Robotically-controlled surgical instruments

• US 8,820,605 B2
• Filed: 02/09/2012
• Issued: 09/02/2014
• Est. Priority Date: 01/31/2006
• 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): Elve, Alexandra
• Assistant Examiner(s): CHUKWURAH, NATHANIEL C
• Application Number:
  US13/369,569
• Publication Number:
  US 20120199630A1
• Time in Patent Office: 936 Days
• Field of Search: 227/175.1, 227/176.1, 227/178.1, 227/19, 606/1, 606/28
• US Class Current: 227/175.1
• CPC Class Codes: A61B 17/00 Surgical instruments, devices or methods, e.g. tourniquets A61B18/00 takes precedence; contraceptive devices, pessaries, or applicators therefor A61F6/00; eye surgery A61F9/007; ear surgery A61F11/00
• 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 17/1114 of the digestive tract, e.g. bowels or oesophagus
• CPC Class Codes: A61B 17/115 Staplers for performing anastomosis in a single operation
• CPC Class Codes: A61B 17/1155 Circular staplers comprising a plurality of staples
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00221 with wireless transmission of data, e.g. by infrared radiation or radiowaves
• CPC Class Codes: A61B 2017/00353 one mechanical instrument performing multiple functions, e.g. cutting and grasping channel for multiple instruments A61B2017/3445; instrument channel A61B2017/22072; replaceable heads A61B2017/2931; suction A61M1/00
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0042 with special provisions for gripping
• 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 2017/07257 characterised by its anvil
• 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 2017/2943 : Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2090/033 : Abutting means, stops, e.g. abutting on tissue or skin
• CPC Class Codes: A61B 2090/064 : for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 2090/065 : for measuring contact or contact pressure
• CPC Class Codes: A61B 2090/069 : using a plummet or weight
• CPC Class Codes: A61B 2090/0803 : Counting the number of times an instrument is used
• 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 34/71 : Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 34/74 : Manipulators with manual electric input means
• CPC Class Codes: A61B 34/76 : Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: A61B 5/4836 : Diagnosis combined with treatment in closed-loop systems or methods A61B5/0036 takes precedence

Abstract

A surgical instrument. Various embodiments of the surgical instrument include an end effector that has a moveable cutting implement. A main drive shaft assembly operably interfaces with the end effector for transmitting an actuation motion to the movable cutting implement therein. A gear drive train is connected to the main drive shaft assembly. The gear drive train is actuated by a motor that is configured to receive control signals from a robotic system. Various embodiments include a sensor arrangement that operably interfaces the end effector to communicate forces experienced by the end effector to the robotic system.

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 a plurality of output motions to a plurality of rotatable body portions supported on the tool drive assembly, said surgical tool comprising:

a surgical end effector comprising;

a first portion;

a second movable portion that is selectively movable between first and second positions relative to said first portion; and

a third movable portion that is selectively movable between primary and secondary positions relative to said first portion; and

an elongated shaft assembly operably coupled to said first portion, said elongated shaft assembly comprising;

an axially movable actuation member in operable communication with said second movable portion of said surgical end effector;

a rotatably movable portion in operable engagement with said axially movable actuation member such that rotation of said rotatably movable portion causes said axially movable actuation member to move axially relative thereto; and

a drive member operably interfacing with said third movable portion of said surgical end effector such that application of an axial control motion to said drive member causes said third movable portion to axially move relative to said first portion of said surgical end effector and wherein said drive member operably interfaces with said rotatably movable portion such that application of a rotary control motion to said drive member causes said axially movable actuation member to move said second movable portion relative to said first portion of said surgical end effector.

2. The surgical tool of claim 1 further comprising a transmission arrangement in operable engagement with said plurality of rotatable body portions supported on the tool drive assembly and in operable engagement with said drive member wherein:

upon application of a first rotary output motion to said transmission arrangement by one of said rotatable body portions causes said transmission arrangement to apply said axial control motion to said drive member and wherein;

upon application of a second rotary output motion to said transmission arrangement by another one of said rotatable body portions causes said transmission arrangement to apply said rotary control motion to said drive member.

