Including joint movement with counter-control for joint motion and calibration

Abstract

This invention provides a surgical tool comprising a drive housing, a shaft extending from the drive housing, an end effector located at the end of the shaft and having opposing jaws and cutting elements, and a wrist configured to rotate the end effector in a plane and capable of articulation. The wrist articulates via opposing translations of a pair of drive members. This invention provides various systems for locating one or more drive inputs that cause movement in the wrist and / or the end effector, or for controlling the articulation of the drive inputs.

Description

Background Technology

[0001] Minimally invasive surgical (MIS) instruments are generally superior to traditional open surgical devices due to reduced postoperative recovery time and minimized scarring. The most common MIS procedures can be endoscopic, and the most common form of endoscopic surgery is laparoscopic surgery, in which one or more small incisions are made in the patient's abdomen, and a cannula is inserted through these incisions to create access to the abdominal cavity. The cannula is used to introduce various instruments and tools into the abdominal cavity and provides air insufflation to elevate the abdominal wall above organs. Instruments can be used to engage and / or manipulate tissue in a variety of ways to achieve diagnostic or therapeutic effects.

[0002] Each surgical instrument typically includes an end effector positioned at its distal end. Exemplary end effectors include clamps, grippers, scissors, suture devices, and needle holders, and are similar to those used in routine (open) surgery, except that the end effector of each instrument is separated from its shank by an approximately 12-inch-long shaft. A camera or image-capturing device, such as an endoscope, is also typically introduced into the abdominal cavity to allow the surgeon to observe the surgical field and the operation of the end effector during the procedure. The surgeon can observe the surgery in real time via a visual monitor that communicates with the image-capturing device.

[0003] A surgical stapler is a type of end-effector capable of cutting and simultaneously suturing (fastening) transversely cut tissue. Also alternatively referred to as a "linear cutter," a surgical stapler includes opposing jaws capable of opening and closing to grasp and release tissue. Once the tissue is grasped or clamped between the opposing jaws, the end-effector can be "fired" to advance a cutting element or blade distally to transversely cut the grasped tissue. As the cutting element advances, staples housed within the end-effector are progressively deployed to seal the opposite sides of the transversely cut tissue.

[0004] Surgical instruments include articulated wrists configured to allow end effectors to enter at an angle to a desired orientation. Therefore, there is a need for an articulated wrist with a connector providing high degrees of freedom. A system is also needed to power the articulated wrist, enabling it to move smoothly through tissue, providing external loads on the wrist and maintaining its articulated position under such loads. Furthermore, a system is needed to reposition the surgical drive inputs, repositioning the articulated wrist to a non-articular orientation when the surgical instrument is mounted in the robotic manipulator, allowing it to be inserted into the abdominal cavity via a cannula. Attached Figure Description

[0005] The following figures are included to illustrate certain aspects of this disclosure and should not be considered as exclusive embodiments. The subject matter disclosed herein is capable of numerous modifications, alterations, combinations, and equivalents in form and function without departing from the scope of this disclosure.

[0006] Figure 1 This is a block diagram of an exemplary robotic surgical system that can incorporate some or all of the principles of this disclosure.

[0007] Figure 2 yes Figure 1 An exemplary implementation of one of the main consoles in the main console.

[0008] Figure 3 It is based on one or more implementation schemes. Figure 1 An example of a robot manipulator.

[0009] Figure 4 It is an isometric side view of an exemplary surgical tool that can incorporate some or all of the principles of this disclosure.

[0010] Figure 5 It shows that Figure 4 The wrist has the potential degrees of freedom for joint movement (pivot).

[0011] Figure 6 It is based on one or more implementation schemes. Figure 4 Bottom view of the drive housing.

[0012] Figure 7A and Figure 7B It is based on one or more implementation schemes. Figure 4 An isometric view of the exposed interior of the drive housing.

[0013] Figure 8A and Figure 8B It is a description Figures 7A to 7B An exposed isometric view of an exemplary gear train within a surgical instrument.

[0014] Figure 9A and Figure 9B yes Figure 4 Exposed bottom view of surgical instruments.

[0015] Figure 10A The present disclosure illustrates one or more embodiments that can be used... Figure 9A and Figure 9B An example of a surgical tool is a wrist capable of joint movement.

[0016] Figure 10B It is based on one or more embodiments of this disclosure. Figure 10A An exploded view of the wrist, which is capable of joint movement.

[0017] Figures 11A to 11C Programmable to various embodiments according to this disclosure are shown. Figure 6 In computer systems to control Figure 6 Various exemplary algorithms for the operation of the driver.

[0018] Figure 12 A set of graphs is shown to illustrate exemplary operation of an exemplary relocation system according to one or more embodiments of this disclosure.

[0019] Figure 13 It shows Figures 10A to 10B An exposed view of an exemplary connector at the wrist.

[0020] Figure 14 It is a control according to one or more embodiments of this disclosure Figure 13 A schematic diagram of an exemplary method for joint movement of a connector.

[0021] Figure 15A and Figure 15B yes Figure 13 The top exposed view of the wrist shows Figure 14 An example operation of the method.

[0022] Figure 16 It is a control according to one or more embodiments of this disclosure Figure 13 A schematic diagram of another exemplary method for the joint movement of the connector.

[0023] Figure 17A and Figure 17B This is a graph illustrating exemplary differential control for actuating a wrist according to one or more embodiments of the present disclosure.

[0024] Figure 18 Force-to-distance curves of an exemplary closed system according to one or more embodiments of the present disclosure are shown. Detailed Implementation

[0025] This disclosure relates to robotic surgery, and more specifically, to a wrist or joint capable of articulation, a system for repositioning the articulated wrist, and a system for ensuring accurate positioning of the wrist, the articulated wrist being used to position the end effector of a surgical tool to a desired position for moving the wrist joint to a desired position when subjected to an external load, and to maintain said position when subjected to a load.

[0026] Figures 1 to 3The structure and operation of an exemplary robotic surgical system and its associated components are illustrated. While applicable to robotic surgical systems, it should be noted that the principles of this disclosure may be applied equivalently or alternatively to non-robotic surgical systems without departing from the scope of this disclosure.

[0027] Figure 1 This is a block diagram of an exemplary robotic surgical system 100 that can incorporate some or all of the principles of this disclosure. As shown, system 100 may include at least one main console 102a and at least one robotic manipulator 104. The robotic manipulator 104 may be mechanically and / or electrically coupled to one or more robotic arms 106 or otherwise include one or more robotic arms. In some embodiments, the robotic manipulator 104 may be mounted to a transport vehicle (alternatively referred to as an "arm vehicle") that enables the robotic manipulator 104 and the associated robotic arms 106 to move. Each robotic arm 106 may include and otherwise provide tool actuators on which one or more surgical instruments or tools 108 may be mounted to perform various surgical tasks on a patient 110. The operation of the robotic arms 106, the corresponding tool actuators, and the associated tools 108 may be guided by a clinician 112a (e.g., a surgeon) from the main console 102a.

[0028] In some embodiments, a second master console 102b (shown in dashed lines), operated by a second clinician 112b, may also assist in guiding the operation of the robotic arm 106 and the tool 108, in conjunction with the first clinician 112a. In such embodiments, for example, each clinician 112a, 112b may control a different robotic arm 106, or in some cases, complete control of the robotic arm 106 may be transferred between clinicians 112a, 112b. In some embodiments, additional robotic manipulators with additional robotic arms may be used on the patient 110 during surgery, and these additional robotic arms may be controlled by one or more of the master consoles 102a, 102b.

[0029] The robot manipulator 104 and the main control consoles 102a and 102b can communicate with each other via a communication link 114. This communication link can be any type of wired or wireless communication link configured to carry appropriate types of signals (e.g., electrical signals, optical signals, infrared signals, etc.) according to any communication protocol. The communication link 114 can be an actual physical link, or it can be a logical link using one or more actual physical links. When the link is a logical link, the type of physical link can be a data link, uplink, downlink, fiber optic link, point-to-point link, such as those well known in the field of computer networking used to refer to communication facilities connecting network nodes. Therefore, clinicians 112a and 112b can remotely control the robot arm 106 via the communication link 114, thereby enabling clinicians 112a and 112b to remotely perform surgery on patient 110.

[0030] Figure 2 It can be used for control Figure 1 An exemplary embodiment of the main console 102a for operating the robot manipulator 104. As shown, the main console 102a may include a support 202, clinicians 112a, 112b ( Figure 1 He / she can rest his / her forearm on the support while grasping one or more user input devices 203, one in each hand. The user input devices 203 may include, for example, physical controllers, such as, but not limited to, joysticks, exoskeleton gloves, master manipulators, etc., and are capable of movement in multiple degrees of freedom to control the surgical tool 108. Figure 1 The position, orientation, and operation of the surgical instrument 108. In some embodiments, the main console 102a may also include one or more foot pedals 204 that can be engaged by clinicians 112a, 112b to change the configuration of the surgical system and / or generate additional control signals to control the operation of the surgical instrument 108.

[0031] When clinicians 112a, 112b ( Figure 1 While observing surgery via the visual display 206, the user input device 203 and / or foot pedal 204 can be manipulated. Images displayed on the visual display 206 may be obtained from an endoscopic camera or "endoscope". In some embodiments, the visual display 206 may include or otherwise incorporate a force feedback meter or "force indicator" that provides clinicians 112a, 112b with visual indications of the magnitude and direction of the force exerted by surgical tools (i.e., cutting instruments or dynamic clamping members). As will be understood, other sensors may be arranged on the main console 102a to provide indications of other surgical tool measurements, such as, for example, whether the staple cartridge has been loaded into the end effector or whether the anvil has moved to the closed position before firing.

[0032] Figure 3 An example of a robotic manipulator 104 for operating multiple surgical instruments 108 according to one or more embodiments is shown. As shown, the robotic manipulator 104 may include a base 302 supporting a vertically extending column 304. Multiple robotic arms 106 (three shown) are operatively coupled to the column 304 at a carriage 306, the carriage being selectively adjustable to change the height of the robotic arms 106 relative to the base 302, as indicated by arrow A.

[0033] The robotic arm 106 may include links capable of manual joint movement, alternatively referred to as "device joints". In an illustrated embodiment, a surgical tool 108 is mounted to a corresponding tool driver 308 disposed on each robotic arm 106. Each tool driver 308 may include one or more drivers or motors (sometimes referred to as drivers 610a-610f) for interacting with one or more corresponding drive inputs of the surgical tool 108, and actuation of the drive input causes the associated surgical tool 108 to operate.

[0034] One of the surgical tools 108 may include an image capturing device 310, such as an endoscope, which may include, for example, a laparoscope, arthroscopy, hysteroscopy, or alternatively, other imaging modalities such as ultrasound, infrared, fluorescence endoscopy, magnetic resonance imaging, etc. The image capturing device 310 has an observation end located at the distal end of an elongated axis, which allows the observation end to be inserted through an inlet into an internal surgical site within the patient's body. The image capturing device 310 may be communicatively coupled to a visual display 206. Figure 2 It can also transmit images in real time for display on the visual display 206.

[0035] The remaining surgical tools can be communicatively coupled to the clinician's 112a, 112b ( Figure 1 In the main console 102a ( Figure 2 The user input device is held at the location. The movement of the robotic arm 106 and the associated surgical instrument 108 can be controlled by the clinician 112a, 112b through the user input device. As detailed below, the surgical instrument 108 may include or otherwise incorporate an end effector mounted on a corresponding articulated wrist, which is pivotally mounted on the distal end of an associated elongated shaft. The elongated shaft allows the end effector to be inserted through an inlet into an internal surgical site in the patient's body, and the user input device also controls the movement (actuation) of the end effector.

[0036] In use, the robotic manipulator 104 is positioned close to the patient requiring surgery and then typically held stationary until the surgical procedure is completed. The robotic manipulator 104 typically has wheels or casters to enable its movement. Lateral and vertical positioning of the robotic arm 106 can be controlled by clinicians 112a, 112b. Figure 1 The surgical tool 108 and image capture device 310 are positioned to facilitate the transfer of the elongated shaft of the surgical tool 108 and the image capture device 310 to the desired position relative to the surgical site via the inlet. When the surgical tool 108 and image capture device 310 are thus positioned, the robotic arm 106 and carriage 306 can be locked into place.

[0037] Figure 4 This is an isometric side view of an exemplary surgical tool 400 incorporating some or all of the principles of this disclosure. The surgical tool 400 can be used with... Figure 1 and Figure 3 The surgical tools 108 are the same as or similar to those used in robotic surgical systems, and therefore can be used with robotic surgical systems such as... Figure 1 The surgical tool 400 is used in conjunction with a robotic surgical system 100. As shown, the surgical tool 400 includes an elongated shaft 402, an end effector 404, an articulated wrist 406 (alternatively referred to as a "wrist joint") that connects the end effector 404 to the distal end of the shaft 402, and a drive housing 408 that connects to the proximal end of the shaft 402. In applications where the surgical tool 400 is used in conjunction with a robotic surgical system, the drive housing 408 may include a coupling feature that releasably connects the surgical tool 400 to the robotic surgical system. However, the principles of this disclosure are equally applicable to non-robot surgical tools that can otherwise be manually manipulated.

[0038] The terms "proximal" and "distal" are defined herein with respect to a robotic surgical system having an interface configured to mechanically and electrically couple a surgical tool 400 (e.g., a drive housing 408) to a robotic manipulator. The term "proximal" refers to a location of an element closer to the robotic manipulator, and the term "distal" refers to a location of an element closer to the end effector 404 and therefore further away from the robotic manipulator. Furthermore, directional terms such as above, below, up, down, upward, downward, left, right, etc., are used with respect to exemplary embodiments as they are shown in the figures, with upward or upper directions pointing towards the top of the corresponding figure, and downward or lower directions pointing towards the bottom of the corresponding figure.

[0039] Surgical tool 400 may have any of a variety of configurations capable of performing one or more surgical functions. In an illustrated embodiment, end effector 404 includes a surgical stapler configured to cut and suture (tighten) tissue, alternatively referred to as a “linear cutter.” As shown, end effector 404 includes opposing jaws 410, 412 configured to move (articularly) between an open position and a closed position. However, opposing jaws 410, 412 may alternatively form part of other types of jaw-equipped end effectors, such as, but not limited to, tissue grippers, surgical scissors, advanced-energy vascular sealers, clamps, needle actuators, babcock clamps including a pair of opposing gripping jaws, bipolar jaws (e.g., bipolar Maryland grippers, clamps, perforated grippers, etc.). One or both of jaws 410, 412 may be configured to pivot to actuate end effector 404 between an open position and a closed position.

[0040] In the illustrated embodiments, the first jaw 410 may be characterized as or otherwise referred to as a “cabin” jaw, and the second jaw 412 may be characterized as or otherwise referred to as an “anvil” jaw. More specifically, the first jaw 410 may include a frame that receives or supports the staple cartridge, and the second jaw 412 is pivotally supported relative to the first jaw 410 and defined as an anvil to form the surface of staples ejected from the staple cartridge during operation. In use, the second jaw 412 is rotatable between an open, released position and a closed, clamping position. However, in other embodiments, without departing from the scope of this disclosure, the first jaw 410 may be movable (rotated) relative to the second jaw 412.

