Instrument device manipulator with roll mechanism

• US 9,993,313 B2
• Filed: 09/09/2016
• Issued: 06/12/2018
• Est. Priority Date: 10/24/2013
• Status: Active Grant

• Current Assignee: Auris Health, Inc. (Johnson & Johnson)
• Original Assignee: Auris Health, Inc. (Johnson & Johnson)
• Inventors: Schuh, Travis, Bogusky, Joseph, Williams, Matthew, Mintz, David S., Yu, Alan, Kintz, Gregory, Dan, Yoichiro
• Primary Examiner(s): COLEY, ZADE JAMES
• Application Number:
  US15/261,754
• Publication Number:
  US 20170065364A1
• Time in Patent Office: 641 Days
• Field of Search: 606185, 81 5714, 192 30 R
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 34/00 Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/70 Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 46/00 Surgical drapes
• CPC Class Codes: A61B 46/10 specially adapted for instruments, e.g. microscopes
• CPC Class Codes: A61B 90/50 Supports for surgical instruments, e.g. articulated arms

Abstract

An instrument device manipulator (IDM) is attached to a surgical arm of a robotic system and comprises a surgical tool holder and an outer housing. The surgical tool holder includes an attachment interface that can secure a surgical tool in a front-mount configuration (where the attachment interface is on a face opposite of a proximal extension of the surgical tool) or a back-mount configuration (where the attachment interface is on the same face as the proximal extension of the surgical tool). The surgical tool holder may rotate continuously within the outer housing. In a back-mount configuration, the surgical tool holder may have a passage that receives the proximal extension of the tool and allows free rotation of the proximal extension about the rotational axis. A surgical drape separates the IDM and robotic arm from a tool, while allowing electrical and/or optical signals to pass therebetween.

Claims

1. A surgical instrument device manipulator comprising:

a surgical arm operable by a surgical robotics system;

a base fixedly connected to the surgical arm;

a surgical tool holder assembly including a surgical tool holder that is rotatably mounted to the base and configured to removeably attach to a surgical tool such that the surgical tool is fixed to the surgical tool holder when the surgical tool is attached, wherein the surgical tool holder comprises

a first opening on a first side of the surgical tool holder,

a second opening on a second side of the surgical tool holder, and

a passage extending along a passage axis between the first opening and the second opening such that an elongate body of the surgical tool can be inserted through the first opening, the passage, and the second opening; and

at least one drive mechanism coupled between the base and the surgical tool holder assembly to rotate the surgical tool holder around a rotational axis relative to the base such that rotation of the surgical tool holder causes rotation of the surgical tool attached to the surgical tool holder, wherein the rotational axis of the surgical tool holder is co-axially aligned with a longitudinal axis of the surgical tool.

2. The surgical instrument device manipulator of claim 1, wherein the surgical tool comprises a lumen that is co-axially aligned with the rotational axis of the surgical tool holder.

3. The surgical instrument device manipulator of claim 2, wherein a plurality of ball bearings within the surgical tool holder assembly facilitate rotation of the surgical tool holder about the rotational axis of the manipulator.

4. The surgical instrument device manipulator of claim 1, wherein the surgical tool holder comprises a plurality of torque couplers on the first side of the surgical tool holder and positioned around the passage, each torque coupler structured to engage with a respective instrument input on the surgical tool.

5. The surgical instrument device manipulator of claim 4, wherein each of the plurality of torque couplers is configured to rotate with the surgical tool holder in a clockwise or counter-clockwise direction around the rotational axis.

6. The surgical instrument device manipulator of claim 1, further comprising:

one or more slip rings configured to deliver electrical power and signals from the base to the surgical tool holder.

7. The surgical instrument device manipulator of claim 6, wherein a plurality of encoder boards are secured within the surgical tool holder, each encoder board is configured to read and process signals relayed through the at least one slip ring.

8. The surgical instrument device manipulator of claim 1, wherein the surgical tool holder assembly comprises a stator gear that is structured as a ring including gear teeth along the inner circumference of the ring, wherein the stator gear is configured to remain stationary relative to the surgical tool holder.

9. The surgical instrument device manipulator of claim 8, wherein the drive mechanism is coupled to a rotor gear that is configured to mate with the stator gear of the surgical tool holder assembly such that rotation of the rotor gear causes the surgical tool holder to rotate relative to the stator gear.

10. The surgical instrument device manipulator of claim 1, wherein the manipulator comprises a power transmitter and the surgical tool comprises a power receiver configured to receive power inductively from the power transmitter.

11. The surgical instrument device manipulator of claim 1, wherein the manipulator comprises a plurality of optical transmitters and a plurality of optical receivers, and the surgical tool comprises a plurality of respective optical transmitters and a plurality of respective optical receivers.

12. The surgical instrument device manipulator of claim 1, wherein at least one pair of an optical transmitter and an optical receiver is configured to transfer data from the surgical tool to the manipulator.

