Articulated surgical instrument for performing minimally invasive surgery with enhanced dexterity and sensitivity

• US 5,792,135 A
• Filed: 05/16/1997
• Issued: 08/11/1998
• Est. Priority Date: 05/20/1996
• Status: Expired due to Term

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Incorporated (Intuitive Surgical Holdings, LLC)
• Inventors: Madhani, Akhil J., Salisbury, J. Kenneth
• Primary Examiner(s): Dawson, Glenn K.
• Assistant Examiner(s): Woo, Julian W.
• Application Number:
  US08/857,776
• Time in Patent Office: 452 Days
• Field of Search: 604/95, 74/490.02, 74/490.03, 74/490.04, 74/490.05, 74/490.06, 606/1
• US Class Current: 606/1
• 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 17/29 Forceps for use in minimally invasive surgery
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/2939 Details of linkages or pivot points
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2034/306 Wrists with multiple vertebrae
• CPC Class Codes: A61B 2034/715 Cable tensioning mechanisms for removing slack
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/35 for telesurgery
• CPC Class Codes: A61B 34/37 Master-slave robots A61B34/35 takes precedence
• CPC Class Codes: A61B 34/70 Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 34/76 Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: A61B 34/77 Manipulators with motion or force scaling
• CPC Class Codes: B25J 3/04 involving servo mechanisms servo-actuated heads B25J15/02
• CPC Class Codes: B25J 9/104 with cables, chains or ribbons
• CPC Class Codes: Y10T 74/20329 Joint between elements
• CPC Class Codes: Y10T 74/20335 Wrist

Abstract

An articulated surgical instrument for enhancing the performance of minimally invasive surgical procedures. The instrument has a high degree of dexterity, low friction, low inertia and good force reflection. A unique cable and pulley drive system operates to reduce friction and enhance force reflection. A unique wrist mechanism operates to enhance surgical dexterity compared to standard laparoscopic instruments. The system is optimized to reduce the number of actuators required and thus produce a fully functional articulated surgical instrument of minimum size.

Claims

1. An articulated surgical instrument for minimally invasive surgery comprising a support bracket, an elongate support member, a wrist mechanism, a surgical end effector, four actuators and four cables wherein:

the four actuators are mounted on the support bracket;

the elongate support member has a proximal end and a distal end and a support axis running longitudinally along the elongate support member from the proximal end to the distal end;

the proximal end of the support member is coupled to the support bracket by a rotary joint for rotation about the support axis and a linear joint for reciprocal motion along the support axis;

the distal end of the support member is connected to the wrist mechanism;

the wrist mechanism supports the surgical end effector;

the surgical end effector comprises a first work member; and

the four actuators are coupled by the four cables to the wrist mechanism, the rotary joint and the linear joint such that selective actuation of the actuators operates to move the first work member of the surgical end effector about two orthogonal axes with two degrees-of-freedom relative to the support member, extend and retract the support member along the support axis relative to the support bracket and rotate the support member about the support axis relative to the support bracket and thereby move the first work member of the surgical end effector relative to the support bracket with four degrees-of-freedom.

2. The articulated surgical instrument of claim 1 comprising five actuators mounted on the support bracket coupled by five cables to the wrist mechanism, the rotary joint, the linear joint and the end effector wherein:

the end effector comprise a first work member and a second work member which can be moved in a scissor-like action relative to the first work member;

whereby selective actuation of the actuators operates to move the second work member relative to the first work member with one degree-of-freedom and move the first work member relative to the support bracket with four degrees-of-freedom.

3. The articulated surgical instrument of claim 1 comprising a mounting bracket connected to the support bracket wherein the mounting bracket is adapted to releasably connect the articulated surgical instrument to a positioning mechanism.

4. The articulated surgical instrument of claim 2 wherein a first actuator drives a first cable in opposition to a second cable driven by a second actuator to move the first work member with a first degree-of-freedom relative to the support member.

5. The articulated surgical instrument of claim 4 wherein a third actuator drives a third cable in opposition to a fourth cable driven by a fourth actuator to move the second work member relative to the first work member with one degree-of-freedom.

6. The articulated surgical instrument of claim 5 wherein the first and second actuators drive the respective first and second cables in unison in opposition to the third and fourth cables driven in unison by the respective third and fourth actuators in order to move the first work member relative to the support member with a second degree-of-freedom.

7. The articulated surgical instrument of claim 5 wherein the first, second, third and fourth actuators drive respective first, second, third and fourth cables in unison in order to move the elongate support member along the support axis.

8. An articulated surgical instrument for minimally invasive surgery comprising:

actuator means comprising four actuators for operating the articulated surgical instrument;

support means fixed to the four actuators;

a surgical end effector comprising a first work member for manipulating human tissues;

wrist means coupled to the surgical end effector for moving the surgical end effector with two degrees-of-freedom;

an elongate support member coupled to the wrist means for insertion of the surgical end effector into a patient through an aperture;

rotary joint means disposed between the elongate support member and the support bracket for rotation of the elongate support member relative to the support bracket;

linear joint means disposed between the elongate support member and the support bracket for extension and retraction of the elongate support member relative to the support bracket;

cable drive means coupled between the actuator means and the wrist means, the rotary joint means and the linear joint means such that selective actuation of the actuator means operates to move the first work member of the surgical end effector relative to the elongate support member with two degrees-of-freedom, extend and retract the elongate support member relative to the support bracket means and rotate the support member relative to the support bracket means and thereby move the first work member relative to the support bracket means with four degrees-of-freedom.

