Articulation mechanism for a robotic surgical tool

Abstract

A robotic surgical tool includes a drive housing having a first end and a second end, at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the spline, and a carriage movably mounted to the spline. An elongated shaft extends from the carriage and through the first end, an end effector is arranged at a distal end of the elongated shaft, and a wrist is interposed between the end effector and the distal end of the shaft. An activation mechanism is housed in the carriage and operably coupled to the drive gear such that rotation of the drive gear correspondingly actuates the activation mechanism to cause the wrist to articulate the end effector in at least one plane.

Description

Technical Field

[0001] The systems and methods disclosed herein relate to robotic surgical tools, and more specifically to robotic surgical tools comprising a bracket movably mounted to a lead screw and one or more splines capable of being actuated to operate various functions of the robotic surgical tool. Background Technology

[0002] 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's insertion and sealing system is used to introduce various instruments and tools into the abdominal cavity and provides 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.

[0003] Each surgical instrument typically includes an end effector positioned at its distal end. Exemplary end effectors include clamps, grippers, scissors, suture devices, suction irrigators, blades (i.e., RFs), 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.

[0004] Various robotic systems have recently been developed to assist in MIS surgery. Robotic systems can achieve more intuitive hand movements by maintaining a natural hand-eye axis. They can also achieve greater degrees of freedom of movement through "wrist" joints that enable more natural hand-like joint movements and allow access to hard-to-reach spaces. The end effector of the instrument can perform joint movements (mobility) using motors and actuators that form part of a computerized motion system. A user (e.g., a surgeon) can remotely operate the end effector of the instrument by grasping and manipulating one or more controllers in space, which are connected to instrument actuators coupled to the surgical instruments. User input is processed by a computer system integrated into the robotic surgical system, and the instrument actuators respond by actuating the motors and actuators of the motion system. Motion drive cables and / or other mechanical mechanisms manipulate the end effector joints to desired positions and configurations.

[0005] Improvements to robot-enabled medical systems will provide physicians with the ability to perform endoscopic and laparoscopic procedures more efficiently and easily. Summary of the Invention

[0006] The following summary outlines various details of this disclosure to provide a basic understanding. This summary is not an exhaustive overview of the disclosure and is neither intended to identify certain elements of the disclosure nor to depict its scope. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form before the more detailed description presented below.

[0007] The embodiments disclosed herein include a robotic surgical tool comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; and a bracket movably mounted to the at least one spline. An elongated shaft extends from the bracket and through the first end, and an end effector is disposed at the distal end of the elongated shaft. A wrist is inserted between the end effector and the distal end of the shaft, and an activation mechanism is housed in the bracket and operatively coupled to the drive gear such that rotation of the drive gear correspondingly actuates the activation mechanism, thereby causing the wrist to articulate the end effector in at least one plane. In another embodiment, the robotic surgical tool further includes a drive input disposed at the first end and operatively coupled to the at least one spline, such that rotation of the drive input correspondingly rotates the at least one spline and the drive gear. The robotic surgical tool is capable of engaging an instrument actuator disposed at the end of the robotic arm and capable of cooperating with the drive housing at the first end. The instrument actuator provides a drive output that cooperates with the drive input, such that rotation of the drive output correspondingly rotates the drive input, thereby actuating the activation mechanism. In yet another embodiment, the shaft extends through the instrument actuator via a central bore defined longitudinally through the instrument actuator. In yet another embodiment, the carrier includes at least a first layer and a second layer arranged in series, and the drive gear is disposed between portions of the first layer and the second layer and slidably disposed around the at least one second spline. In another embodiment, the activation mechanism includes: a first carrier extending at least partially about the axis and operably coupled to a first drive member extending to the wrist; and a second carrier extending at least partially about the axis and operably coupled to a second drive member extending to the wrist, wherein actuation of the activation mechanism causes the first carrier and the first drive member to move along the axis in a first axial direction and also causes the second carrier and the second drive member to move along the axis in a second axial direction, wherein the first axial direction and the second axial direction are collinear and opposite. In another embodiment, the distal ends of the first drive member and the distal ends of the second drive member operate counteractively at the end effector to cause the end effector to articulate in at least one plane.In another embodiment, the activation mechanism further includes: a first drive gear extending about the shaft and defining an internal thread, the first carrier being radially inserted between the shaft and the first drive gear and defining an external thread capable of engaging the internal threads of the first drive gear; and a second drive gear extending about the shaft and defining an internal thread, the second carrier being radially inserted between the shaft and the second drive gear and defining an external thread capable of engaging the internal threads of the second drive gear, wherein the first and second drive gears are capable of engaging the drive gear such that rotation of the drive gear simultaneously rotates both the first and second drive gears, and wherein the internal threads of the first and second drive gears are in opposite directions, such that rotation of the first and second drive gears causes the first and second carriers to move along the shaft in collinear but opposite axial directions. In another embodiment, a gap is provided between the first and second carriers to allow the first and second carriers to move toward and away from each other during actuation of the activation mechanism. In another embodiment, the activation mechanism further includes: a joint cylinder rotatably disposed about the shaft, the driven gear disposed on the joint cylinder, and the first carrier and the second carrier radially inserted between the shaft and the joint cylinder; a first cam profile and a second cam profile defined in the joint cylinder and extending around the circumference of the joint cylinder at equal but opposite angles; a first driven pin extending through the first cam profile and coupled to the first carrier; and a second driven pin extending through the second cam profile and coupled to the second carrier, wherein as the drive gear rotates the joint cylinder, the first driven pin and the second driven pin are respectively pushed across the first cam profile and the second cam profile, thereby pushing the first carrier and the second carrier in collinear but opposite axial directions. In another embodiment, the activation mechanism further includes: a first articulation torque rod fixed to the bracket and defining a first slot for receiving the head of the first driven pin; and a second articulation torque rod fixed to the bracket and defining a second slot for receiving the head of the second driven pin. In another embodiment, each driven pin includes: a first bearing that presses against the inner wall of the first cam profile or the second cam profile as the articulation cylinder rotates; and a second bearing capable of pressing against the inner wall of the first slot or the second slot as the articulation cylinder rotates. In another embodiment, at least one of the first cam profile and the second cam profile provides an inflection point along the path of the first cam profile and the second cam profile.In another embodiment, the end effector is selected from: surgical suture devices, tissue grippers, surgical scissors, advanced energy vascular closure devices, clamp applicators, needle drivers, Babcock forceps including a pair of opposing gripping jaws, bipolar jaws, aspiration irrigators, endoscopes, laparoscopes, and any combination thereof.

[0008] The embodiments disclosed herein may also include a method comprising positioning a robotic surgical tool near a patient, the robotic surgical tool comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; a bracket movably mounted to the at least one spline; an elongated shaft extending from the bracket and penetrating the first end; an end effector disposed at a distal end of the elongated shaft; a wrist inserted between the end effector and the distal end of the shaft; and an activation mechanism housed in the bracket and operatively coupled to the drive gear. The method may further include: rotating the at least one spline and the drive gear by actuating a drive input disposed at the first end and operatively coupled to the at least one spline; and actuating the activation mechanism with rotation of the drive gear, thereby causing the end effector to articulate in at least one plane at the wrist. In another embodiment, the method further includes: engaging a device actuator at the first end with the drive housing, the device actuator being disposed at the end of the robot arm; engaging a drive output of the device actuator with the drive input when the device actuator is engaged with the drive housing; and actuating the drive output to rotate the drive input, thereby actuating the activation mechanism. In another embodiment, engaging the device actuator at the first end with the drive housing includes causing the shaft, the end effector, and the wrist to extend through a central hole defined as longitudinally passing through the device actuator. In another embodiment, the activation mechanism includes: a first carrier extending at least partially about the shaft and operatively coupled to a first drive member extending to the wrist; and a second carrier extending at least partially about the shaft and operatively coupled to a second drive member extending to the wrist, wherein actuating the activation includes: causing the first carrier and the first drive member to move along the shaft in a first axial direction; and causing the second carrier and the second drive member to move along the shaft in a second axial direction, wherein the first axial direction and the second axial direction are collinear and opposite. In another embodiment, the method further includes causing the distal end of the first drive member and the distal end of the second drive member to operate in opposition at the end actuator, thereby causing the end actuator to perform articulation in the at least one plane.In another embodiment, the activation mechanism further includes a first drive gear extending around the shaft and defining an internal thread, the first carrier being radially inserted between the shaft and the first drive gear and defining an external thread capable of engaging the internal threads of the first drive gear, and a second drive gear extending around the shaft and defining an internal thread, the second carrier being radially inserted between the shaft and the second drive gear and defining an external thread capable of engaging the internal threads of the second drive gear. The method further includes: engaging the drive gear with the first drive gear and the second drive gear; rotating the drive gear thereby simultaneously rotating the first drive gear and the second drive gear, wherein the internal threads of the first drive gear and the internal threads of the second drive gear have opposite thread directions; and causing the first carrier and the second carrier to move along the shaft in collinear but opposite axial directions as the first drive gear and the second drive gear rotate. In another embodiment, the activation mechanism further includes: a joint cylinder rotatably disposed about the shaft, the driven gear disposed on the joint cylinder, and the first carrier and the second carrier radially inserted between the shaft and the joint cylinder; a first cam profile and a second cam profile defined in the joint cylinder and extending about the circumference of the joint cylinder at equal but opposite angles; a first follower pin extending through the first cam profile and coupled to the first carrier; and a second follower pin extending through the second cam profile and coupled to the second carrier. The method further includes: rotating the joint cylinder with the drive gear; pressing the first and second follower pins across the first and second cam profiles respectively as the joint cylinder rotates; and pressing the first and second carriers across the first and second cam profiles, moving them along the shaft in collinear but opposite axial directions.

[0009] The embodiments disclosed herein include a robotic surgical tool comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; a bracket movably mounted to the at least one spline; an elongated shaft extending from the bracket and penetrating the first end, the shaft having an end effector disposed at its distal end; and an activation mechanism housed within the bracket. The activation mechanism includes: an input gear operably coupled to the drive gear such that rotation of the drive gear correspondingly rotates the input gear; and a firing lever defining an external thread capable of threadedly engaging an internal thread of the input gear, the firing lever operably coupled to a blade at the end effector such that longitudinal movement of the firing lever correspondingly moves the blade in the same direction, wherein rotation of the drive gear causes rotation of the input gear, thereby causing longitudinal movement of the firing lever and the blade. In another embodiment, the robotic surgical tool further includes: a drive input disposed at the first end and operatively coupled to the at least one spline, such that rotation of the drive input correspondingly rotates the at least one spline and the drive gear; and an instrument driver disposed at the end of the robotic arm and capable of engaging with the drive housing at the first end, the instrument driver providing a drive output that engages with the drive input, such that rotation of the drive output correspondingly rotates the drive input, thereby actuating the activation mechanism. In yet another embodiment, the shaft extends through the instrument driver by passing through a central hole defined as longitudinally through the instrument driver. In yet another embodiment, the carrier includes at least a first layer and a second layer arranged in series, wherein the drive gear is disposed between portions of the first layer and portions of the second layer and slidably disposed around the at least one second spline. In yet another embodiment, the activation mechanism further includes an idler gear inserted between the drive gear and the input gear to transmit torque from the drive gear to the input gear via a meshing transmission mechanism. In another embodiment, the activation mechanism further includes: a channel retainer coupled to the bracket and pressing against a first side of the input gear; and one or more thrust bearings housed within the bracket and pressing against a second side of the input gear, wherein the channel retainer and the one or more thrust bearings axially secure the input gear in place. In another embodiment, the robotic surgical tool further includes a locking mechanism that axially secures the channel retainer to the bracket.In another embodiment, the internal threads of the input gear are defined on an elongated cylindrical body extending from the input gear, and the firing lever extends within the elongated cylindrical body. In another embodiment, the activation mechanism further includes a firing member inserted between the firing lever and the blade. In yet another embodiment, the end effector is selected from: surgical suture devices, tissue grippers, surgical scissors, high-energy vascular closure devices, clamp applicators, needle drivers, Babcock forceps including a pair of opposing gripping jaws, bipolar jaws, suction flushing devices, endoscopes, laparoscopes, and any combination thereof.

[0010] The embodiments disclosed herein may also include a method comprising positioning a robotic surgical tool near a patient, the robotic surgical tool comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; a bracket movably mounted to the at least one spline; an elongated shaft extending from the bracket and penetrating the first end, the shaft having an end effector disposed at its distal end; and an activation mechanism housed in the bracket and including an input gear and a firing lever, the input gear being operatively coupled to the drive gear such that rotation of the drive gear correspondingly rotates the input gear, the firing lever defining an external thread capable of threadedly engaging with an internal thread of the input gear. The method further includes: rotating the at least one spline and the drive gear by actuating a drive input member disposed at the first end and operably coupled to the at least one spline; and rotating the input gear with the drive gear, thereby longitudinally moving the firing lever and a blade located at the end effector and operably coupled to the firing lever. In another embodiment, the method further includes: engaging a device driver at the first end with the drive housing, the device driver being disposed at the end of the robot arm; engaging a drive output member of the device driver with the drive input member when the device driver is engaged with the drive housing; and actuating the drive output member to rotate the drive input member, thereby actuating the activation mechanism. In yet another embodiment, engaging the device driver at the first end with the drive housing includes extending the shaft and the end effector through a central hole defined as longitudinally passing through the device driver. In yet another embodiment, the activation mechanism further includes an idler gear inserted between the drive gear and the input gear, and the method further includes transmitting torque from the drive gear to the input gear via the idler gear. In another embodiment, the activation mechanism further includes: a channel retainer coupled to the bracket and pressing against a first side of the input gear; and one or more thrust bearings housed within the bracket and pressing against a second side of the input gear, the method further including axially securing the input gear between the channel retainer and the one or more thrust bearings. In another embodiment, the method further includes axially securing the channel retainer to the bracket using a locking mechanism. In another embodiment, the method further includes applying an axial load to the input gear and reducing rotational friction between the input gear and the one or more thrust bearings during longitudinal movement of the firing rod. In another embodiment, the internal threads of the input gear are defined on an elongated cylindrical body extending from the input gear, and wherein the firing rod extends within the elongated cylindrical body.In another embodiment, the activation mechanism further includes a firing member inserted between the firing lever and the blade.

[0011] The embodiments disclosed herein include a robotic surgical tool comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; a bracket movably mounted to the at least one spline; a closure tube extending from the bracket and through the first end, the closure tube having an end effector disposed at a distal end of the closure tube; and an activation mechanism housed within the bracket. The activation mechanism may include: a driven gear operably coupled to the drive gear such that rotation of the drive gear correspondingly rotates the driven gear; and a carrier disposed at a proximal end of the closure tube and operably coupled to the driven gear such that rotation of the driven gear correspondingly moves the carrier and the closure tube axially along the longitudinal axis of the closure tube, wherein axial movement of the closure tube along the longitudinal axis causes the jaws of the end effector to close or open. In another embodiment, the robotic surgical tool further includes: a drive input disposed at the first end and operatively coupled to the at least one spline, such that rotation of the drive input correspondingly rotates the at least one spline and the drive gear; and an instrument driver disposed at the end of the robotic arm and capable of engaging with the drive housing at the first end, the instrument driver providing a drive output that engages with the drive input, such that rotation of the drive output correspondingly rotates the drive input, thereby actuating the activation mechanism. In yet another embodiment, the closure tube extends through the instrument driver by extending through a central hole defined as longitudinally passing through the instrument driver. In yet another embodiment, the bracket includes at least a first layer and a second layer arranged in series, wherein the drive gear is disposed between portions of the first layer and the second layer and slidably disposed around the at least one second spline. In another embodiment, the activation mechanism further includes: a key disposed on the outer surface of the closed tube; and a slot defined in the first layer and sized to receive the key, wherein as the closed tube moves along the longitudinal axis, the key correspondingly translates within the slot to prevent rotation of the closed tube. In another embodiment, the driven gear includes an annular structure extending around the closed tube and defining an internal thread capable of threaded engagement with an external thread defined by the carrier, wherein rotation of the driven gear causes the carrier and the closed tube to move along the longitudinal axis via the threaded engagement between the driven gear and the carrier. In another embodiment, the carrier is radially inserted between a portion of the closed tube and the driven gear and defines an inner radial shoulder capable of engaging with the proximal end of the closed tube.In another embodiment, the activation mechanism further includes: a closing cylinder extending around the closing tube and the carrier, wherein the driven gear is coupled to the closing cylinder such that rotation of the driven gear correspondingly rotates the closing cylinder about the longitudinal axis; a cam profile defined within the closing cylinder; and a follower pin extending through the cam profile and coupled to the carrier such that, as the closing cylinder rotates, the follower pin traverses the cam profile and correspondingly moves the carrier and the closing tube along the longitudinal axis. In another embodiment, the follower pin includes a bearing that presses against the inner wall of the cam profile as the closing cylinder rotates. In another embodiment, the cam profile includes a straight groove extending helically at a constant angle around the circumference of the closing cylinder. In another embodiment, the cam profile includes a slot extending a first distance at a first slope and a second distance at a second slope different from the first slope. In another embodiment, the end effector is selected from: surgical suture devices, tissue grippers, surgical scissors, advanced energy vascular closure devices, clamp applicators, needle drivers, Babcock forceps including a pair of opposing gripping jaws, bipolar jaws, aspiration irrigators, endoscopes, laparoscopes, and any combination thereof.

[0012] The embodiments disclosed herein may also include a method comprising positioning a robotic surgical tool near a patient, the robotic surgical tool comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; a bracket movably mounted to the at least one spline; a closure tube extending from the bracket and penetrating the first end, the closure tube having an end effector disposed at a distal end of the closure tube; and an activation mechanism housed in the bracket and including a driven gear operatively coupled to the drive gear, and further including a carrier disposed at a proximal end of the closure tube and operatively coupled to the driven gear. The method may further include: rotating the at least one spline and the drive gear by actuating a drive input disposed at the first end and operatively coupled to the at least one spline; rotating the driven gear with the drive gear, thereby causing the carrier and the closed tube to move axially along the longitudinal axis of the closed tube; and opening or closing the jaws of the end effector as the closed tube moves axially along the longitudinal axis. In another embodiment, the method further includes: engaging a device actuator at the first end with the drive housing, the device actuator being disposed at the end of the robot arm; engaging a drive output of the device actuator with the drive input when the device actuator is engaged with the drive housing; and actuating the drive output to rotate the drive input, thereby actuating the activation mechanism. In yet another embodiment, engaging the device actuator at the first end with the drive housing includes extending the closed tube and the end effector through a central hole defined as longitudinally passing through the device actuator. In another embodiment, the bracket includes at least a first layer and a second layer arranged in series, and the activation mechanism further includes: a key disposed on the outer surface of the closed tube; and a slot defined in the first layer and sized to receive the key. The method further includes preventing rotation of the closed tube about the longitudinal axis by moving the key within the slot as the closed tube moves axially along the longitudinal axis. In another embodiment, the driven gear includes an annular structure extending around the closed tube and defining an internal thread capable of threaded engagement with an external thread defined by the carrier. Rotation of the driven gear with the drive gear further includes moving the carrier and the closed tube along the longitudinal axis via the threaded engagement between the driven gear and the carrier. In another embodiment, the method further includes changing the pitch of the internal thread and the pitch of the external thread to change the final axial load applied to the closed tube.In another embodiment, the activation mechanism further includes: a closing cylinder extending around the closing tube and the carrier, to which the driven gear is coupled; a cam profile defined within the closing cylinder; and a follower pin extending through the cam profile and coupled to the carrier, wherein causing the driven gear to rotate with the drive gear further includes: causing the closing cylinder to rotate about the longitudinal axis as the drive gear causes the driven gear to rotate; causing the follower pin to traverse the cam profile as the closing cylinder rotates; and causing the carrier and the closing tube to move along the longitudinal axis as the follower pin traverses the cam profile. In another embodiment, the cam profile includes a slot extending a first distance at a first slope and a second distance at a second slope different from the first slope, the method further including altering the mechanical advantages of the activation mechanism by causing the follower pin to traverse from the first slope to the second slope.

[0013] The embodiments disclosed herein include a robotic surgical tool comprising: a drive housing having a first end, a second end, and a lead screw extending between the first end and the second end; a bracket movably mounted to the lead screw at a bracket nut fixed to the bracket; and an elongated shaft extending from the bracket and through the first end, the shaft having an end effector disposed at its distal end, wherein rotation of the lead screw causes axial movement of the bracket and the bracket nut between the first end and the second end, thereby causing the end effector to move distally or proximally. In another embodiment, the robotic surgical tool further includes: a drive input disposed at the first end and operatively coupled to the lead screw, such that rotation of the drive input correspondingly rotates the lead screw; and an instrument driver disposed at the end of the robotic arm and capable of engaging with the drive housing at the first end, the instrument driver providing a drive output capable of engaging the drive input, such that rotation of the drive output correspondingly rotates the drive input, thereby rotating the lead screw. In yet another embodiment, the shaft extends through the instrument driver by extending through a central bore defined as longitudinally passing through the instrument driver. In yet another embodiment, the outer surface of the lead screw defines a helical external thread, and the bracket nut defines a helical internal thread capable of engaging the helical external thread. In yet another embodiment, the pitch of the helical external thread varies along the lead screw. In yet another embodiment, a lubricating coating is applied to the helical external thread to reduce friction against the helical internal thread abutting the bracket nut. In another embodiment, the bracket includes at least a first layer and a second layer arranged in series, and wherein the bracket nut includes a separate component disposed between a portion of the first layer and a portion of the second layer. In another embodiment, the bracket nut defines an anti-rotation feature capable of engaging with a corresponding feature defined on the first or second layer. In another embodiment, the bracket includes at least one layer defining a hole including the bracket nut, and wherein the lead screw extends through the hole. In another embodiment, the bracket nut extends between a proximal end and a distal end of the bracket. In another embodiment, the bracket nut includes at least two bracket nuts rotatably mounted to the lead screw. In another embodiment, the bracket nut includes a distal nut portion located at the distal end of the bracket and a proximal nut portion located at the proximal end of the bracket.

[0014] The embodiments disclosed herein may also include a method for positioning a robotic surgical tool near a patient, the robotic surgical tool comprising: a drive housing having a first end, a second end, and a lead screw extending between the first end and the second end; a bracket movably mounted to the lead screw at a bracket nut fixed to the bracket; and an elongated shaft extending from the bracket and through the first end, the shaft having an end effector disposed at its distal end. The method may further include: rotating the lead screw by actuating a drive input disposed at the first end and operatively coupled to the lead screw; and axially moving the bracket and the bracket nut between the first end and the second end as the lead screw rotates, thereby moving the end effector distally or proximally. In another embodiment, the method further includes: engaging a device actuator at the first end with the drive housing, the device actuator being disposed at the end of the robot arm; engaging a drive output of the device actuator with the drive input when the device actuator is engaged with the drive housing; and actuating the drive output to rotate the drive input, thereby rotating the lead screw. In yet another embodiment, engaging the device actuator at the first end with the drive housing includes extending the shaft, the end effector, and the wrist through a central bore defined as longitudinally passing through the device actuator. In yet another embodiment, the outer surface of the lead screw defines a helical external thread, and the bracket nut defines a helical internal thread capable of engaging the helical external thread, wherein rotating the lead screw includes converting the rotational load of the lead screw into an axial load applied to the bracket through the mechanical interaction of the helical external thread and the helical internal thread. In yet another embodiment, the bracket includes at least a first layer and a second layer arranged in series, and wherein the bracket nut includes a separate component disposed between a portion of the first layer and a portion of the second layer. In another embodiment, the method further includes preventing rotation of the bracket nut by engaging an anti-rotation feature defined on the bracket nut with a corresponding feature defined on the first or second layer. In another embodiment, the bracket includes at least one layer defining a hole including the bracket nut, wherein the lead screw extends through the hole. In another embodiment, the method further includes using the bracket nut to stabilize the bracket against torsion within the drive housing, the bracket nut having portions disposed at or near the distal and proximal ends of the bracket.

[0015] The embodiments disclosed herein include a robotic surgical system comprising a surgical tool including: a drive housing having a first end, a second end, and a bracket movably mounted to the drive housing between the first end and the second end; and an elongated shaft extending from the bracket and penetrating the first end, the shaft having an end effector disposed at its distal end. The robotic surgical system also includes an instrument driver disposed at the end of a robotic arm and comprising: a body having a proximal end, a distal end, and defining a central aperture extending between the proximal end and the distal end, wherein the shaft and the end effector penetrate the instrument driver by extending through the central aperture; an outer housing extending at least partially between the proximal end and the distal end; a tool drive assembly disposed at the proximal end and extending into the outer housing; and a drive motor operatively coupled to and operable such that the tool drive assembly rotates about a central axis relative to the outer housing. A first end of the drive housing is operatively coupled to the tool drive assembly, such that rotation of the tool drive assembly correspondingly rotates the surgical tool about the central axis in the same angular direction. In another embodiment, the tool drive assembly provides one or more drive outputs capable of engaging one or more drive inputs disposed at the first end of the drive housing, wherein rotation of the tool drive assembly and the one or more drive outputs about the central axis correspondingly rotates the one or more drive inputs about the central axis. In yet another embodiment, each drive output is driven by a corresponding actuator mounted to the tool drive assembly and capable of rotating about the central axis as the tool drive assembly rotates. In yet another embodiment, the surgical tool further includes at least one spline extending between the first end and the second end, and a bracket is movably mounted to the at least one spline, wherein the at least one spline is operatively coupled to at least one of the one or more drive inputs, such that rotation of the at least one of the one or more drive inputs correspondingly rotates the at least one spline. In another embodiment, the surgical tool further includes a lead screw extending between the first end and the second end, and the bracket is movably mounted to the lead screw at a bracket nut fixed to the bracket, wherein the lead screw is operably coupled at at least one of the one or more drive inputs at at least one spline, such that rotation of the at least one of the one or more drive inputs correspondingly rotates the lead screw.In another embodiment, the instrument actuator further includes a slip ring coupled to the outer housing to facilitate the transmission of electrical power and signals from the robotic arm to the tool drive assembly to operate the surgical tool. In another embodiment, the tool drive assembly provides one or more interlocking features capable of engaging with one or more complementary recesses located at the first end of the drive housing to operatively engage the surgical tool with the instrument actuator. In another embodiment, the instrument actuator further includes a stator gear fixed to the tool drive assembly and a rotor gear driven by the drive motor and capable of engaging the stator gear, wherein actuation of the rotor gear drives the stator gear, thereby causing the tool drive assembly to rotate about the central axis. In another embodiment, the instrument actuator further includes an inner catheter defining the central bore and coupled to the tool drive assembly, such that rotation of the tool drive assembly correspondingly causes the inner catheter to rotate about the central axis. In another embodiment, the instrument actuator further includes a plurality of bearings disposed between a portion of the tool drive assembly and a portion of the outer housing to allow rotation of the tool drive assembly relative to the outer housing. In another embodiment, the instrument actuator further includes: one or more seals disposed at corresponding one or more radial interfaces between the tool drive assembly and the outer housing; and one or more washers disposed at corresponding one or more axial interfaces between the tool drive assembly and the housing. In another embodiment, the end effector is selected from: surgical suture devices, tissue grippers, surgical scissors, advanced-energy vascular closure devices, clamp applicators, needle drivers, Babcock forceps including a pair of opposing gripping jaws, bipolar jaws, aspiration irrigators, endoscopes, laparoscopes, and any combination thereof.

[0016] The embodiments disclosed herein also include a method of operating a robotic surgical system, the method comprising positioning an instrument actuator near a patient, the instrument actuator comprising: a body having a proximal end, a distal end, and a central aperture extending between the proximal end and the distal end; an outer housing extending at least partially between the proximal end and the distal end; and a tool driving assembly disposed at the proximal end and extending into the outer housing. The method may further comprise coupling a surgical tool to the instrument actuator, the surgical tool comprising: a drive housing having a first end, a second end, and a bracket movably mounted to the drive housing between the first end and the second end, wherein the first end of the drive housing is operatively coupled to the tool driving assembly; and an elongated shaft extending from the bracket and penetrating the first end, the shaft having an end effector disposed at its distal end, wherein the shaft and the end effector penetrate the instrument actuator by extending through the central aperture. The method may further include actuating a drive motor included in the instrument driver and operatively coupled to the tool drive assembly, thereby rotating the tool drive assembly about the central axis relative to the outer housing, and rotating the surgical tool about the central axis when coupled to the tool drive assembly. In another embodiment, the method further includes: engaging one or more drive outputs of the tool drive assembly with one or more drive inputs disposed at the first end of the drive housing; and rotating the one or more drive inputs about the central axis as the tool drive assembly and the one or more drive outputs rotate about the central axis. In yet another embodiment, the instrument driver further includes an actuator mounted to the tool drive assembly and operatively coupled to one of the one or more drive outputs, the method further including: operating the actuator to rotate the one of the one or more drive outputs, thereby driving a corresponding drive input of the one or more drive inputs; and rotating the actuator about the central axis as the tool drive assembly rotates. In another embodiment, the surgical tool further includes at least one spline extending between the first end and the second end, and the bracket is movably mounted to the at least one spline, wherein the at least one spline is operatively coupled to a corresponding drive input of the one or more drive inputs, the method further including rotating the corresponding drive input of the one or more drive inputs, thereby rotating the at least one spline.In another embodiment, the surgical tool further includes a lead screw extending between the first end and the second end, and the bracket is movably mounted to the lead screw at a bracket nut fixed to the bracket, wherein the lead screw is operatively coupled to a corresponding drive input of the one or more drive inputs, and the method further includes: rotating the corresponding drive input of the one or more drive inputs, thereby rotating the lead screw; and axially moving the bracket and the bracket nut between the first end and the second end with rotation of the lead screw, thereby moving the end effector distally or proximally. In another embodiment, the method further includes transmitting electrical power and signals from the robotic arm to the tool drive assembly using a slip ring coupled to the outer housing. In another embodiment, coupling the surgical tool to the instrument drive further includes engaging one or more interlocking features disposed on the tool drive assembly with one or more complementary recesses disposed at the first end of the drive housing. In another embodiment, the instrument actuator further includes a stator gear fixed to the tool drive assembly, and a rotor gear driven by the drive motor and capable of engaging the stator gear, wherein actuating the drive motor further includes: rotating the rotor gear; and driving the stator gear with the rotor gear, thereby causing the tool drive assembly to rotate about the central axis relative to the outer housing.

