Robotics tool bailouts

• US 10,478,256 B2
• Filed: 08/16/2016
• Issued: 11/19/2019
• 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): Elahmadi, Zakaria
• Application Number:
  US15/237,877
• Publication Number:
  US 20180049835A1
• Time in Patent Office: 1,190 Days
• 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 2034/302 specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2090/031 torque limiting
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/32 operating autonomously
• CPC Class Codes: A61B 34/35 for telesurgery

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 having a plurality of motor-driven drive gears;

an elongate shaft extending distally from the housing;

an end effector coupled to a distal end of the elongate shaft;

at least first and second actuation assemblies, each actuation assembly being coupled to one of the plurality of motor-driven drive gears such that each of the motor-driven drive gears is configured to drive a corresponding actuation assembly, the first actuation assembly being configured to operate a first function of the end effector, and the second actuation assembly being configured to operate a second function of the end effector that is different than the first function; and

at least first and second bailout mechanisms, the first bailout mechanism being selectively engageable with the first actuation assembly and being configured to be manually driven to subsequently drive the first actuation assembly, and the second bailout mechanism being selectively engageable with the second actuation assembly and being configured to be manually driven to subsequently drive the second actuation assembly, the first bailout mechanism including a first one-way gear, the second bailout mechanism including a second one-way gear, each of the first and second one-way gears being configured to be rotatable in only one direction to drive the corresponding first and second actuation assembly.

2. The surgical tool of claim 1, wherein each of the first and second one-way gears is configured to selectively engage the corresponding first and second actuation assembly and is configured to drive the corresponding first and second actuation assembly in a reverse direction.

3. The surgical tool of claim 2, wherein each of the first and second one-way gears is accessible from an exterior of the housing and is configured to move into engagement with the corresponding first and second actuation assembly.

4. The surgical tool of claim 1, wherein each of the first and second actuation assemblies is movable from a first position in which the first and second actuation assembly is engaged with the corresponding motor-driven drive gear, to a second position in which the first or second actuation assembly is disengaged with the corresponding motor-driven drive gear.

5. The surgical tool of claim 4, wherein each of the first and second actuation assemblies is configured such that it is prevented from moving from the second position to the first position.

6. The surgical tool of claim 4, wherein each of the first and second actuation assemblies includes a gear mounted on a shaft, the gear being engaged with the corresponding motor-driven drive gear in the first position, and the gear moving away from and out of engagement with the motor-driven drive gear in the second position.

7. The surgical tool of claim 6, wherein the elongate shaft is configured to move with the gear when the gear is moved away from and out of engagement with the motor-driven drive gear, and wherein the elongate shaft includes tabs that engage the housing to prevent movement of the shaft, thereby locking the corresponding first and second actuation assembly in the second position.

8. The surgical tool of claim 6, wherein the gear mounted on the elongate shaft of each of the first and second actuation assemblies is held in engagement with the corresponding motor-driven drive gear by a spring, and wherein a collar is disposed on the elongate shaft and is configured to advance over the spring to release the gear thereby allowing the gear to move out of engagement with the motor-driven drive gear.

9. The surgical tool of claim 1, further comprising a decoupling assembly coupled to the first and second actuation assemblies, the decoupling assembly being configured to simultaneously cause a first gear of the first actuation assembly and a second gear of the second actuation assembly to move out of engagement with the corresponding motor-driven drive gears only upon selectively engagement of at least one of the first and second bailout mechanisms.

10. The surgical tool of claim 9, wherein the first actuation assembly is effective to close opposed jaws of the end effector, and the second actuation assembly is effective to fire a plurality of staples from the end effector.

11. The surgical tool of claim 9, wherein the decoupling assembly includes a threaded shaft and a housing threadably mounted on the threaded shaft, the housing having first and second pusher rods mated thereto and mated to the first and second gears such that rotation of the threaded shaft causes translation of the housing such that the first and second pusher rods push the first and second gears away from the corresponding motor-driven drive gears.

12. The surgical tool of claim 1, wherein each of the first and second bailout mechanisms includes an indicator configured to indicate when the corresponding first and second actuation assembly coupled thereto has failed.

19. The surgical tool of claim 1, wherein when one of the first or second bailout mechanisms is being manually driven, the other bailout mechanism is configured to remain stationary.

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

selectively manually moving a first bailout assembly of a plurality of bailout assemblies into engagement with a first actuation assembly of the plurality of actuation assemblies, each of the plurality of bailout assemblies being selectively manually movable into engagement with a single corresponding actuation assembly of the plurality of actuation assemblies, and manually rotating the first bailout assembly to retract the first actuation assembly and thereby reverse the corresponding function of the end effector while other bailout assemblies of the plurality of bailout assemblies remain stationary.

14. The surgical bailout method of claim 13, further comprising decoupling the first actuation assembly from engagement with the corresponding drive gear when the first bailout assembly is manually moved into engagement with the first action assembly.

15. The surgical bailout method of claim 14, wherein decoupling the first actuation assembly comprises releasing a spring biasing force applied to a gear of the first actuation assembly to allow the gear to move out of engagement with the corresponding drive gear.

16. The surgical bailout method of claim 13, further comprising simultaneously decoupling the first actuation assembly and a second actuation assembly of the plurality of actuation assemblies from engagement with the corresponding drive gears when the first bailout assembly is manually moved into engagement with the first action assembly.

17. The surgical bailout method of claim 13, further comprising moving the first actuation assembly from a first position, in which a gear of the first actuation assembly is positioned in engagement with a corresponding drive gear of the plurality of drive gears, to a second position, in which the gear of the first actuation assembly is spaced apart and disengaged from the corresponding drive gear of the plurality of drive gears.

18. The surgical bailout method of claim 13, further comprising selectively manually moving a second bailout assembly of a plurality of bailout assemblies into engagement with a second actuation assembly of the plurality of actuation assemblies being configured to actuate a corresponding second function of the end effector, and manually rotating the second bailout assembly to retract the second actuation assembly and thereby reverse the second function of the end effector that is distinct from the function reversed by the first bailout assembly.

20. A surgical tool, comprising:

a housing having a plurality of motor-driven drive gears;

an elongate shaft extending distally from the housing;

an end effector coupled to a distal end of the elongate shaft;

at least first and second actuation assemblies, each actuation assembly being coupled to one of the plurality of motor-driven drive gears such that each of the motor-driven drive gears is configured to drive a corresponding actuation assembly, the first actuation assembly being configured to operate a first function of the end effector, and the second actuation assembly being configured to operate a second function of the end effector that is different than the first function; and

at least first and second bailout mechanisms, the first bailout mechanism being selectively engageable with the first actuation assembly and being configured to be manually driven to subsequently drive the first actuation assembly, and the second bailout mechanism being selectively engageable with the second actuation assembly and being configured to be manually driven to subsequently drive the second actuation assembly;

wherein each of the first and second bailout mechanisms is configured to be in engagement with the corresponding first and second actuation assembly only during manual rotation of the first and second bailout mechanism.