Surgical robotic system incorporating electrosurgical unit in surgical instrument

Abstract

A surgical robotic system includes an instrument drive unit having at least one motor and at least one power contact. The system also includes an electrosurgical generator configured to be coupled to the instrument drive unit. The electrosurgical generator includes a generator circuit configured to be coupled to at least one power supply contact and generate electrosurgical energy. The system further includes an electrosurgical instrument configured to be coupled to the instrument drive unit and the electrosurgical generator. The electrosurgical instrument may be actuated by an instrument drive unit and may be powered by an electrosurgical generator.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 445,324, filed February 14, 2023, the entire contents of which are incorporated herein by reference. Background Art

[0003] Surgical robotic systems are used in a variety of surgical procedures, including minimally invasive medical procedures. Some surgical robotic systems include a surgeon's console that controls a surgical robotic arm and a surgical instrument having an end effector (e.g., a clamp or grasping instrument) that is connected to and actuated by the robotic arm. In operation, the robotic arm moves to a position above the patient and then guides the surgical instrument into a small incision via the patient's surgical port or natural orifice to position the end effector at the working site in the patient's body. The surgical robotic system is used with a variety of electrosurgical instruments that are currently powered by conventional generators located outside the sterile barrier. When the electrosurgical generator is remotely located, long wires that conduct the electrosurgical energy need to be extended and routed to the instrument. Summary of the Invention

[0004] According to one embodiment of the present disclosure, a surgical robot system is disclosed. The surgical robot system includes an instrument drive unit having at least one motor and at least one power connection. The system also includes an electrosurgical generator configured to be coupled to the instrument drive unit. The electrosurgical generator includes a generator circuit configured to be coupled to the at least one power connection and to generate electrosurgical energy. The system further includes an electrosurgical instrument configured to be coupled to the instrument drive unit and the electrosurgical generator. The electrosurgical instrument can be actuated by the instrument drive unit and powered by the electrosurgical generator.

[0005] Implementations of the above embodiments may include one or more of the following features. According to one aspect of the above embodiments, the electrosurgical instrument may be a monopolar electric shears, an electrocoagulation hook, an electrocoagulation spatula, an electrocoagulation knife, a bipolar forceps, or a vascular sealer. The electrosurgical instrument may include at least one instrument coupler configured to engage at least one motor. The electrosurgical generator may include at least one generator coupler configured to engage at least one motor and at least one instrument coupler. The instrument drive unit may further include a plurality of first communication contacts, the electrosurgical generator may include a plurality of generator through-communication contacts, and the electrosurgical instrument may include a plurality of second communication contacts, so that the electrosurgical instrument is in electrical communication with the instrument drive unit. The surgical robot system may include a sterile interface module configured to be connected between the instrument drive unit and the electrosurgical generator. The sterile interface module may include at least one interface coupler configured to interconnect at least one generator coupler and at least one instrument coupler. The sterile interface module may include a plurality of interface-through communication contacts configured to provide electrical communication between the instrument drive unit and the electrosurgical instrument via the sterile interface and the electrosurgical generator. The generator circuit may be a current source or a voltage source. The surgical robotic system may include a robotic arm configured to support the instrument drive unit and the electrosurgical instrument.

[0006] According to another embodiment of the present disclosure, a surgical robot system is disclosed. The surgical robot system includes an instrument drive unit having at least one motor and at least one power connection. The system also includes an electrosurgical instrument including an instrument housing configured to be coupled to the instrument drive unit. The electrosurgical instrument is actuable by the instrument drive unit. The system also includes an electrosurgical generator configured to be coupled to the instrument housing of the electrosurgical instrument and to receive input power from the at least one power connection via the electrosurgical instrument. The electrosurgical generator includes generator circuitry configured to generate electrosurgical energy from the input power to power the electrosurgical instrument.

[0007] Implementations of the above embodiments may include one or more of the following features. According to one aspect of the above embodiments, the electrosurgical instrument may be a monopolar electric shears, an electrocoagulation hook, an electrocoagulation spatula, an electrocoagulation knife, a bipolar forceps, or a vascular sealer. The electrosurgical instrument may include at least one instrument coupler configured to engage at least one motor. The electrosurgical generator may include a generator housing having a proximal plate configured to be disposed between the instrument drive unit and the electrosurgical instrument. The proximal plate may include at least one opening to enable engagement between the at least one instrument coupler and the at least one motor. The surgical robot system may include a robotic arm configured to support the instrument drive unit and the electrosurgical instrument. The generator circuit may be a current source or a voltage source. The instrument drive unit may further include a plurality of first communication contacts, and the electrosurgical instrument may include a plurality of second communication contacts, so that the electrosurgical instrument is in electrical communication with the instrument drive unit. The electrosurgical generator may include a plurality of teeth extending from the generator housing and configured to engage with the instrument housing.

