motor module

Abstract

A motor module comprising a primary pinion rotatably drivable by a primary motor, a first primary rack moveably engageable with the primary pinion, and a second primary rack moveably engageable with the primary pinion. Rotation of the primary pinion causes movement of the first primary rack in a first direction, and movement of the second primary rack in a second direction, whereby the first and second primary racks and the primary pinion together form an antagonistic rack and pinion mechanism.

Description

Technical Field

[0001] The present invention relates to a motor module, and particularly, but not exclusively, to a motor module for use in the field of surgical robots and configured to actuate surgical instruments. Background Technology

[0002] Robotic systems are increasingly being used to perform surgical procedures, particularly minimally invasive ones, where miniature surgical instruments can be remotely controlled by the surgeon to perform various actions required for the procedure.

[0003] Known surgical instruments that form part of a robotic surgical system include axes, articulated portions, and end effectors. An axis can extend from other components of the surgical robot that control and drive the movement of the articulated portions and the end effector. Therefore, the axis facilitates the positioning of the articulated portions and the end effector at the desired area on the patient's body. The articulated portions may include multiple joints positioned adjacent to each other to provide the end effector with degrees of freedom of movement relative to the axis. Finally, the end effector can be adapted to perform specific actions required during surgery. For example, the end effector can provide forceps or a scalpel.

[0004] Known end effectors, joint portions, shafts, and their combinations have a relatively small maximum width or diameter, for example, less than 1 cm. However, these portions of known surgical instruments, particularly shafts, can extend to lengths much greater than their maximum width. The narrower width and longer length of surgical instruments enable surgical techniques to be performed as minimally invasive procedures. Furthermore, known surgical instruments are manufactured as disposable or single-use products to ensure their sterility when used in surgical procedures.

[0005] To provide joint portions and end effectors of the required dimensions, known surgical instruments are tendon-driven, wherein a first end of the tendon is attached to a specific joint or portion of the end effector, the tendon extends along the lumen of an axis, and a second end of the tendon is mechanically coupled to a motor. The motor can actuate the tendon, which in turn actuates the joint or end effector to which it is attached.

[0006] To actuate multiple joints, multiple tendons may be required. This, in turn, may require several motors to actuate the tendons.

[0007] Known robotic surgical systems include motor modules configured to provide all the motors needed to actuate surgical instruments. Due to the electronic components involved, the production cost of such motor modules can be expensive, and they are therefore typically manufactured for reuse in multiple surgical procedures.

[0008] Known motor modules can be mechanically coupled to surgical instruments via a driver module configured to receive actuation inputs from the motor module and transmit these actuations to the tendons of the surgical instrument.

[0009] However, known modules rely on rotation provided by a motor as the actuation input. Therefore, the mechanical connection between the motor module and the drive module is complex due to the alignment of the motor-driven actuator in the motor module with the winch in the drive module. This mechanical connection can be further complicated by the need to provide a sterile barrier between the non-sterile motor module and the sterile drive module to prevent contamination of surgical instruments.

[0010] The complex mechanical connections of robotic components can be challenging because medical personnel often possess expertise in the medical field rather than robotics. Therefore, using known surgical robots can be frustrating and / or excessively time-consuming for the medical personnel involved. Summary of the Invention

[0011] According to one aspect of the present invention, a motor module is provided, comprising: a main pinion rotatably driven by a main motor, a first main rack movably engaged with the main pinion, and a second main rack movably engaged with the main pinion; wherein rotation of the main pinion causes movement of the first main rack in a first direction and movement of the second main rack in a second direction, thereby forming an antagonistic rack and pinion mechanism together with the main pinion.

[0012] Each main rack can be movably engaged with the main pinion in any suitable manner. For example, the main pinion may include a plurality of teeth extending from its periphery, and each main rack may include a plurality of teeth extending from the side of the main rack closer to the main pinion, wherein the teeth of the main pinion are adapted to interlock with the teeth of each main rack. When the main motor causes the main pinion to rotate in use, the angular movement of the teeth of the main pinion can generate a force on the teeth of the main rack, and thus cause the main rack to translate relative to the main pinion.

[0013] In another embodiment, the area around the main pinion and the side of each main rack near the main pinion may include a material with a high coefficient of friction, and each main rack may be positioned relative to the main pinion such that the high-friction material contacts each other. When the main motor causes the main pinion to rotate during use, the angular movement of the high-friction surrounding surface of the main pinion can generate a force on the high-friction surface of the main rack, thereby causing the main rack to translate relative to the main pinion.

[0014] The first main rack can be positioned along a first tangent of the main pinion, and the second main rack can be positioned along a second tangent of the main pinion that is different from the first tangent. Therefore, rotation of the main pinion can cause the first and second main racks to move in different directions, for example, along different tangents.

[0015] Furthermore, the positions of the first and second tangents relative to the main pinion can be substantially opposite to each other. Therefore, the rotation of the main pinion in the direction of rotation (i.e., clockwise or counterclockwise) causes the direction of movement of the first main rack (first direction) to be substantially opposite to the direction of movement of the second main rack (second direction). In other words, the first and second main racks move against each other as part of an anti-rack and pinion mechanism.

[0016] The present invention provides a motor module including a rack and pinion mechanism, which converts the rotational movement provided by the motor into translational movement of the first and second racks, thereby avoiding the need to convert the rotational movement into translational movement of tendons within the driver module.

[0017] This simplifies the drive module and reduces its manufacturing cost. Disposable drive modules are advantageous, which may be desirable when the motor module is used in a sterile environment.

[0018] This type of motor module also avoids the need for complex alignment of smaller components, which might require transmitting actuation as rotational movement from the motor module to the driver module. Instead, actuation can be transmitted as translational movement from the motor module to the driver module, where simple alignment of the entire motor module with the entire driver module provides sufficient alignment of the components that form part of each of the motor and driver modules, facilitating the transmission of actuation from one component to another.