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 plurality of rotatable body portions supported on the tool drive assembly of the robotic system.

4. The surgical tool of claim 3 wherein said transmission arrangement comprises:

a first drive assembly operably supported on said tool mounting portion and comprising;

a first rotary drive gear operably supported on said tool mounting portion in operable engagement with said one of said rotatable body portions on the tool drive assembly; and

a first gear drive train operably supported on said tool mounting portion in meshing engagement with said first rotary drive gear and in operable engagement with said drive member to apply said axial control motions thereto and wherein said transmission arrangement further comprises;

a second drive assembly supported on said tool mounting portion and comprising;

a second drive gear operably supported on said tool mounting portion in operable engagement with said another one of said rotatable body portions on the tool drive assembly; and

a closure gear drive train operably supported on said tool mounting portion in operable engagement with said drive member to apply said rotary control motions thereto.

5. The surgical tool of claim 2 wherein said elongated shaft assembly further comprises a tubular member that defines a longitudinal tool axis and is operably supported by 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 plurality of rotatable body portions supported on the tool drive assembly of the robotic system.

6. The surgical tool of claim 5 wherein upon application of another first rotary output motion to said transmission arrangement by a third one of said rotatable body portions causes said transmission arrangement to apply another rotary control motion to said tubular member to cause said tubular member and said surgical end effector to rotate about said longitudinal tool axis.

7. The surgical tool of claim 6 wherein said transmission arrangement comprises a rotation drive assembly operably supported on said tool mounting portion and comprising:

a rotation drive gear operably supported on said tool mounting portion in driving engagement with said third one of said rotatable body portions for receiving said another first rotary output motion therefrom; and

a rotational driven gear operably supported on said tool mounting portion in meshing engagement with said rotation drive gear and said tubular member.

8. The surgical tool of claim 5 wherein:

said first portion of said surgical end effector comprises a surgical staple cartridge;

said second movable portion comprises an anvil that is selectively movable between a first open position and a second closed position relative to said surgical staple cartridge; and

said third movable portion comprises a cutting instrument movably supported in said surgical staple cartridge and being selectively movable between a primary starting position and a secondary ending position.

9. The surgical tool of claim 1 wherein:

said first portion of said surgical end effector comprises a surgical staple cartridge;

said second movable portion comprises an anvil that is selectively movable between a first open position and a second closed position relative to said surgical staple cartridge; and

said third movable portion comprises a cutting instrument movably supported in said surgical staple cartridge and being selectively movable between a primary starting position and a secondary ending position.

10. 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 a plurality of output motions to a plurality of rotatable body portions supported on the tool drive assembly, said surgical tool comprising:

a surgical end effector operably supporting at least two components that are movable in response to separate control motions applied thereto; and

an elongated shaft assembly operably coupled to said surgical end effector and supporting a drive member therein in operable communication with at least one of said at least two movable components, said elongated shaft assembly comprising;

an axially movable portion in operable communication with one of said at least two movable components to apply a first one of said separate control motions thereto; and

a rotatably movable portion in operable engagement with said axially movable portion such that rotation of said rotatably movable portion by said drive member causes said axially movable portion to move axially relative thereto and wherein the surgical tool further comprises;

a tool mounting portion operably coupled to said elongated shaft assembly and comprising a transmission arrangement comprising;

a first drive assembly operably supported on said tool mounting portion in operable engagement with one of said plurality of rotatable body portions supported on the tool drive assembly, said first drive assembly further being in operable engagement with said drive member; and

a second drive assembly operably supported on said tool mounting portion in operable engagement with another one of said plurality of rotatable body portions supported on the tool drive assembly, said second drive assembly further being in operable engagement with said drive member.

11. The surgical tool of claim 10 wherein said surgical end effector comprises an elongated channel coupled to said elongated shaft assembly and operably supporting a surgical staple cartridge therein wherein one of said movable components comprises an anvil that is selectively movable between a first open position and a second closed position relative to said surgical staple cartridge in response to said first one of said separate control motions applied thereto and wherein another one of said movable components comprises a cutting instrument movably supported in said surgical staple cartridge and being selectively movable between a primary starting position and a secondary ending position in response to an application of a second one of said separate control motions thereto.

