Dual drive pinion cross check

Abstract

A robotic surgical system includes a closure system. The closure system includes a first pinion driveably coupled to a first motor, a second pinion driveably coupled to a second motor, and a closure gear selectively driven by the first pinion and the second pinion. The robotic surgical system also includes a control circuit configured to implement a motor cross-check operation. The control circuit is configured to receive a first parameter indicative of a first torque generated by the first motor, receive a second parameter indicative of a second torque generated by the second motor, compare the first parameter to the second parameter, and transmit a signal to a communication device, where the signal is based on the comparison and is indicative of a status of the closure system.

Description

Background Technology

[0001] This disclosure relates to robotic surgical systems. A robotic surgical system may include a central control unit, a surgeon's command console, and a robot with one or more robotic arms. Robotic tools may be releasably mounted to the robotic arms. The number and type of robotic tools may depend on the type of surgical procedure. In some cases, the robotic surgical system may be used in conjunction with one or more displays and / or one or more handheld surgical instruments during the surgical procedure. Summary of the Invention

[0002] In one aspect, this disclosure provides a robotic surgical system including a closure system. The closure system includes a first pinion driven to a first motor, a second pinion driven to a second motor, and a closing gear selectively driven by the first and second pinions. The robotic surgical system also includes control circuitry configured to perform motor cross-checking operations. The control circuitry is configured to receive a first parameter indicating a first torque generated by the first motor, receive a second parameter indicating a second torque generated by the second motor, compare the first parameter with the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicates the state of the closure system.

[0003] In another aspect, this disclosure provides a non-transitory computer-readable medium storing computer-readable instructions that, when executed, cause a machine to receive a first parameter indicating a first torque generated by a first motor of a closed system, receive a second parameter indicating a second torque generated by a second motor of the closed system, and perform a motor cross-check. The first and second motors are configured to simultaneously drive a closed gear. The motor cross-check includes comparing the first parameter with the second parameter and transmitting a signal to a communication device, wherein the signal is based on the comparison and indicates the state of the closed system.

[0004] In another aspect, this disclosure provides a robotic surgical system including a closure system. The closure system includes a first pinion driven to a first motor, a second pinion driven to a second motor, and a closing gear selectively driven by the first and second pinions. The closure system also includes a processor and a memory coupled to the processor. The memory stores instructions executable by the processor to receive a first parameter indicating a first torque from the first motor, a second parameter indicating a second torque from the second motor, and a third parameter indicating a first angular displacement of the first motor. The memory also stores instructions executable by the processor to receive a fourth parameter indicating a second angular displacement of the second motor, and to determine the state of the closure system based on the first, second, third, and fourth parameters. The memory further stores instructions executable by the processor to transmit a signal indicating the state of the closure system to a communication device. Attached Figure Description

[0005] The novel features of various aspects are specifically set forth in the appended claims. However, the described aspects relating to both the organization and the method of operation are best understood by referring to the following description in conjunction with the accompanying drawings, wherein:

[0006] Figure 1 This is a schematic diagram illustrating an operating room including a robotic surgical system according to at least one aspect of the present disclosure, the robotic surgical system having multiple robotic arms.

[0007] Figure 2 It is a perspective view of a robotic arm including a tool actuator according to at least one aspect of this disclosure, and also shows a robotic tool mounted to the tool actuator.

[0008] Figure 3 It is based on at least one aspect of this disclosure Figure 2 The tool driver and the tool driver installed Figure 2 A perspective view of the proximal tool base of a robotic tool.

[0009] Figure 4 It is based on at least one aspect of this disclosure Figure 2 A perspective view of a tool driver that does not have a robot tool base mounted on it.

[0010] Figure 5 It is a plan view of the proximal portion of a robotic tool according to at least one aspect of this disclosure.

[0011] Figure 6 This is a perspective view of a surgical suturing tool according to at least one aspect of this disclosure.

[0012] Figure 6A It is based on at least one aspect of this disclosure Figure 6 A detailed perspective view of a portion of a surgical suturing tool, showing the proximal tool base and the rotary drive housed therein, with some parts removed from the proximal tool base for clarity.

[0013] Figure 6B It is based on at least one aspect of this disclosure Figure 6A A detailed perspective view of a portion of the proximal tool base, with some parts removed for clarity.

[0014] Figure 7 It is for use according to at least one aspect of this disclosure Figure 6 A perspective view of a rotary drive system for a surgical suture tool, wherein the rotary drive system includes a transition nut slidably positioned between a high-torque gear assembly and a high-speed gear assembly.

[0015] Figure 8 It is based on at least one aspect of this disclosure Figure 7 A cross-sectional perspective view of the rotary drive system, with the high-speed gear assembly removed for clarity.

[0016] Figure 9 It is in a high-speed operating state according to at least one aspect of this disclosure. Figure 7 A front view of the rotary drive system, with the transition nut shown as transparent to reveal the components hidden within.

[0017] Figure 10 It is in a transitional state according to at least one aspect of this disclosure. Figure 7 A front view of the rotary drive system, in which the high-torque gear portion is shown as transparent to expose the internal array of inclined grooves.

[0018] Figure 11 It is in a high-torque operating state according to at least one aspect of this disclosure. Figure 7 A front view of the rotary drive system, in which the high-torque gear portion is shown as transparent to expose the internal array of inclined grooves.

[0019] Figure 12 This is a schematic diagram of a dual-drive arrangement of a robotic surgical tool for implementing a cross-checking procedure according to at least one aspect of this disclosure.

[0020] Figure 13 It is based on at least one aspect of this disclosure Figure 12 The cross-inspection procedure is graphically represented by angular displacement and torque over time.

[0021] Figure 14 It is based on at least one aspect of this disclosure and Figure 12 A schematic diagram of the control circuit used in conjunction with the drive arrangement.

[0022] Figure 15 and Figure 16 It is an implementation of the cross-checking procedure based on at least one aspect of this disclosure. Figure 12 A schematic diagram of the dual-drive arrangement.

[0023] Figure 17 It is based on at least one aspect of this disclosure Figure 15 and Figure 16 The cross-inspection procedure is graphically represented by angular displacement and torque over time.

[0024] Figure 18 It is a graphical representation of the angular displacement over time of the cross-inspection procedure according to at least one aspect of this disclosure.

[0025] Figure 19 It is based on at least one aspect of this disclosure Figure 18 A graphical representation of the torque over time for the cross-inspection procedure.

[0026] Figure 20 It is based on at least one aspect of this disclosure Figure 18 and Figure 19 Cross-inspection procedures Figure 19 Torque relative to Figure 18 The graphical representation of angular displacement.

[0027] Figure 21 This is a front view of a robotic surgical tool according to at least one aspect of the present disclosure, the robotic surgical tool including a drive housing, a surgical end effector, and an articulation joint located between the drive housing and the surgical end effector.

[0028] Figure 22 It is based on at least one aspect of this disclosure and Figure 21 A schematic diagram of a control circuit that uses two joint motion input drivers together.

[0029] Figure 23 This is a control schematic diagram of a soft-cushioned joint motion control method for a robotic surgical tool according to at least one aspect of this disclosure.

[0030] Figure 24 This is a front view of a portion of a robotic surgical tool according to at least one aspect of the present disclosure, the robotic surgical tool including a drive housing, a surgical end effector, and an articulated joint located between the drive housing and the surgical end effector, wherein certain features have been removed from the robotic surgical tool for clarity and to expose the interior of the drive housing.

[0031] Figure 25 It is based on at least one aspect of this disclosure. Figure 24 The plane shown is cut off Figure 24 A cross-sectional view of the drive housing.

[0032] Figure 26 This is a front view of a portion of a robotic surgical tool according to at least one aspect of the present disclosure, the robotic surgical tool including an inner shaft, an articulation joint, a surgical end effector, and an articulation system including an articulation yoke.

[0033] Figure 27 It is the proximal portion of the joint kinetic system including the articular yoke according to at least one aspect of this disclosure and Figure 26 A perspective view of a portion of the inner axis of a robotic surgical tool.

[0034] Figure 28 This is an exploded perspective view of the rolled element pad of the joint motion system of a robotic surgical tool according to at least one aspect of this disclosure.

[0035] Figure 29 This is a flowchart describing a method for displaying overlaid features on a visual display of a surgical imaging system according to at least one aspect of the present disclosure.

[0036] Figures 30A to 30D These are front views of a visual display for a surgical imaging system according to at least one aspect of this disclosure, showing portions of a robotic surgical tool during surgery, and illustrating the process of transmitting information to a clinician in the visual display using end effector overlay features.

[0037] Figure 31 This is a schematic diagram of a robotic surgical system according to at least one aspect of the present disclosure.

[0038] Figure 32 This is a perspective view of a surgical robot according to at least one aspect of this disclosure.

[0039] Figure 33 It is based on at least one aspect of this disclosure Figure 31 Tool drivers and robotic surgical systems Figure 32 A perspective view of a surgical robot.

[0040] Figure 34 It is based on at least one aspect of this disclosure and Figure 33 A front view of the surgical tools used with the tool driver.

[0041] Figure 35 It is for actuation according to at least one aspect of this disclosure Figure 34 A plan view of the actuation mechanism of the end effector of a surgical tool.

[0042] Figure 36 It is for making at least one aspect of this disclosure Figure 34 Surgical tools relative to Figure 33 A front view of the actuating mechanism for translation of the tool driver.

[0043] Figure 37 This is a cross-sectional front view of a surgical tool according to at least one aspect of the present disclosure, including a portion of an actuation mechanism for translating the surgical tool relative to a tool driver.

[0044] Figure 38 This is a flowchart illustrating a transverse cutting operation of a surgical tool according to at least one aspect of this disclosure.

[0045] Figure 39 It is a control circuit diagram for implementing a cross-cutting operation according to at least one aspect of this disclosure.

[0046] In several views, corresponding reference symbols indicate corresponding parts. The examples described herein illustrate certain embodiments of the invention in one form, and such examples should not be construed as limiting the scope of the invention in any way. Detailed Implementation

[0047] The applicant of this application also owns the following U.S. patent applications filed on the same date as this application, each of which is incorporated herein by reference in its entirety:

[0048] ● U.S. patent application entitled “SURGICAL TOOL WITH TOOL-BASED TRANSLATION AND LOCK FOR THESAME”, agent file number END9299USNP1 / 200833;

[0049] ● U.S. patent application entitled “ROBOTIC SURGICAL TOOLS HAVING DUAL ARTICULATION DRIVES”, attorney file number END9300USNP1 / 200834; and

[0050] ● The U.S. patent application entitled “TORQUE-BASED TRANSITION BETWEEN OPERATING GEARS”, agent file number END9301USNP1 / 200835.

[0051] The applicant of this application also owns U.S. Patent Application 16 / 553,725, filed on August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION”, the entire contents of which are incorporated herein by reference.

[0052] The applicant of this application also owns U.S. Provisional Patent Application No. 62 / 611,339, filed on December 28, 2017, entitled “ROBOT ASSISTEDSURGICAL PLATFORM,” the entire contents of which are incorporated herein by reference.

[0053] The applicant of this application also owns the following U.S. patent applications filed on March 29, 2018, each of which is incorporated herein by reference in its entirety:

[0054] ● U.S. Patent Application No. 15 / 940,627 entitled “DRIVE ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS”;

[0055] ■ U.S. Patent Application No. 15 / 940,676 entitled “AUTOMATIC TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICALPLATFORMS”; and

[0056] ■ U.S. Patent Application No. 15 / 940,711 entitled “SENSING ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS”.

[0057] Before detailing the various aspects of the robotic surgical platform, it should be noted that the illustrative examples are not limited in application or use to the details of the construction and arrangement of the components shown in the drawings and specifications. The illustrative examples may be implemented or incorporated in other aspects, variations, and modifications, and may be practiced or performed in various ways. Furthermore, unless otherwise specified, the terminology and expressions used herein are chosen for the convenience of the reader in describing the illustrative examples and are not intended to be restrictive. Moreover, it should be understood that one or more of the aspects, expressions, and / or examples described below may be combined with any one or more of the other aspects, expressions, and / or examples described below.

[0058] Minimally invasive surgical procedures (MIS), such as laparoscopic surgery, typically involve techniques designed to minimize tissue damage during surgical procedures. For example, a laparoscopic procedure may involve making multiple small incisions inside the patient (e.g., in the abdomen) and introducing one or more surgical instruments (e.g., end effectors and endoscopes) through these incisions. The surgical procedure can then be performed using the introduced surgical instruments, with visualization aids provided by, for example, an endoscope. Exemplary surgical visualization systems are further described in the following references, the full text of which is incorporated herein by reference:

[0059] ● U.S. Patent Application No. 2020 / 0015923A1, entitled “SURGICAL VISUALIZATION PLATFORM”, was published on January 16, 2020.

[0060] ● U.S. Patent Application No. 2020 / 0015904A1, entitled “SURGICAL VISUALIZATION CONTROLS”, was published on January 16, 2020.

[0061] ● U.S. patent application entitled “CONTROLLING AN EMITTER ASSEMBLY PULSESEQUENCE”, published on January 16, 2020, is published under publication number 2020 / 0015900A1;

[0062] ● U.S. patent application entitled “SINGULAR EMR SOURCE EMITTER ASSEMBLY”, published on January 16, 2020, is published under publication number 2020 / 0015668A1;

[0063] ● U.S. patent application No. 2020 / 0015925A1, entitled “COMBINATION EMITTER AND CAMERA ASSEMBLY”, was published on January 16, 2020.

[0064] ● U.S. Patent Application No. 2020 / 0015899A1, entitled “SURGICAL VISUALIZATION WITH PROXIMITYTRACKING FEATURES”, was published on January 16, 2020.

[0065] ● U.S. patent application entitled “SURGICAL VISUALIZATION OF MULTIPLETARGETS”, published on January 16, 2020, is published under publication number 2020 / 0015903A1;

[0066] ● U.S. Patent 10,792,034, entitled “VISUALIZATION OF SURGICAL DEVICES”, published on October 6, 2020;

[0067] ● U.S. patent application entitled “OPERATIVE COMMUNICATION OF LIGHT”, published on January 16, 2020, is published under publication number 2020 / 0015897A1;

[0068] ● U.S. Patent Application No. 2020 / 0015924A1, entitled “ROBOTIC LIGHT PROJECTION TOOLS”, was published on January 16, 2020.

[0069] ● U.S. patent application No. 2020 / 0015898A1, entitled “SURGICAL VISUALIZATION FEEDBACK SYSTEM”, published on January 16, 2020;

[0070] ● U.S. patent application entitled “SURGICAL VISUALIZATION AND MONITORING”, published on January 16, 2020, is published under publication number 2020 / 0015906A1;

[0071] ● U.S. patent application entitled “INTEGRATION OF IMAGING DATA”, published on January 16, 2020, is published under publication number 2020 / 0015907A1;

[0072] ● U.S. Patent Application No. 2020 / 0015806A1, entitled “ROBOTICALLY-ASSISTED SURGICAL SUTURING SYSTEMS”, was published on January 16, 2020.

[0073] ● U.S. Patent Application No. 2020 / 0015901A1, entitled “SAFETY LOGIC FOR SURGICAL SUTURING SYSTEMS”, was published on January 16, 2020.

[0074] ● U.S. Patent Application Publication 2020 / 0015914A1, entitled "ROBOTIC SYSTEMS WITH SEPARATEPHOTOACOUSTIC RECEIVERS," published on January 16, 2020; and

[0075] ● U.S. Patent Application No. 2020 / 0015902A1, entitled “FORCE SENSOR THROUGH STRUCTURED LIGHTDEFLECTION”, was published on January 16, 2020.