[0019] Furthermore, providing a counter-rack and pinion mechanism with a first and a second main rack moving in opposition to each other facilitates the actuation of a pair of antagonistic tendons. For example, to actuate the connector of a surgical instrument in a first direction, the first tendon can be actuated (pulled), and to actuate the connector in a second direction, the second antagonistic tendon can be actuated (pulled). According to the invention, the counter-rack and pinion mechanism actuates the first tendon by rotation of the main pinion in the first direction and actuates the second tendon by rotation of the main pinion in the second opposite direction.

[0020] In embodiments of the present invention, the motor module may include multiple motors and multiple counter-rack and pinion mechanisms, wherein the main pinion of each counter-rack and pinion mechanism can be driven by a corresponding one of the motors.

[0021] In this embodiment of the invention, the motor module can actuate multiple tendons, and thereby actuate various connectors and end effectors that form surgical instruments. Furthermore, each motor and its associated counter-rack and pinion mechanism can actuate a corresponding pair of counter-tendons.

[0022] In embodiments of the present invention, at least one of the counter-rack and pinion mechanisms may be a double counter-rack and pinion mechanism, which further includes: a third main rack capable of movably engaging with the main pinion and a fourth main rack capable of movably engaging with the main pinion; wherein rotation of the main pinion causes the third main rack to move along the first direction and the fourth main rack to move along the second direction.

[0023] In this embodiment of the invention, the four main racks can be moved by the same main pinion, and therefore by the same motor. Specifically, the main pinion can cause the first and third racks to move in the same direction as each other, and the second and fourth racks to move in the same direction as each other and substantially opposite to the direction of the first and third racks. Thus, two pairs of counteracting actuation can be provided.

[0024] This can be particularly advantageous for providing actuation of surgical instruments comprising two adjacent joints capable of rotating in the same direction. For example, if each joint is capable of providing rotation up to ±45°, then two joints adjacent to each other can be combined to provide rotation up to ±90°.

[0025] A dual-opposing rack and pinion mechanism can provide simultaneous actuation of each associated antagonistic tendon pair in adjacent joints. In other words, a dual-opposing rack and pinion mechanism can be used to simultaneously actuate two adjacent joints. This allows two adjacent joints to actuate complementaryly and avoids situations where their actuations conflict or cancel each other out. Furthermore, the actuation of both joints can be driven by only a single motor, thereby reducing the complexity, size, and cost of the motor module.

[0026] In embodiments of the present invention, the main pinion of the double-opposing rack and pinion mechanism or each double-opposing rack and pinion mechanism may include a first part and a second part, the first main rack and the second main rack can engage with the first part of the main pinion, and the third main rack and the fourth main rack can engage with the second part of the main pinion.

[0027] In this embodiment of the invention, the first and second portions of the main pinion can have different radii, thereby causing the first and second main racks to move at a different gear ratio than the third and fourth main racks. For example, if the second portion has a larger radius than the first portion, then rotation of the main pinion can cause the third and fourth main racks to move a greater distance in their respective directions than the first and second main racks.

[0028] The radii of the first and second parts can be configured to ensure that two adjacent joints of the surgical instrument are each actuated to rotate through the same angle of rotation, although the more distal end of the two joints requires greater tendon actuation.

[0029] In embodiments of the present invention, each main rack may further include an actuating portion, and the motor module may further include an interface plate, the interface plate including a plurality of first orifices and a plurality of second orifices, the actuating portions of each first main rack or each first main rack and third main rack being movable within the corresponding first orifice, and the actuating portions of each second main rack or each second main rack and fourth main rack being movable within the corresponding second orifice.

[0030] In this embodiment of the invention, the interface board can cover and protect the internal components of the motor module, such as one or more motors and one or more main pinions. Furthermore, the interface board can engage with a driver module or a sterile barrier that can in turn engage with the driver module.

[0031] However, in order to actuate the actuator that forms part of the actuator module (which in turn actuates the tendon of the surgical instrument), the interface plate includes an orifice through which the actuating portion of the main rack can interact with the actuator of the actuator module (or the intermediate actuator of the sterile barrier).

[0032] In embodiments of the present invention, each main rack may be capable of linear movement.

[0033] In this embodiment of the invention, the motor module may include linear channels associated with each of the first and second main racks, wherein the respective main racks can be movably received within the linear channels, but are restricted to moving linearly only between the first and second ends of the linear channels.

[0034] In this embodiment of the invention, which also includes one or more double-counteracting racks and pinions, each third and fourth main rack can be movably received in the same linear channel as the associated first or second main rack, or can be movably received in a different linear channel than the associated first or second main rack. In any case, each third and fourth main rack can be restricted to linear movement only between the first and second ends of the linear channel in which it is received.

[0035] Converting the rotational movement provided by the motor into linear movement can be particularly advantageous because the tendon used to actuate the surgical instrument can ideally be linearly actuated parallel to the axis of the surgical instrument. Furthermore, the linear movement of the linear channel and the resulting main rack can be configured to be parallel to the axis of the surgical instrument, thus eliminating the need for Bowden lines or pulleys to significantly alter the tendon's orientation as it leaves the axis.

[0036] In embodiments of the present invention, the motor module may further include a secondary motor and a secondary rack and pinion mechanism, the secondary rack and pinion mechanism including: a secondary pinion rotatably driven by the secondary motor, and a secondary rack movably engaged with the secondary pinion, wherein rotation of the pinion causes movement of the secondary rack.

[0037] In this embodiment of the invention, the secondary rack and pinion mechanism can convert the rotational movement of the secondary motor into a single translational movement of the secondary rack, optionally linearly. The secondary rack and pinion mechanism can be used to actuate independently (rather than in opposition to) tendons, or for actuation of various forms of surgical instruments, such as providing rotation of the surgical instrument shaft.

[0038] The secondary rack can be positioned along the tangent of the secondary pinion and movably engaged with the secondary pinion in any suitable manner. For example, the secondary pinion may include a plurality of teeth extending from its periphery, and the secondary rack may include a plurality of teeth extending from the side of the secondary rack near the secondary pinion, wherein the teeth of the secondary pinion are adapted to interlock with the teeth of the secondary rack. In another example, the periphery of the secondary pinion and the side of the secondary rack near the secondary pinion may include a material with a high coefficient of friction, and the secondary rack may be positioned relative to the secondary pinion such that the high-friction material contacts each other.

