Robotic surgical stapler assembly configured for stapler reloading

Abstract

A robotic surgical stapler assembly configured to be reloaded with a stapler. The robotic surgical assembly includes a drive assembly and an axis assembly. The drive assembly is removably mounted to the surgical robot and includes a roll input, a pitch input, and a clamp / fire input, which are configured to be drivingly coupled to corresponding outputs of the surgical robot. The axis assembly is mounted to the drive assembly and is configured to be removably coupled to the stapler reloading assembly, which includes a reloading roll axis, a reloading pitch axis, and a reloading clamp / fire axis. The axis assembly includes a roll axis, a pitch axis, and a clamp / fire axis. The roll axis is drivingly coupled to the roll input and configured to be removably coupled to the reloading roll axis. The pitch axis is drivingly coupled to the pitch input and configured to be removably coupled to the reloading pitch axis. The clamp / fire axis is drivingly coupled to the clamp / fire input and configured to be removably coupled to the reloading clamp / fire axis.

Description

[0001] This application is a divisional application of Chinese patent application 2017800676552, filed on November 2, 2017, and entitled “ROBOTIC SURGICAL STAPLER ASSEMBLY CONFIGURED TO BE RELOADED WITH STAPLER”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Application No. 62 / 416,454, filed November 2, 2016; the entire disclosure of which is incorporated herein by reference in its entirety for all purposes. Background Art

[0004] Minimally invasive surgical techniques are designed to reduce the amount of external tissue damaged during a diagnostic or surgical procedure, thereby reducing patient recovery time, discomfort, and harmful side effects. As a result, the average length of stay for standard surgical procedures can be significantly shortened using minimally invasive surgical techniques. Additionally, patient recovery time, patient discomfort, surgical side effects, and time off work can also be reduced with minimally invasive surgery.

[0005] A common form of minimally invasive surgery is endoscopy, and a common form of endoscopy is laparoscopy, which is minimally invasive examination and surgery within the abdominal cavity. In standard laparoscopic surgery, the patient's abdomen is inflated with gas, and a cannula sleeve is passed through a small (approximately half an inch or less) incision to provide an entry port for laparoscopic instruments.

[0006] Laparoscopic surgical instruments typically include an endoscope (e.g., a laparoscope) for viewing the surgical field and tools for working at the surgical site. The working tools are generally similar to those used in conventional (open) surgery, except that the working end or end effector of each tool is separated from its handle by an extension tube (also referred to as, for example, an instrument shaft or spindle). The end effector may include, for example, clamps, graspers, scissors, staplers, cautery tools, linear cutters, or needle holders.

[0007] To perform a surgical procedure, the surgeon passes working tools through the cannula sleeve to the internal surgical site and manipulates them from outside the abdomen. The surgeon views the procedure from a monitor that displays images of the surgical site taken from the endoscope. Similar endoscopic techniques are used, for example, for arthroscopy, retroperitoneoscopy, pelvicoscopy, nephroscopy, cystoscopy, proctoscopy, nasoscopy, hysteroscopy, urethroscopy, etc.

[0008] Minimally invasive remote surgical robot systems are being developed to increase the surgeon's flexibility when working on internal surgical sites, and to allow surgeons to operate on patients from a remote position (outside the sterile area). In a remote surgical system, an image of the surgical site is usually provided to the surgeon at a console. While observing the three-dimensional image of the surgical site on a suitable viewer or display, the surgeon performs a surgical procedure on the patient by manipulating the main input or control device of the console. Each main input device controls the movement of a servomechanical actuation / articulated surgical instrument. During a surgical procedure, a remote surgical system can provide mechanical actuation and control of various surgical instruments or tools, which have an end effector that performs various functions (e.g., holding or driving a needle, grasping a blood vessel, dissecting tissue, etc.) for the surgeon in response to the manipulation of the main input device.

[0009] Surgical clamping and cutting instruments (e.g., non-robotic linear clamping, stapling and cutting devices, also known as surgical staplers; and electrosurgical vascular closure devices) have been used in many different surgical procedures. For example, surgical staplers can be used to remove cancerous or abnormal tissue from the gastrointestinal tract. Many known surgical clamping and cutting devices (including known surgical staplers) have opposing jaws for clamping tissue and an articulated knife for cutting the clamped tissue.

[0010] Surgical staplers are usually configured to use replaceable disposable stapler cartridges. Hospitals may have a variety of different types (e.g., different brands and models) of surgical staplers, including different handheld surgical staplers and / or remote surgical robot system surgical staplers. However, each type of surgical stapler can be configured to use a corresponding type of stapler cartridge, resulting in hospitals having to store different types of replaceable stapler cartridges. Storing different types of replaceable stapler cartridges results in additional costs in terms of extra inventory and resources to ensure that an appropriate number of stapler cartridges of each type are stored. Summary of the invention

[0011] The robotic surgical assembly removably mounted to the surgical robot is configured to use a replaceable stapler barrel of a common handheld surgical stapler. The ability to use the same replaceable stapler barrel as a common handheld surgical stapler can help reduce the number and type of stapler barrels stocked by a hospital, thereby reducing associated costs. Using the same stapler barrel as a common handheld surgical stapler can also reduce training costs and help reduce surgical errors associated with having to use different types of replaceable stapler barrels.

[0012] Thus, in one aspect, a robotic surgical assembly includes a drive assembly removably mounted to a surgical robot and an axis assembly mounted to the drive assembly. The drive assembly includes a chassis, a roll input configured to drivingly couple with a roll output of the surgical robot, a pitch input configured to drivingly couple with a pitch output of the surgical robot, and a clamp / fire input configured to drivingly couple with a clamp / fire output of the surgical robot. The shaft assembly is elongated along the axis and is configured to be removably coupled to a stapler reload assembly, which includes: an end effector operable to clamp and staple tissue; a reload roll axis to which the end effector is pivotally mounted; a reload pitch axis that is translatable along the axis to reorient the end effector relative to the reload roll axis; and a reload clamp / fire axis that is drivingly coupled to the end effector and translatable along the axis to actuate the end effector to clamp and staple tissue. The shaft assembly includes a roll axis, a pitch axis, and a clamp / fire axis. The roll axis is drivingly coupled to the drive assembly so that rotation of the roll input causes the roll axis to rotate about the axis. The roll axis has a proximal portion that is configured to be removably coupled to the reload roll axis. The pitch axis is drivingly coupled to the drive assembly so that rotation of the pitch input causes the pitch axis to translate along the axis. The pitch axis has a proximal portion configured to be removably coupled to the reload pitch axis. The clamp / fire axis is drivingly coupled to the drive assembly such that rotation of the clamp / fire input translates the clamp / fire axis along the axis axis. The clamp / fire axis has a proximal portion configured to be removably coupled to the reload clamp / fire axis.