[0008] According to another embodiment of the present disclosure, a surgical robot system is disclosed. The surgical robot system includes an instrument drive unit having multiple motors, multiple power contacts, and multiple communication contacts. The system also includes an electrosurgical generator configured to be coupled to the instrument drive unit. The electrosurgical generator includes a generator circuit configured to be coupled to the multiple power contacts and to generate electrosurgical energy via multiple output power contacts. The generator also includes multiple generator couplers and multiple generator through-communication contacts, the multiple generator couplers being configured to engage the multiple motors. The system further includes an electrosurgical instrument configured to be coupled to the electrosurgical generator. The electrosurgical instrument can be actuated by the instrument drive unit and can be powered by the electrosurgical generator. The electrosurgical instrument also includes multiple electrosurgical contacts and multiple instrument couplers, the multiple electrosurgical contacts being configured to be electrically coupled to the multiple output power contacts, and the multiple instrument couplers being configured to engage the multiple generator couplers. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Various embodiments of the present disclosure are described herein with reference to the accompanying drawings, in which:

[0010] Figure 1 is a schematic diagram of a surgical robotic system according to an embodiment of the present disclosure, the surgical robotic system including a control tower, a control console, and one or more surgical robotic arms each disposed on a movable cart;

[0011] Figure 2 According to the embodiment of the present disclosure Figure 1 A three-dimensional diagram of a surgical robot arm of a surgical robot system;

[0012] Figure 3 is a perspective view of a mobile cart having a mounting arm according to an embodiment of the present disclosure, the mounting arm having Figure 1 The surgical robotic arm of the surgical robotic system;

[0013] Figure 4 According to the embodiment of the present disclosure Figure 1 A schematic diagram of the computer architecture of a surgical robot system;

[0014] Figure 5 is positioned around an operating table according to aspects of the present disclosure Figure 1 A plan view of a movable cart;

[0015] Figure 6 is a perspective view of an instrument drive unit and a surgical instrument according to an embodiment of the present disclosure, wherein the components are separated;

[0016] Figure 7 is a side view of an integrated electrosurgical generator, instrument drive unit, and surgical instrument disconnected from one another according to an embodiment of the present disclosure;

[0017] Figure 8 yes Figure 7 A side view of an electrosurgical generator, an instrument drive unit, and a surgical instrument connected to each other;

[0018] Figure 9 is a perspective view of a sterile interface module according to an embodiment of the present disclosure;

[0019] Figure 10 yes Figure 7 A partial cross-sectional view of an electrosurgical generator and surgical instruments coupled to a sterile interface module;

[0020] Figure 11 is a schematic diagram of an electrosurgical generator according to an embodiment of the present disclosure;

[0021] 12A to 12C An electrosurgical generator and surgical instrument according to another embodiment of the present disclosure are shown;

[0022] Figure 13A and Figure 13B Shown is a device coupled to a drive unit. 12A to 12C electrosurgical generators and surgical instruments; and

[0023] Figure 14A and Figure 14B Electrosurgical generators and surgical instruments according to further embodiments of the present disclosure are shown. DETAILED DESCRIPTION

[0024] Embodiments of the surgical robotic system disclosed herein are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.

[0025] As will be described in detail below, the present disclosure relates to a surgical robotic system that includes a surgeon's console, a control tower, and one or more movable carts having a surgical robotic arm coupled to a mounting arm. The surgeon's console receives user input via one or more interface devices. The input is processed by the control tower into movement commands for moving the surgical robotic arm and instruments and / or cameras coupled thereto. Thus, the surgeon's console enables remote operation of the surgical arm and attached instruments / cameras. The surgical robotic arm includes a controller that is configured to process movement commands to control one or more actuators of the robotic arm, which in turn move the robotic arm and instruments in response to the movement commands.

[0026] refer to Figure 1 The surgical robotic system 10 includes a control tower 20 that is connected to all components of the surgical robotic system 10, including a surgeon's console 30 and one or more mobile carts 60. Each mobile cart 60 includes a robotic arm 40 having a surgical instrument 50 coupled thereto. The robotic arm 40 is also coupled to the mobile cart 60. The robotic system 10 may include any number of mobile carts 60 and / or any number of robotic arms 40.

[0027] The surgical instrument 50 is configured for use during minimally invasive surgery. In an embodiment, the surgical instrument 50 can be configured for open surgery. In another embodiment, the surgical instrument 50 can be an electrosurgical clamp configured to seal tissue by compressing the tissue between the jaw members and applying an electrosurgical current thereto. In yet another embodiment, the surgical instrument 50 can be a surgical stapler comprising a pair of jaws configured to grasp and clamp tissue, simultaneously deploy a plurality of tissue fasteners (e.g., staples) and cut the stapled tissue. In yet another embodiment, the surgical instrument 50 can be a surgical clip applicator comprising a pair of jaws configured to apply a surgical clip to the tissue.

[0028] One of the robotic arms 40 may include an endoscopic camera 51 configured to capture a video of the surgical site. The endoscopic camera 51 may be a stereoscopic endoscope configured to capture two side-by-side (i.e., left and right) images of the surgical site to produce a video stream of the surgical scene. The endoscopic camera 51 is coupled to a video processing device 56, which may be located within the control tower 20. The video processing device 56 may be any computing device described below that is configured to receive a video feed from the endoscopic camera 51 and output a processed video stream.

[0029] The surgeon console 30 includes a first display 32 that displays a video feed of the surgical site provided by a camera 51 disposed on the robotic arm 40, and a second display 34 that displays a user interface for controlling the surgical robotic system 10. The first display 32 and the second display 34 may be touch screens that allow for the display of various graphical user inputs.

