Compact actuation configuration and expandable instrument receiver for robotically controlled surgical instruments

Abstract

A robotic system assembly includes a robotic manipulator including an actuator assembly, and a surgical instrument having a base body mountable to the actuator assembly. The base includes a first control input and a second control input, wherein the first control input and the second control input are positioned on different sides of the base. The actuator assembly is movable between an open position and a closed position to facilitate removal and replacement of the surgical instrument. When in the closed position, a drive element of the actuator assembly is positioned to drive the first and second control inputs of the surgical instrument to cause movement or actuation of an end effector.

Description

[0001] This application is a continuation-in-part of U.S. Application No. 16 / 732,307, filed December 31, 2019, which claims the benefit of U.S. Provisional Application Nos. 62 / 874,988, filed July 17, 2019, and 62 / 787,254, filed December 31, 2018. This application also claims the benefit of U.S. Provisional Application Nos. 62 / 874,988, filed July 17, 2019, 62 / 875,003, filed July 17, 2019, 62 / 874,985, filed July 17, 2019, and 62 / 874,982, filed July 17, 2019. Technical Field

[0002] The present invention relates to the field of surgical devices and systems, including those using electromechanical actuation. Background Art

[0003] Various types of surgical robotic systems exist or are being developed on the market. Some surgical robotic systems use multiple robotic arms. Each arm carries a surgical instrument or a camera for capturing images from the body to display on a monitor. A typical configuration allows two or three instruments and cameras to be supported and manipulated by the system. The input to the system is generated based on input from the surgeon at the main console, typically using an input device such as an input handle. The movement and actuation of the surgical instruments and cameras are controlled based on user input. The images captured by the camera are displayed on a display at the surgeon's console. The console can be located to the patient's side, within the sterile area, or outside the sterile area.

[0004] The robotic arm / manipulator includes a portion, typically located at a terminal end of the arm, designed to support and manipulate a surgical device assembly. The surgical device assembly includes a surgical instrument having a shaft and a distal end effector located on the shaft. The end effector is positionable within a patient's body.

[0005] Typically, the proximal housing on the instrument shaft includes an actuation mechanism that receives motion transmitted from an actuator that drives the instrument's functions. The end effector can be one of a variety of different types of end effectors used in surgery, including but not limited to end effectors having one or more of the following features: jaws that open and close, a section at the distal end of the shaft that bends or articulates with one or more degrees of freedom, a tip that rolls axially relative to the shaft, or a shaft that rolls axially relative to the manipulator arm. The instrument actuator that drives the end effector's motion is typically located in the terminal portion of the robotic manipulator and may be a motor or other type of motor (e.g., a hydraulic or pneumatic motor). In some cases, the instrument actuator is located in the proximal housing of the surgical device assembly, while in other configurations, some instrument actuators are located in the proximal housing while others are located in the robotic manipulator. In the latter example, some of the end effector's motion can be driven using one or more motors located in the terminal portion of the manipulator, while other motions can be driven using a motor located in the proximal housing.

[0006] During the surgical procedure, these instruments are replaceable, thereby allowing one instrument to be removed from the manipulator and replaced with another. The actuator interface engagement at the proximal housing and the manipulator may involve the use of mechanical snaps, magnetic couplings, or sliding interfaces that rigidly dock the instrument to the manipulator to resist the external forces from the robot and the patient. There is a mechanical interface that engages with the surgical instrument. At this interface, the motion generated by the instrument actuator in the robotic manipulator is transmitted to one or more mechanical inputs of the proximal housing to control the degree of freedom of the instrument and, if applicable, also control the opening and closing function of the clamping jaws of the instrument. This motion can be transmitted by a cover positioned between the sterile instrument and the non-sterile manipulator arm. In some current robotic systems, the mechanical control interface includes an actuator that is only arranged on one side or plane of the instrument. For example, in the configuration shown in US 6491701, all driven elements 118 that receive mechanical motion are located on the same face of the proximal end of the instrument shaft 102 of the housing 108.

[0007] In the embodiment shown in US 9358682, a transverse sliding pin 314 extends laterally from one side of a housing mounted to the proximal end of the instrument. The transverse sliding pin 314 is movable to open and close the jaws of the instrument (patented Figure 18 When the instrument is mounted to the manipulator arm, the sliding pin 314 is engaged by a corresponding component 430 in the manipulator arm ( Figure 19) is received. When the jaws need to be opened / closed, component 430 is translated on the carrier by the motor in the laparoscopic instrument actuator 400 of the manipulator arm, thereby advancing the sliding pin 314 to actuate the jaws. U.S. application 2016 / 20160058513 also shows a robotically controlled surgical instrument that is removably attached to the manipulator arm and describes a similar configuration in which a sliding pin is used for jaw actuation. The U.S. application also describes a system that can provide not only jaw actuation, but also additional electromechanically driven motion of the instrument end effector, such as articulation or rotation. However, the motor for these additional motions is enclosed in a housing at the proximal end of the instrument, and therefore there is no need to transmit mechanical motion from the motor in the arm to a mechanical actuator of the housing.