[0013] In many embodiments of the robotic surgical assembly, the roll axis, pitch axis, and clamp / fire axis are coaxial with the axis centerline. For example, the roll axis can have a roll axis lumen extending along the axis centerline. The pitch axis can be housed in the roll axis lumen and constrained to rotate with the roll axis about the axis centerline. The pitch axis can have a pitch axis lumen extending along the axis centerline. The clamp / fire axis can be housed in the pitch axis lumen and constrained to rotate with the roll axis about the axis centerline.

[0014] In many embodiments of the robotic surgical assembly, the drive assembly includes an output gear constrained to rotate around an axis. For example, the drive assembly may include a roll output gear drivingly coupled to a roll input. The roll output gear may be attached to a roll axis and constrained to rotate around an axis. The drive assembly may include a pitch output gear drivingly coupled to the pitch input and constrained to rotate around the axis. The pitch output gear may be drivingly coupled to the pitch axis through a threaded interface that converts the rotation of the pitch output gear into a translation of the pitch axis along the axis. The drive assembly may include a clamping / firing output gear drivingly coupled to the clamping / firing input and constrained to rotate around the axis. The clamping / firing output gear may be drivingly coupled to the clamping / firing axis through a threaded interface that converts the rotation of the clamping / firing output gear into a translation of the clamping / firing axis along the axis.

[0015] In many embodiments of the robotic surgical assembly, the drive assembly includes an output bearing configured to constrain the output gear to rotate around the axis. For example, the drive assembly may include a shaft bearing having an outer ring engaged with the chassis and an inner ring engaged with the rolling output gear. The shaft bearing may be configured to constrain the rolling output gear to rotate around the axis. The drive assembly may include a rolling output gear bearing having an outer ring engaged with the rolling output gear and an inner ring engaged with the pitch output gear. The rolling output gear bearing may be configured to constrain the pitch output gear to rotate around the axis. The drive assembly may include a pitch output gear bearing having an outer ring engaged with the pitch output gear and an inner ring engaged with the clamping / firing output gear. The pitch output gear roller bearing may be configured to constrain the clamping / firing output gear to rotate around the axis. The drive assembly may include an upper chassis supported by the chassis and a clamping / firing output gear bearing having an inner race engaged with the upper chassis and an outer race engaged with the clamping / firing output gear. The upper chassis may be detachably mounted to the chassis.

[0016] In an embodiment of a robotic surgical assembly including an output gear, the output gear is drivingly coupled to the roll input, the pitch input, and the clamp / fire input. For example, the drive assembly may include: (a) a clamp / fire input shaft rotationally coupled to the clamp / fire input; (b) a clamp / fire input gear rotationally coupled to the clamp / fire input shaft, the clamp / fire input gear having external gear teeth drivingly engaging external gear teeth of the clamp / fire output gear; and (c) clamp / fire input shaft bearings, each clamp / fire input shaft bearing having an outer race engaged with the chassis and an inner race engaged with the clamp / fire input shaft. The drive assembly may include: (a) a pitch input shaft rotationally coupled to the pitch input; (b) a pitch input gear rotationally coupled to the pitch input shaft, the pitch input gear having external gear teeth drivingly engaging external gear teeth of the pitch output gear; and (c) pitch input shaft bearings, each pitch input shaft bearing having an outer race engaged with the chassis and an inner race engaged with the pitch input shaft. The drive assembly may include: (a) a rolling input shaft, which is rotationally coupled to the rolling input; (b) rolling input shaft bearings, each rolling input shaft bearing having an outer ring engaged with the chassis and an inner ring engaged with the rolling input shaft; (c) a rolling input gear, which is rotationally coupled to the rolling input shaft; (d) an idler gear, which has external teeth that are drivenly meshed by the external teeth of the rolling input gear and drivingly meshed with the external teeth of the rolling output gear.

[0017] In another aspect, a robotic surgical method of actuating a stapler reloading assembly is provided. The method includes removably mounting a drive assembly of a robotic surgical assembly to a surgical robot so as to: (a) engage a roll output of the surgical robot with a roll input of the drive assembly; (b) engage a pitch output of the surgical robot with a pitch input of the drive assembly; and (c) engage a clamp / fire output of the surgical robot with a clamp / fire input of the drive assembly. The method also includes removably mounting the stapler reloading assembly to a distal end of a shaft assembly of the robotic surgical assembly so as to: (a) engage a roll axis of the robotic surgical assembly with a roll axis of the stapler reloading assembly; (b) engage a pitch axis of the robotic surgical assembly with a pitch axis of the stapler reloading assembly; and (c) engage a clamp / fire axis of the robotic surgical assembly with a clamp / fire axis of the stapler reloading assembly. A roll axis drive mechanism is actuated by rotating the roll output of the surgical robot to rotate the roll axis of the shaft assembly, the roll axis drive mechanism drivingly coupling the roll axis of the shaft assembly to the roll input of the drive assembly. A pitch axis drive mechanism is actuated by rotating the pitch output of the surgical robot to translate the pitch axis of the shaft assembly relative to the stapler reloading assembly, the pitch axis drive mechanism drivingly coupling the pitch axis of the shaft assembly to the pitch input of the drive assembly. A pitch axis drive mechanism is actuated by rotating the pitch output of the surgical robot to translate the clamping / firing axis of the shaft assembly relative to the stapler reloading assembly, the pitch axis drive mechanism drivingly coupling the clamping / firing axis of the shaft assembly to the pitch input of the drive assembly.

