Robotically-controlled surgical end effector system with rotary actuated closure systems

• US 8,573,465 B2
• Filed: 02/09/2012
• Issued: 11/05/2013
• Est. Priority Date: 02/14/2008
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Shelton, Frederick E. IV
• Primary Examiner(s): Nash, Brian D
• Application Number:
  US13/369,666
• Publication Number:
  US 20120205421A1
• Time in Patent Office: 635 Days
• Field of Search: 227/19, 227/180.1, 227/175.1, 227/179.1
• US Class Current: 227/180.1
• 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 17/0686 having a forming anvil staying below the tissue during stapling
• 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 17/076 for removing surgical staples or wound clamps
• CPC Class Codes: A61B 17/105 Wound clamp magazines for packaging sharps A61B50/3001
• CPC Class Codes: A61B 17/115 Staplers for performing anastomosis in a single operation
• 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 17/3209 Incision instruments
• CPC Class Codes: A61B 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00115 with audible or visual output with imaging means A61B90/37, A61B34/20
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00415 having power generation near the working tip of the tool
• 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 2017/00734 battery operated
• CPC Class Codes: A61B 2017/0688 Packages or dispensers for surgical staplers
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07228 Arrangement of the staples
• 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 2017/2903 : transferring rotary motion
• CPC Class Codes: A61B 2017/2917 : with flexible part
• 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 2017/2933 : camming or guiding means
• CPC Class Codes: A61B 2017/2936 : Pins in guiding slots
• CPC Class Codes: A61B 2017/320052 : Guides for cutting instruments by marking A61B2090/395
• 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 2018/00196 : reciprocating lengthwise
• CPC Class Codes: A61B 2018/00601 : Cutting
• CPC Class Codes: A61B 2018/0063 : Sealing
• CPC Class Codes: A61B 2018/1455 : having a moving blade for cutting tissue grasped by the jaws
• CPC Class Codes: A61B 2034/302 : specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2090/0811 : 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 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 50/20 : Holders specially adapted for surgical or diagnostic appliances or instruments drapes with means to hold surgical instruments A61B46/23; for catheters A61M25/02
• CPC Class Codes: A61B 50/24 : Stands Mayo stands A61B50/15
• CPC Class Codes: A61B 50/26 : floor-based
• CPC Class Codes: A61B 50/36 : for collecting or disposing of used articles

Abstract

A self contained motor-powered disposable loading unit for use with a robotic system configured to generate control systems therefor. The disposable loading unit may contain a battery that is retained in a disconnected position when the disposable loading unit is not in use and is moved to a connected position when the disposable loading unit is coupled to the robotic system to permit the motor to be selectively powered thereby. Indicators may be supported on the disposable loading unit to indicate when the axial drive assembly thereof is in a starting position and an ending position. Another indicator may be provided to indicate when the anvil assembly is in a closed position.

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 at least to said selectively movable component portion; and

an elongated shaft assembly operably coupled to said surgical end effector, said elongated shaft assembly comprising;

an axially movable portion in operable communication with said at least one selectively movable component portion of said surgical end effector; and

a rotatably movable portion with said axially movable portion such that rotation of said rotatably movable portion causes said axially movable portion to move axially relative thereto and wherein said surgical tool further comprises a transmission arrangement in operable engagement with said at least one rotary body portions supported on the tool drive assembly and in operable engagement with said rotatably movable portion of said elongated shaft assembly to apply rotary actuation motions thereto from said at least one rotary body portion to cause said axially movable portion of said elongated shaft assembly to move said selectively movable component between said first and second positions, and wherein said rotatably movable portion further comprises a rotary drive shaft assembly comprising;

a closure drive nut in threaded engagement with said axially movable portion; and

a closure clutch assembly selectively movable between a neutral disengaged position to a first closure drive position wherein said closure clutch assembly is in driving engagement with said closure drive nut upon receipt of axial control motions from said transmission arrangement.

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 said elongated shaft assembly is coupled to a tool mounting portion that operably supports said transmission arrangement thereon, said tool mounting portion attachable to said tool drive assembly such that said transmission arrangement is in operable engagement with said at least one rotary body portions supported on the tool drive assembly of the robotic system.