[0041] The wrist 406 enables the end effector 404 to articulate (pivot) relative to the axis 402, thereby positioning the end effector 404 in the desired orientation and position relative to the surgical site. Figure 5 The potential degrees of freedom for joint movement (pivot) of the wrist 406 are shown. The wrist 406 can have any of a variety of configurations. Typically, the wrist 406 includes a joint configured to allow pivotal movement of the end effector 404 relative to axis 402. The degrees of freedom of the wrist 406 are represented by three translational variables (i.e., forward / backward, undulation, and sway) and three rotational variables (i.e., Euler angles or roll, pitch, and yaw). The translational and rotational variables describe the position and orientation of a component of the surgical system (e.g., the end effector 404) relative to a given reference Cartesian coordinate system. Figure 5As shown, "advance and retreat" refers to forward and backward translational movement, "undulation" refers to up and down translational movement, and "sway" refers to left and right translational movement. Regarding rotational terms, "roll" refers to tilting left and right, "pitch" refers to tilting forward and backward, and "yaw" refers to turning left and right.

[0042] Pivoting motion may include pitch motion about a first axis (e.g., the X-axis) of the wrist 406, yaw motion about a second axis (e.g., the Y-axis) of the wrist 406, and combinations thereof, such that the end effector 404 rotates 360° about the wrist 406. In other applications, pivoting motion may be limited to movement in a single plane, such as pitch motion only about the first axis of the wrist 406 or yaw motion only about the second axis of the wrist 406, such that the end effector 404 moves only in a single plane.

[0043] See you again Figure 4 The surgical tool 400 may include multiple drive components, etc., forming part of an actuation system (in... Figure 4 (Obstructed in the middle), the actuation system is configured to facilitate articulation of the wrist 406 and actuation (operation) of the end effector 404 (e.g., clamping, firing, rotation, articulation, energy delivery, etc.). Some drive members may extend to the wrist 406, and selective actuation of these drive members causes the end effector 404 to articulate (pivot) relative to the axis 402 at the wrist 406. The end effector 404 in Figure 4 The image shows the end effector 404 in a non-jointed position, where the longitudinal axis A2 of the end effector 404 is substantially aligned with the longitudinal axis A1 of the shaft 402, such that the end effector 404 forms a substantially zero angle with respect to the shaft 402. In the jointed position, the longitudinal axes A1 and A2 will be offset from each other at an angle, such that the end effector 404 forms a non-zero angle with respect to the shaft 402.

[0044] Other actuating members may extend to end effector 404, and selective actuation of these actuating members may cause end effector 404 to be actuated (operated). In an illustrated embodiment, actuating end effector 404 may include closing and / or opening a second jaw 412 relative to a first jaw 410 (or vice versa), thereby enabling end effector 404 to grip (clamp) onto tissue. Furthermore, once tissue is gripped or clamped between opposing jaws 410, 412, actuating end effector 404 may also include “firing” end effector 404, which may refer to causing a cutting element or blade (not visible) to advance distally within a slot 414 defined in the second jaw 410. With its distal movement, the cutting element may transection any tissue gripped between opposing jaws 410, 412. Furthermore, as the cutting element advances distally, multiple staples contained within the staple cartridge (i.e., housed within the first jaw 410) can be pushed (cam-driven) into deformable contact with corresponding anvil surfaces (e.g., recesses) disposed on the second jaw 412. The deployed staples can form multiple rows of staples sealing opposite sides of the transversely cut tissue.

[0045] In some implementations, the surgical tool 400 may be configured to apply energy, such as radio frequency (RF) energy, to tissue. In such cases, the actuated end effector 404 may also include applying energy to tissue gripped or clamped between two opposing jaws to cauterize or seal the captured tissue, after which the tissue may be transversely cut.

[0046] In some embodiments, the surgical tool 400 may also include a manual closure device 416 accessible to a user from outside the drive housing 408. As shown, the manual closure device 416 may include a knob that can be gripped by a user. The manual closure device 416 may be operatively coupled to various gears and / or drive components within the drive housing 408 to allow a clinician to manually open and close the jaws 410, 412. In some cases, the clinician may be able to fully clamp and fully release the jaws 410, 412 using the manual closure device 416. The manual closure device 416 may be particularly useful to a clinician when the surgical tool 400 is disengaged from the surgical robot, as the ability to open and close the jaws 410, 412 eliminates the need to apply unintended stress to the internal drive components or parts. In cases where a clinician wishes to manually open the jaws 410, 412 while the surgical tool 400 is still attached to the surgical robot, the clinician may rotate the manual closure device 416 to attempt to open the end effector 404.

[0047] Figure 6 A bottom view of a drive housing 408 according to one or more embodiments is shown. As shown, the drive housing 408 may include a tool mounting portion 602 for operatively coupling the drive housing 408 to a tool driver 604. The tool driver 604 may be coupled to... Figure 3 The tool driver 308 is the same as or similar to it, and therefore can be used with Figure 1 and Figure 3 The robot manipulator 104 is used in conjunction with the robot. Installing the drive housing 408 onto the tool driver 604 will position the drive housing 408 to communicate with the computer system 606, which can communicate with the main controllers 102a and 102b. Figure 1 The computer system 608 monitors and boots the operation of the drive housing 408 via the operation of the tool driver 604, thereby enabling the user (e.g., Figure 1 The clinicians (112a, 112b) can control the operation of the drive housing 408 through the operation of the main controllers (102a, 102b).

[0048] The tool mounting portion 602 includes and otherwise provides an interface for mechanically, magnetically, and / or electrically coupling the drive housing 408 to the tool driver 604. In at least one embodiment, the tool mounting portion 602 connects the drive housing 408 to the tool driver 604 via a sterile barrier (not shown). As shown, the interface of the tool mounting portion 602 may include and support a plurality of inputs, such as drive inputs 608a, 608b, 608c, 608d, 608e, and 608f. Each drive input 608a-608f may include a rotatable disk or disc configured to align (mate) and engage with corresponding drivers 610a, 610b, 610c, 610d, 610e, and 610f of the tool driver 604. Each drive input 608a-608f and its corresponding driver 610a-610f provide or define one or more matching surface features 612 and 614, which are configured to facilitate mating engagement between the opposing surface features 612, 614, such that movement (rotation) of a given driver 610a-610f correspondingly causes movement (rotation) of the associated drive input 608a-608f.

[0049] Each of the tool actuators 610a-610f of the tool actuator 604 may include, or otherwise include, a motor 616 configured to actuate the corresponding actuator 610a-610f, and actuation of a given actuator 610a-610f correspondingly causes actuation of a mating drive input 608a-608f, which facilitates the operation of the mechanism of the drive housing 408. More specifically, actuation of the motor 616 may cause rotational movement of the corresponding actuator 610a-610f, which in turn causes rotation of the associated drive input 608a-608f. Each motor 616 may communicate with the computer system 606, and based on input signals provided by a user (e.g., a surgeon), the computer system 606 may selectively actuate any one of the motors 616 and thereby drive the corresponding actuator 610a-610f.

[0050] In some embodiments, the first drive input 608a controls the rotation of the shaft 402 about its longitudinal axis A1 via the actuation of the first driver 610a. Depending on the rotation direction of the first drive input 608a, the shaft 402 can rotate clockwise or counterclockwise, thereby correspondingly actuating the end effector 404 ( Figure 4 ) rotate in the same direction. The second drive input 608b and the third drive input 608c are respectively actuated by the controllable end effector 404 via the second driver 610b and the third driver 610c at the wrist 406 ( Figure 4 The joint movement at the point is as follows: The fourth drive input 608d and the fifth drive input 608e, respectively, via the actuation of the fourth driver 610d and the fifth driver 610e, can cause the outer portion of the shaft 402 (referred to herein as the "closed tube") to advance and retract, thereby closing and opening the jaws 410, 412 ( Figure 4 Finally, the actuation of the sixth drive input 608f via the sixth driver 610f can cause the end effector 404 to fire, which may require the distal deployment of cutting elements to transversely cut the tissue held by the jaws 410, 412 and simultaneously deploy staples contained in the staple cartridge, which is housed within the first jaw 410.

[0051] The tool mounting section 602 may also include one or more electrical connectors 618 (two shown) configured to mate with corresponding electrical connectors 620 (two shown) provided by the tool driver 604 to facilitate communication between the drive housing 408 and the tool driver 604. Alternatively, the drive housing 408 may wirelessly communicate with the tool driver 604, such as via a near-field communication connection. The drive housing 408 may also accommodate or otherwise include an internal computer 622, which may include memory 624 and / or a microprocessor 626. Memory 624 may include one or more databases or libraries stored in the drive housing 408 and more specifically with the surgical tool 400 (… Figure 4 Related data. In some implementations, memory 624 may include non-transitory computer-readable media, such as read-only memory (ROM), which may be PROM, EPROM, EEPROM, etc. Fitting drive housing 408 to tool driver 604 places internal computer 622 in communication with computer system 606.

[0052] Computer system 606 can be programmed and otherwise configured to monitor surgical instrument 400 using various sensors and / or electromechanical devices (collectively referred to herein as “monitoring devices”). Figure 4 The operation of the surgical instrument 400 is monitored. Each monitoring device may be designed to monitor one or more operating parameters of the surgical instrument 400 and report the measured operating parameters to a computer system 606 for processing. The computer system 606 may, for example, communicate with one or more torque sensors 628 and / or one or more rotary encoders 630, each of which may be characterized as a monitoring device designed to monitor operating parameters of the surgical instrument 400. The torque sensor 628 may, for example, be configured to monitor torque, and the rotary encoder 630 may be configured to monitor motion (rotational or linear).

[0053] Torque sensor 628 and rotary encoder 630 may be integrated into motor 616 of some or all of the drives 610a-610f, but may alternatively be operatively coupled to one or more drive inputs 608a-608f. Torque sensor 628 may be configured to measure the real-time torque load on motor 616, corresponding to the assumed torque load of drives 610a-610f and / or drive inputs 608a-608f. Rotary encoder 630 may measure the rotational motion or output of motor 616, corresponding to the rotational motion of drives 610a-610f and / or drive inputs 608a-608f. Monitoring the torque load and rotational motion of motor 616 can help determine whether surgical tool 400 is operating according to commands provided by computer system 606.

[0054] See Figure 7A and Figure 7B as well as Figure 8A and Figure 8B The image shows an exposed isometric view of the interior of a drive housing 408 according to one or more embodiments. Figures 7A to 7B The upper portion of the drive housing 408 is omitted to allow for observation of the internal working parts and components. Figures 8A to 8B The upper and lower portions of the drive housing 408 are omitted to allow for observation of the internal working parts and components. Furthermore, Figures 7A to 7B and Figures 8A to 8B Several components that would otherwise be included in the drive housing 408 have been omitted from the drawings to simplify the drawings and to allow for discussion of the depicted components.

[0055] First see Figure 7A The first drive shaft 702a is connected to the first drive input section 608a. Figure 6 The actuation and rotation of the first drive input 608a correspondingly rotate the first drive shaft 702a. A helical drive gear 704 is coupled to the first drive shaft 702a and rotates with it. The helical drive gear 704 meshes with a helical driven gear 706, which is operatively coupled to the shaft 402 and more specifically to an inner grounding member or shaft 708 forming part of the shaft 402. The inner grounding shaft 708 extends concentrically within the outer portion of the shaft 402, referred to herein as a "closed tube". Therefore, the actuation of the first drive input 608a drives the first drive shaft 702a and correspondingly drives the inner grounding shaft 708 to rotate the shaft 402 about the longitudinal axis A1.

[0056] The second drive shaft 702b can be connected to the second drive input section 608b. Figure 6 This causes the actuation and rotation of the second drive input 608b to correspondingly rotate the second drive shaft 702b. In some examples, a drive system or transmission can be provided to adjust the mechanical gain output of one or more motors from the robot manipulator (not shown). For example, if the second drive 610b ( Figure 6 The output torque is relatively low, but the torque supplied by the second drive 610b on the drive shaft 702b can be increased by using one or more meshing gears. (As in...) Figures 8A to 8BIn the best example, a spur gear 709a is attached and keyed to a second drive shaft 702b, such that the spur gear 709a rotates in unison with the drive shaft 702b. Furthermore, a compound pinion 710a is rotatably attached to the second drive shaft 702b, such that the compound pinion 710a can rotate about and relative to the second drive shaft 702b. As shown, the compound pinion 710a includes a first pinion 711a and a second pinion 713a, which are rigidly connected together, causing them to rotate together about the second drive shaft 702b. The second pinion 713a of the compound pinion 710a meshes with a first driven rack 712a, such that as the compound pinion 710a rotates in a first rotational direction, the first driven rack 712a translates correspondingly in a first longitudinal direction; and as the compound pinion 710a rotates in a second rotational direction, the first driven rack 712a translates correspondingly in a second longitudinal direction opposite to the first longitudinal direction.

[0057] In addition, an idler assembly 715a is provided. Figures 8A to 8B The rotation of the second drive shaft 702b is transmitted to the compound pinion 710a, thereby achieving translation of the first driven rack 712a in the first or second longitudinal direction. In the illustrated example, the idler assembly 715a is a compound gear having a first idler 717a and a second idler 719a, the second idler being rigidly connected to the first idler 717a such that they rotate together in unison. Here, the first idler 717a meshes with a spur gear 709a keyed to the second drive shaft 702b, and the second idler 719a meshes with a first pinion 711a in the compound pinion 710a, thereby driving the first driven rack 712a. Therefore, the second drive 610b ( Figure 6 The second drive input 608b rotates, which in turn rotates the second drive shaft 702b and the spur gear 709a connected thereto. The spur gear 709a imparts rotation to the first idler gear 717a in the idler gear assembly 715a, which in turn imparts rotation to the second idler gear 719a when it is bonded to the first idler gear 717a. The second idler gear 719a in the idler gear assembly 715a imparts rotation to the first pinion 711a of the compound pinion 710a, which in turn imparts rotation to the second pinion 713a when it is bonded to the first pinion 711a. As described above, this rotation of the second pinion 713a causes translation of the first drive rack 712a.

[0058] Second drive 610b ( Figure 6The drive system shown, which transmits power between the first driven rack 712a and the second driven rack 710a, is configured to have a cumulative gear ratio that increases the torque applied to the first drive rack 712a by the compound pinion 710a, exceeding the torque initially applied to the drive input 608b by the second drive 610b. Specifically, because the spur gear 709a is smaller (i.e., fewer teeth) than the first idler gear 717a it meshes with, and because the second idler gear 719a is smaller (i.e., fewer teeth) than the first pinion 711 it meshes with, the torque acting on the compound pinion 710a driving the first drive rack 712a is significantly greater than the torque initially applied to the second drive shaft 702b via the second drive 610b.