[0018] In many embodiments of a robotic surgical method of actuating a stapler reloading assembly, a rolling shaft of a rotating shaft assembly includes a rolling output gear that is rotationally coupled to a rolling input and attached to the rolling shaft. For example, rotating the rolling output gear may include: (a) rotating a rolling input shaft rotationally coupled to the rolling input, (b) rotating a rolling input gear rotationally coupled to the rolling input shaft, (c) engaging the outer gear teeth of the rolling input gear with the outer gear teeth of a rolling idler gear, and (d) engaging the outer gear teeth of the rolling idler gear with the outer gear teeth of the rolling output gear. Rotating the rolling output gear may include: (a) engaging the outer race of the shaft bearing with the chassis of the drive assembly, (b) engaging the inner race of the shaft bearing with the rolling output gear, and (c) rotating the inner race of the shaft bearing with the rolling output gear.

[0019] In many embodiments of a robotic surgical method of actuating a stapler reload assembly, a pitch axis of a translation axis assembly includes: (a) a pitch output gear rotationally coupled to a pitch input, and (b) generating translation of the pitch axis from rotation of the pitch output gear via a threaded interface between the pitch axis and the pitch output gear. For example, rotating the pitch output gear may include: (a) rotating the pitch input axis rotationally coupled to the pitch input, (b) rotating the pitch input gear rotationally coupled to the pitch input axis, and (c) engaging outer gear teeth of the pitch input gear with outer gear teeth of the pitch output gear. Rotating the pitch output gear may include: (a) engaging an outer race of a rolling output gear bearing with the rolling output gear, (b) engaging an inner race of a rolling output gear bearing with the pitch output gear, (c) rotating the inner race of the rolling output gear bearing with the pitch output gear, and (d) rotating the outer race of the rolling output gear bearing with the rolling output gear.

[0020] In many embodiments of a robotic surgical method of actuating a stapler reload assembly, a clamp / fire shaft of a translating shaft assembly includes: a clamp / fire output gear that is rotationally drivingly coupled to a clamp / fire input, and (b) generating translation of the clamp / fire shaft from rotation of the clamp / fire output gear via a threaded interface between the clamp / fire shaft and the clamp / fire output gear. For example, rotating the clamp / fire output gear may include: (a) rotating a clamp / fire input shaft that is rotationally coupled to the clamp / fire input, (b) rotating a clamp / fire input gear that is rotationally coupled to the clamp / fire input shaft, and (c) engaging external gear teeth of the clamp / fire input gear with external gear teeth of the clamp / fire output gear. Rotating the clamp / fire output gear may include: (a) engaging the outer race of the pitch output gear bearing with the pitch output gear, (b) engaging the inner race of the pitch output gear bearing with the clamp / fire output gear, (c) rotating the inner race of the pitch output gear bearing with the clamp / fire output gear, and (d) rotating the outer race of the pitch output gear bearing with the pitch output gear. Rotating the clamp / fire output gear may include: (a) engaging the outer race of the clamp / fire output gear bearing with the clamp / fire output gear, (b) engaging the inner race of the clamp / fire output gear bearing with an upper chassis of a drive assembly supported by a chassis of the drive assembly, and (c) rotating the outer race of the clamp / fire output gear bearing with the clamp / fire output gear.

[0021] For a more complete understanding of the nature and advantages of the present invention, reference should be made to the following detailed description and accompanying drawings. Other aspects, objects and advantages of the present invention will become apparent from the following drawings and detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1is a plan view of a minimally invasive robotic surgical system for performing a surgical procedure, in accordance with many embodiments.

[0023] Figure 2 is an illustration of a surgeon's console for a robotic surgical system, in accordance with many embodiments.

[0024] Figure 3 is an illustration of a robotic surgical system electronics cart, in accordance with many embodiments.

[0025] Figure 4 A robotic surgical system is schematically illustrated, in accordance with many embodiments.

[0026] Figure 5 is a front view of a patient side cart (surgical robot) of a robotic surgical system, in accordance with many embodiments.

[0027] Figure 6 is an illustration of a robotic surgical tool that includes a removable stapler reloading portion, in accordance with many embodiments.

[0028] Figure 7 is a simplified schematic diagram of a minimally invasive robotic surgical system including a surgical robot, a surgical stapler base assembly mounted to the surgical robot, and a surgical stapler reload mounted to the surgical stapler base assembly, in accordance with many embodiments.

[0029] Figure 8 is a side view of a surgical stapler base assembly mounted to a surgical robot and a surgical stapler reload mounted to the surgical stapler base assembly, in accordance with many embodiments.

[0030] Fig. 9 According to many embodiments Figure 8 A side view of a surgical stapler base assembly and a surgical stapler reload is shown separated from the surgical stapler base assembly.

[0031] Fig.10 According to many embodiments Figure 8 A simplified schematic side view of a distal end of a surgical stapler base assembly and a proximal end of a surgical stapler reload, showing the surgical stapler reload separated from the surgical stapler base assembly.

[0032] Fig.11 and Fig.12 Shown according to many embodiments Figure 8 Components of a drive assembly of a surgical stapler base assembly.

[0033] Fig.13A and Fig. 13B Shown according to many embodiments Figure 8 A component in a drive assembly of a surgical stapler base assembly for producing translation of a clamping / firing axis.

[0034] Fig.14A and Fig. 14B Shown according to many embodiments Figure 8 A component in a drive assembly of a surgical stapler base assembly for producing translation of a pitch axis.

[0035] Fig.15A , Fig. 15B and Fig.16 Shown according to many embodiments Figure 8 A component in a drive assembly of a surgical stapler base assembly for generating rotation of a rolling shaft.

[0036] Fig.17 According to many embodiments, Figure 8 A cross-sectional view of an output gear assembly of a surgical stapler base. DETAILED DESCRIPTION

[0037] In the following description, various embodiments of the present invention will be described. For the purpose of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will be apparent to those skilled in the art that the present invention may be practiced without the specific details. In addition, well-known features may be omitted or simplified to avoid obscuring the described embodiments.