4. The surgical tool of claim 3 wherein said rotary drive shaft assembly further comprises

a closure drive nut in threaded engagement with said axially movable portion;

and

a closure drive shaft in driving engagement with said closure drive nut and wherein said transmission arrangement comprises a rotary drive assembly supported on said tool mounting portion and operably coupled to said closure drive shaft, said rotary drive assembly operable coupled to one of said 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 rotary drive assembly by said one of said at least one rotatable body portions, said rotary drive assembly applies a rotary closure motion to said closure drive shaft which causes said closure drive nut to rotate and thereby axially drive said axially movable portion into closing engagement with said anvil and upon application of said rotary output motion in a second direction to said rotary drive assembly by said one of said at least one rotatable body portions, said rotary drive assembly applies another rotary closure motion to said closure drive shaft which causes said closure drive nut to rotate in a second direction and thereby axially drive said axially movable portion out of said closing engagement with said anvil into opening engagement therewith.

5. The surgical tool of claim 4 further comprising a cutting instrument that is axially movable within said surgical staple cartridge between a starting position and an ending position in response to a firing motion applied thereto.

6. The surgical tool of claim 5 further comprising:

a knife bar attached to said cutting instrument and movably supported within said elongated shaft assembly; and

a knife drive assembly supported on said tool mounting portion and operably coupled to said knife bar, said knife drive assembly operably coupled to another one of said at least one rotatable body portions supported on the tool drive assembly such that upon application of another rotary output motion in a first direction to said knife drive assembly by said another one of said at least one rotatable body portions, said knife drive assembly applies said firing motion to said knife bar which causes said cutting instrument to move from said starting position to said ending position and upon application of said another rotary output motion in a second direction to said knife drive assembly by said another one of said at least one rotatable body portions, said knife drive assembly applies a retraction motion to said knife bar which causes said cutting instrument to be retracted from said end position to said starting position.

7. The surgical tool of claim 6 wherein said knife drive assembly comprises:

first rotary drive gear operably supported on said tool mounting plate and operably coupled to said another one of said at least one rotatable body portions supported on the tool drive assembly;

a first rotary driven gear operably supported on said tool mounting plate and in meshing engagement with said first rotary drive gear;

a second rotary driven gear operably supported on said tool mounting plate and in meshing engagement with said first rotary driven gear;

a third rotary driven gear operably supported on said tool mounting plate and in meshing engagement with said second rotary driven gear; and

a fourth rotary driven gear operably supported on said tool mounting plate and in meshing engagement with said third rotary driven gear and a threaded portion of said knife bar.

8. The surgical tool of claim 4 wherein said elongated shaft has a proximal end portion rotatably supported on said tool mounting portion for selective rotational travel about a longitudinal tool axis.

9. The surgical tool of claim 8 wherein said transmission arrangement further comprises a rotational gear assembly operably coupled to another one of the at least one rotatable body portions supported on the tool drive assembly and in driving engagement with a portion of said proximal end portion of said elongated shaft assembly such that upon application of another said rotary output motion in a first direction to said rotational gear assembly by said another one of said at least one rotatable body portions, 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 another 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.

10. The surgical tool of claim 4 further comprising at least one sensor in said surgical end effector and communicating with a controller portion of said robotic system for determining an amount of compressive force applied to said anvil by said axially movable portion.

11. The surgical tool of claim 1 wherein said elongated shaft assembly is coupled to a tool mounting portion that operably supports said transmission arrangement thereon, said tool mounting portion attachable to said tool drive assembly such that said transmission arrangement is in operable engagement with said at least one rotary body portion supported on the tool drive assembly of the robotic system.

