torque output and that is different from the first torque threshold.

19. The method of claim 18, wherein the amount of torque applied by the motor to the first actuator is prevented from exceeding the first torque threshold when the motor drives rotation of the first actuator in a first direction, and the amount of torque applied by the motor to the first actuator when the motor drives rotation of the first actuator in a second direction is prevented from exceeding a third torque threshold that is different from the first torque threshold, the first direction being opposite to the second direction;

and

the amount of torque applied by the motor to the second actuator is prevented from exceeding the second torque threshold when the motor drives rotation of the second actuator in the first direction, and the amount of torque applied by the motor to the second actuator when the motor drives rotation of the second actuator in the second direction is prevented from exceeding a fourth torque threshold that is different from the second torque threshold.

20. The method of claim 18, wherein the first function is closing of the end effector at a first speed, and the second function is closing the end effector at a second speed that is greater than the first speed.