[0008] The application describes a robotically controlled surgical instrument having a plurality of mechanical actuators at its proximal end. These mechanical actuators are arranged to receive motion transmitted from an electromechanical actuator in a manipulator arm to drive various end effector functions or motions such as jaw actuation, pitch, roll, and / or yaw. The actuators are arranged in a configuration that is compact and allows the manipulator arm to engage with instruments or adapters of different sizes. The described embodiments also enable the instrument or adapter to be configured so that the actuation interface can be present on more than one surface of the instrument or adapter, including surfaces facing away from each other. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a perspective view of a robotic-assisted surgical system on which the configurations described herein may be included;

[0010] Figure 2 is a perspective view of a robotic manipulator arm with a receiver and instrument assembly mounted thereon;

[0011] Figure 3 It shows Figure 2 A perspective view of a receiver and a surgical instrument separated from the receiver;

[0012] Figure 4 The surgical instrument is shown with its base removed;

[0013] Figure 5 The proximal portion of the surgical instrument is shown;

[0014] Figure 6 and Figure 5 similar, but showing a portion of the housing removed;

[0015] Figure 7 and Figure 6 similar, but showing a portion of the upper carrier removed;

[0016] Figure 8 Shown Figure 2 receiver;

[0017] Figure 9 and Figure 8 similar, but showing a portion of the arm removed;

[0018] Figure 10 is a side view of a carrier and motor assembly of one arm of the receiver;

[0019] Figure 11 is an alternative embodiment of a carrier for the base of an instrument;

[0020] Figure 12 and Figure 13 is a perspective view of an alternative embodiment of a carrier for one of the arms of the receiver;

[0021] Figure 14 and Figure 15 are top plan views of the receiver, showing the receiver in an open position and a closed position, respectively;

[0022] Figure 16 is a perspective view showing the instrument mounted to the receiver;

[0023] Figure 17 is a perspective view showing the rod and connecting rod of the receiver;

[0024] Figure 18 and Figure 15 similar, but showing a portion of the receiver housing removed to allow viewing of the expansion mechanism;

[0025] Figure 19 yes Figure 17 A side view of the apparatus and rod and associated motor;

[0026] Figure 20A is a perspective view showing a state where the receiver is covered;

[0027] Figure 20B and Figure 16 Similar, but showing the cover in place;

[0028] Figure 21 is a perspective view of the cover connector;

[0029] Figure 22 is a rear plan view of the base of the instrument;

[0030] Figure 23 is a perspective view of an alternative embodiment of a base;

[0031] Figure 24 and Figure 23 similar, but showing a portion of the housing removed;

[0032] Figure 25 It shows Figure 23 A perspective view of a pulley mechanism and a spring in a pulley mechanism according to an embodiment of the present invention.

[0033] Figure 26A An example of a cover with an integrated EMI shield is shown;

[0034] Figure 26B yes Figure 26A a cross-sectional view of a portion of the cover shown in ;

[0035] Figure 26C and Figure 26B Similar, but showing an embodiment including electrical connectors and terminals incorporated into the cover

[0036] Figure 27 and Figure 16 Similarly, a graphical user interface provided on the manipulator end effector is also shown.

[0037] Figure 28 and Figure 27 Similar, but illustrates features that provide force feedback to the user during manual repositioning of the manipulator. DETAILED DESCRIPTION

[0038] Although the concepts described herein can be used with a variety of robotic surgical systems, reference will be made to Figure 1 The various embodiments are described with reference to a system of the type shown in . In the illustrated system, the surgeon console 12 has two input devices, such as handles 17, 18. The input device 12 is configured to be manipulated by a user to generate signals for commanding a robotically controlled device to move in multiple degrees of freedom. In use, the user selectively assigns the two handles 17, 18 to two of the robotic manipulators 13, 14, 15, thereby allowing the surgeon to control two of the surgical instruments 10a, 10b and 10c located at the work site (the patient on the bed 2) at any given time. In order to control a third instrument of the instruments located at the work site, one of the two handles 17, 18 can be operatively disconnected from one of the original two instruments and then operatively paired with the third instrument, or another form of input can control the third instrument, as described in the next paragraph. It may optionally be provided Figure 1 A fourth robotic manipulator, not shown, is used to support and manipulate additional instruments.

[0039] One of instruments 10a, 10b, 10c is a camera that captures images of the surgical field in the body cavity. The camera can be moved by its corresponding robotic manipulator using input from various types of input devices, including but not limited to one of handles 17, 18, additional controls on the console, foot pedals, eye tracker 21, voice control, etc. The console may also include a display or monitor 23 configured to display images captured by the camera and optionally display system information, patient information, etc.

[0040] The control unit 30 is operatively connected to the robotic arm and the user interface. The control unit receives user input from the input device corresponding to the desired movement of the surgical instrument and causes the robotic arm to manipulate the surgical instrument accordingly.

[0041] The input devices 17, 18 are configured to be manipulated by a user to generate signals that are processed by the system to generate instructions for commanding movement of the manipulator to move the instrument in multiple degrees of freedom and to appropriately control the operation of the electromechanical actuator / motor that drives the movement and / or actuation of the instrument end effector.

[0042] Sensors can optionally be used to determine the forces applied to a patient by a robotic surgical tool during use. For example, force / torque sensors on a surgical robot manipulator can be used to determine the tactile information needed to provide force feedback to the surgeon at the control console. U.S. Patent 9,855,662, entitled "Force Estimation for a Minimally Invasive Robotic Surgery System," describes a surgical robotic system in which sensors are used to determine the forces applied to a patient by a robotic surgical tool during use. U.S. Patent 9,855,662 describes the use of a 6DOF force / torque sensor attached to a surgical robotic manipulator as a method for determining the tactile information needed to provide force feedback to the surgeon at the user interface. In the presently disclosed embodiment, this type of sensor can optionally be positioned on or just adjacent to the receiver 104. The surgical system allows operating room medical personnel to remove and replace surgical instruments 10a, 10b, 10c carried by the robotic manipulator as needed for the procedure. When an instrument needs to be replaced, the surgeon removes the instrument from the manipulator arm and replaces it with another instrument.