[0038] Minimally invasive robotic surgery

[0039] Referring now to the drawings, in which like reference numerals refer to like parts throughout the several views, Figure 11 is a plan view of a minimally invasive robotic surgery (MIRS) system 10, which is generally used to perform minimally invasive diagnostic or surgical procedures on a patient 12 lying on an operating table 14. The system may include a surgeon's console 16 for use by the surgeon 18 during the procedure. One or more assistants 20 may also participate in the procedure. The MIRS system 10 may also include a patient-side cart 22 (surgical robot) and an electronics cart 24. The patient-side cart 22 may manipulate at least one detachably coupled tool assembly 26 (hereinafter referred to as "tool") through a minimally invasive incision in the body of the patient 12 while the surgeon 18 views the surgical site through the console 16. An image of the surgical site may be obtained through an endoscope 28 (e.g., a stereo endoscope), which may be manipulated by the patient-side cart 22 to orient the endoscope 28. The electronics cart 24 may be used to process the image of the surgical site for subsequent display to the surgeon 18 through the surgeon's console 16. The number of surgical tools 26 used at one time generally depends on the diagnostic or surgical procedure and the space limitations in the operating room, as well as other factors. If it is necessary to change one or more of the tools 26 being used during a procedure, the assistant 20 can remove the tool 26 from the patient side cart 22 and replace it with another tool 26 from the tray 30 in the operating room.

[0040] Figure 2 1 is a perspective view of the surgeon's console 16. The surgeon's console 16 includes a left-eye display 32 and a right-eye display 34 for presenting the surgeon 18 with a coordinated stereoscopic view of the surgical site and enabling depth perception. The console 16 also includes one or more input controls 36, which in turn enable the patient side cart 22 ( Figure 1 The input control device 36 can provide the tool 26 (as shown in FIG. Figure 1 26) to provide the surgeon with telepresence, or the perception that the input control device 36 is integral with the tool 26, so that the surgeon has a strong sense of directly controlling the tool 26. To this end, position, force, and tactile feedback sensors (not shown) may be employed to transmit position, force, and tactile sensations from the tool 26 back to the surgeon's hand via the input control device 36.

[0041] The surgeon's console 16 is typically located in the same room as the patient so that the surgeon can directly monitor the procedure, be physically present if necessary, and speak directly to an assistant rather than over the phone or other communication medium. However, the surgeon may be located in a different room, an entirely different building, or other remote location of the patient that allows for a telesurgical procedure.

[0042] Figure 3is a perspective view of the electronics cart 24. The electronics cart 24 can be coupled to the endoscope 28 and can include a processor to process the captured images for subsequent display, such as on the surgeon's console or on another suitable display located locally and / or remotely to the surgeon. For example, where a stereoscopic endoscope is used, the electronics cart 24 can process the captured images to present the surgeon with a coordinated stereoscopic image of the surgical site. Such coordination can include alignment between opposing images and can include adjusting a stereoscopic working distance of the stereoscopic endoscope. As another example, the image processing can include using previously determined camera calibration parameters to compensate for imaging errors of the image capture device, such as optical aberrations.

[0043] Figure 4 The robotic surgical system 10 is schematically shown. As described above, the surgeon's console 16 can be used by the surgeon to control the patient side cart 22 (surgical robot) during minimally invasive procedures. The patient side cart 22 can use an imaging device such as a stereo endoscope to capture images of the procedure site and output the captured images to the electronics cart 24. As described above, the electronics cart 24 can process the captured images in various ways before any subsequent display. For example, the electronics cart 24 can overlay the captured images with a virtual control interface before displaying the combined images to the surgeon through the surgeon's console 16. The patient side cart 22 can output the captured images for processing outside the electronics cart 24. For example, the patient side cart 22 can output the captured images to the processor 38, which can be used to process the captured images. The images can also be processed by a combination of the electronics cart 24 and the processor 38, which can be coupled together to process the captured images jointly, sequentially, and / or a combination thereof. One or more separate displays 40 may also be coupled to the processor 38 and / or the electronics cart 24 for local and / or remote display of images (eg, images of the procedure site, or other relevant images).

[0044] Figure 5 and Figure 6 The patient side cart 22 and the surgical tool 100 are shown separately. The surgical tool 100 is an example of a surgical tool 26. The patient side cart 22 shown provides manipulation of three surgical tools 26 and an imaging device 28 (e.g., a stereo endoscope for capturing images of the procedure site). Manipulation is provided by a robotic mechanism having a plurality of robotic joints. The imaging device 28 and the surgical tool 26 can be positioned and manipulated through the incision of the patient so that the remote center of motion is maintained at the incision to minimize the size of the incision. The image of the surgical site can include an image of the distal end of the surgical tool 26 when the surgical tool 26 is positioned within the field of view of the imaging device 28.

[0045] Robotic surgical tool configured to be reloaded using a handheld stapler

[0046] The surgical tool 100 includes a robotic surgical assembly 102 and a replaceable stapler reload 200 that is removably coupled to the surgical assembly 102. In many embodiments, the stapler reload 200 is configured for use with an existing handheld surgical stapler.

[0047] The robotic surgical assembly 102 is configured to be removably mounted to a surgical robot (e.g., the patient side cart 22) for clamping, stapling, and cutting tissue using a stapler reload 200. The surgical assembly 102 is configured to be mounted to an instrument holder of the patient side cart 22. The surgical assembly 102 includes a proximal drive assembly 104 and a shaft assembly 106 mounted to the drive assembly 104 and extending distally from the drive assembly 104 along an axis 108. The drive assembly includes: a chassis 110, a rolling input member 112, a pitch input member 114, and a clamping / launching input member 116, wherein the rolling input member 112 is mounted on the chassis 110 and can be rotated relative to the chassis 110 through a corresponding rolling output member of the patient-side cart 22, the pitch input member 114 is mounted on the chassis 110 and can be rotated relative to the chassis 110 through a corresponding pitch output member of the patient-side cart 22, and the clamping / launching input member 116 is mounted on the chassis 110 and can be rotated relative to the chassis 110 through a corresponding clamping / launching output member of the patient-side cart 22.

