Mechanical actuator interface system for robotic surgical tools

• US 7,524,320 B2
• Filed: 12/10/2002
• Issued: 04/28/2009
• Est. Priority Date: 12/08/1998
• Status: Expired due to Fees

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Incorporated (Intuitive Surgical Holdings, LLC)
• Inventors: Julian, Chris A., Guthart, Gary S., Cooper, Thomas G., Tierney, Michael J., Younge, Robert G., Blumenkranz, Stephen J.
• Primary Examiner(s): Robert; Eduardo C
• Assistant Examiner(s): Swiger, III; James L
• Application Number:
  US10/316,666
• Publication Number:
  US 20030083673A1
• Time in Patent Office: 2,331 Days
• Field of Search: 606/1, 606/130, 700/259, 700/260, 700/263
• US Class Current: 606/130
• 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 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00482 with a code
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2090/0803 Counting the number of times an instrument is used
• CPC Class Codes: A61B 2090/0818 Redundant systems, e.g. using two independent measuring systems and comparing the signals
• CPC Class Codes: A61B 2090/506 using a parallelogram linkage, e.g. panthograph
• 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 34/71 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 46/13 the drapes entering the patient's body
• CPC Class Codes: A61B 90/361 Image-producing devices, e.g. surgical cameras
• CPC Class Codes: A61B 90/90 Identification means for patients or instruments, e.g. tags
• CPC Class Codes: A61B 90/98 using electromagnetic means, e.g. transponders
• CPC Class Codes: G06Q 30/02 Marketing; Price estimation or determination; Fundraising
• CPC Class Codes: G16H 40/63 for local operation
• CPC Class Codes: H01H 36/0046 Limit switches, also fail-safe operation or anti-tamper considerations
• CPC Class Codes: H01H 85/0056 : Heat conducting or heat absorbing means associated with the fusible member, e.g. for providing time delay
• CPC Class Codes: Y10S 901/41 : Tool
• CPC Class Codes: Y10T 74/20305 : Robotic arm
• CPC Class Codes: Y10T 74/20311 : including power cable or connector

Abstract

Robotic surgical tools, systems, and methods for preparing for and performing robotic surgery include a memory mounted on the tool. The memory can perform a number of functions when the tool is loaded on the tool manipulator: first, the memory can provide a signal verifying that the tool is compatible with that particular robotic system. Secondly, the tool memory may identify the tool-type to the robotic system so that the robotic system can reconfigure its programming. Thirdly, the memory of the tool may indicate tool-specific information, including measured calibration offsets indicating misalignment of the tool drive system, tool life data, or the like. This information may be stored in a read only memory (ROM), or in a nonvolatile memory which can be written to only a single time. The invention further provides improved engagement structures for coupling robotic surgical tools with manipulator structures.

Claims

1. A robotic surgical system, comprising:

a drive assembly, said drive assembly operatively coupled to a control unit operable by inputs from an operator;

a surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion and a distal portion, said instrument including at least one distal end effector member, said proximal portion comprising a first plurality of movable bodies;

said instrument comprising a plurality of joints, at least one of said joints being coupled to said end effector member, said joints being coupled to said first plurality of movable bodies by a plurality of drive members; and

said drive assembly having a second plurality of movable bodies, said second plurality of movable bodies engageable with said first plurality of movable bodies such that the operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies, rotation of said one of said second plurality of bodies about said single rotational axis generating a corresponding rotation of said one of said first plurality of bodies about said single rotational axis when said first and second plurality of bodies are operatively engaged.

2. The robotic surgical system of claim 1, wherein said instrument includes at least a shaft portion extending between said proximal and distal portions, at least one of said joints is disposed adjacent said distal portion, and said distal joint is coupled with at least one of said plurality of drive members which is housed within said shaft portion.

3. The robotic surgical system of claim 2, wherein one of said movable bodies causes rotation of the shaft portion.

4. The system of claim 1, further comprising a sterile coupling adaptor, said sterile adaptor being engageable with a surgical drape, and said adaptor including a plurality of intermediate movable bodies each transmissively couplable to corresponding ones of said first and second pluralities of movable bodies.

5. The robotic surgical system of claim 1, wherein said instrument includes at least two end effector members, each end effector member being movable independently of the other as a result of movement of at least two drive members, each drive member being engaged to one of said first plurality of movable bodies.

6. The robotic surgical system of claim 1, wherein said proximal and distal portions define an instrument axis extending generally from the proximal portion towards the distal portion, and one of the movable bodies engaged on the instrument causes rotation of the instrument about said instrument axis.

7. A robotic surgical system, comprising:

a drive assembly, said drive assembly operatively coupled to a control unit operable by inputs from an operator;

a surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion and a distal portion, said instrument including at least one distal end effector member, said proximal portion comprising a first plurality of movable bodies;

said instrument comprising a plurality of joints, at least one of said joints being coupled to said end effector member, said joints being coupled to said first plurality of movable bodies by a plurality of drive members; and

said drive assembly having a second plurality of movable bodies, said second plurality of movable bodies engageable with said first plurality of movable bodies such that the operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies when said first and second plurality of bodies are operatively engaged, wherein at least one of said drive members comprises a flexible cable.

