Robotic surgical systems and instrument drive units

• US 10,639,113 B2
• Filed: 04/28/2015
• Issued: 05/05/2020
• Est. Priority Date: 05/13/2014
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Grover, Simon R., Kilby, Charles F., Fuller, Daniel L.
• Primary Examiner(s): Layno, Carl H
• Assistant Examiner(s): Lau, Michael J
• Application Number:
  US15/309,833
• Publication Number:
  US 20170265951A1
• Time in Patent Office: 1,834 Days
• Field of Search: 606 1, 606130
• 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 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00225 Systems for controlling multiple different instruments, e.g. microsurgical systems
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/2931 with releasable head
• CPC Class Codes: A61B 2017/2943 Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2034/742 Joysticks
• CPC Class Codes: A61B 2090/064 for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/35 for telesurgery
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 34/74 Manipulators with manual electric input means
• CPC Class Codes: A61B 46/10 specially adapted for instruments, e.g. microscopes

Abstract

An instrument control unit for use with a surgical instrument, is provided. The instrument control unit comprises first and second plates, first and second lead screws, first and second yokes, and first and second motors. The first and second plates define a sleeve therebetween. Each of the first and second lead screws is disposed between the first and second plates. Each of the first and second yokes is threadedly engaged with its respective lead screw. The motors are disposed in mechanical cooperation with respective lead screws. Actuation of the motors causes rotation of its respective lead screw, which results in movement of its respective yoke along the longitudinal axis, and which is configured to effect a first function of a surgical instrument engaged with the instrument control unit.

Claims

1. An instrument control unit for use with a surgical instrument, the instrument control unit comprising:

a first plate;

a second plate disposed in spaced relation from the first plate, the first plate and the second plate defining a sleeve therebetween, the sleeve configured to accept a surgical instrument at least partially therein, the sleeve defining a longitudinal axis;

a first lead screw disposed between the first plate and the second plate;

a second lead screw disposed between the first plate and the second plate;

a first yoke threadedly engaged with the first lead screw;

a second yoke threadedly engaged with the second lead screw;

a first motor disposed in mechanical cooperation with the first lead screw such that actuation of the first motor causes rotation of the first lead screw, which results in movement of the first yoke along the longitudinal axis, and wherein movement of the first yoke along the longitudinal axis is configured to effect a first function of a surgical instrument engaged with the instrument control unit;

a second motor disposed in mechanical cooperation with the second lead screw such that actuation of the second motor causes rotation of the second lead screw, which results in movement of the second yoke along the longitudinal axis, and wherein movement of the second yoke along the longitudinal axis is configured to effect a second function of a surgical instrument engaged with the instrument control unit; and

a control device configured to remotely control actuation of the first motor and the second motor.

2. The instrument control unit according to claim 1, wherein the first plate includes an arcuate portion and the second plate includes an arcuate portion, wherein the sleeve is defined between the arcuate portion of the first plate and the arcuate portion of the second plate.

3. The instrument control unit according to claim 1, wherein each of the first yoke and the second yoke is arcuate.

4. The instrument control unit according to claim 1, further comprising a third lead screw disposed between the first plate and the second plate, a third yoke threadedly engaged with the third lead screw, and a third motor disposed in mechanical cooperation with the third lead screw such that actuation of the third motor causes rotation of the third lead screw, which results in movement of the third yoke along the longitudinal axis, and wherein movement of the third yoke along the longitudinal axis is configured to effect a third function of a surgical instrument engaged with the instrument control unit.

5. The instrument control unit according to claim 4, further comprising a fourth lead screw disposed between the first plate and the second plate, a fourth yoke threadedly engaged with the fourth lead screw, and a fourth motor disposed in mechanical cooperation with the fourth lead screw such that actuation of the fourth motor causes rotation of the fourth lead screw, which results in movement of the fourth yoke along the longitudinal axis, and wherein movement of the fourth yoke along the longitudinal axis is configured to effect a fourth function of a surgical instrument engaged with the instrument control unit.

6. The instrument control unit according to claim 5, further comprising a first interface gear and a fifth motor disposed in mechanical communication with the first interface gear, wherein actuation of the fifth motor results in rotation of the first interface gear, which is configured to effect a fifth function of a surgical instrument engaged with the instrument control unit.

7. The instrument control unit according to claim 6, further comprising a second interface gear and a sixth motor disposed in mechanical communication with the second interface gear, wherein actuation of the sixth motor results in rotation of the second interface gear, which is configured to effect a sixth function of a surgical instrument engaged with the instrument control unit.

8. The instrument control unit according to claim 5, wherein at least a majority of each of the first motor, the second motor, the third motor, and the fourth motor is disposed between the first plate and the second plate.

9. The instrument control unit according to claim 5, wherein each of the first motor, the second motor, the third motor, and the fourth motor includes a shaft that extends through at least one of the first plate and the second plate.