[0076] MIS can offer several beneficial effects, such as reducing patient scarring, alleviating patient pain, shortening patient recovery time, and / or reducing medical costs associated with patient recovery. Recent technological advancements have allowed robotic systems to perform more MIS procedures. Robotic systems typically include one or more robotic arms used to manipulate surgical instruments based on commands from a remote operator (e.g., a surgeon / clinician). The robotic arms may, for example, support various surgical devices at their distal end, such as surgical end effectors, imaging devices, and cannulas for providing access to the patient's body cavities and organs.

[0077] Existing robot-assisted surgical systems typically consist of a surgeon's console and a patient-side trolley, with one or more interactive robotic arms controlled from the console. For example, one robotic arm may support a camera, while other robotic arms may support robotic tools such as scalpels, scissors, grippers, and suture devices. Various exemplary robotic tools are further described in this paper.

[0078] The robotic surgical system disclosed herein can be a software-controlled electromechanical system designed for surgeons to perform MIS procedures. The robotic surgical system can be used with endoscopes, compatible endoscopic instruments, and accessories. The system can be used by trained physicians in an operating room environment to aid in the accurate control of compatible endoscopic instruments during robot-assisted urological, gynecological, gastric, and other laparoscopic surgical procedures. Compatible endoscopic instruments and accessories used with the surgical system are designed for endoscopic manipulation of tissue, including, for example, ligation, grasping, cutting, blunt and sharp dissection, traction, joining, electrocautery, and suturing.

[0079] Figure 1An exemplary operating room environment is illustrated. A robotic surgical system 100 is shown situated within an operating room, and includes a user console 110, a control tower 130, and a surgical robot 120 having one or more robotic surgical arms 122 mounted on a surgical platform 124 (e.g., a table or bed). Clinicians can attach surgical instruments with end effectors to the distal ends of the robotic arms 122 to perform surgical procedures. The robotic arms 122 are tabletop mounted, but in other configurations, they may be mounted to a cart, floor, ceiling, sidewall, or other suitable support surface. In various cases, the robotic arms may be supported by a self-supporting robot with a base and / or column, as further described in U.S. Patent Application 16 / 553,725, filed August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION”. The full text of U.S. Patent Application 16 / 553,725, filed on August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION,” is incorporated herein by reference.

[0080] Typically, the user (such as a surgeon or other operator) is located at user console 110 to remotely operate the robotic arm 122 and / or surgical instruments via remote control. User console 110 may be located in the same operating room as the robotic system 100, such as... Figure 1 As shown. In other environments, the user console 110 may be located in an adjacent or nearby room, or operated remotely from a remote location in a different building, city, or country. The user console 110 may include a seat 112, a pedal 114, one or more handheld user interface devices (UIDs) 116, and a display 118 configured to display a view, for example, of a surgical site within a patient's body. As shown in the exemplary user console 110, a surgeon seated in the seat 112 and viewing the open display 118 can manipulate the pedal 114 and / or the handheld user interface device 116 to remotely control the robotic arm 122 and / or surgical instruments mounted to the distal end of the arm 122. Exemplary robotic input devices and / or sensor arrangements are further described in the following references, the full text of which is incorporated herein by reference:

[0081] ● U.S. Patent Application No. 2020 / 0289219A1, entitled “INPUT CONTROLS FOR ROBOTIC SURGERY,” was published on September 17, 2020.

[0082] ● U.S. Patent Application No. 2020 / 0289228A1, entitled “DUAL MODE CONTROLS FOR ROBOTIC SURGERY,” was published on September 17, 2020.

[0083] ● U.S. Patent Application No. 2020 / 0289216A1, entitled “MOTION CAPTURE CONTROLS FOR ROBOTICSURGERY”, was published on September 17, 2020.

[0084] ● U.S. Patent Application No. 2020 / 0289229A1, entitled “ROBOTIC SURGICAL CONTROLS HAVING FEEDBACK CAPABILITIES”, was published on September 17, 2020.

[0085] ● U.S. patent application No. 2020 / 0289230A1, entitled “ROBOTIC SURGICAL CONTROLS WITH FORCEFEEDBACK”, was published on September 17, 2020.

[0086] ● U.S. Patent Application No. 2020 / 0289217A1, entitled “JAW COORDINATION OF ROBOTIC SURGICAL CONTROLS”, was published on September 17, 2020.

[0087] ● U.S. Patent Application No. 2020 / 0289220A1, entitled “ROBOTIC SURGICAL SYSTEMS WITH MECHANISMS FOR SCALING SURGICAL TOOL MOTION ACCORDING TO TISSUE PROXIMITY”, was published on September 17, 2020.

[0088] ● U.S. Patent Application No. 2020 / 0289205A1, entitled “ROBOTIC SURGICAL SYSTEMS WITH MECHANISMS FOR SCALING CAMERA MAGNIFICATION ACCORDING TO PROXIMITY OF SURGICAL TOOL TOTISSUE”, was published on September 17, 2020.

[0089] ● U.S. Patent Application No. 2020 / 0289221A1, entitled “ROBOTIC SURGICAL SYSTEMS WITH SELECTIVELYLOCKABLE END EFFECTORS”, was published on September 17, 2020.

[0090] ● U.S. Patent Application Publication 2020 / 0289222A1, entitled “SELECTABLE VARIABLE RESPONSE OF SHAFTMOTION OF SURGICAL ROBOTIC SYSTEMS,” published on September 17, 2020; and

[0091] ● U.S. Patent Application No. 2020 / 0289223A1, entitled “SEGMENTED CONTROL INPUTS FOR SURGICALROBOTIC SYSTEMS”, was published on September 17, 2020.

[0092] In some variants, the user can also operate the robotic surgical system 100 in an "OTB" (on-bed) mode, where the user is positioned to the patient's side and simultaneously manipulates the robot-driven tools / end effectors attached to it (e.g., a handheld user interface device 116 held in one hand) and manual laparoscopic tools. For example, the user's left hand can manipulate the handheld user interface device 116 to control the robotic surgical components, while the user's right hand can manipulate the manual laparoscopic tools. In these variants, the user can perform both robot-assisted MIS and manual laparoscopic surgery on the patient.

[0093] In some respects, communication between the surgical robot 120 and the user console 110 can be achieved via a control tower 130, which can translate user input from the user console 110 into robot control commands and transmit those commands to the surgical robot 120. The control tower 130 can also transmit status and feedback from the robot 120 back to the user console 110. The connection between the surgical robot 120, the user console 110, and the control tower 130 can be wired and / or wireless, and can be proprietary and / or implemented using any of a variety of data communication protocols. Any wired connection can be built into the floor and / or walls or ceiling of the operating room. The robotic surgical system 100 can provide video output to one or more displays, including displays within the operating room and remote displays accessed via the Internet or other networks. Video output or feeds can also be encrypted to ensure privacy, and all or part of the video output can be stored on a server or electronic healthcare record system.

[0094] The robotic surgical system 100 can uniquely identify each tool (endoscope and / or surgical instrument) when attached to its arm 122, and can display the tool type and arm position on the display 118 at the user console 110 and / or on the touchscreen display on the control tower 130. The corresponding tool function can be enabled and activated using the master UID 116 and foot pedal 114. A patient-side assistant can attach and detach tools as needed throughout the procedure. The surgeon, seated at the user console 110, can begin surgical procedures using tools controlled by two master UIDs 116 and foot pedal 114. The system translates the surgeon's hand, wrist, and / or finger movements into precise, real-time movements of the surgical instruments via the master UID 116. Therefore, the system continuously monitors each surgical maneuver performed by the surgeon and can pause instrument movement if the system cannot accurately reflect the surgeon's hand movements.

[0095] Figure 2 The image shows a robotic arm 200. The robotic arm 200 can be integrated with a surgical robot 120. Figure 1 In, for example, robotic arm 200 may correspond to robotic arm 122 of surgical robot 120. Figure 1 A robotic arm 200 is described above. The robotic arm 200 includes a tool actuator 220 and a cannula 221. A robotic surgical tool 250 is mounted to the tool actuator 220 and housed within the cannula 221. The robotic arm 200 includes links (e.g., links 201, 202, 203, 204, 205, 206, 207, 208A, 208B) and actuation joint modules (e.g., joints 211, 212, 213, 214, 215, 216, 217) for actuating the links relative to each other. The joint modules may include various types, such as pitch joints or roll joints, which substantially constrain the movement of adjacent links about certain axes relative to other axes. The tool actuator 220 is attached to the distal end of the robotic arm 200 and includes a sleeve or cannula 221 extending distally therefrom. The cannula 221 is configured to receive and guide the surgical tool 250 into the patient. Robotic tool 250 also includes an articulated joint or wrist 256 and an end effector 258 located at the distal end. Figure 2 The connector modules 211, 212, 213, 214, 215, 216, and 217 of the robotic arm 200 can be actuated to position and orient the tool driver 220, which actuates the robotic wrist 256 and the end effector 258 to perform robotic surgery.

[0096] Figure 3 The tool driver 220, on which surgical tools 250 are mounted, is shown, and Figure 4A tool actuator 22 without surgical instruments mounted is shown. The tool actuator 220 includes an elongated base (or “layer”) 222 having a longitudinal track 223 and a tool carriage 224 slidably engaged with the longitudinal track 223. The layer 222 may be configured to be coupled to the distal end of a robotic arm 200 such that joint movements of the robotic arm 200 position and / or orient the tool actuator 220 in place. Additionally, the tool carriage 224 is configured to receive a tool base 252 of a robotic tool 250. The robotic tool 250 also includes a tool shaft 254 extending from the tool base 252 and through a cannula 221.

[0097] Generally, the tool carriage 224 provides various degrees of freedom for the robotic tool 250 to which it is attached. For example, the longitudinal movement of the tool carriage 224 along the longitudinal track 223 provides the surgical tool 250 with a translational degree of freedom along the tool axis. Alternative translational degrees of freedom (e.g., along the insertion axis) are further described herein.

[0098] Additionally, the tool carriage 224 provides rotational freedom for the surgical tool 250 about its axis of rotation, and various degrees of freedom for actuation or articulation (e.g., grasping or cutting) of the end effector of the surgical tool. For example, the tool carriage 224 includes one or more motor drivers (e.g., linear axis drivers or rotary axis drivers) whose outputs can be coupled to the input drive mechanism of the surgical tool. A first motor driver actuates a first degree of freedom, a second motor driver actuates a second degree of freedom, and so on for all additional motor drivers in the tool carriage. For example, at least one motor driver actuates rotation of the tool shaft in a first direction (e.g., clockwise), and another motor driver actuates rotation of the tool shaft in a counteracting manner in a second direction opposite to the first direction (e.g., counterclockwise). Alternatively, at least one motor driver actuates rotation of the tool shaft in two directions (e.g., clockwise and counterclockwise). Such actuation of the tool may involve, for example, a cable drive mechanism or assembly of mechanisms in the tool coupled to the outputs of the motor drivers in the tool carriage. Exemplary variations of the tool carriage are further described below.

[0099] The tool carriage 224 is configured to actuate a set of joint movements of the robot wrist 256 and end effector 258 via a system of gears, shafts, cables, and / or lines manipulated and controlled by an actuator. See also Figure 4 The tool carriage 224 includes six motors and six corresponding rotary actuators 260, 262, 264, 266, 268 and 270, which are the rotary inputs of the robotic tool. The rotary actuators 260, 262, 264, 266, 268 and 270 are arranged in two rows and extend longitudinally along the base. Figure 4The rotary actuators 260, 262, 264, 266, 268, and 270 are slightly staggered to reduce the overall width of the tool carriage 224, making the tool carriage 224 more compact. Rotary actuators 260, 264, and 268 are arranged in the first row, and rotary actuators 262, 266, and 270 are arranged in a second row slightly longitudinally offset from the first row. A tool carriage with six rotary actuators is further described in, for example, U.S. Patent Application Publication 2020 / 0138534, entitled "ROBOTIC SURGICAL SYSTEM," published May 7, 2020, and U.S. Patent Application 16 / 553,725, filed August 28, 2019, entitled "ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION." The full text of U.S. Patent Application Publication 2020 / 0138534 entitled “ROBOTIC SURGICAL SYSTEM”, published on May 7, 2020, and U.S. Patent Application 16 / 553,725 entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION”, filed on August 28, 2019, are each incorporated herein by reference.

[0100] In other cases, the tool carriage 224 may include different configurations of actuation actuators. For example, U.S. Patent Application Publication 2019 / 0201111, published July 4, 2019, entitled “DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS,” describes tool carriages with various drive arrangements. U.S. Patent 9,072,535, published July 7, 2015, entitled “SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS,” also describes tool carriages with various drive arrangements. U.S. Patent 9,072,535, entitled “SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS”, published July 7, 2015, and U.S. Patent Application Publication 2019 / 0201111, entitled “DRIVE ARRANGEMENTSFOR ROBOTIC-ASSISTED SURGICAL PLATFORMS”, published July 4, 2019, are each incorporated herein by reference in their entirety. Alternative drive arrangements are further described herein.

[0101] See now Figure 5 The image shows the proximal portion of the robotic tool 350. The robotic tool 350 is similar in many respects to the robotic tool 250. Figure 2 and Figure 3 ), and can be adapted to, for example, tool driver 220 ( Figures 2 to 4 ) and surgical robot 120 ( Figure 1 Used together. The proximal portion of the robotic tool 350 includes a tool base 352; an elongated shaft 354 extends distally from the base 352 toward the end effector. The base 352 includes six rotary actuators 360, 362, 364, 366, 368, and 370, which are configured to engage with inputs driven by six rotary motors on the tool carriage, such as rotary actuators 260, 262, 264, 266, 268, and 270 on the tool carriage 224. Figure 4In various cases, each rotary actuator 360, 362, 364, 366, 368, and 370 may be associated with a degree of freedom of the robotic tool 350. In other cases, one or more rotary actuators may correspond to multiple degrees of freedom via a transmission. Exemplary drive arrangements for robotic tools are further described in U.S. Patent Application Publication 2019 / 0201111, entitled “DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS,” published July 4, 2019, the entire contents of which are incorporated herein by reference.

[0102] Each rotary actuator 360, 362, 364, 366, 368, and 370 includes a rotatable disk or disc configured to interact with the corresponding rotary actuators 260, 262, 264, 266, 268, and 270. Figure 4 Alignment and mating. For example, rotary actuators 260, 262, 264, 266, 268, and 270, and rotary actuators 360, 362, 364, 366, 368, and 370 each include one or more mating surface features 240. Figure 4 ) and 340 ( Figure 5 The mating surface features are configured to facilitate mating engagement between opposing surface features 240, 340, such that the movement (i.e., rotation) of a given rotary actuator 260, 262, 264, 266, 268, and 270 correspondingly causes the associated rotary actuator 360, 362, 364, 366, 368, and 370 to move (i.e., rotate).

[0103] The tool carriage 224 may include torque sensors and rotary encoders, which may be integrated into the motors of some or all of the rotary drives 260, 262, 264, 266, 268, and 270. The torque sensors may be configured to measure the real-time torque load on the motors, corresponding to the torque load presented by the rotary drives 260, 262, 264, 266, 268, and 270 and / or the rotary drives 360, 362, 364, 366, 368, and 370 in the robotic tool 350 connected thereto. The rotary encoders may measure the rotational motion or output of the motors, corresponding to the rotational motion of the rotary drives 260, 262, 264, 266, 268, and 270 and / or the rotary drives 360, 362, 364, 366, 368, and 370. Monitoring the torque load and rotational motion of the motors can help determine whether the surgical tool 350 is operating according to commands provided by the control tower 130. In addition or alternatively, the torque sensor and / or rotary encoder may be operatively coupled to one or more rotary drives of rotary drives 360, 362, 364, 366, 368 and 370 in the robot tool 350.