[0043] Typically, the assembly includes a surgical instrument having a base configured such that its driven members (which receive mechanical drive inputs to actuate the function of the instrument's end effector) are disposed on more than one side, face, facet, or plane of the base located at the proximal end of the instrument. The base is the base that is received by an arm in use, within which are electromechanical or hydraulic actuators that drive the mechanical outputs. To maintain sterility of the surgical instrument, the system is designed to facilitate the use of a surgical drape positioned between the base of the instrument and the corresponding mechanical drive outputs on the arm. Positioning the instrument actuators on more than one side, facet, face, or plane of the instrument helps to distribute the forces and deformations applied by these actuators to the drape, thereby allowing multiple mechanical inputs to be transmitted to the instrument while preserving the drape.

[0044] Reference Figure 2 and Figure 3 , this application describes an assembly 100 of a surgical instrument 102 and a receiver 104. The receiver 104 is configured to removably receive the instrument 102. The receiver can be mounted to a support or manipulator 15, which can be a robotic manipulator that automatically manipulates the instrument 102 in one or more degrees of freedom during a procedure, or a support that remains stationary during a surgical embodiment of a surgical instrument for a robotic surgical system. When the surgical instrument 102 and receiver 104 are assembled, the receiver transfers motion generated by an electromechanical actuator (e.g., a motor or hydraulic / pneumatic actuator) in the receiver 104 or arm 15 to a mechanical actuator of the instrument to cause motion of a portion of the instrument. Examples of types of motion include, but are not limited to, articulation of one or more degrees of freedom (pitch, yaw), bending of one or more degrees of freedom, end effector rolling, jaw actuation, etc. As described above, the surgeon moves the input devices 17, 18 ( Figure 1 ) provides input to the system, and the system processes this information to develop commands for the associated electromechanical actuators to move the instrument and operate the instrument end effector when appropriate.

[0045] The surgical instrument 102 includes an elongated shaft 106 that is preferably rigid, but in alternative systems the elongated shaft 106 may be flexible or partially flexible. An end effector 108 is positioned at the distal end of the shaft 106, and a proximal body or base assembly 110 is positioned at the proximal end. The base assembly 110 (also referred to as the "base") may include an enclosed or partially enclosed structure, such as a housing or box, or the base assembly 110 may be a frame or plate. The base 110 includes a mechanical input actuator 112 that is exposed to the exterior of the surgical instrument 102. In Figure 3In the embodiment, two actuators 112 are exposed at a first side of the base 110. A second set of two actuators 112 are exposed at an opposite second side of the base 110, preferably but optionally having the same Figure 3 The same or similar configuration as shown in . Figure 22 A rear view of the base 110 is shown in FIG.

[0046] Each of the actuators 112 is movable between a first position and a second position relative to the base 110. In the particular configuration shown in the drawings, the actuators are movable relative to the housing, for example Figure 3 The invention relates to a device for moving longitudinally between a first (more distal) position and a second (more proximal) position as shown in FIG. However, the direction of movement need not be longitudinal and may extend in any direction.

[0047] In this configuration, the base assembly therefore has four drive inputs 122 exposed to its exterior. In this configuration, the base has two parallel flat faces, wherein two of these inputs are positioned on each of the faces. Although it may be preferred to include inputs on opposite sides of the proximal body, other arrangements of inputs on multiple faces of the proximal body may be used instead. Each of these configurations advantageously arranges the drive inputs in a manner that maximizes the distance between the control inputs, thereby minimizing stress in the sterile cover as described below, which is positioned between the proximal body and the receiver 104.

[0048] Reference Figure 4, a drive cable 114 extends through the shaft 106 to the end effector 108. Many different types of instruments having any of a variety of functions may be used in the disclosed system. The instrument depicted in the drawings is of the type described in co-owned co-pending application No. 16 / 732,306, filed on December 31, 2019 (Agent No.: TRX-12700R), entitled Articulating Surgical Instrument, which is incorporated herein by reference. The instrument uses four drive cables 114, two of which terminate at one of the jaw members and the other two of the four drive cables 114 terminate at the other jaw member. This can be two cables that are looped around the end effector (so that each of the two free ends of each cable loop is at the proximal end), or it can be four separate cables. As described in the co-pending application, the tension on the cables is varied in different combinations to affect the pitch and yaw motion of the jaw members and the jaw opening and closing function. Other instruments used with this system will have other numbers of cables, the specific number being determined by the instrument function, the instrument's degrees of freedom, and the specific configuration of the instrument's actuating components. Note that in this specification, the terms "tendon," "wire," and "cable" are used broadly to encompass any type of tendon that may be used for the purposes described.