13. The surgical instrument device manipulator of claim 1, wherein at least one pair of an optical transmitter and an optical receiver is configured to transfer data from the manipulator to the surgical tool.

14. The surgical instrument device manipulator of claim 1, wherein a wireless point-to-point data connection is used for high bandwidth communication from the manipulator to the surgical robotics system.

15. The surgical instrument device manipulator of claim 1, wherein an optical transmitter of the surgical tool may be configured to transmit a signal to an optical receiver of the surgical tool holder, wherein the signal is used to determine the orientation of the surgical tool with respect to the surgical tool holder.

16. A surgical instrument device manipulator comprising:

a surgical arm operable by a surgical robotics system;

a base fixedly connected to the surgical arm;

a surgical tool holder assembly including a surgical tool holder that is rotatably mounted to the base and configured to removeably attach to a surgical tool such that the surgical tool is fixed to the surgical tool holder when the surgical tool is attached;

at least one drive mechanism coupled between the base and the surgical tool holder assembly to rotate the surgical tool holder relative to the base such that rotation of the surgical tool holder causes rotation of the surgical tool attached to the surgical tool holder; and

a power transmitter, wherein the surgical tool comprises a power receiver configured to receive power inductively from the power transmitter, and wherein the power transmitter and the power receiver are centered around the passage of the manipulator.

17. A surgical instrument device manipulator comprising:

a surgical arm operable by a surgical robotics system;

a base fixedly connected to the surgical arm;

a surgical tool holder assembly including a surgical tool holder that is rotatably mounted to the base and configured to removeably attach to a surgical tool such that the surgical tool is fixed to the surgical tool holder when the surgical tool is attached;

at least one drive mechanism coupled between the base and the surgical tool holder assembly to rotate the surgical tool holder relative to the base such that rotation of the surgical tool holder causes rotation of the surgical tool attached to the surgical tool holder; and

a plurality of optical transmitters and a plurality of optical receivers, wherein the surgical tool comprises a plurality of respective optical transmitters and a plurality of respective optical receivers, and wherein the plurality of optical transmitters and the plurality of optical receivers are symmetrically oriented with respect to a plurality of instrument inputs and a plurality of torque couplers such that the surgical tool may be attached to the surgical tool holder in any orientation.

18. A surgical instrument device manipulator comprising:

a surgical arm operable by a surgical robotics system;

a base fixedly connected to the surgical arm;

a surgical tool holder assembly including a surgical tool holder that is rotatably mounted to the base and configured to removeably attach to a surgical tool such that the surgical tool is fixed to the surgical tool holder when the surgical tool is attached, wherein the surgical tool holder comprises

a first opening on a first side of the surgical tool holder,

a second opening on a second side of the surgical tool holder, and

a passage extending along a passage axis between the first opening and the second opening such that an elongate body of the surgical tool can be inserted through the first opening, the passage, and the second opening; and

at least one drive mechanism coupled between the base and the surgical tool holder assembly to rotate the surgical tool holder around a rotational axis relative to the base such that rotation of the surgical tool holder causes rotation of the surgical tool attached to the surgical tool holder, wherein the surgical tool holder comprises a plurality of torque couplers on the first side of the surgical tool holder and positioned around the passage, each torque coupler structured to engage with a respective instrument input on the surgical tool.

19. The surgical instrument device manipulator of claim 18, wherein the surgical tool comprises a lumen that is co-axially aligned with a rotational axis of the manipulator.

20. The surgical instrument device manipulator of claim 18, wherein each of the plurality of torque couplers is configured to rotate with the surgical tool holder in a clockwise or counter-clockwise direction around the rotational axis.

21. The surgical instrument device manipulator of claim 18, wherein the surgical tool holder assembly comprises a stator gear that is structured as a ring including gear teeth along the inner circumference of the ring, wherein the stator gear is configured to remain stationary relative to the surgical tool holder.

22. The surgical instrument device manipulator of claim 18, wherein an optical transmitter of the surgical tool may be configured to transmit a signal to an optical receiver of the surgical tool holder, wherein the signal is used to determine the orientation of the surgical tool with respect to the surgical tool holder.

23. The surgical instrument device manipulator of claim 18, wherein the manipulator comprises a power transmitter and the surgical tool comprises a power receiver configured to receive power inductively from the power transmitter.

24. The surgical instrument device manipulator of claim 18, wherein the manipulator comprises a plurality of optical transmitters and a plurality of optical receivers, and the surgical tool comprises a plurality of respective optical transmitters and a plurality of respective optical receivers.

25. The surgical instrument device manipulator of claim 18, wherein at least one pair of an optical transmitter and an optical receiver is configured to transfer data from the surgical tool to the manipulator.

26. The surgical instrument device manipulator of claim 18, further comprising one or more slip rings configured to deliver electrical power and signals from the base to the surgical tool holder.