[0017] The embodiments disclosed herein include a robotic surgical tool comprising: a drive housing having a first end, a second end, and a lead screw extending between the first end and the second end; a bracket movably mounted to the lead screw at a bracket nut fixed to the bracket; an activation mechanism including a drive gear rotatably mounted to the bracket and rotatably actuating the activation mechanism; and a torsion cable extending between the drive gear and a drive input disposed at the first end, wherein a step of rotating the drive input rotates the torsion cable, thereby transmitting a torsional load along the torsion cable to the drive gear to actuate the activation mechanism. In another embodiment, the surgical tool further includes an instrument actuator disposed at the end of a robotic arm and capable of engaging with the drive housing at the first end, the instrument actuator providing a drive output capable of engaging the drive input such that rotation of the drive output correspondingly rotates the drive input, thereby rotating the torsion cable to actuate the activation mechanism. In another embodiment, the drive input is a first drive input and the drive output is a first drive output. The robotic surgical system further includes: a second drive input disposed at the first end and operatively coupled to the lead screw, such that rotation of the second drive input correspondingly rotates the lead screw; and a second drive output provided by the instrument actuator and capable of cooperating with the second drive input, such that rotation of the second drive output correspondingly rotates the second drive input, thereby rotating the lead screw. In another embodiment, the robotic surgical tool further includes: an elongated shaft extending from the bracket and penetrating the first end; an end effector disposed at the distal end of the shaft; and a wrist inserted between the shaft and the end effector, wherein actuation of the activation mechanism causes at least one of the following to occur: opening or closing the jaws of the end effector; articulating the end effector at the wrist; and advancing or retracting the blade at the end effector. In another embodiment, the end effector is selected from: surgical suture devices, tissue grippers, surgical scissors, advanced energy vascular closure devices, clamp applicators, needle drivers, Babcock forceps including a pair of opposing gripping jaws, bipolar jaws, aspiration irrigators, endoscopes, laparoscopes, and any combination thereof.In another embodiment, the robotic surgical tool further includes: an elongated shaft extending from the bracket and penetrating the first end; and an end effector disposed at the distal end of the shaft, wherein the activation mechanism further includes: a driven gear rotatably mounted to the bracket and operably coupled to the drive gear such that rotation of the drive gear correspondingly rotates the driven gear; and a firing lever operably coupled to the driven gear such that rotation of the driven gear causes the firing lever to translate axially along the shaft and causes the blade at the end effector to move. In another embodiment, the robotic surgical tool further includes a tensioning system comprising: a tensioning pulley; a fixed pulley anchored to the drive housing, wherein the torsion cable wiring passes through the tensioning pulley and the fixed pulley; one or more bracket pulleys anchored to the drive housing; and a bracket cable wiring passing through the one or more bracket pulleys and extending between the bracket and the tensioning pulley, wherein as the bracket moves back and forth on the lead screw, the tensioning pulley maintains tension in the torsion cable by traveling in an axial direction opposite to the bracket. In another embodiment, the activation mechanism further includes a driven gear disposed on the outer periphery of the bracket nut and operatively coupled to the drive gear, such that rotation of the drive gear correspondingly causes the bracket nut to rotate relative to the lead screw, thereby pushing the bracket to move axially along the lead screw. In another embodiment, the robotic surgical tool further includes one or more idler gears inserted between the drive gear and the driven gear to transmit torque from the drive gear to the driven gear.

[0018] The embodiments disclosed herein may also include a method of operating a robotic surgical tool, the method comprising positioning the robotic surgical tool near a patient, the robotic surgical tool comprising: a drive housing having a first end, a second end, and a lead screw extending between the first end and the second end; a bracket movably mounted to the lead screw at a bracket nut fixed to the bracket; an activation mechanism including a drive gear rotatably mounted to the bracket; and a torsion cable extending between the drive gear and a drive input disposed at the first end. The method further comprises: rotating the drive input, thereby rotating the torsion cable; and transmitting a torsional load along the torsion cable to the drive gear as the torsion cable rotates, thereby actuating the activation mechanism. In another embodiment, an instrument actuator disposed at the end of a robotic arm engages with the drive housing at the first end, and the instrument actuator provides a drive output capable of engaging the drive input, the method further comprising rotating the drive output, thereby rotating the drive input and the torsion cable to actuate the activation mechanism. In another embodiment, the drive input is a first drive input and the drive output is a first drive output, the method further comprising: rotating a second output provided by the instrument driver, thereby rotating a second drive input disposed at the first end and operatively coupled to the lead screw; rotating the lead screw as the second drive input rotates; and moving the bracket along the lead screw as the lead screw rotates. In another embodiment, the surgical tool further comprises: an elongated shaft extending from the bracket and penetrating the first end; an end effector disposed at the distal end of the shaft; and a wrist inserted between the shaft and the end effector, wherein actuation of the activation mechanism includes at least one of: opening or closing the jaws of the end effector; articulating the end effector at the wrist; and advancing or retracting the blade at the end effector. In another embodiment, the surgical tool further includes: an elongated shaft extending from the bracket and penetrating the first end; an end effector disposed at the distal end of the shaft; the method further includes: rotating a drive gear with the torsion cable, the drive gear being operatively coupled to a driven gear rotatably mounted to the bracket and operatively coupled to a firing lever; rotating the driven gear with the rotation of the drive gear, thereby causing the firing lever to translate axially along the shaft; and moving a blade at the end effector with the axial translation of the firing lever.In another embodiment, the method further includes maintaining tension in the torsion cable using a tensioning system comprising: a tensioning pulley; a fixed pulley anchored to the drive housing, wherein the torsion cable is routed through the tensioning pulley and the fixed pulley; one or more bracket pulleys anchored to the drive housing; and a bracket cable routed through the one or more bracket pulleys and extending between the bracket and the tensioning pulley. The method further includes moving the tensioning pulley in an axial direction opposite to that of the bracket as the bracket reciprocates on the lead screw. In another embodiment, the method further includes feeding the torsion cable through the tensioning pulley and the fixed pulley as the tensioning pulley moves in that axial direction; and feeding the bracket cable through the one or more bracket pulleys as the bracket reciprocates on the lead screw. In another embodiment, the activation mechanism further includes a driven gear disposed on the outer periphery of the bracket nut and operatively coupled to the drive gear. The method further includes: rotating the drive gear with the torsion cable, thereby rotating the driven gear; and rotating the bracket nut with the rotation of the driven gear, thereby pushing the bracket to move axially along the lead screw. In another embodiment, the method further includes one or more idler gears inserted between the drive gear and the driven gear to transmit torque from the drive gear to the driven gear.

[0019] The embodiments disclosed herein may also include another robotic surgical system comprising: a drive housing having a first end, a second end, and a lead screw extending between the first end and the second end; a bracket movably mounted to the lead screw at a bracket nut fixed to the bracket; an elongated shaft extending from the bracket and penetrating the first end; and an end effector disposed at a distal end of the shaft; a drive gear rotatably mounted to the bracket; a driven gear rotatably mounted to the bracket and operably coupled to the drive gear such that rotation of the drive gear correspondingly rotates the driven gear; and a firing lever operably coupled to the driven gear such that rotation of the driven gear causes the firing lever to translate axially along the shaft and causes a knife at the end effector to move. In another embodiment, the robotic surgical tool further includes a tensioning system comprising: a tensioning pulley; a fixed pulley anchored to the drive housing, wherein the torsion cable wiring passes through the tensioning pulley and the fixed pulley; one or more bracket pulleys anchored to the drive housing; and a bracket cable wiring passing through the one or more bracket pulleys and extending between the bracket and the tensioning pulley, wherein as the bracket moves back and forth on the lead screw, the tensioning pulley maintains tension in the torsion cable by traveling in an axial direction opposite to the bracket. Attached Figure Description

[0020] The disclosed aspects will be described below in conjunction with the accompanying drawings, which are provided to illustrate and not limit the disclosed aspects, wherein similar reference numerals denote similar elements.

[0021] Figure 1 An implementation scheme of a cart-based robotic system deployed for the diagnosis and / or treatment of bronchoscopy procedures is shown.

[0022] Figure 2 Depicting Figure 1 Another aspect of robotic systems.

[0023] Figure 3A The setup for ureteroscopy is shown. Figure 1 The implementation plan for the robot system.

[0024] Figure 3B The diagram shows the arrangement used for vascular procedures. Figure 1 The implementation plan for the robot system.

[0025] Figure 4 An implementation scheme of a table-based robotic system deployed for bronchoscopy procedures is shown.

[0026] Figure 5Provided Figure 4 An alternative view of the robot system.

[0027] Figure 6 An exemplary system configured to retract a robotic arm is shown.

[0028] Figure 7A An implementation scheme of a table-based robotic system constructed for ureteroscopy procedures is shown.

[0029] Figure 7B An implementation scheme of a table-based robotic system constructed for laparoscopic procedures is shown.

[0030] Figure 7C It shows Figures 4 to 7B An implementation scheme for a platform-based robot system with pitch and tilt adjustment.

[0031] Figure 8 Provided Figure 4 A detailed illustration of the interface between the platform and the column of the platform-based robot system in Figure 7.

[0032] Figure 9A An alternative implementation of a stage-based robotic system is shown.

[0033] Figure 9B It shows Figure 9A An end view of a platform-based robotic system.

[0034] Figure 9C An end view of a platform-based robotic system with a robotic arm attached is shown.

[0035] Figure 10 An exemplary device driver is shown.

[0036] Figure 11 An exemplary medical device with paired instrument drivers is shown.

[0037] Figure 12 An alternative design of the instrument actuator and the instrument is shown, wherein the axis of the actuator is parallel to the axis of the slender axis of the instrument.

[0038] Figure 13 An instrument with an instrument-based insertion architecture is shown.

[0039] Figure 14 An example controller is shown.

[0040] Figure 15 A block diagram according to an exemplary embodiment is depicted, illustrating the estimation Figures 1 to 7C The location of one or more components of a robotic system (such as...) Figures 11 to 13A positioning system for the location of instruments.

[0041] Figure 16 It is an isometric side view of an exemplary surgical tool that can incorporate some or all of the principles of this disclosure.

[0042] Figure 17A It is a releasable connection to an exemplary device driver according to one or more embodiments. Figure 16 An isometric view of surgical tools.

[0043] Figure 17B Provided Figure 17A Separate isometric end views of the instrument driver and surgical tools.

[0044] Figure 18A and Figure 18B They are Figure 16 Enlarged isometric and side views of the bracket and the second activation mechanism.

[0045] Figure 18C It is based on one or more implementation schemes. Figure 16 A side view of the isometric cross-section of the second activation mechanism.

[0046] Figure 19 It is based on one or more implementation schemes. Figure 16 Enlarged view of the end effector and Figure 16 An exposed view of the wrist.

[0047] Figure 20 yes Figures 18A to 18C An enlarged cross-sectional side view of another embodiment of the second activation mechanism.

[0048] Figure 21A and Figure 21B These are enlarged isometric top and bottom views of an exemplary bracket according to one or more embodiments.

[0049] Figure 22A and Figure 22B These are based on one or more implementation schemes. Figures 21A to 21B Isometric top and bottom views of part of the activation mechanism.

[0050] Figure 23 yes Figures 21A to 21B A cross-sectional side view of the bracket.

[0051] Figure 24 yes Figure 16 Another enlarged isometric view of the bracket.

[0052] Figure 25 yes Figure 24 An enlarged view of the proximal end of the bracket and the third activation mechanism.

[0053] Figure 26 It is based on one or more implementation schemes. Figure 24 and Figure 25 The isometric cross-sectional side view of the third activation mechanism.

[0054] Figure 27 It is based on one or more implementation schemes. Figure 16 An enlarged sectional view of the end effector.

[0055] Figure 28A yes Figure 16 An enlarged isometric view of another embodiment of the bracket.

[0056] Figure 28B It is based on one or more implementation schemes. Figure 28A An enlarged isometric view of the first activation mechanism.

[0057] Figure 28C yes Figures 28A to 28B A side view of the isometric cross-section of the first activation mechanism.

[0058] Figure 29 It is based on one or more implementation schemes. Figure 16 A magnified view of the end effector and wrist.

[0059] Figure 30A It is based on one or more additional implementation schemes. Figure 21A and Figure 21B Another enlarged isometric top view of the bracket.

[0060] Figure 30B It is based on one or more implementation schemes. Figure 30A A magnified view of the activation mechanism.

[0061] Figure 30C yes Figures 30A to 30B Part of the bracket and Figures 30A to 30B A cross-sectional side view of the activation mechanism.

[0062] Figure 31 It is based on one or more implementation schemes. Figures 30A to 30C An isometric view of an exemplary embodiment of a closed tube.

[0063] Figure 32 yes Figure 16 Another enlarged isometric view of the bracket.

[0064] Figure 33A and Figure 33B It is based on one or more exemplary embodiments. Figure 16 and Figure 32 An isometric end view of the bracket nut.

[0065] Figure 34A and Figure 34B These are based on one or more implementation schemes. Figure 16 Isometric views of the first and second ends of the handle.

[0066] Figure 35 It is based on one or more additional implementation schemes. Figure 16 Another example of a handle.

[0067] Figure 36A It is based on one or more implementation schemes. Figure 17A and Figure 17B A perspective view of the instrument driver, and Figure 36B It is releasably coupled to the instrument driver according to one or more embodiments. Figure 16 An isometric view of surgical tools.

[0068] Figure 37A It is based on one or more implementation schemes. Figures 36A to 36B A schematic diagram of an exemplary embodiment of a device driver.

[0069] Figure 37B It is based on one or more implementation schemes. Figure 37A A cross-sectional view of the instrument driver.

[0070] Figure 37C The following are illustrated according to one or more implementation schemes. Figure 37A A partial exploded perspective view of the internal mechanical and electronic components of the instrument driver.

[0071] Figure 37D It is based on one or more implementation schemes. Figure 37A A partial exploded perspective view of the internal electronic components of the instrument driver.

[0072] Figure 38 It is based on one or more implementation schemes. Figure 37A Enlarged perspective view of the various electronic components of the instrument driver.

[0073] Figure 39A and Figure 39B It is based on one or more additional implementation schemes. Figure 16 A partial cross-sectional side view of another example of the handle.

[0074] Figure 40A and Figure 40B It is based on one or more additional implementation schemes. Figure 16 A partial cross-sectional side view of another example of the handle.

[0075] Figure 40C yes Figures 40A to 40B An alternative implementation of the drive housing.

[0076] Figures 41A to 41C It is based on one or more additional implementation schemes. Figure 16 A partial cross-sectional side view of an alternative embodiment of the drive housing. Detailed Implementation

[0077] 1. Overview .

[0078] The aspects of this disclosure can be integrated into robot-enabled medical systems capable of performing a variety of medical procedures, including both minimally invasive (e.g., laparoscopy) and non-invasive (e.g., endoscopy) procedures. In endoscopic procedures, the system may be able to perform bronchoscopy, ureteroscopy, gastroscopy, etc.

[0079] In addition to executing a wide range of procedures, the system can provide additional benefits such as enhanced imaging and guidance to assist physicians. Furthermore, the system allows physicians to execute procedures from an ergonomic orientation, eliminating the need for cumbersome arm movements and positioning. Additionally, the system provides physicians with improved ease of use, enabling one or more instruments within the system to be controlled by a single user.

[0080] For illustrative purposes, various embodiments will be described below in conjunction with the accompanying drawings. It should be understood that many other specific embodiments of the disclosed concepts are possible, and various advantages can be achieved using the disclosed specific embodiments. Titles are included herein for reference and to aid in locating the various sections. These titled sections are not intended to limit the scope of the concepts described therein. Such concepts may be applicable throughout the specification.

[0081] A. Robotic System – Trolley .

[0082] Robot-enabled medical systems can be configured in a variety of ways, depending on specific procedures. Figure 1An embodiment of a cart-based robot-enabled system 100 arranged for diagnostic and / or therapeutic bronchoscopy procedures is illustrated. For bronchoscopy procedures, the robot system 100 may include a cart 102 having one or more robotic arms 104 (three are shown) to deliver medical instruments (alternatively referred to as “surgical tools”) (such as a manipulable endoscope 106 (e.g., a surgery-specific bronchoscope for bronchoscopy)) to a natural orifice entry point (i.e., the patient’s mouth) to deliver diagnostic and / or therapeutic tools. As shown, the cart 102 may be positioned near the patient’s upper torso to provide access to the entry point. Similarly, the robotic arms 104 may be actuated to position the bronchoscope relative to the entry point. The same approach may be used when performing GI procedures using a gastroscope (a dedicated endoscope for gastrointestinal (GI) procedures). Figure 1 The layout within.

[0083] Once the trolley 102 is correctly positioned near the patient, the robotic arm 104 inserts the maneuverable endoscope 106 into the patient's body robotically, manually, or in a combination thereof. The maneuverable endoscope 106 may include at least two telescopic components, such as an inner guide portion and an outer sheath portion, each coupled to a separate instrument actuator in a set of instrument actuators 108. As shown, each instrument actuator 108 is coupled to the distal end of a corresponding robotic arm in the robotic arm 104. This linear arrangement of the instrument actuators 108, which facilitates coaxial alignment of the guide portion and the sheath portion, creates a “virtual track” 110, which can be repositioned in space by maneuvering the robotic arm 104 to different angles and / or positions. Translation of the instrument actuators 108 along the virtual track 110 causes the inner guide portion to extend or retract relative to the outer sheath portion, thus effectively advancing or retracting the endoscope 106 relative to the patient.

[0084] As shown in the figures, the virtual track 110 (and other virtual tracks described herein) is depicted using dashed lines and therefore does not constitute any physical structure of system 100. The angles of the virtual track 110 can be adjusted, translated, and pivoted based on clinical application or physician preference. For example, in bronchoscopy, the angles and positions of the virtual track 110, as shown, represent a trade-off between providing the physician with access to endoscope 106 and minimizing friction caused by the endoscope 106 bending into the patient's mouth.

[0085] After insertion into the patient's mouth, the endoscope 106 can be guided downwards through the patient's trachea and lungs using precise commands from the robotic system 100 until the target destination or surgical site is reached. To enhance navigation through the patient's lung network and / or reach the desired target, the endoscope 106 can be manipulated to telescopically extend the inner guide portion from the outer sheath portion to achieve enhanced articulation and a larger radius of flexion. The use of separate instrument actuators 108 also allows the guide portion and sheath portion to be driven independently of each other.

[0086] For example, endoscope 106 can be guided to deliver a biopsy needle to a target, such as a lesion or nodule in a patient's lung. The needle can be deployed downwards along a working channel that extends the length of endoscope 106 to obtain a tissue sample to be analyzed by a pathologist. Depending on the pathological findings, additional tools can be deployed downwards along the working channel of the endoscope for additional biopsies. After the tissue sample is identified as malignant, endoscope 106 can be used to deliver endoscopic tools to remove potentially cancerous tissue. In some cases, diagnostic and therapeutic procedures can be delivered in a separate procedure. In these cases, endoscope 106 can also be used to deliver reference markers to “mark” the location of the target nodule. In other cases, diagnostic and therapeutic procedures can be delivered during the same procedure.

[0087] System 100 may also include a movable tower 112, which can be connected to the cart 102 via support cables to provide control, electronic, fluid, optical, sensor, and / or electrical power support to the cart 102. Placing such functionality in the tower 112 allows for easier adjustment and / or repositioning of the smaller form factor of the cart 102 by the operating physician and his / her staff. Additionally, the division between the cart / table and the support tower 112 reduces operating room clutter and facilitates improved clinical workflow. While the cart 102 can be positioned close to the patient, the tower 112 can optionally be retracted in a remote location to avoid obstructing the path during procedures.

[0088] To support the aforementioned robotic system, tower 112 may include components of a computer-based control system that stores computer program instructions in a non-transitory computer-readable storage medium such as a permanent magnet memory drive, a solid-state drive, etc. Whether execution occurs in tower 112 or trolley 102, the execution of these instructions can control the entire system or its subsystems. For example, when executed by the processor of the computer system, the instructions can cause components of the robotic system to actuate relevant brackets and arm mounts, actuate the robotic arm, and control medical devices. For example, in response to receiving a control signal, a motor in the joint of the robotic arm 104 can position the arm into a specific posture or angular orientation.

[0089] Tower 112 may also include one or more of a pump, flow meter, valve controller, and / or fluid passages to provide controlled flushing and suction capabilities to system 100, which can be deployed via endoscope 106. These components may also be controlled using a computer system of tower 112. In some embodiments, flushing and suction capabilities may be delivered directly to endoscope 106 via a separate cable.

[0090] Tower 112 may include voltage and surge protectors designed to provide filtered and protected electrical power to cart 102, thereby avoiding the placement of power transformers and other auxiliary power components in cart 102, resulting in a smaller and more portable cart 102.

[0091] Tower 112 may also include support devices for sensors deployed throughout the robotic system 100. For example, tower 112 may include optoelectronic devices for detecting, receiving, and processing data received from optical sensors or cameras throughout the robotic system 100. In conjunction with a control system, such optoelectronic devices can be used to generate real-time images for display in any number of consoles deployed throughout the system (including display in tower 112). Similarly, tower 112 may also include electronic subsystems for receiving and processing signals received from deployed electromagnetic (EM) sensors. Tower 112 may also be used to house and position an EM field generator for detection by EM sensors in or on a medical device.

[0092] In addition to other consoles available in the rest of the system (e.g., a console mounted to cart 102), tower 112 may also include console 114. Console 114 may include a user interface and display (e.g., a touchscreen) for physician operators. Consoles in system 100 are generally designed to provide both robot control and preoperative and real-time information for procedures, such as navigation and positioning information for endoscope 106. When console 114 is not the only console available to the physician, it may be used by a second operator (such as a nurse) to monitor the patient's health or vital signs and system operation, as well as to provide procedure-specific data, such as navigation and positioning information. In other embodiments, console 114 may be housed within the main body, separate from tower 112.

[0093] Tower 112 can be connected to cart 102 and endoscope 106 via one or more cable connectors 116. In some embodiments, support functionality from tower 112 can be provided via a single cable 116 extending to cart 102, thus simplifying the operating room and eliminating clutter. In other embodiments, specific functions can be coupled in separate wiring and connections. For example, while electrical power can be provided to cart 102 via a single cable, support for control, optics, fluid, and / or navigation can also be provided via one or more separate cables.

[0094] Figure 2 Provided from Figure 1 Detailed illustration of an implementation of a cart 102 in a cart-based robot-enabled system 100. The cart 102 typically includes an elongated support structure 202 (also referred to as a “post”), a cart base 204, and a console 206 at the top of the post 202. The post 202 may include one or more brackets, such as a bracket 208 (alternatively an “arm support”) for supporting the deployment of a robotic arm 104. The bracket 208 may include a separately configurable arm mount that rotates along a vertical axis to adjust the base 214 of the robotic arm 104 for better positioning relative to the patient. The bracket 208 also includes a bracket interface 210 that allows the bracket 208 to translate vertically along the post 202.

[0095] The bracket interface 210 is connected to the post 202 via a slot, such as slot 212, which is positioned on the opposite side of the post 202 to guide the vertical translation of the bracket 208. Slot 212 includes a vertical translation interface to position and hold the bracket 208 relative to the trolley base 204 at various vertical heights. The vertical translation of the bracket 208 allows the trolley 102 to adjust the reach of the robotic arm 104 to accommodate various table heights, patient sizes, and physician preferences. Similarly, individually configurable arm mounts on the bracket 208 allow the base 214 of the robotic arm 104 to be angled in various configurations.

[0096] In some embodiments, slot 212 may be supplemented with a slot cover (not shown) flush with and parallel to the slot surface to prevent dust and fluid from entering the internal cavity of column 202 and the vertical translation interface during vertical translation of bracket 208. The slot cover can be deployed via a pair of spring reels positioned near the vertical top and bottom of slot 212. The cover is coiled within the reels until it is deployed to extend and retract from its coiled state during vertical up-and-down translation of bracket 208. The spring load of the reels provides the force to retract the cover into the reels as bracket 208 translates toward the reels, while maintaining a tight seal as bracket 208 translates away from the reels. The cover can be attached to bracket 208 using, for example, a bracket in bracket interface 210 to ensure proper extension and retraction of the cover during translation of bracket 208.

[0097] The column 202 may internally include mechanisms such as gears and motors, which are designed to mechanically translate the bracket 208 using vertically aligned lead screws in response to control signals generated in response to user input (e.g., input from console 206).

[0098] A robotic arm 104 typically includes a robotic arm base 214 and end effectors 216 (three shown) separated by a series of links 218 connected by a corresponding series of joints 220, each joint 220 including an independent actuator, and each actuator including an independently controllable motor. Each independently controllable joint 220 represents an independent degree of freedom available to the corresponding robotic arm 104. In the illustrated embodiment, each arm 104 has seven joints 220, thus providing seven degrees of freedom. Multiple joints 220 result in multiple degrees of freedom, thereby allowing “redundant” degrees of freedom. Redundant degrees of freedom allow the robotic arm 104 to position its corresponding end effector 216 in a specific orientation, orientation, and trajectory in space using different link orientations and joint angles. This allows the system 100 to locate and guide medical devices from desired points in space, while allowing physicians to move the arm joints 220 to a clinically advantageous orientation away from the patient to achieve greater proximity while avoiding arm collisions.

[0099] The trolley base 204 balances the weight of the column 202, bracket 208, and arm 104 on the floor. Therefore, the trolley base 204 houses heavier components such as electronics, motors, power sources, and components that enable the trolley to move and / or be secured. For example, the trolley base 204 includes rolling casters 222 that allow the trolley to be easily moved around the room before the procedure. Once in the correct position, the casters 222 can be secured with wheel locks to hold the trolley 102 in the correct position during the procedure.

[0100] The console 206, positioned at the vertical end of column 202, allows both a user interface for receiving user input and a display screen (or dual-purpose device, such as, for example, touchscreen 224) to provide both preoperative and intraoperative data to the physician user. Potential preoperative data on touchscreen 224 may include preoperative planning, navigation, and mapping data derived from preoperative computed tomography (CT) scans and / or records from preoperative patient interviews. Intraoperative data on touchscreen 224 may include optical information from tools and sensors, coordinate information from sensors, and important patient statistics such as respiration, heart rate, and / or pulse. Console 206 can be positioned and tilted to allow the physician to access the console from the side of column 202 opposite to bracket 208. From this orientation, the physician can operate console 206 from behind cart 102 while simultaneously observing console 206, robotic arm 104, and the patient. As shown, console 206 also includes a handle 226 for assisting in manipulating and stabilizing cart 102.

[0101] Figure 3A The setup for ureteroscopy is shown. Figure 1An implementation of system 100 is described. In a ureteroscopy procedure, a trolley 102 can be positioned to deliver a ureteroscope 302 (a procedure-specific endoscope designed to traverse the patient's urethra and ureter) to the patient's lower abdominal region. During ureteroscopy, it is desirable for the ureteroscope 302 to be directly aligned with the patient's urethra to reduce friction and force on sensitive anatomical structures. As shown, the trolley 102 can be aligned at the foot of the table to allow the robotic arm 104 to position the ureteroscope 302 for direct linear access into the patient's urethra. The robotic arm 104 can insert the ureteroscope 302 directly into the patient's lower abdomen through the urethra from the foot of the table along a virtual track 304.

[0102] After insertion into the urethra, using control techniques similar to those used in bronchoscopy, the ureteroscope 302 can be navigated to the bladder, ureter, and / or kidney for diagnostic and / or therapeutic applications. For example, the ureteroscope 302 can be guided into the ureter and kidney to break up accumulated kidney stones using a laser or ultrasonic lithotripsy device deployed downwards along the working channel of the ureteroscope 302. After lithotripsy is complete, the remaining stone fragments can be removed using a basket deployed downwards along the working channel of the ureteroscope 302.

[0103] Figure 3B The diagram shows the arrangement used for vascular procedures. Figure 1 Another embodiment of system 100. In vascular procedures, system 100 may be configured such that a trolley 102 can deliver a medical device 306 (such as a maneuverable catheter) to an entry point in the femoral artery in the patient's leg. The femoral artery presents both a large diameter for navigation and a relatively less circuitous and tortuous path to the patient's heart, which simplifies navigation. As in ureteroscopy procedures, trolley 102 may be positioned toward the patient's leg and lower abdomen to allow robotic arm 104 to provide a virtual track 308 for direct linear access to the femoral artery entry point in the patient's thigh / hip region. After insertion into the artery, the medical device 306 can be guided and advanced by translating device actuator 108. Alternatively, trolley 102 may be positioned around the patient's upper abdomen to reach alternative vascular entry points, such as, for example, the carotid and brachial arteries near the patient's shoulder and wrist.