[0049] Four cables extend to the base 110 assembly. In this embodiment, where the base comprises a housing, the cables extend from the shaft 106 into the housing where they are joined to the actuator 112. Figure 6 The base is shown with a portion of the housing removed to allow a clearer view of the actuators 112. Each actuator 112 includes a carrier 118 that is movable along a track 120. In this embodiment, these structures are oriented for longitudinal movement of the carrier, but in other embodiments, the movement can be in different directions. A portion of the carrier 118 is exposed through a window in the base and includes a drive input or member 122 that extends laterally from the carrier and can optionally extend through the outermost plane of the window (see FIG. Figure 5 ).exist Figure 7 , the carrier for the upper actuator is partially disassembled showing the proximal end of the cable 114 mounted to the carrier 118. The cable may extend around the pulley or through a cable path defined by features of the base assembly. In this configuration, the second cable end is similarly connected to the Figure 71 and 12. The base assembly 100 includes a carrier 118 for the lower actuator in the base, and the remaining two cable ends are connected to the carrier at an opposite side (not shown) of the base 100. In this manner, the base assembly is arranged to have actuators 112 exposed at least on two sides or faces of the base. Each actuator 112 is connected to one of the cables 114 such that movement of the actuator in a first direction relative to the base increases the tension on the corresponding cable, and movement of the actuator in a second, different (or opposite) direction decreases the tension on the cable. In the illustrated embodiment, movement of the actuator carrier 118 in a proximal direction increases or decreases (depending on the routing of the cable) the tension on the cable, and movement of the carrier in a distal direction has the opposite effect on the cable tension.

[0050] In this embodiment, an extension spring 124 is connected between the base carrier 118 and the support structure (in this case, to the outer housing 126 or partition 128 that divides the housing interior into two laterally adjacent areas). Applying a force to the carrier to actively move the carrier in a direction opposing the spring force (in this case, the distal direction) increases the tension on the corresponding cable. When the applied force is released, the spring force will move the carrier back to or toward the initial position and reduce the tension on the cable. In other embodiments, the carrier can alternatively be actively moved in two directions rather than using spring force in one direction of movement.

[0051] Reference Figure 8 The receiver 104 of the illustrated embodiment has a generally U-shaped cross-section with two elongated sides and a seating portion spanning between the two sides. The sides of the "U" are formed by a pair of distally extending arm segments 130a, 130b that provide an opening in the receiver into which the base 110 is received when the system is assembled ( Figure 3 ). Drive members 132, also referred to as "drive outputs," extend inwardly from arm sections 130a, 130b. Drive members 132 are positioned so that when the instrument is mounted to receiver 104, each drive input member 122 ( Figure 5 and Figure 6 ) contacts a corresponding one of the drive output members 132. Figure 8 Two drive members 132 can be seen in FIG. Two further drive members extend from arm 130b but are obscured in the figure. Figure 9 , a portion of arm 130a is removed to illustrate that drive member 132 is carried by carrier 134 housed within arms 130a, 130b. Figure 10) drives linear movement of the carrier 134, and thereby drives linear movement of the drive members 132 along their respective arm sections 132a, b.

[0052] The type of contact between the receiver's drive member 132 and the corresponding driven member 122 of the instrument's drive member is selected based on the nature of the drive motion being transmitted to the driven member 122. In the illustrated linear drive configuration, the components can be configured so that the instrument's carrier can be pushed, pulled, or both pushed and pulled by the receiver's corresponding drive member. Additionally, different carriers can be configured differently, with some being pushed only and others being pulled only (or some other combination of push, pull, and bidirectional drive).

[0053] In the case of driving motion in a single direction, contact between the drive member 132 and the driven member 122 need only be in the direction of motion. Figures 3 to 10 In the embodiment, the driving member 132 and the driven member 122 are configured so that the driving member 132 pushes the driven member in the distal direction, but due to the combination Figure 7 The presence of the spring 124 discussed does not necessarily pull the driven member in the proximal direction. Therefore, the surface or area of ​​each drive member 132 facing the direction of motion (here, the distal direction) contacts the driven member 122. Therefore, in this example, the drive member and the driven member do not necessarily cooperate with each other or engage in other ways, although the drive member and the driven member can be paired with each other or engage in other ways. Alternatively, these members 122, 132 can simply be configured to have opposing surfaces (which surfaces can optionally be flat) that contact each other. If the motion is driven in the proximal direction rather than the distal direction in this embodiment, the proximal face of the drive member will contact the driven member.

[0054] In other embodiments, the motion of the driven member is driven in two directions. In a linear drive arrangement such as that shown in the accompanying drawings, this may mean that the driving member can both pull and push the driven member. In such embodiments, the driving member and the driven member are configured to engage, mate, or otherwise be designed to come into contact regardless of the direction of motion. For example, Figure 11 An alternative carrier 120a for the instrument is shown, the carrier 120a including a drive member 132 ( Figure 10 ) mating driven member 122a.

[0055] Figure 12 A receiver carrier is shown on which the drive member 132a comprises a wall of a concave receiver shaped to receive a Figure 5 A driven member 122 of the type shown in . Figure 13Receiver carriers are shown with two different drive member designs. The drive member 132 on the upper carrier is similar to those previously discussed. The drive member 132a on the lower carrier includes walls of a concave receiver shaped to receive a Figure 5 1. In this configuration, the upper carrier can drive the corresponding driven member in a single direction (push or pull), while the lower carrier can drive the corresponding driven member in a push and pull manner.

[0056] Receiver 104 can be a receiver that is expanded to receive base 110. In this embodiment, receiver 104 can be moved from a closed position to an open position by increasing the spacing between arms 130a, 130b. Once moved to the open position, any instrument held by the receiver can be removed and the base of a first instrument or a replacement instrument can be received. When the receiver moves from the open position to the closed position in which base 110 is captured by receiver 104, the receiver can also move to reduce the spacing between the arms. When in a closed system with base 110 between arms 130a, 130b, the drive input 122 of the base is operatively engaged with the drive output 132 of the receiver (although not necessarily physically engaged as discussed above).