[0039] In embodiments of the present invention, the motor module may include any suitable number of auxiliary motors and auxiliary rack and pinion mechanisms.

[0040] In an embodiment of the invention, the motor module can be removably mounted on a mounting bracket and can move along the mounting bracket.

[0041] In this embodiment of the invention, a sterile barrier and a actuator module with associated surgical instruments can also be removably mounted on a mounting bracket. The mounting bracket can be adapted to position the surgical instruments relative to the patient in a desired location. For example, the mounting bracket can be coupled to a first end of a manipulator arm, the second end of which can be mounted to a surface (e.g., a floor or operating table). The manipulator arm can provide multiple degrees of freedom to allow the mounting bracket to be selectively positioned to allow the surgical instruments desired access to the patient.

[0042] The motor module and drive module can be moved along the mounting bracket to provide degrees of freedom between the motor module (and drive module) and the patient. For example, this can allow surgical instruments to move toward and away from the patient.

[0043] In embodiments of the invention, multiple motor modules can be simultaneously and removably mounted on a mounting bracket to allow multiple surgical instruments to be positioned together and used together in surgical procedures.

[0044] In embodiments of the present invention, the mounting bracket may include a translation rack, and the motor module may further include a translation motor and a translation pinion, the translation pinion being rotatably driven by the translation motor and engaging with the translation rack when the motor module is mounted on the mounting bracket, such that rotation of the translation pinion causes movement of the motor module relative to the mounting bracket.

[0045] In this embodiment of the invention, the translation pinion can be movably engaged with the translation rack, wherein rotation of the translation pinion causes the translation pinion to roll along the translation rack. The combination of the translation pinion and the translation rack can provide a conversion between rotational movement of the translation motor and translational movement of the motor module relative to the mounting bracket, and optionally linear movement.

[0046] The translation rack and translation pinion can each be positioned such that when the motor module is mounted on the mounting bracket, the translation rack is positioned along the tangent of the translation pinion.

[0047] The translation pinion can engage with the translation rack in any suitable manner. For example, the translation pinion may include a plurality of teeth extending from its periphery, and the translation rack may include a plurality of teeth extending from the side of the translation rack near the translation pinion (when the motor module is mounted on the mounting bracket), wherein the teeth of the translation pinion are adapted to interlock with the teeth of the translation rack. In another example, the periphery of the translation pinion and the side of the translation rack near the translation pinion (when the motor module is mounted on the mounting bracket) may include a material with a high coefficient of friction, and the translation rack may be positioned relative to the translation pinion such that the high-friction material contacts each other.

[0048] In embodiments of the present invention, the motor module may include any suitable number of translation motors and translation pinions, and the mounting bracket may include any suitable number of translation racks.

[0049] In an embodiment of the invention, the motor module may further include a gear assembly that is rotatably driven by a translation motor and is rotatably and mechanically coupled to a translation pinion such that the translation pinion is rotatably driven by the translation motor via the gear assembly.

[0050] In this embodiment of the invention, the gear mechanism can be adapted to provide rotation of the translation pinion about different axes to the translation motor. This can be advantageous because it allows the translation pinion to be positioned near the edge or side of the motor module, such that a portion of the translation pinion can extend outward from the motor module to engage with the translation rack when the motor module is mounted on the mounting bracket. Simultaneously, the translation motor can be positioned more centrally within the motor module, allowing it to be covered and protected by the motor module's housing.

[0051] Similarly, the gear mechanism can be adapted to provide gear transmission of the rotation of the translation pinion relative to the rotation generated by the translation motor. For example, the translation pinion can be geared to rotate at a larger angular velocity than the translation motor to provide a translation by a motor module with greater responsiveness than the input provided by the motor. Alternatively, the translation pinion can be geared to rotate at a lower angular velocity than the translation motor to provide translational movement that can be achieved by the motor module with higher precision.

[0052] In embodiments of the invention, the motor module can be configured to actuate surgical instruments. Additionally, the motor module may further include an instrument mounting bracket capable of being mechanically coupled to the surgical instruments, allowing the instruments to be removably mounted on the motor module.

[0053] In this embodiment of the invention, surgical instruments can be directly mounted to the motor module, or can be mounted to the motor module via a driver module and / or a sterile barrier.

[0054] Instrument mounting brackets may include means for facilitating the slidable engagement of surgical instruments (directly or indirectly) with a motor module, such as channels, recesses, or ridges configured to slidably engage with corresponding channels, recesses, or ridges forming part of a surgical instrument, or associated actuator modules or sterile barriers.

[0055] Furthermore, the instrument mounting bracket may include means for facilitating the (direct or indirect) lockable engagement of surgical instruments to the motor module, such as a latch configured to lockably engage with a corresponding recess forming part of the surgical instrument, or an associated actuator module or sterile barrier. Alternatively, the means for facilitating the (direct or indirect) lockable engagement of the surgical instruments may be a recess for receiving a latch forming part of the surgical instrument, or an associated actuator module or sterile barrier.

[0056] However, in embodiments of the invention, the motor module can be configured to actuate other instruments. For example, the motor module can be part of a robotic system configured to perform other tasks in manufacturing processes, bomb disposal, or in environments too small or uninhabitable for humans.

[0057] In an embodiment of the invention, the motor module includes a processor capable of being electrically connected to at least one motor.

[0058] In this embodiment of the invention, the processor can receive control signals from a control module that forms part of the robotic surgical system. Based on the control signals, the processor can selectively provide electrical power to the motor or individual motors that form part of the motor module, so as to enable the motors to provide rotational movement.

[0059] In some embodiments of the present invention, the processor may be mounted on a motherboard and may be electrically connected to at least one motor via the motherboard.