[0048] The stapler reload 200 is a disposable, replaceable assembly that is removably mounted to the shaft assembly 106. The stapler reload 200 includes a proximal shaft assembly 202 and a stapler end effector 204. The proximal shaft assembly 202 is removably mounted to the distal end of the shaft assembly 106. The end effector 204 is pivotally attached to the distal end of the proximal shaft assembly 202. The end effector 204 includes an upper jaw 206 and a stapler barrel assembly 208. The stapler barrel assembly 208 is pivotally mounted relative to the upper jaw 206 and can be actuated from an open position to a closed position to clamp tissue between the stapler barrel assembly 208 and the upper jaw 206. The stapler barrel assembly 208 includes an actuation input that can be translated distally to close the stapler barrel 208, thereby clamping the tissue between the stapler barrel 208 and the upper jaw 206 to deploy the stapler from the stapler barrel assembly 208 and cut the stapled tissue. The deployed stapler passes through the tissue clamped between the stapler barrel 208 and the upper jaw 206 and contacts the anvil surface of the upper jaw 206, which forms the end of the stapler, to hold the stapler in the stapled tissue.

[0049] Figure 7 is a simplified schematic diagram of components of an embodiment of a minimally invasive robotic surgery (MIRS) system 10. The illustrated components of the robotic surgical system 10 include a surgical robot 22, a surgical stapler base assembly 102 mounted to the surgical robot 22, a surgical stapler reload 200 mounted to the surgical stapler base assembly 102, an electronics cart 24, and a surgical console 16.

[0050] The surgical robot 22 includes a motor unit and an instrument holder 42 to which a surgical stapler base assembly 102 is removably mounted. The motor unit and instrument holder 42 are operable to controllably actuate the surgical stapler base assembly 102, thereby controllably actuating the surgical stapler reload 200. The motor unit and instrument holder 42 include a roll motor 44, a roll output 46 drivingly coupled to the roll motor 44, a pitch motor 48, a pitch output 50 drivingly coupled to the pitch motor 48, a clamp / fire motor 52, and a clamp / fire output 54 drivingly coupled to the clamp / fire motor 52. The roll motor 44 can be controllably operated to controllably rotate the roll output 46 relative to the motor unit and instrument holder 42. Similarly, pitch motor 48 may be controllably operated to controllably rotate pitch output 50 relative to the motor unit and instrument holder 42 , and clamp / fire motor 52 may be controllably operated to controllably rotate clamp / fire output 54 relative to the motor unit and instrument holder 42 .

[0051] The surgical stapler base assembly 102 is configured to actuate a surgical stapler reload 200 in response to actuation of the surgical stapler base assembly 102 via the motor unit and the instrument holder 42. The base assembly 102 includes a roll input 112, a roll drive assembly 118, a base roll axis 120, a pitch input 114, a pitch drive assembly 122, a base pitch axis 124, a clamp / fire input 116, a clamp / fire drive assembly 126, and a base clamp / fire axis 128. When the mount assembly 102 is mounted to the motor unit and instrument holder 42, the roll input 112 is drivingly coupled to the roll output 46 such that rotation of the roll output 46 produces a matching rotation of the roll input 112, the pitch input 114 is drivingly coupled to the pitch output 50 such that rotation of the pitch output 50 produces a matching rotation of the pitch input 114, and the clamp / fire input 116 is drivingly coupled to the clamp / fire output 54 such that rotation of the clamp / fire output 54 produces a matching rotation of the clamp / fire input 116. The base roll axis 120 is drivingly coupled to the roll input 112 via the roll drive assembly 118 such that rotation of the roll input 112 produces a corresponding rotation of the base roll axis 120 about the shaft centerline 108. The base pitch axis 124 is drivingly coupled to the pitch input 114 via the pitch drive assembly 122 such that rotation of the pitch input 114 produces a corresponding translation of the base pitch axis 124 along the shaft centerline 108. The base clamp / fire axis 128 is drivingly coupled to the clamp / fire input 116 via the clamp / fire drive assembly 126 such that rotation of the clamp / fire input 116 produces corresponding translation of the base clamp / fire axis 128 along the axis axis 108 .

[0052] The surgical stapler reload 200 includes a reload roll axis 210, a reload pitch axis 212, a reload pitch drive assembly 214, a reload clamp / fire axis 216, a reload clamp / fire drive assembly 218, and a stapler end effector 204. When the stapler reload 200 is mounted to the base assembly 102, the reload roll axis 210 is coupled to the base roll axis 120 so that the reload roll axis 210 rotates around the axis centerline 108 along with the base roll axis 120, the reload pitch axis 212 is coupled to the base pitch axis 124 so that the reload pitch axis 212 translates along the axis centerline 108 along with the base pitch axis 124, and the reload clamp / fire axis 216 is coupled to the base clamp / fire axis 128 so that the reload clamp / fire axis 216 translates along the axis centerline 108 along with the base clamp / fire axis 128. The stapler end effector 204 may be pivotally mounted to a reloading roller axis 210. The stapler end effector 204 is drivingly coupled to the reloading pitch axis 212 via a reloading pitch drive assembly 214 such that translation of the reloading pitch axis 212 along the axis centerline 108 reorients the stapler end effector 204 relative to the reloading roller axis 210. The stapler end effector 204 is also drivingly coupled to the reloading clamping / firing axis 216 via a reloading clamping / firing assembly 218 such that translation of the reloading clamping / firing axis 216 along the axis centerline 108 may be used to actuate the stapler barrel assembly 208 to clamp tissue between the stapler barrel assembly 208 and the upper jaw 206 to deploy a stapler from the stapler barrel assembly 208 and cut the stapled tissue.

[0053] Figure 8 A side view of the surgical tool 100 is shown with the drive assembly 104 mounted to the motor unit and instrument holder 42. In the illustrated configuration, the motor unit and instrument holder 42 are operable to controllably rotate the roll output 46, the pitch output 50, and the clamp / fire output 54 to controllably actuate the surgical base assembly 102 to controllably articulate / actuate the stapler reload 200.