[0057] The expansion can be achieved in a variety of ways. In the example shown in the drawings, the arms 130a, 130b are in the open position ( Figure 14 ) and closed position ( Figure 15 ) pivots between the arms 130a, 130b. In other configurations, the arms 130a, 130b can move in parallel. When the receiver is closed to engage the base of the instrument, the arms of the receiver 104 reach around both sides of the base 110 to hold the base and position the drive outputs at positions where the arms will move the drive inputs to actuate the degrees of freedom or other functions of the instrument as described.

[0058] The receiver can be selectively opened and / or closed manually or electromechanically by moving the arms toward / away from the other arm. In a first embodiment, the arms 130a, 130b are pivoted relative to the proximal ends of the arms by a rotatable lever or knob 138 having a connecting rod 140 spiraling outward from it. When the lever / knob is manually rotated in a first direction, the connecting rod 140 moves the arms 130a, 130b to the open position. Rotating the lever / knob in the opposite direction cams the arms to the closed position. Additionally or alternatively, the connecting rod 140 can be rotated by actuation of a motor 142. A switch 144 on the receiver 104 can be used by a surgical assistant to activate the motor 142 to easily open and then close the receiver during instrument exchanges.

[0059] The system can include features that facilitate alignment and retention of the instrument adapter when the actuator assembly of the manipulator arm is open. Examples include protrusions 146 on the base 110 or receiver 104 that are received in corresponding seats 148 ( FIG. 20 ) on the receiver 104 or base 110. The proximal face of the base 110 can additionally include alignment features. Figure 22 The receiving convex portion 150 ( Figure 21 ) is a concave portion 150 (e.g., a recess, notch, hole, or similar alignment feature) of the base 110, as discussed below in conjunction with the cover. Thus, this embodiment has engagement and / or control features on three sides of the base 110. It should be understood that control points (drive inputs) can exist on any side of the base and can be actuated by any electromechanical actuator of the receiver / manipulator, or by an operator at the bedside. Additionally, these control points can share an axis, have parallel axes, slide linearly along the same plane, or can be a combination of unrelated motions (i.e., non-planar, non-parallel, or not sharing the same axis).

[0060] Finally, there is no requirement for the base to have defined planes or interface points. For example, the adapter body may be spherical or cylindrical in nature, with the control points arranged across the surface of the body.

[0061] The second embodiment is similar to the first embodiment, having a "U" shaped configuration, but rather than angling the sides of the "U" to reach the open position, the sides are expanded while maintaining parallel interior surfaces. In this embodiment, a four-bar mechanism may be used in conjunction with a lever or knob system or motor to drive the system open and closed.

[0062] Each of these concepts allows for expansion of the space between the sides of the "U," and this feature enables the acceptance of bases of varying widths for instruments, cameras, or other adapters (e.g., removable adapters on the proximal end of a camera or instrument, allowing cameras or instruments from different manufacturers to be used with the system). For instruments with bases of varying widths, the system identifies the instrument and closes the appropriate amount to securely hold the instrument base or adapter. For example, a non-contact reed switch plate can be used to identify instruments or adapters of varying widths. One digital readout would result in a 30mm gap between arms 130a, 130b, while another might result in a 40mm gap. For a mechanical solution, a lever system can be used where instruments are pushed at varying distances on the lever system. For example, the lever system could allow for inputs ranging from 0mm to 4mm, where 0mm is fully open and 4mm is fully closed. One instrument could push 4mm to create a 30mm gap, or fully closed, between arms 130a, 130b, while another instrument could push 3mm to create a 40mm gap.

[0063] It should be noted that the shape and size of the "U" shaped portion and the space defined by the arms 130a, 130b can be adjusted to accommodate a variety of instruments or adapters. Additionally, while a "U" shape may be preferred for this application, other shapes having at least two partially opposing sides, where the sides may not have parallel opposing faces, may be used.

[0064] Another advantage of the "U" shaped embodiment is the ability to engage some instruments so that they share the axis of the receiver, but engage other instruments so that they do not share an axis. For example, a receiver engaged with a camera system may be able to hold the camera so that the camera axis and the receiver axis are at an angle of up to 90 degrees relative to each other. This would allow the camera and light cord to "pass through" the receiver rather than having to go around it. Other instruments, such as harmonic energy devices or staplers, could also benefit from this feature while allowing the mass of the instrument to be as close as possible to the 6DOF force sensor.

[0065] Reference Figure 20A and Figure 20B, the receiver 104 is typically a non-sterile component covered by a sterile cover 154 or barrier before the sterile surgical instruments are attached. At the interface between the driving element and the driven element, the above-mentioned motion is transmitted through the cover to control the freedom of the instrument. In one embodiment of the cover 154, the cover material is shaped to match the geometry of the receiver, and the cover has two "fingers" to cover the arms 130a, 130b that open and close. It is best to ensure that the cover is properly oriented with the receiver and that the area for the instruments is clear for the instruments to be engaged and removed. In this embodiment, the cover includes an embedded plastic "cover connector" 156, which is adhered so that the connector has a geometry that extends to both sides of the cover. One side of the shroud connector includes a mating pin, post, tapered element, etc. that mates with a concave portion (e.g., a recess, tapered notch, hole, or similar alignment feature) located in the seating portion of the receiver 104, while the other side mates with the concave portion 150 on the proximal face of the base. The mating pin can provide retention for the orientation of the manipulator and instrument, and the shroud and instrument.