[0060] In some embodiments of the invention, the motor module may include any suitable number of processors. For example, the motor module may include processors for controlling individual motors, or the motor module may include processors for controlling various types of motors (i.e., processors for controlling all main motors, processors for controlling all auxiliary motors, and processors for controlling all translation motors).

[0061] In embodiments of the present invention, the motor module may include a safety watchdog that can be electrically connected to the processor.

[0062] In this embodiment of the invention, the security watchdog can monitor errors in the motor module, such as a faulty motor, a motor that cannot complete its controlled movement (which can indicate a blockage in the system), or a processor that cannot execute control signals.

[0063] In some embodiments of the present invention, the security watchdog may be mounted on the motherboard and electrically connected to the processor or processors via the motherboard. The security watchdog may also be electrically connected to one or more motors via the motherboard.

[0064] In an embodiment of the invention, the motor module further includes a cooling fan.

[0065] In this embodiment of the invention, a cooling fan can be operated to allow airflow through the motor module and promote cooling of internal components. Furthermore, the cooling fan can be oriented to allow airflow parallel to one or more motors and one or more processors to improve the cooling of these components.

[0066] In an embodiment of the present invention, the motor module further includes a heat dissipation device.

[0067] In this embodiment, the heat dissipation device can absorb heat generated by one or more processors, a security watchdog, and / or one or more motors during use of the motor module. Therefore, the heat dissipation device helps prevent overheating of the components of the motor module. The motor module can include any suitable number of heat dissipation devices; for example, each processor and security watchdog can be accompanied by a separate heat dissipation device.

[0068] Each heat dissipation device may include a cooling surface having features such as channels, grooves, ridges, or fins, which increase the surface area of ​​the heat dissipation device and improve heat dissipation from the heat dissipation device. Additionally, the channels, grooves, ridges, or fins may extend parallel to the direction of airflow caused by the cooling fan to further improve heat dissipation from the heat dissipation device and cooling of related components. Attached Figure Description

[0069] The invention will now be described by way of example only with reference to the accompanying drawings, in which:

[0070] Figure 1 This is a schematic diagram of a motor module according to an embodiment of the present invention;

[0071] Figure 2 yes Figure 1 A schematic diagram of a motor module, showing multiple motors that form part of the motor module;

[0072] Figure 3 It is formed Figure 1 A schematic diagram of the counter-rack and pinion mechanism, which is part of the motor module;

[0073] Figure 4 It is formed Figure 1 A schematic diagram of multiple counter-rack and pinion mechanisms as part of a motor module;

[0074] Figure 5 It is formed Figure 1 A schematic diagram of a double-counter rack and pinion mechanism, which is part of the motor module;

[0075] Figure 6 It is formed Figure 1A schematic diagram of multiple double-counteracting rack and pinion mechanisms as part of a motor module;

[0076] Figure 7 and Figure 8 It is formed Figure 1 A schematic diagram of a secondary rack and pinion mechanism, which is part of the motor module;

[0077] Figure 9 and Figure 10 They are the formation Figure 1 A schematic diagram of a translation pinion, which is part of the motor module;

[0078] Figure 11 and Figure 12 This is a schematic diagram of a motor module including an interface board according to another embodiment of the present invention;

[0079] Figure 13a , Figure 13b and Figure 13c yes Figure 11 and Figure 12 A schematic diagram of the motor module along with the mounting bracket, sterile barrier, actuator module, and surgical instruments;

[0080] Figure 14 and Figure 15 yes Figure 13a , Figure 13b and Figure 13c A schematic diagram of the first and second sides of the sterile barrier;

[0081] Figure 16 yes Figure 13a , Figure 13b and Figure 13c A schematic diagram of surgical instruments; and

[0082] Figure 17 and Figure 18 It is formed Figure 1 and Figure 11 as well as Figure 12 A schematic diagram of the internal components of a portion of the motor module shown. Detailed Implementation

[0083] First refer to Figure 1 The motor module according to an embodiment of the present invention is generally shown by reference numeral 2. Motor module 2 includes three opposing rack and pinion mechanisms 10, two double opposing rack and pinion mechanisms 20, a secondary rack and pinion mechanism 30, and a translational pinion 36. The motor module also includes a housing 46 (in... Figure 13a , Figure 13b and Figure 13c (This is shown more clearly in the text).

[0084] However, other embodiments of the invention may include more or fewer of these features.

[0085] Each counter-rack and pinion mechanism 10 includes a first main rack 11, a second main rack 12, and a main pinion 16.

[0086] Each double-opposing rack and pinion mechanism 20 includes a first main rack 21, a second main rack 22, a third main rack 23, a fourth main rack 24, and a main pinion 26.

[0087] The secondary rack and pinion mechanism 30 includes a secondary rack 32 and a secondary pinion 34.

[0088] Motor module 2 also includes a plurality of motors, each of which is associated with a corresponding one of the counter-rack and pinion mechanism 10, the double counter-rack and pinion mechanism 20, the secondary rack and pinion mechanism 30, and the translation pinion 36.

[0089] The positions of each motor are indicated by the reference numerals A, B, C, D, E, F, and G.

[0090] Figure 2 The lower side of motor module 2 is shown, with the outer casing 46 removed to expose the inner casing 47. Motor module 2 includes five main motors 4, auxiliary motors 6, and translation motors 8, each mounted in the inner casing 47. Three main motors 4 are located at positions B, C, and D, and are connected to... Figure 1 The counter-rack and pinion mechanism 10 shown is associated with this. The remaining two main motors 4 are located at positions A and E, and are connected to... Figure 1 The double-opposing rack and pinion mechanism 20 shown is associated.

[0091] The translation motor 8 is positioned at position F and is associated with the translation pinion 36.

[0092] The auxiliary motor 6 is located at position G and is associated with the auxiliary rack and pinion mechanism 30.

[0093] Refer again Figure 1 There is also a position F' located on the opposite side of position F in motor module 2. The translation motor 8 can be positioned at position F' instead of position F, and the translation pinion 36 can be correspondingly positioned on the motor module 2 opposite to its position. Figure 1 The two motor modules 2 are positioned on opposite sides. The possibility of positioning and actuating the translation pinion 36 on either side of the motor module 2 allows the two motor modules 2 to be configured such that they are symmetrical to each other.