[0104] B. Robot System – Unit .

[0105] Implementation plans for robot-enabled medical systems can also incorporate patient-integrated tables. Integrating tables reduces the amount of capital equipment in the operating room by removing trolleys, allowing for greater accessibility to the patient. Figure 4An embodiment of such a robot-enabled system 400 arranged for a bronchoscopy procedure is shown. As shown, system 400 includes a support structure or column 402 for supporting a platform 404 (shown as a “table” or “bed”) on a floor. Much like trolley-based systems, the end effectors of the robotic arm 406 of system 400 include instrument actuators 408 designed to manipulate elongated medical instruments, such as a bronchoscope 410, via or along a virtual track 412 formed by the linear alignment of the instrument actuators 408. In practice, a C-arm for providing fluorescein imaging can be positioned above the patient’s upper abdominal region by placing the transmitter and detector around the table 404.

[0106] Figure 5 An alternative view of a system 400 without a patient and medical devices is provided for discussion purposes. As shown, a column 402 may include one or more brackets 502, shown as annular in system 400, from which one or more robotic arms 406 may be based. The brackets 502 may translate along a vertical column interface 504 extending the length (height) of the column 402 to provide different vantage points from which the robotic arms 406 may be positioned to reach the patient. The brackets 502 may be rotated about the column 402 using mechanical motors positioned within the column 402 to allow the robotic arms 406 access to multiple sides of the table 404, such as the sides of the patient. In embodiments with multiple brackets 502, the brackets 502 may be individually positioned on the column 402 and may translate and / or rotate independently of the other brackets 502. While the brackets 502 need not be circular around the column 402, the annular shape shown facilitates rotation of the brackets 502 about the column 402 while maintaining structural balance. The rotation and translation of the bracket 502 allow the system 400 to align medical instruments such as endoscopes and laparoscopes to different entry points on the patient.

[0107] In (the following is relative to) Figure 9A In other embodiments (discussed in more detail), system 400 may include a patient examination table or bed with an adjustable arm support in the form of a rod or track extending beside the patient examination table or bed. One or more robotic arms 406 (e.g., via a shoulder with an elbow joint) may be attached to the adjustable arm support, which can be vertically adjusted. By providing vertical adjustment, the robotic arms 406 can advantageously be compactly stored under the patient examination table or bed and subsequently raised during procedures.

[0108] Arm 406 can be mounted on bracket 502 via a set of arm mounts 506 comprising a series of joints, which can be individually rotatable and / or telescopically extended to provide additional constructability to robotic arm 406. Additionally, arm mounts 506 can be positioned on bracket 502 such that, when bracket 502 is properly rotated, arm mounts 506 can be positioned on the same side of table 404 (e.g., ...). Figure 5 As shown), on the opposite side of platform 404 (as shown) Figure 7B (as shown) or on the adjacent side of platform 404 (not shown).

[0109] Column 402 structurally supports platform 404 and provides a path for the vertical translation of bracket 502. Internally, column 402 may be equipped with a lead screw for guiding the vertical translation of the bracket, and a motor for mechanizing the translation of the bracket based on the lead screw. Column 402 may also transmit power and control signals to bracket 502 and the robotic arm 406 mounted thereon.

[0110] Taiwan Base 508 has the same Figure 2 The trolley base 204 of the illustrated trolley 102 functions similarly, accommodating heavier components to balance the table / bed 404, column 402, bracket 502, and robotic arm 406. The table base 508 may also incorporate rigid casters to provide stability during operation. Casters deployed from the bottom of the table base 508 extend in opposite directions on either side of the base 508 and retract when the system 400 requires movement.

[0111] In some embodiments, system 400 may also include a tower (not shown) that divides the functionality of system 400 between the table and the tower to reduce the form factor and volume of table 404. As in previously disclosed embodiments, the tower may provide table 404 with a variety of support functions, such as processing, computing and control capabilities, electrical power, fluid and / or optical, and sensor processing. The tower may also be movable to be positioned away from the patient, thereby improving physician accessibility and eliminating clutter in the operating room. Additionally, placing components in the tower allows for more storage space in the table base 508 for potential retraction of the robotic arm 406. The tower may also include a main controller or console that provides a user interface such as a keyboard and / or the tower for user input, and a display (or touchscreen) for preoperative and intraoperative information such as real-time imaging, navigation, and tracking information. In some embodiments, the tower may also include a holder for gas canisters to be used for inflatation.

[0112] In some implementations, the base can be retracted and stored when not in use. Figure 6An embodiment of a system 400 configured to retract a robotic arm in a stage-based system implementation is shown. In system 400, one or more brackets 602 (not shown) are vertically translatable into a base 604 to retract one or more robotic arms 606, one or more arm mounts 608, and the brackets 602 within the base 604. A base cover 610 is translatable and retractable to open to deploy the brackets 602, arm mounts 608, and arms 606 around a post 612, and to close to retract the brackets, arm mounts, and arms, and to protect them when not in use. The base cover 610 may be sealed along the edge of its opening using a membrane 614 to prevent dust and fluid from entering when closed.

[0113] Figure 7A An embodiment of a robot-enabled table-based system 400 configured for a ureteroscopy procedure is shown. During ureteroscopy, table 404 may include a rotating portion 702 for positioning the patient at an angle to the column 402 and table base 508. The rotating portion 702 may rotate or pivot about a pivot point (e.g., below the patient's head) to position the bottom portion of the rotating portion 702 away from the column 402. For example, pivoting of the rotating portion 702 allows a C-arm (not shown) to be positioned above the patient's lower abdomen without competing for space with the column (not shown) below table 404. By rotating a bracket (not shown) about the column 402, a robotic arm 406 can insert the ureteroscope 704 directly into the patient's groin region along a virtual track 706 to reach the urethra. During ureteroscopy, stirrups 708 may also be attached to the rotating portion 702 of table 404 to support the position of the patient's legs during the procedure and allow full access to the patient's groin region.

[0114] Figure 7B An embodiment of a system 400 arranged for a laparoscopic procedure is shown. In a laparoscopic procedure, minimally invasive instruments are inserted into the patient's anatomical structures through one or more small incisions in the patient's abdominal wall. In some embodiments, the minimally invasive instruments include elongated rigid members, such as axes, for accessing the anatomical structures within the patient. After the patient's abdominal cavity is inflated, the instruments can be guided to perform surgical or medical tasks, such as grasping, cutting, ablation, suturing, etc. In some embodiments, the instruments may include a scope, such as a laparoscope. Figure 7B As shown, the bracket 502 of the system 400 can be rotated and vertically adjusted to position the pair of robotic arms 406 on opposite sides of the table 404, so that the instrument 710 can be positioned through the smallest incision on both sides of the patient to reach his / her abdominal cavity using the arm mount 506.

[0115] To accommodate laparoscopic procedures, the system 400 can also tilt the platform to the desired angle. Figure 7CAn embodiment of a system 400 with pitch or tilt adjustment is shown. For example... Figure 7C As shown, system 400 can adapt to the tilt of platform 404 to position one part of platform 404 at a greater distance from the base plate than another part. Additionally, arm mount 506 can rotate to match the tilt, ensuring that arm 406 maintains the same planar relationship with platform 404. To accommodate steeper angles, column 402 may also include a telescopic portion 712 that allows vertical extension of column 402 to prevent platform 404 from contacting the floor or colliding with base 508.

[0116] Figure 8 Detailed illustrations are provided of the interface between stage 404 and column 402. The pitch-rotation mechanism 802 can be configured to change the pitch angle of stage 404 relative to column 402 with multiple degrees of freedom. The pitch-rotation mechanism 802 is achieved by positioning orthogonal axes A and B at the column interface, each axis being actuated by separate motors 804a and 804b in response to an electrical pitch angle command. Rotation along one screw 806a enables tilt adjustment along axis A, while rotation along the other screw 806b enables tilt adjustment along axis B. In some embodiments, a ball joint can be used to change the pitch angle of stage 404 relative to column 402 with multiple degrees of freedom.

[0117] For example, pitch adjustment is particularly useful when attempting to position the table in the Trendrenburg position (i.e., positioning the patient's lower abdomen higher than the floor) for lower abdominal surgery. The head-down, feet-up position causes the patient's internal organs to slide down to his / her upper abdomen by gravity, clearing the abdominal cavity to allow minimally invasive instruments to enter and perform lower abdominal surgical or medical procedures, such as laparoscopic prostatectomy.

[0118] Figure 9A and Figure 9B Isometric and end views of an alternative embodiment of a stage-based surgical robot system 900 are shown, respectively. The surgical robot system 900 includes components configured to support one or more robotic arms relative to a stage 904 (see, for example...). Figure 9COne or more adjustable arm supports 902 are provided. In the illustrated embodiment, a single adjustable arm support 902 is shown, but additional arm supports may be positioned on the opposite side of the stage 904. The adjustable arm support 902 may be configured such that it is movable relative to the stage 904 to adjust and / or change the orientation of the adjustable arm support 902 and / or any robotic arm attached to it relative to the stage 904. For example, the adjustable arm support 902 may be adjustable relative to the stage 904 with one or more degrees of freedom. The adjustable arm support 902 provides high flexibility to the system 900, including the ability to easily retract the one or more adjustable arm supports 902 and any robotic arms attached to them under the stage 904. The adjustable arm support 902 may be raised from a retracted orientation to an orientation below the upper surface of the stage 904. In other embodiments, the adjustable arm support 902 can be raised from a retracted position to a position above the upper surface of the platform 904.

[0119] The adjustable arm support 902 provides several degrees of freedom, including lifting, lateral translation, and tilting. Figure 9A and Figure 9B In the exemplary embodiment, the arm support 902 is configured to have four degrees of freedom, which are in Figure 9A The arrows indicate the first degree of freedom, which allows adjustment of the adjustable arm support 902 in the z-direction (“Z-lift”). For example, the adjustable arm support 902 may include a bracket 906 configured to move up or down along or relative to the column 908 of the support platform 904. The second degree of freedom allows the adjustable arm support 902 to tilt. For example, the adjustable arm support 902 may include a rotary joint that allows the adjustable arm support 902 to be aligned with the bed in a head-down, feet-up position. The third degree of freedom allows the adjustable arm support 902 to “pivot upwards”, which can be used to adjust the distance between one side of the platform 904 and the adjustable arm support 902. The fourth degree of freedom allows the adjustable arm support 902 to translate along the longitudinal length of the platform.

[0120] Figure 9A and Figure 9B The surgical robot system 900 may include a platform 904 supported by a column 908 mounted to a base 910. The base 910 and column 908 support the platform 904 relative to a support surface. A floor axis 912 and a support axis 914 are... Figure 9B As shown in the image.

[0121] An adjustable arm support 902 may be mounted to a column 908. In other embodiments, the arm support 902 may be mounted to a platform 904 or a base 910. The adjustable arm support 902 may include a bracket 906, a rod or rail connector 916, and a rod or rail 918. In some embodiments, one or more robotic arms mounted to the rail 918 may translate and move relative to each other.

[0122] The bracket 906 can be attached to the post 908 via a first connector 920, which allows the bracket 906 to move relative to the post 908 (e.g., such as moving up and down along a first axis or vertical axis 922). The first connector 920 can provide a first degree of freedom (“Z-lift”) to the adjustable arm support 902. The adjustable arm support 902 may include a second connector 924, which provides a second degree of freedom (tilt) to the adjustable arm support 902. The adjustable arm support 902 may include a third connector 926, which provides a third degree of freedom (“upward pivot”) to the adjustable arm support 902. An additional connector 928 may be provided (in... Figure 9B (As shown in the diagram), the additional joint mechanically constrains the third joint 926 to maintain the orientation of the track 918 when the track connector 916 rotates about the third axis 930. The adjustable arm support 902 may include a fourth joint 932 that can provide a fourth degree of freedom (translation) for the adjustable arm support 902 along the fourth axis 934.

[0123] Figure 9C An end view of a surgical robot system 900 with two adjustable arm supports 902a and 902b mounted on opposite sides of a stage 904 is shown. A first robotic arm 936a is attached to a rod or rail 918a of a first adjustable arm support 902a. The first robotic arm 936a includes a base 938a attached to the first rail 918a. The distal end of the first robotic arm 936a includes an instrument drive mechanism or input 940a that can be attached to one or more robotic medical instruments or tools. Similarly, a second robotic arm 936b includes a base 938a attached to a second rail 918b. The distal end of the second robotic arm 936b includes an instrument drive mechanism or input 940b configured to be attached to one or more robotic medical instruments or tools.

[0124] In some embodiments, one or more of the robotic arms 936a and 936b include an arm with seven or more degrees of freedom. In some embodiments, one or more of the robotic arms 936a and 936b may include eight degrees of freedom, including an insertion axis (including one degree of freedom for insertion), a wrist (including three degrees of freedom for wrist pitch, yaw, and roll), an elbow (including one degree of freedom for elbow pitch), a shoulder (including two degrees of freedom for shoulder pitch and yaw), and a base 938a and 938b (including one degree of freedom for translation). In some embodiments, the insertion degree of freedom may be provided by the robotic arms 936a and 936b, while in other embodiments, the instrument itself provides insertion via an instrument-based insertion architecture.

[0125] C. Instrument drivers and interfaces .

[0126] The end effector of the system's robotic arm includes (i) an instrument actuator (alternatively referred to as a "tool actuator," "instrument drive mechanism," "instrument device manipulator," and "drive input") incorporating electromechanical devices for actuating the medical device, and (ii) a removable or detachable medical device that may not contain any electromechanical components, such as motors. This dichotomy may be driven by the need to sterilize medical devices used in medical procedures, and the inability to adequately sterilize expensive capital equipment due to its complex mechanical components and sensitive electronics. Therefore, the medical device can be designed to be detached, removed, and interchanged from the instrument actuator (and thus from the system) for individual sterilization or disposal by a physician or physician staff. In contrast, the instrument actuator does not need to be altered or sterilized and can be covered for protection.

[0127] Figure 10 An exemplary instrument actuator 1000 according to one or more embodiments is illustrated. Positioned at the distal end of a robotic arm, the instrument actuator 1000 includes one or more drive outputs 1002 arranged parallel to the axis to provide controlled torque to a medical device via a corresponding drive shaft 1004. Each drive output 1002 includes a separate drive shaft 1004 for interacting with the device, a gear head 1006 for converting motor shaft rotation into desired torque, a motor 1008 for generating drive torque, and an encoder 1010 for measuring the speed of the motor shaft and providing feedback to a control circuit 1012, which can also be used to receive control signals and actuate the drive output 1002. Each drive output 1002 is independently controlled and motorized, and the instrument actuator 1000 can provide multiple (e.g., ...) drive outputs to the medical device. Figure 10(At least two) independent drive outputs are shown. In operation, the control circuit 1012 receives a control signal, transmits a motor signal to the motor 1008, compares the final motor speed measured by the encoder 1010 with the desired speed, and modulates the motor signal to generate the desired torque.

[0128] For procedures requiring a sterile environment, the robotic system can incorporate a drive interface, such as a sterile adapter connected to a sterile cover, positioned between the instrument actuator and the medical device. The primary purpose of the sterile adapter is to transmit angular motion from the drive shaft of the instrument actuator to the drive input of the device, while maintaining physical separation between the drive shaft and the drive input, and thus maintaining sterility. Therefore, an exemplary sterile adapter may include a series of rotary inputs and rotary outputs designed to mate with the drive shaft of the instrument actuator and the drive input on the device. The sterile cover, composed of a thin, flexible material (such as transparent or translucent plastic), is connected to the sterile adapter and designed to cover the capital device, such as an instrument actuator, robotic arm, and trolley (in trolley-based systems) or table (in table-based systems). The use of the cover allows the capital device to be positioned near the patient while still within an area that does not require sterilization (i.e., a non-sterile area). On the other side of the sterile cover, the medical device can dock with the patient in an area that requires sterilization (i.e., a sterile area).

[0129] D. Medical devices .

[0130] Figure 11 An exemplary medical device 1100 with paired instrument actuators 1102 is shown. Similar to other instruments designed for use with robotic systems, the medical device 1100 (alternatively referred to as a “surgical tool”) includes an elongated shaft 1104 (or elongated body) and an instrument base 1106. The instrument base 1106, also referred to as an “instrument handle” due to its intended design for manual interaction by a physician, typically includes rotatable drive inputs 1108 (e.g., jacks, pulleys, or reels) designed to mate with drive outputs 1110 on drive interfaces extending through the distal end of the robotic arm 1112. When physically connected, latched, and / or coupled, the mating drive inputs 1108 of the instrument base 1106 may share a rotational axis with the drive outputs 1110 in the instrument actuators 1102 to allow torque to be transmitted from the drive outputs 1110 to the drive inputs 1108. In some implementations, the drive output 1110 may include a spline designed to mate with a jack on the drive input 1108.

[0131] The elongated shaft 1104 is designed to be delivered through an anatomical opening or cavity (e.g., as in endoscopy) or through a minimally invasive incision (e.g., as in laparoscopy). The elongated shaft 1104 can be flexible (e.g., having endoscope-like properties) or rigid (e.g., having laparoscopy-like properties), or a customized combination of both flexible and rigid portions. When designed for laparoscopy, the distal end of the shaft 1104 can be connected to an end effector extending from a connector wrist formed by a connecting fork having at least one degree of freedom and a surgical tool or medical instrument (such as, for example, a gripper or scissors), which can be actuated based on forces from a tendon when the drive input 1008 rotates in response to torque received from the drive output 1110 of the instrument driver 1102. When designed for use in endoscopy, the distal end of the flexible elongated shaft 1104 may include a manipulable or controllable bending segment that articulates and bends based on torque received from the drive output 1110 of the instrument actuator 1102.

[0132] In some embodiments, torque from the instrument actuator 1102 is transmitted downwards along the shaft 1104 to the elongated shaft 1104 using tendons. These individual tendons (e.g., traction cables) may be individually anchored to individual drive inputs 1108 within the instrument handle 1106. From the handle 1106, the tendons are guided downwards along one or more traction cavities of the elongated shaft 1104 and anchored at the distal portion of the elongated shaft 1104, or at the wrist at the distal portion of the elongated shaft. During surgical procedures such as laparoscopy, endoscopy, or hybrid procedures, these tendons may be coupled to distally mounted end effectors, such as wrists, grippers, or scissors. In such an arrangement, torque applied to the drive input 1108 transmits tension to the tendons, thereby causing the end effector to be actuated in some way. In some embodiments, during surgical procedures, the tendons may cause the connector to rotate about the axis, thereby causing the end effector to move in one direction or the other. Alternatively, the tendon may be connected to one or more jaws of the gripper at the distal end of the elongated shaft 1104, wherein tension from the tendon causes the gripper to close.

[0133] During endoscopy, tendons can be attached via adhesives, control rings, or other mechanical fasteners to flexural or articulated segments positioned along an elongated axis 1104 (e.g., at the distal end). When fixedly attached to the distal end of a flexural segment, torque applied to a drive input 1108 is transmitted down the tendon, causing the softer flexural segment (sometimes referred to as an articulated segment or region) to flex or articulate. Along non-flexural segments, it can be advantageous to helve or coil individual traction cavities that guide individual tendons along the wall (or inside) of the endoscope axis to balance radial forces caused by tension in the traction lines. For specific purposes, the angle of the helices and / or the spacing between them can be varied or designed, with tighter helices exhibiting less axial compression under load, while lower helical amounts cause greater axial compression under load but also exhibit restricted flexion. Alternatively, traction cavities can be guided parallel to the longitudinal axis of the elongated axis 1104 to allow controlled articulation within the desired flexural or articulated segment.

[0134] In endoscopic procedures, the elongated shaft 1104 accommodates multiple components to assist in robotic procedures. The shaft may include a working channel for deploying surgical instruments (or medical devices), irrigation components, and / or suction components to an operating area at the distal end of the shaft 1104. The shaft 1104 may also accommodate wires and / or optical fibers to transmit signals to / from optical components at the distal end, which may include an optical camera. The shaft 1104 may also accommodate optical fibers to carry light from a proximal light source (such as a light-emitting diode) to the distal end of the shaft.

[0135] At the distal end of the instrument 1100, the distal end may also include an opening for delivering tools for diagnostic and / or treatment, irrigation, and aspiration to the surgical site. The distal end may also include a port for a camera (such as a fiberoptic endoscope or digital camera) to capture images of the internal anatomical space. Relatedly, the distal end may also include a port for a light source used to illuminate the anatomical space when the camera is used.

[0136] exist Figure 11 In the example, the axis of the drive shaft, and therefore the axis of the drive input, is orthogonal to the axis of the elongated shaft. However, this arrangement complicates the rolling capability of the elongated shaft 1104. Rolling the elongated shaft along its axis while keeping the drive input 1108 stationary can cause undesirable tangling of the tendon as it extends from the drive input 1108 and enters the traction cavity within the elongated shaft 1104. Such eventual tangling of the tendon can disrupt any control algorithm designed to predict the movement of the flexible elongated shaft during endoscopic procedures.

[0137] Figure 12An alternative design of a circular instrument actuator 1200 and a corresponding instrument 1202 (alternatively referred to as a "surgical tool") is shown, wherein the axis of the drive unit is parallel to the axis of the elongated shaft 1206 of the instrument 1202. As shown, the instrument actuator 1200 includes four drive units, wherein corresponding drive outputs 1208 are aligned parallel to each other at the end of the robotic arm 1210. The drive units and their respective drive outputs 1208 are housed in a rotating assembly 1212 of the instrument actuator 1200, driven by one of the drive units within assembly 1212. In response to torque provided by the rotating drive unit, the rotating assembly 1212 rotates along a circular bearing that connects the rotating assembly 1212 to the non-rotating portion 1214 of the instrument actuator 1200. Electrical power and control signals are transmitted from the non-rotating portion 1214 of the instrument actuator 1200 to the rotating assembly 1212 via electrical contacts, which are held by rotation of a brush slip ring connector (not shown). In other embodiments, the rotating assembly 1212 may be responsive to a separate drive unit integrated into the non-rotatable portion 1214 and is therefore not parallel to other drive units. The rotating assembly 1212 allows the instrument driver 1200 to allow the drive unit and its corresponding drive output 1208 to rotate as a single unit about the instrument driver axis 1216.

[0138] Similar to previously disclosed embodiments, the instrument 1202 may include an elongated shaft 1206 and an instrument base 1218 (shown in dashed lines) comprising a plurality of drive inputs 1220 (such as jacks, pulleys, and reels) configured to mate with a drive output 1208 of the instrument actuator 1200. Unlike previously disclosed embodiments, the instrument shaft 1206 extends from the center of the instrument base 1218, the axis of which is substantially parallel to the axes of the drive inputs 1220, rather than as... Figure 11 It is orthogonal as in the design.

[0139] When coupled to the rotating assembly 1212 of the instrument driver 1200, the medical instrument 1202, including the instrument base 1218 and the instrument shaft 1206, rotates in combination with the rotating assembly 1212 about the instrument driver axis 1216. Since the instrument shaft 1206 is positioned at the center of the instrument base 1218, it is coaxial with the instrument driver axis 1216 when attached. Therefore, rotation of the rotating assembly 1212 causes the instrument shaft 1206 to rotate about its own longitudinal axis. Furthermore, when the instrument base 1218 rotates together with the instrument shaft 1206, any tendons connected to the drive input 1220 in the instrument base 1218 do not become entangled during rotation. Therefore, the parallelism of the axes of the drive output 1208, the drive input 1220, and the instrument shaft 1206 allows the shaft to rotate without causing any control tendons to become entangled.

[0140] Figure 13 A medical device 1300 with a device-based insertion architecture according to some embodiments is illustrated. The device 1300 (alternatively referred to as a “surgical instrument”) is coupled to any of the device actuators discussed herein and, as shown, may include an elongated shaft 1302, an end actuator 1304 connected to the shaft 1302, and a shank 1306 coupled to the shaft 1302. The elongated shaft 1302 includes a tubular member having a proximal portion 1308a and a distal portion 1308b. The elongated shaft 1302 includes one or more channels or grooves 1310 along its outer surface and configured to receive one or more wires or cables 1312 passing through it. Thus, one or more cables 1312 extend along the outer surface of the elongated shaft 1302. In other embodiments, the cables 1312 may also extend through the elongated shaft 1302. Manipulation of cable 1312 (e.g., via a machine driver) causes actuation of end effector 1304.

[0141] The instrument handle 1306 (also referred to as the instrument base) typically includes an attachment interface 1314 having one or more mechanical inputs 1316, such as jacks, pulleys, or spools, which are designed to reciprocately engage with one or more drive outputs on the attachment surface of the instrument actuator.

[0142] In some embodiments, the instrument 1300 includes a series of pulleys or cables that enable the elongated shaft 1302 to translate relative to the handle 1306. In other words, the instrument 1300 itself includes an instrument-based insertion architecture that adapts to the insertion of the instrument, thereby minimizing reliance on a robotic arm to provide the insertion of the instrument 1300. In other embodiments, the robotic arm may be largely responsible for the instrument insertion.

[0143] E. Controller .

[0144] Any of the robotic systems described herein may include an input device or controller for manipulating a device attached to a robotic arm. In some embodiments, the controller may be coupled to the device (e.g., communicatively, electronically, electrically, wirelessly, and / or mechanically) such that manipulation of the controller, for example via master-slave control, causes corresponding manipulation of the device.

[0145] Figure 14This is a perspective view of an embodiment of controller 1400. In this embodiment, controller 1400 includes a hybrid controller that may have both impedance and admittance control. In other embodiments, controller 1400 may utilize only impedance or passive control. In other embodiments, controller 1400 may utilize only admittance control. By being a hybrid controller, controller 1400 advantageously has lower perceived inertia during use.

[0146] In the illustrated embodiment, the controller 1400 is configured to allow manipulation of two medical devices and includes two handles 1402. Each handle 1402 is connected to a universal joint 1404, and each universal joint 1404 is connected to a positioning platform 1406.

[0147] like Figure 14 As shown, each positioning platform 1406 includes a selectively compliant assembly robotic arm (SCARA) 1408 connected to a post 1410 via a prism joint 1412. The prism joint 1412 is configured to translate along the post 1410 (e.g., along track 1414) to allow each handle 1402 to translate in the z-direction, thus providing a first degree of freedom. The SCARA arm 1408 is configured to allow the handles 1402 to move in the xy-plane, thus providing two additional degrees of freedom.

[0148] In some embodiments, one or more load sensors are located within the controller 1400. For example, in some embodiments, load sensors (not shown) are located within the body of each gimbal in the gimbal 1404. By providing load sensors, portions of the controller 1400 can operate under admittance control, thereby advantageously reducing the sense inertia of the controller 1400 during use. In some embodiments, the positioning platform 1406 is configured for admittance control, while the gimbal 1404 is configured for impedance control. In other embodiments, the gimbal 1404 is configured for admittance control, while the positioning platform 1406 is configured for impedance control. Thus, for some embodiments, the translational or orientational degrees of freedom of the positioning platform 1406 may depend on admittance control, while the rotational degrees of freedom of the gimbal 1404 may depend on impedance control.

[0149] F. Navigation and Control .

[0150] Traditional endoscopy can involve the use of fluoroscopy (e.g., delivered via a C-arm) and other forms of radiation-based imaging modalities to provide intracavitary guidance to the operating physician. In contrast, the robotic system envisioned in this disclosure can provide radiation-free navigation and positioning, reducing physician exposure to radiation and the amount of equipment required in the operating room. As used herein, the term "positioning" can refer to determining and / or monitoring the orientation of an object in a reference coordinate system. Techniques such as preoperative mapping, computer vision, real-time EM tracking, and robot command data can be used individually or in combination to achieve a radiation-free operating environment. In other cases where radiation-based imaging modalities are still used, preoperative mapping, computer vision, real-time EM tracking, and robot command data can be used individually or in combination to improve upon information obtained solely through radiation-based imaging modalities.

[0151] Figure 15 This is a block diagram illustrating a positioning system 1500 for estimating the position of one or more components of a robotic system (such as the position of a machine) according to an exemplary embodiment. The positioning system 1500 may be a group of one or more computer devices configured to execute one or more instructions. The computer devices may be embodied by a processor (or multiple processors) and computer-readable storage among the components discussed above. By way of example and not limitation, the computer device may be located in... Figure 1 Tower 112 shown Figures 1 to 3B The trolley 102 shown Figure 4 To the bed shown in Figure 9, etc.

[0152] like Figure 15 As shown, the positioning system 1500 may include a positioning module 1502 that processes input data 1504a, 1504b, 1504c, and 1504d to generate position data 1506 for the distal end of a medical device. The position data 1506 may be data or logic representing the position and / or orientation of the distal end of the device relative to a reference frame. The reference frame may be relative to a patient's anatomy or a known object (such as an EM field generator) (see the discussion of EM field generators below).

[0153] The various input data 1504a-d are now described in more detail. Preoperative mapping can be accomplished using a collection of low-dose CT scans. The preoperative CT scans are reconstructed into three-dimensional images, which are visualized, for example, as “slices” of cross-sectional views of the patient’s internal anatomy. When analyzed in whole, image-based models of the anatomical cavities, spaces, and structures of the patient’s anatomical structures, such as the patient’s lung network, can be generated. Techniques such as centerline geometry can be determined and approximated from CT images to form a three-dimensional volume of the patient’s anatomy, which is referred to as model data 1504a (also referred to as “preoperative model data” when generated using only preoperative CT scans). The use of centerline geometry is discussed in U.S. Patent Application 14 / 523,760, the contents of which are incorporated herein by reference in their entirety. Network topology models can also be derived from CT images and are particularly well-suited for bronchoscopy.

