Tension regulation of remotely actuated instruments, and related devices, systems, and methods

• US 11,234,784 B2
• Filed: 09/21/2017
• Issued: 02/01/2022
• Est. Priority Date: 09/22/2016
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Alden, Donald
• Primary Examiner(s): Luan, Scott
• Application Number:
  US16/334,986
• Publication Number:
  US 20190314101A1
• Time in Patent Office: 1,594 Days
• CPC Class Codes: A61B 2017/00212 using remote controls
• CPC Class Codes: A61B 2017/00371 Multiple actuation, e.g. pushing of two buttons, or two working tips becoming operational
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/715 Cable tensioning mechanisms for removing slack
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms

Abstract

A surgical instrument includes a shaft with a proximal end and a distal end, a movable component coupled at the distal end of the shaft, a force transmission mechanism coupled at the proximal end of the shaft, and an actuation element with a first end coupled to the force transmission mechanism and a second end coupled to the movable component. The actuation element being configured to transmit an actuation force from the force transmission mechanism to the movable component. A coil spring is coupled to the actuation element between the first and second ends. First and second ends of the coil spring are coupled to longitudinally separated locations on the actuation element. The coil spring is configured to passively expand and contract in response to tension changes in the actuation element. A distance between the longitudinally separated locations changes as the coil spring passively expands and contracts.

Claims

1. A surgical instrument, comprising:

a shaft having a proximal end and a distal end;

a movable component coupled to the distal end of the shaft;

a force transmission mechanism coupled to the proximal end of the shaft;

an actuation element comprising a first end coupled to the force transmission mechanism, a second end coupled to the movable component, and having a continuous length extending from the first end to the second end, the actuation element being configured to transmit an actuation force from the force transmission mechanism to the movable component; and

a coil spring coupled to the actuation element at a location between the first and second ends, wherein;

first and second portions of the coil spring are coupled to first and second locations on the actuation element, the first and second locations spaced longitudinally apart from each other along the continuous length of the actuation element, and

in response to a change in tension in the actuation element, the coil spring is configured to passively expand or contract and to alter a distance between the first and second locations on the actuation element.

2. The surgical instrument of claim 1, wherein the change in tension in the actuation element comprises a change in configuration of the actuation element from taut to slack.

3. The surgical instrument of claim 1, wherein the first and second portions of the coil spring comprise bent portions configured to couple the first and second portions of the coil spring to the actuation element.

4. The surgical instrument of claim 3, wherein the actuation element further comprises first and second stop members positioned respectively at the first and second locations on the actuation element, wherein the bent portions of the first and second portions of the coil spring abut the respective first and second stop members to couple the coil spring to the actuation element.

5. The surgical instrument of claim 1, wherein:

in an expanded configuration of the coil spring, the actuation element is taut between the first and second locations on the actuation element, and

in a contracted configuration of the coil spring, a portion of the actuation element is slack between the first and second locations on the actuation element.

6. The surgical instrument of claim 5, wherein, in the contracted configuration of the coil spring, the slack in the actuation element is compensated for by an at least partially collapsed portion of the actuation element between the first and second locations on the actuation element.

7. The surgical instrument of claim 1, wherein the coil spring is configured to maintain tension in the actuation element, the tension being sufficient to transmit the actuation force from the first end of the actuation element to the second end of the actuation element.

8. The surgical instrument of claim 1, further comprising first and second end caps coupled respectively with the first and second portions of the coil spring.

9. The surgical instrument of claim 8, wherein the actuation element further comprises first and second stop members positioned respectively at the longitudinally spaced locations on the actuation element, wherein the first and second end caps abut the respective first and second stop members to couple the coil spring to the actuation element.

10. A surgical instrument comprising:

a proximal drive element;

a distal movable component;

an actuation element coupled between the proximal drive element and the distal movable component;

a first stop coupled to the actuation element at a first location;

a second stop coupled to the actuation element at a second location spaced apart from the first location, the actuation element having a continuous length extending from the first location to the second location; and

a spring having a first end engaged with the first stop, a second end engaged with the second stop, and windings that encircle the actuation element between the first and second locations.

11. The surgical instrument of claim 10:

wherein the spring is a tension spring; and

wherein the first end of the spring engaged with the first stop and the second end of the spring engaged with the second stop are engaged inside the windings of the spring.

12. The surgical instrument of claim 10:

wherein the spring is a compression spring; and

wherein the first end of the spring engaged with the first stop and the second end of the spring engaged with the second stop are engaged outside the windings of the spring.

13. The surgical instrument of claim 12:

wherein the actuation element comprises a first element and a second element, the first and second elements being separate from each other; and

wherein the first stop is coupled at an end of the first element, and the second stop is coupled at an end of the second element.

14. A surgical instrument, comprising:

a shaft comprising a proximal end and a distal end;

a movable component coupled at the distal end of the shaft;

a force transmission mechanism coupled at the proximal end of the shaft; and

a tensile actuation element comprising;

a first actuation element portion comprising a first end and a second end, the first end of the first actuation element portion being coupled to the movable component,

a second actuation element portion comprising a first end and a second end, the second end of the second actuation element portion being coupled to the force transmission mechanism, and

a coil spring comprising coils surrounding an interior space, a first end portion and a second end portion, the first end portion of the coil spring being directly coupled to the second end of the first actuation element portion, and the second end portion of the coil spring being directly coupled to the first end of the second actuation element portion,

wherein;

the first actuation element portion extends at least partially through the interior space of the coil spring,

the second actuation element portion extends at least partially through the interior space of the coil spring, and

the coil spring is in a state such that the coil spring is configured to maintain a preload tension in the tensile actuation element between the force transmission mechanism to the movable component and is configured to maintain a distance between the first end portion and the second end portion of the coil spring on a condition that actuation tension less than the preload tension is transmitted from the force transmission mechanism to the movable component.

15. The surgical instrument of claim 14, further comprising:

a first stop member disposed proximate an end of the first actuation element portion; and

a second stop member disposed proximate an end of the second actuation element portion,

wherein the first and second end portions of the coil spring comprise bent portions abutting the respective first and second stop members to affix the first and second end portions of the coil spring to the actuation element.

16. The surgical instrument of claim 14, wherein an end portion of the first actuation element portion and an end portion of the second actuation element portion are configured to laterally overlap one another.

17. The surgical instrument of claim 16, wherein the coil spring is configured to maintain tension in the actuation element by altering a distance over which the first actuation element portion and the second actuation element portion overlap.

18. The surgical instrument of claim 17, wherein the coil spring is configured to expand from a fully compressed position to an at least partially expanded position in response to tension changes caused by slack in the actuation element.

19. The surgical instrument of claim 14:

wherein the second end of the first actuation element portion extends past the first end portion of the coil spring and through the interior space of the coil spring to the second end portion of the coil spring; and

wherein the first end of the second actuation element portion extends past the second end portion of the coil spring and through the interior space of the coil spring to the first end portion of the coil spring.