[0094] Figure 3 It shows the formation Figure 1This is a portion of the counter-rack and pinion mechanism 10 of the motor module 2 shown. A first main rack and second main racks 11, 12 are each movably engaged with a main pinion 16, wherein rotation of the main pinion 16 causes movement of the first main rack 11 in a first direction and movement of the second main rack 12 in a second direction. For example, clockwise rotation of the main pinion 16 will cause the first main rack 11 to move upward and the second main rack 12 to move downward. Simultaneously, counterclockwise rotation of the main pinion 16 will cause the first main rack and the second main racks 11, 12 to move in opposite directions (downward and upward, respectively).

[0095] When used to actuate surgical instruments, the antagonistic movement of the first and second main racks 11, 12 can facilitate the actuation of a pair of antagonistic tendons forming part of the surgical instrument. For example, to actuate the connector of the surgical instrument in a first direction, the first tendon can be actuated (pulled), and to actuate the connector in a second direction, the second antagonistic tendon can be actuated (pulled). The antagonistic rack and pinion mechanism 10 can actuate the first tendon by rotating the main pinion 16 in the first direction, and actuate the second tendon by rotating the main pinion 16 in the second opposite direction.

[0096] Each of the first and second main racks 11 and 12 includes an actuating portion 15 and is capable of linear movement within a linear channel 44 that forms part of the motor module 2.

[0097] Each linear channel 44 can restrict the positioning of the associated first or second main rack 11, 12, such that it remains in contact with and tangential to the associated main pinion 16. Furthermore, the linear channel 44 can restrict the movement of the associated first or second main rack 11, 12, such that it can move linearly only between the first and second ends of the linear channel 44.

[0098] Linear channel 44 can be constructed within motor module 2 such that when motor module 2 is used with surgical instruments, linear channel 44 is parallel to the axis of the surgical instrument shaft. Therefore, the linear movement of the main racks 11, 12, and particularly the actuating portion 15, can be parallel to the desired movement of the tendon of the surgical instrument. This eliminates the need for significant changes in tendon orientation via Bowden lines or pulleys when the tendon leaves the axis so that it can be actuated by the actuating portion forming part of the counter-rack and pinion mechanism 10 of motor module 2.

[0099] Figure 4 It shows the formation Figure 1The motor module 2 shown comprises all three counter-rack and pinion mechanisms 10. In this embodiment of the invention, the main pinion 16 includes a plurality of teeth extending from its periphery, and the first and second main racks 11, 12 each include a plurality of teeth extending from the side of the main racks 11, 12 near the main pinion 16. The teeth of the main pinion 16 are adapted to interlock with the teeth of each main rack 11, 12. When in use, the main motor 4 ( Figure 2 As shown, when the main pinion 16 rotates, the angular movement of the teeth of the main pinion can generate a force on the teeth of the main rack, thereby causing the main racks 11 and 12 to move translationally relative to the main pinion 16.

[0100] In other embodiments of the invention, the first main rack and the second main racks 11, 12 can be movably engaged with the main pinion 16 in any suitable manner.

[0101] Figure 5 It shows the formation Figure 1 One of the double-opposing rack and pinion mechanisms 20 in part of the motor module 2 shown. The first, second, third, and fourth main racks 21, 22, 23, and 24 are each movably engaged with a main pinion 26, wherein rotation of the main pinion 26 causes simultaneous movement of the first and third main racks 21 and 23 in a first direction, and simultaneous movement of the second and fourth main racks 22 and 24 in a second direction. For example, clockwise rotation of the main pinion 26 will cause the first and third main racks 21 and 23 to move upwards, and the second and fourth main racks 22 and 24 to move downwards.

[0102] Therefore, the double-opposing rack and pinion mechanism 20 provides two pairs of main racks that can move in opposition (the first opposing pair is the first main rack and the second main rack 21, 22, and the second opposing pair is the third main rack and the fourth main rack 23, 24).

[0103] This could be particularly advantageous for providing actuation of surgical instruments comprising two adjacent joints capable of rotating in the same direction (see [link]). Figure 16 (Example of adjacent joints). The dual-counter rack and pinion mechanism 20 can provide simultaneous actuation of each associated antagonistic tendon pair in the adjacent joints. In other words, the dual-counter rack and pinion mechanism 20 can be used to simultaneously actuate two adjacent joints. This allows the two adjacent joints to be actuated complementaryly to each other. Furthermore, the actuation of the two joints can be driven by only a single main motor 4, thereby reducing the complexity, size, and cost of the motor module 2.

[0104] Each of the first, second, third, and fourth main racks 21, 22, 23, and 24 includes an actuating portion 25 and is capable of interacting with the forming... Figure 3The first and second main racks, which are part of the counter-rack and pinion mechanism shown, move linearly within the linear channel 44 in a similar manner.

[0105] Each linear channel 44 can restrict the positioning of the associated first and third main racks 21, 23 or the second and fourth main racks 22, 24, such that they remain in contact with and tangential to the associated main pinion 26. Furthermore, the linear channel 44 can restrict the movement of the associated first and third main racks 21, 23 or the second and fourth main racks 22, 24, such that they can move linearly only between the first and second ends of the linear channel 44.

[0106] Similar to the linear channel 44 associated with the counter-rack and pinion mechanism 10, the linear channel 44 associated with the double counter-rack and pinion mechanism 20 can be constructed within the motor module 2 such that, when the motor module 2 is used with a surgical instrument, the linear channel 44 is parallel to the axis of the surgical instrument shaft. Therefore, the linear movement of the main racks 21, 22, 23, 24, and especially the actuating portion 25, can be parallel to the desired movement of the tendon of the surgical instrument.

