Systems and tools for use with surgical robotic manipulators

• US 10,456,207 B2
• Filed: 10/20/2017
• Issued: 10/29/2019
• Est. Priority Date: 10/21/2016
• Status: Active Grant

• Current Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Original Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Inventors: Flatt, James E.
• Primary Examiner(s): Sevilla, Christian A
• Application Number:
  US15/789,562
• Publication Number:
  US 20180110572A1
• Time in Patent Office: 739 Days
• CPC Class Codes: A61B 17/14 Surgical saws A61B17/1637 takes precedence; tooth saws A61C3/12 ; Accessories therefor
• CPC Class Codes: A61B 17/162 Chucks or tool parts which are to be held in a chuck
• CPC Class Codes: A61B 17/1624 Drive mechanisms therefor
• CPC Class Codes: A61B 17/1631 Special drive shafts, e.g. flexible shafts A61B17/1642, A61B17/164 take precedence
• CPC Class Codes: A61B 17/32002 with continuously rotating, oscillating or reciprocating cutting instruments
• CPC Class Codes: A61B 17/320068 using mechanical vibrations, e.g. ultrasonic A61B17/22012 takes precedence; dental tooth drilling devices operated by vibration A61C3/03; removing intra-ocular material using mechanical vibrations A61F9/00745
• CPC Class Codes: A61B 18/082 Probes or electrodes therefor
• CPC Class Codes: A61B 18/148 having a short, rigid shaft for accessing the inner body transcutaneously, e.g. for neurosurgery or arthroscopy
• CPC Class Codes: A61B 18/18 by applying electromagnetic radiation, e.g. microwaves radiation therapy A61N5/00
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2018/00172 Connectors and adapters therefor
• CPC Class Codes: A61B 2018/00208 actively driven, e.g. by a motor
• CPC Class Codes: A61B 2018/00565 Bone
• CPC Class Codes: A61B 2018/00601 Cutting
• CPC Class Codes: A61B 2018/1807 using light other than laser radiation
• CPC Class Codes: A61B 2034/2055 Optical tracking systems
• CPC Class Codes: A61B 2034/2057 Details of tracking cameras
• CPC Class Codes: A61B 2034/2059 Mechanical position encoders
• CPC Class Codes: A61B 2034/2068 using pointers, e.g. pointers having reference marks for determining coordinates of body points
• CPC Class Codes: A61B 34/20 Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis
• CPC Class Codes: A61B 34/30 : Surgical robots
• CPC Class Codes: A61B 34/70 : Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 90/98 : using electromagnetic means, e.g. transponders
• CPC Class Codes: F16D 1/087 : due to other loading elements in the hub or shaft

Abstract

A tool for use with a surgical robotic manipulator that comprises an energy applicator including a shaft extending along an axis between a proximal end and a distal end. The shaft has an axial-force receiving surface. A tool assembly comprises a support structure to support the energy applicator, an axial connector assembly arranged to engage and releasably lock the energy applicator to the support structure in a locked state, a drive system coupled to the support structure to rotatably drive the shaft of the energy applicator about the axis, a collet assembly cooperating with the axial connector assembly and configured to apply a force to the axial-force receiving surface of the energy applicator in the locked state, and a reference surface. The force includes an axial component directing the energy applicator proximally into continuous contact with the reference surface in the locked state.

Claims

1. A tool comprising:

an energy applicator including a shaft extending along an axis between a proximal end and a distal end, said shaft having an axial-force receiving surface; and

a tool assembly comprising;

a support structure to support said energy applicator;

an axial connector assembly arranged to engage and releasably lock said energy applicator to said support structure in a locked state;

a drive system coupled to said support structure to rotatably drive said shaft of said energy applicator about said axis;

a collet assembly cooperating with said axial connector assembly to apply a force to said axial-force receiving surface of said energy applicator in said locked state; and

a reference surface, wherein said force includes an axial component directing said energy applicator proximally into continuous contact with said reference surface in said locked state.

2. The tool as set forth in claim 1, wherein said collet assembly comprises a lock collar movable relative to said support structure to move said axial connector assembly from said locked state to an unlocked state.