[0030] The surgeon's console 30 also includes a plurality of user interface devices, such as foot pedals 36 and a pair of handle controllers 38a and 38b, which a user utilizes to remotely control the robotic arm 40. The surgeon's console further includes armrests 33 for supporting the clinician's arms while operating the handle controllers 38a and 38b.

[0031] The control tower 20 includes a display 23 (which may be a touchscreen) and outputs on a graphical user interface (GUI). The control tower 20 also serves as an interface between the surgeon's console 30 and one or more robotic arms 40. Specifically, the control tower 20 is configured to control the robotic arms 40 based on a set of programmable instructions and / or input commands from the surgeon's console 30, so as to move the robotic arms 40 and corresponding surgical instruments 50 in a manner such that the robotic arms 40 and surgical instruments 50 execute a desired movement sequence in response to input from the foot pedals 36 and hand controllers 38a and 38b. The foot pedals 36 can be used to enable and disable the hand controllers 38a and 38b, reposition camera movement, and activate / deactivate electrosurgery. In particular, the foot pedals 36 can be used to perform a clutching action on the hand controllers 38a and 38b. By depressing one of the foot pedals 36, the clutch is activated, which disconnects the hand controllers 38a and / or 38b from the robotic arm 40 and the corresponding instrument 50 or camera 51 attached thereto (i.e., prevents movement input). This enables the user to reposition the hand controllers 38a and 38b without moving the robotic arm(s) 40 and instrument 50 and / or camera 51. This is useful when reaching the control boundaries of the surgical space.

[0032] Each of the control tower 20, surgeon console 30 and robotic arm 40 includes a corresponding computer 21, 31, 41. The computers 21, 31, 41 are interconnected with each other using any suitable communication network based on wired or wireless communication protocols. As used herein, the term "network", whether plural or singular, means a data network, including but not limited to the Internet, an intranet, a wide area network, or a local area network, and is not limited to the full scope of the definition of a communication network covered by the present disclosure. Suitable protocols include, but are not limited to, Transmission Control Protocol / Internet Protocol (TCP / IP), Datagram Protocol / Internet Protocol (UDP / IP) and / or Datagram Congestion Control Protocol (DCCP). Wireless communication can be achieved via one or more wireless configurations, such as radio frequency, optical, Wi-Fi, Bluetooth (an open wireless protocol for exchanging data between fixed and mobile devices over short distances using short wavelength radio waves to create a personal area network (PAN)), (A set of specifications for advanced communication protocols using small, low-power digital radios based on the IEEE 122.15.4-1203 Wireless Personal Area Network (WPAN) standard).

[0033] Computer 21,31,41 can include any suitable processor (not shown), the processor is operably connected to memory (not shown), the memory can include one or more of volatile, non-volatile, magnetic, optical or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM) or flash memory. The processor can be any suitable processor (e.g., control circuit) suitable for performing the operations, calculations, and / or instruction sets described in the present disclosure, including but not limited to hardware processors, field programmable gate arrays (FPGAs), digital signal processors (DSPs), central processing units (CPUs), microprocessors and combinations thereof. It will be understood by those skilled in the art that a processor can be replaced by using any logical processor (e.g., control circuit) suitable for performing the algorithms, calculations and / or instruction sets described herein.

[0034] refer to Figure 2 Each of the robotic arms 40 may include a plurality of links 42a, 42b, 42c interconnected at joints 44a, 44b, and 44c, respectively. Other configurations of links and joints may be used, as known to those skilled in the art. Joint 44a is configured to secure the robotic arm 40 to the mobile cart 60 and defines a first longitudinal axis. Figure 3The movable cart 60 includes an elevator 67 and a mounting arm 61, which provides a base for mounting the robotic arm 40. The elevator 67 allows the mounting arm 61 to move vertically. The movable cart 60 also includes a display 69 for displaying information about the robotic arm 40. In embodiments, the robotic arm 40 may include any type and / or any number of joints.

[0035] The installation arm 61 includes a first link 62a, a second link 62b, and a third link 62c, which provide lateral maneuverability of the robot arm 40. The links 62a, 62b, and 62c are interconnected at joints 63a and 63b, and each joint may include an actuator (not shown) for rotating the links 62b and 62b relative to each other and relative to the link 62c. In particular, the links 62a, 62b, and 62c can move in their corresponding lateral planes parallel to each other, thereby allowing the robot arm 40 to extend relative to the patient (e.g., an operating table). In an embodiment, the robot arm 40 can be coupled to an operating table (not shown). The installation arm 61 includes a control device 65 for adjusting the movement of the links 62a, 62b, and 62c and the elevator 67. In an embodiment, the installation arm 61 may include any type and / or any number of joints.

[0036] The third link 62c can include a rotatable base 64 having two degrees of freedom. Specifically, the rotatable base 64 includes a first actuator 64a and a second actuator 64b. The first actuator 64a can rotate about a first fixed arm axis perpendicular to the plane defined by the third link 62c, and the second actuator 64b can rotate about a second fixed arm axis transverse to the first fixed arm axis. The first actuator 64a and the second actuator 64b allow for full three-dimensional orientation of the robotic arm 40.