12. The surgical tool of claim 11 wherein said elongated shaft assembly further comprises a spine assembly comprising:

a proximal spine shaft that is operably supported on said tool mounting portion and has a distal end portion that protrudes from said tool mounting portion and a proximal end portion in operable engagement with said transmission arrangement;

a distal spine shaft that is coupled to an elongated channel supporting said surgical staple cartridge therein and is movably coupled to said distal end portion of said proximal spine shaft;

a drive sleeve coupled to a clutch plate portion of said closure clutch assembly, said drive sleeve movably supported on said distal spine shaft and coupled to said distal end portion of said proximal spine shaft such that axial movement of said proximal spine shaft causes said clutch plate portion to move between said neutral disengaged position and said first closure drive position; and

a drive shaft in operable engagement with said drive sleeve and said transmission arrangement to selectively apply rotary control motions to said drive sleeve.

13. The surgical tool of claim 12 wherein said transmission arrangement comprises:

a shifter drive assembly supported on said tool mounting portion and operably interfacing with said proximal end portion of said proximal spine shaft, said shifter drive assembly operably coupled to one of said 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 shifter drive assembly by said at least one rotatable body portion, said shifter drive assembly axially moves said proximal spine shaft and said drive sleeve to bring said clutch plate into said driving engagement with said closure drive nut and upon application of said rotary output motion in a second direction to said shifter drive assembly, said shifter drive assembly axially moves said proximal spine shaft and drive sleeve in a second direction to move said clutch plate from said driving engagement with said closure drive nut to said neutral position; and

a rotary drive assembly supported on said tool mounting portion and operably coupled to said drive shaft, said rotary drive assembly operable coupled to another one of said at least one rotatable body portions supported on the tool drive assembly such that upon application of another rotary output motion in a first direction to said rotary drive assembly by said another one of said at least one rotatable body portions, said rotary drive assembly applies a rotary closure motion to said drive shaft which causes said closure drive nut to rotate and thereby axially drive said axially movable portion into closing engagement with said anvil and upon application of said another rotary output motion in a second direction to said rotary drive assembly by said another one of said at least one rotatable body portions, said rotary drive assembly applies another rotary closure motion to said drive shaft which causes said closure drive nut to rotate in a second direction and thereby axially drive said axially movable portion out of said closing engagement with said anvil into opening engagement therewith.

14. The surgical tool of claim 13 wherein said surgical end effector further comprises a cutting instrument that is axially movable within said surgical staple cartridge between a starting position and an ending position in response to a firing motion applied thereto by said drive sleeve.

15. The surgical tool of claim 14 wherein said clutch plate portion is configured to move between said neutral position and a firing position wherein said clutch plate portion is in driving engagement with a knife drive shaft assembly operably supported within said elongated shaft assembly and in operable engagement with said cutting instrument.

16. The surgical tool of claim 15 further comprising a rotary end effector shaft operably supported within said surgical end effector and operably supporting said cutting instrument thereon such that rotation of said rotary end effector shaft in a first direction drives said cutting instrument from said starting position to said ending position and rotation of said rotary end effector shaft in a second direction drives said cutting instrument from said ending position to said starting position and wherein said knife drive assembly comprises a knife shaft segment in meshing engagement with said rotary end effector shaft and configured to be drivingly engaged by said clutch plate portion when said clutch plate portion is in said firing position.

17. The surgical tool of claim 11 wherein said elongated shaft has a proximal end portion rotatably supported on said tool mounting portion for selective rotational travel about a longitudinal tool axis.

18. The surgical tool of claim 17 wherein said transmission arrangement comprises a rotational gear assembly operably coupled to one of the at least one rotatable body portions supported on the tool drive assembly and in driving engagement with a portion of said proximal end portion of said elongated shaft assembly such that upon application of a rotary output motion in a first direction to said rotational gear assembly by said one of said at least one rotatable body portions, 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.

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 defining a longitudinal tool axis and comprising;

a spine assembly coupled to said elongated channel;

a closure tube configured for operable interaction with said anvil to move said anvil between said open and closed positions;

a closure drive nut in threaded engagement with said closure tube;

a closure clutch selectively movable between a neutral disengaged position and a first closure drive position wherein said closure clutch is in driving engagement with said closure drive nut and to a firing drive position wherein said closure clutch assembly is in driving engagement with a portion of a knife drive shaft assembly operably supported within said elongated shaft assembly and in operable engagement with said cutting instrument; and

a drive shaft operably interfacing with said closure clutch and wherein said surgical tool further comprises;