12. The surgical tool of claim 11 wherein said first drive assembly comprises:

a first rotary drive gear operably supported on said tool mounting portion in operable engagement with said one of said rotatable body portions on the tool drive assembly; and

a first gear drive train operably supported on said tool mounting portion in meshing engagement with said first rotary drive gear and in operable engagement with said drive member to apply said first one of said separate control motions thereto.

13. The surgical tool of claim 11 wherein said second drive assembly comprises:

a second drive gear operably supported on said tool mounting portion in operable engagement with said another one of said rotatable body portions on the tool drive assembly; and

a closure gear drive train operably supported on said tool mounting portion in operable engagement with said drive member to apply said second one of said separate control motions thereto.

14. The surgical tool of claim 10 wherein said elongated shaft assembly has a proximal end portion rotatably supported on said tool mounting portion for selective rotational travel about a longitudinal tool axis.

15. The surgical tool of claim 14 wherein said transmission arrangement further comprises a rotation drive assembly comprising:

a rotation drive gear operably supported on said tool mounting portion in driving engagement with a third one of said rotatable body portions for receiving corresponding rotary output motions therefrom; and

a rotational driven gear operably supported on said tool mounting portion in meshing engagement with said rotation drive gear and said proximal end of said elongated shaft assembly such that upon application of said corresponding rotary output motions to said rotation drive gear causes said rotational driven gear to rotate said elongated shaft assembly and said surgical end effector about said longitudinal tool axis.

16. The surgical tool of claim 10 wherein said rotatably movable portion comprises a closure drive nut in threaded engagement with said axially movable portion and in operable engagement with said drive member such that application of a rotary motion to said drive member by said first drive assembly causes said closure drive nut to rotate and thereby drive said axially movable portion.

17. The surgical tool of claim 16 wherein said surgical end effector comprises an elongated channel coupled to said elongated shaft assembly and operably supporting a surgical staple cartridge therein wherein one of said movable components comprises an anvil that is selectively movable between a first open position and a second closed position relative to said surgical staple cartridge in response to said first one of said separate control motions applied thereto by said axially movable portion of said elongated shaft assembly and wherein another one of said movable components comprises a cutting instrument movably supported in said surgical staple cartridge and being selectively movable between a primary starting position and a secondary ending position in response to a second one of said separate control motions applied thereto by said drive member.

18. 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 a plurality of output motions to a plurality of rotatable body portions supported on the tool drive assembly, said surgical tool comprising:

a surgical end effector comprising;

an elongated channel configured to operably support a surgical staple cartridge therein;

an anvil movably supported on said elongated channel and being selectively movable between a first open position and a second closed position relative to said elongated channel; and

a cutting instrument supported for travel through said elongated channel between a primary starting position and a secondary ending position and wherein said surgical tool further comprises;

an elongated shaft assembly operably coupled to said elongated channel, said elongated shaft assembly comprising;

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

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

a drive shaft in operable engagement with said closure drive nut to apply rotary control motions thereto, said drive shaft being operably coupled to said cutting instrument for driving said cutting instrument between said primary starting position and said secondary ending position and wherein said surgical tool further comprises;

a tool mounting portion operably supporting a proximal end of said elongated shaft 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 drive assembly operably supported on said tool mounting portion in operable engagement with a first one of said plurality of rotatable body portions supported on the tool drive assembly and in operable engagement with said drive shaft for applying said rotary control motions thereto;

a second drive assembly operably supported on said tool mounting portion in operable engagement with a second one of said plurality of rotatable body portions supported on the tool drive assembly and in operable engagement with said drive shaft for applying axial control motions thereto; and

a third drive assembly operably supported on said tool mounting portion in operable engagement with a third one of said plurality of rotatable body portions supported on the tool drive assembly and in operable engagement with said elongated shaft assembly for applying other rotary control motions thereto to rotate said elongated shaft assembly and said surgical end effector about a longitudinal tool axis.