DRIVE INTERFACE FOR OPERABLY COUPLING A MANIPULATABLE SURGICAL TOOL TO A ROBOT

• US 20120211546A1
• Filed: 02/09/2012
• Published: 08/23/2012
• Est. Priority Date: 01/10/2007
• Status: Active Grant

• Current Assignee: Ethicon, LLC (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV
• Granted Patent: US 8,479,969 B2
• Time in Patent Office: Days
• US Class Current: 227/177.1
• 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 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 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 17/1222 Packages or dispensers therefor clip magazines incorporated in a clip-applying instrument A61B17/128; for surgical articles A61B50/30
• CPC Class Codes: A61B 17/295 combined with cutting implements
• CPC Class Codes: A61B 17/32 Surgical cutting instruments A61B18/042 takes precedence; suture cutters A61B17/0467; instruments for ligaturing or cutting A61B17/128; instruments for rupturing the amniotic membrane A61B17/4208; specially adapted knives for eye surgery A61F9/0133
• CPC Class Codes: A61B 17/320092 with additional movable means for clamping or cutting tissue, e.g. with a pivoting jaw
• CPC Class Codes: A61B 2017/00022 Sensing or detecting at the treatment site
• CPC Class Codes: A61B 2017/00039 Electric or electromagnetic phenomena other than conductivity, e.g. capacity, inductivity, Hall effect
• CPC Class Codes: A61B 2017/00212 using remote controls
• CPC Class Codes: A61B 2017/00221 with wireless transmission of data, e.g. by infrared radiation or radiowaves
• CPC Class Codes: A61B 2017/00362 Packages or dispensers for MIS instruments A61B2017/0479 takes precedence
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• 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 2017/07214 Stapler heads
• 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 2017/2927 : the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2943 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/320093 : additional movable means performing cutting operation
• CPC Class Codes: A61B 2017/320094 : additional movable means performing clamping operation
• CPC Class Codes: A61B 2017/320095 : with sealing or cauterizing means
• CPC Class Codes: A61B 2017/320097 : with stapling means
• CPC Class Codes: A61B 2034/2053 : Tracking an applied voltage gradient
• CPC Class Codes: A61B 2034/2059 : Mechanical position encoders
• CPC Class Codes: A61B 2034/2072 : Reference field transducer attached to an instrument or patient
• CPC Class Codes: A61B 2034/302 : specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2090/065 : for measuring contact or contact pressure
• 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 2090/0814 : Preventing re-use
• CPC Class Codes: A61B 2562/028 : Microscale sensors, e.g. electromechanical sensors [MEMS]
• CPC Class Codes: A61B 34/30 : Surgical robots
• CPC Class Codes: A61B 34/71 : Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 50/36 : for collecting or disposing of used articles
• CPC Class Codes: A61B 90/98 : using electromagnetic means, e.g. transponders
• CPC Class Codes: B65B 5/04 : Packaging single articles
• CPC Class Codes: B65B 55/16 : by irradiation
• CPC Class Codes: B65B 55/18 : by liquids or gases B65B55/14 takes precedence

Abstract

A surgical instrument for use with a robotic system that has a control unit and a shaft portion that includes an electrically conductive elongated member that is attached to a portion of the robotic system. The elongated member is configured to transmit control motions from the robotic system to an end effector.

Claims

1. A surgical tool for use with a robotic system that has 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 control motions applied to said selectively movable component portion;

an elongated shaft assembly operably coupled to said surgical end effector, said elongated shaft assembly comprising at least one gear-driven portion that is in operable communication with said at least one selectively movable component portion of said surgical end effector;

a tool mounting portion operably coupled to said elongated 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 transmission assembly in operable engagement with said driven element and in meshing engagement with a corresponding one of said at least one gear-driven portions to apply actuation motions thereto to cause said corresponding one of said at least one gear driven portions to apply at least one control motion to said selectively movable component.