[0107] Figure 6 It shows the formation Figure 1 The motor module 2 shown has two counter-rotating rack and pinion mechanisms 20. In this embodiment of the invention, the main pinion 26 includes a first portion 27 and a second portion 28, wherein the first main rack and the second main racks 21, 22 are capable of engaging with the first portion 27, and the third main rack and the fourth main racks 23, 24 are capable of engaging with the second portion 28.

[0108] Furthermore, the first and second portions 27 and 28 have different radii, which allows the first and second main racks 21 and 22 to move at a different gear ratio than the third and fourth main racks 23 and 24. In this embodiment of the invention, the second portion 28 has a larger radius than the first portion 27, such that in use, rotation of the main pinion 26 causes the third and fourth main racks 23 and 24 to move a greater distance in their respective directions than the first and second main racks 21 and 22.

[0109] The radii of the first and second portions 27, 28 can be configured to ensure that, if the motor module 2 is used to actuate a surgical instrument having two adjacent joints, both joints can be actuated to rotate through the same angle of rotation, although the more distal end of the two joints requires greater tendon actuation. For example, in this embodiment of the invention, the third and fourth main racks 23, 24 can be configured to actuate a pair of antagonistic tendons associated with the more distal end of the adjacent joint forming part of the surgical instrument, because they will provide greater actuation compared to that provided by the first and second main racks 21, 22.

[0110] Figure 7 and Figure 8 It shows the formation Figure 1 The illustrated motor module 2 includes a secondary rack and pinion mechanism 30. The secondary rack 32 is movably engaged with a secondary pinion 34, wherein rotation of the secondary pinion 34 causes movement of the secondary rack 32. For example, in this embodiment of the invention, clockwise rotation of the secondary pinion 34 causes the secondary rack 32 to move to the right, while counterclockwise rotation causes the secondary rack 32 to move to the left.

[0111] The secondary rack 32 includes an actuating portion 35 through which the secondary rack and pinion mechanism 30 actuates one aspect of the surgical instrument. In this embodiment of the invention, the secondary rack and pinion mechanism 30 is configured to provide translational movement perpendicular to the movement provided by the primary rack and pinion mechanisms 10, 20. The "side-to-side" movement of the secondary rack 32 can, for example, provide rotation of the surgical instrument's axis about its axis.

[0112] Special reference Figure 7 The secondary rack 32 is movable within a linear channel 44, similar to the linear channel 44 associated with the counter-rack and pinion mechanism and the double counter-rack and pinion mechanism 10, 20. The linear channel 44 can restrict the positioning of the secondary rack 32 such that the secondary rack 32 remains in contact with and tangential to the associated secondary pinion 34. Furthermore, the linear channel 44 can restrict the movement of the secondary rack 32 such that it can move linearly only between the first and second ends of the linear channel 44.

[0113] Figure 9 and Figure 10 It shows the formation Figure 1 The translation pinion 36 is a part of the motor module 2 shown.

[0114] Special Reference Figure 9The translation pinion 36 is positioned to extend at least partially from the motor module 2 so that it can interact with the translation rack (see FIG13 for further details). To allow the translation pinion 36 to be positioned close to the edge of the motor module while still being driven by the translation motor 8 located at position F, this embodiment of the invention also includes a gear mechanism 37 (such as...). Figure 10 As shown), the gear mechanism is adapted to provide rotation of the translation pinion 36 about an axis different from that of the translation motor (position F).

[0115] Figure 11 and Figure 12 It shows the relationship with Figure 1 The motor module 2 shown is similar to the motor module 102, except that it also includes an interface board 140 and an instrument mounting bracket. In this embodiment of the invention, the instrument mounting bracket includes a pair of channels 50a and a latch 50b, the pair of channels 50a facilitating slidable engagement of surgical instruments via a sterile barrier, and the latch 50b facilitating lockable engagement of surgical instruments via a sterile barrier. (Similar to...) Figure 2 Similarly, the outer casing 46 has been removed to expose the inner casing 47 and motors 4, 6, and 8.

[0116] Specific reference Figure 11 The interface plate 140 includes a plurality of first orifices 141 and a plurality of second orifices 142. Actuating portions 15, 25 of each first main rack 11 or of each first main rack and third main rack 21, 23 are movable within a corresponding first orifice 141. Similarly, actuating portions 15, 25 of each second main rack 12 or of each second main rack and fourth main rack 22, 24 are movable within a corresponding second orifice 142. Furthermore, an actuating portion 35 forming part of the secondary rack 32 is movable within a secondary orifice 144.

[0117] Interface board 140 covers and protects the internal components of motor module 102, such as motors 4, 6, and 8 (e.g. Figure 2 (as shown) and pinions 16, 26, 34, 36 (as shown) Figure 1 (As shown).

[0118] Now for reference Figure 12 Translation pinion 36 (similar to) Figure 1 , 9 The translation pinion shown in Figure 10 extends from the motor module 2, allowing it to engage with the translation rack that forms part of the mounting bracket.

[0119] Figure 13a , Figure 13b and Figure 13c A motor module 102 is shown, having an outer housing 46 covering motors 4, 6, and 8. The motor module 102 is removably mounted on a mounting bracket 60, allowing the translation pinion 36 (in...) Figure 12 (shown more clearly in the image) and the translation rack 61 forming part of the mounting bracket 60 (especially in the image) Figure 13c (As shown in the image) the connection.

[0120] Gear assembly 37 (e.g.) Figure 10 (As shown) can be adapted to provide rotation of the translation pinion relative to that of the translation motor 8 (e.g.) Figure 2 The rotation generated by the gear drive (as shown). For example, the translation pinion 36 can be geared to a speed greater than that of the translation motor 8 (as shown). Figure 2 (As shown) a large angular velocity rotation to provide a greater responsiveness to the input provided by the motor module 102 along the mounting bracket 60 for translation. Alternatively, the translation pinion 36 can be geared to rotate at a lower angular velocity than the translation motor 8 to provide translational movement that can be achieved by the motor module 102 with higher precision than the mounting bracket 60.

[0121] Figure 13a , Figure 13b and Figure 13c A surgical instrument 70 extending from a actuator module 62 is also shown, the actuator module 62 being removably mounted to a sterile barrier 64, which in turn is removably mounted to a motor module 102.