[0104] See you again Figure 5 The rotary actuators 360, 362, 364, 366, 368, and 370 in the tool base 352 can realize various degrees of freedom of the robotic tool 350. For example, rotary actuator 360 can correspond to the pitch motion of the robotic tool 350, rotary actuator 362 can correspond to the roll motion of the robotic tool 350, rotary actuator 364 can correspond to the first yaw motion of the robotic tool 350, rotary actuator 366 can correspond to the second yaw motion of the robotic tool 350 in the opposite direction to the first yaw motion, rotary actuator 368 can correspond to the clamping motion of the robotic tool 350 (e.g., closing of the jaws), and rotary actuator 370 can correspond to the firing motion of the robotic tool 350 (e.g., cutting and suturing tissue). In such cases, a single rotary actuator coupled to a single rotary input in the tool carriage is configured to close the jaws.

[0105] Compared to an arrangement where each motor and its corresponding rotary input is dedicated to a single degree of freedom, a drive system allows for a greater number of degrees of freedom. In certain situations, to achieve higher torque states—such as when firing the firing member through thick and / or tough tissue, which requires high torque input—more than one rotary input on the tool carriage can be driven to a single degree of freedom. Such a drive arrangement is described in U.S. Patent Application Publication 2019 / 0201111, entitled “DRIVEARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS,” published July 4, 2019, the entire contents of which are incorporated herein by reference. In other cases, as further described herein, a single rotary actuator in base 352 can be selectively switched between a high-speed mode and a high-torque mode via a torque-changing member.

[0106] Robotic tool 350 can be a suture tool configured to grip, cut, and suture tissue. See now. Figure 6 The image shows a surgical suture tool 450. Surgical tool 450 is similar to surgical tool 350 in many respects and is therefore compatible with robotic surgical systems such as robotic surgical system 100. Figure 1 ) and with robotic arm 200 ( Figure 2 ) and tool driver 220 ( Figure 2 and Figure 3 ) used in combination. Surgical suture tool 450 includes, in many respects, a tool base 352 ( Figure 5 The tool base or proximal housing 452, and includes, for example, rotary actuators 360, 362, 364, 366, 368, and 370. Figure 5 The six rotary actuators 460, 462, 464, 466, 468 and 470 ( Figure 6A and Figure 6B An elongated shaft 454 extends distally from the tool base 452. A distal end effector 456 is coupled to the distal end of the elongated shaft 454 at an articulated joint or wrist joint 458. The distal end effector 456 includes a first jaw 480 and a second jaw 482. The first jaw 480 and the second jaw 482 are configured to hold tissue between them. For example, the first jaw 480 is a movable anvil, and the second jaw 482 is configured to support a fastener magazine therein.

[0107] In other cases, the distal end effector 456 may include a fixed anvil and a movable fastener magazine. In other cases, both jaws 480, 482 may be pivotable or otherwise movable between an open configuration and a clamping configuration to clamp tissue.

[0108] However, the opposing jaws 480, 482 can form part of other types of jawed end effectors, such as, but not limited to, tissue grippers, surgical scissors, advanced-energy vascular sealers, clamp applicators, needle drivers, Babcock clamps including a pair of opposing gripping jaws, bipolar jaws (e.g., bipolar Maryland grippers, clamps, perforated 20 grippers, etc.). One or both of jaws 480, 482 can be configured to pivot to actuate end effector 456 between an open position and a closed position.

[0109] The articulation joint 458 enables the end effector 456 to articulate or pivot relative to the axis 454, thereby positioning the end effector 456 in a desired orientation and position relative to the surgical site. Generally, the articulation joint 458 includes a joint configured to allow pivoting movement of the end effector 456 relative to the axis 454. The degrees of freedom of the wrist 458 can be represented by three translational variables (i.e., forward and backward, undulation, and yaw) and three rotational variables (i.e., Euler angles or roll, pitch, and yaw). The translational and rotational variables describe the position and orientation of a component of the surgical system (e.g., the end effector 456) relative to a given reference Cartesian coordinate system. "Forward and backward" can refer to forward and backward translational movements, "undulation" can refer to up and down translational movements, and "yaw" can refer to left and right translational movements. Regarding rotational terms, "roll" can refer to left and right tilting, "pitch" can refer to forward and backward tilting, and "yaw" can refer to left and right rotation.

[0110] Pivoting motion may include pitch motion about a first axis (e.g., the X-axis) of the articulated joint 458, yaw motion about a second axis (e.g., the Y-axis) of the articulated joint 458, and combinations thereof, to allow end effector 456 to rotate 360° about the articulated joint 458. In other applications, pivoting motion at the articulated joint 458 may be limited to motion in a single plane, such as pitch motion only about the first axis of the articulated joint 458 or yaw motion only about the second axis of the articulated joint 458, such that end effector 456 moves only in a single plane.

[0111] The surgical tool 450 includes drive members forming part of an actuation system configured to facilitate articulation of the articulated joint 458 and actuation (operation) of the end effector 456 (e.g., clamping, firing, rotation, articulation, energy delivery, etc.). Some drive members may extend to the articulated joint 458, and selective actuation of these drive members causes the end effector 456 to articulate relative to the axis 454 at the articulated joint 458. The end effector 456 in... Figure 6The end effector 456 is shown in a non-jointed position, in which the longitudinal axis A2 of the end effector 456 is substantially aligned with the longitudinal axis A1 of the shaft 454, such that the end effector 456 forms a substantially zero angle with respect to the shaft 454. In the jointed position, the longitudinal axes A1 and A2 will be offset at an angle to each other, such that the end effector 456 forms a non-zero angle with respect to the shaft 454.

[0112] Other actuating members may extend to the end effector 456, and selective actuation of these actuating members may cause the end effector 456 to actuate, manipulate, or perform a surgical function. In an illustrated embodiment, actuating the end effector 456 may include closing and / or opening a second jaw 480 (or vice versa) relative to a first jaw 482, thereby enabling the end effector 456 to grasp or clamp onto tissue. Furthermore, once tissue is grasped or clamped between opposing jaws 480, 482, actuating the end effector 456 may also include “firing” the end effector 456, which may refer to causing a cutting element or blade to advance distally within a slot 484 defined in the second jaw 482. As the cutting element moves distally, it can transection any tissue grasped between opposing jaws 480, 482. Furthermore, as the cutting element advances distally, multiple staples contained within the staple cartridge (e.g., housed within the first jaw 482) can be pushed or cam-driven to deform into contact with corresponding anvil surfaces (e.g., staple-forming recesses) disposed on the second jaw 480. The deployed staples can form multiple rows that seal opposite sides of tissue that can be transversely cut by a knife or other cutting element.

[0113] In some aspects of this disclosure, the surgical tool 450 may be configured to apply energy, such as radio frequency (RF) energy, to tissue. In such cases, the actuating end effector 456 may also include applying energy to tissue gripped or held between two opposing jaws to, for example, cauterize or seal the captured tissue.

[0114] In some aspects of this disclosure, the surgical tool 450 may also include a manual closure device 486 accessible to a user from the base of the tool or from outside the drive housing 452. The manual closure device 486 includes a clinician-gripable and actuable knob. The manual closure device 486 is operatively coupled to various gears and / or drive components within the drive housing 452 to allow the clinician to manually open and close the jaws 480, 482. In some cases, the clinician can fully clamp and fully release the jaws 480, 482 using the manual closure device 486. The manual closure device is further described, for example, in U.S. Patent Application 16 / 553,725, filed August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION”.

[0115] See Figure 6A and Figure 6B The upper portion of the drive housing 452 is omitted in this view to expose various internal working parts and components. For clarity, several components that would otherwise be included within the drive housing 452 are also omitted. Rotary drives 460, 462, 464, 466, 468, and 470 are housed in the tool base 452 and are drivably coupled to a rotary drive (e.g., tool drive 220) on a tool driver. Figure 6A and Figure 6B The drive arrangements are configured to transmit rotational motion from rotary drives 460, 462, 464, 466, 468, and 470 along axis 454 to articulated joint 458 and / or end effector 456. These drive arrangements are merely exemplary; alternative drive arrangements are also contemplated for transmitting force and motion from rotary drives 460, 462, 464, 466, 468, and 470 toward end effector 456.

[0116] In various applications requiring high speed and high torque, the use of a single rotary actuator is desirable. For example, it may be desirable to maximize the speed output from the rotary actuator in some cases and the torque output in others. Gear trains can increase the speed of the rotary actuator; however, such gear trains can correspondingly reduce the maximum torque transmitted by the rotary actuator via the gear train. In some cases, a first rotary actuator may be used for high torque degrees of freedom (e.g., tissue clamping), and a second rotary actuator may be used for high speed degrees of freedom (e.g., tissue grasping). U.S. Patent Application Publication 2019 / 0201111, published July 4, 2019, entitled “DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICALPLATFORMS,” describes a drive arrangement in which the first rotary actuator corresponds to a “high force” degree of freedom and the second rotary actuator corresponds to a “low force” degree of freedom. The dependence on two rotary actuators prevents these two rotary actuators from being used for other simultaneously actuated and / or degrees of freedom. Therefore, one less rotary actuator can be used for other degrees of freedom, such as joint movements for end effectors.

[0117] The motor driving the rotary actuator in a tool actuator can be limited to a maximum rotational speed per second. For example, the motor of a robotic tool can rotate at a maximum speed of four revolutions per second, or 240 RPM. Some robotic suturing tools utilize a drive screw to close the jaws and / or fire fasteners from the jaws. When using such a drive screw, eight to ten rotations of the drive screw may be required to close the jaws. In such cases, completing these rotations and fully closing the jaws may take two to three seconds. Similarly, completing these rotations and fully opening the jaws may also take two to three seconds. Using a gear train can increase the output speed and thus reduce the time required to open and close the jaws; however, such a gear train also reduces the maximum torque output, which may be problematic for certain surgical functions, such as clamping, cutting thick and / or tough tissue, and / or firing staples into thick and / or tough tissue. The aforementioned maximum motor speed, estimated number of drive screw rotations, and jaw opening / closing time are exemplary. In other cases, motors with different motor speeds and / or different drive screw arrangements may be utilized.

[0118] In some cases, the rotary drive can switch between a high-torque operating state and a high-speed operating state to selectively deliver higher speed or higher torque. For example, a higher speed can be used during jaw closure or gripping with an end effector, and a higher torque can be used during clamping or firing of the end effector. A torque conversion member in the proximal housing of the robotic tool can switch the rotary drive between a high-speed drive on a first side and a high-torque drive on a second side. In various cases, a threshold torque applied to the torque conversion member can achieve the conversion. For example, when the threshold torque is reached, a spring-actuated tilting cam surface of the conversion member can shift from the high-speed drive towards the high-torque drive to driveably engage the rotary drive with the high-torque drive, and thus transmit the highest maximum torque to the output gear.

[0119] For example, a surgical tool used with a robotic surgical system may be configured to receive rotational input from the robotic surgical system, and the surgical tool may include: a distal end effector including jaws for clamping tissue therebetween; an intermediate shaft portion coupled to the distal end effector; and a proximal housing coupled to the intermediate shaft portion, the proximal housing including an arrangement of rotary actuators, the rotary actuators including a first rotary actuator. The first rotary actuator may include: an input shaft configured to receive rotational input from the robotic surgical system; a transition nut slidably positioned on the input shaft; an output gear; a high-speed gear configured to selectively drive the output gear; a high-torque gear configured to selectively drive the output gear; and a spring arrangement configured to bias the transition nut along the input shaft from a high-speed operating state to a high-torque operating state when a threshold torque is obtained, in which the transition nut is driven to engage with the high-speed gear in the high-speed operating state and with the high-torque gear in the high-torque operating state.

[0120] The aforementioned arrangement utilizes a single rotary actuator to achieve higher speeds during a first operating state and higher torques during a second operating state. Therefore, other rotary actuators can be freely used for joint movements or other surgical functions. The robotic tool can also achieve rapid or even higher-speed closure or gripping without the need for rapid gripping mechanisms, such as those in the jaws, to accelerate jaw closure. Furthermore, a torque conversion feature can transition between a high-speed operating state and a high-torque operating state upon receiving a threshold torque. No complex programming or mechanisms are required to achieve this transition, allowing the jaws to open and close rapidly to manipulate or grip tissue while also delivering sufficient torque for, for example, clamping and / or cutting tissue. Since robotic suturing tools typically require high speeds to clamp the jaws onto tissue and high torque to fire staples and / or cut tissue, the torque conversion feature in the tool base can seamlessly and automatically switch between operating states to meet the necessary torque and speed requirements in both cases.

[0121] See Figures 7 to 11 The diagram illustrates a rotary drive system 500. The rotary drive system 500 is positioned within the tool base or proximal housing of a robotic tool, such as the tool base 352 of a robotic tool 350. Figure 5 ) or the tool base 452 of the robotic stitching tool 450 ( Figure 6 The tool base includes a frame 590 that supports the rotational movement of components of the rotary drive system 500. In this case, the rotary drive system 500 is one of the rotary drives in the tool base and is selectively coupled to one of the rotary drives 260, 262, 264, 266, 268, and 270 in the carriage 224 of the tool drive 220. Figure 4 For example, the rotary drive system 500 may correspond to the base 352 (). Figure 5 One of the rotary drives 360, 362, 364, 366, 368 and 370 in the carriage 224, and the motor in the carriage 224 is configured to transmit rotary motion to the rotary drive system 500 during use.

[0122] As further described herein, the tool base of a robotic tool may include, for example, a different number of rotary actuators. Furthermore, the rotary drive system 500 may be incorporated into various proximal housings and / or tool bases of different robotic tools, for example, having one or more different surgical functions.

[0123] The rotary drive system 500 is configured to drive the output shaft 502. In some cases, the output shaft 502 is configured to drive a rotary drive screw. The rotation of the rotary drive screw can realize the jaws 480, 482 ( Figure 6The rotary drive screw's opening and closing motion grips and clamps the tissue within it. The rotary drive screw is further described in U.S. Provisional Patent Application 63 / 057,430, filed July 28, 2020, entitled "SURGICALINSTRUMENTS WITH TORSION SPINE DRIVE ARRANGEMENTS". The rotary drive shaft is described in U.S. Patent Application Publication 2014 / 0001231, published January 2, 2014, entitled "FIRING SYSTEM LOCKOUT ARRANGEMENTS FOR SURGICAL INSTRUMENTS". The full text of U.S. Provisional Patent Application No. 63 / 057,430, filed July 28, 2020, entitled “SURGICAL INSTRUMENTS WITH TORSION SPINE DRIVE ARRANGEMENTS”, and U.S. Patent Application Publication No. 2014 / 0001231, published January 2, 2014, entitled “FIRING SYSTEM LOCKOUT ARRANGEMENTS FOR SURGICAL INSTRUMENTS”, are incorporated herein by reference.

[0124] The rotary drive system 500 includes an input shaft 504 configured to receive rotary input from the robotic surgical system. For example, the motor in carriage 224 is configured to be able to receive rotary input from the robotic tool drive 220. Figure 3 The rotary drive system 500 drives the rotation of the input shaft 504. The rotary drive system 500 includes a transition nut 506 slidably positioned on the input shaft 504. As further described herein, the transition nut 506 enables the rotary drive system 500 to operate at high speed based on the torque applied to the transition nut 506. Figure 9 ) and high torque operating conditions Figure 11 The rotary drive system 500 also includes a spring arrangement configured to bias the transition nut 506 from a high-speed operating state to a high-torque operating state along the input shaft 504. In the high-speed operating state, the transition nut 506 is driven to engage with the high-speed gear train 521. In the high-torque operating state, the transition nut 506 is driven to engage with the high-torque gear 530.