[0054] Fig. 9 2 is a side view of the surgical stapler base assembly 102 and the surgical stapler reload 200, which shows the surgical stapler reload 200 separated from the surgical stapler base assembly 102. Fig.10 Discussed in greater detail, the base assembly 102 includes a distal portion 130 that is configured to receive and drivingly couple with a proximal portion 220 of the stapler reload 200 .

[0055] Fig.10is a simplified schematic side view of the distal portion 130 of the surgical stapler base assembly 102 and the proximal portion 220 of the stapler reload 200. The distal portion 130 of the base assembly 102 includes the distal portion 132 of the base roll axis 120, the distal portion 134 of the base pitch axis 124, and the distal portion 136 of the base clamp / fire axis 128. The proximal portion 220 of the stapler reload 200 includes the proximal portion 222 of the reload roll axis 210, the proximal portion 224 of the reload pitch axis 212, and the proximal portion 226 of the reload clamp / fire axis 216. In the illustrated embodiment, the proximal portion 132 of the base roll axis 120 includes a protruding feature 138 that is configured to be inserted into a slot 228 in the reload roll axis 210 to rotationally couple the reload roll axis 210 to the base roll axis 120. In many embodiments, the retention mechanism prevents accidental separation of the stapler reload 200 from the base assembly 102. In the illustrated embodiment, the distal portion 134 of the base pitch shaft 124 includes a spring-loaded coupling feature 140 that is configured to be received in and engage a shaped slot 230 in the proximal portion 224 of the reload pitch shaft 212 to constrain the reload pitch shaft 212 to translate along the axis line 108 with the base pitch shaft 124. In a similar manner, in the illustrated embodiment, the distal portion 136 of the base clamp / fire shaft 128 includes a coupling feature 142 that is configured to engage a coupling feature 232 of the reload clamp / fire shaft 216 to constrain the reload clamp / fire shaft 216 to translate along the axis line 108 with the base clamp / fire shaft 128.

[0056] Fig.11 and Fig.12Components of a drive assembly 100 are shown for drivingly coupling a base roll axis 120 with a roll input 112, drivingly coupling a base pitch axis 124 with a pitch input 114, and drivingly coupling a base clamp / fire axis 128 with a clamp / fire input 116. Drive assembly 104 includes chassis 110, roll output gear 144, pitch output gear 146, clamp / fire output gear 148, roll input axis 150, roll input gear 152, roll idler gear 154, pitch input axis 156, pitch input gear 158, clamp / fire input axis 160, and clamp / fire input gear 162. As described in more detail herein, roll output gear 144, pitch output gear 146, and clamp / fire output gear 148 are coaxially mounted for rotation about axis centerline 108. The roll output gear 144 is rotationally coupled to the base roll axis 120 so that the base roll axis 120 is rotated by rotating the roll output gear 144. The base pitch axis 124 is threadedly engaged with the pitch output gear 146 so that the base pitch axis 124 is translated along the axis centerline 108 by rotation of the pitch output gear 146. The base clamp / fire axis 128 is threadedly engaged with the clamp / fire output gear 148 so that the base clamp / fire axis 128 is translated along the axis centerline 108 by rotation of the clamp / fire output gear 148. The roll input gear 152 is mounted to and rotationally coupled to the roll input axis 150, which is rotationally coupled to the roll input 112. The roll input gear 152 includes external gear teeth that mesh with external gear teeth of a roll idler gear 154 to rotate the roll idler gear 154 in response to rotation of the roll input 112. The external teeth of the roll idler gear 154 mesh with the external gear teeth of the roll output gear 144 to rotate the roll output gear 144 in response to the rotation of the roll idler gear 154. The pitch input gear 154 is mounted to and rotationally coupled to the pitch input shaft 156, which is rotationally coupled to the pitch input 114. The pitch input gear 158 includes external gear teeth that mesh with the external gear teeth of the pitch output gear 146 to rotate the pitch output gear 146 in response to the rotation of the pitch input gear 158. The clamp / launch input gear 162 is mounted to and rotationally coupled to the clamp / launch input shaft 160, which is rotationally coupled to the clamp / launch input 116. The clamp / fire input gear 162 includes external gear teeth that mesh with the external gear teeth of the clamp / fire output gear 148 to rotate the clamp / fire output gear 148 in response to rotation of the clamp / fire input gear 162 .

[0057] Fig.13A and Fig. 13BComponents of the drive assembly 104 of the surgical stapler base assembly 102 for producing translation of the base clamp / fire shaft 128 are shown. In the illustrated embodiment, the clamp / fire input 116 and the clamp / fire input shaft 160 form an integral component. Fig.13A , the clamp / fire input 116, the clamp / fire input shaft 160, the clamp / fire input gear 162, the clamp / fire output gear 148, and the base clamp / fire shaft 128 are shown in isolation to better illustrate how the base clamp / fire shaft 128 is translated along the shaft axis 108 by the rotation of the clamp / fire input 116. Specifically, the rotation of the clamp / fire input 116 relative to the chassis 110 causes the clamp / fire input shaft 160 to rotate relative to the chassis 110, the rotation of the clamp / fire input shaft 160 causes the clamp / fire input gear 162 to rotate relative to the chassis 110, and the rotation of the clamp / fire input gear 162 causes the clamp / fire output gear 148 to rotate relative to the chassis 110. In many embodiments, the base clamp / fire shaft 128 is constrained to rotate with the base rolling shaft 120, so that rotation of the clamp / fire output gear 148 produces rotation of the clamp / fire output gear 148 relative to the base clamp / fire shaft 128 without matching rotation of the base rolling shaft 120 and the clamp / fire output gear 148. The clamp / fire output gear 148 and the base clamp / fire shaft 128 are engaged by the clamp / fire threaded interface 164. Rotation of the clamp / fire output gear 148 relative to the base clamp / fire shaft 128 produces translation of the base clamp / fire shaft 128 along the axis 108 through the clamp / fire threaded interface 164.