[0059] The first driven rack 712a includes a first fork 714a capable of engaging with the first articulated yoke 716a. More specifically, the first fork 714a is configured to be received in an annular slot 718a defined in the first articulated yoke 716a. Figure 7A and Figure 8B Within this, the first articulated yoke 716a rotates about the longitudinal axis A1 as the inner grounding shaft 708 rotates. Furthermore, when subjected to rotation of the second drive shaft 702b, the engagement between the first fork 714a and the annular slot 718a allows the first driven rack 712a to drive the first articulated yoke 716a along the longitudinal axis A1 (distal or proximal). The first articulated yoke 716a can be coupled to the first drive member 720a, which extends distally to the wrist 406. Figure 4 As shown in the figure, the first drive member 720a is arranged in a corresponding slot defined in the inner grounding shaft 708, such that the inner grounding shaft 708 and the first drive member 720a together extend distally to the wrist 406. Figures 8A-8B The first drive member is guided during the movement of the first joint yoke 716a along the longitudinal axis A1. The axial movement of the first joint yoke 716a correspondingly moves the first drive member 720a, which causes the wrist 406 and the end effector 404 to move. Figure 4 Perform joint movements.

[0060] The third drive shaft 702c is connected to the third drive input section 608c. Figure 6 This causes the actuation and rotation of the third drive input 608c to correspondingly rotate the third drive shaft 702c. Similar to the description of the second drive shaft 702b coupled to the second drive input 608b, a drive system or transmission can be provided to adjust the mechanical gain, and thus change the rotation caused by the third drive 610c ( Figure 6The initial torque or speed applied to the third drive shaft 702c. In the illustrated example, the spur gear 709b is attached and keyed to the third drive shaft 702c such that the spur gear 709b rotates in unison with the third drive shaft 702c. The compound pinion 710b is rotatably attached to the third drive shaft 702c such that the compound pinion 710b can rotate about and relative to the third drive shaft 702c. As shown, the compound pinion 710b includes a first pinion 711b and a second pinion 713b, which are rigidly connected together such that they rotate together about the third drive shaft 702c. The second pinion 713b of the compound pinion 710b meshes with a second driven rack 712b such that rotating the compound pinion 710b in the first rotational direction corresponds to translating the second driven rack 712b in the first longitudinal direction. The rotating compound pinion 710b in the second rotational direction translates the second driven rack 712b in the second longitudinal direction, which is opposite to the first longitudinal direction.

[0061] Furthermore, an idler assembly 715b is provided to transmit the rotation of the third drive shaft 702c to the compound pinion 710b, thereby achieving translation of the second driven rack 712b in the first or second longitudinal direction. In the illustrated example, the idler assembly 715b is a compound gear having a first idler 717b and a second idler 719b, the second idler being rigidly connected to the first idler 717b such that they rotate together in unison. Here, the first idler 717b meshes with a spur gear 709b keyed to the third drive shaft 702c, and the second idler 719b meshes with a first pinion 711b in the compound pinion 710b, thereby driving the second driven rack 712b. Thus, the third drive 610c ( Figure 6 The third drive input 608c rotates, which in turn rotates the third drive shaft 702c and the spur gear 709b connected thereto. The spur gear 709b imparts rotation to the first idler gear 717b in the idler gear assembly 715b, which in turn also imparts rotation to the second idler gear 719b when it is bonded to the first idler gear 717b. The second idler gear 719b in the idler gear assembly 715b imparts rotation to the first pinion 711b in the compound pinion 710b, which in turn imparts rotation to the second pinion 713b when it is bonded to the first pinion 711b. As described above, this rotation of the second pinion 713b causes translation of the first drive rack 712b. The drive system shown, which transmits power between the third driver 610c and the second driven rack 712b, is configured to have a cumulative gear ratio that causes an increase in the output torque acting on the compound pinion 710b and thus applied to the second drive rack 712b, exceeding the torque initially applied by the third driver 610c to the third drive input 608c.

[0062] The second driven rack 712b includes a second fork 714b capable of engaging with the second articulated yoke 716b. More specifically, the second fork 714b is configured to be received within an annular slot 718b defined in the second articulated yoke 716b, allowing the second articulated yoke 716b to rotate about the longitudinal axis A1 as the inner grounding shaft 708 rotates. Furthermore, when subjected to rotation by the third drive shaft 702c, the engagement between the second fork 714b and the annular slot 718b allows the second driven rack 712b to drive the second articulated yoke 716b along the longitudinal axis A1 (towards the distal or proximal side). The second articulated yoke 716b can be coupled to the second drive member 720b (…). Figure 7A The second drive member extends distally to the wrist 406. Figure 4 The second drive member 720b is arranged in a corresponding slot defined in the inner grounding shaft 708, such that the inner grounding shaft 708 and the second drive member 720b together extend distally to the wrist 406. Figures 8A-8B The second drive member is guided during the movement of the second articulator yoke 716b along the longitudinal axis A1. The axial movement of the second articulator yoke 716b correspondingly moves the second drive member 720b, which causes the wrist 406 and end effector 404 to move. Figure 4 Perform joint movements.

[0063] Therefore, the axial movement of the first articulated yoke 716a and the second articulated yoke 716b along the longitudinal axis A1 cooperatively actuates the drive members 720a and 720b, thereby causing the end effector 404 to perform articulated movements, as referenced herein. Figures 9A to 9B and Figures 10A to 10BFurthermore, in at least one embodiment, the first articulated yoke 716a and the second articulated yoke 716b operate dominantly, such that one of the articulated yokes 716a, 716b pulls one of the drive members 720a, 720b proximally, while the other articulated yoke 716a, 716b pushes the other drive member 720a, 720b distally. However, in some embodiments, the first articulated yoke 716a and the second articulated yoke 716b can operate independently without the other operating (being affected); for example, they can operate in opposition to each other while reducing the force effect of the other. In counter-operation, one of the articulated yokes 716a and 716b pulls (or pushes) its associated drive member 720a and 720b proximally (or distally) with a first force, while the other of the articulated yokes 716a and 716b pulls (or pushes) its associated drive member 720a and 720b proximally (or distally) with a second force, wherein the first force is greater than the second force, such that the first force can overcome the second force, as well as internal losses of the device (i.e., friction) and the load imposed on the end effector 404 by the external environment, thereby ensuring that the articulated yokes 716a and 716b providing the first force move proximally (or distally), while the articulated yokes 716a and 716b providing the second force move distally (or proximally). As described below, computer system 606 ( Figure 6 It can be configured to control drivers 610b and 610c. Figure 6 The driver drives the drive inputs 608b-608c and the interconnecting drive shafts 702b-702c, thereby synchronizing the actuation of the joint motion yokes 716a and 716b.

[0064] Fourth drive shaft 702d ( Figure 7A ) and the fifth drive shaft 702e ( Figure 7B They can be connected to the fourth drive input unit 608d and the fifth drive input unit 608e respectively. Figure 6 This causes the actuation and rotation of the fourth drive input 608d and the fifth drive input 608e to correspondingly rotate the fourth drive shaft 702d and the fifth drive shaft 702e. The rotation of the fourth drive shaft 702d and the fifth drive shaft 702e can cause a portion of the shaft 402 to advance or retract. More specifically, the outer portion of the shaft 402 may include a closing tube 722, which is axially translated to cause the jaws 410, 412 ( Figure 4 It moves between the open and closed positions. As shown, each drive shaft 702d, 702e has a spur gear 724 attached thereto, and the two spur gears 724 are positioned to mesh with the main drive gear 725 mounted to the closed yoke 726.

[0065] The closing yoke 726 is rotatably mounted to the closing tube 722, but is axially fixed thereto. This allows the closing tube 722 to rotate with the inner grounding shaft 708, but also allows the closing yoke 726 to advance or retract the closing tube 722. Protrusion 727 ( Figure 8A The protrusion extends from or is otherwise connected to the closed yoke 726, and interacts with a cam surface or slot defined within the main drive gear 725 to facilitate axial movement of the closed yoke 726. Thus, rotating the spur gear 724 causes the main drive gear 725 to rotate, which correspondingly causes axial translation of the closed yoke 726 and the interconnected closed tube 722.

[0066] The main drive gear 725 can also be operatively coupled to a manual closing device 416 disposed on the exterior of the drive housing 408. As shown, the manual closing device 416 may include a drive gear 728 meshing with a driven gear 729 mounted to the main drive gear 725. Thus, a user can grasp and rotate the manual closing device 416 to correspondingly rotate the main drive gear 725, thereby abutting against the driven gear 729 and driving the drive gear 728, causing the closing yoke 426 to move distally and proximally, thereby closing and opening the jaws 410, 412. Figure 4 As generally described above. In one example, the main drive gear 725 meshes with the spur gear 724 and includes a central bore that allows the main drive gear 725 to be rotatably mounted relative to the spur gear 724 on the drive housing 408. Figures 7A to 7B The spiral cam groove is defined in the main drive gear 725 and closes the yoke 726. Figures 7A to 7B ) protrusion 727 ( Figure 8A The main drive gear 725 is received therein when acted upon by the spur gear 724. Under the action of the spur gear 724, the main drive gear 725 is able to rotate about an axis extending through the central hole. As the main drive gear 725 rotates, the protrusion follows the helical cam groove, and the curvature of the helical cam groove forces the interconnected closing yoke 726 to translate longitudinally relative to the main drive gear 725. When the closing yoke 726 moves distally, the closing tube 722 ( Figures 7A to 7B Correspondingly, it moves in the distal direction, causing jaws 410, 412 ( Figure 4 The closing mechanism is activated. In contrast, when the closing yoke 726 moves proximally, the closing tube 722 moves accordingly in the proximal direction, causing the jaws 410 and 412 to open.

[0067] Figure 9A and Figure 9B An exposed bottom view of a surgical tool 400 according to one or more embodiments is shown. Most of the transmission and actuation mechanisms described above are shown, but... Figures 9A to 9BThe entire drive housing 408 and the closed tube 722 of shaft 402 are omitted from the drawings to allow observation of the internal working parts and components used to articulate the drive members 720a, 720b and wrist 406. Furthermore, several components that would otherwise be included within the drive housing 408 are omitted from these drawings to simplify the figures and facilitate discussion of the depicted components.

[0068] refer to Figure 9A An inner grounding shaft 708 extends distally within shaft 402 and connects to wrist 406. Drive members 720a and 720b extend distally toward wrist 406 within corresponding slots 802a and 802b defined within the inner grounding shaft 708. The corresponding slots 802a and 802b may be located on opposite sides of the inner grounding shaft 708, or may be defined at other locations around the inner grounding shaft 708 in other examples. As described below, movement of the drive members 720a and 720b causes articulation of wrist 406. Furthermore, the inner grounding shaft 708 is configured to enable rotation of wrist 406 about longitudinal axis A1, even when wrist 406 is articulated to an angularly offset position relative to longitudinal axis A1.

[0069] In the illustrated example, a locking or grounding recess (obscured in the view) is formed in the underside of the distal end of the inner grounding shaft 708, and the grounding recess defines a pair of locking tabs 804a, 804b configured to interlock with other components of the wrist 406. Here, the base 806 of the wrist 406 is integrally fixed within the grounding recess of the inner grounding shaft 708 via the locking tabs 804a, 804b, such that the inner grounding shaft 708 carries the wrist 406 when rotating about the longitudinal axis A1 when the first drive input 608a is actuated. Furthermore, slots 802a, 802b extend through the grounding recess and the locking tabs 804a, 804b, wherein the lower boundary of the slots 802a, 802b is defined by the upper surface of the base 806, as described below.

[0070] The wrist 406 also includes a joint motion member 808 to which the end effector 404 can be mounted. The joint motion member 808 is connected to the base 806 and the drive members 720a and 720b, such that movement of the drive members 720a and 720b causes the joint motion member 808 to articulate relative to the base 806. Therefore, the wrist 406 and the end effector 404 extending distally therefrom can be angled off-center via movement of the drive members 720a and 720b.

[0071] exist Figure 9B In the figure, the inner grounding shaft 708 has been removed. As shown, the drive members 720a and 720b are interconnected at their distal ends via a third link member, which is referenced herein. Figure 10BDescribed and referred to herein as the "distal connector". Therefore, the drive members 720a, 720b and the distal connector together constitute a linkage mechanism configured to allow the articulated member 808 to articulate relative to the base 806 in a plane parallel to the longitudinal axis A1. With this configuration, the drive members 720a, 720b are positioned along the longitudinal axis A1 in their corresponding slots 802a, 802b ( Figure 9A The wrist 406 undergoes counter-translational movement within the plane, such that when the first drive member 720a moves distally, the second drive member 702b moves proximally, and vice versa. More specifically, the distal movement of the first drive member 720a acts on the articulatory member 808, causing the articulatory member 808 to rotate clockwise and thereby push the second drive member 720b proximally. Thus, when the second drive member 720b moves proximally, the first drive member 720a moves distally, causing the wrist 406 to articulate in the plane, causing it to deflect at a non-zero angle relative to the inner ground axis 708. As described above, the wrist 406 is also configured to rotate together with the inner ground axis 708 about the longitudinal axis A1, thereby causing the articulatory member 808 therein to undergo a planar rotation of articulation (about 360° around the longitudinal axis A1).

[0072] Figure 10A A bottom view of a wrist 406 according to one or more embodiments is shown. As shown, a base 806 is attached to an inner grounding shaft 708 and is arranged within a closing tube 722. Here, the closing tube 722 includes a distal connecting fork 1002 having a pair of holes 1004. Furthermore, a closing connector 1006 with a pair of pins 1008, 1010 is provided, and when the base 806 and the inner grounding shaft 708 are arranged within the closing tube 722, the first pin 1008 of the closing connector 1006 is received in one of the holes 1004 in the distal connecting fork 1002. The closing connector 1006 is used to transmit a closing action around the articulated joint. For example, the closing connector 1006 can transmit the closing load or translation of the closing tube 722 to a closing ring (not shown), which can be coupled to a second pin 1010 of the closing connector 1006, which pulls or pushes the upper jaw (anvil) open or close. Furthermore, the joint motion member 808 is rotatable about the joint motion axis A3, which in the illustrated example is shown as a second pin 1010 extending through the closing connector 1006.

[0073] Figure 10B It shows Figure 10AAn exploded isometric view of the wrist portion 406. As mentioned, the grounding member 708 includes a grounding recess configured to rigidly secure the base 806 thereto. As shown, the inner grounding shaft 708 includes a pair of grounding recesses 1012, 1014 formed in the distal end of the inner grounding shaft 708. As shown, the grounding recesses 1012, 1014 define or provide locking tabs 804a, 804b configured to engage the base 806 and suppress relative rotation therebetween. In the illustrated example, the base 806 includes a pair of recesses 1016a and 1016b configured to receive the locking tabs 804a, 804b, and the pair of recesses 1016a, 1016b define a proximal locking flange 1018 configured to be received within the grounding recess 1014 during assembly. When the base 806 is assembled on the inner grounding shaft 708, and the locking tabs 804a, 804b extend into the recesses 1016a, 1016b and the proximal locking flange 1018 extends into the grounding recess 1014, the base 806 will rotate together with the inner grounding shaft 708 as described above.