10. The instrument control unit according to claim 1, wherein each of the first plate and the second plate includes two portions that are hingedly connected to each other, and wherein each of the first plate and the second plate is configured to move between an open position to accept a surgical instrument at least partially within the sleeve, and a closed position to surround a diameter of a surgical instrument.

11. The instrument control unit of claim 1, further comprising a drape essentially enclosing the first plate, the second plate, the first lead screw, the second lead screw, the first motor and the second motor, while permitting longitudinal movement of the first yoke and the second yoke to be transferred to a portion of a surgical instrument engaged with the instrument control unit.

12. The instrument control unit of claim 11, further comprising a first interface collar and a second interface collar, the first interface collar configured to mechanically engage the first yoke and a portion of a surgical instrument engaged with the instrument control unit, the second interface collar configured to mechanically engage the second yoke and a portion of a surgical instrument engaged with the instrument control unit, and wherein the drape is secured to the first interface collar and the second interface collar.

13. An instrument control unit for use with a surgical instrument, the instrument control unit comprising:

a first plate;

a second plate disposed in spaced relation from the first plate, the first plate and the second plate defining a sleeve therebetween, the sleeve configured to accept a surgical instrument at least partially therein, the sleeve defining a longitudinal axis;

a first lead screw disposed between the first plate and the second plate;

a second lead screw disposed between the first plate and the second plate;

a third lead screw disposed between the first plate and the second plate;

a first yoke threadedly engaged with the first lead screw;

a second yoke threadedly engaged with the second lead screw;

a third yoke threadedly engaged with the third lead screw;

a first motor disposed in mechanical cooperation with the first lead screw such that actuation of the first motor causes rotation of the first lead screw, which results in movement of the first yoke along the longitudinal axis, and wherein movement of the first yoke along the longitudinal axis is configured to effect a first function of a surgical instrument engaged with the instrument control unit;

a second motor disposed in mechanical cooperation with the second lead screw such that actuation of the second motor causes rotation of the second lead screw, which results in movement of the second yoke along the longitudinal axis, and wherein movement of the second yoke along the longitudinal axis is configured to effect a second function of a surgical instrument engaged with the instrument control unit; and

a third motor disposed in mechanical cooperation with the third lead screw such that actuation of the third motor causes rotation of the third lead screw, which results in movement of the third yoke along the longitudinal axis, and wherein movement of the third yoke along the longitudinal axis is configured to effect a third function of a surgical instrument engaged with the instrument control unit.

14. An instrument control unit for use with a surgical instrument, the instrument control unit comprising:

a first plate;

a second plate disposed in spaced relation from the first plate, the first plate and the second plate defining a sleeve therebetween, the sleeve configured to accept a surgical instrument at least partially therein, the sleeve defining a longitudinal axis, each of the first plate and the second plate includes two portions that are hingedly connected to each other, and each of the first plate and the second plate is configured to move between an open position to accept a surgical instrument at least partially within the sleeve, and a closed position to surround a diameter of a surgical instrument;

a first lead screw disposed between the first plate and the second plate;

a second lead screw disposed between the first plate and the second plate;

a first yoke threadedly engaged with the first lead screw;

a second yoke threadedly engaged with the second lead screw;

a first motor disposed in mechanical cooperation with the first lead screw such that actuation of the first motor causes rotation of the first lead screw, which results in movement of the first yoke along the longitudinal axis, and wherein movement of the first yoke along the longitudinal axis is configured to effect a first function of a surgical instrument engaged with the instrument control unit; and

a second motor disposed in mechanical cooperation with the second lead screw such that actuation of the second motor causes rotation of the second lead screw, which results in movement of the second yoke along the longitudinal axis, and wherein movement of the second yoke along the longitudinal axis is configured to effect a second function of a surgical instrument engaged with the instrument control unit.

15. An instrument control unit for use with a surgical instrument, the instrument control unit comprising:

a first plate;

a second plate disposed in spaced relation from the first plate, the first plate and the second plate defining a sleeve therebetween, the sleeve configured to accept a surgical instrument at least partially therein, the sleeve defining a longitudinal axis;

a first lead screw disposed between the first plate and the second plate;

a second lead screw disposed between the first plate and the second plate;

a first yoke threadedly engaged with the first lead screw;

a second yoke threadedly engaged with the second lead screw;

a first motor disposed in mechanical cooperation with the first lead screw such that actuation of the first motor causes rotation of the first lead screw, which results in movement of the first yoke along the longitudinal axis, and wherein movement of the first yoke along the longitudinal axis is configured to effect a first function of a surgical instrument engaged with the instrument control unit;

a second motor disposed in mechanical cooperation with the second lead screw such that actuation of the second motor causes rotation of the second lead screw, which results in movement of the second yoke along the longitudinal axis, and wherein movement of the second yoke along the longitudinal axis is configured to effect a second function of a surgical instrument engaged with the instrument control unit; and

a drape essentially enclosing the first plate, the second plate, the first lead screw, the second lead screw, the first motor, and the second motor, while permitting longitudinal movement of the first yoke and the second yoke to be transferred to a portion of a surgical instrument engaged with the instrument control unit.