[0154] In some implementations, the device may be equipped with a camera to provide visual data 1504b. The positioning module 1502 may process the visual data 1504b to enable one or more vision-based position tracking methods. For example, preoperative model data may be used in conjunction with the visual data 1504b to enable computer vision-based tracking of a medical device (e.g., an endoscope or an instrument propelled through the working channel of an endoscope). For example, using preoperative model data 1504a, a robotic system may generate a library of expected endoscope images based on the model, with each image linked to a position within the model, based on the expected path of the endoscope's travel. In operation, the robotic system may refer to this library to compare real-time images captured at a camera (e.g., a camera at the distal end of the endoscope) with those images in the image library to aid in positioning.

[0155] Other computer vision-based tracking techniques use feature tracking to determine camera motion, and thus, endoscope motion. Some features of the positioning module 1502 can identify circular geometries corresponding to anatomical cavities in the preoperative model data 1504a and track changes in those geometries to determine which anatomical cavity has been selected, as well as track the relative rotation and / or translational motion of the camera. The use of topology maps can further enhance vision-based algorithms or techniques.

[0156] Optical flow (another computer vision-based technique) analyzes the displacement and translation of image pixels in a video sequence within visual data 1504b to infer camera motion. Examples of optical flow techniques can include motion detection, object segmentation computation, brightness, motion compensation coding, stereo parallax measurement, and more. Through multiple iterations and comparisons of multiple frames, the motion and position of the camera (and therefore the endoscope) can be determined.

[0157] The positioning module 1502 can use real-time EM tracking to generate the real-time position of the endoscope in a global coordinate system that can be registered to the patient's anatomy represented by a preoperative model. In EM tracking, an EM sensor (or tracker), including one or more sensor coils embedded in one or more locations and orientations within the medical instrument (e.g., an endoscopic tool), measures changes in the EM field generated by one or more static EM field generators positioned at known locations. The positional information detected by the EM sensor is stored as EM data 1504c. The EM field generator (or transmitter) can be placed close to the patient to generate a low-intensity magnetic field detectable by the embedded sensor. The magnetic field induces a small current in the sensor coil of the EM sensor, which can be analyzed to determine the distance and angle between the EM sensor and the EM field generator. These distances and orientations can be "registered" to the patient's anatomy (e.g., a preoperative model) during surgery to determine the geometric transformations that align a single location in the coordinate system with its orientation in the preoperative model of the patient's anatomy. Once registered, an embedded EM tracker in one or more orientations of the medical device (e.g., the distal end of an endoscope) can provide real-time indication of the medical device’s progress through the patient’s anatomy.

[0158] Robot commands and kinematic data 1504d can also be used by the positioning module 1502 to provide orientation data 1506 for the robotic system. Device pitch and yaw, derived from joint movement commands, can be determined during preoperative calibration. During surgery, these calibration measurements can be combined with known insertion depth information to estimate the instrument's orientation. Alternatively, these calculations can be analyzed in conjunction with EM, vision, and / or topology modeling to estimate the medical device's orientation within the network.

[0159] Figure 15 As shown, the positioning module 1502 can use multiple other input data. For example, although in Figure 15 Although not shown, the device using shape sensing fibers can provide shape data, which the positioning module 1502 can use to determine the position and shape of the device.

[0160] The localization module 1502 can use the input data 1504a-d in combination. In some cases, this combination can use a probabilistic method, where the localization module 1502 assigns confidence weights to the position determined from each of the input data 1504a-d. Therefore, in cases where the EM data 1504c may be unreliable (possibly due to EM interference), the confidence of the position determined by the EM data 1504c may be reduced, and the localization module 1502 may rely more heavily on the visual data 1504b and / or robot commands and kinematic data 1504d.

[0161] As discussed above, the robotic systems discussed in this paper can be designed as a combination of one or more of the technologies mentioned above. The computer-based control system of a robotic system located in a tower, bed, and / or trolley can store computer program instructions in, for example, a non-transitory computer-readable storage medium (such as a permanent magnetic storage drive, a solid-state drive, etc.). When executed, these computer program instructions cause the system to receive and analyze sensor data and user commands, generate control signals for the entire system, and display navigation and positioning data, such as the instrument's position in a global coordinate system, anatomical diagrams, etc.

[0162] 2. Introduction .

[0163] Embodiments of this disclosure relate to systems and techniques for articulating an end effector of a robotic surgical tool. The robotic surgical tool may include a drive housing having a first end and at least one spline extending from the first end and including a drive gear that rotates with rotation of the spline. A carriage is movably mounted to the spline for translation along the z-axis, and an elongated shaft extends from the carriage and passes through the first end. An end effector may be disposed at the distal end of the elongated shaft, and an articulated wrist is inserted between the end effector and the distal end of the shaft. An activation mechanism is housed in or otherwise carried by the carriage and is operatively coupled to the drive gear such that rotation of the drive gear correspondingly actuates the activation mechanism. With actuation of the activation mechanism, the wrist correspondingly articulates the end effector in at least one plane.

[0164] 3. Description .

[0165] Figure 16 This is an isometric side view of an exemplary surgical tool 1600 incorporating some or all of the principles of this disclosure. The surgical tool 1600 may be similar in some respects to the above references. Figures 11 to 13 Any of the aforementioned medical devices, and therefore compatible with robotic surgical systems (such as...) Figures 1 to 13 The surgical tool 1600 is used in conjunction with robot enabling systems 100, 400, and 900. As shown, the surgical tool 1600 includes an elongated shaft 1602, an end effector 1604 disposed at the distal end of the shaft 1602, and an articulated wrist 1606 (optionally referred to as a "wrist connector") inserted between the end effector 1604 and the distal end of the shaft 1602 and connecting the end effector to the distal end of the shaft.

[0166] The terms "proximal" and "distal" are defined herein with respect to a robotic surgical system having an interface configured to mechanically and electrically connect surgical instruments 1600 to a robotic manipulator. The term "proximal" refers to the location of an element closer to the robotic manipulator, and the term "distal" refers to the location of an element closer to the end effector 1604 and therefore closer to the patient during operation. 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 direction pointing towards the top of the corresponding figure, and downward or lower direction pointing towards the bottom of the corresponding figure.

[0167] Surgical tool 1600 may have any of a variety of configurations capable of performing one or more surgical functions. In an illustrated embodiment, end effector 1604 includes a surgical stapler configured to cut and suture (tighten) tissue, alternatively referred to as a "linear cutter". As shown, end effector 1604 includes opposing jaws 1610, 1612 configured to move (articularly) between an open and closed position. Alternatively, end effector 1604 may include other types of instruments requiring opposing jaws, such as, but not limited to, other surgical staplers (e.g., circular staplers and linear staplers), tissue grippers, surgical scissors, advanced-energy vascular closure devices, clamps, needle actuators, Babcock forceps including a pair of opposing gripping jaws, bipolar jaws (e.g., bipolar Maryland grippers, clamps, perforated grippers, etc.), etc. In other embodiments, end effector 1604 may alternatively include any end effector or instrument capable of operating in conjunction with currently disclosed robotic surgical systems and methods. Such end effectors or instruments include, but are not limited to, suction flushers, endoscopes (e.g., cameras), or any combination thereof.

[0168] One or both of jaws 1610 and 1612 may be configured to pivot to actuate end effector 1604 between an open position and a closed position. In the illustrated example, the second jaw 1612 is rotatable (pivotable) relative to the first jaw 1610 to move between an open, unclamped position and a closed, clamped position. However, in other embodiments, without departing from the scope of this disclosure, the first jaw 1610 may move (rotate) relative to the second jaw 1612. In still other embodiments, both jaws 1610 and 1612 may be movable to actuate end effector 1604 between an open position and a closed position.

[0169] In the illustrated example, the first jaw 1610 is referred to as a “cabin” or “channel” jaw, and the second jaw 1612 is referred to as an “anvil” jaw. The first jaw 1610 may include a frame that houses or supports the staple cartridge, and the second jaw 1612 is pivotally supported relative to the first jaw 1610 and defines a surface that operates as an anvil to deform staples ejected from the staple cartridge during operation.

[0170] The wrist 1606 enables the end effector 1604 to articulate (pivot) relative to the axis 1602, thereby positioning the end effector 1604 in various desired orientations and positions relative to the surgical site. In the illustrated embodiment, the wrist 1606 is designed to allow the end effector 1604 to pivot (rotate) left and right relative to the longitudinal axis A1 of the axis 1602. However, in other embodiments, the wrist 1606 may be designed to provide multiple degrees of freedom, including one or more translational variables (i.e., forward and backward, heave and yaw) and / or one or more rotational variables (i.e., Euler angles or roll, pitch and yaw). Translational and rotational variables describe the position and orientation of a component of the surgical system (e.g., the end effector 1604) relative to a given reference Cartesian coordinate system. "Forward and backward" refers to forward and backward translational movements, "heave and yaw" refers to up and down translational movements, and "yaw" refers to left and right translational movements. Regarding rotational terms, "roll" refers to left and right tilting, "pitch" refers to forward and backward tilting, and "yaw" refers to left and right rotation.

[0171] In the illustrated embodiment, the pivoting movement at wrist 1606 is restricted to movement in a single plane, e.g., yaw movement only relative to the longitudinal axis A1. End effector 1604 in Figure 16 The image is shown in a non-jointed position, in which the longitudinal axis of the end effector 1604 is substantially aligned with the longitudinal axis A1 of the shaft 1602, such that the end effector 1604 forms a substantially zero angle with respect to the shaft 1602. In the jointed position, the longitudinal axis of the end effector 1604 will be angularly offset from the longitudinal axis A1, such that the end effector 1604 will be oriented at a non-zero angle with respect to the shaft 1602.

[0172] See still Figure 16 The surgical tool 1600 may include a drive housing 1614 housing an actuation system designed to facilitate joint movements of the wrist 1606 and actuation (operation) of the end effector 1604 (e.g., gripping, firing, rotation, joint movement, energy delivery, etc.). The drive housing 1614 (alternatively referred to as a “tower”) provides various coupling features that releasably couple the surgical tool 1600 to the instrument actuator of a robotic surgical system, as described in more detail below.

[0173] The drive housing 1614 includes a plurality of drive members extending to the wrist 1606 and the end effector 1604 (in Figure 16 (Obscured). Selective actuation of one or more of the drive members causes the end effector 1604 to articulate (pivot) relative to the axis 1602 at the wrist 1606. Selective actuation of one or more other drive members causes the end effector 1604 to be actuated (operated). Actuating the end effector 1604 may include closing and / or opening the jaws 1610, 1612, thereby enabling the end effector 1604 to grasp (clamp) onto tissue. Once tissue is grasped or clamped between the opposing jaws 1610, 1612, actuating the end effector 1604 may also include “firing” the end effector 1604, which may refer to causing a cutting element or blade (not visible) to advance distally within a slot 1616 defined in the first jaw 1610. As it moves distally, the cutting element transversely cuts any tissue grasped between the opposing jaws 1610, 1612. Furthermore, as the cutting element advances distally, multiple staples contained within the staple cartridge (e.g., housed within the first jaw 1610) are pushed (cam-driven) into deformable contact with corresponding anvil surfaces (e.g., recesses) disposed on the second jaw 1612. The deployed staples can form multiple rows of staples sealing opposite sides of the transversely cut tissue.

[0174] As shown, the drive housing 1614 has a first end or "distal" end 1618a and a second end or "proximal" end 1618b opposite to the first end 1618a. The first end 1618a is also referred to as a "handle". In some embodiments, one or more struts 1620 (two are shown) extend longitudinally between the first end 1618a and the second end 1618b to help fix the distance between the first end 1618a and the second end 1618b, provide advantageous structural stability to the drive housing 1614, and secure the first end 1618a to the second end 1618b. However, in other embodiments, the struts 1620 may be omitted without departing from the scope of this disclosure.

[0175] The drive housing 1614 may also include a lead screw 1622 and one or more splines 1624 extending longitudinally between the first end 1618a and the second end 1618b. In the illustrated embodiment, the drive housing 1614 includes a first spline 1624a, a second spline 1624b, and a third spline 1624c. Although only three splines 1624a-c are shown in the drive housing 1614, more or fewer splines may be included without departing from the scope of this disclosure. Unlike the support bar 1620, the lead screw 1622 and splines 1624a-c are rotatably mounted to the first end 1618a and the second end 1618b. As described in more detail below, selective rotation of the lead screw 1622 and splines 1624a-c causes various functions of the drive housing 1614 to occur, such as translating the end effector 1604 along the longitudinal axis A1 (e.g., translation along the z-axis), thereby causing the end effector 1604 to articulate (pivot) at the wrist 1606, causing the jaws 1610, 1612 to open and close, and causing the end effector 1604 to fire (operate).

[0176] The drive housing 1614 also includes a bracket 1626 movably mounted along the lead screw 1622 and splines 1624a-c, and housing various activation mechanisms configured to cause specific functional operation of the end effector 1604. The bracket 1626 may include two or more layers. Figure 16 The layers shown are a first layer 1628a, a second layer 1628b, a third layer 1628c, a fourth layer 1628d, and a fifth layer 1628e. Lead screws 1622 and splines 1624a-c each extend through portions of one or more of the layers 1628a-e to allow the bracket 1626 to translate relative to the lead screws 1622 and splines 1624a-c along the longitudinal axis A1. In some embodiments, the layers 1628a-e may be tandemly secured to each other using one or more mechanical fasteners 1630 (two visible) extending between the first layer 1628a and the fifth layer 1628e and passing through coaxial alignment holes defined in some or all of the layers 1628a-e. Although five layers 1628a-e are shown, more or fewer layers may be included in the bracket 1626 without departing from the scope of this disclosure.

[0177] Shaft 1602 is coupled to bracket 1626 and extends distally from the bracket through a first end 1618a of drive housing 1614. In an illustrated embodiment, for example, shaft 1602 penetrates the first end 1618a at a central hole 1632 defined to pass through the first end 1618a. Bracket 1626 is movable (e.g., z-axis translation) along longitudinal axis A1 between the first end 1618a and the second end 1618b, thereby enabling the end actuator 1604 to be advanced or retracted relative to drive housing 1614, as indicated by arrow B. More specifically, in some embodiments, bracket 1626 includes bracket nut 1634 mounted to lead screw 1622 and secured between third layer 1628c and fourth layer 1628d. The outer surface of lead screw 1622 defines a helical external thread, and bracket nut 1634 defines a corresponding helical internal thread (not shown) capable of engaging the helical external thread of lead screw 1622. Therefore, the rotation of the lead screw 1622 causes the bracket nut 1634 to advance or retract the bracket 1626 along the longitudinal axis A1, and correspondingly advance or retract the end actuator 1604 relative to the drive housing 1614.

[0178] As indicated, the lead screw 1622 and splines 1624a-c are rotatably mounted to the first end 1618a and the second end 1618b. More specifically, the first end 1618a of the drive housing 1614 may include one or more rotatable drive inputs actuated to independently drive (rotate) the lead screw 1622 and splines 1624a-c. In the illustrated embodiment, the drive housing 1614 includes a first drive input 1636a, a second drive input 1636b, and a third drive input 1636c (covered by shaft 1602, see [link]). Figure 17B The drive input 1636a-d and the fourth drive input 1636d. As described below, each drive input 1636a-d can cooperate with a corresponding drive output of the instrument actuator such that movement (rotation) of a given drive output correspondingly causes movement (rotation) of the associated drive input 1636a-d, thereby rotating the mating lead screw 1622 or splines 1624a-c. Although only four drive inputs 1636a-d are shown, depending on the specific application, the drive housing 1614 may include more or fewer than four drive inputs.

[0179] The first drive input 1636a is operably coupled to the lead screw 1622 such that rotation of the first drive input 1636a correspondingly rotates the lead screw 1622, causing the bracket nut 1634 and the bracket 1626 to advance or retract along the longitudinal axis A1 according to the direction of rotation of the lead screw 1622. As used herein, the phrase "operably coupled" refers to a direct or indirect coupling in which movement of one component causes a corresponding movement of the other component. Such operable coupling with respect to the first drive input 1636a operably coupled to the lead screw 1622 can be facilitated by intermeshing gears (not shown) arranged in the second end 1618a, but can alternatively be facilitated by other mechanical means (such as cables, pulleys, drive rods, direct couplings, etc.) without departing from the scope of this disclosure.

[0180] The second drive input 1636b is operably coupled to the first spline 1624a, such that rotation of the second drive input 1636b correspondingly rotates the first spline 1624a. In some embodiments, the first spline 1624a is operably coupled to the first activation mechanism 1638a of the bracket 1626, and the first activation mechanism 1638a is operable to open and close the jaws 1610, 1612. Therefore, depending on the direction of rotation of the first spline 1624a, rotating the second drive input 1636b will correspondingly actuate the first activation mechanism 1638a, thereby opening or closing the jaws 1610, 1612.

[0181] The third drive input 1636c can be operatively coupled to the second spline 1624b, such that rotation of the third drive input 1636c correspondingly rotates the second spline 1624b. In some embodiments, the second spline 1624b can be operatively coupled to the second activation mechanism 1638b of the bracket 1626, and the second activation mechanism 1638b can be operatively configured to articulate the end effector 1604 at the wrist 1606. Therefore, depending on the direction of rotation of the second spline 1624b, rotation of the third drive input 1636c will correspondingly actuate the second activation mechanism 1638b, thereby causing the wrist 1606 to articulate with at least one degree of freedom.

[0182] The fourth drive input 1636d is operably coupled to the third spline 1624c, such that rotation of the fourth drive input 1636d correspondingly rotates the third spline 1624c. In some embodiments, the third spline 1624c is operably coupled to the third activation mechanism 1638c of the bracket 1626, and the third activation mechanism 1638c may be operable to actuate the cutting element (blade) at the end effector 1604. Therefore, depending on the direction of rotation of the third spline 1624c, rotation of the fourth drive input 1636d will correspondingly actuate the third activation mechanism 1638c, thereby causing the blade to advance or retract.

[0183] In the illustrated embodiment, and as described in more detail below, the activation mechanism 1638a-c includes a meshing gear assembly comprising one or more drive gears driven by rotation of the corresponding splines 1624a-c and configured to drive one or more corresponding driven gears that cause a specific functional operation of the end effector 1604. However, it is also contemplated herein that the activation mechanism 1638a-c may be operated by other types of mechanical cooperation (such as, but not limited to, belts or cables).

[0184] In some embodiments, the drive housing 1614 may include a shield 1640 sized to receive and otherwise surround the bracket 1626, the lead screw 1622, and the splines 1624a-c. In an illustrated embodiment, the shield 1640 includes a tubular or cylindrical structure having a first end 1642a capable of engaging with a first end 1618a of the drive housing 1614 and a second end 1642b capable of engaging with a second end 1618b of the drive housing 1614. The bracket 1626, the lead screw 1622, and the splines 1624a-c may all be accommodated within the shield 1640, and the bracket 1626 may engage with one or more tracks 1644 (shown in dashed lines) fixed to the shield 1640 and move back and forth (travel) on said tracks. The track 1644 extends longitudinally and is parallel to the lead screw 1622, and is sized to be received within corresponding recesses 1646 defined on the outer periphery of the bracket 1626, and more specifically on the outer periphery of one or more bracket layers 1628a-e. As the bracket 1626 translates along the longitudinal axis A1, the track 1644 helps maintain the angular position of the bracket 1626 and bears any torsional loads that might otherwise adversely affect the movement or operation of the bracket 1626.

[0185] Figure 17A It is releasably coupled to the exemplary instrument driver 1702 according to one or more embodiments. Figure 16An isometric view of the surgical instrument 1600. The instrument actuator 1702 is similar in some respects to... Figure 11 and Figure 12 The instrument actuators 1102 and 1200 are used, and therefore can be best understood with reference to them. Similar to, for example, instrument actuators 1102 and 1200, instrument actuator 1702 may be mounted to or otherwise positioned at the end of a robotic arm (not shown) and is designed to provide the prime mover required to operate surgical tool 1600. However, unlike instrument actuators 1102 and 1200, the shaft 1602 of surgical tool 1600 extends through and penetrates instrument actuator 1702.

[0186] The instrument actuator 1702 has a body 1704 having a first end or "proximal" end 1706a and a second end or "distal" end 1706b opposite the first end 1706a. In the illustrated embodiment, the first end 1706a of the instrument actuator 1702 is capable of engaging with and releasably coupled to the first end 1618a of the drive housing 1614, and the shaft 1602 of the surgical tool 1600 extends through the body 1704 and extends distally from the second end 1706b.

[0187] Figure 17B Depicting Figure 17ASeparate isometric end views of the instrument actuator 1702 and the surgical tool 1600. With jaws 1610, 1612 closed, the shaft 1602 and end effector 1604 can penetrate the instrument actuator 1702 by extending through a central bore 1708 defined longitudinally through the body 1704 between the first end 1706a and the second end 1706b. To align the surgical tool 1600 with the instrument actuator 1702 at a suitable angular orientation, one or more alignment guides 1710 may be provided or otherwise defined within the central bore 1708 and configured to engage one or more corresponding alignment features 1712 provided on the surgical tool 1600. In the illustrated embodiment, the alignment feature 1712 includes a protrusion or projection defined on or otherwise provided by an alignment nozzle 1714 extending distally from a first end 1618a of the drive housing 1614. In one or more embodiments, the alignment guide 1710 may include a curved or arched shoulder or lip configured to receive and guide the alignment feature 1712 as the alignment nozzle 1714 enters the central bore 1708. As a result, as the alignment nozzle 1714 is advanced distally through the central bore 1708, the surgical instrument 1600 is oriented to be aligned at an appropriate angle with the instrument actuator 1702. In other embodiments, without departing from the scope of this disclosure, the alignment nozzle 1714 may be omitted and the alignment feature 1712 may alternatively be provided on the shaft 1602.

[0188] As shown in the figure, a drive interface 1716 is disposed at a first end 1706a of the instrument actuator 1702, and a driven interface 1718 is disposed at a first end 1618a of the drive housing 1614. The drive interface 1716 and the driven interface 1718 can be configured to mechanically, magnetically, and / or electrically connect the drive housing 1614 to the instrument actuator 1702. To achieve this, the drive interface 1716 and the driven interface 1718 can provide one or more engaging positioning features configured to secure the drive housing 1614 to the instrument actuator 1702. In an illustrated embodiment, for example, the drive interface 1716 provides one or more interlocking features 1720 (three shown) configured to position and engage with one or more complementary recesses 1722 (two shown, one obscured) disposed on the driven interface 1718. In some embodiments, feature 1720 may be configured to engage and align with recess 1722, for example, via an interference fit or snap-fit.

[0189] The instrument driver 1702 also includes one or more drive outputs extending through the drive interface 1716 to mate with drive inputs 1636a-d disposed at a first end 1618a of the drive housing 1614. More specifically, the instrument driver 1702 includes a first drive output 1724a mateable with the first drive input 1636a, a second drive output 1724b mateable with the second drive input 1636b, a third drive output 1724b mateable with the third drive input 1636c, and a fourth drive output 1724d mateable with the fourth drive input 1636d. In some embodiments, as shown, the drive outputs 1724a-d may define splines or features designed to mate with corresponding spline sockets of the drive inputs 1636a-d. Once properly engaged, the drive inputs 1636a-d will share a rotational axis with their corresponding drive outputs 1724a-d, allowing rotational torque to be transmitted from the drive outputs 1724a-d to the corresponding drive inputs 1636a-d. In some embodiments, each drive output 1724a-d may be spring-loaded and originally biased outwards away from the drive interface 1716. Each drive output 1724a-d may be able to retract partially or completely into the drive interface 1716.

[0190] In some implementations, the instrument driver 1702 may include additional drive outputs, in Figure 17B The fifth drive output 1724e and the sixth drive output 1724f are depicted in the diagram. The fifth drive output 1724e and the sixth drive output 1724f can be configured to mate with additional drive inputs (not shown) of the drive housing 1614 to facilitate one or more additional functions of the surgical tool 1600. However, in the illustrated embodiment, the drive housing 1614 does not include additional drive inputs that mate with the fifth drive output 1724e and the sixth drive output 1724f. Instead, the driven interface 1718 defines corresponding recesses 1726 configured to receive the fifth drive output 1724e and the sixth drive output 1724f. However, in other applications, the fifth drive input and / or the sixth drive input (not shown) may be included in the drive housing 1614 to cooperate with the fifth drive output 1724e and the sixth drive output 1724f, or the surgical tool 1600 may be replaced with another surgical tool having a fifth drive input and / or the sixth drive input that will be driven by the fifth drive output 1724e and / or the sixth drive output 1724f.

[0191] Although not shown, in some embodiments, an instrument sterile adapter (ISA) may be placed at the interface between the instrument driver 1702 and the surgical instrument 1600. In such applications, the interlocking feature 1720 may operate as an alignment feature and possibly a latch for placing, stabilizing, and securing the ISA. The stability of the ISA may be achieved by a nasal cone feature provided by the ISA and extending into the central bore 1708 of the instrument driver 1702. The latch may occur with the interlocking feature 1720 or at other locations at the interface. In some cases, the ISA will provide means to aid alignment and facilitate latching the surgical instrument 1600 to the ISA and simultaneously to the instrument driver 1702.

[0192] Joint movement mechanism

[0193] Figure 18A This is an enlarged isometric view of an embodiment of the bracket 1626 and the second activation mechanism 1638b. As described above, the second spline 1624b can be operatively coupled to the second activation mechanism 1638b, such that (via...) Figure 16 and Figure 17B The rotation of the third drive input 1636c causes the second spline 1624b to rotate, which in turn actuates the second activation mechanism 1638b, thereby causing the wrist 1606 ( Figure 16 The joint movement is performed. As shown, the second spline 1624b extends longitudinally through a coaxial alignment hole 1802 defined in the second layer 1628b and the third layer 1628c of the bracket 1626. In some embodiments, for example, each hole 1802 may be defined in a corresponding convex angle 1804 provided by each of the second layer 1628b and the third layer 1628c.

[0194] The drive gear 1806 may be included together with the second spline 1624b and located between the second layer 1628b and the third layer 1628c, and more specifically between the convex corners 1804 of each layer 1628b, 1628c. The second spline 1624b may have a cross-sectional shape capable of engaging with the drive gear 1806, such that rotation of the second spline 1624b correspondingly drives rotation of the drive gear 1806. In some embodiments, the drive gear 1806 may include a separate component slidably disposed around the second spline 1624b. In such embodiments, as the bracket 1626 moves along the longitudinal axis A1 ( Figure 16 The drive gear 1806 will move along the length of the second spline 1624b, as if it were trapped between the second layer 1628b and the third layer 1628c. However, in other embodiments, the second spline 1624b may be shaped as the drive gear 1806 and otherwise configured to operate as a drive gear to advantageously reduce the number of component parts.

[0195] The drive gear 1806 can be positioned on the bracket 1626 to simultaneously mesh with the first or "distal end" drive gear 1808a and the second or "proximal end" drive gear 1808b. Therefore, as the spline 1624b rotates, the drive gear 1806 simultaneously drives the first drive gear 1808a and the second drive gear 1808b.

[0196] Figure 18B This is an enlarged side view of bracket 1626 and the second activation mechanism 1638b. Figure 18B The second layer 1626b and the third layer 1626c of bracket 1626 are omitted. Figure 18A This allows for a more comprehensive view of the second activation mechanism 1638b. The first transmission gear 1808a and the second transmission gear 1808b may include an annular structure extending around the shaft 1602, and more specifically, an annular structure extending around an inner grounding member or shaft 1810 forming part of the shaft 1602. The inner grounding shaft 1810 extends concentrically within the outer portion of the shaft 1602, referred to herein as the closed tube 1812.

[0197] The second activation mechanism 1638b may further include a first or "distal" carrier 1814a (partially visible) and a second or "proximal" carrier 1814b (shown in dashed lines). The first carrier 1814a is radially inserted between the inner grounding shaft 1810 and at least a portion of the first drive gear 1808a, and the second carrier 1814b is radially inserted between the inner grounding shaft 1810 and at least a portion of the second drive gear 1808b. The internal threads of the first drive gear 1808a and the second drive gear 1808b are in opposite directions (i.e., one is left-handed and the other is right-handed), and the first drive gear 1808a can be threadedly engaged with the external thread defined by the first carrier 1814a, while the second drive gear 1808b can be threadedly engaged with the external thread defined by the second carrier 1814b.

[0198] Figure 18C This is an isometric cross-sectional side view of the second activation mechanism 1638b according to one or more embodiments. As shown, as described above, the first carrier 1814a and the second carrier 1814b are radially inserted into the inner grounding shaft 1810 and the first transmission gear 1808a and the second transmission gear 1808b, respectively. Furthermore, the first carrier 1814a can be operatively coupled to or otherwise cooperate with the first drive member 1816a, which extends distally to the wrist 1606. Figure 16As shown in the figure, a first drive member 1816a is arranged within a corresponding slot 1818 defined in the inner grounding shaft 1810, which guides the first drive member 1816a as it extends to the wrist 1606. Similarly, a second carrier 1814b may be operatively coupled to or otherwise engage with the second drive member 1816b, which extends distally to the wrist 1606. The second drive member 1816b is also arranged within a corresponding slot 1820 defined in the inner grounding shaft 1810, which guides the second drive member as it extends to the wrist 1606.