[0074] Furthermore, slots 802a and 802b are shown extending longitudinally along the inner grounding axis 708. Slots 802a and 802b are each defined or delimited by the upper surface 1020 and the lower surface 1022 of the inner grounding axis 708. In the illustrated example, the upper surface 1020 is substantially continuous along the length of the inner grounding axis 708, but the lower surface 1022 is discontinuous or broken due to grounding recesses 1012 and 1014. As shown, the lower surface 1022 is absent along the distal portion of the inner grounding axis 708 corresponding to the grounding recess 1012, and the grounding recess 1014 is inserted into the proximal portion of the lower surface 1022 and the distal portion of the lower surface 1022 extending along the locking tabs 804a and 804b.

[0075] However, the base 806 includes a lower surface 1024 that defines or delineates portions of slots 802a and 802b at locations corresponding to the grounding recesses 1012 and 1014. As shown, the lower surface 1024 of the base 806 extends along the proximal locking flange 1018 of the base 806, but is discontinuous and is interrupted via notches 1016a and 1016b, and then extends distally therefrom. Therefore, when the base 806 is assembled on the inner grounding shaft 708, the slots 802a and 802b are defined by the upper surface 1020 and the lower surface 1022 of the inner grounding shaft 708 along their proximal portions and along the locking tabs 804a and 804b; while the slots 802a and 802b are defined by the upper surface 1020 of the inner grounding shaft 708 and the lower surface 1024 of the base 806 at positions along the inner grounding shaft 708 corresponding to the grounding recesses 1012 and 1014.

[0076] The base 806 has an upper portion 1026 and a lower portion 1028. As shown, a lower surface 1024 defines an upper surface of the lower portion 1028 of the base 806, thereby separating the upper portion 1026 from the lower portion 1028. The base 806 also includes an articulated portion 1030 located at a distal end of the base 806. The articulated portion 1030 is configured to receive an articulated member 808 and allow the articulated member 808 to rotate relative to the base 806. As shown, the articulated portion 1030 includes an extension member 1032 extending distally from the upper portion 1026 of the base 806 and a pivot 1034 oriented on the articulated axis A3 to receive the articulated member 808. As shown, the pivot 1034 extends downward from the upper portion 1026 toward the lower portion 1028. Furthermore, the articulation portion 1030 includes a recess 1036 formed in a lower portion 1028 at the distal end of the base 806, the recess being configured to receive the articulation member 808 and allow it to rotate within the recess 1036. As shown, a pivot 1034 extends downward into the recess 1036, and the distal surface 1038 of the lower portion 1028 includes a curvature corresponding to the curvature of the articulation member 808, as described below.

[0077] Furthermore, a recess 1040 is formed in the distal end of the extension member 1032 to receive a distal connector interconnected with the drive members 720a, 720b, as described below. The recess 1040 is defined by a sliding surface 1042 on which the distal connector can slide and an upper distal surface 1044 on which the distal connector can articulate or pivot, and the upper distal surface 1044 may include a curvature corresponding to the curvature of the distal connector. Moreover, in the illustrated example, the lower distal surface 1046 of the extension member 1032 includes a curvature corresponding to the curvature of the articulated member 808.

[0078] The articulated motion component 808 includes an end effector mounting portion 1050 located at its distal end and a connecting portion 1052 extending proximally from the end effector mounting portion 1050. The end effector mounting portion 1050 is configured to receive an end effector, such as... Figure 4 The surgical tool 400 shown has an end effector 404. The connecting portion 1052 is configured to be received and rotatably connected within a recess 1036 in the distal end of the base 806, such that it can articulate relative to the base 806 when actuated by the drive members 720a, 720b.

[0079] The articulation member 808 includes a hole 1054 extending through the connecting portion 1052. The hole 1054 is configured to receive a pivot 1034 of the base 806, and is therefore oriented along the articulation axis A3 when the articulation member 808 is assembled onto the base 806. When the base 806 and the articulation member 808 are assembled with the pivot 1034 extending through the hole 1054, the connecting portion 1052 of the articulation member 808 is disposed within a recess 1036 defined in the lower portion 1028 of the base 806, such that the articulation member 808 can rotate relative to the base 806 about the articulation axis A3. Here, the proximal side 1056 of the connecting portion 1052 abuts the distal side 1038 of the base 806, and therefore includes a curvature corresponding to the curvature of the distal side 1038 of the lower portion 1028, as described above. Furthermore, when the articulation member 808 is assembled on the base 806, the proximal side 1058 of the end effector mounting portion 1050 abuts the lower distal side 1046 of the extension member 1032. Therefore, the proximal side 1058 includes a curvature corresponding to the curvature of the lower distal side 1046 of the extension member 1032, and in some examples, the curvature of the proximal side 1058 is defined by a radius equal to the sweep distance by which the extension member 1032 extends beyond the articulation axis A3 (i.e., the distance between the articulation axis A3 and the lower distal side 1046).

[0080] The articulation member 808 includes a pair of drive pins 1060a, 1060b configured to engage with drive members 720a, 720b. Here, the drive pins 1060a, 1060b extend upward from the upper surface 1062 of the connecting portion 1052. When the base 806 and the articulation member 808 are assembled together, and the connecting portion 1052 is rotatably disposed within the recess 1036 and the pivot 1034 extends through the hole 1054, the upper surface 1062 of the connecting portion 1052 is substantially aligned with or planar with the lower surface 1024 of the base 806, allowing the drive members 720a, 720b to slide freely thereon. Furthermore, the drive pins 1060a, 1060b extend upward from the upper surface 1062 of the connecting portion 1052 a sufficient distance to engage with the drive members 720a, 720b when riding in slots 802a, 802b.

[0081] In the illustrated example, drive pins 1060a and 1060b extend upward from the upper surface 1062 and each terminates at pin ends 1064a and 1064b. Here, pin ends 1064a and 1064b are cylindrical members extending upward from the drive pins 1060a and 1060b, and have a decreasing diameter at their coaxial extensions from the drive pins 1060a and 1060b. Pin ends 1064a and 1064b each define a surface 1066 that is substantially aligned with or planar with the upper surface 1068 of the base 806 extending onto its extension member 1032. Therefore, when the base 806 and the articulated member 808 are assembled together, the drive pins 1060a and 1060b extend upward from the sliding surface 1042, and the pin ends 1064a and 1064b extend upward from the drive pins 1060a and 1060b, such that the surface 1066 of the pin ends 1064a and 1064b is oriented parallel to the upper surface 1068 of the base 806. However, in other examples, the drive pins 1060a and 1060b and / or the pin ends 1064a and 1064b may extend upward at different heights, and in some examples, the drive pins 1060a and 1060b do not include the pin ends 1064a and 1064b, such that the drive pins 1060a and 1060b are cylindrical members with a uniform diameter.

[0082] Figure 10B Drive members 720a and 720b are also shown, each providing distal ends 1070a and 1070b respectively configured to engage the articulation member 808. Drive pin holes 1072 are provided at the distal ends 1070a and 1070b of each drive member 720a and 720b, and are configured to receive drive pins 1060a and 1060b of the articulation member 808 when the articulation member 808 is assembled on the base 806, and to allow the drive pins 1060a and 1060b to translate laterally within the corresponding holes 1072 when the drive members 720a and 720b are actuated to perform articulation of the wrist 406. The drive pin holes 1072 may have various geometries, such as rectangular or square geometries. In the illustrated example, the drive pin holes 1072 have a generally rectangular shape with rounded corners, which allows the drive pins 1060a and 1060b to translate relative to each other during articulation. Regardless of its shape, the size of the drive pin hole 1072 is set to receive drive pins 1060a, 1060b or at least a portion thereof.

[0083] Furthermore, the distal ends 1070a and 1070b of the drive members 720a and 720b are constrained together via the distal connector 1074. As described above, the drive members 720a and 720b and the distal connector 1074 together form a linkage that causes the articulated motion member 808 to perform articulation. The distal connector 1074 includes a pair of wings 1076a and 1076b corresponding to the distal ends 1070a and 1070b of the drive members 720a and 720b, and each wing 1076a and 1076b includes a hole 1078 configured to receive one or a portion of one of the drive pins 1060a and 1060b. In the illustrated example, the hole 1078 is a circular hole configured to receive the pin ends 1064a and 1064b of the drive pins 1060a and 1060b. In examples where the drive pins 1060a and 1060b do not include the pin ends 1064a and 1064b with reduced diameters, the hole 1078 may be a circular hole sized to receive the drive pins 1060a and 1060b. However, the hole 1078 may also have various other shapes. In some examples, the hole 1078 is shaped to correspond to the drive pin holes 1072 of the drive members 720a and 720b. Furthermore, the distal connector 1074 includes a bridging portion 1080 that interconnects the wings 1076a and 1076b, and the bridging portion 1080 includes an internal pivot surface 1082 configured to engage and pivot on the upper distal surface 1044 of the extension member 1032 (of the base 806). Here, the pivot surface 1082 includes a curvature corresponding to the curvature of the upper distal surface 1044.

[0084] During assembly, drive pins 1060a and 1060b connect drive members 720a and 720b to the distal connector 1074. For example, drive members 720a and 720b extend distally along lower surfaces 1022 and 1024 in slots 802a and 802b, and distal ends 1070a and 1070b extend above the connecting portion 1052 of the articulated member 808, wherein the lower portions of drive pins 1060a and 1060b extend upward into holes 1072 in drive members 720a and 720b. Furthermore, the distal connector 1074 is arranged in the recess 1042 of the base 806, wherein the bridging portion 1080 is provided on the sliding surface 1042, and the pivoting surface 1082 abuts the upper distal surface 1044, such that the pin ends 1064a, 1064b of the drive pins 1060a, 1060b extend upward through the hole 1078 of the distal connector 1074. The translation of the drive members 720a, 720b pushes and pulls the drive pins 1060a, 1060b of the joint motion member 808, thereby causing the joint motion member 808 to rotate about the joint motion axis A3. Therefore, the joint motion member 808 can rotate about the joint motion axis A3, thereby engaging the drive input portions 608b, 608c ( Figure 6 The 610b and 610c drivers ( Figure 6 Activation of the wrist 406 enables joint movement.

[0085] See you again Figure 7A and Figure 7B The sixth drive shaft 702f is connected to the sixth drive input unit 608f. Figure 6 This causes the actuation and rotation of the sixth drive input unit 608f to correspondingly rotate the sixth drive shaft 702f. Rotating the sixth drive shaft 702f allows it to extend and retract through the shaft 402 to reach the end effector 404. Figure 4 The firing lever (not shown). The distal end of the firing lever is operatively connected to the cutting element (blade), such that axial movement of the firing lever correspondingly moves the cutting element distally or proximally to transversely cut the tissue held between jaws 410, 412. Figure 4 In some implementations, the distal movement of the firing lever also deploys a pin, as described above.

[0086] A spur gear 730 is connected to a sixth drive shaft 702f, such that rotation of the sixth drive shaft 702f correspondingly rotates the spur gear 730. The spur gear 730 meshes with a second spur gear 732 attached to a first transmission drive shaft 734. A third spur gear (not visible) is connected to the first transmission drive shaft 734 and meshes with a fourth spur gear 736 attached to a second transmission drive shaft 738. Finally, an output pinion 740 (… Figure 7AThe output pinion 740 is connected to the second drive shaft 738 and meshes with the rack and pinion drive 742 of the firing member 744, such that rotation of the output pinion 740 causes axial translation of the firing member 744. The firing member 744 can be connected to the aforementioned firing rod (not shown). Therefore, rotation of the sixth drive shaft 702f will drive axial translation of the firing member 744, which correspondingly drives the firing rod in the same direction to advance and retract the cutting element at the end actuator 404. Figure 4 ).

[0087] As mentioned above, tool driver 604 ( Figure 6 This includes drive input units 608a-608f configured to actuate corresponding drive input units. Figure 6 One or more drives 610a-610f Figure 6 And each driver 610a-610f can be powered by a corresponding motor 616. Figure 6 Power is provided. The engagement between the actuators 610a-610f and their corresponding drive inputs 608a-608f allows the actuators 610a-610f to be activated to impart rotation to the corresponding drive shafts 702a-f extending from the drive inputs 608a-608f. As mentioned, the wrist 406 performs joint movements by driving the second drive input 608b and the third drive input 608c, which can be driven one at a time by the second actuator 610b and the third actuator 610c. However, to increase the available torque, the drive inputs 608b, 608c can be driven counteractingly by the two actuators 610b, 610c simultaneously.

[0088] When the joint movement of the wrist 406 is controlled by actuators 610b and 610c, the potential torque is increased to achieve the desired joint movement of the wrist 406. Simultaneous operation of actuators 610b and 610c may introduce an over-constraint mechanism, thereby impairing the operation of the surgical tool 400. Therefore, the robotic surgical system 100 may include a computer system 600. Figure 6 The computer system is configured to control and synchronize drives 610b, 610c (or...). Figure 6 The operation of any two or more drives (610a-610f) is made more efficient as a single input (i.e., as a single drive). This can help prevent over-constraint of the drive components connected to them, such as drive inputs 608b, 608c ( Figure 6 ), drive shafts 702b, 702c Figures 7A to 7B ), joint movement yokes 716a, 716b ( Figures 7A to 7B )wait.

[0089] Figures 11A to 11CProgrammable to various embodiments according to this disclosure are shown. Figure 6 In the computer system 600, the second drive 610b and the third drive 610c are controlled. Figure 6 Various exemplary algorithms for the operation of ) are described. Each algorithm identifies and operates a "master motor" corresponding to one of the drivers 610b and 610c, and a "slave motor" corresponding to the other of the drivers 610b and 610c. As described above, the second driver 610b and the third driver 610c are operatively connected to the drive input units 608b and 608c ( Figure 6 This causes the corresponding drive shafts 702b and 702c to rotate. The algorithm described herein may include software code instructions programmed into the computer system 600 to help prevent mechanical engagement of the internal drive mechanisms connected to the drives 610b and 610c within the drive housing 408.

[0090] It should be noted that although this article describes the exemplary algorithm in relation to the operation of the drives 610b, 610c causing the drive shafts 702b, 702c to rotate, it can also be described in relation to the drives 610a-610f ( Figure 6 Any other drive in the drive shaft 702e and 702d utilizes one or more algorithms. For example, one or more of these algorithms may alternatively (or otherwise) be configured to control the fifth drive 610e and sixth drive 610f operatively coupled to the fifth drive shaft 702e and the sixth drive shaft 702d to cause jaws 410, 412 ( Figure 4 () clamping.

