Gear train assemblies for robotic surgical systems

• US 10,220,522 B2
• Filed: 10/23/2014
• Issued: 03/05/2019
• Est. Priority Date: 12/12/2013
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Rockrohr, Brian
• Primary Examiner(s): Bui, Vy
• Application Number:
  US15/102,908
• Publication Number:
  US 20160303745A1
• Time in Patent Office: 1,594 Days
• Field of Search: 606 1, 606 34, 606 51, 606130, 606169
• 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 17/29 Forceps for use in minimally invasive surgery
• CPC Class Codes: A61B 2017/00323 Cables or rods
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/2932 Transmission of forces to jaw members
• CPC Class Codes: A61B 2017/2943 Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: B25J 15/0213 actuated by gears
• CPC Class Codes: B25J 17/0258 Two-dimensional joints
• CPC Class Codes: B25J 9/102 Gears specially adapted therefor, e.g. reduction gears gearings in general F16H

Abstract

An end effector for use and connection to a robot arm of a robotic surgical system, wherein the end effector is controlled and/or articulated by at least one cable extending from a respective motor of a control device of the robot surgical system, is provided. The end effector includes at least one gear train that transmits forces from the at least one motor of the control device to at least one of the proximal bracket of the wrist assembly, the distal bracket of the wrist assembly and the jaw assembly. The gear train enables at least one of a pivoting of the distal hub assembly relative to the proximal hub; a rotation of the distal bracket relative to the proximal bracket; and an opening/closing of the jaw assembly.

Claims

1. An end effector connectable to a robot arm of a robotic surgical system and actuated by at least one motor of a control device of the robot surgical system, the end effector comprising:

a wrist assembly including;

a proximal hub defining a respective longitudinal axis; and

a distal hub assembly defining a respective longitudinal axis, the distal hub assembly includes;

a proximal bracket pivotally connected to the proximal hub; and

a distal bracket pivotally connected to the proximal bracket, the distal bracket being rotatable relative to the proximal bracket along the longitudinal axis of the distal hub assembly; and

a jaw assembly including a pair of jaws pivotally supported on the distal bracket, each jaw including;

a proximal portion pivotally connected to the distal bracket; and

a distal portion extending distally of the proximal portion thereof; and

at least one gear train supported in the wrist assembly, wherein the at last one gear train transmits forces from the at least one motor of the control device to at least one of the proximal bracket of the wrist assembly, the distal bracket of the wrist assembly and the jaw assembly;

the at least one gear train enabling at least one of;

a pivoting of the distal hub assembly relative to the proximal hub;

a rotation of the distal bracket relative to the proximal bracket; and

an opening or closing of the jaw assembly.

2. The end effector according to claim 1, wherein the at least one gear train includes a first gear train comprising:

a first gear rotatably supported in the proximal hub, the first gear of the proximal hub being in operative communication with at least one motor of the control system; and

a first gear non-rotatably supported on the proximal bracket of the distal hub assembly, wherein the first gear of the proximal bracket defines a rotation axis that is co-axial with a pivot axis of the distal hub assembly relative to the proximal hub, wherein the first gear of the proximal bracket is in meshing engagement with the first gear of the proximal hub.

3. The end effector according to claim 2, wherein the at least one gear train includes a second gear train comprising:

a second gear rotatably supported in the proximal hub, the second gear of the proximal hub being in operative communication with at least one motor of the control system, the first gear and the second gear of the proximal hub being concentric;

a second gear rotatably supported in the proximal bracket of the distal hub assembly, wherein the first gear and the second gear of the proximal bracket are concentric; and

a further second gear rotatably supported in the proximal bracket of the distal hub assembly, wherein the further second gear defines a rotation axis that is co-axial with the longitudinal axis of the distal hub assembly, the further second gear being non-rotatably supported on a stem extending from the distal bracket,

wherein the further second gear of the proximal bracket is in meshing engagement with the second gear of the proximal bracket, and wherein the second gear of the proximal bracket is in meshing engagement with the second gear of the proximal hub.