[0125] See also Figure 8 and Figure 9The spring arrangement includes a bias spring 528 that applies force to the transition nut 506 and pushes the transition nut 506 toward the high-speed gear train 521. The bias spring 528 is a helical compression spring housed in an internal cavity between the frame 590 and the transition nut 506. For example, the bias spring 528 is longitudinally aligned with the input axis AI. A first end of the bias spring 528 abuts a second portion 560 of the transition nut 506, and a second end of the bias spring 528 abuts the frame 590. The bias spring 528 is positioned to bias the transition nut 506 to a high-speed operating state. Alternative spring arrangements and geometries are conceivable.

[0126] In the arrangement shown, the high-speed gear train 521 includes a gripping gear 510. A row of helical teeth 512 on the gripping gear 510 extends toward the transition nut 506, as further described herein.

[0127] A high-speed gear train 521 and a high-torque gear 530 are configured to selectively drive an output gear 501. The high-speed gear train 521 includes the high-speed gear 520 and additional gears (e.g., gear 524). Gears 520 and 524 form the gear train 521, which is configured to increase the maximum output speed to the output gear 501 and thus increase the maximum output speed to the output shaft 502. The output shaft 502 is longitudinally aligned with the output axis AO. In other cases, the gear train 521 may include a different number and / or arrangement of gears, which may similarly reduce the maximum torque that the gear train 521 can transmit to the output gear 501 and increase the maximum speed. For example, the gear train 521 may define a speed ratio greater than one and a torque ratio less than one. A first bevel gear 532 connects the gear train 521 and its high-speed gear 520 to the output gear 501. A second bevel gear 534 connects the high-torque gear 530 to the output gear 501.

[0128] Input shaft 504 drives transition nut 506 to rotate about input axis AI. The rotation of transition nut 506 is transmitted to output gear 501 via either high-speed gear 520 or high-torque gear 530. For example, transition nut 506 includes a first portion 550 and a second portion 560 flexibly or non-rigidly spaced from the first portion 550 along input axis AI by spring 570. For example, spring 570 provides flexibility and elasticity when the transition nut slides in / out of engagement with gear teeth 512. First portion 550 includes a first end 552 adjacent to high-torque gear 530. Second portion 560 includes a second end 562 adjacent to gear train 521 and its gripping gear 510.

[0129] In the first portion 550, the transition nut 506 includes an array of helical teeth 554 surrounding its periphery. The helical teeth 554 extend to the first end 552. The helical teeth 554 are helical ridges or external threads. For example, the helical teeth 554 are defined by pairs of helical or angled surfaces that are angled relative to the axis of rotation (input axis AI) of the transition nut 506. For example, each helical tooth 554 includes a bottom ramp, a top ramp that is substantially parallel to or equidistant from the bottom ramp along its length, and a top surface located between the bottom ramp and the top ramp.

[0130] When the transition nut 506 is in a high-torque operating state, the helical teeth 554 engage the helical sockets 536 in the high-torque gear 530. The helical sockets 536 define a geometry complementary to the helical teeth 554, such that each helical socket 536 tightly receives one of the helical teeth 554. Furthermore, the complementary helical geometry acts as a screw, i.e., the helical teeth 554 are externally threaded and the helical sockets 536 are internally threaded, causing the helical teeth 554 to "tighten" into the helical sockets 536, pulling the transition nut 506 along the input axis AI and further engaging it with the high-torque gear 530. More specifically, when the helical features 554, 536 are engaged, the complementary geometry is configured to further drive the transition nut 506 towards the high-torque gear 530 along the input axis 504 and input axis AI, such that the helical teeth 554 are fully received in the helical sockets 536 and pulled into drive engagement with the high-torque gear 530. Furthermore, when the rotation direction of the transition nut 506 is reversed, the complementary tilt geometry can again be used as a screw, such that the “loosening” rotation of the tilt tooth 554 relative to the tilt socket 536 along the input axis AI pulls the transition nut 506 away from the high-torque gear 530 and toward the high-speed gear 520.

[0131] In other cases, for example, the high-torque gear 530 may include helical teeth or external threads, and the first portion 550 of the transition nut 506 may include helical sockets or internal threads.

[0132] The transition nut 506 includes an array of teeth 564 surrounding the periphery of the second portion 560. The teeth 564 extend to the second end 562. The teeth 564 define a generally serrated geometry, and the top of each tooth 564 is narrower than its bottom. For example, each angled tooth 564 includes a first angled surface, a second angled surface extending toward the first angled surface, and a top surface located between the first and second angled surfaces. In such cases, the teeth are, for example, truncated triangular prisms. Alternative tooth geometries are conceivable.

[0133] When the transition nut 506 is in high-speed operating condition, tooth 564 engages the corresponding tooth 512 in the gripping gear 510. For example, the inclined surface on each tooth 512 is configured to slide along the complementary inclined surface on the tooth 512, allowing teeth 564, 512 to move between an engaged position and a disengaged position. A biasing spring 528 is configured to bias tooth 564 into engagement with tooth 512. For example, spring 570 can facilitate transitions between different operating states if teeth 564 and 512 are not precisely aligned when moving to engagement. In various cases, spring 528 can also facilitate transitions between operating states, such as when the angular direction is reversed by the motor to reverse the rotation direction of the drive screw and retract the firing member, and, for example, when the torque-based transition nut 506 disengages the high-torque gear 530 and moves it into engagement with the high-speed gear 520.

[0134] The transformation operation of the rotary drive system 500 is shown in Figures 9 to 11 middle. Figure 9 The high-speed operating state of the rotary drive system 500 is illustrated. Although this operating state is referred to as high-speed operating state, the reader will understand that the maximum speed depends on several factors, such as the characteristics of the motor. However, the high-speed operating state can be designed and optimized to output a higher maximum speed to the output gear 501 than that of the high-torque operating state. In other words, the maximum speed can be considered "high-speed" relative to the maximum speed in the high-torque operating state.

[0135] Figure 11 The high-torque operating state of the rotary drive system 500 is illustrated. The torque output to the output gear 501 during the high-torque operating state also depends on several factors, including, for example, the characteristics of the motor. However, the high-torque operating state can be designed and optimized to output a higher maximum torque to the output gear 501 than in the high-speed operating state. In other words, the maximum torque can be considered a "high torque" relative to the maximum torque in the high-speed operating state.

[0136] Figure 10 The transition between high-speed operation and high-torque operation is shown.

[0137] See you again Figure 9 Spring 528 has biased transition nut 506 to engage with high-speed gear train 520. Specifically, bias spring 528 applies force to transition nut 506 along input axis AI and in the direction of high-speed transmission (i.e., toward gripping gear 510 of gear train 521). The array of teeth 564 on second part 560 meshes with the array of teeth 512 on gripping gear 510.

[0138] In this arrangement, the rotational motion of the input shaft 504 (e.g., provided by a motor in the tool driver) is transmitted to a transition nut 506, which causes the gripping gear 510 to rotate, thereby rotating the gear train 521. The gear train 521 is configured to increase the maximum speed, such that the maximum speed delivered to the output gear 501 via the first bevel gear 532 is optimized for high-speed applications. For example, the high-speed output can be used to close the jaws to grip and manipulate tissue. Figure 9 The document includes arrows showing exemplary rotational directions of the transition nut 506, clamping gear 510, gear train 521, and output gear 501.

[0139] See now Figure 10 When the torque applied to the transition nut 506 exceeds a threshold, the torque at least partially overcomes the spring force of the spring arrangement. The array of teeth 564 on the second portion 560 of the transition nut 506 is configured to ride or slide along the complementary inclined surface of the array of teeth 512 on the gripping gear 510 as the transition nut 506 rotates and moves along the input axis AI toward the high-torque gear assembly (i.e., the high-torque gear 530). When the torque reaches the threshold, compression of the bias spring 528 displaces the transition nut 506 from engagement with the gripping gear 510. Furthermore, when the gripping gear 510 releases the transition nut 506 from engagement or drive engagement, the array of inclined teeth 554 on the first portion 550 of the transition nut 506 engages the inclined socket 536 in the high-torque gear 530. During engagement, the inclined socket 536 can "grip" or "pinch" the transition nut 506 to further pull the teeth 554 into the socket 536. Figure 11 The arrangement shown is such that the transition nut 506 is completely disengaged from the gripping gear 510 and fully engaged with the high-torque gear.

[0140] exist Figure 11 In high-torque operating conditions, the rotational motion of the input shaft 504 (e.g., provided by a motor in the tool driver) is transmitted to the transition nut 506, which causes the high-torque gear 530 to rotate. The high-torque gear 530 is configured to optimize the torque delivered to the output gear 501 via the second bevel gear 534. Specifically, the torque is optimized for high-torque applications, such as clamping tissue via an end effector. Figure 11 The document includes arrows illustrating exemplary rotational directions of the transition nut 506, the high-torque gear 530, and the output gear 501.

[0141] At the end of the firing stroke, the drive arrangement is configured to reverse the firing member. For example, the drive arrangement can reverse the angular direction of the transition nut 506 to retract the firing member. The reversal of the transition nut 506 can correspond to a "loosening" rotation of the transition nut 506, causing the transition nut 506 to displace away from the high-torque gear 530 along the input axis AI. In this arrangement, the return stroke of the firing member and the associated reversal of the transition nut 506 and the output gear 501 can automatically switch the drive arrangement to a high-speed operating state.

[0142] Due to the geometry of the high-torque gear 530 and the second bevel gear 534, the torque supplied to the output gear 501 can be increased to eight times the torque in the high-torque operating state. In other cases, the torque output can be increased, for example, to double or quadruple. Variations in the number, size, and arrangement of the gears between the high-torque gear 530 and the output gear 501 can further increase the torque output.

[0143] Due to the geometry of gear train 521 and the first bevel gear 532, the speed supplied to output gear 501 can be increased to four times the speed under high-torque operation. In other cases, the torque output can be increased, for example, by two or eight times. For example, additional speed gears in gear train 521 can further increase the speed output. Variations in the number, size, and arrangement of gears between high-speed gear 520 and output gear 501 can further increase the speed output.

[0144] In various situations, robotic tools rely on software integrated into the operating system and processor of a robotic surgical system to mitigate risks and avoid malfunctions. Redundant systems and / or cross-checks can control certain robotic tools performing high-severity tasks to mitigate the risks associated with those tasks. For example, clamping can be a high-severity task because, in some cases, inadequate clamping can lead to an increased likelihood and / or a greater incidence of staple deformation, and thus inadequate tissue sealing. For instance, robotic suturing tools for clamping and / or cutting tissue may rely on redundant systems (e.g., mechanical and electrical locking) and various cross-checks to ensure that closing motion, clamping force, and firing stroke meet predetermined standards and / or thresholds. Various cross-checks can increase the cost and / or complexity of the system and may require additional maintenance and user support over time. In some cases, cross-checks for surgical tools and / or surgical functions may be beneficial without adding unnecessary cost and complexity to the system.

[0145] Some robotic tools utilize multiple motors to achieve certain surgical functions. For example, robotic suturing tools may use dual motors to advance closure components, perform closure strokes, and / or clamp tissue. For instance, cross-checking algorithms that rely on dual-motor closure systems to create cross-checking algorithms can mitigate risks and avoid failures associated with high-severity clamping errors.

[0146] For example, a robotic surgical system may include a closure system comprising a first pinion driven to a first motor, a second pinion driven to a second motor, and a closing gear selectively driven by the first and second pinions. The robotic surgical system may also include control circuitry configured to perform motor cross-checking operations, wherein the control circuitry is configured to receive a first parameter indicating a first torque generated by the first motor, receive a second parameter indicating a second torque generated by the second motor, compare the first parameter with the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicates the state of the closure system.

[0147] In various cases, the control circuitry of this robotic surgical system can also be configured to determine when the closed system reaches a steady state during motor cross-checking operations, and to compare a first parameter with a second parameter after the closed system reaches a steady state.

[0148] Motor cross-check operations can be performed after homing operations and / or clamping events.

[0149] This robotic surgical system can mitigate certain risks and avoid failures associated with high-severity clamping errors. Furthermore, this cross-checking improves the handling of surgical tools without requiring, for example, redundant motor control and / or dedicated safety handling units.

[0150] Figure 12 An exemplary drive arrangement 800 is shown. The drive arrangement 800 is used to grip the jaws of an end effector, such as end effector 456. Figure 6 The jaws 480 and 482 of the robotic surgical system. In other cases, the robotic surgical system may utilize the drive arrangement to achieve additional and alternative surgical functions, such as firing fasteners into tissue and / or cutting tissue. The drive arrangement 800 includes a first pinion 802 and a second pinion 804. A motor and a corresponding rotary actuator are configured to drive pinions 802 and 804. For example, in some aspects of this disclosure, each of the drive pinions 802 and 804 may be driven by one of the motors and a tool driver 220. Figure 4 Driven by one of the corresponding rotary drivers 260, 262, 264, 266, 268 and 270 in ).

[0151] Pinions 802 and 804 drive a closing gear 806, which achieves the closing motion of the end effector. For example, the torque on pinions 802 and 804, and in some cases the torque applied to the closing gear 806, can be monitored and compared during cross-checking procedures to determine whether the drive arrangement 800 is functioning correctly or malfunctioning. The robotic surgical system can perform cross-checking procedures at different times during the service life and / or usage cycle of the robotic tool. For example, one or more cross-checking procedures can be performed whenever a robotic tool is mounted to a tool driver on the robotic arm. In addition, or alternatively, in some cases, the robotic surgical system can perform cross-checking at the completion of a homing operation and / or each closing event (e.g., closing stroke). For example, when a robotic tool is mounted to a tool driver, the robotic system can undergo a homing operation, where the positions of various components are determined and recorded to determine various limits of the system. The retrieval procedure is further described in, for example, U.S. Patent Application 16 / 553,725, filed August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION.” In some cases, clinicians may selectively perform cross-checking and / or exceed recommended cross-checking procedures.

[0152] In one example, for cross-inspection procedures of the robot tool, the first drive pinion 802 moves along the first direction indicated by arrow 808 ( Figure 12 The second drive pinion 804 rotates clockwise in the view and in the second direction indicated by arrow 810. Figure 12 (Counterclockwise in the view). The first direction is opposite to the second direction. Due to the arrangement of the drive pinions 802 and 804 relative to the closed gear 806, when the drive pinions 802 and 804 rotate in opposite or relative directions, the closed gear 806 may rock, sway, or otherwise move within the backlash defined by the gear teeth. For example, the closed gear 806 may make a clicking sound when contacted due to the backlash allowed by the gear teeth.

[0153] A graphical representation 820 of the torque and angular displacement of the drive arrangement 800 over time is shown. Figure 13In the middle. From time t0 to t1, the closed gear 806 may shift or make a clicking sound within the backlash defined by the gear teeth. When the drive pinions 802 and 804 have no backlash, they input torque onto each other at time t1 and continue to apply opposing torques onto each other through the dynamic zone 822, during which the absolute torque value fluctuates / oscillates. After the dynamic zone 822, the drive arrangement 800 enters the steady-state zone 824 at time t2, during which the torque measured by the drive pinions 802 and 804 can be substantially smooth and exhibit less fluctuation over time. One or more measures can be used to determine and / or calculate when the drive pinions 802 and 804 reach a steady state and enter the steady-state zone.