[0091] exist Figure 11A In this embodiment, the first algorithm 1100a can be configured to use feedback control of the position of the "master motor" to achieve a device target set by the clinician 112a. More specifically, the first algorithm 1100a can be configured to directly control the slave current based on the master current. Here, the target slave current is equal to the actual master current output to the "master motor". In the illustrated example, the second driver 610b is designated as the "master motor", and the third driver 610c is designated as the "slave motor". The clinician 112a can clamp or manipulate the user input device 203 to achieve a desired orientation or wrist angle for the wrist joint 406. Therefore, the clinician 112a inputs the desired orientation or wrist angle of the wrist 406 to the computer system 600 via manipulation of the user input device 203. Figure 6 Similarly, the clinician 112a can clamp or manipulate the user input device 203 to achieve clamping of jaws 410, 412. Figure 4The desired orientation or closing angle of the jaws 410, 412 is input into the computer system 606 by moving either or both of them into the desired orientation or closing angle. The computer system 606 then uses an algorithm 1100a to convert the desired orientation or wrist angle of the wrist 406 (and / or the desired orientation or closing angle of the jaws 410, 412, etc., the position target of the end effector 404, etc.) into the position target of the main motor using a formula for the movement or positioning of the wrist 406 (and / or the jaws 410, 412, etc.). In one example, the formula is:

[0092]

[0093]

[0094] In these formulas, "pin radius" is the distance between the central axis of the pivot 1034 (of the base 806) and the central axis of one of the pins 1060a and 1060b (of the joint movement member 808), as evaluated in the plane in which the wrist 406 performs joint movement, where "gear radius" is the radius of the second pinion 713a and 713b of the compound pinions 710a and 710b, and "gear ratio" is the combined gear ratio of the spur gears 709a and 709b, the idler gear assembly 715a and 715b, and the first pinion 711a and 711b.

[0095] Through algorithm 1100a, computer system 606 ( Figure 6 The actual position (e.g., angular position) of the "master motor" relative to a master motor position target can be continuously monitored, and then the actual position of the master motor is subtracted from the master motor target position to obtain the master position error. Based on algorithm 1100a, the computer system 606 can then supply voltage to the "master motor" through the master or main control loop according to the master position error, the change of the master position error, and / or the accumulation of the master position error over time. At the same time, the master position error of the master control loop is fed to the auxiliary or slave control loop of the "slave motor".

[0096] In some implementations, algorithm 1100a may utilize a lookup table to convert the master position error into a target current for the slave motor, and the feedback controller in the control loop monitors the actual current of the slave motor and adjusts the voltage supplied to the slave motor to achieve the target current. In doing so, the master motor is used to achieve the target motor position (corresponding to the desired orientation or angle of the wrist 406 and / or the desired closing angle of the jaws 410, 412), where the slave motor cooperates by helping to push or pull internal drive components in the same direction driven by the master motor, rather than resisting or pushing such internal drive components in the opposite direction driven by the master motor. For example, when the second actuator 610b causes the drive shaft 702b to rotate to translate the first drive member 720a distally and thereby articulates the wrist 406, the third actuator 610c will help achieve such desired articulation by rotating the third drive shaft 702c and thereby moving the second drive member 720b proximally. Therefore, the two actuators 610b, 610c can work together to complementaryly induce joint movement of wrist 406 (i.e., dominantly), rather than having only one of the actuators 610b, 610c operate independently (i.e., antagonistically) if one of the actuators 610b, 610c may counteract the force output by the other.

[0097] Figure 11B It can be programmed to Figure 6 A schematic diagram of another algorithm 1100b in the computer system 606. The second algorithm 1100b can be configured to control the slave current based on the proportion of the master current. Here, the target slave current is equal to the proportion of the actual master current output to the "master motor".

[0098] Figure 11C It can be programmed to Figure 6 A schematic diagram of the third algorithm 1100c in the computer system 606. The third algorithm 1100c can be configured to control the slave current based on the ratio of the main current and the direction change sensed in the "main motor". More specifically, the direction change of the "main motor" is sensed as a change in the main current between positive and negative values ​​(and vice versa), and each such direction change generates a decaying current peak, which is added to the proportion of the actual main current output to the "main motor". In addition to the proportional main current, the exponentially decaying current peak generated after each direction change of the "main motor" is used to help the "slave motor" catch up with the "main motor".

[0099] As described in this article, Figure 6 The drivers 610a-610f are configured to be able to communicate with the corresponding drive inputs 608a-608f ( Figure 6 ) to cause the associated drive shaft 702a-f connected thereto ( Figures 7A to 7BThe rotation of the end effector 404 causes the end effector 404 to rotate. Figure 4 ) and / or wrist 406 ( Figure 4 Various movements of the tool 400. Each drive input 608a-608f may have an intermediate or non-articular position in which it does not impart corresponding movement to the end effector 404 and / or wrist 406, but the drive input 608a-608f may sometimes be in the tool 400 ( Figure 6 The drive inputs 608a-608f may be moved from their intermediate position before being coupled to the tool driver 604. In some cases, such as, the drive inputs 608a-608f may have been previously actuated from their intermediate position to cause movement in the end effector 404 and / or wrist 406 during previous use. In other cases, or otherwise, one or more of the drive inputs 608a-608f may be rotated out of their intermediate position during sterilization or cleaning.

[0100] However, it is important to be able to quickly and accurately return drive inputs 608a-608f to an intermediate position during or before use. To ensure that the actuators 610a-610f do not command drive inputs 608a-608f to positions that could damage the surgical tool 400, a system can be provided to accurately “return” the surgical tool 400 or one or more subsystems of the surgical tool 400. For example, drive inputs 608a-608f may have a starting position corresponding to a known position of the end effector 404 and / or wrist 406, and returning the surgical tool 400 to its position can associate the angular position of the actuators 610a-610f and the drive inputs 608a-608f associated therewith with the known position of the end effector 404 and / or wrist 406. This relationship can not only be used to suppress over-actuation (or over-rotation) of the drive inputs 608a-608f that might otherwise damage the surgical tool 400, but it can also be used to establish the actual position of the end effector 404 and / or the wrist 406 in space.

[0101] Conventional homing systems typically utilize mechanical limit switches and closely monitor the torque output of the actuators 610a-610f to locate the starting position of the drive inputs 608a-608f. However, for this to work, the actuators 610a-610f must rotate slowly to detect torque peaks before encountering a hard stop, potentially damaging components associated with the limit switches. This can add significant time to the homing sequence, especially when using surgical tools with high gear ratios.

[0102] According to the embodiments of this disclosure, the robotic surgical system 100 ( Figure 1The device may include a return system configured to enable the drive inputs 608a-608f to quickly return to their intermediate position. Surgical tool 400 Figure 4 The drive inputs 608a-608f can be manufactured to be mounted on a sterile barrier of a robot manipulator, such that the rotational positions of the drive inputs 608a-608f are known. For example, when in a certain rotational position, the drive inputs 608a-608f can each be bonded to their corresponding drivers 610a-610f. This allows the homing system to be coupled to the tool driver 604 in the surgical tool 400. Figure 6 When the relative rotation (angular) position of the drive inputs 608a-608f is identified, the relative rotation position of the drive inputs 608a-608f is associated with the specific cumulative motor position of the drivers 610a-610f known to the homing system.

[0103] During manufacturing, the surgical tool 400 is calibrated to determine the absolute rotational value when each of the drive inputs 608a-608f is in its starting position (e.g., 180°), and when the surgical tool 400 is coupled to the tool driver 604 ( Figure 6 When these known calibrated starting positions are in use, they are stored in the memory of the surgical tool 400 and are accessible by the surgical system 100. A window or “slow zone” is a series of rotational positions around the known calibrated starting position when the drive inputs 608a-608f are in the starting position (e.g., 180° ± 40°), which can be constructed around the known calibrated starting position and similarly stored in the memory of the surgical tool 400 (e.g., ...). Figure 6 In the computer system 606). The homing system can be integrated with the rotary encoder 630 ( Figure 6 The system communicates to determine the angular and / or rotational position of each drive input 608a-608f. When drive inputs 608a-608f rotate near the corresponding "slow zone" based on the absolute motor position of the drives 610a-610f as measured by the corresponding rotary encoder 630, the homing system can be programmed to reduce the speed at which the drives 610a-610f rotate.

[0104] Figure 12 The illustration shows a surgical tool 400 configured to intelligently adjust based on the rotational position of the drivers 610a-610f and / or the drive inputs 608a-608f operatively coupled thereto, according to one or more embodiments. Figure 4The upper, middle, and lower diagrams illustrate the operation of an exemplary return system for the return speed of a surgical instrument 400. In the illustrated example, the surgical instrument 400 is manufactured such that the initial position of one of the drive inputs 608a-608f occurs at an absolute angular position of 180°, and the surgical instrument 400 is calibrated to determine that the drive inputs 608a-608f can rotate (clockwise or counterclockwise) six (6) full revolutions from this initial position until the limit is reached. The intermediate position of the drive inputs 608a-608f is located at the midpoint of the total range. The position of the subsystem before the intermediate position will be negative; while the position of the subsystem after the intermediate position will be positive. In this example, the surgical instrument 400 has a gear ratio such that three (3) rotations of one of the drive inputs 608a-608f result in one (1) rotation of the end effector 404. This information can be stored in the surgical instrument 400, such as in a computer system 606. Figure 6 ) or internal computer 622 ( Figure 6 ) memory 624 ( Figure 6 The drive housing 408 is fitted into the tool driver 604, which places the internal computer 622 in communication with the computer system 606. Furthermore, an 80° “slow zone” is designed to cover the absolute angular positions of the drive inputs 608a-608f, thus providing a 40° buffer (e.g., 180° ± 40°) before and after an absolute angular position of 180°, which corresponds to the drive inputs 608a-608f in their initial positions, and this information is also stored in the surgical tool 400.

[0105] exist Figure 12 The figure above shows the angular position of the end effector 404 in degrees compared to the relative subsystem position in degrees. In this example, the surgical tool 400 begins its homing procedure from a maximum of six (6) full rotations from its starting position. The figure shows the subsystem starting at the negative extreme of its position, moving toward the intermediate position, and continuing in that direction until it reaches its positive extreme.

[0106] Figure 12The intermediate diagram shows an absolute angular measurement in degrees of the rotational position of one of the drive inputs 608a-608f compared to the relative subsystem position in degrees. This diagram shows one of the drive inputs 608a-608f returning to an absolute angular position of 0° after reaching 360°, as it displays the absolute position of the drive inputs 608a-608f rather than the incremental position. The diagram shows the potential intermediate position occurring at an absolute angular position of 180° bonded to a known relative subsystem position, and how the drivers 610a-610f rotate the drive inputs 608a-608f six (6) full revolutions until the actual intermediate position is reached. Furthermore, the diagram shows an 80° “slow zone” constructed around the absolute angular position of one of the drive inputs 608a-608f, and how the “slow zone” bonds to the known cumulative position of the drivers 610a-610f.

[0107] Figure 12 The following diagram illustrates how the homing system can adjust the speed of the drivers 610a-610f driving the drive inputs 608a-608f based on the relative subsystem position in degrees. Here, the diagram shows the drivers 610a-610f rotating the drive inputs 608a-608f at a first speed when the drive inputs 608a-608f are not oriented in the "slow zone," and then gradually reducing the speed to a second speed less than the first speed when the drive inputs 608a-608f are oriented in the "slow zone."

[0108] Figure 13 A joint motion connector 1300 for facilitating joint movement of a wrist 406 according to one or more embodiments of the present disclosure is shown. As described above, the wrist 406 can perform joint movement in a plane by counteractingly actuating a linkage assembly. More specifically, the wrist 406 can rotate clockwise by pushing a first drive member 720a while pulling a second drive member 720b, and the wrist 406 can rotate counterclockwise by pulling the first drive member 720a while pushing the second drive member 720b. Thus, the connector 1300 can rotate via counteracting translation of the first drive member 720a and the second drive member 720b, and as previously described, the drive members 720a, 720b are respectively connected via a second drive input 608b and a third drive input 608c. Figure 4 The operation of ) is actuated, which is then actuated by the second driver 610b and the third driver 610c respectively. Figure 4 )drive.

[0109] However, during surgery, the end effector 404 and wrist 406 may be positioned within a body cavity and potentially adjacent to patient tissue. In this case, the articulation joint 1300 may potentially need to move adjacent tissue. Therefore, in order to move the wrist 406 to the desired orientation, the robotic surgical system 100 may be configured to enable the second actuator 610b and the third actuator 610c ( Figure 4 The drive members 720a and 720b are translated with forces sufficient to overcome any external loads exerted by the tissue during surgery, and maintain or preserve the desired orientation even when subjected to such external loads.

[0110] Figure 14 It is available via one or more implementation schemes. Figure 13 A schematic diagram of an exemplary control scheme 1400 for controlling the joint movement of wrist 406 via joint 1300. In the illustrated example, control scheme 1400 utilizes an algorithm that allows smooth and continuous joint movement of joint 1300, locks joint 1300 so that it cannot be moved by external loads, and actively resists any external loads when joint 1300 moves to a desired angle.

[0111] In the illustrated example, control scheme 1400 begins at starting point 1402. Control scheme 1400 first determines whether the mechanism that causes joint 1300 to articulate is correctly positioned, such as at node 1404. If joint 1300 is not correctly positioned, control scheme 1400 initiates a positioning sequence or positioning process, such as at 1406. During the repositioning process of 1406, any slack in the joint 1300 mechanism is eliminated by similarly opposing joint movements (i.e., pulling and pushing, respectively) of the drive members 720a and 720b to the specified torque or current of the corresponding actuators 610b and 610c, thereby repositioning the joint 1300; the joint 1300 is jointed (clockwise or counterclockwise) and the angular limits are recorded to find the starting position of the actuators 610b and 610c; and the joint 1300 is jointed until the actuators 610b and 610c are in their starting positions, wherein the drive members 720a and 720b are under tension and compression, respectively.

[0112] If connector 1300 is correctly positioned, clinician 112a can guide or command the robot to move the joints of connector 1300 to the desired joint motion angle. More specifically, if control scheme 1400 determines that the mechanism of connector 1300 is correctly positioned, a joint motion command input can be provided to control scheme 1400, as at 1408. The joint motion command input can indicate the desired joint motion angle of connector 1300 for clinician 112a. Control scheme 1400 continues operation by comparing the new joint motion command of connector 1300 (i.e., the "new joint motion angle command") with the old joint motion command of connector 1300 (i.e., the "old joint motion command"), as at 1410. Here, control scheme 1400 can determine whether the new joint motion command of connector 1300 is less than, greater than, or equal to the old joint motion command of connector 1300. Based on the relative values ​​of the new and old joint movement commands, control scheme 1400 initiates individual joint movement processes, as described herein in joint movement processes 1412a, 1412b and 1412c.

[0113] Furthermore, the relative values ​​of the new and old joint movement commands indicate whether the clinician 112a desires to move the wrist 406. For example, the clinician 112a may desire to move the connector 1300 clockwise or counterclockwise, or to maintain the connector 1300 in a specific position. If the clinician 112a commands the connector 1300 to move the wrist 406 clockwise, the control scheme 1400 initiates a first joint movement process, as at 1412a. If the clinician 112a commands the connector 1300 to move the wrist 406 counterclockwise, the control scheme 1400 initiates a second joint movement process, as at 1412b. If the clinician 112a does not command the connector 1300 to move the wrist 406, meaning the wrist 406 will remain in its position, the control scheme 1400 initiates a third joint movement process, as at 1412c.

