Surgical instrument coupling mechanism

• US 20040049205A1
• Filed: 11/21/2002
• Published: 03/11/2004
• Est. Priority Date: 09/09/2002
• Status: Active Grant

• Current Assignee: Auris Health, Inc. (Johnson & Johnson)
• Original Assignee: endoVia Medical, Inc. (Johnson & Johnson)
• Inventors: Lee, Woojin, Mazzuca, Michael J., Gorhan, Michael C.
• Granted Patent: US 7,331,967 B2
• Time in Patent Office: Days
• US Class Current: 606/130
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/715 Cable tensioning mechanisms for removing slack
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/37 Master-slave robots A61B34/35 takes precedence
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 46/10 specially adapted for instruments, e.g. microscopes
• CPC Class Codes: A61B 90/361 Image-producing devices, e.g. surgical cameras

Abstract

A surgical apparatus includes a slider mechanism, a surgical instrument coupled to the slider mechanism, and a single cable bundle that couples the slider mechanism and instrument to a driver. The single cable bundle includes a first cable that operates the slider mechanism and thus the instrument with one degree-of-freedom of movement, and a second cable that operates the instrument itself with another degree-of-freedom of movement. The cable bundle is attached to the slider mechanism at a location that is stationary.

Claims

1. A remotely controlled medical apparatus with two or more degrees of freedom of movement comprising:

a carriage;

two fixed pulleys at fixed locations on the carriage;

two sliding pulleys linearly movable on the carriage relative to the stationary pulleys;

a remotely controlled driver capstan coupled to the two stationary pulleys and the two sliding pulleys with a first cable segment wrapped around one of the sliding pulleys and one of the stationary pulleys, and a second cable segment wrapped around the other sliding pulley and the other stationary pulley, each segment having an end attached to an anchor; and

a driven capstan on the carriage coupled to the two sliding pulleys with a third cable segment and driven by opposed linear movement of the sliding pulleys.

2. The apparatus of claim 1 further comprising two pulley sliders that slide along respective tracks, each sliding pulley being mounted in a respective pulley slider.

3. The apparatus of claim 1 further comprising a medical instrument coupled to the carriage, and a motor coupled to the driver capstan with a fourth cable segment, the motor moving the medical instrument with one degree-of-freedom.

4. The apparatus of claim 3 further comprising one or more of the two fixed pulleys, the two sliding pulleys, and the driven capstan on the carriage, and respective one or more driver capstans, and respective one or more motors, each the one or motors being coupled to a respective capstan with a respective fourth cable segment, the one or more motors moving the medical instrument with an associated degree-of-freedom.

5. The apparatus of claim 4 wherein two or more of the two fixed pulleys, the two sliding pulleys, and the driven capstan are arranged in a stacked configuration.

6. The apparatus of claim 3 further comprising a linear drive mechanism that moves the carriage in a linear manner.

7. The apparatus of claim 6 further comprising a linear drive motor, the linear drive mechanism including a pulley arrangement coupled to the linear drive motor.

8. The apparatus of claim 6 further comprising an angle drive mechanism that pivots the carriage about an axis of rotation, the axis of rotation being perpendicular to the linear movement of the carriage.

9. The apparatus of claim 8 further comprising an angle drive motor, the angle drive mechanism including a pulley arrangement coupled to the angle drive motor.

10. The apparatus of claim 3 further comprising a remote controller coupled to the motor, and to an input device for interfacing with a user, the input device transmitting instructions from the user to the remote controller to direct the operation of the motor to move the medical instrument.

11. A remotely controlled medical apparatus for applying rotary movement to a driven element on a moveable carriage of a surgical apparatus from a driver element not on the carriage comprising:

a pair of first flexible drive segments extending from the driver element to relatively stationary anchors, each through a pair of mounted pulleys, in each pair of pulleys, a first pulley in a fixed position on the carriage, and a second pulley moveable relative to the carriage; and

a pair of second flexible drive segments, each fixed at one end to one of the second pulleys and coupled to the driven element to rotate the driven element.

12. The apparatus of claim 11 wherein the pair of first flexible drive segments is a single length of material.

13. The apparatus of claim 11 wherein the pair of second flexible drive segments is a single length of material.

14. A remotely controlled medical apparatus comprising:

a slider mechanism;

a surgical instrument coupled to the slider mechanism; and

a single cable bundle that couples the slider mechanism and instrument to a driver, the single cable bundle including a first cable that operates the slider mechanism and thus the instrument with one degree-of-freedom of movement, and a second cable that operates the instrument itself with another degree-of-freedom of movement, the cable bundle being attached to the slider mechanism at a location that is stationary.

15. The apparatus of claim 14 wherein the slider mechanism includes a linear drive mechanism that moves the surgical instrument in a linear manner, the first cable being associated with the linear drive mechanism.

16. The apparatus of claim 15 further comprising an angle drive mechanism, wherein the cable bundle includes a respective drive cable for the angle drive mechanism, the angle drive mechanism rotating the surgical instrument about an axis of rotation, the axis of rotation being perpendicular to the linear movement of the surgical instrument.

17. The apparatus of claim 15 wherein the surgical instrument includes a tool having one or more degrees-of-freedom of movement, the cable bundle including a respective drive cable for each of the one or more degrees-of-freedom of movement, the one or more degrees-of-freedom of movement being decoupled from the linear movement.

18. The apparatus of claim 15 wherein the surgical instrument includes a detachable adaptor that facilitates coupling of the surgical instrument to the slider mechanism.