[0199] The first transmission gear 1808a defines an internal thread 1822a that engages with an external thread 1824a defined on the outer surface of the first carrier 1814a, and similarly, the second transmission gear 1808b defines an internal thread 1822b that engages with an external thread 1824b defined on the outer surface of the second carrier 1814b. The internal threads 1822a and 1822b have opposite thread directions; that is, one includes a left-hand thread and the other includes a right-hand thread. Therefore, as the drive gear 1806 rotates, it simultaneously drives both transmission gears 1808a and 1808b to rotate. Due to the opposite thread engagement of the internal threads 1822a and 1822b, this consequently drives the corresponding carriers 1814a and 1814b simultaneously in collinear but opposite axial directions. Depending on the rotation direction of the drive gear 1806, the carriers 1814a and 1814b can move axially closer to or further away from each other.

[0200] The first carrier 1814a and the second carrier 1814b are relative to the inner grounding shaft 1810 and along the longitudinal axis A1. Figure 16 The opposite axial movement of the actuator 1604 correspondingly causes the drive members 1816a and 1816b to move in the same opposite axial direction, thereby causing the end actuator 1604 to move. Figure 16 and Figure 17BThe first carrier 1814a and the second carrier 1814b operate in opposition to each other, such that one of the carriers 1814a and 1814b pulls one of the drive members 1816a and 1816b proximally, while the other carrier 1814a and 1814b similarly pushes the other drive member 1816a and 1816b distally. A gap 1826 provided between the carriers 1814a and 1814b along the inner ground axis 1810 allows the carriers 1814a and 1814b to move toward and away from each other, thereby providing clearance for clockwise and counterclockwise articulation. As the carriers 1814a and 1814b are axially pulled toward each other, the end effector 1604 will articulate in a first direction, and as the carriers 1814a and 1814b are axially moved away from each other, the end effector 1604 will articulate in a second direction opposite to the first direction.

[0201] See Figure 19 See also Figure 18C An enlarged view of the end effector 1604 and an exposed view of the wrist 1606 according to one or more embodiments are shown. Figure 19 Middle, inner ground shaft 1810 ( Figures 18B to 18C The [missing information] has been removed to allow observation of how drive members 1816a, 1816b interconnect with or otherwise operably connect to end effector 1604. In the illustrated embodiment, end effector 1604 is mounted to end effector mount 1902, which defines or otherwise provides two articulated pins 1904, and the distal end of each drive member 1816a, 1816b is rotatably mounted to a corresponding articulated pin 1904. Drive members 1816a, 1816b are also interconnected at their distal ends via a distal link 1906 to collectively form a link configured to facilitate articulation of end effector mount 1902, and thus end effector 1604, in a plane parallel to longitudinal axis A1.

[0202] In this configuration, drive members 1816a and 1816b translate in a counteracting and parallel manner along the longitudinal axis A1, such that as the first drive member 1816a moves distally, the second drive member 1816b moves proximally, and vice versa. Furthermore, the distal movement of the first drive member 1816a and the simultaneous proximal movement of the second drive member 1816b work synergistically on the end effector mount 1902, causing the end effector 1604 to rotate counterclockwise, as indicated by arrow C1. Conversely, the proximal movement of the first drive member 1816a and the simultaneous distal movement of the second drive member 1816b work synergistically on the end effector mount 1902, causing the end effector 1604 to rotate clockwise, as indicated by arrow C2.

[0203] Figure 20 This is an enlarged cross-sectional side view of another embodiment of the second activation mechanism 1638b. Figure 20 The implementation shown is similar in some respects to Figures 18A to 18C The implementation scheme of the second activation mechanism 1638b can be referenced for optimal understanding. Similar to, for example... Figures 18A to 18C Implementation plan, Figure 20 The second activation mechanism 1638b includes a first carrier 1814a and a second carrier 1814b, respectively radially inserted between the inner grounding shaft 1810 and the first drive gear 1808a and the second drive gear 1808b. Furthermore, the first carrier 1814a is operably coupled to or otherwise engages with the first drive member 1816a, and the second carrier 1814b is operably coupled to or otherwise engages with the second drive member 1816b, and the drive members 1816a and 1816b extend distally to the wrist 1606. Figure 16 and Figure 19 The internal thread 1822a of the first transmission gear 1808a mates with the external thread 1824a of the first carrier 1814a, and similarly the internal thread 1822b of the second transmission gear 1808b mates with the external thread 1824b of the second carrier 1814b, and the thread directions of the internal threads 1822a and 1822b are opposite.

[0204] However, with Figures 18A to 18C The implementation scheme of the second activation mechanism 1638b is different. Figure 20The implementation scheme includes two splines and two corresponding drive gears. More specifically, the first drive gear 2002a may be included together with the second spline 1624b, such that rotation of the second spline 1624b correspondingly rotates the first drive gear 2002a, and the second drive gear 2002b may be included together with the fourth spline 1624d, such that rotation of the fourth spline 1624d correspondingly rotates the second drive gear 2002b. As described above, the third drive output element 1724b ( Figure 17B It can drive the third driver input device 1636c. Figure 16 and Figure 17B This allows the second spline 1624b to rotate. In one or more embodiments, the fourth spline 1624d may be located at the first end 1618a of the drive housing 1614. Figure 16 and Figure 17B ) can be operatively connected to the fifth drive input (not shown) and by the fifth drive output 1724e or the sixth drive output 1724f ( Figure 17B One of the drive outputs 1724e or 1724f is driven. In such embodiments, actuation of the fifth drive output 1724e or the sixth drive output 1724f will correspondingly cause the fourth spline 1624d to rotate, thereby causing the second drive gear 2002b to rotate.

[0205] Two drive gears 2002a and 2002b can be located between the second layer 1628b and the third layer 1628c. The first drive gear 2002a can be positioned to mesh with the first transmission gear 1808a, and the second drive gear 2002b can be positioned to mesh with the second transmission gear 1808b. As the first drive gear 2002a rotates, the first transmission gear 1808a rotates accordingly and drives the first carrier 1814a axially along the longitudinal axis A1 due to the threaded engagement of the meshing internal threads 1822a and external threads 1824a. Similarly, as the second drive gear 2002b rotates, the second transmission gear 1808b rotates accordingly and drives the second carrier 1814b axially along the longitudinal axis A1 due to the threaded engagement of the meshing internal threads 1822b and external threads 1824b. Depending on the rotation direction of the drive gears 2002a and 2002b, the carriers 1814a and 1814b can move axially toward or away from each other.

[0206] The first carrier 1814a and the second carrier 1814b move axially along the longitudinal axis A1 in a coordinated manner, actuating the drive components 1816a and 1816b, thereby causing the end effector 1604 ( Figure 16 and Figure 19The joint movement is performed. In at least one embodiment, the first carrier 1814a and the second carrier 1814b operate in opposition, such that one of the carriers 1814a and 1814b pulls one of the drive members 1816a and 1816b proximally, while the other carrier 1814a and 1814b pushes the other drive member 1816a and 1816b distally. However, in some embodiments, the first carrier 1814a and the second carrier 1814b can operate independently without the other operating (being affected), thus operating in opposition while reducing the force effect of the other. In counter-operation, one of the carriers 1814a and 1814b pulls (or pushes) its associated drive member 1816a and 1816b proximally (or distally) with a first force, while the other of the carriers 1814a and 1814b pulls (or pushes) its associated drive member 1816a and 1816b 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 loads applied to the end effector 1604 via the external environment. It will be understood that this ensures that the carriers 1814a and 1814b providing the first force move proximally (or distally), while the carriers 1815a and 1815b providing the second force move distally (or proximally).

[0207] The software stored on the computer system can be configured to control drive outputs 1724b and 1724e or 1724f. Figure 17B These drive outputs respectively drive the rotation of the second spline 1624b and the fourth spline 1624d, thereby synchronizing the actuation (movement) of the carriers 1814a, 1814b and the corresponding drive members 1816a, 1816b. In some embodiments, the software can also be configured to reduce the lag or relaxation (delay) of the movement of the carriers 1814a, 1814b, which correspondingly reduces the lag or relaxation (delay) of the joint movement of the end effector 1604. For example... Figure 20 In the implementation scheme, one drive output element 1724b or 1724e, 1724f can rotate counterclockwise, while the other drive output element 1724b or 1724e, 1724f compensates by rotating clockwise. Furthermore, one drive output element 1724b or 1724e, 1724f can lag behind or precede the other, depending on the mechanism's lag or transmission. Therefore, such a control algorithm can be used to compensate for, reduce lag, and reduce the lag of drive input elements 1636a-d. Figure 16 and Figure 17B Slowing of one or more drive inputs in ).

[0208] See you again Figure 19 See also Figure 20To enable the end effector 1604 to perform a clockwise joint movement C2, the first drive member 1816a moves proximally and the second drive member 1816b moves distally. In this operation, the first drive member 1816a can move proximally a greater distance than the second drive member 1816b moves distally, which allows the second drive member 1816b to maintain less tension than the first drive member 1816a during its movement, thus helping to reduce hysteresis and / or relaxation. To enable the end effector 1604 to perform a counterclockwise joint movement C1, the second drive member 1816b moves proximally and the first drive member 1816a moves distally. In this operation, the second drive member 1816b moves proximally a greater distance than the first drive member 1816a moves distally, which allows the first drive member 1816a to maintain less tension than the second drive member 1816b during its movement, which again helps to reduce hysteresis and / or relaxation.

[0209] Figure 21A and Figure 21B These are enlarged isometric top and bottom views, respectively, of an exemplary bracket 2100 according to one or more embodiments. The bracket 2100 may be similar in some respects to... Figure 16 and Figures 18A to 18C The bracket 1626 is the best reference for understanding its function. In some applications, bracket 2100 can replace... Figure 16 The bracket 1626 in the drive housing 1614. As shown, the bracket may include two or more layers. Figures 21A to 21B The first layer 2102a, the second layer 2102b, the third layer 2102c, and the fourth layer 2102d are shown. Although four layers 2102a-e are shown, more or fewer layers may be included in the bracket 2100 without departing from the scope of this disclosure. A shaft 1602 is coupled to and extends distally from the bracket 2100, and the bracket 2100 can be translated along the longitudinal axis A1 by moving the lead screw 1622 up and down (back and forth), as referenced above. Figure 16 Roughly described. As the bracket 2100 moves along the longitudinal axis A1, the end effector 1604 ( Figure 16 (Correspondingly advance or retract)

[0210] In the illustrated embodiment, the bracket 2100 includes an end effector 1604 operable at the wrist 1606 ( Figure 16 and Figure 19 The activation mechanism 2104 performs joint movement at the location. The activation mechanism 2104 may be similar in some respects to the second activation mechanism 1638b. Figure 16 and Figures 18A to 18CAnd it can be actuated by rotation of the second spline 1624b. In the illustrated embodiment, the second spline 1624b is operatively coupled to the activation mechanism 2104, such that (e.g., via...) Figure 16 and Figure 17B The rotation of the third drive input 1636c causes the second spline 1624b to rotate, correspondingly actuating the activation mechanism 2104, thereby causing the wrist 1606 to perform articulation. More specifically, the drive gear 1806 is included together with the second spline 1624b and positioned to mesh with the driven gear 2106, which is coupled to or otherwise forms part of the articulation cylinder 2108. As the spline 1624b rotates, the drive gear 1806 drives the driven gear 2106 and correspondingly causes the articulation cylinder 2108 to rotate about the longitudinal axis A1.

[0211] The articulated movement cylinder 2108 defines or otherwise provides one or more cam grooves or profiles, in Figures 21A to 21B The middle part is shown as the first cam profile 2110a ( Figure 21A ) and the second cam profile 2110b ( Figure 21B ). The activation mechanism 2104 also includes a first driven pin 2112a (). Figure 21A ) and the second moving pin 2112b ( Figure 21B The first cam pin 2112a extends through the first cam profile 2110a and is connected to the first carrier 2114a. Figure 21A ), and the second cam extends from the moving pin 2112b through the second cam profile 2110b and is connected to the second carrier 2114b. Figure 21B Each cam profile 2110a, 2110b extends around the circumference of the articulated cylinder 2108 (e.g., in a spiral pattern), but these profiles are defined at opposite angles.

[0212] As the drive gear 1806 drives the driven gear 2106, the articulated cylinder 2108 rotates correspondingly around the longitudinal axis A1, thus pushing the driven pins 2112a and 2112b across the cam profiles 2110a and 2110b at opposite angles. As the driven pins 2112a and 2112b cross the cam profiles 2110a and 2110b, they push the carriers 2114a and 2114b below along the longitudinal axis A1 in collinear but opposite axial directions. Depending on the rotation direction of the drive gear 1806, the carriers 1814a and 1814b can move axially closer to or further away from each other.

[0213] In some implementations, as shown in the figure, the activation mechanism 2104 may further include a first joint motion torque rod 2116a. Figure 21A ) and the second joint motion torque rod 2116b ( Figure 21B The articulated torque rods 2116a, 2116b are secured to the bracket 2100 using one or more mechanical fasteners 2118 (e.g., screws, bolts, etc.). In the illustrated embodiment, the articulated torque rods 2116a, 2116b extend between the second layer 2102b and the third layer 2102c, and can be secured to each layer 2102b, 2102c at each end. Each articulated torque rod 2116a, 2116b may define a slot 2120, which is sized to receive the head of the corresponding follower pin 2112a, 2112b. During actuation / operation of the activation mechanism 2104, the articulated torque rods 2116a, 2116b may help maintain the axial position of the corresponding follower pin 2112a, 2112b. More specifically, as the articulated cylinder 2108 rotates, the driven pins 2112a and 2112b will also have a tendency to rotate as they traverse the corresponding cam profiles 2110a and 2110b. Receiving the head of each driven pin 2112a and 2112b within the slot 2120 of each fixed articulated torque rod 2116a and 2116b will help prevent the driven pins 2112a and 2112b from rotating, and instead maintain their axial position.

[0214] Figure 22A and Figure 22B These are isometric top and bottom views, respectively, of a portion of the activation mechanism 2104 according to one or more embodiments. Figures 22A to 22B Many components of the bracket 2100 are omitted to allow for a more comprehensive view of the various components of the activation mechanism 2104. As shown, the articulated cylinder 2108 may include a generally cylindrical structure extending around axis 1602 and more specifically around inner grounding axis 1810. A first carrier 2114a and a second carrier 2114b are inserted between the inner grounding axis 1810 and the articulated cylinder 2108 and are capable of independent movement along the longitudinal axis A1. The first carrier 2114a may be operatively coupled to the first drive member 1816a. Figure 22A The first drive member extends distally within at least part of a slot 1818 defined in the inner grounding shaft 1810 to the wrist 1606. Figure 16 Furthermore, the second carrier 2114b can be operatively connected to the second drive member 1816b. Figure 22B The second drive member extends distally into the wrist 1606 within a slot 1820 defined in the inner grounding shaft 1810, at least partially.

[0215] Follower pins 2112a and 2112b extend through corresponding cam profiles 2110a and 2110b, respectively, and are coupled to associated carriers 2114a and 2114b. In some embodiments, one or both of the follower pins 2112a and 2112b may be made of or coated with a lubricating material, and these follower pins are configured to press against the inner walls of the cam profiles 2110a and 2110b as the articulated cylinder 2108 rotates, thereby reducing friction. However, in other embodiments, and as shown, one or both of the follower pins 2112a and 2112b may include one or more bearings, shown as a first bearing 2202a and a second bearing 2202b. In the illustrated embodiment, the first bearing 2202a and the second bearing 2202b are stacked on top of each other, and the shaft of each follower pin 2112a, 2112b extends through the first bearing 2202a and the second bearing 2202b. The first bearing 2202a can be configured to rotate with the articulated cylinder 2108 and be pushed from the moving pins 2112a and 2112b across the cam profiles 2110a and 2110b respectively, pressing against the inner walls of the cam profiles 2110a and 2110b, thus reducing friction. The second bearing 2202b can be configured to press against the corresponding torque articulated rods 2116a and 2116b. Figures 21A to 21B The slot 2120 in ) Figures 21A to 21B On the inner wall of the joint, to prevent the driven pins 2112a and 2112b from rotating and moving as the joint movement cylinder 2108 rotates.

[0216] The articulated cylinder 2108 has a first end 2204a and a second end 2204b, and the driven gear 2106 may be defined or otherwise disposed at or near the first end 2204a, but may alternatively be disposed at or near the second end 2204b, or at any other location between the first end 2204a and the second end 2204b. When the actuation activation mechanism 2104 is activated, the drive gear 1806 drives the driven gear 2106, thereby causing the articulated cylinder 2108 to rotate about the longitudinal axis A1. As the articulated cylinder 2108 rotates, the driven pins 2112a and 2112b are pushed along the longitudinal axis A1 in collinear but opposite axial directions, so that they traverse the cam profiles 2110a and 2110b respectively, and correspondingly push the interconnected carriers 2114a and 2114b. As the carriers 2114a and 2114b move axially, the interconnected drive components 1816a and 1816b move simultaneously in the same direction, thereby causing the end effector 1604 ( Figure 16 and Figure 19 Perform joint movements as described above.

[0217] In some embodiments, cam profiles 2110a, 2110b may include straight grooves extending at a constant angle but in opposite angular directions around the circumference of the articulated cylinder 2108. For example, if the first cam profile 2110a extends at a positive angle (e.g., 15° or 75°) relative to the longitudinal axis A1, the second cam profile 2110b will extend at an equal but opposite negative angle (e.g., -15° or -75°) relative to the longitudinal axis A1. In embodiments where cam profiles 2110a, 2110b are straight, at the end actuator 1604 ( Figure 16 and Figure 19 During the joint movement of the cams, the movement and force applied to the carriers 2114a, 2114b and the drive members 1816a, 1816b will be constant. In such embodiments, the cam profiles 2110a, 2110b can be characterized as helical cam grooves, and the follower pins 2112a, 2112b can be characterized as linear cam followers.

[0218] However, in other embodiments, one or both of the cam profiles 2110a, 2110b may not be perfectly straight, but may instead deviate at one or more inflection points along the length (path) of the cam profiles 2110a, 2110b. More specifically, depending on the direction at the inflection point, the cam profiles 2110a, 2110b may deviate from a straight line and define a sharper or gentler path 2206 (shown in dashed lines). Higher or lower angles of the cam profiles 2110a, 2110b will alter the mechanical advantages gained as the driven pins 2112a, 2112b traverse the cam profiles 2110a, 2110b respectively and act on the interconnected carriers 2114a, 2114b. This also demonstrates its ability to make the system easier to reverse drive and to allow the end effector 1604 (in the event of a power outage) to operate. Figure 16 and Figure 19 Returning to a position aligned with the longitudinal axis A1 is advantageous.

[0219] In some embodiments, the ends of cam profiles 2110a, 2110b may be characterized or otherwise operated to be responsive to the instrument actuator 1702. Figures 17A to 17B The physical stops are detected by various input torque sensors associated with the cam profiles 2110a, 2110b. In other embodiments, the ends of the cam profiles 2110a, 2110b may be position-controlled, which would provide additional travel distance to compensate for tolerances and thus minimize mechanical damage in the event of slight overshoot (e.g., without load accumulation).

[0220] Figure 23This is a cross-sectional side view of the bracket 2100. As shown, the first carrier 2114a and the second carrier 2114b are radially inserted between the inner grounding shaft 1810 and the articulated cylinder 2108, as described above. Furthermore, the first carrier 2114a is operatively connected to or otherwise engages with the first drive member 1816a, and the second carrier 2114b is operatively connected to or otherwise engages with the second drive member 1816b. Moving pins 2112a and 2112b extend through slots 2120 in the articulated torque rods 2116a and 2116b, respectively, and through corresponding cam profiles 2110a and 2110b, to engage with the associated carriers 2114a and 2114b. In some embodiments, the driven pins 2112a, 2112b may be threaded to the corresponding carriers 2114a, 2114b, but may alternatively be secured to the carriers 2114a, 2114b in other ways, such as by interference (shrinkage) fit, welding, adhesive, snap-fit, or any combination thereof. In other embodiments, without departing from the scope of this disclosure, the driven pins 2112a, 2112b may simply be received in the corresponding holes defined in the carriers 2114a, 2114b, and may not necessarily be secured to the carriers.

[0221] As shown in the figure, the first bearing 2202a presses against the inner wall of the corresponding cam profiles 2110a, 2110b, and the second bearing 2202b can press against the inner wall of the slot 2120 defined in the corresponding torque joint movement rods 2116a, 2116b. Placing the heads of the follower pins 2112a, 2112b in the slot 2120 helps ensure that all movements of the interconnected carriers 2114a, 2114b are linear rather than rotational as the follower pins 2112a, 2112b traverse the cam profiles 2110a, 2110b respectively. Therefore, to eliminate lateral torsion of the follower pins 2112a, 2112b, the follower pins 2112a, 2112b are received within the slot 2120, which restricts the rotational movement of the follower pins 2112a, 2112b.

[0222] When the actuator activating mechanism 2104 is activated, the drive gear 1806 ( Figures 21A to 21B , Figures 22A to 22BThe driven gear 2106 is driven, causing the articulated cylinder 2108 to rotate about the longitudinal axis A1. As the articulated cylinder 2108 rotates, the driven pins 2112a and 2112b are pushed across the cam profiles 2110a and 2110b respectively along the longitudinal axis A1 in collinear but opposite axial directions, and are pushed against the corresponding carriers 2114a and 2114b due to the cam profiles 2110a and 2110b at opposite angles. Depending on the rotation direction of the drive gear 1806, the carriers 2114a and 2114b can move axially closer to or further away from each other.

[0223] The opposite axial movement of the first carrier 2114a and the second carrier 2114b relative to the inner grounding shaft 1810 correspondingly causes the drive members 1816a and 1816b to move in the same opposite axial direction, thereby causing the end effector 1604 ( Figure 16 and Figure 17B The end effector 1604 performs articulation in a first direction as the carriers 2114a and 2114b move axially toward each other. In at least one embodiment, the first carrier 2114a and the second carrier 2114b operate in opposition to each other, such that one of the carriers 2114a and 2114b pulls one of the drive members 1816a and 1816b proximally, while the other carrier 2114a and 2114b similarly pushes the other drive member 1816a and 1816b distally. As the carriers 2114a and 2114b are axially pulled toward each other, the end effector 1604 will perform articulation in a first direction, and as the carriers 2114a and 2114b move axially away from each other, the end effector 1604 will perform articulation in a second direction opposite to the first direction.

[0224] Firing mechanism on translation system

[0225] Figure 24 yes Figure 16 Another enlarged isometric view of the bracket 1626 is provided, and an enlarged view of the third activation mechanism 1638c briefly described above is also provided. As described above, the third spline 1624c can be operatively coupled to the third activation mechanism 1638c, such that (via...) Figure 16 and Figure 17B The rotation of the fourth drive input 1636d causes the third spline 1624c to rotate, which in turn actuates the third activation mechanism 1638c, thereby causing the end effector 1604 ( Figure 16 , Figure 17B , Figure 19 The cutting element (blade) at the point is "fired". As described above, the "firing" end actuator 1604 refers to advancing or retracting the cutting element (blade) according to the rotation direction of the third spline 1624c.

[0226] As shown, the third spline 1624c extends longitudinally through a coaxial alignment hole 2402 defined in the fourth layer 1628d and the fifth layer 1628e of the bracket 1626. A drive gear 2404 can be coupled to the third spline 1624c and is configured to rotate with the third spline 1624c. As shown, the drive gear 2404 can be located between adjacent portions of the fourth layer 1628d and the fifth layer 1628e. In some embodiments, the drive gear 2404 may comprise a separate component disposed around the third spline 1624c and capable of translating (sliding) along the third spline 1624c as the bracket 1626 moves along the longitudinal axis A1. However, in other embodiments, the third spline 1624c may be shaped as the drive gear 2404 and otherwise configured to operate as a drive gear, advantageously reducing the number of components.

[0227] The drive gear 2404 can be configured to drive the input gear 2406, which is also mounted to the bracket 1626 and forms part of the third activation mechanism 1638c. In some embodiments, the drive gear 2404 can be positioned to directly mesh with the input gear 2406, thereby directly driving the input gear 2406 as the third spline 1624c rotates. However, in other embodiments, an idler gear 2408 can be inserted between the drive gear 2404 and the input gear 2406, and torque can otherwise be transmitted from the drive gear 2404 to the input gear 2406 via a meshing transmission mechanism.

[0228] Figure 25 This is an enlarged view of the proximal end of bracket 1626 and the third activation mechanism 1638c. Figure 25 Various components of the bracket 1626, such as the fifth layer 1628e, are omitted to allow for a more comprehensive view of the third activation mechanism 1638c. As shown, the drive gear 2404 is coupled to or forms part of the third spline 1624c and meshes with the idler gear 2408, which correspondingly meshes with the input gear 2406. However, in other embodiments, without departing from the scope of this disclosure, the drive gear 2404 may alternatively be directly coupled to and drive the input gear 2406.

[0229] As described in more detail below, the input gear 2406 can be rotatably secured to the bracket 1626 using a channel retainer 2502 (partially visible only), and the channel retainer 2502 can be axially secured to the bracket 1626 using a locking mechanism 2504. In the illustrated embodiment, the locking mechanism 2504 is depicted as a C-ring or an E-ring, but may alternatively include any other means or mechanism capable of axially securing the channel retainer 2502 to the bracket 1626.

[0230] The third activation mechanism 1638c also includes a firing lever 2506 capable of extending longitudinally through the bracket 1626. In at least one embodiment, as shown, the firing lever 2506 may also extend at least partially through the input gear 2406. The firing lever 2506 extends along the longitudinal axis A1 ( Figure 24 ) Towards end effector 1604 ( Figure 16 , Figure 17B , Figure 19 The firing lever 2506 extends and is operatively coupled to the cutting element (blade) such that longitudinal movement of the firing lever 2506 correspondingly moves the blade in the same direction. In some embodiments, the firing lever 2506 extends to the end effector 1604 and is directly coupled to the blade. However, in other embodiments, the firing lever 2506 is coupled to a firing member (not shown) at a point between the bracket 1626 and the end effector 1604, and the firing member extends to the end effector 1604 to be directly coupled to the blade. In either case, actuation of the third activation mechanism 1638c causes the blade to "fire," i.e., advance or retract, depending on the rotation direction of the third spline 1624c.

[0231] Figure 26 This is an isometric cross-sectional side view of the third activation mechanism 1638c according to one or more embodiments. As shown, the drive gear 2404 meshes with the idler gear 2408, which in turn meshes with the input gear 2406. Alternatively, as described above, the drive gear 2404 may mesh directly with the input gear 2406.

[0232] The input gear 2406 may include, or may otherwise be coupled to, an elongated cylindrical body 2602 having a first end or "distal" end 2604a and a second end or "proximal" end 2604b opposite the first end 2604a. As shown, the input gear 2406 is located at or near the second end 2604b. The elongated cylindrical body 2602 extends distally from the input gear 2406 within a shaft 1602, and more specifically, within an inner grounding shaft 1810 at least partially disposed within a closed tube 1812. A channel retainer 2502 also extends within the inner grounding shaft 1810 and helps to rotatably secure the input gear 2406 and the elongated cylindrical body 2602 to a bracket 1626. As shown, the channel retainer 2502 may include a cylindrical member sized to accommodate the elongated cylindrical body 2602 within it. The channel retainer 2502 can be axially secured to the bracket 1626 by means of a locking mechanism 2504, which can be received in a groove 2606 defined on the proximal end of the channel retainer 2502.

[0233] The channel retainer 2502 may provide or otherwise define an inner radial shoulder 2608 configured to engage a first end 2604a of the elongated cylindrical body 2602, thereby preventing distal movement of the elongated cylindrical body 2602. At a second end 2604b of the elongated cylindrical body 2602, the channel retainer 2502 presses against one axial side (i.e., the distal end) of the input gear 2406, while one or more thrust bearings 2610 (three shown) press against the opposite axial side (i.e., the proximal end) of the input gear 2406. In one or more embodiments, the thrust bearings 2610 may be received within a recess 2611 defined in the fifth layer 1628e and secured in place as the fifth layer 1628e is coupled to the fourth layer 1628d. Therefore, the input gear 2406 is axially fixed in the appropriate position between the channel retainer 2502 and the thrust bearing 2610, but is simultaneously allowed to rotate about the longitudinal axis A1. The thrust bearing 2610 can be configured to withstand the axial load on the input gear 2406 when the third activation mechanism 1638c is actuated. The thrust bearing 2610 also proves advantageous in reducing the rotational friction of the input gear 2406 when the firing lever 2506 is driven (fired).

[0234] Some or all of the firing levers 2506 may be provided with or otherwise defined by external threads 2612, which are configured to engage threadedly with internal threads 2614 located at or near the first end 2604a of the elongated cylindrical body 2602. In exemplary operation of the third activation mechanism 1638c, the third spline 1624c rotates (via...) Figure 16 and Figure 17B The rotation of the fourth drive input 1636d and the corresponding rotation of the drive gear 2404 drive the input gear 2406 (directly or via the idler gear 2408). Rotation of the input gear 2406 correspondingly rotates the elongated cylindrical body 2602 in the same angular direction, causing the internal thread 2614 of the drive body 2602 to press against the external thread 2612 of the firing rod 2506, thereby advancing or retracting the firing linkage 2506 along the longitudinal axis A1, as indicated by arrow D. The longitudinal movement of the firing rod 2506 correspondingly moves the blade at the end effector 1604 in the same direction (…). Figure 16 , Figure 17B , Figure 19 ).