[0114] In the illustrated example, if control scheme 1400 determines at decision node 1410 that the new joint movement command is less than the old joint movement command, meaning that joint 1300 will move clockwise, then control scheme 1400 initiates the first joint movement process 1412a. Here, the first joint movement process 1412a places the second actuator 610b associated with the first drive member 720a in its position mode and actuates the third actuator 610c to the command angle at a predetermined speed limit. Simultaneously, the first joint movement process 1412a places the third actuator 610c associated with the second drive member 720b in torque (or current) mode to apply a predetermined torque (or current) to the third actuator 610c, causing it to pull the second drive member 720b with a constant force.

[0115] In the illustrated example, if control scheme 1400 determines at decision node 1410 that the new joint movement command is greater than the old joint movement command, meaning that joint 1300 will move counterclockwise, then control scheme 1400 initiates the second joint movement process 1412b. Here, the second joint movement process 1412b places the second actuator 610b associated with the first drive member 720a into torque (or current) mode to apply a specified torque (or current) to the second actuator 610b, causing it to pull the first drive member 720a with a constant force. Simultaneously, the second joint movement process 1412b places the third actuator 610c into its position mode and actuates the third actuator 610c to the command angle at a specified speed limit.

[0116] In the illustrated example, if control scheme 1400 determines at decision node 1410 that the new joint movement command is equal to the old joint movement command, meaning that the joint movement command has not changed and the connector 1300 will remain stationary, then control scheme 1400 initiates the third joint movement process 1412c. Here, the third joint movement process 1412c waits for either the second actuator 610b or the third actuator 610c, which is in position mode, to move to its commanded angle, and then places both the second actuator 610b and the third actuator 610c in position mode to hold or maintain the connector 1300 at a position corresponding to the desired joint movement angle of the wrist 406.

[0117] Furthermore, the third joint movement process 1412c can adjust the final command angle or position of one of the second actuators 610b or the third actuator 610c, which follows the movement of the other of the second actuators 610b or the third actuator 610c, such that the final pretension in the drive members 720a, 720b will be equal to the initial pretension in the drive members 720a, 720b, because the amount of torque applied to the joint 1300 by each of the drive members 720a, 720b varies according to the angle of the joint 1300. Specifically, the wrist 406 of the joint movement subsystem is initially positioned by moving the second actuator 610b and the third actuator 610c, such that there is a certain amount of pretension in the drive members 720a, 720b, and then the second actuator 610b moves in response to a new joint movement command input by the clinician 112a. When the second actuator 610b moves, thereby pulling its corresponding drive member 720a, another motor (i.e., the third actuator 610c) can be disabled (i.e., idled) or placed in current mode and subjected to a minimum current. Here, when the second actuator 610b moves to achieve its final destination, in which the connector 1300 moves to an angular position corresponding to the joint movement command, the third actuator 610c is placed in position mode and set to the target position, and the target position changes with the joint movement command such that the tension of the drive members 720a, 720b will be equal to the pretension initially applied to the drive members 720a, 720b. Therefore, the angular distance between the second actuator 610b and the third actuator 610c can vary with the joint movement angle of the connector 1300. For example, if the second actuator 610b and the third actuator 610c are initially separated by fifty degrees (50°) with a pretension torque of 0.1 Nm, and then the joint 1300 moves to an angle of ten degrees (10°), the second actuator 610b and the third actuator 610c will move such that they are separated by sixty degrees (60°) to have equal pretension in the drive members 720a, 720b.

[0118] Figure 15A and Figure 15B It shows Figure 14 An exemplary operation of the control scheme 1400. Specifically, Figure 15A The application of the first joint movement process 1412a is shown when the actuators 610b and 610c are controlled to make the joint 1300 move clockwise. Figure 15B The application of the second joint movement process 1412b is shown when the control actuators 610b and 610c cause the joint 1300 to move counterclockwise. Figure 15AIn this configuration, control scheme 1400 has placed the second actuator 610b in a position mode. In this position mode, control scheme 1400 monitors the movement of the second actuator 610b that translates the first drive member 720a. Furthermore, in this position mode, control scheme 1400 allows the third actuator 610c to control the second drive member 720b to pull with a limited motor torque. Additionally, control scheme 1400 has placed the third actuator 610c in a torque (or current) mode, in which the third actuator 610c applies a constant pulling (or pushing) force to the second drive member 720b.

[0119] exist Figure 15B In this configuration, control scheme 1400 has placed the third actuator 610c in a position mode, wherein control scheme 1400 monitors the movement of the third actuator 610c that causes the translation (movement) of the second drive member 720b, and wherein control scheme 1400 allows the second actuator 610b to control the first drive member 720a to pull at a limited motor speed. Furthermore, control scheme 1400 has placed the second actuator 610b in a torque (or current) mode, wherein the second actuator 610b applies a constant pulling (or pushing) force to the first drive member 720a.

[0120] It is generally desirable to make the joint 1300 move as quickly as possible, thereby enhancing the surgical tool 400. Figure 4 The responsiveness of the joint 1300 is limited. However, the amount of articulation that the joint 1300 can perform is physically limited, and when the joint 1300 is articulated at high speed, if the joint 1300 reaches its limit at an increased speed, the internal components of the surgical tool 400 may be damaged. For example, the impact caused by the joint 1300 reaching its limit at high speed may damage the articulation component 808. Figures 9A to 9B and Figures 10A to 10B The drive pins 1060a and 1060b ( Figure 10B ) and / or drive components 720a, 720b. Therefore, this document discloses a system and method for controlling the joint 1300 and preventing it from reaching its physical limits at increasing speeds, thereby minimizing or avoiding impacts on the underlying mechanism that enables articulation between the joint 1300 and the wrist 406.

[0121] Figure 16 It is a method for rapidly controlling joint movement of the wrist 406 according to one or more embodiments while preventing Figure 13A schematic diagram of an alternative exemplary control method or scheme 1600 for the connector 1300 to reach its physical limits at high speed. In the illustrated example, control scheme 1600 allows actuators 610b, 610c to cause translation (motion) of drive members 720a, 720b and thereby articulation of connector 1300, to move at maximum speed when the instantaneous angle of connector 1300, estimated or measured based on feedback of the position of actuators 610b, 610c, is within defined safety limits. When it is determined that the instantaneous angle of connector 1300 is outside the defined safety limits, control scheme 1600 slows down the speed of actuators 610b, 610c when connector 1300 articulates at an angle close to the physical limits of connector 1300.

[0122] The joint 1300 has a known range of motion that defines the amount by which the wrist 406 can be angled from its non-jointed position when it extends straight along the longitudinal axis A1 of the shaft 402. For example, the joint 1300 may be configured to be able to reach its physical limits relative to the longitudinal axis A1 ( Figure 4 The joint moves 60 degrees (clockwise) or counterclockwise. Therefore, in this example, the range of motion of joint 1300 will be ±60 degrees (±60°) with respect to the longitudinal axis A1, such that joint 1300 has a physical limit at 60 degrees (60°) in any direction from the longitudinal axis A1, thereby providing joint 1300 with a total range of joint motion of 120 degrees (120°). Safety limits can be defined at any point within the joint range. For example, safety limits can be defined at ±55 degrees (±55°) with respect to the longitudinal axis A1, such that joint 1300 has a safety limit at 55 degrees (55°) in any direction from the longitudinal axis A1, thereby providing joint 1300 with a range of joint motion of 110 degrees (110°) between the safety limits.

[0123] In this example, control scheme 1600 operates actuators 610b and 610c at a first speed when joint 1300 performs articulation at an instantaneous angle ∠A (∠A < ±55°) less than ±55 degrees with respect to the longitudinal axis A1, and then reduces the speed of actuators 610b and 610c when the instantaneous angle ∠A of joint 1300 is greater than or equal to 55 degrees (∠A ≥ ±55°). Therefore, control scheme 1600 slows down actuators 610b and 610c when the instantaneous angle ∠A of joint 1300 approaches or nears physical limits (e.g., ±60° > ∠A ≥ ±55°), and accelerates actuators 610b and 610c when the instantaneous angle ∠A of joint 1300 is within safe limits (e.g., ∠A is between -55° and 55°).

[0124] When control scheme 1600 determines that the instantaneous angle ∠A of connector 1300 exceeds a safety limit (e.g., -60° ≥ ∠A ≥ -55° or 55° ≤ ∠A ≤ 60°), control scheme 1600 slows down drivers 610b and 610c. In one example, control scheme 1600 slows drivers 610b and 610c to a second speed, which is less than the first speed at which drivers 610b and 610c operate when the instantaneous angle ∠A of connector 1300 is within the safety limit. However, in other examples, control scheme 1600 continuously reduces the speed of drivers 610b and 610c as connector 1300 approaches physical limits, such that control scheme 1600 operates drivers 610b and 610c at a reduced speed range when the instantaneous angle ∠A of connector 1300 exceeds the safety limit. For example, control scheme 1600 can slow down drivers 610b and 610c when the instantaneous angle ∠A of connector 1300 is at a safe limit, and then further slow down drivers 610b and 610c when the instantaneous angle ∠A of connector 1300 approaches the physical limit.

[0125] Therefore, after initializing control scheme 1600, as follows Figure 16 As indicated by starting point 1602, control scheme 1600 is configured to receive a command joint movement angle, indicating the angle at which the connector 1300 will move the joint, as shown at 1604. More specifically, control scheme 1600 includes input from clinician 112a, which indicates the angle at which clinician 112a expects to move the wrist 406. Upon receiving the command joint movement angle input via input 1604, control scheme 1600 initiates a process for adjusting the command joint movement angle based on a speed control algorithm, as shown at 1606.

[0126] After process initialization, control scheme 1600 receives feedback 1608 indicating the position of drivers 610b and 610c, as shown at 1608. Then, control scheme 1600 uses the feedback information to estimate the current angle of joint movement of connector 1300, as shown at 1610. Then, control scheme 1600 determines whether the joint movement angle of connector 1300 is close to its physical limit, as shown at 1612. If the joint movement angle of connector 1300 is not close to or is within the range before the limit, control scheme 1600 initiates an instruction that does not change the commanded joint movement angle of connector 1300 (i.e., maintains the commanded joint movement angle), as shown at 1614. Control scheme 1600 may terminate at this point, as indicated by stop point 1616. Various other systems or control schemes may be initiated after stop point 1616. For example, stop point 1616 of control scheme 1600 may correspond to the starting point 1402 of control scheme 1400 detailed above. Therefore, the robotic surgical system 100 can be configured to continuously operate control scheme 1600 and control scheme 1400.

[0127] If the joint motion angle of connector 1300 is close to (or within range before its limit), control scheme 1600 initiates a command that causes connector 1300 to move at a specified or permissible speed before reaching stop point 1616, as at 1618. Therefore, the command will cause actuators 610b, 610c to rapidly move connector 1300 to the desired joint motion angle or the physical limit of connector 1300, to the extent that the desired joint motion angle is within the permissible range of motion of connector 1300. In the illustrated example, the command at 1618 continuously compares the current commanded joint motion angle with a previously commanded joint motion angle to determine when the motor position of actuators 610b, 610c approaches the physical limit of connector 1300. The command may calculate the permissible speed at which actuators 610b, 610c operate to allow joint motion of connector 1300 based on how close connector 1300 is to its physical limit or based on the position of connector 1300 within a safe zone immediately preceding its physical limit.

[0128] Control scheme 1600 can be configured to change the speed of motors 130a and 130b when joint 1300 is articulating between its physical limits based on how close joint 1300 is to its physical limits. For example, a command at 1618 can scale the speed of drivers 610b and 610c (e.g., linear or nonlinear) from a maximum speed to a minimum speed when joint 1300 is close to its physical limits. In one example, the command instructs drivers 610b and 610c to operate at a command speed equal to the difference between the current command joint angle and the previous command joint angle divided by the time step between these two measurements (i.e., command speed = (current command joint angle – previous command joint angle) / time step). If the command speed is less than the permissible speed calculated by control scheme 1600, command 1618 does not need to change the command joint angle. However, if the command speed is greater than or equal to the permissible speed calculated by control scheme 1600, command 1618 changes the command joint angle such that the command speed will equal the permissible speed.

[0129] Figure 1 The robotic surgical system 100 can be configured to enable surgical instruments 400 ( Figure 4 According to clinician 112a ( Figure 1 The surgical tool 400 responds accurately to the instructions of the clinician 112a. However, various conditions may exist (or exist during use) that impair or inhibit the accurate response of the surgical tool 400 to inputs from the clinician 112a. For example, the accuracy of the surgical tool 400 may be affected by conditions such as mechanical wear, frictional changes, user misuse, and wear and tear, and these conditions may change during use. To ensure that the operation of the surgical tool 400 is related to the commands input by the clinician 112a (i.e., positional accuracy), the robotic surgical system 100 may include a robust error detection system to compensate for various conditions that may change during the use of the surgical tool 400. Such error detection systems can be used to ensure the accuracy of various functions of the surgical tool 400, including homing sequences, joint movements of the wrist 406, closure and / or gripping of the jaws 410, 412, etc. Therefore, a control system and scheme for ensuring the accuracy of the surgical tool 400 by detecting errors in the position of the surgical tool 400 based on position values ​​recorded on the surgical tool 400 during manufacturing are disclosed herein.

[0130] In some embodiments, the surgical tool 400 may include an end effector 404 ( Figure 4 ) and / or wrist 406 ( Figure 4The various movements of the end effector 404 and / or wrist 406 are restricted to physical features (or stops) within a predefined range of motion. These features may be set or calibrated into the surgical tool 400 during its manufacture to correspond to various movements or positions of the end effector 404 and / or wrist 406. For example, the features may be set during manufacture to relate to the fully forward position of the end effector 404, the fully articulated position of the wrist 406, the starting position of the wrist 406, or any other desired position.

[0131] As described above, the surgical instrument 400 may include an internal computer 622. Figure 4 The internal computer may include memory 624 ( Figure 4 The location of the physical features can be stored in memory 624 and used as a target to determine whether it operates accurately. For example, the surgical tool 400 can be calibrated during manufacturing to determine the position of a given drive input 608a-608f. Figure 6 The system determines how many revolutions are needed to move the end effector 404 and / or wrist 406 to the desired position and the specific angle at which the drive inputs 608a-608f are oriented when in the desired position; this information can be stored in memory 624. Furthermore, each surgical tool 400 can be calibrated during its manufacture to measure the torque exhibited on the drive inputs 608a-608f when they are fully rotated from their starting position in each direction, and this torque information can be recorded in memory 624. Moreover, the relative positions of the drive inputs 608a-608f can be recorded in memory 624 when two or more of them are used to move the end effector 404 and / or wrist 406. With any or all of this information stored in memory, the accuracy control system can provide feeds specific to a particular surgical tool 400 engaged in the robot manipulator.