8. A robotic surgical system, comprising:

a drive assembly comprising a plurality of links, joints and motors, said drive assembly operatively coupled to a control unit operable by inputs from an operator;

a surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion and a distal portion, said instrument including at least one distal end effector member, said proximal portion comprising a first plurality of movable bodies;

said instrument comprising a plurality of joints, at least one of said joints being coupled to said end effector member, said joints being coupled to said first plurality of movable bodies by a plurality of drive members;

said drive assembly having a second plurality of movable bodies coupled to said plurality of motors, said second plurality of movable bodies removably engageable with said first plurality of movable bodies such that said operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies, rotation of said one of said second plurality of bodies about said single rotational axis generating a corresponding rotation of said one of said first plurality of bodies about said single rotational axis when said first and second plurality of movable bodies are operatively engaged.

9. The robotic surgical system of claim 8, wherein said instrument further comprises at least a second distal end effector member, each of said end effector members being movable independently of the other as a result of movement of at least two drive members, each drive member being engaged to one of said first plurality of movable bodies.

10. The robotic surgical system of claim 8, wherein said instrument includes at least a shaft portion extending between said proximal and distal portions, at least one of said joints is disposed adjacent said distal portion, and said distal joint is coupled with at least one of said plurality of drive members which is housed within said shaft portion.

11. The robotic surgical system of claim 10, wherein one of said movable bodies causes rotation of the shaft portion.

12. The system of claim 8, further comprising a sterile coupling adaptor, said sterile adaptor being engageable with a surgical drape, and said adaptor including a plurality of intermediate movable bodies each transmissively couplable to corresponding ones of said first and second pluralities of movable bodies.

13. The robotic surgical system of claim 8, wherein said instrument includes at least two end effector members, each end effector member being movable independently of the other as a result of movement of at least two drive members, each drive member being engaged to one of said first plurality of movable bodies.

14. The robotic surgical system of claim 8, wherein said proximal and distal portions define an instrument axis extending generally from the proximal portion towards the distal portion, and one of the movable bodies causes rotation of the instrument about said instrument axis.

15. A robotic surgical system, comprising:

a drive assembly comprising a plurality of links, joints and motors, said drive assembly operatively coupled to a control unit operable by inputs from an operator;

a surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion and a distal portion, said instrument including at least one distal end effector member, said proximal portion comprising a first plurality of movable bodies;

said instrument comprising a plurality of joints, at least one of said joints being coupled to said end effector member, said joints being coupled to said first plurality of movable bodies by a plurality of drive members;

said drive assembly having a second plurality of movable bodies coupled to said plurality of motors, said second plurality of movable bodies removably engageable with said first plurality of movable bodies such that said operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies when said first and second plurality of movable bodies are operatively engaged, wherein at least one of said instrument drive members is a flexible cable.

16. A robotic surgical system, comprising:

a drive assembly comprising a plurality of linkages and motors, said drive assembly operatively coupled to a control unit comprising a computer, said control unit operable by inputs from an operator;

surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion having an interface and a distal portion, and the proximal portion comprising a first plurality of movable bodies;

said instrument including at least first and second distal end effector members, said first and second members coupled to corresponding first and second drive members;

said instrument further comprising a plurality of distal joints, at least one of said joints being coupled to said end effector members in such a manner that said end effector members are movable independently of each other as a result of movement of said drive members, each drive member being engaged to one of said first plurality of movable bodies;

said joints being coupled to said first plurality of movable bodies by a plurality of drive members;

said drive assembly having a second plurality of movable bodies coupled to said plurality of motors, said second plurality of movable bodies removably engageable with said first plurality of movable bodies such that said operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies, rotation of said one of said second plurality of bodies about said single rotational axis generating a corresponding rotation of said one of said first plurality of bodies about said single rotational axis when said first and second plurality of movable bodies are operatively engaged.

17. The robotic surgical system of claim 16, wherein at least one of said first plurality of movable bodies includes an arcuate edge.

18. The robotic surgical system of claim 16, wherein each of said first plurality of movable bodies engages with one of said plurality of drive members.

19. The robotic surgical system of claim 16, wherein each of said first plurality of movable bodies includes a major surface, each of said first plurality of movable bodies being rotatable about an axis normal to its major surface.

20. The robotic surgical system of claim 16, wherein each of said first plurality of movable bodies includes an arcuate edge and a major surface, each of said first plurality of movable bodies being rotatable about an axis normal to its major surface.

21. The robotic surgical system of claim 16, wherein at least one of said first plurality of movable bodies is asymmetric relative to said axis.

22. The robotic surgical system of claim 16, wherein each of said first plurality of movable bodies of said instrument removably mechanically engages with one of said second plurality of movable bodies of said drive assembly.

23. The robotic surgical system of claim 16, wherein each of said first plurality of movable bodies of said instrument are removably mechanically engageable with one of said second plurality of movable bodies of said drive assembly substantially simultaneously.