[0154] The torque of each drive pinion 802 and 804 can be monitored during cross-checking procedures. For example, the control circuitry can monitor and compare the torque throughout the steady-state region 824. If the magnitudes of opposing torques are close to each other, i.e., within a certain predefined threshold, the control circuitry can infer that the torque value is reliable. However, if the magnitudes of opposing torques are significantly different from each other, i.e., beyond the predefined threshold difference, the robotic surgical system may enter an error or fault state. For example, the robotic surgical system may determine that the robotic tool is in a fault state. The robotic surgical system can warn the user of the error / fault state and / or implement one or more latches (absolute and / or arbitrary) upon entering an error / fault state. In some cases, an error / fault state may require recalibration and / or re-inspection of the robotic tool.

[0155] For dual-drive pinion arrangements such as drive arrangement 800 ( Figure 12 The control circuit 828 is shown for example in... Figure 14 In the middle. Control circuit 828 includes processor 840 that communicates with memory 842 and communication device 844. First drive system 850 and second drive system 852 communicate with processor 840. First drive system 850 includes motor 854, input driver 856 coupled to motor 854, torque sensor 830 and rotary encoder / position sensor 834. Input driver 856 may correspond to, for example, a first pinion 802 in drive arrangement 800 ( Figure 12 The second drive system 852 includes a motor 858, an input driver 860 coupled to the motor 858, a torque sensor 832, and a rotary encoder / position sensor 836. The input driver 860 may correspond, for example, to a second pinion 804 in the drive arrangement 800. Figure 12 In this case, torque sensors 830 and 832 determine the torque on the first drive pinion 802 and the second drive pinion 804, respectively. Furthermore, position sensors 834 and 836 determine the angular positions of the first drive pinion 802 and the second drive pinion 804, respectively.

[0156] The control circuit 828 also includes an output driver 862, a torque sensor 864, and a rotary encoder / position sensor 866. The output driver 862 may correspond to, for example, a closed gear 806 in the drive arrangement 800. Figure 12 In such cases, torque sensor 864 determines the output torque applied to closed gear 806, and position sensor 866 determines the angular position of closed gear 806.

[0157] During the cross-check procedure, torque sensors 830, 832 and position sensors 834, 836 are configured to transmit signals indicating the torque and angular position of input drivers 856, 860 to processor 840. Torque sensor 864 and position sensor 866 can also communicate with processor 840 and are configured to transmit signals indicating the torque and angular position of output driver 862. The torque detected by torque sensors 830, 832, and 864 and transmitted to processor 840 is monitored over time and can be recorded in memory 842.

[0158] In various situations, processor 840 is configured to determine when the dual-drive pinion system reaches a steady state and, in the steady-state operating state, compare the input torque detected by torque sensors 832 and 834. If the comparison between the absolute torques determined by torque sensors 832 and 834 exceeds a threshold, control circuitry 828 is configured to enter a fault state. Operation in the fault state is stored in memory 842 and implemented by processor 840, and includes, for example, providing output signals to a clinician or another surgical system with communication device 844 and / or implementing one or more interlocks to protect the integrity of the robotic tool and patient safety.

[0159] Another cross-check operation for robotic tools is shown in Figures 15 to 17 In various situations, Figures 15 to 17 The cross-check operation can be used in conjunction with the drive arrangement 800 and the control circuit 828. To perform this cross-check operation, the first drive pinion 802 moves along the first direction indicated by arrow 908 (…). Figure 15 The second drive pinion 804 rotates counterclockwise in the view and also rotates in the first direction indicated by arrow 910. Figure 15 (Counterclockwise in the view). Due to the arrangement of the drive pinions 802 and 804 relative to the closed gear 806, the rotation of the drive pinions 802 and 804 in the first direction is also configured to cause the closed gear 806 to also rotate in the first direction (counterclockwise). Figure 15(In the view, it rotates counterclockwise), for example as shown by arrow 912. In such cases, drive pinions 802 and 804 work together to rotate the closing gear until the closing gear completes its entire closing stroke. The complete closing stroke is typically completed, for example, when clamping tissue or during a "return" operation.

[0160] Now, please refer to Figure 16 The torque on the drive pinions 802 and 804 is then released when they reach their lowest point. Afterward, one drive pinion can be configured to maintain its position during cross-checking operations, while the other pinion is driven against it via the output gear 806. For example, the first pinion 802 can attempt to move in the second direction indicated by arrow 908' ( Figure 16 Rotate clockwise in the view, the second direction is... Figure 15 Arrow 908 in the diagram points in opposite directions, while the second pinion 804 resists rotation. In this case, the first pinion 802 moves through the backlash region defined between the meshing gear teeth, and then pinions 802 and 804 have opposite torques, which can be monitored and compared during cross-checking operations.

[0161] Figure 15 and Figure 16 The graphical representation of torque and angular displacement over time for the drive arrangement 800 and the cross-check sequence shown in Figure 920 is presented in... Figure 17 At time t1, the closed stroke begins, during which pinions 802 and 804 cooperatively drive the closed gear 806 through the closed zone 926. In the closed zone 926, the torque and angular displacement of pinions 802 and 804 and the closed gear 806 increase. At time t2, the closed stroke is completed, and the torque on the closed gear 806 is released.

[0162] The driving torque is released, and at time t2, the first pinion 802 reverses direction. Figure 16 The motion then passes through the backlash defined by the meshing gear teeth during zone 928. For cross-checking operations, dynamic zone 922 is followed by steady-state zone 924, which is similar to dynamic zone 822 and steady-state zone 824, respectively. Figure 13 ).exist Figure 17During the cross-check operation, the torque on the first pinion 802 continues until it reaches a non-zero absolute torque. When the first pinion 802 generates a non-zero absolute torque, the second pinion 804 generates the opposite torque at time t3, marking the beginning of the dynamic zone 922. In the dynamic zone 922, the absolute torque values ​​of the first pinion 802 and the second pinion 804, which are in opposite directions, increase. When the steady-state zone 924 is reached at time t4, the absolute torques on the drive pinions 802 and 804 remain substantially constant values ​​that are opposite to each other. At time t5, the steady-state zone 924 ends, and the cross-check procedure is completed.

[0163] The opposing torques of each drive pinion 802 and 804 can be Figures 15 to 17 Monitoring is performed during cross-checking procedures. For example, torque can be monitored and compared during the steady-state region 924. If the magnitudes of opposing torques are close to each other, i.e., within a certain predefined threshold, the control circuitry can infer that the torque value is reliable. However, if the magnitudes of opposing torques are significantly different from each other, the robotic surgical system may enter an error or fault state. For example, the robotic surgical system may determine that the robotic tool is in a fault state. The robotic surgical system may warn the user of the error / fault state and / or implement one or more latches (absolute and / or arbitrary). In some cases, a fault state may require recalibration and / or re-inspection of the robotic tool.

[0164] Alternatively, the cross-check procedure can monitor the angular travel of pinions 802 and 804 from the end of their closed stroke at time t2 to the beginning of the steady-state region 924 at time t4. The angular travel is the difference between a first plateau period indicating the angular displacement of the first drive pinion 802 and a second plateau period indicating the angular displacement of the first drive pinion 802. In other words, the first drive pinion 802 rotates from a first position at the end of its closed stroke 926 to a second position at the beginning of the steady-state region 924, and the difference in angular position can be compared with a stored backlash value. For example, the backlash value can be measured during manufacturing and stored in the memory of the robotic tool and / or robotic surgical system. If the angular travel of the first drive pinion 802 does not match the stored backlash value (within a certain threshold), the processor can signal an error or fault condition. Conversely, if the angular travel is sufficiently close to the stored backlash value, the processor can send a signal indicating that the robotic tool has passed the check.

[0165] In various situations, the aforementioned sequence can be repeated, wherein the second pinion 804 switches the direction of rotation while the first pinion 802 attempts to maintain a constant angular position. During the "return" operation, the opposing torque value and angular travel of the second drive pinion 804 can be monitored and compared, for example, as further described herein with respect to the first drive pinion 802.

[0166] Another cross-examination procedure for surgical instruments is shown. Figures 18 to 20 In various situations, Figures 18 to 20 The cross-check operation can be used with drive arrangement 800 and control circuit 828. Figure 20 In this process, the stiffness of one of the drive pinions 802 and 804 can be compared with the stored stiffness value to determine whether the drive pinions 802 and 804 pass the cross-check. Figure 20 The stiffness 1006, represented graphically in the figure, reflects... Figure 18 and Figure 19 The angular position and torque measurement results.

[0167] More specifically, driving pinions 802 and 804 and closing gear 806 ( Figure 15 The angular position over time is shown in Figure 18 The graphic representation is in 1000. The torque on the driving pinions 802 and 804 over time is shown in... Figure 19 The graphic representation is in 1002. Initially, as referenced in this article... Figure 15 The drive pinions 802 and 804 work together to rotate the closed gear 806 until the closed gear completes its entire closed stroke at time t1. Afterward, the closed gear 806 can descend to its lowest point, preventing further rotation of the closed gear 806 after time t1. For cross-checking operations, one of the drive pinions 802 and 804 can apply additional torque to the closed gear 806 at its lowest point, while the other drive pinion floats or hovers within the backlash region of the gear teeth. Figure 18 and Figure 19 In the example, the first pinion 802 continues to apply torque to the closed gear 806 at time t2, while allowing the second pinion 804 to move or shift through the backlash.

[0168] In this arrangement, the closed gear 806 cannot rotate further; however, when the first drive pinion 802 continues to apply torque to the closed gear 806, the stiffness 1006 of the first drive pinion 802 when applying torque to the closed gear 806 remains constant. Figure 20 The stiffness 1006 can be calculated based on torque and position measurements taken after time t2. The graphical representation 1004, showing the stiffness 1006 relative to a two-dimensional stiffness threshold 1008, conveys the comparison made during the cross-checking operation. For example, if stiffness 1006 falls outside the stiffness threshold 1008, the system can indicate an error or fault condition.

[0169] In various cases, for example, the stiffness threshold 1008 can be defined by adding or subtracting a value corresponding to the threshold amount, percentage, and / or standard deviation from the slope of the stiffness of the torque relative to the angular displacement.

[0170] In various situations, the above sequence can be repeated, wherein the second pinion 804 continues to apply torque to the closed gear 806, while the first pinion 802 rotates freely. The stiffness of the second pinion 804 can be compared with the threshold stiffness to determine the fault or malfunction state of the second pinion 804.

[0171] In various situations, one or more cross-check procedures can be performed after the homing operation and / or clamping event of a dual-motor closure system. Cross-check procedures can verify the integrity of the system and its motors without requiring, for example, redundant motor controllers or dedicated safety handling units. In such cases, the dual-motor closure system can be cross-checked without adding additional cost and / or complexity. The reader will further understand that, in some circumstances, such cross-check procedures can be performed relative to other dual-motor systems of robotic surgical tools.

[0172] In some cases, robotic surgical tools with articulated joints may define a range of motion, with hard stops or mechanical limits at the ends of this range. For example, interference at the mechanical limits can prevent movement beyond those limits and beyond the range of motion. The articulated joint may reach its mechanical limits when the ends of the range of motion are reached. In some cases, resisting mechanical limits at the ends of the range of motion to drive the joint motion of a robotic surgical tool can damage the tool and / or its articulation system over time. For example, damage to a robotic surgical tool can be a function of the impact force, velocity, and / or torque of the rotary drive input.

[0173] In some cases, to avoid hitting mechanical limits, control circuitry can control the joint motion system such that the joint joint is restricted to a narrower range of motion than the full range of motion of the joint. For example, the mechanical limits of the joint range of motion can be stored in memory and / or acquired during repositioning operations. The joint motion system can effectively reduce the operating range of the joint joint to less than the full range of motion of the joint to maintain a safe region or range of motion away from the mechanical limits. For example, the safe region can be configured to account for measurement errors in the joint joint during repositioning operations and / or changes in the joint over time. The safe region reduces the usable range of motion of the joint joint and may therefore unduly limit the range of motion of robotic surgical tools in some cases.

[0174] Alternatively, in certain situations, it may be advantageous to maximize the range of motion of the joint and to move the joint joint within its full range of motion until its mechanical limits, while minimizing damage to the robotic surgical tool or its joint mechanism. Such a joint motion actuator can be robust enough to drive the joint joint through its entire range of motion until its mechanical limits. For example, the joint motion actuator system can be configured to detect areas within the range of motion where the device approaches and moves away from its mechanical limits. Furthermore, the joint motion actuator can operate the joint joint differently in areas closer to its mechanical limits to avoid damaging the joint mechanism while still functioning fully and efficiently. For example, when the joint joint angle is in the range of motion far from its mechanical limits, the joint joint can operate at full speed and / or torque. When the joint joint angle is in the range of motion closer to its mechanical limits, the joint joint can operate at limited speed and / or limited torque. Limited speed and / or torque allows the joint joint to approach its mechanical limits and gently or smoothly touch those limits to avoid damaging the joint mechanism. In other words, the articulated joint can gently touch the mechanical limits of the articulated joint, and thus minimize wear and / or damage to the drive mechanism and / or the articulated joint, for example, due to contact.

[0175] In one aspect of this disclosure, control circuitry used with a robotic surgical system may be configured to receive parameters indicating the rotational position of an articular motor configured to drive an articular joint of a robotic surgical tool. The articular motor may be configured to move through a first position range and a second position range. The first and second position ranges may be non-overlapping ranges. The control circuitry may also be configured to implement a first operating state and a second operating state when parameters correspond to a transition of the articular motor from the first position range to the second position range. The second operating state may differ from the first operating state. The control circuitry may also be configured to re-implement the first operating state when parameters correspond to a return of the articular motor from the second position range to the first position range by a threshold anti-jitter angle.

[0176] In some cases, the aforementioned articulation actuators can provide a greater range of motion than articulation systems where joint movement is confined outside a safe zone defined as an area adjacent to mechanical limits. Such articulation actuators can reduce the likelihood of hitting mechanical limits at significant speeds and / or torques, thus avoiding high impact loads that could, for example, damage the articulation system and / or robotic surgical tools.

[0177] See Figure 21The image shows a robotic surgical tool 3100. The robotic surgical tool 3100 can be controlled by a control circuit 3020 (…). Figure 22 It can be controlled and is compatible with robotic surgical systems such as the Robotic Surgical System 100. Figure 1 ) and with robotic arm 200 ( Figure 2 ) and tool driver 220 ( Figure 2 and Figure 3 ) used in combination. The robotic surgical tool 3100 includes, in many respects, a tool base 352 ( Figure 5 The tool base or proximal housing 3102, and includes, for example, a tool base 352 ( Figure 5 The rotary drives 360, 362, 364, 366, 368, and 370 of the tool base 3102 are six rotary drives 3160, 3162, 3164, 3166, 3168, and 3170. Similar to the rotary drive of the tool base 352, the rotary drive of the tool base 3102 is configured to cooperate with six motor-driven rotary inputs or drives on the tool carriage, such as rotary drives 260, 262, 264, 266, 268, and 270 on the tool carriage 224. Figure 4 In various cases, each rotary actuator 3160, 3162, 3164, 3166, 3168 and 3170 can be associated with a degree of freedom of the robotic surgical tool 3100.

[0178] Control circuits, such as control circuit 3020 ( Figure 22 It can communicate with one or more torque sensors and / or one or more rotary encoders, such as torque sensors 3030, 3032 and position sensors 3034, 3036. The torque sensors and / or rotary encoders can be monitoring devices configured to monitor operating parameters of the robotic surgical tool 3100. The torque sensors, for example, can be configured to monitor torque, and the rotary encoders can be configured to monitor motion (rotational or linear). The torque sensors and rotary encoders can be integrated with drives 260, 262, 264, 266, 268, and 270. Figure 5The torque sensor and / or rotary encoder may be operatively coupled to one or more of the rotary input drivers 3160, 3162, 3164, 3166, 3168, and 3170 on the tool base 3102. The torque sensor may be configured to measure the real-time torque load on the motor, which in various cases corresponds to the torque load of drivers 260, 262, 264, 266, 268, and 270 and / or drive inputs 3160, 3162, 3164, 3166, 3168, and 3170. The rotary encoder may measure the rotational motion or output of the motor, which corresponds to the rotational motion of drivers 260, 262, 264, 266, 268, and 270 and / or drive inputs 3160, 3162, 3164, 3166, 3168, and 3170. Monitoring the motor's torque load and rotational motion can help determine whether the robotic surgical tool 3100 is operating according to commands provided by the control circuitry.