[0132] In various examples, the accuracy control system can be used to enable one or more of the drive inputs 608a-608f ( Figure 6 ) Reset. Two or more of the drive inputs 608a-608f are actuated to cause the surgical tool 400 ( Figure 4 In an example of a specific movement, the actual angular positions of the drive inputs 608a-608f when they are in the starting position and the relative positions of the drive inputs 608a-608f when they are in the starting position (i.e., the angular difference between them) are stored in the onboard memory 624 of the surgical tool 400 during manufacturing. Figure 6Then, when the surgical instrument 400 is mounted on the robot manipulator, the accuracy control system reads the position of one of the drive inputs 608a-608f as it rotates in the "start" direction, and simultaneously calculates the position of the associated drive inputs 608a-608f via relative position data stored in the memory 624, until all associated drive inputs 608a-608f reach the position recorded in the memory within a certain error.

[0133] In an example where only one of the drive inputs 608a-608f is used to cause a specific movement of the surgical tool 400, the starting position of the specific drive input 608a-608f is stored in memory 624. Figure 6 In this process, the accuracy control system can determine the position of the corresponding driver 610a-610f by comparing the actual angular position of the drive inputs 608a-608f with the "original" position stored in memory when the surgical tool 400 was installed in the robot manipulator. Figure 6 The accuracy control system determines whether a specific drive input 608a-608f is in its "starting position" when rotated in the "original" direction. In these examples, if a specific driver 610a-610f causes the corresponding drive input 608a-608f to rotate less than 360°, the accuracy control system can establish the starting position of the drive input 608a-608f when the surgical tool 400 is mounted on the robot manipulator. In some examples, if any of the drive inputs 608a-608f travels more than 360°, the "starting" position recorded in memory 624 can be combined with other homing control schemes as described herein for a confirmation check. Therefore, the accuracy control system can check whether the drive inputs 608a-608f are in their starting positions based on information stored in onboard memory 624.

[0134] In some examples, the accuracy control system can be extended to cross-check other non-initial positions of the drive inputs 608a-608f. For example, the accuracy control system can be used to cross-check the actual or momentary position of the surgical tool 400 realized during operation with the position stored in memory 624. Figure 6 The set values ​​in the ) are compared to accurately rotate the drive input section 608a-608f. Figure 6 One or more of the following to achieve surgical tools 400 ( Figure 4 The desired movement or position of the surgical tool 400. In these examples, the surgical tool 400 is calibrated during manufacturing, wherein the end effector 404 ( Figure 4 ) and / or wrist 406 ( Figure 4 The positions of the various drive input sections 608a-608f and the corresponding drivers 610a-610f are as follows: Figure 6 The torque applied to it is related, and such calibration information is stored in the memory 624 of the surgical tool 400. For example, the rotational position and / or torque of any of the drive inputs 608a-608f corresponding to the fully advanced position of the end effector 404 (e.g., fully expanded jaws 410, 412), the full angular position of the wrist 406, and / or the starting position of the end effector 404 and / or the wrist 406, etc., can be recorded in the memory 624. This stored information provides a specific or unique target for a particular surgical tool 400 mounted in a robotic manipulator. If the robotic surgical system 100 ( Figure 1 If one or more of the actuators 610a-610f are driven to a specific position, and the actual realized position of the end effector 404 and / or wrist 406 of the surgical tool 400 is not related to the position information stored in the memory 624, the accuracy control system will report an error in the position.

[0135] In some examples, the accuracy control system and two or more of the drive input units 608a-608f ( Figure 6 For example, an accuracy control system can be combined with a control wrist 406 ( Figure 4 The drive input sections 608b and 608c are used together, and / or with control jaws 410 and 412. Figure 4 The drive inputs 608d and 608e are used together. In these examples, during the manufacture of the surgical tool 400, when the surgical tool 400 is in a predetermined desired position (i.e., the desired position of the end effector 404 and / or the wrist 406), the absolute angular position of two or more of the drive inputs 608a-608f is read and stored in the memory 624. Figure 6 In the memory 624, the relative angular positions (i.e., the angular difference between drive inputs 608a-608f) corresponding to the set position of the surgical tool 400 are also recorded. The absolute angles of drive inputs 608a-608f correspond to globally consistent angles that are consistent over time and within the robot-power cycle. For example, graphic arrows can be provided on drive inputs 608a-608f such that it can be determined that the angle of drive inputs 608a-608f is "absolute zero" when such graphic arrows are aligned with the corresponding graphic arrows on the robot's tool driver 604. When the surgical tool 400 is mounted in the robot manipulator and the clinician 112a inputs a command to move the surgical tool 400 to the desired position, if the actual position of drive inputs 608a-608f corresponding to the clinician 112a's desired movement does not match the position information stored in the memory 624, the accuracy control system will report an error.

[0136] In other examples, the accuracy control system is combined with only one of the drive inputs 608a-608f. In these examples, the absolute position of one of the drive inputs 608a-608f corresponding to the set desired position of the surgical tool 400 is stored in its memory 624 during manufacturing or calibration, and during use, the accuracy control system can check whether the surgical tool 400 is in the desired position.

[0137] In some examples, the accuracy control system can be configured to detect jaws 410, 412 ( Figure 4 The closure error of the drive input sections 608a-608f (corresponding to the closure of jaws 410, 412) is due to the failure of the jaws to close. Figure 6 The actual position of the jaws 410, 412 does not match the fully closed position of the drive inputs 608a-608f set during manufacturing. In some examples, the accuracy control system may be configured to detect opening errors of the jaws 410, 412, where the actual position of the drive inputs 608a-608f corresponding to the fully open position of the jaws 410, 412 does not match the fully open position of the drive inputs 608a-608f set during manufacturing. In some examples, the accuracy control system may be configured to detect gripping errors of the jaws 410, 412, where the actual position of the drive inputs 608a-608f corresponding to the gripping of the jaws 410, 412 relative to each other at a set position does not match the gripping position of the drive inputs 608a-608f set during manufacturing. In some examples, the accuracy control system may be configured to monitor changes in any of the above positions when using the surgical tool 400, and if they change by a specified amount (or more), the accuracy control system may be configured to report wear errors.

[0138] Robotic Surgical System 100 ( Figure 1 It may also include or incorporate a control scheme that synchronizes the movement of drive components 720a and 720b, which means that tool driver 604 ( Figure 6 The second driver 610b () Figure 6 The first drive member 720a is translated, and the third drive member 610c causes an equal and opposite translation of the second drive member 720b. For example, the wrist 406 ( Figure 4The left hand joint movement is achieved by moving the first drive member 720a proximally by a distance "x" while simultaneously moving the second drive member 720b distally by a distance "-x". The robotic surgical system 100 commands the actuators 610b and 610c (engaging drive inputs 608b and 608c) to rotate by distances "x" and "-x" respectively to the motor positions required to cause translation of the drive members 720a and 720b. Therefore, the actuator position commands R3 and R4 can be calculated based on the input from the clinician 112a (i.e., joint movement angle commands) to synchronously translate the drive members 720a and 720b. The actuator position commands R3 and R4 can be calculated using the following formula:

[0139]

[0140]

[0141] This control scheme converts the input from clinician 112a (i.e., joint motion angle command) into rotation of actuators 610b and 610c. In this control scheme, the values ​​“x” and “-x” are not directly calculated because the input from clinician 112a is the desired angle of the moving wrist 406, and from this input, the control scheme outputs rotation input or control (i.e., actuator position commands R3 and R4) for actuators 610b and 610c. To calculate “x”, the formula would be x = R3 * gear ratio * 2 * π * gear radius, and “-x” can be calculated similarly. The aforementioned formula includes a mathematical representation of the physical components of the surgical tool 400, wherein the pin radius is the distance from the center of the pivot 1034 to the center of the drive pins 1060a, 1060b, the gear ratio is the ratio generated from the spur gears 709a, 709b through the idler gear assemblies 715a, 715b (i.e., compound gears) to the compound pinions 710a, 710b, and the gear radius is the radius of the second pinions 713a, 713b (of the compound pinions 710a, 710b) that interact with the drive racks 712a, 712b.

[0142] However, this synchronized control scheme may not accurately move the wrist 406 to the desired joint movement angle commanded by the clinician 112a. For example, even if the clinician 112a inputs a desired joint movement angle of 45°, friction due to wear may cause the wrist 406 to move only 40 degrees. In addition to reduced joint accuracy, this synchronized control scheme may result in reduced mechanical gain as the wrist 406 moves at an increasing angle over time.

[0143] Therefore, the robotic surgical system 100 may include an improved control scheme configured to enhance the joint movement of the wrist 406. In some examples, the robotic surgical system 100 includes a differential control scheme for controlling the movement of the drive components 720a, 720b to more accurately move the wrist 406 joint to the desired wrist position input by the clinician 112a. In various examples, the differential control scheme may also increase the maximum angle of joint movement that the wrist 406 can joint and increase the mechanical gain of the wrist 406 (i.e., the force by which it can joint).

[0144] The differential control scheme utilizes the formula described above and modifies it with a constant α or a mathematical function to passively control the calculated actuator position commands R3 and R4, thereby causing the drive members 720a and 720b to move. For example, the differential control scheme achieves the left hand joint movement of the wrist 406 by moving the first drive member 720a a distance "x" via the first motor command R3 and simultaneously moving the second drive member 720b a distance "-x-α" via the second motor command R4. Therefore, one side of the joint movement system can move more (or less) than the other side. In this example, if the geometry is perfect and there is no friction, the constant α will increase the tension in the system. If the constant α is constant, the tension increase is applied only when the commanded joint movement angle is greater than (or less than) 0. However, the constant α can be described as increasing or decreasing with the commanded joint movement angle, and as described below, the constant α can be an empirically determined value and / or based on a mathematical function.

[0145] In some examples, the constant α can be determined empirically. In these examples, the constant α can be determined empirically during the testing, manufacturing, and / or calibration of the surgical tool 400, and therefore the constant α can be unique for each surgical tool 400. Here, the constant α can act as a correction factor between nominal conditions and actual conditions that take into account friction and wear (e.g., tension of drive members 720a, 720b) ​​to control the gear / linkage mechanism of the wrist 406. In one example, during manufacturing, each surgical tool 400 is placed in a test device that senses the joint motion angle of the wrist 406 while rotating drive inputs 608b, 608c. The constant α can be adjusted to minimize the error between the actual measured joint motion angle of the wrist 406 and the expected joint motion angle of the wrist 406, and then the value of the constant α can be stored in the memory of the surgical tool 400 for use by the robotic surgical system 100 during operation. When the actual measured joint motion angle of the wrist 406 is minimized, the value of the constant α is flashed to the surgical tool 400, making it available to the robotic surgical system 100.

[0146] In other examples, the constant α can be a value modified by a function. In these examples, a value can be assigned to the constant α, or it can be determined empirically as described above. In any case, the constant α can be modified by various functions of the desired angle input by the clinician 112a (i.e., the joint motion angle of the command), such as linear functions, sine functions, exponential functions, polynomial functions, or any combination thereof. Therefore, the drive position commands R3, R4 are calculated to translate the drive members 720a, 720b by a distance (i.e., "x" or "-x") based on the input from the clinician 112a (i.e., the joint motion angle of the command) by subtracting a correction factor, where the correction factor derived from the distance is a function of the joint motion angle of the command multiplied by the constant α.

[0147] In one example, the correction factor is a sine function of the modification constant α. Here, the constant α is a value multiplied by the sine of the desired angle (i.e., the joint movement angle of the command) input by the clinician 112a, such that the driver position commands R3, R4 are calculated using the following formula.

[0148] If the joint movement angle of the command is >0:

[0149]

[0150]

[0151] If the joint movement angle of the command is <0:

[0152]

[0153]

[0154] In another example, the correction factor is a linear function of a constant α. Here, the constant α is a value multiplied by the linear factor m (i.e., the slope) multiplied by the desired angle (i.e., the joint movement angle of the command) input by the clinician 112a plus b (i.e., the intercept), such that the driver position commands R3, R4 are calculated using the following formula.

[0155] If the joint movement angle of the command is >0:

[0156]

[0157]

[0158] If the joint movement angle of the command is <0:

[0159]

[0160]

[0161] In other examples, the correction factor is a polynomial function with a constant α. For example, a polynomial function (where a, b, and c are constants) could be as follows.

[0162] If the joint movement angle of the command is >0:

[0163]

[0164]

[0165] If the joint movement angle of the command is <0:

[0166]

[0167]

[0168] In other examples, the correction factor is an exponential function with a constant α. For example, an exponential function (where e is a constant) can be as follows.

[0169] If the joint movement angle of the command is >0:

[0170]

[0171]

[0172] If the joint movement angle of the command is <0:

[0173]

[0174]

[0175] Figure 17A and Figure 17B This illustrates drive input units 608b, 608c (using the aforementioned formula) according to one or more embodiments. Figure 6 The actual angular position output of each in the equation is compared with the graphical representation of the expected angular input. Specifically, Figure 17A The actual angular positions of the second drive input unit 608b were plotted for each desired angular position (i.e., the commanded joint motion angle) input by the clinician 112a under the current control scheme, sinusoidal control scheme, and linear control scheme. Similarly, Figure 17BThe actual angular positions of the third drive input 608c were plotted for each desired angular position (i.e., the commanded joint motion angle) input by the clinician 112a under the current control scheme, sinusoidal control scheme, and linear control scheme. Therefore, when the end effector 404 moves to the right (from the center), the angular displacement of the right drive input increases at a greater rate than that of the left drive input, and when the end effector 404 moves to the left (from the center), the angular displacement of the left drive input increases at a greater rate than that of the right drive input.

[0176] The surgical instruments 400 described and illustrated herein Figure 4 It is configured as a "rotational surgical tool" because it includes a rotary drive input section 608a-608f on the robotic manipulator. Figure 6 Each of the rotary drive input sections corresponds to a driver 610a-610f. Figure 6 Rotation. However, in other examples, the surgical tool 400 may be configured differently such that it can be actuated by a drive configured to impart different types of mechanical energy. For example, the surgical tool 400 may be configured as a linear drive tool having one or more linear drive inputs as described in U.S. Patent Application Publication No. 2018 / 0168745, the contents of which are hereby incorporated by reference. In some examples, the surgical tool 400 may include a combination of both rotation and linear drive inputs.

[0177] In some implementations, the robotic surgical system 100 ( Figure 1 It may include a closure control system configured to optimize the closure of tube 722. Figures 7A to 7B and 8A to Figure 8B The closing stroke of the jaws 410 and 412 is monitored by the closing control system to determine the closing stroke of the closing tube 722 along the longitudinal axis A1. Figure 4 , Figure 6 and Figures 7A to 7B The inflection point where the translation goes too far (i.e., overtravel). Therefore, a closed-loop control system can limit the drive input (e.g., Figure 6The actuation of the fourth drive input 608d and the fifth drive input 608e translates the closure tube 722 to the minimum stroke distance required to close the jaws 410, 412 in a particular application. The closure control system can thereby increase the reliability of the surgical tool 400 by limiting the application of high forces as needed. For example, when manipulating thicker tissue, an increased force is typically applied to the closure tube 722; while when manipulating tissue with a smaller thickness, a smaller amount of force is applied. Furthermore, the closure tube 722 will not experience over-closure events during the closure of the jaws 410, 412. Additionally, when the mechanism is less sensitive to mechanical variations and / or tolerances, the closure control system reduces the maximum closure stroke of the closure tube 722. Therefore, instead of a mechanism that translates the closure tube 722 to the maximum possible value required (depending on tissue variations and / or mechanical variations), the mechanism only needs to translate the closure tube 722 by a sufficient amount to achieve the inflection point.