[0037] Actuator 48b of joint 44b is coupled to joint 44c via strap 45a, and joint 44c is in turn coupled to joint 46b via strap 45b. Joint 44c may include a transfer case coupling straps 45a and 45b such that actuator 48b is configured to rotate each of links 42b, 42c and retainer 46 relative to one another. More specifically, links 42b, 42c, and retainer 46 are passively coupled to actuator 48b, which forces rotation about a pivot point "P" located at the intersection of a first axis defined by link 42a and a second axis defined by retainer 46. In other words, pivot point "P" is the remote center of motion (RCM) of robotic arm 40. Thus, actuator 48b controls the angle θ between the first and second axes, thereby allowing surgical instrument 50 to be oriented. Due to the interconnection of the links 42a, 42b, 42c and the retainer 46 via the straps 45a and 45b, the angle between the links 42a, 42b, 42c and the retainer 46 is also adjusted to achieve the desired angle θ. In embodiments, some or all of the joints 44a, 44b, 44c may include actuators to eliminate the need for mechanical linkages.

[0038] The joints 44a and 44b include actuators 48a and 48b that are configured to drive the joints 44a, 44b, 44c relative to each other via a series of belts 45a and 45b or other mechanical linkages, such as drive rods, cables, or levers, etc. In particular, the actuator 48a is configured to rotate the robotic arm 40 about the longitudinal axis defined by the link 42a.

[0039] refer to Figure 2 , the holder 46 defines a second longitudinal axis and is configured to receive an instrument drive unit (IDU) 52 ( Figure 1 ). The IDU 52 is configured to be coupled to the actuation mechanisms of the surgical instrument 50 and the camera 51 and is configured to move (e.g., rotate) and actuate the instrument 50 and / or the camera 51. The IDU 52 transmits the actuation force from its actuator to the surgical instrument 50 to actuate components of the end effector 49 of the surgical instrument 50. The holder 46 includes a sliding mechanism 46a that is configured to move the IDU 52 along a second longitudinal axis defined by the holder 46. The holder 46 also includes a joint 46b that rotates the holder 46 relative to the link 42c. During endoscopic surgery, the instrument 50 can be passed through the endoscope access port 55 ( Figure 3 ) is inserted. The holder 46 also includes a port lock 46c ( Figure 2 ).

[0040] The IDU 52 is attached to the holder 46, and then the sterile interface module (SIM) 43 is attached to the distal portion of the IDU 52. The SIM 43 is configured to secure a sterile drape (not shown) to the IDU 52. The instrument 50 is then attached to the SIM 43. The instrument 50 is then inserted through the access port 55 by moving the IDU 52 along the holder 46. The SIM 43 includes a plurality of drive shafts that are configured to transmit rotation of the various motors of the IDU 52 to the instrument 50, thereby actuating the instrument 50. In addition, the SIM 43 provides a sterile barrier between the instrument 50 and the other components of the robotic arm 40, including the IDU 52.

[0041] The robot 40 also includes a mounting arm 61 and a plurality of manual override buttons 53 ( Figure 1 ), the mounting arm can be used in manual mode. The user can press one or more of these buttons 53 to move the component associated with the button 53.

[0042] refer to Figure 4 Each of the computers 21, 31, and 41 of the surgical robotic system 10 may include multiple controllers, which may be implemented in hardware and / or software. The computer 21 of the control tower 20 includes a controller 21a and a safety viewer 21b. The controller 21a receives data from the computer 31 of the surgeon's console 30 regarding the current position and / or orientation of the handle controllers 38a and 38b, as well as the status of the foot pedals 36 and other buttons. The controller 21a processes these input positions to determine the desired drive commands for each joint of the robotic arm 40 and / or the IDU 52, and transmits these desired drive commands to the computer 41 of the robotic arm 40. The controller 21a also receives the actual joint angles measured by the encoders of the actuators 48a and 48b and uses this information to determine force feedback commands, which are transmitted back to the computer 31 of the surgeon's console 30 to provide tactile feedback through the handle controllers 38a and 38b. The safety observer 21b performs validity checks on data entering and exiting the controller 21a and, if an error in the data transmission is detected, notifies the system fault handler to place the computer 21 and / or surgical robotic system 10 into a safe state.

[0043] Computer 41 includes multiple controllers, namely, a cart master controller 41a, a placement arm controller 41b, a robotic arm controller 41c, and an instrument drive unit (IDU) controller 41d. The cart master controller 41a receives and processes joint commands from controller 21a of computer 21 and transmits them to the placement arm controller 41b, the robotic arm controller 41c, and the IDU controller 41d. The cart master controller 41a also manages instrument exchange and the overall status of the movable cart 60, robotic arm 40, and IDU 52. The cart master controller 41a also transmits actual joint angles back to controller 21a.

[0044] Each of the joints 63a and 63b, as well as the rotatable base 64 of the mounting arm 61, is a passive joint (i.e., lacking an actuator) that allows manual user adjustment. The joints 63a and 63b and the rotatable base 64 include brakes that are disengaged by the user to configure the mounting arm 61. When the brakes are engaged, the mounting arm controller 41b monitors the sliding of each of the joints 63a and 63b and the rotatable base 64 of the mounting arm 61. When the brakes are disengaged, the mounting arm controller 41b can be freely moved by the operator without affecting the control of other joints. The robot arm controller 41c controls each of the joints 44a and 44b of the robot arm 40 and calculates the desired motor torque required for gravity compensation, friction compensation, and closed-loop position control of the robot arm 40. The robot arm controller 41c calculates movement commands based on the calculated torques. These calculated motor commands are then transmitted to one or more of the actuators 48a and 48b in the robot arm 40. The actual joint positions are then transmitted by actuators 48a and 48b back to the robot controller 41c.