[0066] In this embodiment, the central concave element 152 of the cover connector has two rings that allow mating geometry to snap into place, providing a retaining force. In this case, the mating geometry could be a coil spring. During the covering process, the cover is positioned over the arms 130a, 130b of the receiver. The inward-facing surface of the cover connector 156 is positioned so that the concave member is inserted into the concave portion located at the seat of the receiver, and the outward-facing surface of the cover connector similarly snaps into engagement with the proximal surface of the instrument base 110.

[0067] Because the shroud connector extends through both sides of the shroud, it can be used as a sterile conduit for a variety of mechanical, electrical, optical, or other tasks. A non-inclusive list of these features or tasks is listed below.

[0068] • Shroud connectors can be used to provide electrical signals between the robotic manipulator and the instrument, including power, ground, communication, etc.

[0069] o This power can be used to power instrument identification devices such as RFID transceivers, cameras, proximity sensors, or switches (including Hall sensors and reed switches.) These devices may be able to determine what instrument shaft is attached to a given base / adapter, while allowing certain bases / adapters to be universal for various instrument types.

[0070] o This energy can also power sensors such as force and torque or displacement devices as a way to measure activity within an instrument or instrument adapter. These measurements can enable better instrument control or user feedback, such as force feedback or tactile response.

[0071] o The electrical energy can be used for monopolar / bipolar or advanced energy devices without the need for cables that can wrap around the manipulator or instrument as the manipulator rotates.

[0072] Shroud connectors can be used to provide optical signals or optical transmission between robotic manipulators and instruments

[0073] o These optical signals can be used for communication purposes, including device identification via spectroscopy or other methods

[0074] These optical signals can be used with rod lens instruments to obtain intraoperative viewpoints without the need for a camera like other endoscopes.

[0075] o The optical signal can be coupled to a sensor, such as an optical fiber, which measures deflection, which can be used to interpret the force on the instrument or adapter.

[0076] The cover connector can also be used for other features. In this embodiment, for example, the proximal surface of the base has a flush port intended for cleaning the instrument adapter and instrument shaft after a surgical procedure. If left open during the procedure, this flush port provides a leak path for CO2 to escape from the surgical site. The cover connector is used to plug this flush port, eliminating the leak path while also eliminating components in the instrument adapter, such as a check valve or an elastomeric flush port cover.

[0077] Second embodiment

[0078] As discussed, in the first embodiment, the assembly is configured to transmit linear motion of a push / pull variation from the drive output to the drive input, but other embodiments are contemplated in which rotational motion or a combination of linear and rotational motion can be transmitted. See, e.g. Figures 23 to 25 The second embodiment, Figures 23 to 25 An alternative base 110b is shown. Here, each of the drive elements 122b extends from a pulley 123 that is rotatably mounted to a structure within the base (e.g., a bulkhead). Each cable is coupled to a corresponding one of the pulleys 123. Drive output 132 ( Figure 8) causes the corresponding pulley 123 to rotate and thus changes the tension in the cable. This affects the movement or actuation of the end effector as described in conjunction with the first embodiment. The extension spring 125 can be used to return the pulley to an unbiased position when the drive member is removed or the force acting on the drive member is reduced, in a manner similar to that described in the first embodiment.

[0079] Covers with integrated EMI shielding

[0080] The manipulator and related components can be covered by a drape using various types of materials suitable for surgical drapes. Figures 26A to 26C One example of a covering that may be used is described. It should be noted that the covering may be used to cover the disclosed components, to cover components of alternative surgical robotic systems other than those described above, and to cover many other components of sterile equipment (other than surgical robotic systems).

[0081] If used with the embodiments described herein, a cover such as a Figure 20A and Figure 20B is shown positioned above the receiver 104 of this embodiment.

[0082] The cover 200 is formed from a stretchable multilayer polymer containing an integrated circuit printed with conductive (or insulating) ink 204. The printed circuit can function as a flexible Faraday cage to shield the contained device from electrostatic discharge and / or electromagnetic interference. The ink can be printed in a mesh pattern or other pattern suitable for forming a Faraday shield. The printed circuit can also serve as a passive functional circuit, such as capacitive sensing (buttons), resistive sensing (strain measurement), antenna (RFID), etc. Printed traces can be sandwiched between the stack of layers 202 of the cover material. In the case where electrical signals are to be transmitted from one side of the cover to the other, the printed traces can be connected to conductive pads 205 for transmitting electrical signals into and out of the printed circuit. Similarly, the printed circuit can be connected to molded parts and features, such as connectors 210 and through-holes 208. The cover can take any desired form and can be formed from a flat sheet (or roll) of material.

[0083] The cover 200 provides a low-cost and effective method for shielding instrument actuators from ESD or EMI generated by high-energy instruments that may be mounted thereto. In shielding applications, this method reduces the complexity of designing electrical seals (e.g., springs) between moving interfaces in the device and eliminates the need for conductive plating on external coverings. This method can also be used to bridge gaps in enclosed devices that might otherwise be difficult to shield. This method can also add functionality to distal covers on surgical robotic arms.

[0084] Graphical user interface on the manipulator

[0085] The graphical user interface may be located on the manipulator.This feature may be applied to any surgical robotic manipulator, and while it is suitable for use with the configuration described above, it is equally suitable for use on components of other surgical robotic systems.

[0086] In some robotic systems, each manipulator may be individually identified using color coding, color-coded tape, numbers, or other markings in one or more locations on each manipulator for the convenience of the surgical staff. Additionally, the cart supporting each manipulator may include a screen for displaying error messages and a series of lights to indicate the status of the machine.