[0178] Figure 18 A force-distance graph of an exemplary closure control system according to one or more embodiments is shown. In this example, the closure control system is configured to be actuated by an appropriate drive input (e.g., Figure 6 The corresponding drivers (e.g., the fourth drive input section 608d and the fifth drive input section 608e) are respectively. Figure 6 The fourth actuator 610d and the fifth actuator 610e) extend the closed tube 722. Figures 7A to 7B and Figures 8A to 8B The current required to drive the driver is recorded and utilized using the memory 624 stored in the surgical tool 400. Figure 6 The constant in the memory 624 is converted into force. Furthermore, the angular position of the actuator is recorded and converted into travel amount via a mechanism-dependent constant stored in memory 624. When the closure tube 722 is closed, the closure control system calculates the derivative of force with respect to distance and uses a low-pass filter to remove peaks in the curve caused by noise. Then, when the filtered derivative of force with respect to distance exceeds the mechanism-dependent threshold stored in the memory of the surgical tool 400, the closure control system stops further travel of the closure tube 722 and / or other closure mechanisms and reports that the surgical tool 400 is fully clamped. Upon receiving the report that the surgical tool 400 is fully clamped, the robotic surgical system 100 ( Figure 1 It can guide the firing of surgical instruments 400, thereby cutting across and applying the staple to the tissue held therein.

[0179] The implementation plan disclosed in this article includes:

[0180] A. A surgical tool comprising a drive housing, a shaft extending from the drive housing, a wrist disposed at an end of the shaft, and a linkage assembly actuated to perform articulated movements of the wrist in a plane, and including a first drive member extending from the drive housing and operatively connected to the wrist within the shaft, and a second drive member extending from the drive housing and operatively connected to the wrist within the shaft. Actuation of the first drive member and the second drive member in opposite axial directions within the shaft performs articulated movements of the wrist in the plane.

[0181] B. A method for locating a rotatable drive input of a robotic surgical tool, the method comprising recording a starting position of the drive input in a memory of the robotic surgical tool, establishing a slow zone covering a known angular amplitude away from the starting position, rotating the drive input toward the starting position, and slowing the rotational speed of the drive input upon reaching the slow zone.

[0182] C. A system for controlling joint movement of a joint in a surgical tool driven by a robotic manipulator, the surgical tool having a first drive member and a second drive member operatively coupled to the joint and arranged to translate in opposite directions when actuated by respective first and second drives of the robotic manipulator, wherein, upon receiving a command for rotating the joint in a first rotational direction, the first drive member is actuated and thereby pushes the first drive member distally, and simultaneously the second drive member is actuated and thereby pulls the second drive member proximally, thereby rotating the joint in the first rotational direction, wherein, upon receiving a command for rotating the joint in a second rotational direction opposite to the first rotational direction, the second drive member is actuated and thereby pushes the second drive member distally, and simultaneously the first drive member is actuated and thereby pulls the first drive member proximally, thereby rotating the joint in the second rotational direction.

[0183] D. A system for controlling the counter-translational movement of a pair of drive members in a surgical instrument, the surgical instrument being mountable to a robotic manipulator having a first driver operable to translate a first drive member and a second driver operable to translate a second drive member, wherein, upon receiving a desired joint motion angle input, the system determines a first driver position command and a second driver position command, at which the first driver and the second driver will respectively cause translation of the first drive member and the second drive member to achieve the desired joint motion angle input, wherein the first driver command causes the first drive member to translate a distance in a proximal direction, and the second driver command causes the second drive member to translate the distance in a distal direction, and wherein the distance is modified by a correction factor.

[0184] Each of embodiments A, B, C, and D may have one or more of the following additional elements in any combination: Element 1: wherein the wrist includes a base and an articulated member, the articulated member being rotatable relative to the base when acted upon by the first drive member and the second drive member. Element 2: wherein the base includes a pivot disposed within a bore of the articulated member, the pivot defining an axis of articulation about which the articulated member rotates. Element 3: wherein the first drive member is coupled to a first drive pin of the articulated member, and the second drive member is coupled to a second drive pin of the articulated member. Element 4: wherein the linkage assembly further includes a distal connector that connects the distal ends of the first drive member and the second drive member at the wrist. Element 5: wherein the first drive pin of the articulated member is disposed within a first bore of the distal connector, and the second drive pin of the articulated member is disposed within a second bore of the distal connector. Element 6: wherein the base is connected to an inner grounding shaft extending proximally within the shaft. Element 7: The first drive member and the second drive member are respectively arranged in a first slot and a second slot defined within the inner grounding member. Element 8: At least a portion of the first slot and the second slot is defined between the upper surface of the inner grounding member and the lower surface of the base. Element 9: The system further includes a first drive shaft rotatably mounted within the drive housing and operatively coupled to the first drive member such that rotation of the first drive shaft causes axial movement of the first drive member; and a second drive shaft rotatably mounted within the drive housing and operatively coupled to the second drive member such that rotation of the second drive shaft causes axial movement of the second drive member. Element 10: The first drive shaft is operatively coupled to the first drive member via a first gear arrangement having a gear ratio greater than or less than 1:1, and the second drive shaft is operatively coupled to the second drive member via a second gear arrangement having a gear ratio greater than or less than 1:1. Element 11: Further includes a first articulated yoke and a second articulated yoke, the first articulated yoke being arranged about the inner grounding axis and operatively coupled to the proximal end of the first drive member, and the second articulated yoke being arranged about the inner grounding axis and operatively coupled to the proximal end of the second drive member, wherein axial translation of the first articulated yoke and the second articulated yoke causes axial translation of the first drive member and the second drive member, respectively. Element 12: The first articulated yoke and the second articulated yoke are arranged about the inner grounding axis such that they rotate together with the inner grounding axis.Element 13: wherein the first drive shaft is operatively connected to the first drive member via a first drive rack, the first drive rack having a first yoke capable of engaging a first articulated yoke operatively connected to a proximal end of the first drive member, and wherein the second drive shaft is operatively connected to the second drive member via a second drive rack, the second drive rack having a second yoke capable of engaging a second articulated yoke operatively connected to a proximal end of the second drive member.

[0185] Element 14: Further includes measuring the rotational position of the drive input using a rotary encoder. Element 15: Further includes detecting a peak torque using one or more torque sensors when the drive input reaches the starting position.

[0186] Element 16: wherein the first and second actuators of the robot manipulator maintain equal tension or compression in the first and second drive members until a command is given to rotate the joint in the first or second rotation direction. Element 17: wherein the tension or compression applied by the first and second motors depends on the joint movement angle of the joint.

[0187] Element 18: The correction factor is an empirically determined constant of the surgical instrument. Element 19: The correction factor is the product of a constant and a function, wherein the function is selected from the group consisting of linear functions, sine functions, exponential functions, polynomial functions, and any combination thereof.

[0188] As a non-limiting example, exemplary combinations applicable to A, B, C, and D include: element 1 and element 2; element 1 and element 3; element 3 and element 4; element 4 and element 5; element 1 and element 6; element 6 and element 7; element 7 and element 8; element 9 and element 10; element 7 and element 11; element 11 and element 12; element 10 and element 13; and element 16 and element 17.

[0189] Therefore, the systems and methods disclosed herein are highly suitable for achieving the aforementioned results and advantages, as well as those inherent therein. The specific embodiments disclosed above are merely exemplary, as the teachings of this disclosure can be modified and implemented in different but equivalent ways that will be apparent to those skilled in the art. Furthermore, there are no limitations on the details of the constructions or designs shown herein, except as described in the following claims. It is therefore apparent that the specific exemplary embodiments disclosed above may be changed, combined, or modified, and all such changes are considered to be within the scope of this disclosure. The systems and methods illustratively disclosed herein may be suitably implemented in the absence of any elements not specifically disclosed herein and / or any optional elements disclosed herein. While compositions and methods are described according to various components or steps “comprising,” “containing,” or “including,” such compositions and methods may also be “substantially composed of various components or steps” or “composed of various components or steps.” All numerical values ​​and ranges disclosed above may vary in some quantities. Whenever a numerical range with a lower and upper limit is disclosed, any numerical value falling within that range and any included range are specifically disclosed. Specifically, each range of values ​​disclosed herein (in the form of "about a to about b" or equivalent "about a to b" or equivalent "from about ab") should be understood to list each numerical value and range covered within a broader range of values. Furthermore, the terms in the claims have their ordinary, general meaning unless otherwise expressly and clearly defined by the patentee. Additionally, the indefinite articles "a" or "an" used in the claims are defined herein as referring to one or more elements introduced therein, rather than a single element. If the use of words or terms in this specification conflicts in any way with one or more patents or other documents that may be incorporated herein by reference, the definitions consistent with this specification shall prevail.

[0190] As used herein, the phrase "at least one of..." preceding a series of items (separated by the terms "and" or "or") modifies the list as a whole, not each member of the list (i.e., each item). The phrase "at least one of..." allows for the meaning of at least one of any of the items, and / or at least one of any combination of the items, and / or at least one of each of the items. As an example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" respectively mean: only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

Claims

1. A surgical tool, comprising: a drive housing; a shaft extending from the drive housing; a wrist arranged at an end of the shaft; and a linkage assembly actuatable to articulate the wrist in a plane and comprising: a first drive member extending within the shaft from the drive housing and operatively connected to the wrist; and a second drive member extending within the shaft from the drive housing and operatively connected to the wrist, wherein actuation of the first and second drive members within the shaft in opposite axial directions articulates the wrist in the plane, wherein the wrist comprises a base and an articulation member rotatable relative to the base when acted upon by the first and second drive members, wherein the first drive member is coupled to a first drive pin of the articulation member and the second drive member is coupled to a second drive pin of the articulation member, and wherein a distal end of the first drive member has a drive pin aperture that receives the first drive pin of the articulation member and a distal end of the second drive member has a drive pin aperture that receives the second drive pin of the articulation member, and the drive pin apertures are configured to allow lateral translation of the drive pins within the corresponding drive pin apertures when the drive members are actuated to articulate the wrist. the base comprises a pivot disposed within a bore of the articulation member, the pivot defining an articulation axis about which the articulation member rotates.

2. The surgical tool of claim 1, wherein, the linkage assembly further comprises a distal link coupling distal ends of the first and second drive members at the wrist.

3. The surgical tool of claim 1, wherein, the first drive pin of the articulation member is disposed within a first bore of the distal link and the second drive pin of the articulation member is disposed within a second bore of the distal link.

4. The surgical tool of claim 3, wherein, the base is connected to an inner ground shaft extending proximally within the shaft.

5. The surgical tool of claim 1, wherein, the first and second drive members are disposed within first and second slots defined within the inner ground shaft, respectively.

6. The surgical tool of claim 5, wherein, at least a portion of the first and second slots are defined between an upper surface of the inner ground shaft and a lower surface of the base.

7. The surgical tool of claim 6, wherein, 8. The surgical tool of claim 1, further comprising: a first drive shaft rotatably mounted within the drive housing and operatively coupled to the first drive member such that rotation of the first drive shaft causes axial movement of the first drive member; and a second drive shaft rotatably mounted within the drive housing and operatively coupled to the second drive member such that rotation of the second drive shaft causes axial movement of the second drive member. ​ ​ 9. The surgical tool of claim 8, wherein, The first drive shaft is operatively coupled to the first drive member via a first gear arrangement having a gear tooth ratio greater or less than 1 : 1, and the second drive shaft is operatively coupled to the second drive member via a second gear arrangement having a gear tooth ratio greater or less than 1 :

1.

10. The surgical tool of claim 5, further comprising a first articulation yoke and a second articulation yoke, the first articulation yoke being disposed about the inner ground shaft and operatively coupled to a proximal end of the first drive member, the second articulation yoke being disposed about the inner ground shaft and operatively coupled to a proximal end of the second drive member, wherein axial translation of the first and second articulation yokes causes axial translation of the first and second drive members, respectively.

11. The surgical tool of claim 10, wherein, The first and second articulation yokes are disposed about the inner ground shaft such that they rotate with the inner ground shaft.

12. The surgical tool of claim 8, wherein, The first drive shaft is operatively coupled to the first drive member via a first drive rack having a first yoke engageable with a first articulation yoke operatively coupled to a proximal end of the first drive member, and wherein the second drive shaft is operatively coupled to the second drive member via a second drive rack having a second yoke engageable with a second articulation yoke operatively coupled to a proximal end of the second drive member.

13. A surgical system for controlling articulation of a wrist in a surgical tool driven by a robotic manipulator, the surgical tool being in accordance with any one of claims 1-12, the first and second drive members of the surgical tool being operatively coupled to the wrist and arranged to translate in opposite directions when actuated by respective first and second drives of the robotic manipulator, wherein, The surgical system is configured to: upon receiving a command to rotate a wrist of the surgical tool in a first rotational direction, actuate the first drive to thereby push the first drive member distally, and simultaneously actuate the second drive to thereby pull the second drive member proximally, thereby causing the wrist to rotate in the first rotational direction, and upon receiving a command to rotate the wrist in a second rotational direction opposite the first rotational direction, actuate the second drive to thereby push the second drive member distally, and simultaneously actuate the first drive to thereby pull the first drive member proximally, thereby causing the wrist to rotate in the second rotational direction.

14. The surgical system of claim 13, wherein, The first and second drives of the robotic manipulator maintain equal tension or compression in the first and second drive members until a command to rotate the wrist in the first or second rotational direction.

15. The surgical system of claim 14, wherein, The tension or compression exerted by the first and second drives is dependent on an articulation angle of the wrist.

16. A surgical system comprising: The surgical tool of any of claims 1-12, and a robotic manipulator capable of driving the surgical tool and having a first drive operable to translate the first drive member of the surgical tool and a second drive operable to translate the second drive member of the surgical tool, wherein the surgical system is configured to: Upon receipt of a desired articulation angle input, a first driver position command and a second driver position command are determined at which the first driver and the second driver will respectively cause translation of the first drive member and the second drive member to achieve the desired articulation angle input, wherein in response to a position command of the first driver, the first driver translates the first drive member in a proximal direction by a distance, and in response to a position command of the second driver, the second driver translates the second drive member in a distal direction by the distance, and wherein the distance is modified by a correction factor.

17. The surgical system of claim 16, wherein, The correction factor is an empirically determined constant of the surgical tool.

18. The surgical system of claim 16, wherein, The correction factor is a product of a constant and a function, and wherein the function is selected from the group consisting of a linear function, a sinusoidal function, an exponential function, a polynomial function, and any combination thereof. The correction factor is a product of a constant and a function, and wherein the function is selected from the group consisting of a linear function, a sinusoidal function, an exponential function, a polynomial function, and any combination thereof.

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