[0045] The IDU controller 41d receives the desired joint angles of the surgical instrument 50 (such as wrist angle and jaw angle) and calculates the desired current for the motors in the IDU 52. The IDU controller 41d calculates the actual angles based on the motor positions and transmits these actual angles back to the cart main controller 41a.

[0046] The robotic arm 40 is controlled in response to the posture of a handle controller (e.g., handle controller 38a) controlling the robotic arm 40, which is transformed into a desired posture of the robotic arm 40 by a hand-eye transformation function executed by the controller 21a. The hand-eye function, as well as other functions described herein, are implemented in software executable by the controller 21a or any other suitable controller described herein. The posture of one of the handle controllers 38a can be implemented as a coordinate position and roll-pitch-yaw (RPY) orientation relative to a coordinate reference system fixed to the surgeon's console 30. The desired posture of the instrument 50 is relative to the fixed system on the robotic arm 40. The posture of the handle controller 38a is then scaled by a zoom function executed by the controller 21a. In an embodiment, the zoom function can reduce the coordinate position and enlarge the orientation. In addition, the controller 21a can also perform a clutch function for disengaging the handle controller 38a from the robotic arm 40. In particular, if certain movement limits or other boundaries are exceeded, the controller 21a stops transmitting movement commands from the handle controller 38a to the robotic arm 40 and essentially acts like a virtual clutch mechanism, eg, limiting the mechanical input from affecting the mechanical output.

[0047] The desired pose of the manipulator 40 is based on the pose of the handle controller 38a and then passed through the inverse kinematics function executed by the controller 21a. The inverse kinematics function calculates the angles of the joints 44a, 44b, 44c of the manipulator 40 to achieve the scaled and adjusted pose input by the handle controller 38a. The calculated angles are then passed to the manipulator controller 41c, which includes a joint axis controller with a proportional-derivative (PD) controller, a friction estimator module, a gravity compensator module, and a double-sided saturation block configured to limit the command torque of the motors of the joints 44a, 44b, 44c.

[0048] refer to Figure 5 , the surgical robotic system 10 is set up around an operating table 90. The system 10 includes movable carts 60a-d, which may be numbered "1" through "4." During set up, each of the carts 60a-d is positioned around the operating table 90. The position and orientation of the carts 60a-d depends on a number of factors, such as the placement of the plurality of access ports 55a-d, which in turn depends on the procedure being performed. Once the port placement is determined, the access ports 55a-d are inserted into the patient's body, and the carts 60a-d are positioned to insert the instruments 50 and endoscopic camera 51 into the corresponding ports 55a-d.

[0049] During use, by locking the buckle 46c ( Figure 2 ) is attached to access port 55 ( Figure 3) and each of the robotic arms 40a-d is attached to one of the access ports 55a-d inserted into the patient's body. The IDU 52 is attached to the holder 46, and then the SIM 43 is attached to the distal portion of the IDU 52. Thereafter, the instrument 50 is attached to the SIM 43. The instrument 50 is then inserted through the access port 55 by moving the IDU 52 along the holder 46.

[0050] refer to Figure 6 , showing the IDU 52 in more detail, which is configured to transmit power and actuation force from its motors 152a-d to the instrument 50 to drive the components of the instrument 50 to move, such as articulating, rotating, pitching, yaw, clamping, cutting, etc. The IDU 52 is also configured to power the instrument 50, which is an electrosurgical instrument, which may include, but is not limited to, monopolar shears, electrocoagulation hooks, electrocoagulation spatulas, electrocoagulation knives, bipolar forceps, and vessel sealers.

[0051] The IDU 52 includes a motor group 150 and a sterile barrier housing 151. The motor group 150 includes motors 152a-d for controlling various operations of the instrument 50. The instrument 50 is removably coupled to the IDU 52. When the motors 152a-d in the motor group 150 are actuated, the rotation of the drive transmission shafts 154a, 154b, 154c, 154d of the motors 152a-d are respectively transmitted to the drive assembly of the instrument 50. The instrument 50 is configured to convert the rotational force / movement supplied by the IDU 52 (e.g., via the motors 152a-d of the motor group 150) into longitudinal movement or translation of the cable or drive shaft to achieve various functions of the end effector assembly 140 (Figure 13C).

[0052] Each of motors 152a-d includes a current sensor 153, a torque sensor 155, and an encoder sensor 157. For simplicity, only the operation of motor 152a will be described below. Sensors 153, 155, and 157 monitor the performance of motor 152a. Current sensor 153 is configured to measure the current consumption of motor 152a, and torque sensor 155 is configured to measure motor torque. Torque sensor 155 can be any force or strain sensor including one or more strain gauges configured to convert mechanical force and / or strain into a sensor signal indicating the torque output by motor 152a. Encoder 157 can be any device that provides a sensor signal indicating the number of revolutions of motor 152a, such as a mechanical encoder or an optical encoder. Parameters measured and / or determined by encoder 157 can include speed, distance, revolutions per minute, position, and the like. The sensor signals from sensors 153, 155, and 157 are transmitted to IDU controller 41d, which then controls motors 152a-d based on these sensor signals. Specifically, motors 152a-d are controlled by actuator controller 159, which controls the output torque and angular velocity of motors 152a-d. In embodiments, additional position sensors may also be used, including but not limited to potentiometers, Hall effect sensors, accelerometers, and gyroscopes coupled to the movable components and configured to detect travel distance. In embodiments, a single controller may perform the functions of both IDU controller 41d and actuator controller 159.