2. The surgical tool of claim 1 wherein said another component portion of said end effector comprises a surgical staple cartridge and wherein one of said at least one component portion that is selectively movable comprises an anvil that is selectively movable between a first open position and a second closed position relative to said surgical staple cartridge.

3. The surgical tool of claim 2 wherein surgical staple cartridge is supported in an elongated channel and wherein said elongated shaft assembly comprises:

a spine assembly comprising a proximal end portion supported on said tool mounting portion and a distal end portion that is coupled to said elongated channel; and

a closure tube assembly movably supported on said spine assembly, said closure tube assembly comprising a distal end configured for operable interaction with said anvil and a proximal end portion configured for operable interaction with said transmission assembly.

4. The surgical tool of claim 3 wherein one of said at least one gear driven portions comprises a tube gear segment on said proximal end portion of said closure tube assembly that is in operable engagement with said transmission assembly.

5. The surgical tool of claim 4 wherein said transmission assembly comprises a closure transmission assembly comprising a closure sled movably supported on said tool mounting portion and operably supporting said proximal end portion of said closure tube assembly thereon, said closure sled configured for meshing engagement with a closure gear assembly operably coupled to one of the at least one rotatable body portions supported on the tool drive assembly such that upon application of a rotary output motion in a first direction to said closure gear assembly by said at least one rotatable body portion, said closure tube assembly is driven distally on said spine assembly into closing engagement with said anvil to move said anvil from said first open position to said second closed position and upon application of said rotary output motion in a second direction to said closure gear assembly, said closure tube assembly is driven proximally on said spine assembly to enable said anvil to move to said open position.

6. The surgical tool of claim 1 wherein said another component portion of said end effector comprises a surgical staple cartridge and wherein one of said at least one component portion that is selectively movable comprises a cutting instrument that is axially movable within said surgical staple cartridge between a starting position and an ending position.

7. The surgical tool of claim 6 wherein said at least one gear driven portion comprises a knife bar that is movably supported within said elongated shaft assembly for selective axial travel therein, said knife bar interfacing with said cutting instrument and said transmission assembly.

8. The surgical tool of claim 7 wherein said knife bar has a knife gear rack formed on a proximal end thereof and wherein said transmission assembly comprises a knife transmission assembly comprising a knife gear assembly in meshing engagement with said knife gear rack, said knife gear assembly operably coupled to one of the at least one rotatable body portions supported on the tool drive assembly such that upon application of a rotary output motion in a first direction to said knife gear assembly by said at least one rotatable body portion, said knife bar drives said cutting instrument distally through said surgical staple cartridge and upon application of said rotary output motion in a second direction to said knife gear assembly, said knife bar moves said cutting instrument proximally through said surgical staple cartridge.

9. The surgical tool of claim 6 wherein said surgical staple cartridge is supported in an elongated channel coupled to said elongated shaft assembly and wherein said cutting instrument comprises:

a rotary end effector drive shaft operably supported within an elongated channel operably supporting said surgical staple cartridge therein; and

a knife member having a tissue-cutting portion thereon threadedly received on said rotary end effector drive shaft such that rotation of said rotary end effector drive shaft in a first direction causes said knife member to move in a distal direction through said surgical staple cartridge and when said rotary end effector drive shaft is rotated in a second direction, said knife member moves in a proximal direction through said surgical staple cartridge.

10. The surgical tool of claim 9 wherein one of said at least one of said gear driven portions comprises an elongated proximal drive shaft operably supported in said elongated shaft assembly and having a distal end in driving engagement with said rotary end effector drive shaft, and wherein said transmission assembly comprises a rotary drive transmission operably supported on said tool mounting portion and in driving engagement with a proximal end of said proximal drive shaft and operably coupled to one of the at least one rotatable body portions supported on the tool drive assembly such that, upon application of a rotary output motion in one direction to said rotary drive transmission by said at least one rotatable body portion, said proximal drive shaft rotates said rotary end effector drive shaft in said first direction and upon application of said rotary output motion in a second direction to rotary drive transmission, said proximal drive shaft causes said rotary end effector drive shaft to rotate in said second direction.

