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

• US 10,485,618 B2
• Filed: 04/11/2018
• Issued: 11/26/2019
• 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): Masih, Karen
• Application Number:
  US15/950,276
• Publication Number:
  US 20180228561A1
• Time in Patent Office: 594 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 first motor of a robotic surgical system, the robotic surgical system being configured to releasably and replaceably couple to a surgical tool, and the first motor having a maximum torque output;

a first actuator of the robotic surgical system, the first motor being configured to apply an amount of torque to the first actuator and thereby cause movement of an end effector of the surgical tool, in which the amount of torque applied by the first motor to the first actuator does not exceed a first torque threshold that is less than the maximum torque output;

a second actuator of the robotic surgical system, the first motor being configured to apply an amount of torque to the second actuator and thereby cause movement of the end effector of the surgical tool, in which the amount of torque applied by the first motor to the second actuator does not exceed a second torque threshold that is less than the maximum torque output and that is different from the first torque threshold;

a second motor of the robotic surgical system; and

a third actuator of the robotic surgical system;

wherein the first motor is a single motor, and the second motor is configured to apply an amount of torque to the third actuator and thereby cause movement of the end effector of the surgical tool.

2. The system of claim 1, wherein the movement of the end effector caused by the amount of torque applied to the first actuator is different from the movement of the end effector caused by the amount of torque applied to the second actuator.

3. The system of claim 2, wherein the movement of the end effector caused by the amount of torque applied to the first actuator is closing of the end effector at a first speed, and the movement of the end effector caused by the amount of torque applied to the second actuator is closing the end effector at a second speed that is greater than the first speed.

4. The system of claim 1, further comprising a first torque limiting mechanism configured to prevent the amount of torque applied by the first motor to the first actuator from exceeding the first torque threshold;

and

a second torque limiting mechanism configured to prevent the amount of torque applied by the first motor to the second actuator from exceeding the second torque threshold.

5. The system of claim 4, wherein the first and second torque limiting mechanisms each include a rotatable gear.

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

7. The system of claim 1, further comprising a tool driver including the first motor and the first and second actuators, the tool driver being configured to releasably and replaceably couple to a housing of the surgical tool.

8. The system of claim 1, wherein the surgical tool is a surgical stapler.

9. A surgical system, comprising:

a motor of a robotic surgical system, the robotic surgical system being configured to releasably and replaceably couple to a surgical tool, and the motor having a maximum torque output;

a first actuator of the robotic surgical system, the motor being configured to apply an amount of torque to the first actuator and thereby cause a first movement of an end effector of the surgical tool;

a first torque limiting mechanism configured to prevent the amount of torque applied by the motor to the first actuator from exceeding a first torque threshold that is less than the maximum torque output;

a second actuator of the robotic surgical system, the motor being configured to apply an amount of torque to the second actuator and thereby cause a second movement of the end effector of the surgical tool, the second movement being different from the first movement; and

a second torque limiting mechanism configured to prevent the amount of torque applied by the motor to the second actuator from exceeding a second torque threshold that is less than the maximum torque output and that is different from the first torque threshold.

10. The system of claim 9, further comprising an additional motor of the robotic surgical system, and an additional actuator of the robotic surgical system;

wherein the motor is a single motor, and the additional motor is configured to apply an amount of torque to the additional actuator and thereby cause movement of the end effector.

11. The system of claim 9, wherein the first torque limiting mechanism includes engaged first and second rotatable members;

and

the second torque limiting mechanism includes engaged third and fourth rotatable members.

12. The system of claim 9, wherein the first and second actuators each include a rotatable gear.

13. The system of claim 9, further comprising a tool driver including the motor and the first and second actuators, the tool driver being configured to releasably and replaceably couple to a housing of the surgical tool.

14. The system of claim 9, wherein the surgical tool is a surgical stapler.

15. A surgical method, comprising:

rotating a first gear of a robotic surgical system to actuate a single motor of the robotic surgical system so as to output a first amount of torque and thereby cause an end effector of a surgical tool operatively coupled to the single motor to cause a first movement of the end effector in a body of a patient;

preventing the first amount of torque output by the single motor from exceeding a first torque threshold that is less than the maximum torque output;

rotating a second gear of the robotic surgical system to actuate the single motor so as to output a second amount of torque and thereby cause a second movement of the end effector in the body of the patient that is different from the first movement of the end effector; and

preventing the second amount of torque output by the single motor from exceeding a second torque threshold that is less than the maximum torque output and that is different from the first torque threshold.

16. The method of claim 15, wherein preventing the first amount of torque output by the single motor from exceeding the first torque threshold includes engagement of first and second rotatable members;

and

preventing the second amount of torque output by the single motor from exceeding the second torque threshold includes engagement of third and fourth rotatable members.

18. The method of claim 15, further comprising releasably engaging a tool driver of the robotic surgical system to a proximal housing of the surgical tool, the end effector being located at a distal end of the surgical tool.

17. A surgical method, comprising:

actuating a single motor of a robotic surgical system to output a first amount of torque and thereby cause an end effector of a surgical tool operatively coupled to the single motor to cause a first movement of the end effector in a body of a patient;

preventing the first amount of torque output by the motor from exceeding a first torque threshold that is less than the maximum torque output;

actuating the single motor of the robotic surgical system to output a second amount of torque and thereby cause a second movement of the end effector in the body of the patient that is different from the first movement of the end effector;

preventing the second amount of torque output by the motor from exceeding a second torque threshold that is less than the maximum torque output and that is different from the first torque threshold; and

actuating an additional motor of the robotic surgical system to output a third amount of torque and thereby cause a third movement of the end effector in the body of the patient that is different from the first and second movements of the end effector.

19. The method of claim 17, further comprising releasably engaging a tool driver of the robotic surgical system to a proximal housing of the surgical tool, the end effector being located at a distal end of the surgical tool.