Robotics tool bailouts

• US 10,080,622 B2
• Filed: 08/16/2016
• Issued: 09/25/2018
• 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.
• Primary Examiner(s): Ho, Ha Dinh
• Application Number:
  US15/237,886
• Publication Number:
  US 20180049836A1
• Time in Patent Office: 770 Days
• Field of Search: 74665 L
• CPC Class Codes: A61B 17/00234 for minimally invasive surgery A61B17/0218, A61B17/0469, A61B17/12013, A61B17/1285, A61B17/29, A61B17/320016 take precedence
• CPC Class Codes: A61B 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/1285 for minimally invasive surgery
• CPC Class Codes: A61B 2017/00221 with wireless transmission of data, e.g. by infrared radiation or radiowaves
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2090/031 torque limiting
• CPC Class Codes: A61B 2090/033 Abutting means, stops, e.g. abutting on tissue or skin
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 90/03 Automatic limiting or abutting means, e.g. for safety

Abstract

Methods and devices are provided for robotic surgery, and in particular for retracting and/or bailing out robotic tools. For example, surgical tools, methods, and systems are provided having bailout assemblies for selectively bailing out one or more functions of an end effector of a surgical tool. Surgical tools, methods, and systems are also provided with bailout assemblies for simultaneously bailing out a plurality of functions of an end effector of a surgical tool.

Claims

1. A surgical tool, comprising:

a housing;

an elongate shaft extending distally from the housing;

an end effector disposed at a distal end of the elongate shaft; and

a plurality of actuation assemblies coupled to a plurality of motor-driven drive gears, each of the motor-driven drive gears being configured to drive a corresponding actuation assembly, each of the actuation assemblies being configured to operate a function of the end effector, and

a bailout mechanism configured to manually drive at least two of the plurality of actuation assemblies simultaneously to reverse the corresponding functions of the end effector.

2. The tool of claim 1, wherein each motor-driven drive gear is selectively movable between a first position, in which the motor-driven drive gear has a coupling positioned to engage an external motor, and a second position, in which the coupling is positioned such that it is prevented from engaging an external motor.

3. The tool of claim 1, wherein the bailout mechanism includes a crank arm configured to engage and drive the at least two actuation assemblies simultaneously.

4. The tool of claim 1, wherein the bailout mechanism includes a bailout drive gear, and wherein each of the plurality of actuation assemblies includes a gear that is selectively movable into engagement with the bailout drive gear such that rotation of the bailout drive gear can simultaneously drive at least two of the plurality of actuation assemblies.

5. The tool of claim 4, wherein each of the plurality of actuation assemblies is coupled to a switch disposed on the housing and configured to move the gear of the actuation assembly into engagement with the bailout drive gear.

6. The tool of claim 5, wherein each switch is configured to simultaneously move a corresponding motor-driven drive gear into a position in which the motor-driven drive gear is prevented from engaging with an external motor.

7. The surgical system of claim 1, wherein the bailout mechanism is configured to be manually rotated to manually drive the at least two actuation assemblies.

8. The surgical system of claim 1, wherein the bailout mechanism includes a drive recess configured to receive a drive tool.

9. The surgical system of claim 8, wherein the drive tool includes a ratchet.

10. The surgical system of claim 1, further comprising at least one indicator connected to at least one of the plurality of actuation assemblies and configured to indicate when the corresponding actuation assembly has failed.

11. The surgical system of claim 1, further comprising a plurality of bailout switches, each coupled to a corresponding actuation assembly, each bailout switch being configured to cause the corresponding actuation assembly to move into engagement with the bailout mechanism.

12. The surgical tool of claim 1, wherein the housing is configured to couple to a plurality of motors on a tool driver of a surgical system.

13. A surgical bailout method, comprising:

selectively actuating a plurality of motors in a tool driver of a robotic arm to selectively drive a plurality of drive gears disposed within a housing of a surgical tool, each of the plurality of drive gears driving an actuation assembly extending through an elongate shaft of the surgical tool to thereby actuate a function of an end effector of the tool; and

actuating a bailout assembly to simultaneously counter rotate at least two of the plurality of actuation assemblies to reverse the corresponding functions of the end effector.

14. The method of claim 13, further comprising, prior to actuating the bailout assembly, decoupling the drive gears of the at least two of the plurality of actuation assemblies from the corresponding motors.

15. The method of claim 14, wherein, simultaneously with decoupling, the at least two of the plurality of actuation assemblies moves into engagement with the bailout assembly.

16. The method of claim 14, wherein decoupling the drive gears of the at least two of the plurality of actuation assemblies from the corresponding motors comprises actuating a switch to move a coupling on a shaft having the drive gear mounted thereon away from and out of engagement with the motor.

17. The method of claim 13, wherein actuating the bailout assembly comprises rotating a tool coupled to the bailout assembly to counter rotate the at least two of the plurality of actuation assemblies.

18. The method of claim 13, wherein actuating the bailout assembly causes a bailout gear to rotate, which in turn causes a gear on each of the at least two of the plurality of actuation assemblies to rotate.

19. The method of claim 13, wherein the tool includes a plurality of indicators and each indicator indicating when an actuation assembly coupled thereto has failed.