11. The surgical tool of claim 1 wherein said elongated shaft assembly comprises a distal end portion operably coupled to said surgical end effector and a proximal end rotatably supported on said tool mounting portion for selective rotational travel about a longitudinal tool axis.

12. The surgical tool of claim 11 wherein said at least one gear-driven portion comprises a tube gear segment on said proximal end portion of said elongated shaft assembly and wherein said transmission assembly comprises a rotational transmission assembly comprising a rotational gear assembly operably coupled to one of the at least one rotatable body portions supported on the tool drive assembly such that upon application of a rotary output motion in a first direction to said rotational gear assembly by said at least one rotatable body portion, said rotational gear assembly rotates said elongated shaft assembly and said surgical end effector in a first rotary direction about said longitudinal tool axis and upon application of said rotary output motion in a second direction to said rotational gear assembly, said rotational gear assembly rotates said elongated shaft assembly and said surgical end effector about said longitudinal tool axis in a second rotary direction.

13. The surgical tool of claim 1 wherein said elongated shaft assembly defines a longitudinal tool axis and further comprises an articulation joint therein that facilitates selective articulation of said surgical end effector about an articulation axis that is substantially transverse to said longitudinal tool axis.

14. The surgical tool of claim 13 wherein said elongated shaft assembly comprises:

a distal spine portion operably coupled to said end effector; and

a proximal spine portion pivotally coupled to said distal portion at said articulation joint and comprising a distal end portion operably supported on said tool mounting portion.

15. The surgical tool of claim 14 wherein said at least one gear-driven portion comprises an articulation system interfacing with said distal spine portion and said transmission assembly.

16. The surgical tool of claim 15 wherein said transmission assembly comprises an articulation transmission and wherein said articulation system comprises:

a first articulation bar having a distal end coupled to said proximal portion of said elongated shaft assembly at a first lateral point that is laterally offset in a first lateral direction from said articulation axis, said first articulation bar having a proximal end that operably interfaces with said articulation transmission; and

a second articulation bar having a distal end coupled to said proximal portion of said elongated shaft assembly at a second lateral point that is laterally offset in a second lateral direction from said articulation axis, said second articulation bar having a proximal end that operably interfaces with said articulation transmission.

17. The surgical tool of claim 16 wherein said articulation transmission comprises:

an articulation gear assembly operably coupled to one of the at least one rotatable body portions supported on the tool drive assembly; and

an articulation nut in meshing engagement with said articulation gear assembly and rotatably supported on said proximal spine portion for rotary travel thereon in response to actuation motions from said articulation gear assembly and wherein said distal ends of said first and second articulation bars each operably interface with said articulation nut such that upon application of a first actuation motion to said articulation nut by said articulation gear assembly causes said first articulation bar to move axially in a first direction and said second articulation bar to move axially in a second direction that is opposite to said first direction and upon application of a second actuation motion to said articulation nut from said articulation gear assembly causes said first articulation bar to axially move in said second direction and said second articulation bar to axially move in said first direction.

18. The surgical tool of claim 17 wherein each said distal end of said first and second articulation bars have a guide rod protruding therefrom that is slidably received with corresponding helical slots in said articulation nut.

19. A surgical tool for use with a robotic system that has a tool drive assembly that is operatively coupled to a controller of the robotic system that is operable by inputs from an operator and is configured to provide a plurality of rotary output motions to a plurality of corresponding rotatable body portions supported on the tool drive assembly, said surgical tool comprising:

an end effector, comprising;

an elongated channel;

a surgical staple cartridge supported within said elongated channel;

a cutting instrument axially movable within said surgical staple cartridge between a starting position and an ending position; and

an anvil movably supported relative to said elongated channel and being selectively movable between an open position relative to said surgical staple cartridge and a closed position relative to said surgical staple cartridge and wherein said surgical tool further comprises;

an elongated shaft assembly comprising;

a spine assembly coupled to said elongated channel;

a closure tube assembly movably supported on said spine assembly, said closure tube assembly having a distal end portion configured for operable interaction with said anvil and wherein said surgical tool further comprises;

a tool mounting portion coupled to a distal end of said spine assembly and configured to operably interface with the tool drive assembly of the robotic system when coupled thereto, said tool mounting portion comprising;