4. The end effector according to claim 3, wherein the at least one gear train includes a third gear train comprising:

a third gear rotatably supported in the proximal hub, the third gear of the proximal hub being in operative communication with at least one motor of the control system, the first, second and third gears of the proximal hub being concentric with one another;

a third gear rotatably supported in the proximal bracket of the distal hub assembly, wherein the first, second and third gears of the proximal bracket are concentric with one another; and

a further third gear rotatably supported in the proximal bracket of the distal hub assembly, wherein the further third gear is co-axial and concentric with the further second gear of the proximal bracket, the further third gear being non-rotatably supported on a stem extending from a gear rotatably supported in the distal bracket,

wherein the further third gear of the proximal bracket is in meshing engagement with the third gear of the proximal bracket, and wherein the third gear of the proximal bracket is in meshing engagement with the third gear of the proximal hub.

5. The end effector according to claim 4, wherein the at least one gear train includes a gear rotatably supported in the distal bracket of the distal hub assembly, the gear of the distal bracket being keyed to the further third gear of the proximal bracket, and wherein the proximal portion of each jaw is in meshing engagement with the gear of the distal bracket.

6. The end effector according to claim 4, wherein the first gear that is rotatably supported in the proximal hub defines a first diameter;

wherein the second gear that is rotatably supported in the proximal hub defines a second diameter smaller than the first diameter; and

wherein the third gear that is rotatably supported in the proximal hub defines a third diameter that is smaller than the second diameter.

7. The end effector according to claim 4, wherein the first gear that is non-rotatably supported on the proximal bracket defines a first diameter;

wherein the second gear that is rotatably supported on the proximal bracket defines a second diameter smaller than the first diameter; and

wherein the third gear that is rotatably supported on the proximal bracket defines a third diameter that is smaller than the second diameter.

8. The end effector according to claim 4, wherein the further second gear that is rotatably supported on the proximal bracket defines a diameter;

and wherein the further third gear that is rotatably supported in the proximal bracket defines a diameter that is smaller than the diameter of the further second gear.

9. The end effector according to claim 7, wherein the proximal bracket is U-shaped including a pair of spaced apart upright supports extending in a proximal direction that are interconnected by a backspan, and wherein the first gear that is non-rotatably supported on the proximal bracket and the second and third gears that are rotatably supported on the proximal bracket are supported on one of the proximally extending upright supports of the proximal bracket.

10. The end effector according to claim 9, wherein the further second gear and the further third gear, that are rotatably supported on the proximal bracket, are supported on the backspan of the proximal bracket.

11. The end effector according to claim 4, further comprising:

a first drive tube extending through the proximal hub and supporting the first gear on a distal end thereof, the first drive tube defining a lumen therethrough;

a second drive tube extending through the proximal hub and through the lumen of the first drive tube, the second drive tube supporting the second gear on a distal end thereof, the second drive tube defining a lumen therethrough; and

a third drive tube extending through the proximal hub and through the lumen of the second drive tube, the third drive tube supporting the third gear on a distal end thereof.

12. The end effector according to claim 11, wherein the first gear that is rotatably supported in the proximal hub defines a first diameter;

wherein the second gear that is rotatably supported in the proximal hub defines a second diameter smaller than the first diameter; and

wherein the third gear that is rotatably supported in the proximal hub defines a third diameter that is smaller than the second diameter.

13. An end effector connectable to a robot arm of a robotic surgical system, wherein the end effector is actuated by at least one motor of a control device of the robot surgical system, the end effector comprising:

a wrist assembly including;

a proximal hub defining a respective longitudinal axis; and

a distal hub assembly including;

a proximal bracket pivotally connected to the proximal hub, the proximal bracket defining a longitudinal axis, the proximal bracket being pivotable about a first pivot axis that extends transversely to the longitudinal axis of the proximal hub; and

a distal bracket pivotally connected to the proximal bracket, the distal bracket defining a longitudinal axis, the distal bracket being pivotable about a second pivot axis that extends transversely to the longitudinal axis of the proximal hub and transversely to the first pivot axis; and

a jaw assembly including a pair of jaws pivotally supported on the distal bracket, each jaw including;

a proximal portion pivotally connected to the distal bracket; and

a distal portion extending distally of the proximal portion thereof; and

at least one gear train supported in the wrist assembly, wherein the at last one gear train transmits forces from the at least one motor of the control device to at least one of the proximal bracket of the wrist assembly, the distal bracket of the wrist assembly and the jaw assembly;

the at least one gear train enabling at least one of;

a pivoting of the proximal bracket relative to the proximal hub;

a pivoting of the distal bracket relative to the proximal bracket; and

an opening or closing of the jaw assembly.