[0053] Instrument 50 includes a housing 120, a shaft 130 extending distally from housing 120, and an end effector assembly (not shown) extending distally from shaft 130. Housing 120 of instrument 50 is configured to be selectively coupled to IDU 52 of a robot so that motors 152a-d of IDU 52 can operate end effector assembly 140 of instrument 50. Housing 120 of instrument 50 supports a drive assembly that is mechanically actuated by motors 152a-d of IDU 52.

[0054] The surgical instrument 50 also includes a storage device 158 having a non-volatile storage medium (e.g., EEPROM) configured to store any data related to the surgical instrument 50, including but not limited to usage counts, identification information, model number, serial number, calibration data, etc. In an embodiment, the data may be encrypted and decrypted only by the IDU controller 41 d. The IDU controller 41 d may also use the data to authenticate the surgical instrument 50. The storage device 158 may be configured in a read-only mode or a read / write mode to allow the IDU controller 41 d to read data from the storage device 158 and write data to the storage device.

[0055] refer to Figures 7 to 10 , the system 10 includes a portable electrosurgical generator 200 that is configured to be coupled to the instrument 50 and receive electrical energy, e.g., DC power, from the IDU 52. This configuration avoids locating the electrosurgical generator remote from the robotic arm 40 (e.g., at the control tower 20) and avoiding extending cables from the generator to the instrument 50.

[0056] The electrosurgical generator 200 includes a housing 202 having a distal side 204 configured to engage with the SIM 43 and a proximal side 206 configured to engage with the instrument 50, as shown. Figure 7 and Figure 8 Specifically, the apparatus 50 includes a plurality of couplers 164a-d ( Figure 6 ), which are actuated by motors 152a-d. The motors 152a-d are engaged with the couplers 164a-d via the SIM 43, which also includes through couplers 160a-d ( Figure 9 ). Similarly, the generator 200 includes generator couplers 262a-d ( Figure 10 ). Thus, the motors 152a-d of the IDU 52 engage with the couplers 160a-d of the SIM 43, which in turn engage with the generator couplers 262a-d, and finally engage with the couplers 164a-d of the instrument 50.

[0057] refer to Figure 6 、 Figure 9 ,as well as Figure 10 , the IDU 52 includes a plurality of (eg, a pair of) power supply contacts 170 and a plurality of communication contacts 172 ( Figure 6 ), which in turn couple to a plurality of through-power contacts 180 and a plurality of through-communication contacts 182 of SIM 43. Generator 200 includes input power contacts 280 and through-communication contacts 282, which are configured to couple to contacts 170 and 172 of IDU 52 via contacts 180 and 182 of SIM 43, respectively. Instrument 50 also includes a plurality of electrosurgical contacts 190 and a plurality of communication contacts 192 ( Figure 6 ), which are configured to couple with a plurality of output power contacts 284 and a through-communication contact 282 of the generator 200. Thus, the generator 200 provides a communication path between the IDU 52 and SIM 43 at the proximal end and the instrument 50 at the distal end. In an embodiment, the SIM 43 may be omitted, and the IDU 52 may be coupled directly to the generator 200. Any other suitable means may be used to couple the sterile drape to the robotic arm 40.

[0058] The generator 200 also receives input power from the IDU 52 and outputs electrosurgical radio frequency (RF) energy. The electrosurgical generator 200 is a miniaturized electrosurgical generator and includes circuit components designed to generate high-frequency current and deliver it to tissue in order to perform a surgical procedure. The electrosurgical generator 200 includes a power supply that provides the electrical energy required to operate the generator. The power supply may include a transformer, rectification, and filtering circuits that convert the input power into the appropriate voltage and current levels required by the generator. The electrosurgical generator 200 also includes a high-frequency oscillator that generates a high-frequency current for performing a surgical procedure. The high-frequency oscillator may include an oscillation circuit that generates AC at a specific radio frequency (e.g., 480 kHz) and a power amplifier that boosts the output of the oscillator to a desired level.

[0059] The electrosurgical generator 200 can be controlled by the surgeon's console 30 or the control tower 20. This allows the user to adjust the settings of the electrosurgical generator 200, such as output power, intensity, or amplitude parameters, and select a desired mode (e.g., coagulation, vessel sealing, cauterization, cutting, mixing, etc.). Such controls can be implemented in a graphical user interface that presents buttons, switches, sliders, and knobs that the user can use to adjust the generator settings. In an embodiment, the electrosurgical generator 200 can be activated by one of the foot pedals 36.

