Apparatus for pitch and yaw rotation

• US 9,717,486 B2
• Filed: 11/10/2014
• Issued: 08/01/2017
• Est. Priority Date: 06/29/2001
• Status: Expired due to Term

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Cooper, Thomas G., Anderson, S. Christopher, Chang, Stacey, Williams, Dustin, Wallace, Daniel T.
• Primary Examiner(s): Nguyen, Victor
• Application Number:
  US14/536,899
• Publication Number:
  US 20150066002A1
• Time in Patent Office: 995 Days
• CPC Class Codes: A61B 1/0055 Constructional details of insertion parts, e.g. vertebral elements
• CPC Class Codes: A61B 1/0057 Constructional details of force transmission elements, e.g. control wires
• CPC Class Codes: A61B 1/008 Articulations
• 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 2017/00314 Separate linked members
• CPC Class Codes: A61B 2017/0069 with universal joint, cardan joint
• CPC Class Codes: A61B 2017/2908 Multiple segments connected by articulations
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/2936 Pins in guiding slots
• CPC Class Codes: A61B 2034/304 including a freely orientable platform, e.g. so called 'Stewart platforms'
• 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 34/30 Surgical robots
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 34/72 Micromanipulators

Abstract

The present invention is directed to a tool having a wrist mechanism that provides pitch and yaw rotation in such a way that the tool has no singularity in roll, pitch, and yaw. A positively positionable multi-disk wrist mechanism includes a plurality of disks or vertebrae stacked in series. Each vertebra is configured to rotate in pitch or in yaw with respect to each neighboring vertebra. Actuation cables are used to manipulate and control movement of the vertebrae. In specific embodiments, some of the cables are distal cables that extend from a proximal vertebra through one or more intermediate vertebrae to a distal vertebra, while the remaining cables are medial cables that extend from the proximal vertebra to one or more of the intermediate vertebrae. The cables are actuated by a pivoted plate cable actuator mechanism. In specific embodiments, the actuator mechanism includes a plurality of small radius holes or grooves for receiving the medial cables and a plurality of large radius holes or grooves for receiving the distal cables. The holes or grooves restrain the medial cables to a small radius of motion and the distal cables to a large radius of motion, so that the medial cables to the medial vertebra move only a fraction of the amount as the distal cables to the distal vertebra, so as to achieve precise control and manipulation of the vertebrae.

Claims

1. An apparatus comprising:

a mount;

a gimbal ring coupled to the mount to rotate about a first axis;

an actuator plate mounted to the gimbal ring to rotate about a second axis orthogonal to the first axis, the actuator plate comprising a first actuator connection and a second actuator connection;

first and second actuator links rotatably coupled to the first and second actuator connections, respectively, to produce pitch and yaw rotations of the actuator plate; and

a first gear section rotatably coupled to the first actuator link to longitudinally move the first actuator link and a second gear section rotatably coupled to the second actuator link to longitudinally move the second actuator link, the first gear section comprising a first gear quadrant and a first drive gear, the second gear section comprising a second gear quadrant and a second drive gear, the apparatus further comprising first and second drive spools configured to actuate the first and second drive gears, respectively.

2. The apparatus of claim 1, the actuator plate further comprising a first plurality of apertures having a first radius from the center of the actuator plate and a second plurality of apertures having a second radius from the center of the actuator plate, the second radius larger than the first radius, the apparatus further comprising:

a shaft having a proximal end and a distal end, the proximal end coupled to the actuator plate;

a flexible wrist coupled to the distal end of the shaft, the flexible wrist comprising at least one medial disk and at least one distal disk;

a first plurality of cables extending from the actuator plate through the first plurality of apertures to the at least one medial disk of the flexible wrist; and

a second plurality of cables extending from the actuator plate through the second plurality of apertures to the at least one distal disk of the flexible wrist.

3. The apparatus of claim 2, further comprising a lock plate coupled to the actuator plate, the lock plate comprising at least one wedge configured to mate with at least one corresponding wedge in the actuator plate to lock the first and second plurality of cables in place.

4. The apparatus of claim 2, further comprising a helical drive gear and a follower gear coupled to the shaft to produce roll rotation of the shaft about a longitudinal axis.

5. The apparatus of claim 1, the first and second gear quadrants configured to rotate around a common pivot axis.

6. The apparatus of claim 1, further comprising a surgical instrument comprising a shaft having a proximal end and a distal working end actuatable by a plurality of tendon elements coupled to the proximal end, the actuator plate including a plurality of apertures, each aperture being drivingly coupleable to at least one of the plurality of tendons.

7. The apparatus of claim 6, the actuator plate being pivotable about at least one pivot axis, each aperture being spaced apart from at least one of the pivot axes.

8. The apparatus of claim 7, wherein at least one of the plurality of apertures is spaced apart from at least a first pivot axis and at least one of the plurality of apertures is space apart from at least a second pivot axis;

the first and second actuator links configured to controllably pivot the actuator plate selectably about each of the pivot axes, so that movement of the actuator plate about either of the first and second pivot axes moves at least one tendon to actuate the distal working end.

9. The apparatus of claim 8, wherein the actuator plate has a central axis, each of the first and second pivot axes intersect the central axis, and the plurality of apertures includes a first set of apertures spaced apart from the central axis at a first radial distance.

10. The apparatus of claim 6, wherein different ones of the plurality of apertures are spaced at different distances from the at least one pivot axis, so that selectable pivoting of the actuator plate about the at least one pivot axis moves different ones of the respective coupled tendons by different amounts relative to the shaft.

11. The apparatus of claim 6, the shaft comprising a plurality of adjacent segment vertebrae, at least two tendon elements passing through at least two apertures in each adjacent vertebrae, wherein the at least two apertures in each of the vertebra are spaced apart on opposite sides of a neutral axis of the shaft to define an aperture plane.

12. The apparatus of claim 11, further comprising at least one inter-vertebral engagement element coupled to each of the vertebrae, the engagement element pivotally engaging adjacent vertebrae so as to define at least two spaced-apart parallel cooperating pivot axes, each one of the pivot axes being aligned generally within the aperture plane of a respective one of the adjacent vertebra, such that each vertebra is pivotally movable about its respective pivot axes, so as to balance the motion of the tendons on opposite sides of the neutral axis when the flexible member is deflected in a bending direction.

13. The apparatus of claim 12, wherein the pivot axes are virtual axes, the at least one engagement element is a cooperating opposed pair of elements each having a contour in movable contact with the other, and the engagement contours are shaped to produce the virtual axes as the vertebrae are moved relative to one another in a bending direction.

14. The apparatus of claim 12, wherein the at least one engagement element is an engagement strut having at least one opposed space-apart pair of bearing portions, each bearing portion engaging a respective one of the vertebrae at an engagement point generally within the aperture plane of the vertebra, so as to define a pivot axis in each aperture plane.

15. The apparatus of claim 1, wherein the first and second actuator links are controllable by a robotic surgical system.