3. The tool as set forth in claim 1, wherein said collet assembly comprises a lock collar slidable relative to said support structure to move said axial connector assembly from said locked state to an unlocked state.

4. The tool as set forth in claim 2, wherein said axial connector assembly comprises a cam member, a locking sleeve, and at least one engagement member, wherein said at least one engagement member is arranged to apply said axial component of said force to said axial-force receiving surface of said energy applicator when said axial connector assembly is in said locked state.

5. The tool as set forth in claim 4, wherein said at least one engagement member is further defined as a plurality of engagement members.

6. The tool as set forth in claim 5, wherein said plurality of engagement members are further defined as a plurality of ball bearings.

7. The tool as set forth in claim 6, wherein said locking sleeve defines a plurality of openings extending radially therethrough to receive said plurality of ball bearings.

8. The tool as set forth in claim 4, wherein said cam member has a cam surface arranged at a first acute angle to said axis and said axial-force receiving surface is arranged at a second acute angle to said axis, wherein said at least one engagement member contacts both of said cam surface and said axial-force receiving surface in said locked state;

and

wherein said first acute angle is different than said second acute angle.

9. The tool as set forth in claim 8, wherein said first acute angle differs from said second acute angle in a range of from 6 to 10 degrees.

10. The tool as set forth in claim 2, wherein said collet assembly includes a release member coupled to said lock collar, said release member configured to be actuated by a user to move said lock collar and place said axial connector assembly in said unlocked state.

11. The tool as set forth in claim 10, including a spring member cooperating with said lock collar to bias said lock collar toward a position in which said axial connector assembly is in said locked state.

12. The tool as set forth in claim 1, wherein said drive system comprises a drive member and a counterweighted clutch assembly supported by and selectively rotatable relative to said drive member, said counterweighted clutch assembly configured to receive said shaft of said energy applicator for selectively coupling said shaft to said drive member.

13. The tool as set forth in claim 12, wherein said drive system further comprises an actuator coupled to said drive member for rotatably driving said drive member.

14. The tool as set forth in claim 1, including an identification tag fixed to said proximal end of said energy applicator, wherein said tool assembly comprises a reader for communicating with said identification tag, said identification tag including calibration data.

15. The tool as set forth in claim 1, wherein said shaft comprises an annular recess disposed between said proximal end and said distal end with said annular recess being at least partially defined by said axial-force receiving surface.

16. The tool as set forth in claim 15, wherein said axial-force receiving surface comprises a conical surface.

17. The tool as set forth in claim 16, wherein said shaft has an outer surface and said annular recess has a bottom, said conical surface extending a first axial distance from said outer surface toward said bottom.

18. The tool as set forth in claim 17, wherein said annular recess is at least partially defined by a distal surface, said distal surface extending a second axial distance from said outer surface toward said bottom, wherein said second axial distance is less than said first axial distance.

19. The tool as set forth in claim 1, wherein said axial-force receiving surface is arranged at an acute angle relative to said axis, said acute angle being in a range of from 6 to 14 degrees.

20. The tool as set forth in claim 1, including a protective sheath releasably coupled to said tool assembly to be arranged concentrically about said shaft of said energy applicator.

21. The tool as set forth in claim 20, including a bearing supported in said protective sheath such that said bearing is releasable, along with said protective sheath, from said tool assembly.

22. A tool assembly for use with an energy applicator having a shaft extending along an axis between a proximal end and a distal end, the shaft having an axial-force receiving surface, said tool assembly comprising:

a support structure to support said energy applicator;

an axial connector assembly arranged to engage and releasably lock the energy applicator to said support structure in a locked state;

a drive system coupled to said support structure to rotatably drive the shaft of the energy applicator about said axis;

a collet assembly cooperating with said axial connector assembly to apply a force to the axial-force receiving surface of the energy applicator when said axial connector assembly engages and releasably locks the energy applicator to said support structure in said locked state; and

a reference surface, wherein said force includes an axial component directing the energy applicator proximally into continuous contact with said reference surface in said locked state.