[0060] The electrosurgical generator 200 may have any suitable power supply architecture and topology suitable for generating electrosurgical energy, and Figure 11 The generator circuit 201 is exemplary. The generator circuit 201 is configured as a current source. In an embodiment, the generator circuit 201 can be configured as a voltage source. The generator circuit 201 has a buck converter 210 and an RF stage 220. The buck converter 210 is a switch-mode power supply that can use two switches (e.g., a transistor and a diode). The buck converter 210 is coupled to a voltage source 212, which can be DC power provided by the IDU 52 through the input power contact 180. The buck converter 210 includes a field effect transistor (FET) 214, a diode 216, and an inductor 218. The buck converter alternately uses the FET 214 and the diode 216 to connect the inductor 218 to the voltage source 212 to store energy in the inductor 218 and release energy from the inductor 218 to the load.

[0061] RF stage 220 (i.e., a high-frequency oscillator) includes a transformer 222 having primary windings 224a and 224b and a secondary winding 226. Primary windings 224a and 224b are coupled to FETs 221a and 221b, respectively. Secondary winding 226 of transformer 222 outputs RF energy to a pair of output power contacts 284. The turns ratio of transformer 222 can be varied to limit the maximum voltage output of secondary winding 226. Generator circuit 201 can include a controller 240 comprising a microprocessor operably connected to a memory, which can be a volatile type of memory (e.g., RAM) and / or a non-volatile type of memory. Controller 240 includes an output port operably connected to FETs 214, 221a, and 221b, thereby allowing controller 240 to control the output of generator circuit 201 according to an open-loop control scheme and / or a closed-loop control scheme. Those skilled in the art will appreciate that the microprocessor may be replaced by any logic processor or analog circuit (eg, control circuit) suitable for performing the calculations discussed herein.

[0062] The generator circuit 201 can implement closed-loop control and / or open-loop control schemes, both of which include a sensor circuit 230 having multiple sensors that measure various tissue and energy characteristics (e.g., tissue impedance, tissue temperature, output current and / or voltage, etc.) and provide feedback to the controller 240. Current sensors can be provided in the working current path or the return current path, or both, and voltage can be sensed at the working electrode(s). The controller 240 then transmits appropriate signals to control the output of the generator circuit 201. The controller 240 also receives input signals from the generator or instrument input control. The controller 240 uses the input signals to adjust the electrical energy output by the generator circuit 201 and / or the controller performs other control functions on the generator circuit.

[0063] The sensor circuit 230 measures the current (I) and voltage (V) supplied by the transformer 222 in real time to characterize the electrosurgical process during matched sinusoidal periods (e.g., half a cycle) and non-sinusoidal periods (e.g., approximately 15 cycles) within a predetermined sampling period. This allows the measured electrical characteristics to be used as dynamic input control variables for feedback control. The current and voltage values ​​can also be used to calculate other electrical parameters, such as power (P = V * I) and impedance (Z = V / I). The sensor circuit 230 also measures the characteristics of the current and voltage waveforms and determines their shapes.

[0064] 12A to 12C 、 Figure 13A ,as well as Figure 13BAn electrosurgical generator 300 according to another embodiment of the present disclosure is shown. The electrosurgical generator 300 is substantially similar to the electrosurgical generator 200 in terms of electrosurgical output functionality, and only mechanical differences are described. The electrosurgical generator 300 includes a housing 302 having a proximal plate 304 configured to engage with the SIM 43 and a proximal plate 304 configured to engage with the instrument 50 (e.g., Figure 13A and Figure 13B The bottom surface 306 (shown) 12A to 12C Plate 304 includes a plurality of openings 362a-d that allow couplers 160a-d of SIM 43 to engage with couplers 164a-d of instrument 50. In an embodiment, SIM 43 may be omitted, and IDU 52 may be coupled directly to instrument 50.

[0065] The distal plate 304 also includes power contact openings 380 and communication contact openings 382 that are configured to couple the contacts 190 and 192 of the instrument 50 with the contacts 170 and 172 of the IDU 52 and / or through the contacts 180 and 182 of the SIM 43. The bottom surface 306 of the generator 300 includes an electrical connection interface 390 ( Figure 12A ), the electrical connection interface includes a plurality of electrical contacts for receiving electrical energy from the IDU 52 and outputting RF energy to the instrument 50, and for transmitting control signals to and from the IDU 52 and the instrument 50.

[0066] Figure 14A and Figure 14B An electrosurgical generator 400 according to another embodiment of the present disclosure is shown. The electrosurgical generator 400 is substantially similar to the electrosurgical generator 200 in terms of electrosurgical output functionality, and only the mechanical differences are described. The electrosurgical generator 400 includes a housing 402 having a proximal surface 404 and a bottom surface 406 configured to engage with the instrument 50, as shown. Figure 14A and Figure 14B In this embodiment, the device 50 can be directly coupled to the SIM 43 and / or the IDU 52. Thus, the contacts 190 and 192 of the device 50 are directly coupled to the contacts 170 and 172 of the IDU 52 and / or the contacts 180 and 182 of the SIM 43.

[0067] The generator 400 may include a plurality of teeth 408 extending from a bottom surface 406. The plurality of teeth 408 are configured to engage with the housing 120 of the instrument 50. The housing 120 may include a plurality of corresponding slots for engaging with the teeth 408. The generator 400 also includes an electrical connection interface 490 that includes a plurality of electrical contacts for receiving electrical energy from the IDU 52 and outputting RF energy to the instrument 50, and for transmitting control signals to and from the IDU 52 and the instrument 50. The generator 400 can be coupled to the housing 120 of the instrument 50 by initially inserting the teeth 408 into the housing 120 (i.e., step 1) and then sliding the generator 400 proximally to engage the teeth 408 with the housing 120 (i.e., step 2). The interface 490 is also inserted into a connector (not shown) disposed in the housing 120.