[0087] Sometimes during a surgical procedure, a surgical assistant or other operating room staff may need to reposition the manipulator. This can be accomplished by applying manual force to the robotic arm and physically moving the robotic arm to the desired orientation or position. This can be a purely manual activity as with prior art systems, or it can be a power-assisted activity. In either case, it would be advantageous to inform the user of the forces on the instrument as the user performs manually driven movements. Typically, in order to move the manipulator when it is not being actively remotely operated from the surgeon's console, the user takes action (e.g., simultaneously pressing two buttons on the manipulator) to unlock the manipulator so that she / he can manually move the end effector of the manipulator to the desired position.

[0088] The embodiments described in this section integrate instrument status and error message communication, manipulator identification, and easy user access to a touch point to manipulate the arm at a single location on the manipulator arm that is easily accessible to the user regardless of the orientation of the manipulator's end effector.

[0089] A first embodiment includes a surgical robotic system comprising at least one manipulator arm. Figure 27 As shown in , the manipulator arm (e.g., Figure 1 13, 14, 15) has an end effector with at least one degree of freedom away from the manipulator arm. In this particular embodiment, the receiver 104 is part of the end effector. In use, as described above, the surgical instrument 106 can be removably attached to the end effector.

[0090] Located on the end effector is a capacitive display screen 212 on which various information can be displayed. In this embodiment, the display screen 212 is cylindrical and extends around the body of the end effector. The screen can be configured to change color, display text or icons, or other GUI items to communicate machine status, arm identification, instrument identification, etc. to the user. Icons can be displayed and selected via the touch screen to perform tasks such as calibration, homing, or docking the end effector to a trocar.

[0091] Additionally, user touch gestures on the capacitive screen can cause the machine to respond. For example, touching two spaced-apart points can unlock degrees of freedom to allow manipulation or manual movement of the manipulator around its joints. Swiping can switch between menus or tell the machine to enter a specific state (cover, etc.). Gestures interacting with the display can also be used to cause the system to place the manipulator in the following state: to be used for and / or cause the activation of the manipulator's actuators to configure the manipulator in a position or orientation suitable for performing different tasks (docking instruments, exchanging instruments, calibrating, homing, storing, covering, etc.).

[0092] In a preferred configuration, the touch screen completely surrounds the end effector. In this configuration, the capacitive points are always easily accessible. In addition, an inertial measurement unit (IMU) on or contained in the end effector provides feedback to the system indicating the orientation of the end effector. Based on this feedback, the system will maintain or change the position and orientation of information and menus displayed on the GUI so that from the operator's perspective, the information / menus are always in a specific orientation, regardless of the rotation of the end effector relative to the operator. In other words, the IMU will detect the orientation of the end effector, and the system's processor will select a screen area that will be visible to the user in that orientation and cause the relevant information and menus to be displayed in that area, and preferably in an orientation that can be easily read by the user.

[0093] This feature improves the ease of use of the surgical system by displaying all available information about the system in an easily accessible location on the patient's side. The contact points can surround the entire end effector, meaning that regardless of the orientation of the end effector, they are always accessible and located in the same location (from the user's perspective). The display can include a color-changing display that allows color to be used to indicate different operating states or to identify different arms to the user.

[0094] Force notification during manually driven motion of the manipulator

[0095] As mentioned in the previous section, sometimes during a surgical procedure, a surgical assistant or other operating room staff may need to reposition the manipulator. This can be accomplished by applying manual force to the manipulator and physically moving it to the desired orientation or position. This can be a purely manual activity, as with some commercially available systems, or it can be power-assisted. In either case, it would be advantageous to inform the user about the forces on the instrument as the user performs manually driven movements.

[0096] As also discussed in this application, a force / torque sensor, which may be a 6DOF force / torque sensor, may be attached to the manipulator and used to determine the tactile information needed to provide force feedback to the surgeon at the user interface. Figure 28 is an end effector as described above. Within the manipulator, in an area near the instrument location, is a 6DOF force / torque sensor 214, which, as described above, is used to measure the forces experienced by the surgical instrument so that the system can communicate these forces to the user via a tactile interface. Near the sensor 214 is at least one notification component 216, which can be at least one of a vibration transducer and a visual indicator or light emitter. In the case of a vibration transducer, positioning the vibration transducer on the manipulator near the sensor 214 helps avoid interfering with the force measurement of the sensor 214. The visual indicator can be a light, an LED or a collection of LEDs, an image display, etc. If a GUI of the type described in the previous section is used, the visual indicator can be part of the GUI. These components are used to alert the user to the presence of forces against the instrument when manually repositioning the system.

[0097] During manual actuation (a movement performed by a user controlling the movement of the arm with their hand), when force is applied to an instrument attached to the arm, a vibration and visual alarm are emitted from the light emitter. This alerts the person moving the arm that the instrument is contacting tissue or other structures, allowing additional precautions to be taken if necessary. This is particularly beneficial, for example, if the instrument is being inserted into a trocar positioned at an incision site while it is engaged to the arm.

[0098] The visual indicator can be configured to provide directional information to the user to advise the surgeon. For example, the visual indicator can provide a visual indication of the direction the arm should move in order to reduce the force between the instrument and tissue or other objects. If the light emitter is a light ring or LED ring that surrounds a portion of the arm, a quarter of these lights may be illuminated to mark the direction the user should push the arm, or the direction of the force against the instrument. If a flexible display or GUI is used, one or more arrows or other symbols, icons, text, etc. can be displayed for the same purpose. In some cases, the system can be configured so that the amplitude / frequency of the vibration and the intensity / flicker of the light are proportional to the force measured on the force sensor 214.