9. The articulated surgical instrument of claim 8 wherein:

the actuator means comprises five actuators;

the actuator means is coupled by the cable drive means to the surgical end effector, the wrist means, the rotary joint means and the linear joint means;

the surgical end effector comprises a second work member opposed to the first work member; and

selective actuation of the actuator means operates to move the second work member of the surgical end effector relative to the first work member of the surgical end effector with one degrees-of-freedom.

10. The articulated surgical instrument of claim 9 further comprising a mounting means, connected to the support means, for releasably mounting the articulated surgical instrument to a positioning device.

11. The articulated surgical instrument of claim 9 wherein the actuator means drives a first cable in opposition to a second cable to move the first work member means relative to support member with one degree-of-freedom.

12. The articulated surgical instrument of claim 11 wherein the actuator means drives a third cable in opposition to a fourth cable to move the second work member means relative to the first work member with one degree-of-freedom.

13. The articulated surgical instrument of claim 12 wherein the actuator means drives the first and second cables in unison in opposition to the third and fourth cables driven in unison in order to move the first work member relative to the second work member with a second degree-of-freedom.

14. The articulated surgical instrument of claim 13 wherein the actuator means drives the first, second, third and fourth cables in unison in order to extend and retract the elongate support member relative to the support bracket means.

15. A method of operating an articulated surgical instrument for minimally invasive surgery comprising the steps of:

providing an articulated surgical instrument which has a support bracket, an elongate support member having a proximal end, a distal end and a support axis running longitudinally from the proximal end to the distal end, a rotary joint disposed between the support member and the support bracket for rotation of the support member about the support axis relative to the support bracket, a linear joint disposed between the support member and the support bracket for extension and retraction of the support member along the support axis relative to the support bracket;

a surgical end effector for manipulation of human tissues and a wrist mechanism disposed between the end effector and the distal end of the elongate support member for providing pivotal motion of the end effector with two degrees-of-freedom;

providing a cable drive system comprising first, second, third and fourth actuators coupled to respective first, second, third and fourth cables;

inserting the distal end of the elongate support member through a small aperture to a surgical worksite inside a patient

selectively operating the first, second, third and fourth actuators to drive the respective first, second, third and fourth cables to operate the wrist mechanism and move the end effector with two degrees-of-freedom relative to the support member; and

manipulating human tissues with the end effector.

16. The method of manipulating an articulated surgical instrument as defined in claim 15 wherein the end effector comprises a first work member and the method comprises the further steps of:

operating the first actuator to drive the first cable; and

operating the second actuator to drive the second cable in opposition to the first cable in order to move the first work member relative to the second end effector with a first degree-of-freedom.

17. The method of manipulating an articulated surgical instrument as defined in claim 16 wherein the end effector comprises a second work member opposed to the first work member and the method comprises the further steps of:

operating the third actuator to drive the third cable; and

operating the fourth actuator to drive the fourth cable in opposition to the first cable in order to move the second work member relative to the first work member with one degree-of-freedom.

18. The method of manipulating an articulated surgical instrument as defined in claim 17 wherein the method comprises the further steps of:

operating the first and second actuators to drive respective first and second cables in unison;

operating the third and fourth actuators to drive the respective third and fourth cables in unison in opposition to the first and second cables in order to operate the wrist mechanism to move the first work member of the end effector relative to the support member with a second degree-of-freedom.

19. The method of manipulating an articulated surgical instrument as defined in claim 17 wherein the method comprises the additional steps of:

operating the first, second, third and fourth actuators to drive respective first, second, third and fourth cables in unison in order to move the elongate support member along a longitudinal axis of the elongate support member.

20. The method of manipulating an articulated surgical instrument as defined in claim 15 wherein:

the step of providing an articulated surgical instrument further comprises providing fifth, sixth, seventh and eighth intermediate idler pulleys; and

the method comprises the additional steps of engaging the fifth, sixth, seventh and eighth intermediate idler pulleys with the first, second, third and fourth cables respectively.

21. An articulated surgical instrument for minimally invasive surgery comprising a plurality of actuators, a plurality of cables, a support bracket, an elongate support member, a wrist mechanism and a surgical end effector wherein:

the elongate support member has a proximal end and a distal end and a support axis running longitudinally along the elongate support member from the proximal end to the distal end;

the proximal end of the support member is coupled to the support bracket by one or more joints having X degrees-of-freedom of movement relative to the support bracket;

the wrist mechanism couples the surgical end effector to the distal end of the support member providing Y degrees-of-freedom of movement of the end effector relative to the support member;

the surgical end effector has one or more components having Z degrees of freedom of movement relative to one another;

the motion about said each degree-of-freedom of movement is provided by an actuator and a cable;

the number of actuators is equal to X+Y+Z;

the number of cables passing through the elongate support member is no greater than Y+Z+2.

22. The articulated surgical instrument of claim 21 wherein the number of cables passing through the elongate support member is no greater than Y+Z+1.

23. The articulated surgical instrument of claim 21 wherein X=2, Y=2 and Z=1.