[0068] It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be interpreted as limiting, but merely as illustrations of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the appended claims.

Claims

1. A surgical robot system, comprising: an instrument drive unit, the instrument drive unit comprising at least one motor and at least one power connection; an electrosurgical generator configured to be coupled to the instrument drive unit, the electrosurgical generator comprising a generator circuit configured to be coupled to the at least one power connection and to generate electrosurgical energy; as well as An electrosurgical instrument is configured to be coupled to the instrument drive unit and the electrosurgical generator, the electrosurgical instrument being actuatable by the instrument drive unit and energizable by the electrosurgical generator.

2. The surgical robot system according to claim 1, wherein: The electrosurgical instrument is selected from the group consisting of: a monopolar electric scissors, an electric coagulation hook, an electric coagulation spatula, an electric coagulation knife, a bipolar forceps, and a vessel sealer.

3. The surgical robot system according to claim 1, wherein: The electrosurgical instrument includes at least one instrument coupler configured to engage the at least one motor.

4. The surgical robot system according to claim 3, wherein: The electrosurgical generator includes at least one generator coupler configured to engage the at least one motor and the at least one instrument coupler.

5. The surgical robot system according to claim 4, wherein: The instrument drive unit further includes a plurality of first communication contacts, the electrosurgical generator includes a plurality of generator-through communication contacts, and the electrosurgical instrument includes a plurality of second communication contacts, such that the electrosurgical instrument is in electrical communication with the instrument drive unit. 6 . The surgical robotic system of claim 5 , further comprising a sterile interface module configured to be coupled between the instrument drive unit and the electrosurgical generator.

7. The surgical robot system according to claim 6, wherein: The sterile interface module includes at least one interface coupler configured to interconnect the at least one generator coupler and the at least one instrument coupler.

8. The surgical robot system according to claim 7, wherein: The sterile interface module includes a plurality of interface-through communication contacts configured to provide electrical communication between the instrument drive unit and the electrosurgical instrument through the sterile interface and an electrosurgical generator.

9. The surgical robot system according to claim 1, wherein: The generator circuit is at least one of a current source or a voltage source.

10. The surgical robot system according to claim 1, further comprising: A robotic arm is configured to support the instrument drive unit and the electrosurgical instrument.

11. A surgical robot system, comprising: an instrument drive unit, the instrument drive unit comprising at least one motor and at least one power connection; an electrosurgical instrument comprising an instrument housing configured to be coupled to the instrument drive unit, the electrosurgical instrument being actuatable by the instrument drive unit; as well as an electrosurgical generator configured to be coupled to the instrument housing of the electrosurgical instrument and to receive input power from the at least one power connection through the electrosurgical instrument, the electrosurgical generator including a generator circuit configured to generate electrosurgical energy from the input power to power the electrosurgical instrument.

12. The surgical robot system according to claim 11, wherein: The electrosurgical instrument is selected from the group consisting of: a monopolar electric scissors, an electric coagulation hook, an electric coagulation spatula, an electric coagulation knife, a bipolar forceps, and a vessel sealer.

13. The surgical robot system according to claim 11, wherein: The electrosurgical instrument includes at least one instrument coupler configured to engage the at least one motor.

14. The surgical robot system according to claim 13, wherein: The electrosurgical generator includes a generator housing having a proximal plate configured to be positioned between the instrument drive unit and the electrosurgical instrument.

15. The surgical robot system according to claim 14, wherein: The proximal plate includes at least one opening to enable engagement between at least one instrument coupler and the at least one motor.

16. The surgical robot system according to claim 11, further comprising: A robotic arm is configured to support the instrument drive unit and the electrosurgical instrument.

17. The surgical robot system according to claim 11, wherein: The generator circuit is at least one of a current source or a voltage source.

18. The surgical robot system according to claim 11, wherein: The instrument drive unit further includes a plurality of first communication contacts, and the electrosurgical instrument includes a plurality of second communication contacts, such that the electrosurgical instrument is in electrical communication with the instrument drive unit.

19. The surgical robot system according to claim 11, wherein: The electrosurgical generator includes a plurality of teeth extending from the generator housing and configured to engage the instrument housing.

20. A surgical robot system comprising: An instrument drive unit, the instrument drive unit comprising a plurality of motors, a plurality of power supply contacts, and a plurality of communication contacts; an electrosurgical generator configured to be coupled to the instrument drive unit, the electrosurgical generator comprising: a generator circuit configured to couple to the plurality of power supply contacts and generate electrosurgical energy through a plurality of output power contacts; a plurality of generator couplers configured to engage the plurality of motors; and Multiple generators communicate through the communication point; and An electrosurgical instrument configured to be coupled to the electrosurgical electrical generator, the electrosurgical instrument being actuatable by the instrument drive unit and being energizable by the electrosurgical generator, the electrosurgical instrument comprising: a plurality of electrosurgical contacts configured to be electrically coupled to the plurality of output power contacts; and A plurality of instrument couplers are configured to engage the plurality of generator couplers.

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