[0122] The sterile barrier 64 may include a pair of channels 50a (e.g. Figure 11 and Figure 12 Sliding engagement features (as shown) that engage with the latch 50b (such as channels, ridges, or grooves that are complementaryly constructed), and features that can engage with the latch 50b (as shown). Figure 11 and Figure 12 (As shown) Lockable engagement features, such as a recess configured to receive latch 50b. In use, by sliding sterile barrier 64 on interface plate 140, sterile barrier 64 engages with channel 50a until the latch recess of sterile barrier 64 aligns with latch 50b, thereby allowing motor module 102 to be lockably engaged with sterile barrier. Sterile barrier 64 can be slidably mounted on motor module 102.

[0123] The actuator module 62 can be mounted to the sterile barrier 64 in a similar manner or by any suitable means, such that surgical instruments associated with the actuator module are indirectly and removably mounted to the motor module 102.

[0124] Figure 14 A first side 66 of a sterile barrier 64 that can be removably mounted to the motor module 102 is shown, and Figure 15 A second side 68 of a sterile barrier 64 for mounting the driver module 62 is shown. The sterile barrier 64 includes a plurality of movable translateers 67.

[0125] In order for the motor module 102 to actuate the surgical instrument, the actuating parts 15, 25 and 35 (e.g. Figure 11 (As shown) can engage with the translator 67 via a first side of the sterile barrier 66. The translator 67 extends through the sterile barrier 64, allowing it to engage with the actuator forming part of the actuator module 62 via a second side 68. Movement of the actuation portions 15, 25, and 35 of the motor module 102 can cause corresponding movement of the translator 67, which in turn can cause movement of the actuator of the actuator module 62. Movement of the actuator of the actuator module can lead to actuation of surgical instruments, possibly via tendons.

[0126] Figure 16 A surgical instrument 70 extending from the driver module 62 is shown (e.g., Figure 13a , Figure 13b and Figure 13c (As shown). The surgical instrument 70 includes a shaft 72 extending from the actuator module 62, a joint portion 74 coupled to the shaft 72, and an end effector 76 coupled to the joint portion 74.

[0127] The surgical instrument 70 is capable of performing several of the following actuations:

[0128] - The forward or backward translation of the surgical instrument 70

[0129] - Clockwise or counterclockwise rotation of surgical instruments 70

[0130] - The upward or downward actuation of the first pitch joint 81 and the second pitch joint 82,

[0131] - The leftward or rightward actuation of the first yaw joint 83 and the second yaw joint 84

[0132] - Upward or downward actuation of the wrist joint 85

[0133] - The clockwise or counterclockwise actuation of the left claw 86

[0134] - The clockwise or counterclockwise actuation of the right claw 87

[0135] - The actuation of claws 86 and 87 in the same direction at the same speed results in movement similar to that of a joint, and

[0136] - Actuation of claws 86 and 87 in opposite directions causes the claws to open / close.

[0137] Reference Figures 1 to 1 The corresponding features shown in 3, each of the actuations listed above, can be caused by motor module 2 or 102 respectively.

[0138] Translation pinion 36

[0139] The translation motor 8 located at position F can rotate the translation pinion 36 clockwise or counterclockwise, causing it to roll along the translation rack that forms part of the mounting bracket 60. As a result, the motor module 2 / 102 (and the surgical instrument 70 mounted thereon) can be translated backward and forward relative to the mounting bracket 60.

[0140] 30 auxiliary rack and pinion mechanism

[0141] The auxiliary motor 6, located at position G, can rotate the auxiliary pinion 34 clockwise or counterclockwise to cause the auxiliary rack 32 to translate to the left or right. The resulting movement of the actuating part 35 can be converted within the drive module to provide clockwise or counterclockwise rotation of the surgical instrument 70.

[0142] Double-opposing rack and pinion mechanism 20

[0143] The main motor 4, located at position A, can rotate the main pinion 26 of the corresponding double-opposing rack and pinion mechanism 20 clockwise, causing the corresponding second and fourth main racks 22 and 24 to move away from the surgical instrument 70 (where the surgical instrument is located at...). Figure 1 (at the top). This movement of the second and fourth main racks 22, 24 can pull the tendons associated with the pitch joints 81, 82, causing them to actuate upwards. Conversely, the counterclockwise rotation of the main pinion 26 causes the corresponding first and third main racks 21, 23 to move away from the surgical instrument 70, thereby pulling the tendons also associated with the pitch joints 81, 82, causing them to actuate downwards.

[0144] Similarly, the main motor 4 located at position E can rotate the main pinion 26 of the corresponding double counter-rotating rack and pinion mechanism 20 clockwise or counterclockwise, thereby actuating the yaw joints 83 and 84 to the right or left, respectively.

[0145] Counter rack and pinion mechanism 10

[0146] The main motor 4, located at position C, can rotate the main pinion 16 of the corresponding counter-rack and pinion mechanism 10 clockwise, causing the corresponding second main rack 12 to move away from the surgical instrument 70. This movement of the second main rack can pull the tendon associated with the wrist joint 85, causing it to actuate upwards. Conversely, the counter-clockwise rotation of the main pinion 16 causes the corresponding first main rack 11 to move away from the surgical instrument 70, thereby pulling another of the counter-tendons associated with the wrist joint 85, causing the wrist joint 85 to actuate downwards.

[0147] Similarly, the main motors 4 located at positions D and B can each rotate the main pinion 16 of the corresponding counter-rack and pinion mechanism clockwise or counterclockwise to pull the tendons associated with the left pawl 86 and the right pawl 87, respectively. In each case, clockwise rotation of the main pinion 16 results in clockwise actuation of the associated pawls 86 and 87, and counterclockwise rotation of the main pinion 16 results in counterclockwise actuation of the associated pawls 86 and 87.

