Robotically powered surgical device with manually-actuatable reversing system

• US 9,408,606 B2
• Filed: 06/28/2012
• Issued: 08/09/2016
• Est. Priority Date: 06/28/2012
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery LLC (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV
• Primary Examiner(s): Gerrity, Stephen F
• Assistant Examiner(s): Kotis, Joshua
• Application Number:
  US13/536,323
• Publication Number:
  US 20140001235A1
• Time in Patent Office: 1,503 Days
• Field of Search: 227/178.1, 744/05
• US Class Current: 1/1
• 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 17/295 combined with cutting implements
• CPC Class Codes: A61B 17/320016 Endoscopic cutting instruments, e.g. arthroscopes, resectoscopes A61B10/0233, A61B17/29, A61B17/3207 take precedence
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/003 Steerable
• CPC Class Codes: A61B 2017/00309 Cut-outs or slits
• CPC Class Codes: A61B 2017/00314 Separate linked members
• CPC Class Codes: A61B 2017/00323 Cables or rods
• CPC Class Codes: A61B 2017/00327 with actuating members moving in opposite directions
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable
• CPC Class Codes: A61B 2017/00464 for use with different instruments
• CPC Class Codes: A61B 2017/00473 Distal part, e.g. tip or head A61B2017/00464 takes precedence
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00685 Archimedes screw
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/00876 magnetic
• CPC Class Codes: A61B 2017/07257 characterised by its anvil
• CPC Class Codes: A61B 2017/07271 : characterised by its cartridge
• CPC Class Codes: A61B 2017/07278 : characterised by its sled or its staple holder
• CPC Class Codes: A61B 2017/07285 : characterised by its cutter
• CPC Class Codes: A61B 2017/2903 : transferring rotary motion
• CPC Class Codes: A61B 2017/2905 : flexible
• CPC Class Codes: A61B 2017/2908 : Multiple segments connected by articulations
• CPC Class Codes: A61B 2017/2923 : Toothed members, e.g. rack and pinion
• 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 2017/2931 : with releasable head
• CPC Class Codes: A61B 2017/2939 : Details of linkages or pivot points
• CPC Class Codes: A61B 2017/2943 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2946 : Locking means
• CPC Class Codes: A61B 2034/306 : Wrists with multiple vertebrae
• CPC Class Codes: A61B 2090/0811 : for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument
• CPC Class Codes: A61B 2090/0812 : indicating loosening or shifting of parts of an instrument, signaling maladjustment of parts
• CPC Class Codes: A61B 2090/0814 : Preventing re-use
• 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 34/70 : Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 34/71 : Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 34/74 : Manipulators with manual electric input means
• CPC Class Codes: A61M 2039/1061 : Break-apart tubing connectors or couplings
• CPC Class Codes: A61M 39/00 : Tubes, tube connectors, tube couplings, valves, access sites or the like, specially adapted for medical use for respiratory devices, e.g. tracheal tubes A61M16/00; artificial heart valves A61F2/24
• CPC Class Codes: A61M 39/1055 : Rotating or swivel joints in general F16L27/00
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 74/18056 : Rotary to or from reciprocating or oscillating
• CPC Class Codes: Y10T 74/20329 : Joint between elements

Abstract

A surgical tool for use with a robotic system that includes a tool drive assembly that is operatively coupled to a control unit of the robotic system that is operable by inputs from an operator and is configured to robotically-generate output motions. A drive system is configured to interface with a corresponding portion of the tool drive assembly for receiving the robotically-generated output motions and applying the output motions to a drive shaft assembly which is configured to apply control motions to a surgical end effector operably coupled thereto. A manually-actuatable control system operably interfaces with the drive shaft assembly to facilitate the selective application of manually-generated control motions to the drive shaft assembly.

Claims

1. A surgical tool for use with a robotic system that includes a tool drive assembly that is operatively coupled to a control unit of the robotic system that is operable by inputs from an operator and is configured to provide at least one rotary output motion to at least one rotatable body portion supported on the tool drive assembly, said surgical tool comprising:

a surgical end effector comprising at least one component portion that is selectively movable between first and second positions relative to at least one other component portion thereof in response to rotary control motions applied to the at least one selectively movable component portion;

an elongate shaft assembly operably coupled to the surgical end effector, the elongate shaft assembly comprising at least one rotary drive shaft that is in operable communication with the at least one selectively movable component portion of the surgical end effector;

a tool mounting portion operably coupled to the elongate shaft assembly, the tool mounting portion being configured to operably interface with the tool drive assembly when coupled thereto, said tool mounting portion comprising;

a driven element rotatably supported on said tool mounting portion and configured for driving engagement with a corresponding one of the at least one rotatable body portions of the tool drive assembly to receive corresponding rotary output motions therefrom; and

a drive system, comprising;

a rotary drive gear in driving engagement with the driven element;

a first rotary driven gear in meshing engagement with the rotary drive gear; and

a second rotary driven gear movably mounted to the at least one rotary drive shaft of the elongate shaft assembly for movement into and out of meshing engagement with the first rotary driven gear;

wherein the drive system is in operable engagement with the at least one rotary drive shaft to apply robotically-generated actuation motions thereto to cause said at least one rotary drive shaft to apply at least one said rotary control motion to the at least one selectively movable component portion, and wherein the surgical tool further comprises;

a manually-actuatable reversing system operably interfacing with the elongate shaft assembly to selectively move the second rotary driven gear out of meshing engagement with the first rotary driven gear and apply manually-generated, rotary control motions to the second rotary driven gear and said at least one rotary drive shaft.

