MOTOR INTERFACE FOR PARALLEL DRIVE SHAFTS WITHIN AN INDEPENDENTLY ROTATING MEMBER

• US 20110118754A1
• Filed: 11/12/2010
• Published: 05/19/2011
• Est. Priority Date: 11/13/2009
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Schena, Bruce Michael, Burbank, William A., Murphy, Todd E., Dachs, Gregory W. II, McDonald, William A.
• Granted Patent: US 8,640,788 B2
• Time in Patent Office: Days
• US Class Current: 606/130
• 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 17/072 for applying a row of staples in a single action , e.g. the staples being applied simultaneously
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/115 Staplers for performing anastomosis in a single operation
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/2902 characterized by features of the actuating rod
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2034/302 specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: H04W 84/12 WLAN [Wireless Local Area Networks]

Abstract

Mechanisms, assemblies, systems, tools, and methods incorporating the use of an offset drive shaft within an independently rotating member are provided. An example mechanism includes a base and a main shaft mounted to rotate relative to the base, a first drive shaft mounted inside the main shaft, and a first drive feature engaged with the first drive shaft. The main shaft includes a proximal end, a distal end, and a main shaft rotational axis defined therebetween. The first drive shaft is offset from the main shaft rotational axis. A first drive feature rotational axis is defined for the first drive feature and is fixed relative to the base as the main shaft rotates. The first drive feature rotates the first drive shaft.

Claims

1. A mechanism comprising:

a base;

a main shaft mounted to rotate relative to the base and comprising a proximal end, a distal end, and a main shaft rotational axis defined therebetween;

a first drive shaft mounted inside the main shaft and offset from the main shaft rotational axis; and

a first drive feature engaged with the first drive shaft, wherein

a first drive feature rotational axis is defined for the first drive feature and is fixed relative to the base as the main shaft rotates, and

the first drive feature rotates the first drive shaft.

2. The mechanism of claim 1, wherein the main shaft rotational axis and the first drive feature rotational axis are coincident.

3. The mechanism of claim 1, wherein the engagement between the first drive feature and the first drive shaft permits an axial movement of the first drive shaft relative to the base.

4. The mechanism of claim 1, wherein the first drive feature is engaged with the first drive shaft through an opening in the main shaft.

5. The mechanism of claim 4, wherein the first drive shaft comprises a second drive feature that protrudes through the main shaft opening and engages the first drive feature.

6. The mechanism of claim 5, wherein:

the second drive feature comprises external gear teeth; and

the first drive feature comprises an internal ring gear.

7. The mechanism of claim 1, further comprising a third drive feature, wherein:

a third drive feature rotational axis is defined for the third drive feature;

the third drive feature is engaged with the main shaft; and

the third drive feature rotational axis remains fixed relative to the base as the third drive feature rotates the main shaft.

8. The mechanism of claim 7, further comprising:

a second drive shaft mounted inside the main shaft and offset from the main shaft rotational axis; and

a fourth drive feature engaged with the second drive shaft, wherein

a fourth drive feature rotational axis is defined for the fourth drive feature,

the fourth drive feature rotational axis is fixed relative to the base as the main shaft rotates, and

the fourth drive feature rotates the second drive shaft.

9. The mechanism of claim 1, further comprising

a second drive shaft mounted inside the main shaft and offset from the main shaft rotational axis;

and

a fourth drive feature engaged with the second drive shaft, wherein

a fourth drive feature rotational axis is defined for the fourth drive feature,

the fourth drive feature rotational axis is fixed relative to the base as the main shaft rotates, and

the fourth drive feature rotates the second drive shaft.

10. The mechanism of claim 9, wherein the fourth drive feature is engaged with the second drive shaft through an opening in the main shaft.

11. The mechanism of claim 1, wherein the main shaft comprises a recess configured to interface with a bearing supporting the first drive shaft, and the mechanism further comprises the bearing supporting the first drive shaft.

12. The mechanism of claim 11, further comprising a retaining ring to retain the bearing supporting the first drive shaft.

13. The mechanism of claim 1, further comprising an end effector coupled with the distal end of the main shaft and to the first drive shaft, wherein:

the end effector is rotated by a rotation of the main shaft; and

a rotation of the first drive shaft relative to the main shaft actuates the end effector.

14. The mechanism of claim 1, further comprising:

a control cable drive feature coupled with the base; and

a control cable engaged with the control cable drive feature, the control cable routed within the main shaft between the main shaft proximal and distal ends.

15. The mechanism of claim 14, further comprising an end effector coupled with the control cable, wherein a motion of the control cable actuates the end effector.

16. A robotic assembly, comprising:

a base;

a main shaft mounted to rotate relative to the base and comprising a proximal end, a distal end, and a main shaft rotational axis defined therebetween;

a drive shaft mounted inside the main shaft and offset from the main shaft rotational axis;

an actuation assembly coupled with the main shaft and the drive shaft, the actuation assembly operable to independently

rotate the main shaft relative to the base, and

rotate the drive shaft relative to the main shaft; and

an end effector coupled with the main shaft, the end effector comprising a shaft driven actuation mechanism coupled with the drive shaft.