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

a closure gear assembly supported on said tool mounting portion and being operably coupled to the first driven disc for receiving said first rotary output motions therefrom;

a closure sled operably supporting a proximal end of said closure tube assembly on said tool mounting portion and supported in meshing engagement with said closure gear assembly such that upon application of one said first rotary output motions in a first direction to said closure gear assembly, said closure tube assembly is driven distally on said spine assembly into closing engagement with said anvil to move said anvil from said first open position to said second closed position and upon application of another one of said first rotary output motions in a second direction to said closure gear assembly, said closure tube assembly is driven proximally on said spine assembly to enable said anvil to move to said open position;

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

a knife gear assembly supported on said tool mounting portion and being operably coupled to said second rotatable body portion for receiving said second rotary output motions therefrom;

a knife bar having a distal end operably interfacing with said cutting instrument and having a proximal end portion in meshing engagement with said knife gear assembly such that upon application of the second rotary output motion in a first direction to said knife gear assembly by said second driven disc, said knife bar drives said cutting instrument distally through said staple cartridge and upon application of another one of said second rotary output motions in a second direction to said knife gear assembly, said knife bar moves said cutting instrument proximally through said surgical staple cartridge;

a third driven disc rotatably supported on said tool mounting portion and configured for driving engagement with a corresponding third rotatable body portion of the drive assembly of the robotic system to receive corresponding third rotary output motions therefrom; and

a rotational gear assembly operably supported on said tool mounting portion and in meshing engagement with a tube gear segment on a proximal end portion of the closure tube assembly and operably coupled to the third driven disc such that upon application of a third rotary output motion in a first direction to said rotational gear assembly by said third driven disc, said rotational gear assembly rotates said elongated shaft assembly and said surgical end effector in a first rotary direction about said longitudinal tool axis and upon application of said rotary output motion in a second direction to said rotational gear assembly, said rotational gear assembly rotates said elongated shaft assembly and said surgical end effector about said longitudinal tool axis in a second rotary direction.

20. The surgical tool of claim 19 wherein said spine assembly comprises:

a distal spine portion operably coupled to said elongated channel of said effector; and

a proximal spine portion pivotally coupled to said distal spine portion and having a proximal end portion operably supported on said tool mounting portion and wherein said closure tube assembly comprises;

a distal closure tube portion operably supported on said distal spine portion; and

a proximal closure tube portion pivotally attached to said distal closure tube portion and wherein said surgical tool comprises;

a first articulation bar having a distal end coupled to said proximal portion of said elongated shaft assembly at a first lateral point that is laterally offset in a first lateral direction from said articulation axis;

a second articulation bar having a distal end coupled to said proximal portion of said elongated shaft assembly at a second lateral point that is laterally offset in a second lateral direction from said articulation axis;

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

an articulation gear assembly operably supported on said tool mounting portion and operably coupled to the fourth driven disc to receive said fourth rotary output motions therefrom; and

an articulation nut in meshing engagement with said articulation gear assembly and rotatably supported on said proximal spine portion for rotary travel thereon in response to said fourth rotary output motions from said articulation gear assembly and wherein said distal ends of said first and second articulation bars each operably interface with said articulation nut such that an application of a fourth rotary output motion to said articulation nut by said articulation gear assembly causes said first articulation bar to move axially in a first direction and said second articulation bar to move axially in a second direction that is opposite to said first direction and upon application of another fourth rotary output motion to said articulation nut from said articulation gear assembly causes said first articulation bar to axially move in said second direction and said second articulation bar to axially move in said first direction.