24. The robotic surgical system of claim 16, wherein each of said first plurality of movable bodies of said instrument comprises a plurality of mechanical protrusions, each of said first plurality of movable bodies removably mechanically engageable with said second plurality of movable bodies of said drive assembly via said mechanical protrusions.

25. The robotic surgical system of claim 16, wherein each of said first plurality of movable bodies of said instrument comprises at least one mechanical protrusion, each of said first plurality of movable bodies removably mechanically engageable with said second plurality of movable bodies of said drive assembly via said mechanical protrusion, wherein each of said first plurality of movable bodies is mechanically asymmetric relative to a rotational axis of each of said first plurality of movable bodies.

26. The system of claim 16, wherein a sterile adaptor is interposed between said first plurality of movable bodies of said instrument and said second set of movable bodies of said drive assembly.

27. The robotic surgical system of claim 26, wherein said first set of movable bodies of said instrument engages said sterile adaptor and said sterile adaptor engages said second set of movable bodies of said drive assembly.

28. A robotic surgical system, comprising:

a drive assembly comprising a plurality of linkages and motors, said drive assembly operatively coupled to a control unit comprising a computer, said control unit operable by inputs from an operator;

a surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion having an interface and a distal portion, and the proximal portion comprising a first plurality of movable bodies;

said instrument including at least first and second distal end effector members, said first and second members coupled to corresponding first and second drive members;

said instrument further comprising a plurality of distal joints, at least one of said joints being coupled to said end effector members in such a manner that said end effector members are movable independently of each other as a result of movement of said drive members, each drive member being engaged to one of said first plurality of movable bodies;

said joints being coupled to said first plurality of movable bodies by a plurality of drive members;

said drive assembly having a second plurality of movable bodies coupled to said plurality of motors, said second plurality of movable bodies removably engageable with said first plurality of movable bodies such that said operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies when said first and second plurality of movable bodies are operatively engaged, wherein each of said first plurality of movable bodies is substantially similarly shaped.

29. A robotic surgical system, comprising:

a drive assembly comprising a plurality of linkages and motors, said drive assembly operatively coupled to a control unit comprising a computer, said control unit operable by inputs from an operator;

a surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion having an interface and a distal portion, and the proximal portion comprising a first plurality of movable bodies;

said instrument including at least first and second distal end effector members, said first and second members coupled to corresponding first and second drive members;

said instrument further comprising a plurality of distal joints, at least one of said joints being coupled to said end effector members in such a manner that said end effector members are movable independently of each other as a result of movement of said drive members, each drive member being engaged to one of said first plurality of movable bodies;

said joints being coupled to said first plurality of movable bodies by a plurality of drive members;

said drive assembly having a second plurality of movable bodies coupled to said plurality of motors, said second plurality of movable bodies removably engageable with said first plurality of movable bodies such that said operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies when said first and second plurality of movable bodies are operatively engaged, wherein each of said first plurality of movable bodies engages with one of said plurality of drive members, each of said drive members engaging with each of said movable bodies in a similar manner.

30. A robotic surgical system, comprising:

a drive assembly comprising a plurality of linkages and motors, said drive assembly operatively coupled to a control unit comprising a computer, said control unit operable by inputs from an operator;

a surgical instrument removably couplable to said drive assembly, said instrument having a proximal portion having an interface and a distal portion, and the proximal portion comprising a first plurality of movable bodies;

said instrument including at least first and second distal end effector members, said first and second members coupled to corresponding first and second drive members;

said instrument further comprising a plurality of distal joints, at least one of said joints being coupled to said end effector members in such a manner that said end effector members are movable independently of each other as a result of movement of said drive members, each drive member being engaged to one of said first plurality of movable bodies;

said joints being coupled to said first plurality of movable bodies by a plurality of drive members;

said drive assembly having a second plurality of movable bodies coupled to said plurality of motors, said second plurality of movable bodies removably engageable with said first plurality of movable bodies such that said operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of at least one of said joints;

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies when said first and second plurality of movable bodies are operatively engaged, wherein said instrument further comprises a proximal latch for releasing said surgical instrument from said drive assembly.

31. A robotic surgical system, comprising:

a drive assembly, said drive assembly operatively coupled to a control unit operable by inputs from an operator;

a surgical instrument having an elongate shaft with a proximal portion and a distal portion, said instrument removably couplable to said drive assembly, said proximal portion comprising a first plurality of movable bodies, said distal portion coupled to said first plurality of movable bodies by a plurality of drive members, and said distal portion movable in at least one degree of freedom;

said drive assembly having a second plurality of movable bodies, said second plurality of movable bodies engageable with said first plurality of movable bodies such that the operator'"'"'s inputs to the control unit cause the drive members to move, thereby producing a corresponding movement of said distal portion; and

wherein at least one of said first plurality of movable bodies is a rotatable body, at least one of said second plurality of movable bodies is a corresponding rotatable body, and said at least one of said first plurality of movable bodies shares a single rotational axis with said corresponding one of said second plurality of movable bodies of said one of said second plurality of bodies about said single rotational axis generating a corresponding rotation of said one of said first plurality of bodies about said single rotational axis when said first and second plurality of movable bodies are operatively engaged.