2. The surgical tool of claim 1 wherein the manually-actuatable reversing system comprises:

a reversing gear in meshing engagement with the second rotary driven gear; and

a ratchet gear supported for selective meshing engagement with the reversing gear such that manual actuation of the ratchet gear applies the manually-generated, rotary control motions to the reversing gear.

3. The surgical tool of claim 2 wherein said ratchet gear is mounted for selective pivotal travel relative to the reversing gear between an actuated and an unactuated position such that as the reversing gear is pivoted from the unactuated position to the actuated position, the reversing gear axially biases the second rotary driven gear out of meshing engagement with the first rotary driven gear.

4. The surgical tool of claim 1, wherein said at least one selectively movable component portion comprises a firing element operably interfacing with said at least one rotary drive shaft and is movably responsive to said rotary control motions applied thereto.

5. The surgical tool of claim 1, wherein said surgical end effector further comprises:

a staple cartridge;

a plurality of staples removably stored within said staple cartridge; and

an anvil.

6. A surgical tool for use with a robotic system that includes a tool drive assembly that is operatively coupled to a control unit of the robotic system that is operable by inputs from an operator and is configured to provide at least one rotary output motion to at least one rotatable body portion supported on the tool drive assembly, said surgical tool comprising:

a surgical end effector, comprising;

a staple cartridge;

a plurality of staples removably stored within said staple cartridge; and

a firing sled selectively movable between first and second positions relative to said staple cartridge in response to rotary control motions applied to said firing sled, wherein said firing sled is configured to eject said staples from said staple cartridge;

an elongate shaft assembly operably coupled to said surgical end effector, said elongate shaft assembly comprising a rotary drive shaft that is in operable communication with said firing sled;

a tool mounting portion operably coupled to said elongate shaft assembly, said tool mounting portion being configured to operably interface with the tool drive assembly when coupled thereto, said tool mounting portion comprising;

a driven element rotatably supported on said tool mounting portion and configured for driving engagement with a corresponding one of the at least one rotatable body portions of the tool drive assembly to receive corresponding rotary output motions therefrom; and

a drive system, comprising;

a rotary drive gear in driving engagement with said driven element;

a first rotary driven gear in meshing engagement with said rotary drive gear; and

a second rotary driven gear movably mounted to said rotary drive shaft of said elongate shaft assembly for movement into and out of meshing engagement with said first rotary driven gear;

wherein the drive system is in operable engagement with said driven element to apply robotically-generated, rotary actuation motions thereto to cause said rotary drive shaft to apply at least one said rotary control motion to said firing sled to move said firing sled in a forward direction; and

means for moving said second rotary driven gear out of meshing engagement with said first rotary driven gear to apply manually-generated, rotary actuation motions to said second rotary driven gear to cause said rotary drive shaft to apply at least one said rotary control motion to said firing sled to move said firing sled in a reversing direction.

7. The surgical tool of claim 6, wherein said means comprises:

a reversing gear in meshing engagement with said second rotary driven gear; and

a ratchet gear supported for selective meshing engagement with said reversing gear such that manual actuation of said ratchet gear applies the manually-generated, rotary control motions to said reversing gear.

8. The surgical tool of claim 7, wherein said ratchet gear is mounted for selective pivotal travel relative to said reversing gear between an actuated and an unactuated position such that as said reversing gear is pivoted from the unactuated position to the actuated position, said reversing gear axially biases said second rotary driven gear out of meshing engagement with said first rotary driven gear.

9. A surgical instrument for use with a robotic system, said surgical instrument comprising:

an end effector, comprising;

a staple cartridge;

a plurality of staples removably stored within said staple cartridge; and

a firing sled movable relative to said staple cartridge between a first position and a second position in response to rotary control motions applied to said firing sled, wherein said firing sled is configured to eject said staples from said staple cartridge;

a shaft assembly operably coupled to said end effector, said shaft assembly comprising a rotary drive shaft to apply said rotary control motions to said firing sled;

a tool mounting portion operably coupled to said shaft assembly, said tool mounting portion configured to operably interface with the robotic system, said tool mounting portion comprising;

a driven element rotatably supported on said tool mounting portion and configured for driving engagement with the robotic system to receive corresponding rotary output motions therefrom; and

a drive system, comprising;

a rotary drive gear in driving engagement with said driven element;

a first rotary driven gear in meshing engagement with said rotary drive gear; and

a second rotary driven gear movably mounted to said rotary drive shaft of said shaft assembly for movement into and out of meshing engagement with said first rotary driven gear

wherein the drive system is in operable engagement with said driven element to apply robotically-generated actuation motions to said driven element to cause said rotary drive shaft to apply at least one said rotary control motion to said firing sled; and

a manually-actuated reversing system configured for operable engagement with said drive system to selectively move said second rotary driven gear out of meshing engagement with said first rotary driven gear and apply manually-generated, rotary control motions to said second rotary driven gear to cause said rotary drive shaft to apply at least one said rotary control motion to said firing sled to move said firing sled in a reversing direction.

10. The surgical instrument of claim 9, wherein said manually-actuated reversing system comprises:

a reversing gear in meshing engagement with said second rotary driven gear; and

a ratchet gear supported for selective meshing engagement with said reversing gear such that manual actuation of said ratchet gear applies the manually-generated, rotary control motions to said reversing gear.

11. The surgical instrument of claim 10, wherein said ratchet gear is mounted for selective pivotal travel relative to said reversing gear between an actuated and an unactuated position such that as said reversing gear is pivoted from the unactuated position to the actuated position, said reversing gear axially biases said second rotary driven gear out of meshing engagement with said first rotary driven gear.