[0235] See Figure 27 See also Figure 26 An enlarged cross-sectional view of an end effector 1604 according to one or more embodiments is shown. As described above, the end effector 1604 includes opposing jaws 1610, 1612 movable between an open position and a closed position, and... Figure 27 The jaws 1610 and 1612 are depicted in the open position. The end effector 1604 may also include a blade 2702 that can linearly displace within a slot 1616 defined in the second jaw 1610 to cut tissue gripped between the jaws 1610 and 1612. As the blade 2702 advances distally within the slot 1616, a slider or cam wedge 2704 simultaneously engages a plurality of staples (not shown) contained within the first jaw 1610 (e.g., within a staple cartridge), and pushes (cam movement) the staples into deformable contact with opposing anvil surfaces (e.g., recesses) disposed on the second jaw 1612. Properly deployed staples help seal opposite sides of the transversely cut tissue.

[0236] As shown in the figure, the blade 2702 is operably coupled to extending towards the proximal side (i.e., in...). Figure 27 The firing lever 2706 (on the right side) is operatively connected at its proximal end to Figures 25 to 26 The firing member 2506. However, in other embodiments, without departing from the scope of this disclosure, the blade 2702 may be directly coupled to the firing lever 2506. As described above, actuation of the firing lever 2506 causes the firing member 2706 to advance and retract, and correspondingly causes the blade 2702 to advance and retract, such that the blade can cut across the tissue gripped between the jaws 1610, 1612. As described above, distal movement of the firing member 2706 also correspondingly moves the cam wedge 2704 to deploy the pin.

[0237] In some implementations, the firing lever 2506 ( Figures 25 to 26 Movement along the distal direction can also cause jaws 1610, 1612 to close. More specifically, in one or more embodiments, lever 2506 (or firing member 2706) or blade 2702 may include features or structures (not shown) configured to engage anvil 2708 disposed on the upper jaw 1612. In such embodiments, as the firing lever 2506 advances distally, this feature or structure will axially engage the angled surface of the anvil 2708 and force the second jaw 1612 to close. This method is often referred to as "blade-based" closure, and in such embodiments, jaws 1610, 1612 may be spring-biased to the open position when blade 2702 is fully retracted. However, in other embodiments, as the firing lever 2506 advances distally, closing tube 1812 ( Figure 26 The jaws can be advanced simultaneously in the same direction to engage the anvil 2708 and force the second jaw 1612 to close. This method is often referred to as "tube-based" closure.

[0238] Clamping mechanism on translation system

[0239] Figure 28A yes Figure 16An enlarged isometric view of another embodiment of the bracket 1626 is provided, and an enlarged view of at least one embodiment of the first activation mechanism 1638a briefly described above is also provided. As described herein, the first activation mechanism 1638a can be actuated or otherwise activated to engage the end effector 1604 ( Figure 16 and Figure 17B Open or close the jaws of clamps 1610 and 1612 at the location. Figure 16 and Figure 17B More specifically, the first spline 1624a can be operatively coupled to the first activation mechanism 1638a, such that (via...) Figure 16 and Figure 17B The rotation of the second drive input 1636b causes the first spline 1624a to rotate, which in turn actuates the first activation mechanism 1638a, thereby opening or closing the jaws 1610 and 1612 according to the rotation direction of the first spline 1624a.

[0240] As shown, a first spindle 1624a extends longitudinally through a coaxial alignment hole 2802 (only one visible) defined in the first layer 1628a and the second layer 1628b of the bracket 1626. A drive gear 2804 may be included together with the first spindle 1624a and located between adjacent portions of the first layer 1628a and the second layer 1628b. The first spindle 1624a may have a cross-sectional shape capable of engaging with a corresponding internal shape of the drive gear 2804, such that rotation of the first spindle 1624a correspondingly drives rotation of the drive gear 2804. In some embodiments, the drive gear 2804 may include a separate component slidably disposed around the outer surface of the first spindle 1624a. In such embodiments, as the bracket 1626 travels along the longitudinal axis A1 ( Figure 16 As the carrier 1626 moves back and forth on the first spindle 1624a, the drive gear 2804 will correspondingly move along the length of the first spindle 1624a, as if trapped between the first layer 1628a and the second layer 1628b. In such embodiments, the hole 2802 may include or otherwise define a bearing surface (e.g., between the face of the drive gear 2804 and layers 1628a, 1628b and / or between the outer diameter collar of the drive gear 2804 and the inner diameter of the hole 2820) to help reduce friction as the carrier 1626 moves back and forth on the first spindle 1624a. However, in other embodiments, the first spindle 1624a may be shaped as a drive gear and otherwise configured to operate as a drive gear. In such embodiments, the drive gear 2804 may be omitted to advantageously reduce the number of components.

[0241] The first activation mechanism 1638a may include a driven gear 2806, and a drive gear 2804 may be positioned on the bracket 1626 to engage with or otherwise mesh with the driven gear 2806. However, in other embodiments, one or more intermediate gears (e.g., idler gears) may be inserted between the drive gear 2804 and the driven gear 2806. Thus, as the first spline 1624a rotates, the drive gear 2804 is able to drive the driven gear 2806 to rotate, thereby actuating the first activation mechanism 1638a. As shown, the driven gear 2806 may also be located between adjacent portions of the first layer 1628a and the second layer 1628b of the bracket 1626.

[0242] The first activation mechanism 1638a may further include a key 2808 (shown in dashed lines) disposed or otherwise defined on the outer surface of the shaft 1602, and more specifically on the outer surface of the closed tube 1812 of the shaft 1602. The key 2808 may be received within a slot 2810 defined in a bracket 1626, and more specifically in the first layer 1628a. In the illustrated embodiment, the key 2808 is depicted as an elongated member or protrusion, and the slot 2810 may be defined with an opening sized to receive the key 2808. Actuation of the first activation mechanism 1638a causes the closed tube 1812 to translate along the longitudinal axis A1, which correspondingly causes the key 2808 to translate longitudinally within the slot 2810. With the key 2808 housed within the slot 2810, rotation of the closing tube 1812 is prevented during longitudinal movement of the closing tube 1812 caused by the actuation of the first activation mechanism 1638a.

[0243] Figure 28B This is an enlarged isometric view of the first activation mechanism 1638a according to one or more embodiments. Figure 28B Various components of the bracket 1626, including the first layer 1626a and the second layer 1626b, are omitted. Figure 28A This allows for a more comprehensive view of the first activation mechanism 1638a. As shown, the driven gear 2806 may include an annular structure extending around a closed tube 1812 surrounding the shaft 1602, and a key 2808 is depicted as being coupled to or otherwise defined on the outer surface of the closed tube 1812. Furthermore, when the first spline 1624a rotates, the gear teeth of the driven gear 2806 mesh with the gear teeth of the drive gear 2804, enabling the drive gear 2804 to rotate the driven gear 2806.

[0244] The first activation mechanism 1638a may further include a carrier 2812 disposed at the proximal end of the closed tube 1812. The driven gear 2806 has an internal thread and is configured to engage threadedly with the external thread defined by the carrier 2812. Therefore, as the drive gear 2804 rotates, the driven gear 2806 rotates accordingly, causing the closed tube 1812 to rotate along the longitudinal axis A1 via the threaded engagement between the driven gear 2806 and the carrier 2812. Figure 28A The closed tube 1812 can be moved to the distal side (i.e., towards the direction of rotation of the drive gear 2804) according to the direction of rotation of the drive gear 2804. Figure 28B (to the left) or toward the near side (i.e., toward) Figure 28B (The right side of the middle) drive.

[0245] In some embodiments, the carrier 2812 may form an integral part of the closed tube 1812, thereby constituting the proximal end of the shaft 1602. In such embodiments, the proximal end of the shaft 1602 may be threaded to form the carrier 2812. However, in other embodiments, the carrier 2812 may include a separate component disposed at the proximal end of the closed tube 1812. In such embodiments, the carrier 2812 may be configured to receive the proximal end of the closed tube 1812 and may be radially inserted between a portion of the closed tube 1812 and the driven gear 2806. In either case, the carrier 2812 is positioned along the longitudinal axis A1 ( Figure 28A The movement of ) will correspondingly cause the closed tube 1812 to move in the same axial direction.

[0246] Figure 28C This is an isometric cross-sectional side view of the first activation mechanism 1638a according to one or more embodiments. In the illustrated embodiment, the carrier 2812 includes a separate component disposed at the proximal end 2814 of the closed tube 1812 and radially inserted between a portion of the closed tube 1812 and the driven gear 2806. In such embodiments, the carrier 2812 may define an inner radial shoulder 2816 capable of engaging with the proximal end 2814 of the closed tube 1812. However, as stated above, without departing from the scope of this disclosure, the carrier 2812 may alternatively form an integral portion of the closed tube 1812 at the proximal end 2814.

[0247] Driven gear 2806 defines an internal thread 2818a, which can engage with an external thread 2818b defined on the outer surface of carrier 2812. As driven gear 2806 is rotated about longitudinal axis A1, the threaded engagement between internal thread 2818a and external thread 2818b causes carrier 2812 to advance or retract axially along longitudinal axis A1, and correspondingly causes closed tube 1812 to advance or retract in the same axial direction. As carrier 2812 moves distally (i.e., in...) Figure 28C The inner radial shoulder 2816 presses against the proximal end 2814 of the closed tube 1812, thereby pushing the closed tube 1812 in the same distal direction. Pushing the closed tube 1812 distally forces the jaws 1610, 1612 ( Figure 16 and Figure 17B ) Closed, and towards the proximal side (i.e., in Figure 28C (From center to right) Retract the closed tube 1812 to allow jaws 1610 and 1612 to open.

[0248] In some embodiments, the pitch of the internal threads 2818a and external threads 2818b and / or the gear ratio between the drive gear 2804 and the driven gear 2806 can be varied or otherwise optimized to change the load and speed required to move the closure tube 1812. This can prove advantageous because jaw closure typically serves two functions: 1) gripping tissue for manipulation, which may require more precise movement (e.g., low load, speed control, precision, etc.), and 2) applying tissue compression requirements to transverse the tissue and form staples (e.g., high load). As fluid is expelled from the tissue, the speed of the final stage of compression is critical for tissue stability, and compression is optimized for suturing and transverse cutting. Therefore, the compression speed should be slow and slower than the general movement of jaw closure in air. Furthermore, as the closure tube 1812 advances or retracts, the key 2808 will slidably engage and be defined in the bracket 1626 ( Figure 28A The first layer 1628a Figure 28A The slot 2810 in ) Figure 28A This prevents the closed tube 1812 from rotating during longitudinal movement. This can be advantageous, as the first activation mechanism 1638a is actuated to allow only axial translation of the closed tube 1812.

[0249] See Figure 29 See also Figure 28C An enlarged view of an end effector 1604 and a wrist 1606 according to one or more embodiments is shown. As shown, the wrist 1606 may include a first or "proximal" connecting fork 2902a, a second or "distal" connecting fork 2902b, and a closing link 2904 configured to operably engage the proximal connecting fork 2902a and the distal connecting fork 2902b across the wrist 1606. The proximal connecting fork 2902a may be engaged to or otherwise form part of the distal end of the closing tube 1812, and the distal connecting fork 2902b may be engaged to or otherwise form part of the closing loop 2906.

[0250] As described above, axial movement of the closing tube 1812 along the longitudinal axis A1 correspondingly moves the proximal connecting fork 2902a in the same axial direction, and the closing link 2904 is configured to transmit an axial load through the wrist 1606 to close the jaws 1610, 1612 of the end effector 1604. More specifically, the closing link 2904 defines a pair of protrusions 2908 configured to engage with corresponding holes 2910 defined in each of the proximal connecting forks 2902a and the distal connecting fork 2902b. The closing link 2904 can transmit the closing load or translation of the closing tube 1812 from the distal connecting fork 2902b to the proximal connecting fork 2902a, and the closing ring 2906 will correspondingly push or pull the upper jaw 1612 to open or close the upper jaw 1612. To close the upper jaws 1612, the closing ring 2906 is forced against the shoulder 2912 located at or near the rear of the upper jaws 1612, which pushes the upper jaws 1612 downwards and into the closed position. To open the upper jaws 1612, the closing ring 2906 retracts proximally by retracting the closing tube 1812, and the closing ring 2906 helps pull the upper jaws 1612 back toward the open position. Alternatively, the upper jaws 1612 may be spring-loaded and biased to the open position, and the retraction of the closing ring 2906 removes the load on the shoulder 2912, which allows the spring force to move the upper jaws 1612 to the open position.

[0251] Figure 30A It is based on one or more additional implementation schemes. Figures 21A to 21B An enlarged isometric top view of the bracket 2100. In the illustrated embodiment, the bracket 2100 includes components similar in some respects to... Figures 28A to 28C The activation mechanism 3002 of the first activation mechanism 1638a. Similar to, for example, the first activation mechanism 1638a, the activation mechanism 3002 can be actuated by rotation of the first spline 1624a and is operable to open or close the end actuator 1604. Figure 16 , Figure 17B and Figure 29 ) jaws 1610, 1612 ( Figure 16 , Figure 17B and Figure 29 More specifically, the first spline 1624a can be operatively coupled to the activation mechanism 3002, such that (e.g., via...) Figure 16 and Figure 17B The rotation of the second drive input 1636b causes the first spline 1624a to rotate, which in turn actuates the activation mechanism 3002, thereby causing the closed tube 1812 of the shaft 1602 to advance or retract along the longitudinal axis A1.

[0252] The activation mechanism 3002 includes a driven gear 3004, and the drive gear 2804 of the first spline 1624a can be positioned to mesh with the driven gear 3004, such that rotation of the drive gear 2804 will correspondingly cause the driven gear 3004 to rotate in the same direction. As shown, the driven gear 3004 can be coupled to the closed cylinder 3006 or otherwise form part of the closed cylinder. As the spline 1624b rotates, the drive gear 2804 drives the driven gear 3004 and causes the closed cylinder 3006 to rotate about the longitudinal axis A1.

[0253] The closing cylinder 3006 can be positioned between the first layer 2102a and the second layer 2102b in the bracket 2100. One or more thrust bearings can be arranged at one or both axial ends of the closing cylinder 3006 to help bear the axial load on the closing cylinder 3006 when the activation mechanism 3002 is operated. In the illustrated embodiment, one or more first thrust bearings 3008a (one shown) are arranged at the distal end of the closing cylinder 3006 and can be inserted between the closing cylinder 3006 and the first layer 2102a. In one or more embodiments, without departing from the scope of this disclosure, one or more additional thrust bearings (not shown) can be arranged at the proximal end of the closing cylinder 3006 and inserted between the closing cylinder 3006 and a portion of the second layer 2102b. As the closing cylinder 3006 rotates, the thrust bearings 3008a can prove advantageous in reducing rotational friction.

[0254] The activation mechanism 3002 may also include a key 2808 (shown in dashed lines) disposed or otherwise defined on the outer surface of the closed tube 1812. The key 2808 may be received within a slot 3010 defined in the first layer 2102a of the bracket 2100. Actuating the activation mechanism 3002 causes the closed tube 1812 to translate along the longitudinal axis A1, which correspondingly causes the key 2808 to translate longitudinally within the slot 3010, thereby helping to prevent the closed tube 1812 from rotating during the longitudinal movement of the closed tube 1812.

[0255] Figure 30B This is an enlarged isometric view of the activation mechanism 3002 according to one or more embodiments. Figure 30B Various components of the bracket 2100, such as the first layer 2102a, are omitted. Figure 30A This allows for a more comprehensive view of the various components of the activation mechanism 3002. As shown, the closing cylinder 3006 may include a generally cylindrical structure extending around the shaft 1602 and more specifically around the closing tube 1812. The closing cylinder 3006 defines or otherwise provides one or more cam grooves or profiles, in Figure 30BThe diagram shows a first cam profile 3014a and a second cam profile 3014b. Each cam profile 3014a, 3014b extends a distance around the circumference of the closed cylinder 3006 (e.g., in a generally spiral pattern). Although the closed cylinder 3006 provides two cam profiles 3014a, 3014b, it is contemplated herein to include only one cam profile without departing from the scope of this disclosure.

[0256] As shown, the activation mechanism 3002 also includes a first follower pin 3016a and a second follower pin 3016b. The first follower pin 3016a and the second follower pin 3016b extend through the first cam profile 3014a and the second cam profile 3014b, respectively, and are operatively coupled (directly or indirectly) to the proximal end of the closing tube 1812. In an illustrated embodiment, the first follower pin 3016a and the second follower pin 3016b are each coupled to a carrier 3018 disposed at the proximal end of the closing tube 1812. In some embodiments, the carrier 3018 may form an integral part of the closing tube 1812, thereby constituting the proximal end of the closing tube 1812. However, in other embodiments, the carrier 3018 may include a separate component disposed at the proximal end of the closing tube 1812. In such embodiments, the carrier 3018 may be configured to receive the proximal end of the closing tube 1812 and may be radially inserted between a portion of the closing tube 1812 and the closing cylinder 3006. In either case, the movement of the carrier 3018 along the longitudinal axis A1 will correspondingly cause the closed tube 1812 to move in the same axial direction.

[0257] As the drive gear 2804 drives the driven gear 3004, the closing cylinder 3006 rotates correspondingly around the longitudinal axis A1, thus pushing the driven pins 3016a and 3016b across the cam profiles 3014a and 3014b respectively. As the driven pins 3016a and 3016b cross the cam profiles 3014a and 3014b, the carrier 3018 moves along the longitudinal axis A1 and the closing tube 1812 is pushed in the same axial direction. Depending on the rotation direction of the drive gear 2804, the carrier 3018 and the closing tube 1812 can move towards the distal side (i.e., in...). Figure 30B (From the center to the left) or towards the near side (i.e., in) Figure 30B Move from center to right, thereby causing end effector 1604 ( Figure 16 , Figure 17B and Figure 29 ) jaws 1610, 1612 ( Figure 16 , Figure 17B and Figure 29 (To close or open)

[0258] In some embodiments, as shown in the figures, one or both of the follower pins 3016a, 3016b may include one or more bearings 3020 (one visible), and the shaft of each follower pin 3016a, 3016b extends through the bearing 3020. The bearing 3020 may be configured to rotate with the closed cylinder 3006 and press against the inner walls of the cam profiles 3014a, 3014b, respectively, across the cam profiles 3014a, 3014b. The bearing 3020 helps reduce friction during actuation. Alternatively or additionally, one or both of the follower pins 3016a, 3016b may have a surface finish or include a friction-reducing coating. For example, in at least one embodiment, one or both of the follower pins 3016a, 3016b may be coated with a lubricant or lubricating material, such as polytetrafluoroethylene (PTFE) or... ) or ultra-high molecular weight (UMHL) polymers.

[0259] Figure 30C This is a cross-sectional side view of a portion of the bracket 2100 and the activation mechanism 3002. As shown, the closing cylinder 3006 is positioned between the first layer 2102a and the second layer 2102b. A first thrust bearing 3008a is arranged at the distal end of the closing cylinder 3006 and inserted between the closing cylinder 3006 and the first layer 2102a, and one or more second thrust bearings 3008b (one shown) may be arranged at the proximal end of the closing cylinder 3006 and inserted between the closing cylinder 3006 and a portion of the second layer 2102b. The thrust bearings 3008a and 3008b help to bear the axial load of the closing cylinder 3006 when it rotates and reduce rotational friction.

[0260] In the illustrated embodiment, the carrier 3018 includes a separate component disposed at the proximal end 3022 of the closed tube 1812 and radially inserted between a portion of the closed tube 1812 and the closed sleeve 3006. In such embodiments, the carrier 3018 may define an inner radial shoulder 3024 capable of engaging with the proximal end 3022 of the closed tube 1812. However, as described above, the carrier 3028 may alternatively form an integral portion of the closed tube 1812 at the proximal end 3022.

[0261] Follower pins 3016a and 3016b extend through corresponding cam profiles 3014a and 3014b, respectively, to engage with carrier 3018. In some embodiments, follower pins 3016a and 3016b may be threaded to the corresponding carrier 3018, but may alternatively be secured to carrier 3018 by other means, such as interference (shrink) fit, welding, adhesive, snap-fit, or any combination thereof. In other embodiments, without departing from the scope of this disclosure, follower pins 3016a and 3016b may simply be received in corresponding holes defined in carrier 3018, and not necessarily secured to the carrier. As shown, bearing 3020 can press against the inner walls of the corresponding cam profiles 3014a and 3014b.

[0262] When the actuator activates mechanism 3002, the drive gear 2804 ( Figures 30A to 30B The driven gear 3004 drives the closed cylinder 3006 to rotate about the longitudinal axis A1. As the closed cylinder 3006 rotates, the driven pins 3016a and 3016b traverse the cam profiles 3014a and 3014b respectively, and correspondingly push the carrier 3018 and the closed tube 1812 to move axially along the longitudinal axis A1. Depending on the rotation direction of the drive gear 2804, the carrier 3018 and the closed tube 1812 can move to the distal side (i.e., in...). Figure 30C (From the center to the left) or towards the near side (i.e., in) Figure 30C Move from center to right, thereby causing end effector 1604 ( Figure 16 , Figure 17B and Figure 29 ) jaws 1610, 1612 ( Figure 16 , Figure 17B and Figure 29 The closure tube 1812 can be opened or closed. Furthermore, as the closure tube 1812 advances or retracts, the key 2808 will slidably engage the slot 3010 defined in the first layer 2102a of the bracket 2100, thereby preventing rotation of the closure tube 1812. This advantageously prevents rotation of the closure tube 1812 when the activation mechanism 3002 is actuated, and only allows axial translation of the closure tube 1812.

[0263] Figure 31 This is an isometric view of an exemplary embodiment of the closed cylinder 3006 according to one or more embodiments. Each cam profile 3014a, 3014b may include a slot extending generally helically around a portion of the circumference of the closed cylinder 3006. Thus, the cam profiles 3014a, 3014b can be characterized as helical cam slots, and the follower pins 3016a, 3016b can be characterized as linear cam followers. The cam profiles 3014a, 3014b can demonstrate their ability to facilitate reverse driving of the system and manual opening or closing of jaws 1610, 1612 as needed. Figure 16, Figure 17B and Figure 29 This is advantageous in that respect.

[0264] In some embodiments, each cam profile 3014a, 3014b may include a straight groove extending helically at a constant angle or slope around the circumference of the closed tube 3006. In such embodiments, it is applied to the carrier 3018 and converted into a closed tube 1812 ( Figures 30A to 30C The movement of axial load and force on the activation mechanism 3002 ( Figures 30A to 30C The actuation period will be constant.

[0265] However, in other embodiments, one or both of the cam profiles 3014a, 3014b may not be perfectly straight, but may instead deviate at one or more inflection points 3102 along the helical length (path) of the cam profiles 3014a, 3014b. More specifically, at inflection points 3102, the cam profiles 3014a, 3014b may change from extending a first distance around the circumference of the closed cylinder 3006 with a first slope 3104a to extending a second distance with a second slope 3104b, wherein the second slope 3104b includes a path that is sharper or gentler than the first slope 3104a. Higher or lower angles or slopes of the cam profiles 3014a, 3014b will correspondingly alter the mechanical advantages gained as the moving pins 3016a, 3016b traverse the cam profiles 3014a, 3014b and act on the interconnected carrier 3018. This can result in a higher axial load being applied to the closed tube 1812. Figures 30A to 30B This allows for jaws 1610 and 1612 ( Figure 16 , Figure 17B and Figure 29 The jaws clamp with increased force when needed. More specifically, and as described above, the jaw closure is used to grasp tissue for manipulation, which may require more precise movements and apply compressive force to the tissue, requiring a higher load. Varying slopes 3104a, 3104b can help the jaws 1610, 1612 operate more effectively, as needed.

[0266] Translation via tool driver

[0267] Figure 32 yes Figure 16 Another enlarged isometric view of bracket 1626. See reference. Figure 16 The shaft 1602 discussed is coupled to the bracket 1626 and extends distally from the bracket, penetrating the drive housing 1614. Figure 16 The first end 1618a ( Figure 16 Furthermore, the bracket 1626 is capable of operating along the longitudinal axis A1 at the first end 1618a and the second end 1618b. Figure 16 The end actuator 1604 moves between the drive housing 1614 to advance or retract relative to the drive housing 1614. Figure 16 As indicated by arrow B (i.e., the z-axis is translated).

[0268] In one or more embodiments, as briefly discussed above, axial translation of the bracket 1626 can be achieved through the use of the lead screw 1622 and the bracket nut 1634 and their mechanical interaction. As shown, the bracket 1626 can be at least partially mounted to the lead screw 1622 by extending the lead screw 1622 through one or more portions of the bracket 1626, such as adjacent portions of the third layer 1628c and the fourth layer 1628d. In the illustrated embodiment, the lead screw 1622 extends through a coaxial alignment hole 3202 (only one shown) defined in the adjacent portions of the third layer 1628c and the fourth layer 1628d.

[0269] The bracket 1626 is configured to move back and forth along the axial length of the lead screw 1622 through mechanical interaction with the bracket nut 1634. More specifically, the outer surface of the lead screw 1622 defines a helical external thread, and the bracket nut 1634 defines a corresponding helical internal thread (not shown) that mates with the helical external thread of the lead screw 1622. The bracket nut 1634 is immovably fixed to the bracket 1626 such that rotation of the lead screw 1622 causes the bracket nut 1634 to convert the rotational force of the lead screw 1622 into an axial load applied to the bracket 1626. Therefore, the bracket nut 1634 is pressed against the helical external thread of the lead screw 1622 and moves back and forth, thereby advancing or retracting the bracket 1626 in direction B along the longitudinal axis A1. As the bracket 1626 moves along the longitudinal axis A1, the end effector 1604 ( Figure 16 Correspondingly, the bracket 1626 and the end effector 1604 can advance or retract relative to the drive housing 1614. Depending on the rotation direction of the lead screw 1622, the bracket 1626 and the end effector 1604 can move distally (i.e., towards) Figure 32 (to the left) or toward the near side (i.e., toward) Figure 32 (Move to the right of the middle)

[0270] In some embodiments, the helical external thread of the lead screw 1622 may be uniform (constant) along the entire length of the lead screw 1622. In such embodiments, the helical external thread is defined with a single common pitch between the two ends of the lead screw 1622. However, in other embodiments, the pitch of the helical external thread may vary along portions of the lead screw 1622. As shown, for example, a first portion 3204a of the lead screw 1622 may provide a helical external thread defined with a first pitch, while a second portion 3204b of the lead screw 1622 may provide a helical external thread defined with a second pitch different from the first pitch. In the illustrated embodiment, the second pitch defined on the second portion 3204b is sharper than the first pitch defined on the first portion 3204a. As a result, when the lead screw 1622 rotates at a constant speed, the bracket 1626 will move along the longitudinal axis A1 at a faster speed when moving back and forth on the second part 3204b compared to moving back and forth on the first part 3204a. This demonstrates its ability to allow the operator to advance the end effector (to the surgical site) more quickly along a selected portion of the lead screw 1622. Figure 16 This is advantageous in that respect.

[0271] The lead screw 1622 can be made of a variety of rigid materials, including but not limited to plastics (e.g., extruded polymers), metals (e.g., aluminum, stainless steel, brass, etc.), composite materials (e.g., carbon fiber, glass fiber, etc.) or any combination thereof. The lead screw 1622 may have a smooth surface finish or include a coating that reduces friction against the bracket nut 1634 when the bracket 1626 is under load (i.e., torsional or compressive load). For example, in at least one embodiment, the helical external thread of the lead screw 1622 may be coated with a lubricant or lubricating substance 3205, such as polytetrafluoroethylene (PTFE or...). (or may otherwise include anodized surfaces.)

[0272] In some embodiments, as shown, the bracket nut 1634 may include a separate component mounted to the lead screw 1622 and secured to the bracket 1626 (such as between adjacent portions of the third layer 1628c and the fourth layer 1628d). In such embodiments, the bracket nut 1634 may provide or otherwise define an anti-rotation feature 3206 capable of engaging with a corresponding feature 3208 defined on the bracket 1626. The anti-rotation feature 3206 may be configured to transfer a rotational load borne by the bracket nut 1634 to the bracket 1626 via rotation of the lead screw 1622. As a result, the rotational load may be converted into an axial load that helps move the bracket 1626 along the longitudinal axis A1. In an illustrated embodiment, the anti-rotation feature 3206 includes a flange, and the feature 3208 includes a recess or groove configured to receive the flange.

[0273] However, in other embodiments, the bracket nut 1634 may form an integral part of the bracket 1626. In such embodiments, one or both of the third layer 1628c and the fourth layer 1628d may function as the bracket nut 1634. More specifically, the bracket nut 1634 may be arranged within one or both of the coaxial alignment holes 3202, as indicated by the dashed box 3210. Alternatively, one or both of the coaxial alignment holes 3202 may have internal threads to engage with the helical external threads of the lead screw 1622. In such embodiments, rotation of the lead screw 1622 will correspondingly drive the bracket 1626 distally or proximally as it interacts threadedly with the threaded holes 3202.

[0274] Figure 33A and Figure 33B This is a relative isometric end view of a bracket nut 1634 according to one or more embodiments. As shown, the bracket nut 1634 provides a generally cylindrical body 3302 having a first end 3304a and a second end 3304b opposite to the first end 3304a. A central conduit 3306 may be defined in the body 3302 and extends between the first end 3304a and the second end 3304b. As shown, an internal helical thread 3308 may be defined on the inner wall of the central conduit 3306 and may be configured to interact with a guide screw 1622 ( Figure 32 The external helical thread on the ) is threaded.