[0179] See Figure 22 Two motors, such as drivers 264 and 266, are used to control the motion joint of the drive joint. Figure 5 The control circuit 3020 is shown in Figure 22 In the control circuit 3020, a processor 3040 is included that communicates signals with a memory 3042 and a communication device 3044. A first drive system 3050 and a second drive system 3052 communicate signals with the processor 3040. The first drive system 3050 includes a motor 3054, an input driver 3056 coupled to the motor 3054, a torque sensor 3030, and a rotary encoder / position sensor 3034. For example, the input driver 3056 may correspond to a drive input 3164, and the motor 3054 may correspond to a driver 264. In other aspects of this disclosure, different drivers and drive inputs may correspond to the motor 3054 and the input driver 3056.

[0180] The second drive system 3052 includes a motor 3058, an input driver 3060 coupled to the motor 3058, a torque sensor 3032, and a rotary encoder / position sensor 3036. For example, the input driver 3060 may correspond to a drive input 3166, and the motor 3058 may correspond to a driver 266. In other respects, different drivers and drive inputs may correspond to the motor 3058 and the input driver 3060. In such cases, torque sensors 3030 and 3032 determine the torque on the motor 3054 and motor 3058, respectively. For example, torque sensors 3030 and 3032 may determine the torque on drivers 264 and 266. Furthermore, position sensors 3034 and 3036 determine the angular positions of the motor 3054 and motor 3058, respectively. For example, position sensors 3034 and 3036 may determine the angular positions on drivers 264 and 266.

[0181] The control circuit 3020 also includes an output driver 3062, a torque sensor 3064, and a rotary encoder / position sensor 3066. The output driver 3062 may correspond to, for example, a joint motion connector 3108. Figure 21 In such cases, torque sensor 3064 determines the output torque applied to articulator joint 3108, and position sensor 3066 determines the angular position of articulator joint 3108.

[0182] See also Figure 21 An elongated shaft 3104 extends distally from the tool base 3102; the elongated shaft 3104 includes a proximal end 3110 and a distal end 3112. A distal end actuator 3106 is coupled to the distal end 3112 of the elongated shaft 3104 at a joint joint or wrist joint 3108. In some aspects of this disclosure, the joint joint 3108 is similar to the joint joint 458. Figure 6 ).

[0183] The articulation joint 3108 enables the end effector 3106 to articulate or pivot relative to the axis 3104, thereby positioning the end effector 3106 at a desired orientation and location relative to the surgical site. For example, rotation of rotary actuators 3164 and 3166 can cause rotation of the articulation joint 3108. Specifically, rotation of rotary actuator 3164 in direction 3122 and rotation of rotary actuator 3166 in direction 3124 can cause rotation of the articulation joint 3108 in direction 3120. In other aspects of this disclosure, different directions of rotation and / or rotary actuators can achieve articulation of the articulation joint 3108.

[0184] See Figure 23A soft-cushioned joint motion control process 3000 for a robotic surgical tool is illustrated. The soft-cushioned joint motion control process 3000 is configured to control joint motion motors coupled to a rotary actuator that drives the joint motion system within the robotic surgical tool. For example, the soft-cushioned joint motion control process 3000 is configured to control the joint motion of the joint motion joint 3108 of the robotic surgical tool 3100 under various conditions. The soft-cushioned joint motion control process 3000 is configured to allow the joint motion mechanism to move through its full range of joint motion. When the mechanical limits of the joint are reached, the full range of joint motion is reached through soft cushioning at the mechanical joint limits. In such cases, the joint can slowly and gently impact the mechanical limits without damaging the robotic surgical tool 3100. This soft-cushioned joint motion control process 3000 allows the joint motion joint 3108 to be driven to any position within its full range of joint motion.

[0185] Before initiating remote operation using the surgical robot and robotic surgical tool 3100, the robotic surgical tool 3100 can be attached to the surgical robot, and a homing operation of the robotic surgical tool can be performed. For example, when the robotic surgical tool is mounted to the tool actuator, the robotic system can undergo a homing operation, in which the positions of various components are determined and recorded to determine various limits of the surgical system. For example, the initial position of the rotary input of the rotary actuator attached to the robotic surgical tool can be determined by the homing process. The mechanical limits of joints in the robotic surgical tool, such as articulated joints 3108, can also be determined during the homing process, for example.

[0186] In other cases, the robotic surgical system may not perform a return process, and the mechanical limits and / or current joint position may be stored in memory and retrieved from memory when the robotic surgical tool is attached to the surgical robot.

[0187] If the mechanical limits are reached at high speeds and / or high torques, high impact loads may damage the robotic surgical tool or its joint motion drive system. The reduction in the tool's joint range of motion may be approximately 1%, 2%, 5%, 10%, or higher, to ensure that measurement errors in the joint position do not lead to contact with the mechanical limits of the joint at high speeds and / or high torques.

[0188] Figure 23 A soft-buffered joint motion control process 3000 is described, wherein the two motors drive the joint motion joint without any reduction from the maximum operating range. In some cases, the soft-buffered joint motion control process 3000 may be adapted to have only one motor, and in other cases, more than two motors are used to drive the joint motion.

[0189] See still Figure 23In step 3002 of the soft-cushion joint motion control process 3000, remote operation begins and control circuit 3020 initiates normal joint motion control mode 3006 (or the first operating state). During normal joint motion control mode 3006, motors controlling the joint motion joint, such as rotary actuators 264 and 266 that cooperate with rotary actuators 3164 and 3166, are activated. Figure 4 The motor operates, for example, at normal or standard speed and torque. Additionally, in normal joint motion control mode 3006, the motor driving the joint joint is driven with the desired input reverse kinematics and operates at normal speed and torque. The angles of both input motors can be monitored. In other words, parameters indicating the rotational position of each joint motion motor can be monitored during the first operating state. Furthermore, parameters indicating the position of the joint joint can be monitored during the first operating state.

[0190] If any motor angle exceeds a threshold rotation angle, the control circuit 3020 switches from the normal joint motion control mode 3006 to the upper joint motion buffer control mode 3004 (or the second operating state) or the lower joint motion buffer control mode 3008 (or the third operating state), as further described herein. In other words, the control circuit 3020 operates the joint motion motors in a first operating state (e.g., normal joint motion control mode 3006) within a position range, and switches to a second operating state (e.g., upper joint motion buffer control mode 3004 or lower joint motion buffer control mode 3008) within different position ranges.

[0191] When the angle of the first joint motion motor exceeds the upper joint motion buffer threshold angle, the control circuit 3020 follows path 3010 to switch from normal joint motion control mode 3006 to upper joint motion buffer control mode 3004. In other words, when the rotational position of the first joint motion motor is within a first position range, the control circuit 3020 operates the first and second joint motion motors in a first operating state (e.g., normal joint motion control mode 3006). When the rotational position of the first joint motion motor is within a second position range, the control circuit 3020 operates the first and second joint motion motors in a second operating state (e.g., upper joint motion buffer control mode 3004). In some cases, the first and second position ranges are non-overlapping. In some cases, the first and second position ranges are continuous. When the rotational position of the first joint motion motor moves from the first position range to the second position range, the control circuit 3020 switches the first and second joint motion motors from the first operating state to the second operating state. In some cases, the first joint motion motor and the second joint motion motor can be motors that drive rotary actuators 3164 and 3166, and vice versa.

[0192] In some cases, the upper joint motion buffer threshold angle can be any joint motion angle within 1%, 2%, 5%, 10%, or 15% of the mechanical upper limit of the joint motion joint. Alternatively, the upper joint motion buffer threshold can be any motor rotation angle that ensures the mechanical upper limit is not reached in normal joint motion control mode 3006.

[0193] During the upper joint motion buffer control mode 3004, the angles of the two input motors and the joint joint angle can be monitored. In other words, parameters indicating the positions of the input motors and the joint joint can be monitored during the second operating state. If the joint joint angle increases in the upper joint motion buffer control mode 3004 (i.e., moves towards the mechanical upper limit), the joint motors can be driven with the expected reverse kinematics and operate at limited speeds and / or limited torques. The motor torque and / or motor speed can be limited to less than the standard torque and / or speed allowed during the normal joint motion control mode 3006, which allows the joint joint 3108 to reach its mechanical upper limit without causing high shock loads on the joint motion system or robotic surgical tool 3100. In other words, when the first and second joint motors are in the second operating state and the rotational position of the first joint motor is moving away from the first position range, the maximum permissible speed and maximum permissible torque of the first and second joint motors are lower than the maximum permissible speed and maximum permissible torque in the first operating state.

[0194] In various situations, if the joint motion joint angle decreases in the upper joint motion buffer control mode 3004 (i.e., away from the mechanical upper limit movement), the two joint motion motors are driven with desired reverse kinematics and can operate at normal speed and torque. In other words, when the first and second joint motion motors are in the second operating state and the rotational position of the first joint motion motor is moving towards the first position range, the maximum permissible speed and maximum permissible torque of the first and second joint motion motors can, for example, be the same as the maximum permissible speed and maximum permissible torque in the first operating state. Once the angle of the first joint motion motor decreases beyond the upper joint motion buffer threshold angle and the additional anti-jitter angle, the control circuit 3020 follows path 3012 to switch from the upper joint motion buffer control mode 3004 back to the normal joint motion control mode 3006. In other words, when the rotational position of the first joint motion motor returns from the second position range to the first position range by the threshold anti-jitter angle, the control circuit 3020 re-implements the first operating state for the first and second joint motion motors from the second operating state. The additional anti-shake angle is a small angle that allows for a smooth transition between the upper joint motion buffer control mode 3004 and the normal joint motion control mode 3006. In some cases, the anti-shake angle is less than ten degrees, and can be, for example, one or two degrees. In some cases, the anti-shake angle is zero.

[0195] When the angle of the second joint motion motor exceeds the lower joint motion buffer threshold angle, the control circuit 3020 transitions from the normal joint motion control mode 3006 to the lower joint motion buffer control mode 3008 along path 3014. In other words, when the rotational position of the second joint motion motor is within the third position range, the control circuit 3020 operates the first and second joint motion motors in the first operating state (e.g., normal joint motion control mode 3006). When the rotational position of the second joint motion motor is within the fourth position range, the control circuit 3020 operates the first and second joint motion motors in the third operating state (e.g., lower joint motion buffer control mode 3008). In some cases, the third and fourth position ranges are non-overlapping. In some cases, the third and fourth position ranges are continuous. When the rotational position of the second joint motion motor moves from the third position range to the fourth position range, the control circuit 3020 transitions the first and second joint motion motors from the first operating state to the third operating state. In some cases, the first joint motion motor and the second joint motion motor can be motors that drive rotary actuators 3164 and 3166, and vice versa.

[0196] In some cases, the lower joint motion buffer threshold angle can be any joint motion angle within 1%, 2%, 5%, 10%, or 15% of the mechanical lower limit of the joint motion joint. Alternatively, the lower joint motion buffer threshold can be any motor rotation angle that ensures the mechanical lower limit in normal joint motion operation mode 3006.

[0197] During the lower joint motion buffer control mode 3008, the angles of the two input motors and the joint joint angle can be monitored. In other words, parameters indicating the positions of the input motors and the joint joint can be monitored during the third operating state. If the joint joint angle decreases in the lower joint motion buffer control mode 3008 (i.e., moves towards the mechanical lower limit), the joint motors are driven with the desired reverse kinematics and operate at limited speeds and / or limited torques. The torque and speed of the joint input motors are limited to allow the joint joint to reach its mechanical lower limit without causing high shock loads. In other words, when the first and second joint motors are in the third operating state and the rotational position of the second joint motor is moving away from the third position range, the maximum permissible speed and maximum permissible torque of the first and second joint motors are lower than the maximum permissible speed and maximum permissible torque in the first operating state.

[0198] In various situations, if the joint motion joint angle increases in the lower joint motion buffer control mode 3008 (i.e., moving away from the mechanical lower limit), the two joint motion motors are driven with desired reverse kinematics and operate at normal speed and torque. In other words, when the first and second joint motion motors are in the third operating state and the rotational position of the second joint motion motor is moving towards the third position range, the maximum permissible speed and maximum permissible torque of the first and second joint motion motors can, for example, be the same as the maximum permissible speed and maximum permissible torque in the first operating state. Once the angle of the second joint motion motor increases beyond the lower joint motion buffer threshold angle and the additional anti-jitter angle, the control circuit 3020 follows path 3016 to switch back from the lower joint motion buffer control mode 3008 to the normal joint motion control mode 3006. In other words, when the rotational position of the second joint motion motor returns from the fourth position range to the third position range by the threshold anti-jitter angle, the control circuit 3020 re-implements the first operating state for both the first and second joint motion motors from the third operating state.

[0199] The additional anti-shake angle is a small angle that allows for a smooth transition between the lower joint motion buffer control mode 3008 and the normal joint motion control mode 3006. In some cases, the anti-shake angle is less than ten degrees, and can be, for example, one or two degrees. In some cases, the anti-shake angle can be zero.

[0200] The control circuit 3020 may be implemented as a non-transitory computer-readable medium storing computer-readable instructions. Therefore, a non-transitory computer-readable medium includes any type of tangible machine-readable medium suitable for storing or transmitting electronic instructions or information in a machine-readable form (e.g., a computer) capable of transitioning between operating states and modes 3004, 3006, and / or 3008.

[0201] In various situations, the soft-buffered joint motion control process 3000 can be used to control other joints on robotic surgical tools, where the joints are configured to touch the limits of the mechanical joint during their range of motion.

[0202] See now Figure 24 This image shows a portion of a robotic surgical tool 3200. The robotic surgical tool 3200 is similar in many respects to the robotic surgical tool 3100. The robotic surgical tool 3200 includes an tool base or proximal housing 3202, which is similar in many respects to the tool base 3102 and includes six rotary actuators 3260, 3262, 3264, 3266, 3268, and 3270. Certain portions of the proximal housing 3202 are... Figure 24 The robotic surgical tool 3200 removes to expose the internal portion of the proximal housing 3202 and the components of the joint motion system housed therein, the internal portion including six rotary actuators 3260, 3262, 3264, 3266, 3268 and 3270.

[0203] An elongated shaft 3204 extends distally from the tool base 3202; the elongated shaft 3204 includes a distal end 3210 and a distal end 3212. A distal end effector 3206 is coupled to the distal end 3212 of the elongated shaft 3204 at an articulation joint or wrist joint 3208. In many aspects of this disclosure, the articulation joint 3208 is similar to the articulation joint 3108. The articulation joint 3208 enables the end effector 3206 to articulate or pivot relative to the elongated shaft 3204, and thereby positions the end effector 3206 at a desired orientation and location relative to the surgical site.

[0204] See still Figure 24A rotary actuator 3264 drives a first drive rack 3240. The rotational movement of the rotary actuator 3264 corresponds to linear movement of the first drive rack 3240 in direction 3222 or direction 3232, depending on the rotational direction of the rotary actuator 3264. The first drive rack 3240 includes a first fork 3242 that engages with a first articulated yoke 3244. More specifically, the first fork 3242 is configured to be received within an annular slot 3246 defined in the first articulated yoke 3244. The engagement between the first fork 3242 and the annular slot 3246 allows the first drive rack 3240 to linearly drive the first articulated yoke 3244 along an inner shaft 3280 in direction 3222 or direction 3232. The inner shaft 3280 extends from within the tool base 3202 at position 3218 through an elongated shaft 3204 to the articulated joint 3208.