[0058] Fig.14A and Fig. 14B Components of the drive assembly 104 of the surgical stapler base assembly 102 for producing translation of the base pitch axis 124 are shown. Fig.13A1, the pitch input 114, the pitch input shaft 156, the pitch input gear 158, the pitch output gear 146, and the base pitch shaft 124 are shown in isolation to better illustrate how the rotation of the pitch input 114 produces a translation of the base pitch shaft 124 along the axis line 108. Specifically, the rotation of the pitch input 114 relative to the chassis 110 rotates the pitch input shaft 156 relative to the chassis 110, the rotation of the pitch input shaft 156 rotates the pitch input gear 158 relative to the chassis 110, and the rotation of the pitch input gear 158 rotates the pitch output gear 146 relative to the chassis 110. In many embodiments, the base pitch shaft 124 is constrained to rotate with the base roll shaft 120, so that the rotation of the pitch output gear 146 produces a rotation of the pitch output gear 146 relative to the base pitch shaft 124 without a matching rotation of the base roll shaft 120 and the pitch output gear 146. The pitch output gear 146 and the base pitch axis 124 are coupled via a pitch threaded interface 166 . The rotation of the pitch output gear 146 relative to the base pitch axis 124 generates a translation of the base pitch axis 124 along the axis centerline 108 via the pitch threaded interface 166 .

[0059] Fig.15A , Fig. 15B and Fig.16 Components of the drive assembly 104 of the surgical stapler base assembly 102 for producing rotation of the base rolling axis 120 are shown. Fig.15A In the figure, the rolling input 112, the rolling input shaft 150, the rolling input gear 152, the rolling idler gear 154, the rolling output gear 144 and the base rolling shaft 120 are shown in isolation to better illustrate how the rotation of the base rolling shaft 120 around the axis line 108 is generated by the rotation of the rolling input 112. Specifically, the rotation of the rolling input 112 relative to the chassis 110 causes the rolling input shaft 150 to rotate relative to the chassis 110, the rotation of the rolling input shaft 150 causes the rolling input gear 152 to rotate relative to the chassis 110, the rotation of the rolling input gear 152 causes the rolling idler gear 154 to rotate relative to the chassis 110, the rotation of the rolling idler gear 154 causes the rolling output gear 144 to rotate relative to the chassis 110, and the rotation of the rolling output gear 144 causes the base rolling shaft 120 to rotate relative to the chassis 110.

[0060] Fig.171 is a cross-sectional view through the output gears 144, 146, 148 illustrating roller bearings used to mount the output gears 144, 146, 148 to the chassis 110 and constrain the rotation of the output gears 144, 146, 148 to rotation about the shaft centerline 108. The roller bearings used to mount the output gears 144, 146, 148 include a shaft bearing 168, a rolling output gear bearing 170, a pitch output gear bearing 172, and a clamp / launch output gear bearing 174. The shaft bearing 168 is mounted to the chassis 110 such that the outer race of the shaft bearing 168 engages the chassis 110. The rolling output gear 144 is mounted to the shaft bearing 168 such that the inner race of the shaft bearing 168 engages the rolling output gear 144. The rolling output gear bearing 170 is mounted in a groove of the rolling output gear 144 such that the outer race of the rolling output gear bearing 170 engages the rolling output gear 144. The pitch output gear 146 is mounted to the rolling output gear bearing 170 so that the inner race of the rolling output gear bearing 170 engages with the pitch output gear 146. The pitch output gear bearing 172 is mounted in the groove of the pitch output gear 146 so that the outer race of the pitch output gear bearing 172 engages with the pitch output gear 146. The clamp / launch output gear 148 is mounted to the pitch output gear bearing 172 so that the inner race of the pitch output gear bearing 172 engages with the clamp / launch output gear 148. The clamp / launch output gear bearing 174 is mounted in the groove of the clamp / launch output gear 148 so that the outer race of the clamp / launch output gear bearing 174 engages with the clamp / launch output gear 148. Although Fig.17 Not shown, but the inner race of the clamp / launch gear bearing 174 engages an upper chassis that is coupled to chassis 110 and provides additional support for output gears 144, 146, 148.

[0061] Other variations are within the spirit of the invention. Therefore, while the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described in detail above. However, it should be understood that there is no intention to limit the invention to the particular form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents that fall within the spirit and scope of the invention, as defined in the appended claims.

[0062] The term "force" should be interpreted as including force and torque (especially in the context of the appended claims), unless otherwise specified herein or clearly contradictory to the context. The use of the terms "one" and "an" and "the / said" and similar indicators in the context of describing the present invention (especially in the context of the appended claims) should be interpreted as covering the singular and plural, unless otherwise specified herein or clearly contradictory to the context. Unless otherwise specified, the terms "comprising", "having", "including" and "containing" should be interpreted as open terms (that is, meaning "including but not limited to"). The term "connection" should be interpreted as being partially or entirely included, attached or combined together, even if there is some intervention. Unless otherwise specified herein, the description of the numerical range herein is intended only to be used as a shorthand method for individually referring to each individual value falling within the range, and each individual value is incorporated into this specification as if it is quoted separately in this article. Unless otherwise specified herein or the context is clearly contradictory, all methods described herein can be performed in any suitable order. Unless otherwise stated, the use of any and all examples or exemplary language (e.g., "such as / for example") provided herein is intended only to better illustrate embodiments of the present invention and does not limit the scope of the present invention. No language in the specification should be construed as indicating that any non-claimed element is essential to the practice of the present invention.

[0063] Preferred embodiments of the present invention are described herein, including the best mode of implementing the present invention known to the inventor. After reading the foregoing description, changes in those preferred embodiments may become apparent to those of ordinary skill in the art. The inventor expects that the technician will appropriately adopt these changes, and the inventor hopes that the present invention will be practiced in a manner different from that specifically described herein. Therefore, the present invention includes all modifications and equivalents of the subject matter recorded in the appended claims as allowed by applicable law. In addition, unless otherwise specified herein or the context is clearly contradictory, the present invention encompasses any combination of all possible variations of the above-mentioned elements.