14. The end effector according to claim 13, wherein the at least one gear train includes a first gear train comprising:

a first gear rotatably supported in the proximal hub, the first gear of the proximal hub being in operative communication with at least one motor of the control system; and

a first gear non-rotatably supported on the proximal bracket of the distal hub assembly, wherein the first gear of the proximal bracket defines a rotation axis that is co-axial with the first pivot axis, wherein the first gear of the proximal bracket is in meshing engagement with the first gear of the proximal hub.

15. The end effector according to claim 14, wherein the at least one gear train includes a second gear train comprising:

a second gear rotatably supported in the proximal hub, the second gear of the proximal hub being in operative communication with at least one motor of the control system, the first gear and the second gear of the proximal hub being concentric;

a second gear rotatably supported in the proximal bracket and along the first pivot axis, wherein the first gear and the second gear of the proximal bracket are concentric; and

a proximal second gear rotatably supported in the proximal bracket of the distal hub assembly and along the longitudinal axis of the proximal bracket;

a distal second gear rotatably supported in the proximal bracket of the distal hub assembly and along the longitudinal axis of the proximal bracket, wherein the proximal second gear and the distal second gear are non-rotatably supported on a common shaft; and

a second gear non-rotatably supported on the distal bracket of the distal hub assembly, wherein the second gear of the distal bracket defines a rotation axis that is co-axial with the second pivot axis, wherein the second gear of the distal bracket is in meshing engagement with the distal second gear of the proximal hub.

16. The end effector according to claim 15, wherein the at least one gear train includes a third gear train comprising:

a third gear rotatably supported in the proximal hub, the third gear of the proximal hub being in operative communication with at least one motor of the control system, the first, second and third gears of the proximal hub being concentric with one another;

a proximal third gear rotatably supported in the proximal bracket of the distal hub assembly and along the longitudinal axis of the proximal bracket;

a distal third gear rotatably supported in the proximal bracket of the distal hub assembly and along the longitudinal axis of the proximal bracket, wherein the proximal third gear and the distal third gear of the proximal bracket are non-rotatably supported on a common shaft;

a third gear rotatably supported on the distal bracket of the distal hub assembly, wherein the third gear of the distal bracket defines a rotation axis that is co-axial with the second pivot axis, wherein the third gear of the distal bracket is in meshing engagement with the distal third gear of the proximal bracket;

a proximal third gear rotatably supported in the distal bracket of the distal hub assembly and along the longitudinal axis of the distal bracket, the proximal third gear that is supported in the distal bracket is in meshing engagement with the third gear rotatably supported on the second pivot axis of the distal bracket; and

a distal third gear rotatably supported in the distal bracket of the distal hub assembly and along the longitudinal axis of the distal bracket, wherein the proximal third gear and the distal third gear of the distal bracket are non-rotatably supported on a common shaft;

wherein the proximal portion of each jaw is in meshing engagement with the distal third gear rotatably supported in the distal bracket.

17. The end effector according to claim 16, wherein the first gear that is rotatably supported in the proximal hub defines a first diameter;

wherein the second gear that is rotatably supported in the proximal hub defines a second diameter smaller than the first diameter; and

wherein the third gear that is rotatably supported in the proximal hub defines a third diameter that is smaller than the second diameter.

18. The end effector according to claim 17, wherein the first gear that is non-rotatably supported on the proximal bracket defines a first diameter;

wherein the second gear that is rotatably supported on the first pivot axis of the proximal bracket defines a second diameter smaller than the first diameter; and

wherein the third gear that is rotatably supported on the first pivot axis of the proximal bracket defines a third diameter that is smaller than the second diameter.

19. The end effector according to claim 18, wherein the proximal second gear that is rotatably supported in the proximal bracket defines a diameter;

and wherein the proximal third gear that is rotatably supported in the proximal bracket defines a diameter that is smaller than the diameter of the proximal second gear that is rotatably supported in the proximal bracket of the distal hub assembly.

20. The end effector according to claim 19, wherein the second gear that is non-rotatably supported on the distal bracket defines a diameter;

and wherein the third gear that is rotatably supported on the distal bracket defines a diameter that is smaller that the diameter of the second gear that is non-rotatably supported on the distal bracket.