[0275] In some embodiments, one or both of ends 3304a, 3304b may be provided or otherwise define an anti-rotation feature 3206, which is configured to prevent the bracket nut 1634 from rotating on the guide thread. Figure 32The anti-rotation feature 3206 rotates when moving back and forth on the bracket 1626. In the illustrated embodiment, the anti-rotation feature 3206 is provided at the second end 3304b, but it may alternatively be provided at the first end 3304a or both ends 3304a, 3304b. Once the anti-rotation feature 3206 is received in the bracket 1626, it rotates when moving back and forth on the bracket 1626. Figure 32 The corresponding feature part 3208 on ) Figure 32 Within this space, the bracket nut 1634 will be prevented from rotating relative to the bracket 1626, which allows the rotational force from the lead screw 1622 to be transmitted to the bracket 1626 in the form of an axial load through the bracket nut 1634, causing the bracket 1626 to move axially.

[0276] Figure 34A and Figure 34B These are based on one or more implementation schemes. Figure 16 An isometric view of the first end 1618a and the second end 1618b of the drive housing 1614. A lead screw 1622 extends between the first end 1618a and the second end 1618b of the drive housing 1614 and is rotatably mounted to the first and second ends of the drive housing. More specifically, the first end or "distal" end 3402a of the lead screw 1622 ( Figure 34A ) can be rotatably mounted to the first end 1618a of the drive housing 1614, and the second end or "proximal" end 3402b of the lead screw 1622 ( Figure 34B It is rotatably mounted to the second end 1618b of the drive housing 1614. Each end 3402a, 3402b of the lead screw 1622 is axially supported at the first end 1618a and the second end 1618b, respectively, to help prevent (minimize) linear movement of the lead screw 1622 while allowing unrestricted rotational movement.

[0277] See Figure 34A The driven gear 3404 is disposed at the distal end 3402a of the lead screw 1622 or otherwise forms part of that distal end. The driven gear 3404 is arranged to mesh with a drive gear 3406 rotatably mounted at the first end 1618a of the drive housing 1614. The drive gear 3406 may form a first drive input element 1636a. Figure 16 and Figure 17B A portion of or may otherwise be operably coupled to the first drive input, such that rotation of the first drive input 1636a (via...) Figures 17A to 17BThe first drive output 1724a of the instrument actuator 1702 correspondingly rotates the driven gear 3404, which causes the lead screw 1622 to rotate. In other embodiments, the driven gear 3404 may be driven by a combination of a first drive input 1636a and at least one additional drive input (not shown). Additional drive inputs may be necessary if the torque is high and can be distributed between the two inputs. In at least one embodiment, instead of the arranged mutual meshing of gears, the first drive input 1636a may include a direct input to the lead screw 1622.

[0278] See Figure 34B The proximal end 3402b of the lead screw 1622 is rotatably mounted to the second end 1618a of the drive housing 1614. In some embodiments, one or more thrust bearings 3408 may be arranged at the proximal end 3402b of the lead screw 1622 to reduce rotational friction of the lead screw 1622 during its rotation.

[0279] Figure 35 It is based on one or more additional implementation schemes. Figure 16 Another example of a drive housing 1614. As shown, the drive housing 1614 includes a first end 1618a and a second end 1618b, and splines 1624a-c extending longitudinally between the first end 1618a and the second end 1618b. A bracket 1626 is movably mounted to the splines 1624a-c, and a shaft 1602 extends distally from the bracket 1626 through the first end 1618a of the drive housing 1614 and subsequently through a central bore 1708 of the instrument actuator 1702. The drive housing 1614 can be releasably coupled to the instrument actuator 1702 by extending the shaft 1602 through the central bore 1708 and engaging the drive interface 1716 of the instrument actuator 1702 with the driven interface 1718 of the drive housing 1614, as generally described above.

[0280] The bracket 1626 is movable along the longitudinal axis A1 between the first end 1618a and the second end 1618b, thereby enabling it to translate relative to the drive housing 1614 about the z-axis to advance or retract the end actuator 1604. Figure 16 and Figure 17BIn the illustrated embodiment, translation of the z-axis of the bracket 1626 can be achieved using a cylindrical lead screw 3502 forming part of the drive housing 1614. As shown, the cylindrical lead screw 3502 comprises a hollow cylinder exhibiting a generally circular cross-section. The cylindrical lead screw 3502 is operatively coupled to a first end 1618a of the drive housing 1614 and extends toward a second end 1618b. In some embodiments, as shown, the cylindrical lead screw 3502 stops before reaching the second end 1618b, but may alternatively terminate at the second end 1618b without departing from the scope of this disclosure.

[0281] A cylindrical lead screw 3502 defines an interior 3504, sized to receive splines 1624a-c and a bracket 1626. Furthermore, one or more cam channels or profiles 3506 (three shown) may be defined on the inner surface of the interior 3504 and configured to receive corresponding follower pins 3508 (two visible), which are provided or otherwise defined on the outer periphery of the bracket 1626. In some embodiments, the follower pins 3508 may include tabs or protrusions extending radially outward from the outer periphery of the bracket 1626. The cam profiles 3506 form a parallel helical path extending along all or a portion of the interior 3504, and the follower pins 3508 may be configured to traverse the cam profiles 3506, thereby allowing the bracket 1626 to translate about the z-axis. More specifically, the cylindrical lead screw 3502 can be configured to rotate relative to the bracket 1626 about the longitudinal axis A1, and as the cylindrical lead screw 3502 rotates, the follower pin 3508 will traverse the corresponding cam profile 3506. The helical shape of the cam profile 3506 pushes the bracket 1626 to move proximally or distally along the z-axis depending on the direction of rotation of the cylindrical lead screw 3502.

[0282] In the illustrated embodiment, the cylindrical lead screw 3502 can be rotated by actuation of a drive input associated with the drive housing 1614 and disposed in a first end 1618a. More specifically, the drive housing 1614 may include a fifth drive input 1636e capable of engaging with a fifth drive output 1724e of the instrument actuator 1702. Once properly engaged, the fifth drive input 1636e will share a rotation axis with the fifth drive output 1724e to allow rotational torque to be transmitted from the fifth drive output 1724e to the fifth drive input 1636e. A drive gear 3510 is rotatably mounted to the first end 1618a of the drive housing 1614 at a driven interface 1718. The drive gear 3510 may form part of the fifth drive input 1636e or may be otherwise operably coupled to the fifth drive input such that rotation of the fifth drive input 1636e causes rotation of the drive gear 3510 via the fifth drive output 1724e. The cylindrical lead screw 3502 includes a driven gear 3512 that meshes with the drive gear 3512, such that the rotation of the drive gear 3510 drives the driven gear 3510 accordingly, thereby causing the cylindrical lead screw 3502 to rotate about the longitudinal axis A1.

[0283] In some embodiments, as shown, the driven gear 3512 may include an annular gear defined on the outer surface of the cylindrical lead screw 3502. However, in other embodiments, without departing from the scope of this disclosure, the annular gear may alternatively be defined in the interior 3504, and the drive gear 3510 may be arranged to mesh with the driven gear 3512 within the interior 3504.

[0284] In some embodiments, the cam profile 3506 may be uniform (constant) along the axial length of the cylindrical lead screw 3502. In such embodiments, the cam profile 3506 will be defined between the two ends of the cylindrical lead screw 3502 with a single common pitch (slope). However, in other embodiments, the pitch of the cam profile 3506 may vary along the axial length of the cylindrical lead screw 3502. For example, a first portion of the cam profile 3506 may be defined with a first pitch, while a continuous second portion of the cam profile 3506 may be defined with a second pitch different from the first pitch. For example, the second pitch may be sharper than the first pitch. In such embodiments, without changing the angular velocity of the cylindrical lead screw 3502, the carriage 1626 will translate faster along the z-axis when moving back and forth at the second pitch compared to moving back and forth at the first pitch. It will be appreciated that this can be demonstrated to allow the operator to advance the end effector ( ) more quickly toward the surgical site along a portion of the cylindrical lead screw 3502. Figure 16This is advantageous in that respect. More specifically, at the end of the insertion and / or retraction stroke, profile 3506 can be designed (defined) to mechanically slow down the speed of bracket 1626 to prevent overtravel damage when it approaches the hard stop. Furthermore, at the end of the retraction stroke, profile 3506 can be designed (defined) to increase the speed of bracket 1626 to reduce shaft reversal time. This will correspondingly increase the shaft insertion time when extending the shaft.

[0285] In the illustrated embodiment, a cylindrical lead screw 3502 is disposed within a housing 1640 that extends between a first end 1618a and a second end 1618b of the drive housing 1614. However, in at least one embodiment, the housing 1640 may be omitted from the drive housing 1614. In other embodiments, the cylindrical lead screw 3502 and the housing 1640 may comprise the same structure. In such embodiments, without departing from the scope of this disclosure, a cam profile 3506 may be defined on the inner surface of the housing 1640, and the housing 1640 may be rotatable to facilitate translation along the z-axis of the bracket 1626.

[0286] While the cylindrical lead screw 3502 is described herein with reference to cam profile 3506 and follower pin 3508, it is contemplated herein that the cylindrical lead screw 3502 may alternatively include a ball screw system without departing from the scope of this disclosure. In such embodiments, the cylindrical lead screw 3502 may include a low-friction, ball-bearing-filled lead screw system.

[0287] Fixed roll insertion guide structure

[0288] Figure 36A It is based on one or more implementation schemes. Figure 17A and Figure 17B A perspective view of the instrument driver 1702, and Figure 36B It is releasably connected to the instrument driver 1702. Figure 16 An isometric view of the surgical tool 1600. As briefly discussed above, the instrument actuator 1702 is configured to attach a surgical tool (such as surgical tool 1600) to a surgical robotic arm (e.g., any of the robotic arms 104, 406 described herein). More specifically, the drive interface 1716 at the first end 1706a of the instrument actuator 1702 is compatible with the slave interface 1718 located at the first end 1618a of the drive housing 1614. Figure 17BThe end effector 1604 and the shaft 1602 can penetrate the instrument driver 1702 by extending through a central hole 1708 defined as longitudinally passing through the body 1704, and the alignment guide 1710 within the central hole 1708 helps to orient the surgical instrument 1600 at an angle to the proper orientation relative to the instrument driver 1702.

[0289] In some embodiments, the interlocking feature 1720 provided at the drive interface 1716 and the driven interface 1718 provided at the drive housing 1614 are connected together. Figure 17B Complementary pits 1722 on the surface Figure 17B The drive housing 1614 can be mechanically coupled to the instrument driver 1702. Furthermore, the instrument driver 1702 includes drive inputs 1636a-d that can interact with the drive housing 1614. Figure 17B The drive outputs 1724a-d are matched such that, once properly matched, the drive inputs 1636a-d will share the axis of rotation with the corresponding drive outputs 1724a-d, allowing rotational torque to be transmitted from the drive outputs 1724a-d to the corresponding drive inputs 1636a-d.

[0290] In the illustrated embodiment, the instrument actuator 1702 includes a base 3602 that provides a location for removably mounting the instrument actuator 1702 to the surgical robotic arm of the surgical robotic system. It will be appreciated that the base 3602 can be of various geometries and sizes to suitably mate with and mount to the robotic arm. Mechanical and electrical connections are provided from the robotic arm to the base 3602, and then to various mechanical and electronic components arranged within the instrument actuator 1702 to manipulate power and / or signals from the robotic arm and / or transmit them to the surgical instrument 1600. Signals may include signals of pneumatic pressure, electrical power, electrical signals, and / or optical signals.

[0291] As shown in the figure, the body 1704 of the instrument actuator 1702 provides an outer housing 3604 that can be securely attached to the base 3602. The outer housing 3604 extends generally between a first end 1706a and a second end 1706b of the instrument actuator 1702. In some embodiments, as shown, the outer housing 3604 may be generally cylindrical in shape. However, in other embodiments, the shape of the outer housing 3604 may vary depending on the application. The outer housing 3604 may be made of a variety of materials, including but not limited to metals, plastics, composite materials, or any combination thereof.

[0292] In some embodiments, the instrument actuator 1702 may further include sterile adapters 3606, 3608, which can be used to create a sterile boundary between the instrument actuator 1702 and the surgical instrument 1600. Sterile adapters 3606, 3608 include components located at opposite ends of the body 1704; the sterile adapter 3608 located at the first end 1706a is referred to as the "instrument sterile adapter," and the sterile adapter 3606 located at the second end 1706b is referred to as the "cannula sterile adapter." Sterile adapters 3606, 3608 may be configured to attach a surgical drape (not shown) to the instrument actuator 1702 when the surgical instrument 1600 is secured to the instrument actuator 1702, and the surgical drape operates to isolate the surgical instrument 1600 and the patient from the instrument actuator 1702 and the surgical robotic system. The sterile adapter 3606 may include two layers that rotate substantially with the surgical instrument 1600, and the surgical drape is positioned between these layers and does not roll with the sterile adapter 3606 and the surgical instrument 1600.

[0293] Drive interface 1716, interlocking feature 1720, and drive outputs 1724a-d are all contained within or otherwise mounted to tool drive assembly 3609, which is located at the first end 1706a of instrument actuator 1702 and partially extends into outer housing 3604. As described herein, tool drive assembly 3609 is rotatable about rotation axis 3610 independently of outer housing 3604. When surgical instrument 1600 is mounted to instrument actuator 1702 at tool drive assembly 3609, longitudinal axis A1 of surgical instrument 1600 is coaxially aligned with rotation axis 3610 of tool drive assembly 3609. According to embodiments of this disclosure, tool drive assembly 3609 can be actuated to rotate, thereby correspondingly causing the entire surgical instrument 1600 to rotate or “roll” about its longitudinal axis A1, as indicated by arrow 3612. Figure 36B Therefore, actuation of the tool drive assembly 3609 allows the entire surgical tool 1600, including the shaft 1602, end effector 1604, and drive housing 1614, to continuously roll about the longitudinal axis A1 relative to the stationary base 3602 and outer housing 3604 in either angular direction (i.e., clockwise or counterclockwise). Unlike other surgical tools where the shaft and end effector rotate independently of and relative to the rest of the surgical tool, the shaft 1602, end effector 1604, and drive housing 1614 are rotationally fixed, enabling the entire surgical tool 1600 to rotate as a single integral unit.

[0294] Figure 37A It is based on one or more implementation schemes. Figures 36A to 36BA schematic diagram of an exemplary embodiment of the instrument driver 1702. (Compared to...) Figures 36A to 36B The instrument actuator 1702 described in the text is different. Figure 37A The instrument driver 1702 includes five drive outputs 1724. Furthermore, in Figure 37A The driver interface 1716 is omitted in the text. Figure 36A This allows for observation of the internal components of the tool drive assembly 3609 and its rolling mechanism. As shown, the rolling mechanism includes a stator gear 3702 and a rotor gear 3704 that engages with the stator gear 3702, with each of the gears 3702 and 3704 positioned behind the drive interface 1716 (not shown). Actuation of the tool drive assembly 3609 causes the rotor gear 3704 to drive the stator gear 3702, thereby causing the tool drive assembly 3609 to continuously rotate or "roll" about the rotation axis 3610 in any angular direction.

[0295] More specifically, as shown in the figure, the stator gear 3702 may include an annular gear defining gear teeth along its inner circumference, and the rotor gear 3704 may include a circular gear positioned within the inner circumference of the stator gear 3702 and defining gear teeth along its outer circumference. The gear teeth of the stator gear 3702 have the same pitch as the gear teeth of the rotor gear 3704, allowing these gear teeth to mesh. Both gears 3702 and 3704 may be made of a rigid material, such as metal or hard plastic.

[0296] The stator gear 3702 is fixedly attached to the tool drive assembly 3609, and the rotor gear 3704 is actuable (rotatable) to cause the stator gear 3702 to rotate, which in turn causes the tool drive assembly 3609 to rotate accordingly, which includes a drive interface 1716. Figure 36A ), Interlocking Feature 1720 ( Figure 36A ), and drive output component 1724a-d ( Figure 36A More specifically, the rotor gear 3704 is coupled to a drive mechanism (e.g., a motor) housed within an outer housing 3604, which causes the rotor gear 3704 to rotate clockwise or counterclockwise as needed. The drive mechanism can receive signals from an integrated controller also arranged within the outer housing 3604. As the drive mechanism causes the rotor gear 3704 to rotate, the rotor gear 3704 travels along the gear teeth of the stator gear 3702, thereby causing the tool drive assembly 3609 to rotate. In this configuration, the rotor gear 3704 is capable of rotating continuously in either direction, thus allowing the tool drive assembly 3609 to roll infinitely about the axis of rotation 3610, thereby simultaneously causing the surgical tool 1600 ( Figure 36B Rotate or "roll".

[0297] Figure 37BIt is based on one or more implementation schemes. Figure 37A A cross-sectional side view of the tool actuator 1702. As shown, the tool actuator assembly 3609 is operatively coupled to or otherwise defines an inner catheter 3706 that defines a central aperture 1708, such that rotation of the tool actuator assembly 3609 simultaneously rotates the inner catheter 3706 in the same direction about a rotation axis 3610. As described above, the central aperture 1708 receives a surgical tool 16 ( Figure 36B Shaft 1602 ( Figure 36B This configuration allows the surgical tool 1600 to rotate or roll continuously in either direction about the axis of rotation 3610 with minimal or no constraint. One or more actuators 3708 (one shown), alternatively referred to as a “motor assembly”, are arranged around the inner catheter 3706 and are capable of rotating with the tool drive assembly 3609 as it rotates. The actuators 3708 are designed to drive the drive output 1724 to rotate. The tool drive assembly 3609 may also include a drive motor 3710 configured to drive the tool drive assembly 3609 to rotate within the outer housing 3604.

[0298] The tool drive assembly 3609 may also be provided with or otherwise include a plurality of bearings 3712. Each bearing 3712 includes a mechanical component configured to reduce friction between adjacent moving parts and to facilitate rotation about a rotation axis 3610. More specifically, the bearings 3712 allow the tool drive assembly 3609 to rotate about the rotation axis 3610 relative to an outer housing 3604, which typically remains stationary. As the tool drive assembly 3609 rotates within the outer housing 3604, one bearing 3712 is capable of individually supporting radial or torsional loads. In an illustrated embodiment, the instrument actuator 1702 includes at least two bearings 3712 that are fixedly attached to the tool drive assembly 3609 such that a plurality of components (such as balls or rollers) within the bearings 3712 contact the outer housing 3604. One of the bearings 3712 is disposed at or near a first end 1706a of the instrument actuator 1702, and the other bearing 3712 is disposed at or near a second end 1706b. This configuration improves the rigidity and support between the first and second ends of the tool drive assembly 3609 as it rotates within the outer housing 3604. Alternative embodiments may include additional bearings providing additional support along the length of the tool drive assembly 3609, such as along the length of the inner conduit 3706.

[0299] The tool drive assembly 3609 may also include a plurality of seals 3714 and gaskets 3716 configured to seal various surface interfaces to prevent fluid from entering the outer housing at a given interface. Seals 3714 may be disposed, for example, at various radial interfaces between the outer housing 3604 and the tool drive assembly 3609, and gaskets 3716 may be disposed at various axial interfaces between the outer housing 3604 and the tool drive assembly 3609. Seals 3714 and gaskets 3716 may be made of a highly elastomeric material (e.g., rubber). In some embodiments, one or more seals of seal 3714 may include, for example, O-rings, but may alternatively include any other suitable type of sealing element. It will be appreciated that this configuration and placement of seals 3714 and gaskets 3716 helps maintain the sterility of components within the instrument drive 1702 during surgical procedures.

[0300] Figure 37C A partial exploded perspective view of the internal mechanical and electronic components of an instrument actuator 1702 according to one or more embodiments is shown. The internal mechanical and electronic components of the instrument actuator 1702 include multiple actuators 3708, a drive motor 3710 (partially visible), a torque sensor (not shown), a torque sensor amplifier 3718, a slip ring 3720, multiple encoder boards 3722, multiple motor power boards 3724, and an integrated controller 3726.

[0301] Each actuator 3708 can be coupled to a corresponding drive output 1724 via a drive shaft 3728. In an illustrated embodiment, the instrument driver 1702 includes five drive outputs 1724, and therefore five actuators 3708. The drive shaft 3728 may be a keyed shaft, such that it includes multiple grooves to allow the drive shaft 3728 to be fixedly engaged with the corresponding drive output 1724. The actuator 3708 causes the drive shaft 3728 to rotate in a clockwise or counterclockwise direction, thereby causing the corresponding drive output 1724 to rotate similarly. In some embodiments, the drive shaft 3728 may be torsional rigid but spring-flexible, thus allowing the drive shaft 3728 and the corresponding drive output 1724 to rotate and also allowing axial retraction and extension within the tool drive assembly 3609. Each actuator 3708 may receive an electrical signal from an integrated controller 3726 instructing the direction and amount of rotation of the drive shaft 3728.

[0302] Drive motor 3710 is configured to drive tool drive assembly 3609 to rotate within outer housing 3604. Drive motor 3710 can be structurally equivalent to one of the actuators in actuator 3708, except that drive motor is operatively coupled to rotor gear 3704 and designed to drive stator gear 3702, thereby causing tool drive assembly 3609 to rotate relative to outer housing 3604, as generally described above. Drive motor 3710 causes rotor gear 3704 to rotate clockwise or counterclockwise, thereby causing rotor gear 3704 to travel around the gear teeth of stator gear 3702. This configuration allows tool drive assembly 3609 to roll or rotate continuously without being obstructed by potential tangling of cables or wires. Drive motor 3710 can receive electrical signals from integrated controller 3726 instructing the direction and amount of rotation of rotor gear 3704.

[0303] A torque sensor measures the amount of torque generated on a rotating tool drive assembly 3609. In some embodiments, the torque sensor may be able to measure torque in both clockwise and counterclockwise directions. A torque sensor amplifier 3718 includes circuitry for amplifying the signal measuring the amount of torque generated on the rotating tool drive assembly 3609. In some embodiments, the torque sensor is mounted to a drive motor 3710.

[0304] See Figure 37D See also Figure 37C A partial exploded perspective view of the internal electronics of a tool actuator 1702 according to one or more embodiments is shown. A slip ring 3720 facilitates the transfer of electrical power and signals from a stationary structure to a rotating structure. More specifically, in the illustrated embodiment, the slip ring 3720 is configured as a ring including a central hole configured to align with a central hole 1708 of a tool drive assembly 3609. A first side of the slip ring 3720 includes a plurality of concentric grooves 3730, while an opposite second side of the slip ring 3720 includes a plurality of electronic components for electrical connections provided from the robot arm and base 3602.

[0305] A slip ring 3720 is fixed to an outer housing 3604 at a specific distance from the tool drive assembly 3609 to allocate space for electrical connection and interaction. Multiple concentric grooves 3730 are configured to mate with multiple brushes 3732 attached to an integrated controller 3726, which operates as a computing device within the tool drive assembly 3609. Contact between the grooves 3730 and the brushes 3732 allows electrical power and signals to be transmitted from the robotic arm to the slip ring 3720 and from the slip ring 3720 to the integrated controller 3726. Based on the received signals, the integrated controller 3726 is then configured to send various signals to corresponding components within the tool drive assembly 3609 to cause the surgical tool 1600 (… Figure 36B ) operation.

[0306] Multiple encoder boards 3722 read and process signals received from the surgical robot system via slip ring 3720. Signals received from the surgical robot system may include instructions for surgical instruments 1600. Figure 36B The signal indicating the amount and direction of rotation of the end effector 1604. Figure 36B The encoder board 3722 receives signals indicating the amount and direction of rotation of the surgical tool 1600, signals indicating the operation of a light source on the surgical tool 1600, signals indicating the operation of a video or imaging device on the surgical tool 1600, and other signals designed to operate various functions of the surgical tool 1600. The configuration of the encoder board 3722 allows the entire signal processing to be performed entirely within the tool drive assembly 3609. Multiple motor power boards 3724 each include circuitry for supplying power to the actuator 3708. In some embodiments, the functions of the encoder board 3722 and the integrated controller 3726 may be distributed in a manner different from that described herein, such that the encoder board 3722 and the integrated controller 3726 can perform the same function or some combination thereof.

[0307] In the illustrated embodiment, the tool drive assembly 3609 includes two encoder boards 3722, a torque sensor amplifier 3718, and three motor power boards 3724. These components are fixed to and extend vertically from an integrated controller 3726. This configuration provides space for the actuator 3708 and drive motor 3710 to be positioned within the boundaries of the tool drive assembly 3609.

[0308] Figure 38 This is an enlarged perspective view of the various electronic components of the instrument actuator 1702 according to one or more embodiments. More specifically, the enlarged view depicts the components that facilitate the roll indexing of the tool drive assembly 3609. The roll indexing monitors the angular position of the tool drive assembly 3609 relative to the outer housing 3604, allowing the surgical robot system to monitor the surgical tool 1600 in real time. Figure 36BThe position and angular orientation of the indexing mechanism are shown in the figure. The rolling indexing mechanism includes a microswitch 3802 and one or more bosses 3804 (one shown). The microswitch 3802 may be arranged on the tool drive assembly 3609, and the bosses 3804 may be positioned on the outer housing 3604 and configured to contact the microswitch 3802 when the tool drive assembly 3609 rotates and brings the microswitch close to the bosses 3804. Once contact is established between the microswitch 3802 and one or more bosses 3804, the microswitch 3802 records the time and the angular orientation of the tool drive assembly 3806. Each boss 3804 serves as a single reference point for the microswitch 3802 around the inner circumference of the outer housing 3604.

[0309] In other embodiments, the instrument driver 1702 may include additional means for determining the rotational position, such as by using a rotary drive motor 3710 operably coupled to it. Figures 37B to 37C A dedicated servo mechanism. Alternatively, the absolute rotational position can be determined using a circular encoder, as is generally known to those skilled in the art.

[0310] Robotic instruments with torsion cable actuators for bracket-based architectures

[0311] Figure 39A and Figure 39B It is based on one or more additional implementation schemes. Figure 16 A partial cross-sectional side view of another example of the drive housing 1614. As shown, the drive housing 1614 includes a first end 1618a and a second end 1618b, and the instrument actuator 1702 can be removably coupled to the drive housing 1614 at the first end 1618a. A lead screw 1622 extends longitudinally between the first end 1618a and the second end 1618b, and a bracket 1626 is movably mounted to the lead screw 1622 at a bracket nut 1634 to allow the bracket 1626 to move back and forth on the lead screw 1622 along the longitudinal axis A1. A shaft 1602 extends distally from the bracket 1626 through the first end 1618a of the drive housing 1614 and subsequently through the central bore 1708 of the instrument actuator 1702 (when mounted). The drive housing 1614 can be releasably coupled to the instrument driver 1702 by extending the shaft 1602 through the central bore 1708 and engaging the drive interface 1716 of the instrument driver 1702 with the driven interface 1718 of the drive housing 1614, as generally described above.

[0312] In the illustrated embodiment, the driven interface 1718 of the drive housing 1614 includes a first drive input 3902a and a second drive input 3902b, and the drive interface 1716 includes a first drive output 3904a and a second drive output 3904b. The drive inputs 3902a and 3902b can be substantially similar to... Figure 16 and Figure 17B The drive inputs 1636a-d and the drive outputs 3904a and 3904b can be substantially similar to Figure 17B The drive outputs 1724a-d. Therefore, the drive inputs 3902a, 3902b can cooperate with the drive outputs 3904a, 3904b such that movement (rotation) of a given drive output 3904a, 3904b correspondingly causes movement (rotation) of the associated drive input 3902a, 3902b. Although only two drive inputs 3902a, 3902b and two drive outputs 3904a, 3904b are depicted, more or fewer than two may be included in the drive housing 1614 without departing from the scope of this disclosure.

[0313] The first drive input 3902a is operably coupled to the lead screw 1622, such that rotation of the first drive input 3902a (via rotation of the first drive output 3904a) correspondingly causes the lead screw 1622 to rotate in the same angular direction. As the lead screw 1622 rotates, the bracket nut 1634 is pressed against the lead screw 1622 and moves axially back and forth, simultaneously advancing or retracting the bracket 1626 along the longitudinal axis A1 according to the rotation direction of the lead screw 1622. Furthermore, as the bracket 1626 advances or retracts, the shaft 1602 and the end effector 1604 (located at the distal end of the shaft 1602) also move. Figure 16 and Figures 17A to 17B Correspondingly, it moves to the far side or the near side (i.e., the z-axis is translated).

[0314] In the illustrated embodiment, the activation mechanism 3906 is housed in or otherwise formed part of the bracket 1626, and the second drive input 3902b is operatively coupled to the activation mechanism 3906 such that rotation of the second drive input 3902b (via rotation of the second drive output 3904b) actuates (operates) the activation mechanism 3906. The activation mechanism 3906 may be similar to those described herein. Figure 16 Any of the activation mechanisms 1638a-c described in the other accompanying drawings. Therefore, activation mechanism 3906 can be operable to actuate end effector 1604. Figure 16 and Figures 17A to 17B One or more functions of the jaws, such as opening or closing the jaws of jaws 1610, 1612 ( Figure 16 and Figures 17A to 17B), causing the end effector 1604 to be positioned at the wrist 1606 ( Figure 16 The joint movement, or the advance or retraction of the blade 2702 at the end effector 1604 is performed at the joint. Figure 27 In the illustrated embodiment, the actuation activation mechanism 3906 can cause the firing lever 3908 (similar to...) Figure 25 and Figure 26 The firing lever 2506 moves along the longitudinal axis A1 and correspondingly causes the blade 2702 to move in the same direction, thereby causing the blade 2702 to "fire".