[0064] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

Claims

1. A surgical system, comprising: A drive assembly, which is removably mounted to the manipulator, the drive assembly comprising: Chassis; a roll input rotatably coupled to the chassis and configured to drivingly couple with a roll output of the manipulator; a pitch input rotatably coupled to the chassis and configured to drivingly couple with the pitch output of the manipulator; and a clamp / fire input rotatably coupled to the chassis and configured to drivingly couple with a clamp / fire output of the manipulator; and A shaft assembly extending along an axial centerline and coupled to the drive assembly, the shaft assembly comprising: Roll axis; a rolling output gear attached to the rolling shaft and constrained to rotate about the shaft centerline, the rolling output gear drivingly coupled to the rolling input such that rotation of the rolling input rotates the rolling shaft about the shaft centerline; Pitch axis; a pitch output gear drivingly coupled to the pitch axis via a first threaded interface, the first threaded interface being configured to convert a rotation of the pitch output gear into a translation of the pitch axis along the axis centerline, the pitch output gear being constrained to rotate about the axis centerline and drivingly coupled to the pitch input such that a rotation of the pitch input translates the pitch axis along the axis centerline; clamping / firing axis; and a clamp / fire output gear drivingly coupled to the clamp / fire shaft via a threaded interface, the threaded interface being configured to convert rotation of the clamp / fire output gear into translation of the clamp / fire shaft along the shaft axis, the clamp / fire output gear being constrained to rotate about the shaft axis and drivingly coupled to the clamp / fire input such that rotation of the clamp / fire input translates the clamp / fire shaft along the shaft axis; Wherein the pitch axis and the clamping / launching axis are concentric around the axis centerline.

2. The system of claim 1, wherein the clamp / launch axis is housed within the pitch axis.

3. The system of claim 1, wherein the drive assembly further comprises: a clamp / fire input shaft rotationally coupled to the clamp / fire input; as well as A clamp / fire input gear is rotationally coupled to the clamp / fire input shaft, the clamp / fire input gear having external gear teeth drivingly engaging the external gear teeth of the clamp / fire output gear.

4. The system of claim 1, wherein the drive assembly further comprises: a pitch input shaft rotationally coupled to the pitch input; as well as A pitch input gear is rotationally coupled to the pitch input shaft, the pitch input gear having external gear teeth drivingly engaging the external gear teeth of the pitch output gear.

5. The system of claim 1, wherein: The roll axis is concentric with the pitch axis and the clamp / launch axis about the axis centerline.

6. The system of claim 5, wherein the pitch axis is contained within the roll axis.

7. The system of claim 5, wherein the pitch axis and the clamp / launch axis are constrained to rotate with rotation of the roll axis.

8. The system of claim 5, wherein the drive assembly further comprises: a roll input shaft rotationally coupled to the roll input; a rolling input gear rotationally coupled to the rolling input shaft; as well as An idler gear has external teeth that are drivingly engaged by the external teeth of the rolling input gear, and the external teeth of the idler gear drivingly engage the external teeth of the rolling output gear.

9. A method of engaging a stapler reloading assembly with a drive assembly and engaging the drive assembly with a manipulator of a surgical system according to any one of claims 1-8, the method comprising: The drive assembly is removably mounted to the manipulator by: engaging a roll output of the manipulator with a roll input of a roll shaft coupled to the drive assembly, engaging a pitch output of the manipulator with a pitch input coupled to a pitch axis of the drive assembly; and engaging a clamp / fire output of the manipulator with a clamp / fire input coupled to a clamp / fire shaft of the drive assembly; as well as The stapler reloading assembly is removably mounted to the distal end of the shaft assembly of the drive assembly by: engaging a rolling shaft of the stapler reloading assembly with a distal end of the shaft assembly of the drive assembly; engaging a pitch axis coupling feature of the pitch axis of the drive assembly with a pitch axis of the stapler reload assembly, and Engaging the clamp / fire shaft coupling feature of the clamp / fire shaft of the drive assembly with the clamp / fire shaft of the stapler reloading assembly.

10. The method of claim 9, wherein engaging a pitch axis coupling feature with the pitch axis of the drive assembly comprises engaging a spring loaded pitch axis coupling feature with the pitch axis of the drive assembly.

11. The method of claim 10, wherein engaging a spring loaded pitch axis coupling feature with the pitch axis of the drive assembly comprises engaging the spring loaded pitch axis coupling feature with a slot in the pitch axis of the drive assembly.

12. The method of claim 9, wherein engaging the pitch axis coupling feature with the pitch axis of the drive assembly further comprises inserting at least a portion of the pitch axis of the drive assembly into a recess in a portion of the pitch axis of the reload assembly.

13. The method of claim 9, wherein engaging a clamp / fire shaft coupling feature with the clamp / fire shaft of the drive assembly comprises engaging a spring loaded coupling feature of the clamp / fire shaft coupling feature.

14. The method of claim 13, wherein engaging a spring loaded clamp / fire shaft coupling feature with the clamp / fire shaft of the drive assembly comprises engaging the spring loaded clamp / fire shaft coupling feature with a slot in the clamp / fire shaft of the drive assembly.

15. The method of claim 9 wherein engaging the clamp / fire shaft coupling feature with the clamp / fire shaft of the drive assembly further comprises inserting at least a portion of the clamp / fire shaft of the drive assembly into a recess in a portion of the clamp / fire shaft of the reloading assembly.

16. The method of claim 9, wherein removably mounting the stapler reloading assembly to the distal end of the shaft assembly of the drive assembly comprises aligning a longitudinal axis of the shaft assembly with a longitudinal axis of the stapler reloading assembly.

17. The method of claim 16, wherein removably mounting the stapler reloading assembly to the distal end of the shaft assembly of the drive assembly comprises moving the stapler reloading assembly and the shaft assembly toward each other along the longitudinal axis of the shaft assembly and the longitudinal axis of the stapler reloading assembly.

18. The method of claim 9, wherein removably mounting a stapler reload assembly to a drive assembly comprises engaging a feature of the roller shaft of the stapler reload assembly with the roller shaft of the drive assembly.

19. The method of claim 18, wherein engaging the feature of the rolling shaft of the stapler reloading assembly comprises engaging a protrusion of the rolling shaft of the drive assembly with a groove of the rolling shaft of the stapler reloading assembly.

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