19. The apparatus of claim 18 further comprising a drape positioned between the surgical instrument and the slider mechanism.

20. The apparatus of claim 19 wherein the drape includes a drape insert that couples the adaptor to the slider mechanism.

21. The apparatus of claim 18 further comprising an instrument insert received by the detachable adaptor.

22. The apparatus of claim 21 wherein a portion of the adaptor has a clamshell construction for engaging the instrument insert with the detachable adaptor.

23. The apparatus of claim 21 wherein the instrument insert includes a shaft.

24. The apparatus of claim 23 wherein the adaptor is provided with a seal that between the operation site and the adaptor.

25. The apparatus of claim 24 wherein the seal is positioned about the instrument insert shaft.

26. The apparatus of claim 23 wherein the instrument insert includes an instrument insert release that allows rotation of the shaft relative the remainder of the insert when the insert is engaged with the adaptor.

27. The apparatus of claim 21 wherein the adaptor includes anti-rotation lockouts that prevents one or more drive shafts of the adaptor from rotating when the insert is unengaged with the adaptor.

28. The apparatus of claim 21 wherein the insert includes a cable tensioning mechanism that increases tension in one or more drive cables of the insert when the insert is to be used.

29. The apparatus of claim 14 further comprising a remote controller coupled to the slider mechanism, and to an input device for interfacing with a user, the input device transmitting instructions from the user to the remote controller to direct the operation of the slider mechanism and thus the surgical instrument.

30. A method of moving a surgical instrument with two or more degrees-of-freedom comprising:

pulling one of a first pair of flexible segments with a driver element causing one of a pair of first pulleys to move closer to an associated second pulley of a pair of second pulleys, and the other first pulley to move apart from its associated second pulley, movement of the first pulleys causing rotation of a driven element through a pair of second flexible drive segments.

31. The method of claim 30 further comprising moving the surgical instrument with a linear movement, the linear movement being in addition to the two or more degrees-of-freedom of movement.

32. The method of claim 30 further comprising moving the surgical instrument with a rotational movement, the rotational movement being in addition to the two or more degrees-of-freedom of movement.

33. The method of claim 30 further comprising controlling the movement with a controller coupled to an input device, the controller receiving operating instructions from the input device.

34. A method of moving a surgical instrument with two or more degrees-of-freedom comprising:

coupling the surgical instrument to a slider mechanism;

coupling a single cable bundle to the slider mechanism at a location on the slider mechanism that is stationary; and

pulling one of a first pair of flexible segments of the single cable bundle to operate the slider mechanism and thus the surgical instrument with one degree-of-freedom of movement, and pulling one of a second pair of flexible segments of the single cable bundle to operate the instrument itself with another degree-of-freedom of movement.

35. The method of claim 34 wherein the coupling includes positioning a drape between the surgical instrument and the slider mechanism.

36. The method of claim 34 further comprising inserting an instrument insert into an adaptor of the surgical instrument.

37. The method of claim 36 further comprising forming a seal between a shaft of the insert and the adaptor.

38. The method of claim 34 wherein the pulling on the one of the first pair of flexible segments moves the surgical instrument in a linear manner.

39. The method of claim 34 wherein the pulling of the one of the first pair of flexible segments moves the surgical instrument in a rotational manner.

40. The method of claim 34 further comprising controlling the one or more degrees-of-freedom of movement with a controller coupled to an input device, the controller receiving operating instructions from the input device.

41. A remotely controlled medical apparatus with two or more degrees of freedom of movement comprising:

a means for coupling a surgical instrument to a slider mechanism; and

a means for coupling a single cable bundle to the slider mechanism at a location on the slider mechanism that is stationary; and

a means for pulling one of a first pair of flexible segments of the single cable bundle to operate the slider mechanism and thus the surgical instrument with one degree-of-freedom of movement, and pulling one of a second pair of flexible segments of the single cable bundle to operate the instrument itself with another degree-of-freedom of movement.

42. A surgical instrument system comprising:

a surgical instrument member that carries a distal tool that is useable in performing a medical procedure on a patient;

an instrument holder that is adapted to receive the surgical instrument member and that is positionable to maintain the surgical instrument member at an operative site of the patient;

a coupling mechanism that interconnects the surgical instrument member with a drive unit that is adapted to control multiple degrees-of-freedom of motion of the surgical instrument member;

said surgical instrument member being releasably engageable with said instrument holder;

said instrument holder being releasably engageable with said coupling mechanism.

43. The instrument of claim 42 wherein the surgical instrument member is detachable for substituting another member.

44. The instrument of claim 42 wherein the holder is detachable for substituting another holder.

45. A surgical instrument comprising:

an instrument insert supporting a distal tool;

a holder for the instrument insert;

a stationary drive unit for controlling multiple degrees of freedom of the surgical instrument;

a cable bundle coupled from the drive unit for providing mechanical control to the instrument; and

a coupling mechanism interposed between the cable bundle and the instrument that enables the cable bundle to be attached to the coupling mechanism at a stationary location.

46. A surgical instrument comprising:

a slider mechanism;

a surgical instrument coupled to the slider mechanism;

a single cable bundle that couples the slider mechanism and instrument to a driver; and

a means for operating the slider mechanism and thus the instrument with one degree-of-freedom of movement, a cable of the single cable bundle operating the instrument itself with

another degree-of-freedom of movement, the cable bundle being attached to the slider mechanism at a location that is stationary.