[0205] A first articulated yoke 3244 is coupled to a first articulated band 3248, which extends distally to an articulated joint 3208. As shown, the first articulated band 3248 is arranged in a corresponding slot defined in an inner shaft 3280 such that the inner shaft 3280 guides the first articulated band 3248 as it extends distally to the articulated joint 3208. Axial movement of the first articulated yoke 3244 along a longitudinal axis parallel to the inner shaft 3280 correspondingly moves the first articulated band 3248, which corresponds to articulation of the articulated joint 3208. In some cases, movement of the first articulated yoke 3244 in direction 3232 can cause, for example, the articulated joint 3208 to cause the end effector 3206 to articulate and move in direction 3230. In some cases, the movement of the first articulatory yoke 3244 in the direction 3222 can cause, for example, the articulatory joint 3208 to cause the end effector 3206 to articulate and move in the direction 3220.

[0206] See still Figure 24 A rotary actuator 3266 drives a second drive rack 3250. The rotational motion of the rotary actuator 3266 corresponds to the linear motion of the second drive rack 3250 in direction 3224 or direction 3234, depending on the rotational direction of the rotary actuator 3266. The second drive rack 3250 includes a second fork 3252 that engages with a second articulated yoke 3254. More specifically, the second fork 3252 is configured to be received within an annular slot 3256 defined in the second articulated yoke 3254. Furthermore, the engagement between the second fork 3252 and the annular slot 3246 allows the second drive rack 3250 to linearly drive the second articulated yoke 3254 along the inner axis 3280 in direction 3224 or direction 3234.

[0207] The second articulated yoke 3254 can be coupled to a second articulated band 3258, which extends distally to an articulated joint 3208. As shown, the second articulated band 3258 is arranged in a corresponding slot defined in an inner shaft 3280, such that the inner shaft 3280 guides the second articulated band 3258 as it extends distally to the articulated joint 3208. Axial movement of the second articulated yoke 3254 along a longitudinal axis parallel to the inner shaft 3280 correspondingly moves the second articulated band 3258, which causes the articulated joint 3208 to articulate. In some cases, movement of the second articulated yoke 3254 in direction 3234 can cause, for example, the articulated joint 3208 to cause the end effector 3206 to articulate and move in direction 3230. In some cases, the movement of the second articulatory yoke 3254 in direction 3224 can cause, for example, the articulatory joint 3208 to cause the end effector 3206 to articulate and move in direction 3220.

[0208] The axial movement of the first articulated yoke 3244 and the second articulated yoke 3254 cooperatively actuates the first articulated band 3248 and the second articulated band 3258, thereby causing the end effector 3206 to articulate, as further described herein. The movement of the first articulated yoke 3244 in direction 3232 and the movement of the second articulated yoke 3254 in direction 3234 correspond to the articulation of the end effector 3206 in direction 3230. In other words, the movement of the first articulated yoke 3244 and the second articulated yoke 3254 away from each other corresponds to the articulation of the end effector 3206 in direction 3230. Furthermore, the movement of the first articulated yoke 3244 in direction 3222 and the movement of the second articulated yoke 3254 in direction 3224 correspond to the articulation of the end effector 3206 in direction 3220. In other words, the movement of the first articulated yoke 3244 and the second articulated yoke 3254 toward each other corresponds to the articulation of the end effector 3206 in direction 3220. In at least one aspect of this disclosure, the first articular yoke 3244 and the second articular yoke 3254 operate dominantly such that one of the articular yokes 3244, 3254 pulls one of the articular bands 3248, 3258 proximally, while the other articular yoke 3244, 3254 pushes the other articular band 3248, 3258 distally.

[0209] In other respects, the first articular yoke 3244 and the second articular yoke 3254 can operate independently without the other's operation (influence). In some cases, the first articular yoke 3244 and the second articular yoke 3254 can operate antagonistically, with one reducing the force exerted by the other. In antagonistic operation, one of the articular yokes 3244, 3254 pulls (or pushes) its associated articular band 3248, 3258 proximally (or distally) with a first force, while the other of the articular yokes 3244, 3254 pulls (or pushes) its associated articular band 3248, 3258 proximally (or distally) with a second force. When the first force is greater than the second force, the first force can overcome the second force as well as the internal losses of the device (i.e., friction) and the load applied to the end effector 3206 by the external environment, so that the articulation yokes 3244, 3254 that provide the first force move proximally (or distally), while the articulation yokes 3244, 3254 that provide the second force move distally (or proximally).

[0210] Still mainly see Figure 24 The inner shaft 3280 extends distally within the elongated shaft 3204 and connects to the articulation joint 3208. Articulation bands 3248 and 3258 extend distally toward the articulation joint 3208 within corresponding slots defined within the inner shaft 3280. These corresponding slots may be located on opposite sides of the inner shaft 3280, or in other cases, may be defined at other locations around the inner shaft 3280.

[0211] Figure 25 It is along Figure 24 The diagram shows a cross-sectional view of the proximal housing 3202 taken from a planar cut. Articulated bands 3248 and 3258 are located within slots on either side of the inner shaft 3280. The inner shaft 3280 extends through a second articulated yoke 3254. The second articulated band 3258 is attached to the second articulated yoke 3254. The first articulated band 3248 extends along a slot in the inner shaft 3280 and through the second articulated yoke 3254. A second drive rack 3250 is attached to the second articulated yoke 3254 at the second fork 3252.

[0212] Under various conditions, the sliding of the articulated yokes 3244 and 3254 along the inner axis 3280 can generate friction and corresponding internal losses. To achieve joint movement, the articulated yokes 3244 and 3254 must overcome frictional losses and move along the inner axis 3280. This includes articulated yoke systems (such as those configured to slide along an internal support chassis). Figure 24 and Figure 25Those shown are further described in U.S. Patent Application 16 / 553,725, filed August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION”, the entire contents of which are incorporated herein by reference.

[0213] Friction is generated along the internal moving parts that translate into each other to cause articulation of the end effector. For example, along... Figure 24 The articulated yokes 3244 and 3254 of the inner axis 3280 of the illustrated robotic surgical tool 3200 generate friction during articulation. In some cases, articulation of the end effector can induce significant frictional forces between the internal translational components during normal loading conditions. This frictional force requires the drive mechanism to provide additional input torque to overcome the friction. In various cases, high friction can lead to a brake-like effect, which requires additional input torque from the various subsystems interacting with the translational components to overcome the friction. In various cases, reducing friction on the moving parts of the robotic surgical tool during articulation can be advantageous.

[0214] Articulated motion drive systems that mechanically reduce friction between certain translational components can be advantageous in some situations. Such systems are robust enough to enable articulated movements of the end effector without requiring additional torque input due to frictional losses along the translational surfaces. For example, incorporating rolling elements (e.g., rotary linear ball bearings) between certain translational components can reduce friction and losses between them.

[0215] In one aspect of this disclosure, a robotic surgical tool may include a housing, an end effector, and an elongated shaft extending distally from the housing to the end effector. The robotic surgical tool may also include: an articulation joint configured to articulate the end effector relative to the elongated shaft during joint movement; an inner shaft extending distally from the housing through the elongated shaft; and a joint motion drive system. The joint motion drive system may include an articulation yoke coupled to the inner shaft, an articulation band coupled to the articulation yoke and extending distally along the inner shaft to the articulation joint, and a rolling element located between the inner shaft and the articulation yoke. The articulation yoke may be configured to roll along the rolling element during joint movement.

[0216] In some cases, the aforementioned arrangement can reduce frictional losses between certain translational components of the joint motion drive system. Furthermore, reduced friction improves load handling and requires less input torque. In some cases, small amounts of induced friction may also exist on adjacent subsystems.

[0217] See Figure 26 and Figure 27 The image shows a portion of a robotic surgical tool 3300. The robotic surgical tool 3300 is similar in many respects to the robotic surgical tool 3200. For example, the robotic surgical tool 3300 includes an inner shaft 3380, a joint motion joint 3308, a surgical end effector 3306, and a joint motion system including joint motion yokes 3344 and 3354. The joint motion yokes 3344 and 3354 are similar in many respects to joint motion yokes 3244 and 3254. Figure 24 Unlike the robotic surgical tool 3200, the robotic surgical tool 3300 also includes a rolling element pad 3382 surrounding the inner shaft 3380 between the articulated yokes 3344, 3354 and the inner shaft 3380. The rolling element pad 3382 includes a rotational linear element (e.g., a ball in a continuous circular track) that reduces friction caused by the movement of the articulated yokes 3344, 3354 along the inner shaft 3380.

[0218] The inner shaft 3380 extends distally and is coupled at its distal end to an articulated joint or wrist joint 3308. In various cases, the tool shaft may surround the inner shaft 3380 and also surround a component of the articulated system extending between the proximal housing and the end effector 3306. The inner shaft 3380 may serve as a chassis or support for the tool shaft and other components extending between the proximal housing and the end effector. For example, the inner shaft 3380 may support a firing member.

[0219] The articulation joint 3308 is similar to the articulation joint 3208 in many respects. The articulation joint 3308 enables the end effector 3306 to articulate or pivot relative to the inner axis 3380, and thereby positions the end effector 3306 in the desired orientation and position relative to the surgical site.

[0220] See also Figure 26 and Figure 27A first drive rack 3340 is attached to a first articulated yoke 3344, wherein a first fork 3242 is engageable with the first articulated yoke 3344. More specifically, the first fork 3342 is configured to be received within an annular slot 3346 defined in the first articulated yoke 3344. Furthermore, the engagement between the first fork 3342 and the annular slot 3346 allows the first drive rack 3340 to linearly drive the first articulated yoke 3344 along the inner axis 3380 in direction 3322 or direction 3332. The movement of the first articulated yoke 3344 along the inner axis 3380 in direction 3322 or direction 3332 corresponds to the articulation movement of the end effector 3306 in direction 3320 or direction 3330. A yoke stop 3374 prevents the first articulated yoke 3344 from moving too far proximally along the inner axis 3380, i.e., too far in direction 3332.

[0221] The second drive rack 3350 is attached to the second articulated yoke 3354, wherein the second fork 3352 is engageable with the second articulated yoke 3354. More specifically, the second fork 3352 is configured to be received within an annular slot 3356 defined in the second articulated yoke 3354. Furthermore, the engagement between the second fork 3352 and the annular slot 3356 allows the second drive rack 3350 to linearly drive the second articulated yoke 3354 along the inner axis 3380 in direction 3324 or direction 3334. The movement of the second articulated yoke 3354 along the inner axis 3380 in direction 3324 or direction 3334 corresponds to the articulation movement of the end effector 3306 in direction 3320 or direction 3330.

[0222] Therefore, the axial movements of the first articulated yoke 3344 and the second articulated yoke 3354 cooperatively actuate the first articulated band 3348 and the second articulated band 3358, thereby causing the end effector 3306 to perform articulation, as further described herein. The movement of the first articulated yoke 3344 in direction 3332 and the movement of the second articulated yoke 3354 in direction 3334 correspond to the articulation of the end effector 3306 in direction 3330. In other words, the movement of the first articulated yoke 3344 and the second articulated yoke 3354 away from each other corresponds to the articulation of the end effector 3306 in direction 3330. Furthermore, the movement of the first articulated yoke 3244 in direction 3222 and the movement of the second articulated yoke 3254 in direction 3224 correspond to the articulation of the end effector 3206 in direction 3220. In other words, the movement of the first joint yoke 3244 and the second joint yoke 3254 toward each other corresponds to the joint movement of the end effector 3206 in the direction 3220.

[0223] The articulation yokes 3344 and 3354 are configured to slide along a plurality of rolling element pads 3382 disposed in the inner shaft 3380. In some cases, the rolling element pads 3382 may be press-fitted into recesses or cavities in the inner shaft 3380. In various cases, two, four, or eight rolling element pads 3382 may be arranged around the circumference of the inner shaft 3380. The inner shaft 3380 includes four rolling element pads 3382 around its circumference. The reader will understand that other suitable numbers of rolling element pads 3382 may be present around the circumference of the inner shaft 3380, and the rolling element pads 3382 may be positioned to cover the area along which the articulation yokes 3344 and 3354 move along the inner shaft 3380.

[0224] See now Figure 28 An enlarged view of a rolling element pad 3382 is shown. Each rolling element pad 3382 includes a rolling element retainer 3384, rolling elements or balls 3386, and a rolling element base 3390. The rolling elements 3386 in each rolling element pad 3382 are divided into two groups of rolling elements 3386, which are located in separate and independent continuous annular tracks 3392. The continuous annular tracks 3392 are defined between the rolling element retainer 3384 and the rolling element base 3390. The rolling elements 3386 can roll about their continuous annular tracks 3392, which allows the rolling elements 3386 to move and roll as the articulated yokes 3344, 3354 move relative to the inner shaft 3380. In such cases, the rolling element pad 3382 includes a rotary linear bearing for the articulated yokes 3344, 3354. The slit or window 3388 in the rolling element holder 3384 allows the rolling element 3386 to interact with objects outside the rolling element holder 3384, such as articulated yokes 3344 and 3354. The rolling element 3386 extends beyond the slit 3388, such that the articulated yokes 3344 and 3354 are supported by and located on the rolling element 3386, and do not slide directly on the rolling element holder 3384.

[0225] See also Figure 28 Each rolling element pad 3382 has its rolling element 3386 held by a rolling element retainer 3384 in a continuous annular track 3392. Figure 28 During the linear movement of joint yokes 3344 and 3354 along the inner axis 3380, joint yokes 3344 and 3354 ( Figure 26 and Figure 27The joint yokes 3344 and 3354 slide on the rolling element 3386. The joint yokes 3344 and 3354 do not slide directly on the rolling element retainer 3384, but rather on the rolling element 3386, which radially protrudes beyond the retainer 3384. The rolling element 3386 rolls along a continuous annular track 3392 during the movement of the joint yokes 3344 and 3354.

[0226] exist Figure 28 In this configuration, each rolling element pad 3382 has two continuous ring tracks 3392, and each articulated yoke 3344, 3354 is located on a rolling element 3386 on a different continuous ring track 3392. In this case, the rolling element 3386 associated with each articulated yoke 3344, 3354 ( Figure 26 and Figure 27 The rolling elements 3344 and 3354 can travel in the same direction as the corresponding articulated yokes 3344 and 3354. As described herein, the articulated yokes 3344 and 3354 can move axially relative to each other (towards / together and away from / separated), and therefore, the rolling elements 3386 in the continuous annular track 3392 of the same rolling element pad 3382 can roll simultaneously or synchronously in different directions.

[0227] The rolling element 3386 is configured to reduce friction caused by the movement of the articulated yokes 3344 and 3354. This reduction in friction allows for better manipulation of the articulated joint 3308 and requires less input torque to articulate the end effector 3306 relative to the slender axis of the robotic surgical tool 3300. Furthermore, less induced friction can exist in adjacent subsystems, such as the closure and axis rolling subsystem of the robotic surgical tool.

[0228] In various situations, clinicians may find it difficult to visualize the orientation of robotic surgical tools during surgical procedures. For example, it may be challenging to visualize the orientation of the tool relative to a restricted anatomy, where only the end effector or a portion thereof is visible in the camera view.