[0099] During a remotely driven movement (movement performed by a user remotely controlling the arm using one of the user input devices 17, 18), a visual alarm may be emitted from the light emitter when a force is applied to an instrument attached to the arm (or if a force exceeding a defined threshold is applied).

[0100] This feature can be used with any robotic manipulator and is not limited to the embodiments described herein. Typically, it will be part of a surgical robotic system that includes a manipulator arm including a force sensor and a torque sensor, a surgical instrument that can be mounted to the manipulator arm, and a tactile user input device. The system includes at least one processor and at least one memory storing instructions that can be executed by the at least one processor to: cause the manipulator arm to move the surgical instrument in response to user manipulation of the tactile user input device, cause an actuator of the tactile user input device to apply force feedback to the tactile user input device in response to a signal from a sensor during user manipulation of the tactile user interface, and enable a vibration transducer on the arm in response to a signal from a sensor during manual movement of the manipulator arm by the user. The instructions can also be executed by the at least one processor to enable a visual alarm on the arm in response to a signal from the sensor.

[0101] Note that in addition to or as an alternative to force feedback, the vibration transducer can be used to provide other types of feedback to the user. For example, if the system is configured to use force / torque to determine the pivot point of an instrument passing through an incision, as described in U.S. Patent 9,855,662, a vibration alarm can be enabled to notify the user that the pivot point determination process is complete and the pivot point has been set.

[0102] While certain embodiments have been described above, it should be understood that these embodiments are presented by way of example and not limitation. It will be apparent to those skilled in the relevant art that various changes in form and detail may be made to the present invention without departing from the spirit and scope of the invention. This is particularly true in view of the technology and terminology that may be developed in the relevant art in the future. Furthermore, the features of the various disclosed embodiments may be combined in various ways to produce various additional embodiments.

[0103] Any and all patents, patent applications, and printed publications mentioned above, including for purposes of priority, are incorporated herein by reference.

Claims

1. A robotic system assembly (100), comprising: A robotic manipulator (15) comprising an actuator assembly (104), the actuator assembly comprising a first arm segment (130a) and a second arm segment (130b), at least one of the first arm segment and the second arm segment being movable relative to the other of the first arm segment and the second arm segment to move the actuator assembly between an open position and a closed position, the actuator assembly further comprising: a first drive member and a first motor operable to drive the first drive member relative to the actuator assembly; and a second drive member and a second motor operable to drive the second drive member relative to the actuator assembly; and A surgical instrument (102) having a body (110) that is removably mountable between the first arm segment and the second arm segment of the actuator assembly when the actuator assembly is in the open position and engageable between the first arm segment and the second arm segment when the actuator assembly is in the closed position, the body including a first drive input and a second drive input, each of which is movable relative to the body to actuate movement of at least a portion of the surgical instrument, wherein the first drive input and the second drive input are operably associated with a corresponding one of the first drive member and the second drive member when the body is disposed within the actuator assembly and the actuator assembly is in the closed position.

2. The robotic system assembly according to claim 1, wherein: The actuator assembly includes a first face and a second face, wherein the first drive member is exposed at the first face and the second drive member is exposed at the second face, wherein the first face and the second face are different faces.

3. The robotic system assembly of claim 2, wherein: The first surface faces a first direction, and the second surface faces a second direction opposite to the first direction.

4. The robotic system assembly of claim 1 , wherein: At least one of the first arm section and the second arm section is movable relative to the other of the first arm section and the second arm section by pivoting to move the actuator assembly between the open position and the closed position.

5. The robotic system assembly of claim 4, wherein: Movement of the actuator assembly between the open position and the closed position is initiated in response to electrical or mechanical interaction between the surgical instrument and the manipulator.

6. The robotic system assembly of claim 1 , wherein: The robotic manipulator includes channels for instrument or camera cables.

7. The robotic system assembly of claim 6, wherein: The channel comprises a portion of the actuator assembly.

8. The robotic system assembly of claim 1 , wherein: The first drive input and the second drive input are positioned on different sides of the body.

9. The robotic system assembly of claim 1 , wherein: The first drive input and the second drive input extend from the body in opposite directions.

10. The robotic system assembly of claim 1, wherein: The first drive input portion and the second drive input portion extend from the body in non-parallel directions.

11. The robotic system assembly of claim 1 , wherein: The first drive input and the second drive input are movable longitudinally relative to the body (110) in a proximal direction and a distal direction.

12. The robotic system assembly of claim 1, wherein: The first motor and the second motor are independently operable to independently drive the first drive member and the second drive member.

13. The robotic system assembly of claim 1 , wherein: At least one of the first arm segment and the second arm segment is movable relative to the other of the first arm segment and the second arm segment by rotating to move the actuator assembly between the open position and the closed position.

14. The robotic system assembly of claim 1, wherein: At least one of the first arm section and the second arm section is movable relative to the other of the first arm section and the second arm section by sliding to move the actuator assembly between the open position and the closed position.

15. The robotic system assembly of claim 2, wherein: When the actuator assembly is in the closed position, the first face and the second face are parallel to each other.

16. The robotic system assembly of claim 2, wherein: The actuator assembly further comprises: a third driving member, the third driving member being exposed at the first face, a third motor operable to drive the third drive member relative to the first face, a fourth drive member exposed at the second face, and a fourth motor operable to drive the fourth drive member relative to the second face, The first motor, the second motor, the third motor, and the fourth motor are independently operable to independently drive the first drive member, the second drive member, and the third drive member to actuate the surgical instrument.

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