[0148] Surgical instrument 70 is an example of a surgical instrument that can be actuated by a motor module according to embodiments of the present invention. The motor module according to embodiments of the present invention can be used to actuate any suitable surgical instrument. For example, the shaft may be longer or shorter than the shaft 72 shown, the joint portion may include more or fewer joints than the joint portion 74 shown, and the end effector may differ from the end effector 76 shown. For example, the end effector may be a scalpel, scissors, cauterization tool, suction tool, or injection needle.

[0149] Now refer to Figure 17 The diagram shows the internal components of motor modules 2 and 102. These internal components include four processors 82 and a safety watchdog 84, each mounted on a motherboard 80. The safety watchdog 84 can be electrically connected to each processor 82 via the motherboard 80.

[0150] Each processor 82 can receive control signals from a control module that forms part of the robotic surgical system. Based on the control signals, each processor 82 can selectively provide electrical power to one or more of the motors 4, 6, and 8 that form part of the motor modules 2 and 102, so as to enable the motors to provide rotational movement.

[0151] The safety watchdog 84 can monitor errors in motor modules 2 and 102, such as a faulty motor, a motor that cannot complete its controlled movement (which can indicate a blockage in the system), or a processor that cannot execute control signals.

[0152] In addition, heat sinks 86 are installed on each processor 82 and the security watchdog 84. Each heat sink 86 can absorb the heat generated by the processor 82 and the security watchdog 84 during the use of motor modules 2, 102. Each heat sink 86 includes a finned cooling surface, which increases the surface area of ​​the heat sink 86 and improves heat dissipation. Therefore, each heat sink 86 helps prevent overheating of the components of motor modules 2, 102.

[0153] Now for reference Figure 18 Motherboard 80 is installed on motor modules 2 and 102 (e.g.) Figure 2 and 12The inner housing 47 (shown) positions the processor 82 and the security watchdog 84 around the motors 4, 6, 8. A chassis 48 is also mounted on the inner housing 47, and the chassis 48 is adapted to support the various internal components in their intended positions within the motor modules 2, 102.

[0154] Cooling fan 88 is mounted on chassis 48. The cooling fan is operable to direct airflow over motor modules 2, 102 and help cool internal components, particularly motors 4, 6, 8, processor 82, and heat sink 86. Furthermore, cooling fan 88 is oriented to direct airflow parallel to motors 4, 6, 8, processor 82, and safety watchdog 84.

[0155] Furthermore, the fins of the heat sink 86 extend parallel to the airflow generated by the cooling fan 88. This encourages airflow across the cooling surface of the heat sink and improves heat dissipation, thus further helping to prevent overheating of the components of the motor modules 2, 102.

[0156] Unless the context otherwise indicates, preferences and options for a given aspect, feature, or parameter of the invention should be considered as disclosed in conjunction with any and all preferences and options for all other aspects, features, and parameters of the invention. For example, a motor module according to an embodiment of the invention may include more than one rack and pinion mechanism, or may not include a rack and pinion mechanism, rather than as described above. Figures 1 to 15 The diagram shows a single rack and pinion mechanism.

Claims

1. A motor module comprising: The main pinion, which can be rotatably driven by the main motor, The first main rack, which is movably engaged with the main pinion, and The second main rack is movably engaged with the main pinion; The rotation of the main pinion causes the first main rack to move in a first direction and the second main rack to move in a second direction, thereby forming an anti-rack and pinion mechanism together with the first main rack, the second main rack and the main pinion. The motor module includes multiple motors and multiple counter-rack and pinion mechanisms, wherein the main pinion of each counter-rack and pinion mechanism can be driven by a corresponding one of the motors; At least one of the counter-rack and pinion mechanisms is a double-counter-rack and pinion mechanism, and the double-counter-rack and pinion mechanism further includes: The third main rack, which is movably engaged with the main pinion, and A fourth main rack, which is movably engaged with the main pinion; The rotation of the main pinion causes the third main rack to move along the first direction and the fourth main rack to move along the second direction. Each main rack further includes an actuating portion. The motor module further includes an interface board, which includes multiple first openings and multiple second openings. The actuating parts of each first main rack, or each first main rack and the third main rack, can move within the corresponding first orifice, and The actuating parts of each second main rack or each second main rack and the fourth main rack can move within the corresponding second orifice.

2. The motor module according to claim 1, wherein, The main pinion of the double-opposing rack and pinion mechanism or each double-opposing rack and pinion mechanism comprises a first part and a second part. The first and second main racks can engage with the first portion of the main pinion, and The third and fourth main racks can engage with the second part of the main pinion.

3. The motor module according to claim 1, wherein, Each main rack can move linearly.

4. The motor module according to claim 1, further comprising an auxiliary motor and an auxiliary rack and pinion mechanism, wherein the auxiliary rack and pinion mechanism comprises: A secondary pinion, which can be rotatably driven by the secondary motor. A secondary rack, which is movably engaged with the secondary pinion, wherein rotation of the secondary pinion causes movement of the secondary rack.

5. The motor module according to claim 1, wherein, The motor module can be removably mounted on the mounting bracket and can move along the mounting bracket.

6. The motor module according to claim 5, wherein, The mounting bracket includes a translation rack, and the motor module further includes a translation motor and a translation pinion, the translation pinion being rotatably driven by the translation motor and engaging with the translation rack when the motor module is mounted on the mounting bracket, such that rotation of the translation pinion causes movement of the motor module relative to the mounting bracket.

7. The motor module of claim 6, further comprising a gear assembly rotatably driven by the translation motor and rotatably and mechanically coupled to the translation pinion such that the translation pinion is rotatably driven by the translation motor via the gear assembly.

8. The motor module according to claim 1, wherein, The motor module is configured to actuate surgical instruments.

9. The motor module of claim 8, further comprising an instrument mounting bracket mechanically connectable to a surgical instrument, such that the surgical instrument can be removably mounted to the motor module.

10. The motor module of claim 1, further comprising a processor capable of being electrically connected to at least one motor.

11. The motor module of claim 10, further comprising a security watchdog electrically connected to the processor.

12. The motor module according to any one of claims 1 to 11, further comprising a cooling fan, a finned heat sink, or both.

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