[0315] As shown, the activation mechanism 3906 may include a drive gear 3910 rotatably mounted to a bracket 1626 and configured to drive a driven gear 3912, which is also rotatably mounted to the bracket 1626. The drive gear 3910 and driven gear 3912 may each define gear teeth, and in some embodiments, the drive gear 3910 may be positioned to directly mesh with the driven gear 3912. However, in other embodiments, one or more idler gears (not shown) are inserted between the drive gear 3910 and the driven gear 3912, and torque may otherwise be transmitted from the drive gear 3910 to the driven gear 3912 via a meshing transmission. The driven gear 3912 may be operatively coupled to a firing lever 3908 such that rotation of the driven gear 3912 (via rotation of the drive gear 3912) causes the firing lever 3908 to translate along the longitudinal axis A1, thereby causing the associated cutting element or blade to fire.

[0316] To transmit torsional (rotational) force or load from the second drive input 3902b to the activation mechanism 3906, and more specifically to the drive gear 3910, the drive housing 1614 may also include a torsion cable 3914 extending between the second drive input 3902b and the drive gear 3910. The torsion cable 3914 may include a flexible wire or filament having a first end 3916a connected to the second drive input 3902b and a second end 3916b connected to the drive gear 3910. When driven by rotation (actuation) of the second drive input 3902b, the torsion cable 3914 is able to transmit the torsional load from the first end 3916a to the second end 3916b, thereby causing the drive gear 3910 to rotate.

[0317] A basic example of the twisted cable 3914 is the type of cable traditionally used in vehicle speedometer or tachometer systems; a flexible yet sufficiently strong cable that transmits torque from one end to the other, even when extended along a non-linear path. The twisted cable 3914 can be made from a variety of materials, including but not limited to stainless steel and tungsten.

[0318] The twisted cable 3914 has a fixed length, and in order to allow torque to be transmitted between the first end 1916a and the second end 1916b, the twisted cable 3914 must maintain a constant tension during operation. To achieve this, the drive housing 1614 may also include a constant tension or tensioning system comprising a tension pulley 3918, a fixed pulley 3920, one or more bracket pulleys 3922, and a bracket cable 3924. As shown, the fixed pulley 3920 is coupled to or anchored to the drive housing 1614 at or near the first end 1618a, and the twisted cable 3914 is routed through the tension pulley 3918 and the fixed pulley 3920 in a generally “S”-shaped path / shape. More specifically, the twisted cable 3914 is coupled to and extends from the second drive input 3902b, and is routed around the tension pulley 3918 toward the fixed pulley 3920. Then, the torsion cable 3914 is routed around the fixed pulley 3920 and extends to the drive gear 3910, where it is fixed. Any torsional load borne by the rotation (actuation) of the second drive input 3902b at the first end 3916a of the torsion cable 3914 is transmitted through the tension pulley 3918 and the fixed pulley 3920 to the second end 3916b of the torsion cable 3914, causing the drive gear 3910 to rotate, thereby actuating (operating) the activation mechanism 3906; for example, to perform various instrument-specific functions, such as knife firing, jaw opening and closing, energy activation, wrist movement, etc.

[0319] Tensioning pulley 3918 is suspended on bracket cable 3924 within drive housing 1614 to help maintain constant tension in torsion cable 3914 during operation. More specifically, bracket cable 3924 has a first end 3926a coupled to tensioning pulley 3918 and a second end 3926b coupled to bracket 1626. Bracket cable 3924 is routed through bracket pulley 3922, which may be coupled to or anchored to drive housing 1614, for example, at or near the second end 1618b. In the illustrated embodiment, two bracket pulleys 3922 are present, but alternatively, more or fewer bracket pulleys 3922 may be present without departing from the scope of this disclosure. Because the second end 3916b of the twist cable 3914 is connected to the bracket 1626 and travels with the bracket, the extension of the bracket cable 3914 between the bracket 1626 and the tension pulley 3918 forces the tension pulley 3918 and the bracket 1626 to move in opposite axial directions, while helping to maintain tension in the twist cable 3914 during operation.

[0320] Now continue to refer to Figures 39A to 39B Exemplary operation of the drive housing 1614 is described. Figure 39AIn this configuration, the lead screw 1622 rotates in a first angular direction 3928a (via operation of the first drive input 3902a), causing the bracket 1626 to move proximally, as indicated by arrow 3930a. As the bracket 1626 moves proximally 3930a, the bracket cable 3924 is fed (wired) through the bracket pulley 3922 and allows the tension pulley 3918 to descend distally, as indicated by arrow 3930b. Since the second end 3916b of the twisted cable 3914 is coupled to the bracket 1626, as the bracket 1626 moves proximally 3930a, the twisted cable 3914 is fed (wired) through the tension pulley 3918 and the stationary pulley 3920, and as the bracket moves distally 3930b, the tension pulley 3918 helps maintain a constant tension on the twisted cable 3914. Therefore, a constant tension is maintained in the torsion cable 3914 when the bracket 1626 moves toward the proximal end 3930a or when it remains stationary. Thus, the activation mechanism 3906 can operate continuously during the operation of the drive housing 1614, such as when the bracket 1626 is moving or idle. In some embodiments, a channel or slot (not shown) may be defined within the sidewall or other portion of the drive housing 1614 to facilitate guiding the translational direction of the tension pulley 3918. Additionally, a lightweight tension spring may be added to assist the movement of the tension pulley 3918.

[0321] Similarly, in Figure 39B In the middle, the lead screw 1622 is in the first angular direction 3928a ( Figure 39A The bracket 1626 rotates in the opposite second angular direction 3928b (via operation of the first drive input 3902a), causing the bracket 1626 to move distally 3930b. As the bracket 1626 moves distally 3930b, the bracket cable 3924 is fed (wired) through the bracket pulley 3922 and allows the tension pulley 3918 to rise proximally 3930a. Since the second end 3916b of the twisted cable 3914 is coupled to the bracket 1626, as the bracket 1626 moves distally 3930b, the twisted cable 3914 is fed (wired) through the tension pulley 3918 and the stationary pulley 3920, and as the bracket moves proximally 3930a, the tension pulley 3918 helps maintain a constant tension on the twisted cable 3914. Therefore, a constant tension is maintained in the torsion cable 3914 when the bracket 1626 moves toward the distal side 3930b or when it remains stationary. Furthermore, as described above, a channel or slot (not shown) may be defined within the sidewall or other portion of the drive housing 1614 to facilitate guiding the translational direction of the tension pulley 3918.

[0322] Figure 40A and Figure 40B It is based on one or more additional implementation schemes. Figure 16A partial cross-sectional side view of another example of the drive housing 1614. Figures 40A to 40B The drive housing 1614 is similar in some respects to Figures 39A to 39B The illustrated embodiment of the drive housing 1614 is best understood with reference to it, wherein similar figures correspond to similar components not described again. As shown, the drive housing 1614 includes a first end 1618a and a second end 1618b, and the instrument actuator 1702 can be removably coupled to the drive housing 1614 at the first end 1618a. A lead screw 1622 extends longitudinally between the first end 1618a and the second end 1618b, and a bracket 1626 is movably mounted to the lead screw 1622 at a bracket nut 1634 to allow the bracket 1626 to move back and forth on the lead screw 1622 along the longitudinal axis A1. A shaft 1602 extends distally from the bracket 1626 through the first end 1618a of the drive housing 1614 and subsequently through the center hole 1708 of the instrument actuator 1702 (when mounted). The drive housing 1614 can be releasably coupled to the instrument driver 1702 by extending the shaft 1602 through the central bore 1708 and engaging the drive interface 1716 of the instrument driver 1702 with the driven interface 1718 of the drive housing 1614, as generally described above.

[0323] In the illustrated embodiment, the driven interface 1718 of the drive housing 1614 includes a drive input 4002, and the drive interface 1716 includes a drive output 4004. The drive input 4002 can be substantially similar to... Figure 16 and Figure 17B The drive input devices 1636a-d and the drive output device 4004 can be substantially similar to Figure 17B The drive outputs 1724a-d. Therefore, the drive input 4002 can cooperate with the drive output 4004 such that the movement (rotation) of the drive output 4004 correspondingly causes the associated drive input 4002 to move (rotate).

[0324] In the illustrated embodiment, the activation mechanism 4006 is housed in or otherwise formed part of the bracket 1626, and the drive input 4002 is operatively coupled to the activation mechanism 4006 such that rotation of the drive input 4002 (via rotation of the drive output 4004) actuates (operates) the activation mechanism 4006. While the activation mechanism 4006 may be similar to those described herein... Figure 16 The activation mechanism 4006 is any of the activation mechanisms 1638a-c described in the other accompanying drawings, but in the illustrated embodiment, the activation mechanism 4006 is configured to rotate the lead screw 1622, thereby causing the bracket 1626 to translate axially along the longitudinal axis A1.

[0325] More specifically, the activation mechanism 4006 includes a drive gear 4008 rotatably mounted to the bracket 1626 and configured to drive a driven gear 4010, which is also rotatably mounted to the bracket 1626. In some embodiments, the drive gear 4008 may be positioned to directly mesh with the driven gear 4010. However, in other embodiments, one or more idler gears 4012 (one shown) are inserted between the drive gear 4008 and the driven gear 4010, and torque may otherwise be transmitted from the drive gear 4008 to the driven gear 4010 via a meshing transmission. In some embodiments, the driven gear 4010 forms part of the outer periphery of the bracket nut 1634 or is otherwise defined on the outer periphery of the bracket nut, such that rotation of the driven gear 4010 correspondingly rotates the bracket nut 1634 relative to the lead screw 1622, which remains stationary. As the bracket nut 1634 rotates, the bracket 1626 is pushed and moved axially along the longitudinal axis A1 according to the rotation direction of the bracket nut 1634.

[0326] To transmit torsional (rotational) force or load from drive input 4002 to activation mechanism 4006, and more specifically to drive gear 4008, torsion cable 3914 extends between drive input 4002 and drive gear 4008. Furthermore, utilizing the above references... Figures 39A to 39B The tensioning system maintains the torsion cable 3914 under constant tension. More specifically, the torsion cable 3914 is coupled to and extends from the second drive input 4002, and is routed around the tension pulley 3918 toward the fixed pulley 3920. The torsion cable 3914 is then routed around the fixed pulley 3920 and extends to the drive gear 4008, where it is fixed. Any torsional load borne by the torsion cable 3914 at its first end 3916a via rotation (actuation) of the drive input 4002 is transmitted through the tension pulley 3918 and the fixed pulley 3920 to its second end 3916b, causing the drive gear 4008 to rotate, thereby actuating (operating) the activation mechanism 4006.

[0327] Furthermore, the tension pulley 3918 is also suspended on the bracket cable 3924 within the drive housing 1614 to help maintain a constant tension in the torsion cable 3914 during operation. More specifically, the bracket cable 3924 extends from the tension pulley 3918, passes through the bracket pulley 3922, and extends to the bracket 1626. Because the second end 3916b of the torsion cable 3914 is coupled to the bracket 1626 and travels with the bracket, the extension of the bracket cable 3914 between the bracket 1626 and the tension pulley 3918 forces the tension pulley 3918 and the bracket 1626 to move in opposite axial directions, while helping to maintain tension in the torsion cable 3914 during operation.

[0328] Now continue to refer to Figures 40A to 40B Exemplary operation of the drive housing 1614 is described. Figure 40A In this process, the twisting cable 3914 rotates in a first angular direction (via the operation of the drive input 4002), which causes the drive gear 4008 to rotate, thereby causing the driven gear 4010 to rotate. Rotating the driven gear 4010 correspondingly rotates the bracket nut 1634 relative to the fixed lead screw 1622, which pushes the bracket 1626 along the lead screw 1622 toward the proximal side 3930a. As the bracket 1626 moves toward the proximal side 3930a, the bracket cable 3924 is fed (wired) through the bracket pulley 3922 and allows the tension pulley 3918 to descend toward the distal side 3930b. Since the second end 3916b of the twisted cable 3914 is connected to the bracket 1626, as the bracket 1626 moves toward the proximal side 3930a, the twisted cable 3914 is fed (wired) through the tension pulley 3918 and the stationary pulley 3920, and as the bracket moves toward the distal side 3930b, the tension pulley 3918 helps the twisted cable 3914 maintain a constant tension.

[0329] Similarly, in Figure 40BIn this process, the twisting cable 3914 rotates in a second angular direction opposite to the first angular direction (via the operation of the drive input 4002), which causes the drive gear 4008 to rotate, thereby causing the driven gear 4010 to rotate. Rotating the driven gear 4010 correspondingly rotates the bracket nut 1634 relative to the fixed lead screw 1622, which pushes the bracket 1626 along the lead screw 1622 toward the distal side 3930b. As the bracket 1626 moves toward the distal side 3930b, the bracket cable 3924 is fed (wired) through the bracket pulley 3922 and allows the tension pulley 3918 to rise toward the proximal side 3930a. Since the second end 3916b of the twisted cable 3914 is connected to the bracket 1626, as the bracket 1626 moves toward the distal side 3930b, the twisted cable 3914 is fed (wired) through the tension pulley 3918 and the stationary pulley 3920, and as the bracket moves toward the proximal side 3930a, the tension pulley 3918 helps the twisted cable 3914 maintain a constant tension.

[0330] Figure 40C yes Figures 40A to 40B An alternative embodiment of the drive housing 1614, but which may be alternatively applied without departing from the scope of this disclosure. Figures 39A to 39B The drive housing 1614. With Figures 40A to 40B Similar to the implementation scheme, the tension pulley 3918 is suspended at the first end 3926a of the bracket cable 3924 within the drive housing 1614 to help maintain a constant tension in the torsion cable 3914 during operation. Furthermore, the bracket cable 3924 is routed around the bracket pulley 3922. However, with... Figures 40A to 40B In a different implementation, the bracket cable 3924 is also wired around the mounting pulley 4012 that is connected or secured to the bracket 1626, and the second end 3926b of the bracket cable 3924 is secured to the drive housing 1614, such as at or near its second end 1618b. The inclusion of the mounting pulley 4012 results in the bracket cable 3924 having three wiring lengths, which are equal to three wiring lengths of the twisted cable 3914. This helps ensure that the length released is the same as the length consumed by the axial translation of the shaft 1602.

[0331] Figures 41A to 41C It is based on one or more additional implementation schemes. Figure 16 A partial cross-sectional side view of an alternative embodiment of the drive housing 1614. In the illustrated embodiment, the drive housing 1614 includes components that are similar in some respects to... Figure 16The bracket 4102 of the bracket 1626. For example, the bracket 4102 is movable between a first end 1618a and a second end 1618b of the drive housing 1614 along a longitudinal axis A1 (i.e., translation along the z-axis), and the shaft 1602 extends distally from the bracket 4102. Thus, as the bracket 4102 moves along the longitudinal axis A1, the bracket 4102 is thus able to advance or retract relative to the drive housing 1614 to the end actuator (e.g., ...) attached to the distal end of the shaft 1602. Figure 16 End effector 1604).

[0332] exist Figure 41A In this configuration, bracket 4102 includes a bracket nut 4104 rotatably mounted to lead screw 1622. The bracket nut 4104 may be similar in some respects to... Figure 16 The bracket nut 1634. For example, the bracket nut 4104 defines a corresponding helical internal thread (not shown) that can mate with the helical external thread of the lead screw 1622. Therefore, rotation of the lead screw 1622 causes the bracket nut 4104 to move back and forth on the lead screw 1622 and simultaneously causes the bracket 4102 to advance or retract along the longitudinal axis A1, and correspondingly causes the shaft 1602 to advance or retract.

[0333] The bracket nut 4104 is located at or near the distal end 4106 of the bracket 4102. During operation of the drive housing 1614, such as activating the end actuator 1604... Figure 16 During various functions, the bracket 4102 may experience various torsional and axial forces F, which cause the bracket 4102 to rotate or displace in the direction R. Displacement of the bracket 4102 in the direction R can constrain or inhibit movement of the bracket 4102 along the drive housing 1614. According to embodiments of this disclosure, by positioning portions of the bracket nut 4104 at or near the distal and proximal ends of the bracket 4102, the bracket 4102 can be stabilized and rotation in the direction R minimized or eliminated. In such embodiments, the bracket 4102 may be mounted to the lead screw 1622 at two or more spaced locations or otherwise across the substantial length of the bracket 4102, as described in more detail below.

[0334] exist Figure 41BIn this design, bracket 4102 includes at least two bracket nuts operable to increase the stability of bracket 4102, i.e., to minimize torsion and rotation of bracket 4102 about lead screw 1622. More specifically, bracket 4102 may include a first bracket nut 4104a and a second bracket nut 4104b. The first bracket nut 4104a may be positioned at or near the distal end 4106 of bracket 4102, and the second bracket nut 4104b may be positioned at or near the proximal end 4108 of bracket 4102. Bracket nuts 4104a and 4104b are each mounted to the rotatable lead screw 1622 and are supported by bracket 4102 in a spaced-apart relationship, typically located at opposite ends of bracket 4102.

[0335] In embodiments where the bracket 4102 comprises multiple layers, the bracket nut may be present on at least two layers to allow the bracket to translate in response to rotation of the lead screw 1622. For example, in Figure 41B In this embodiment, the bracket 4102 comprises four stacked layers, depicted as a first layer 4110a, a second layer 4110b, a third layer 4110c, and a fourth layer 4110d. Although four layers are shown, it should be understood that the bracket 4102 may have more or fewer layers without departing from the scope of this disclosure. The first layer 4110a may alternatively be referred to as the “distal layer 4110a,” and the fourth layer 4110d may alternatively be referred to as the “proximal layer 4110d.” In such embodiments, a first bracket nut 4104a may be attached to the distal layer 4110a, and a second bracket nut 4104b may be attached to the proximal layer 4110d. Although not shown, additional bracket nuts attached to other layers (e.g., the second layer 4110b and the third layer 4110c) are contemplated herein.

[0336] In some implementations, as shown in the figure, the first bracket nut 4104a may be attached to or otherwise surround or span two or more layers of the bracket 4102. Figure 41B In this design, the first bracket nut 4104a is depicted as being attached to, or otherwise supported by, the distal layer 4110a, but also extending into the adjacent second layer 4110b. Thus, in some embodiments, the first bracket nut 4104a may extend across both layers 4110a, 4110b, and the second bracket nut 4104b may be secured to a single layer 4110d.

[0337] exist Figure 41CIn this embodiment, the bracket 4102 includes a platform layer 4110e that supports a plurality of other layers (shown as layers 4110f, 4110g, and 4110h). In the illustrated embodiment, a portion of the platform layer 4110e extends generally between the distal end 4106 and the proximal end 4108 of the bracket 4102, but alternatively, without departing from the scope of this disclosure, it may extend only a portion of the distance between the distal end 4106 and the proximal end 4108, or it may extend further than the distance between the distal end 4106 and the proximal end 4108.

[0338] In the illustrated embodiment, bracket 4102 includes an elongated bracket nut 4104c that extends substantially from the distal end 4106 of bracket 4102 to the proximal end 4108. The bracket nut 4104c is mounted to platform layer 4110e, thus enabling the translation of the connecting bracket layer 4110e-h along the lead screw 1622. In some embodiments, the bracket nut 4104c may extend along the entire axial length of platform layer 4110e, but alternatively may extend only along a portion of the axial length of platform layer 4110e. Although not shown, it is contemplated that a second layer in a stack of two or more layers may incorporate an elongated bracket nut similar to the elongated nut 4104c, having a proximal portion 4112a and a distal portion 4112b, supporting the first layer distally and the third layer proximally.

[0339] 4. Implementation System and Terminology .

[0340] The specific embodiments disclosed herein provide systems, methods, and apparatus for use with robotic systems. It should be noted that, as used herein, the terms “couple,” “coupling,” “coupled,” or other variations of the word “couple” can indicate indirect or direct connection. For example, if a first component is “coupled” to a second component, the first component may be indirectly connected to the second component via another component or directly connected to the second component.

[0341] The methods disclosed herein include one or more steps or actions for implementing the methods. The method steps and / or actions may be interchanged without departing from the scope of the claims. In other words, the order and / or use of specific steps and / or actions may be modified without departing from the scope of the claims unless proper operation of the described method requires a specific order of steps or actions.

[0342] As used herein, the term "multiple" means two or more. For example, multiple components indicates two or more components. The term "determine" encompasses a variety of actions, and therefore, "determine" can include calculation, operation, processing, derivation, investigation, lookup (e.g., searching in a table, database, or another data structure), ascertainment, etc. Additionally, "determine" can include receiving (e.g., receiving information), accessing (e.g., accessing data in memory), etc. Furthermore, "determine" can include parsing, selecting, picking, building, etc.

[0343] Unless otherwise explicitly stated, the phrase “based on” does not mean “based on only”. In other words, the phrase “based on” describes both “based on only” and “based on at least”.

[0344] As used herein, the terms “usually” and “substantially” are intended to cover structural or quantitative modifications that do not significantly affect the purpose of the element or quantity modified by the term.

[0345] In order to assist the Patent Office and any reader of this application and any obtained patent in interpreting the claims appended herein, the applicant does not expect any appended claim or claim element to invoke 35 U.SC112(f) unless the words “means for…” or “steps for…” are expressly used in a particular claim.

[0346] The foregoing description of the disclosed specific embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these specific embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other specific embodiments without departing from the scope of the invention. For example, it should be understood that those skilled in the art will be able to employ numerous corresponding alternatives and equivalent structural details, such as equivalent means of fastening, mounting, connecting, or engaging tool components, equivalent mechanisms for generating specific actuating movements, and equivalent mechanisms for delivering electrical energy. Therefore, the invention is not intended to be limited to the specific embodiments shown herein, but is endowed with the broadest scope consistent with the principles and novel features disclosed herein.

Claims

1. A robotic surgical tool, comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; a carriage movably mounted to the at least one spline; an elongate shaft extending from the carriage and through the first end; an end effector arranged at a distal end of the elongate shaft; a wrist interposed between the end effector and the distal end of the shaft; and an activation mechanism housed in the carriage and operably coupled to the drive gear such that rotation of the drive gear correspondingly actuates the activation mechanism, causing the wrist to articulate the end effector in at least one plane, wherein the activation mechanism includes: a first carrier extending at least partially around the shaft and operably coupled to a first drive member extending to the wrist; a second carrier extending at least partially around the shaft and operably coupled to a second drive member extending to the wrist, a first transmission gear extending around the shaft and defining an internal thread, the first carrier being radially interposed between the shaft and the first transmission gear and defining an external thread that can mate with the internal thread of the first transmission gear; and a second transmission gear extending around the shaft and defining an internal thread, the second carrier being radially interposed between the shaft and the second transmission gear and defining an external thread that can mate with the internal thread of the second transmission gear.

2. The robotic surgical tool of claim 1, further comprising: a drive input arranged at the first end and operably coupled to the at least one spline such that rotation of the drive input correspondingly rotates the at least one spline and the drive gear; and wherein the robotic surgical tool is capable of engaging an instrument driver arranged at an end of a robotic arm and capable of mating with the drive housing at the first end, the instrument driver providing a drive output that is capable of mating with the drive input such that rotation of the drive output correspondingly rotates the drive input, actuating the activation mechanism. the shaft extends through the instrument driver via a central bore defined as longitudinally through the instrument driver.

3. The robotic surgical tool of claim 2, wherein, the carriage includes at least first and second layers arranged in series, and wherein the drive gear is arranged between portions of the first and second layers and is slidably disposed around at least one second spline.

4. The robotic surgical tool of claim 1, wherein, ​ 5. The robotic surgical tool of claim 1, wherein, Actuation of the activation mechanism moves the first carrier and the first drive member along the shaft in a first axial direction and also moves the second carrier and the second drive member along the shaft in a second axial direction, wherein the first axial direction and the second axial direction are collinear and opposite.

6. The robotic surgical tool of claim 5, wherein, Distal ends of the first drive member and the second drive member are operatively antagonized at the end effector to articulate the end effector in the at least one plane.

7. The robotic surgical tool of claim 5, wherein, The first drive gear and the second drive gear are mateable with the drive gear such that rotation of the drive gear simultaneously rotates the first drive gear and the second drive gear, and wherein the threads of the first drive gear and the second drive gear are oppositely directed such that rotation of the first drive gear and the second drive gear causes the first carrier and the second carrier to move along the shaft in collinear but opposite axial directions.

8. The robotic surgical tool of claim 7, wherein, A gap is provided between the first carrier and the second carrier to allow the first carrier and the second carrier to move toward and away from each other during actuation of the activation mechanism.

9. The robotic surgical tool of claim 5, wherein, The activation mechanism further comprises: an articulation barrel rotatably disposed about the shaft, a driven gear being disposed on the articulation barrel, and the first carrier and the second carrier being radially interposed between the shaft and the articulation barrel; first and second cam profiles defined in the articulation barrel and extending around a circumference of the articulation barrel at equal but opposite angles; a first driven pin extending through the first cam profile and coupled to the first carrier; and a second driven pin extending through the second cam profile and coupled to the second carrier, wherein as the drive gear rotates the articulation barrel, the first and second driven pins are respectively urged across the first and second cam profiles, thereby urging the first and second carriers in collinear but opposite axial directions.

10. The robotic surgical tool of claim 9, wherein, The activation mechanism further comprises: a first articulation torque rod fixed to the carriage and defining a first slot that receives a head of the first driven pin; and a second articulation torque rod fixed to the carriage and defining a second slot that receives a head of the second driven pin.

11. The robotic surgical tool of claim 10, wherein, Each driven pin comprises: a first bearing that is urged against an inner wall of the first or second cam profile as the articulation barrel rotates; and a second bearing that is urged against an inner wall of the first or second slot as the articulation barrel rotates.

12. The robotic surgical tool of claim 9, wherein, At least one of the first and second cam profiles provides a point of inflection along a path of the first and second cam profiles.

13. The robotic surgical tool of claim 1, wherein, The end effector is selected from the group consisting of: a surgical stapler, a tissue grasper, surgical scissors, an advanced energy vessel sealer, a clip applier, a needle driver, a Babcock forceps including a pair of opposing grasping jaws, bipolar jaws, a suction irrigator, an endoscope, a laparoscope, and any combination thereof.

14. A method of operating a robotic surgical tool, comprising: positioning the robotic surgical tool in proximity to a patient, the robotic surgical tool comprising: a drive housing having a first end and a second end; at least one spline extending between the first end and the second end and including a drive gear that rotates with rotation of the at least one spline; a carriage movably mounted to the at least one spline; an elongate shaft extending from the carriage and penetrating the first end; an end effector arranged at a distal end of the elongate shaft; a wrist interposed between the end effector and the distal end of the shaft; and an activation mechanism housed in the carriage and operably coupled to the drive gear, wherein the activation mechanism comprises: a first carrier extending at least partially around the shaft and operably coupled to a first drive member extending to the wrist; a second carrier extending at least partially around the shaft and operably coupled to a second drive member extending to the wrist; a first transmission gear extending around the shaft and defining internal threads, the first carrier being radially interposed between the shaft and the first transmission gear and defining external threads that are mateable with the internal threads of the first transmission gear; and a second transmission gear extending around the shaft and defining internal threads, the second carrier being radially interposed between the shaft and the second transmission gear and defining external threads that are mateable with the internal threads of the second transmission gear; rotating the at least one spline and the drive gear by actuating a drive input arranged at the first end and operably coupled to the at least one spline; actuating the activation mechanism with rotation of the drive gear, thereby articulating the end effector at the wrist in at least one plane; moving the first carrier and the first drive member in a first axial direction along the shaft; moving the second carrier and the second drive member in a second axial direction along the shaft, wherein the first and second axial directions are collinear and opposite; mating the drive gear with the first and second transmission gears; rotating the drive gear, thereby simultaneously rotating the first and second transmission gears, wherein the thread directions of the internal threads of the first and second transmission gears are opposite; and causing the first carrier and the second carrier to move along the shaft in co-linear but opposite axial directions with rotation of the first drive gear and the second drive gear.

15. The method of claim 14, further comprising: mating an instrument driver at the first end to the drive housing, the instrument driver being arranged at an end of a robotic arm; mating a drive output of the instrument driver to the drive input when the instrument driver is mated to the drive housing; and actuating the drive output to rotate the drive input, thereby actuating the activation mechanism.

16. The method of claim 15, wherein, Mating the instrument driver at the first end to the drive housing includes extending the shaft, the end effector, and the wrist through a central bore defined longitudinally through the instrument driver.

17. The method of claim 14, further comprising antagonistically operating distal ends of the first drive member and the second drive member at the end effector, thereby articulating the end effector in the at least one plane.

18. The method of claim 14, wherein, The activation mechanism further comprises an articulation barrel rotatably disposed about the shaft, a driven gear being disposed on the articulation barrel, and the first carrier and the second carrier being radially interposed between the shaft and the articulation barrel, first and second cam profiles being defined in and extending around a circumference of the articulation barrel at equal but opposite angles, a first driven pin extending through the first cam profile and coupled to the first carrier, and a second driven pin extending through the second cam profile and coupled to the second carrier, the method further comprising: rotating the articulation barrel with the drive gear; urging the first and second driven pins through the first and second cam profiles, respectively, with rotation of the articulation barrel; and urging the first and second carriers along the shaft in co-linear but opposite axial directions with the first and second driven pins traversing the first and second cam profiles, respectively.

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