a tool mounting portion coupled to a proximal 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 shifter drive assembly supported on said tool mounting portion and operably interfacing with said closure clutch, said shifter drive assembly operably coupled to a first one of said 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 shifter drive assembly by said first rotatable body portion, said shifter drive assembly axially moves said closure clutch into said driving engagement with said closure drive nut and upon application of said rotary output motion in a second direction to said shifter drive assembly, said shifter drive assembly axially moves said closure clutch in a second direction into driving engagement with said knife drive shaft assembly;

a rotary drive assembly supported on said tool mounting portion and operably coupled to said drive shaft, said rotary drive assembly operable coupled to a second one of said at least one rotatable body portions supported on the tool drive assembly such that upon application of a second rotary output motion in a first direction to said rotary drive assembly by said second rotatable body portion when said closure clutch is in said driving engagement with said closure drive nut, said rotary drive assembly applies a rotary closure motion to said drive shaft which causes said closure drive nut to rotate and thereby axially drive said closure tube into closing engagement with said anvil and upon application of said second rotary output motion in a second direction to said rotary drive assembly by said second rotatable body portion, said rotary drive assembly applies another rotary closure motion to said drive shaft which causes said closure drive nut to rotate in a second direction and thereby axially drive said closure tube out of said closing engagement with said anvil into opening engagement therewith and upon application of another said second rotary output motion in said first direction when said closure clutch is in said firing drive position with said knife drive shaft assembly causes said cutting instrument to move from said starting to said end position and upon application of said second rotary output motion in said second direction causes said cutting instrument to be retracted from said ending position to said starting position;

a rotational gear assembly operably coupled to a third one of the at least one rotatable body portions supported on the tool drive assembly and in driving engagement with a portion of a proximal end portion of said elongated shaft assembly supported on said tool mounting portion such that upon application of a third rotary output motion in one direction to said rotational gear assembly by said third 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 third rotary output motion in an opposite 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. 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 defining a longitudinal tool axis and comprising;

a spine assembly coupled to said elongated channel;

a closure tube configured for operable interaction with said anvil to move said anvil between said open and closed positions;

a closure drive nut in threaded engagement with said closure tube;

a closure drive shaft in driving engagement with said closure drive nut; and

a knife bar attached to said cutting instrument and movably supported within said spine assembly and wherein said surgical tool further comprises;

a tool mounting portion coupled to a proximal 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 rotary drive assembly supported on said tool mounting portion and operably coupled to said closure drive shaft, said rotary drive assembly operable coupled to a first one of said at least one rotatable body portions supported on the tool drive assembly such that upon application of a first rotary output motion in a first direction to said rotary drive assembly by said first rotatable body portion, said rotary drive assembly applies a rotary closure motion to said closure drive shaft which causes said closure drive nut to rotate and thereby axially drive said closure tube into closing engagement with said anvil and upon application of said first rotary output motion in a second direction to said rotary drive assembly by said first rotatable body portion, said rotary drive assembly applies another rotary closure motion to said closure drive shaft which causes said closure drive nut to rotate in a second direction and thereby axially drive said closure tube out of said closing engagement with said anvil into opening engagement therewith;

a knife drive assembly supported on said tool mounting portion and operably coupled to said knife bar, said knife drive assembly operably coupled to a second one of said at least one rotatable body portions supported on the tool drive assembly such that upon application of a second rotary output motion in a first direction to said knife drive assembly by said second rotatable body portion, said knife drive assembly applies a firing motion to said knife bar which causes said cutting instrument to move from said starting position to said ending position and upon application of said second rotary output motion in a second direction to said knife drive assembly by said second rotatable body portion, said knife drive assembly applies a retraction motion to said knife bar which causes said cutting instrument to be retracted from said end position to said starting position; and

a rotational gear assembly operably coupled to a third one of the at least one rotatable body portions supported on the tool drive assembly and in driving engagement with a portion of a proximal end portion of said elongated shaft assembly supported on said tool mounting portion such that upon application of a third rotary output motion in one direction to said rotational gear assembly by said third 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 third rotary output motion in an opposite 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.