17. The assembly of claim 16, further comprising a second drive shaft mounted inside the main shaft and offset from the main shaft rotational axis, wherein the actuation assembly is further operable to independently rotate the second drive shaft relative to the main shaft, and wherein the end effector further comprises a second shaft driven actuation mechanism coupled with the second drive shaft.

18. The assembly of claim 16, further comprising a control cable coupled with the end effector, the control cable routed within the main shaft between the main shaft proximal and distal ends, wherein a motion of the control cable actuates the end effector.

19. A robotic system, comprising:

a base;

a main shaft mounted to rotate relative to the base and comprising a proximal end, a distal end, and a main shaft rotational axis defined therebetween;

a first drive shaft mounted inside the main shaft and offset from the main shaft rotational axis;

a second drive shaft mounted inside the main shaft and offset from the main shaft rotational axis;

an actuation assembly coupled with the main shaft, the first drive shaft, and the second drive shaft;

a controller comprising an input and an output, the input coupled with an input device to receive at least one input signal from the input device, the output coupled with the actuation assembly to output at least one control signal to the actuation assembly, the controller comprising a processor and a tangible medium containing instructions that when executed cause the processor to generate the at least one control signal in response to the at least one input signal so that the input device can be used by a user to independently

rotate the main shaft relative to the base,

rotate the first drive shaft relative to the main shaft, and

rotate the second drive shaft relative to the main shaft; and

an end effector coupled with the main shaft so that the end effector is rotated by a rotation of the main shaft, the end effector comprising

a first shaft driven actuation mechanism coupled with the first drive shaft, and

a second shaft driven actuation mechanism coupled with the second drive shaft.

20. The system of claim 19, wherein the actuation assembly comprises:

a first motor coupled with the first drive shaft and the controller;

a second motor coupled with the second drive shaft and the controller; and

a main shaft motor coupled with the main shaft and the controller.

21. The system of claim 20, wherein the actuation assembly further comprises:

a first encoder coupled with the first motor and the controller, the first encoder outputting a first motor position signal to the controller in response to a position of the first motor;

a second encoder coupled with the second motor and the controller, the second encoder outputting a second motor position signal to the controller in response to a position of the second motor; and

a main shaft encoder coupled with the main shaft motor and the controller, the main shaft encoder outputting a main shaft position signal to the controller in response to a position of the main shaft motor.

22. The system of claim 19, further comprising a control cable coupled with the end effector, the control cable routed within the main shaft between the main shaft proximal and distal ends, wherein a motion of the control cable actuates the end effector.

23. A robotic tool for mounting on a manipulator having a tool interface with first, second, and third drive features, the tool comprising:

a proximal tool chassis releasably mountable to the tool interface;

a distal end effector having a distal degree of freedom and a shaft driven actuation mechanism;

a main shaft having a proximal end adjacent the chassis, a distal end adjacent the end effector, a bore extending therebetween, and a lateral opening distally of the proximal end; and

a hybrid cable/shaft drive system operatively coupling the drive features of the tool interface to the end effector when the chassis is mounted to the tool interface so that actuation of the first drive feature rotates the main shaft and the end effector relative to the chassis about a main shaft rotational axis, so that cables extending from the chassis distally within the bore of the main shaft couple the distal degree of freedom of the end effector to the second drive feature, and so that a first drive shaft couples the shaft driven actuation mechanism of the end effector to the third drive feature through the lateral opening in the main shaft, the first drive shaft being offset from the main shaft rotational axis.

24. A method for transmitting torque through an offset drive shaft routed within a rotatable main shaft, the method comprising:

supporting a main shaft to rotate relative to a base so that the main shaft rotates about a main shaft rotational axis;

supporting a drive shaft to rotate relative to the main shaft so that the drive shaft rotates about a drive shaft rotational axis that is offset from the main shaft rotational axis;

engaging the drive shaft with a drive feature having a drive feature rotational axis that is fixed relative to the base as the main shaft rotates;

rotating the main shaft relative to the base; and

rotating the drive feature relative to the main shaft so as to rotate the drive shaft relative to the main shaft.

25. The method of claim 24, wherein the main shaft rotates relative to the base and the drive shaft rotates relative to the main shaft simultaneously.

26. A minimally invasive surgical method comprising:

introducing an end effector to an internal surgical site within a patient through a minimally invasive aperture or natural orifice by manipulating a base, wherein the end effector is supported relative to the base by an elongated instrument shaft;

rotating the end effector relative to the base by rotating the instrument shaft relative to the base about an instrument shaft rotational axis; and

performing a surgical task with the end effector by rotating a first drive shaft relative to the instrument shaft so that the first drive shaft actuates the end effector, the first drive shaft rotating relative to the instrument shaft about a first drive shaft rotational axis that is offset from the instrument shaft rotational axis.

27. The method of claim 26, further comprising actuating the end effector by rotating a second drive shaft, the second drive shaft rotating relative to the instrument shaft about a second drive shaft rotational axis that is offset from the instrument shaft rotational axis.