[0229] In some cases, an enhanced presentation of the robotic surgical tool can be shown to the user to demonstrate the tool's orientation. This enhanced presentation can show the robotic surgical tool's connector outside the field of view / camera. The aim is to convey this information to the clinician without unduly distracting them. For example, the orientation can be shown on the display during the transition between the completion of the homing operation and the start of a remote operation. The enhanced presentation of the robotic surgical tool can then be minimized or otherwise moved to a remote and / or inconspicuous location on the display screen to avoid distracting the clinician.

[0230] In some cases, the overlay features of end effectors used in surgical imaging systems can inform clinicians about the function and orientation of robotic surgical tools without distracting them from the surgical procedure. In various situations, the position of the robotic surgical tool relative to the camera has already been calculated by the robotic surgical system for tool mapping purposes.

[0231] Surgical camera view of robotic surgical tool 3530 during surgical procedure is shown. Figures 30A to 30D In a series of views, the orientation of the robotic surgical tool 3530 is conveyed to the clinician in the camera view 3500 using end effector overlay features. In various cases, such features can be overlaid, displayed, and minimized to enhance the presentation of the distal end effector, leveraging the state between the completion of the robotic surgical tool 3530's homing operation and the commencement of a remote operation, for the clinician's benefit and convenience.

[0232] In various situations, control systems such as control tower 130 ( Figure 1 The system can complete the repositioning operation and then wait for the clinician to manually extend the robotic surgical tool 3530 into the surgical field of view. The control system tracks the orientation and position of the robotic surgical tool 3530 relative to the camera and monitors the camera view 3500. In various situations, the control system can wait for a minimum amount of the end effector of the robotic surgical tool 3530 to appear in the field of view, such as... Figure 30A As shown. The control system can then overlay an enhanced representation 3520 of the end effector on top of the actual end effector image on the display screen. While the enhanced representation 3520 can be on the end effector on the display screen, the enhanced representation can also be transparent and / or depicted with a skeleton / dashed line, so that the end effector can also be seen by the clinician.

[0233] Figure 29 This is a flowchart 3400 illustrating the process of displaying an enhanced rendering 3520 on a camera view 3500. In step 3410, the camera view has an abstract enhancement 3510 of a surgical tool 3530 in an inconspicuous position in the camera view 3500, and the surgical tool 3530 is not yet in the camera view 3500. At step 3420, the surgical tool 3530 enters the camera view 3500. When sufficient surgical tools have entered the camera view 3500, step 3430 begins. At step 3430, the enhanced rendering 3520 is overlaid on the camera view 3500. Next, at step 3440, the joint orientation of the surgical tool 3530 is shown to the clinician. At step 3450, the enhanced rendering 3520 is removed by panning and scaling the abstract enhancement 3510. At step 3460, the enhanced rendering 3430 has reached the abstract enhancement 3510 and disappears from the main and / or central portion of the display.

[0234] Enhanced representation 3520 is a conical schematic diagram reflecting the conical orientation of the jaws of robotic surgical tool 3530. In other cases, the enhanced representation can be a different three-dimensional shape, such as a sphere or a prism. In various cases, the shape of enhanced representation 3520 may correspond to the general shape of robotic surgical tool 3530. The reader will understand that alternative robotic surgical tools (e.g., electrosurgical devices, scalpels, applicators, clamps, and / or ultrasonic tools) may employ the end effector superimposed features described herein.

[0235] In various cases, enhanced presentation 3520 can show the joint orientation of surgical tool 3530. Figure 29 (Step 3440). In one example, the connector orientation is shown by leaving the augmented presentation 3520 over the surgical tool 3530 for a period of time. Once this period of time has ended, the augmented presentation 3520 can be scaled down and moved from the actual robotic surgical tool 3530 to a less clinically noticeable location. For example, the augmented presentation 3520 can be moved to the sidebar or corner of the camera view 3500. When the robotic surgical tool 3530 moves during remote operation, the augmented presentation 3520 can then move accordingly, which can aid in the visualization of the robotic surgical tool.

[0236] By rotating the connector of the robotic surgical tool 3530 on the enhanced presentation 3520, the enhanced presentation 3520 can illustrate the orientation and function of the robotic surgical tool 3530. For example, the enhanced presentation 3520 includes markers 3522 and 3524 at its distal end. Markers 3522 and 3524 can be configured to rotate about a longitudinal axis (i.e., a rolling axis) to illustrate the rolling function of the robotic surgical tool 3530. In some cases, for example, markers 3522 and 3524 can serve as... Figure 30A Variations of the line type shown in the enhanced rendering 3520 and / or as different colors are conveyed to clinicians. Markers 3522 and 3524 can also be implemented via other signals that allow functionality (e.g., rotation about the longitudinal axis) to be conveyed to clinicians in a simplified and easily identifiable manner. Markers 3522 and 3524 can also be conveyed in cases where there are breaks in the lines depicting the enhanced rendering 3520.

[0237] An abstract enhancement 3510 of the robotic surgical tool 3530 is shown in an inconspicuous position in the camera view 3500. Figures 30A to 30DIn the middle, an inconspicuous position is the upper left corner of camera view 3500. Alternative positions are also possible, such as on the sidebar or in any corner of camera view 3500. Abstraction enhancement 3510 shows a representation of the robotic surgical tool 3530, illustrating the orientation of the entire robotic surgical tool 3530, including the joint not shown in camera view 3500. These orientations can be challenging for clinicians to understand in a typical view, where much of the slender axis of the robotic surgical tool 3530 is not shown in the camera view. For example, in… Figures 30A to 30D The abstract enhancement 3510 shows the joint motion joint position marker 3512 and the rolling position marker 3514. The representation on the abstract enhancement 3510 can move as the robotic surgical tool 3530 moves, which provides clinicians with feedback and information about the overall orientation of the joint of the robotic surgical tool 3530.

[0238] Figures 30A to 30D It shows from Figure 30A Completely superimposed on Figure 30D The abstract enhancement 3510 in the middle is enhanced by the four animation stages of the 3520. Figure 30A The enhanced rendering 3520 is shown in a fully overlay state. Figure 30B and Figure 30C It is a transition frame to the enhanced rendering 3520, which is a pan and scaled version of the abstract enhancement 3510. Figure 30D This shows the overlay scene with only the top left corner featuring Abstract Enhancement 3510. (Full Overlay Stage) Figure 30A ) and Pure Abstract Enhancement 3510 Stage ( Figure 30D The transition between these can be smooth in the implementation. Enhanced Render 3520 can be panned and scaled to become part of Abstract Enhancement 3510.

[0239] In various cases, for example, rotation about a longitudinal axis is indicated by a roll position marker 3514, and rotation about a joint motion joint is indicated by a joint motion position marker 3512. The roll position marker 3514 and / or the joint motion position marker 3512 may include markings that correspond to the markings on the enhanced presentation 3520. For example, the markings may include the same signal and / or color to convey the correspondence to the clinician.

[0240] The enhanced presentation 3520 can be configured to show the orientation of the surgical tool 3530 by holding it on the robotic surgical tool 3530 for a period of time. Figure 29 (Step 3440). In some aspects of this disclosure, once the time period ends, the enhanced rendering 3520 can move from the robotic surgical tool 3530 to the abstract enhancement 3510. For example, the enhanced rendering 3520 can be translated and scaled to the abstract enhancement 3510 located in an inconspicuous position.

[0241] In some cases, the enhanced presentation 3520 can show the orientation of the surgical tool 3530 by maintaining its superposition on the robotic surgical tool 3530. Figure 29 (Step 3440) continues until the robotic surgical tool 3530 enters remote operation mode and achieves a minimal amount of rolling and / or joint movement. In such cases, the augmented representation 3520 moves along with the robotic surgical tool 3530, which allows clinicians to observe the movement of the augmented representation 3520. Once a minimal amount of travel or movement has been observed, the augmented representation 3520 can be translated and scaled to an abstract augmentation 3510 located in an inconspicuous position.

[0242] In other cases, the enhanced presentation 3520 can be configured to show the orientation of the surgical tool 3530 by causing the enhanced presentation 3520 to automatically oscillate the connector of the robotic surgical tool 3530. Figure 29 (Step 3440). This process can be used to attract the clinician's attention. For example, rolling joints and / or articulated joints can initially oscillate slightly to alert the clinician to their location. After this oscillation, the enhancement presentation 3520 can return to match the orientation of the robotic surgical tool, and then translate and scale to an abstract enhancement 3510 located in an inconspicuous position.

[0243] It should be noted that there are other methods to utilize Enhanced Rendering 3520 and Abstract Enhancement 3510. Figure 29 Step 3440. Any method can be used to show the joint orientation of the surgical tool 3530 using enhanced rendering 3520 and abstract enhancement 3510.

[0244] Robotic Surgical System 2100 shown Figure 31 Various aspects of the robotic surgical system 2100 are further described in, for example, U.S. Patent 10,470,830, entitled "SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES," published November 12, 2019. The entire contents of U.S. Patent 10,470,830, entitled "SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES," published November 12, 2019, are incorporated herein by reference.

[0245] The robotic surgical system 2100 includes a base 2101 that is coupled to one or more robotic arms, such as Figure 31The robotic arm 2102. The base 2101 is communicatively coupled to a command console or user console, as further described in, for example, U.S. Patent 10,470,830, entitled "SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES," published November 12, 2019. In various cases, the command console of the robotic surgical system 2100 is similar in many respects to the user console 110 (…). Figure 1 The base 2101 may be positioned to allow the robotic arm 2102 to enter and perform surgical procedures on a patient, while a user such as a clinician or surgeon can control the robotic surgical system 2100 based on the comfort of a command console. In some cases, the base 2101 may be coupled to a surgical table or bed for patient support. In other cases, the robotic arm may be supported, for example, by a self-supporting robot having a base and / or column, as further described in, for example, U.S. Patent Application 16 / 553,725, filed August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION”.

[0246] In some cases, the base 2101 may include subsystems such as control electronics, pneumatic devices, power supplies, light sources, etc. The robotic arm 2102 includes multiple arm segments 2110 connected at a joint 2111, providing the robotic arm 2102 with multiple degrees of freedom, for example, seven degrees of freedom corresponding to seven arm segments. The base 2101 may include a power supply 2112, a pneumatic pressure device 2113, and control and sensor electronics 2114 (including components such as a central processing unit, data bus, control circuitry, and memory) and associated actuators such as motors to move the robotic arm 2102. The electronics 2114 in the base 2101 may also process and transmit control signals from a command console. The base 2101 also includes wheels 2115 for transporting the robotic surgical system 100.

[0247] In some aspects of this disclosure, the robot arm 2102 includes an assembly joint that uses a combination of a brake and a counterbalancing device to maintain the position of the robot arm 2102. The counterbalancing device may include a gas spring or a coil spring. The brake (in some cases a fail-safe brake) may include mechanical and / or electronic components. Furthermore, the robot arm 2102 may be a gravity-assisted passive support type robot arm.

[0248] Each robotic arm 2102 can be coupled to a tool driver 2117, also referred to herein as an instrument device manipulator (IDM), via a transformation interface 2116. The tool driver 2117 can function as a tool holder. In some cases, the tool driver 2117 can be removable, allowing it to be replaced with different types of tool drivers. For example, in some cases, the robotic surgical system 100 ( Figure 1 ) tool driver 220 ( Figures 2 to 4 ) can be used with tool driver 2117 ( Figure 31 Interchangeability is possible. For example, a first type of tool actuator for manipulating an endoscope can be replaced by a second type of tool actuator for manipulating a laparoscope. The conversion interface 2116 includes connectors for transmitting pneumatic pressure, electrical power, electrical signals, and optical signals from the robotic arm 2102 to the tool actuator 2117. The conversion interface 2116 can be a set screw or a substrate connector. The tool actuator 2117 uses techniques including direct drive, harmonic drive, gear drive, belt and pulley, magnetic drive, etc., to manipulate surgical tools, such as surgical tools 2118. The conversion interface 2116 is interchangeable based on the type of tool actuator 2117 and can be customized for a particular type of surgical procedure. In various cases, the robotic arm 2102 may include joint-level torque sensing and a wrist at the distal end.

[0249] Surgical tool 2118 may be, for example, a laparoscopic tool, an endoscopic tool, and / or an endoscopic tool, capable of performing surgery on a patient at a surgical site. In some aspects of this disclosure, surgical tool 2118 includes a laparoscopic tool that can be inserted into a patient's incision. The laparoscopic tool may include a rigid shaft, a semi-rigid shaft, or a flexible shaft. When designed for laparoscopic surgery, the distal end of the shaft may be connected to an end effector, which may include, for example, a wrist, a grasper, scissors, a staple, or other surgical device. Exemplary end effectors for cutting and securing tissue are further described herein.

[0250] In some aspects of this disclosure, surgical tool 2118 includes an endoscopic surgical tool that is inserted into a patient's anatomy to capture images of the anatomical structures (e.g., body tissue). The endoscopic tool or endoscope may include a tubular and flexible axis. The endoscope includes one or more imaging devices (e.g., a camera or sensor) for capturing images at the surgical site. The imaging device may include one or more optical components, such as optical fibers, fiber arrays, or lenses. The optical components move together with the tip of the surgical tool 2118, such that movement of the tip of the surgical tool 2118 results in changes in the images captured by the imaging device. Exemplary imaging devices and visualization systems are further described herein.

[0251] In other cases, surgical tool 2118 includes an endovascular tool, such as a bronchoscope or urethroscope, that can be inserted through a patient's natural orifice. The endovascular tool may also include a tubular and flexible shaft. When designed for endovascular surgery, the distal end of the shaft may be connected to an end effector, which may include, for example, a wrist, a gripper, scissors, or other surgical device.

[0252] The robotic arm 2102 of the robotic surgical system 2100 can manipulate a surgical instrument 2118 using elongated motion components. These elongated motion components may include drawstrings (also called push-pull wires), cables, fibers, or flexible shafts. For example, the robotic arm 2102 is configured to actuate multiple drawstrings coupled to the instrument 2118 to deflect, articulate, and / or rotate the end effector of the surgical instrument 2118. The drawstrings may be made of both metallic and non-metallic materials, such as stainless steel, Kevlar, tungsten, carbon fiber, etc. In some aspects of this disclosure, the surgical instrument 2118 may exhibit nonlinear behavior in response to forces applied by the elongated motion components. This nonlinear behavior may be based on the stiffness and compressibility of the instrument 2118, and the variability in relaxation or stiffness between the different elongated motion components.

[0253] See also Figure 31 The robotic surgical system 2100 also includes a controller 2120, which may be, for example, a computer processor. The controller 2120 includes a calibration module 2125, an image registration module 2130, and a calibration storage device 2135. The calibration module 2125 can characterize the nonlinear behavior of the tool using a model with a piecewise linear response, along with parameters such as slope, hysteresis, and blind zone values. The robotic surgical system 2100 can more accurately control the surgical tool 2118 by determining accurate values ​​for the parameters. In some cases, some or all of the functions of the controller 2120 are performed externally to the robotic surgical system 2100. For example, some functions may be performed on another computer system or server communicatively connected to the robotic surgical system 2100.

[0254] Another surgical robot, 2200, is shown. Figure 32 Various aspects of the surgical robot 2200 are further described, for example, in U.S. Patent 10,470,830 entitled “SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES”, published on November 12, 2019.

[0255] In some aspects of this disclosure, the surgical robot 2200 can be incorporated into Figure 31In the robotic surgical system 2100, the surgical robot 2200 includes one or more robotic arms 2202, each robotic arm having a tool actuator 2217 and surgical tools 2218 attached thereto. Figure 32 In the surgical robot 2200, robotic arms 2202 are attached to adjustable rails 2250, which are connected to a bed-shaped patient platform 2260. In the surgical robot 2200, three robotic arms 2202 are attached to the adjustable rails 2250 on a first side of the patient platform 2260, and two robotic arms 2202 are attached to the adjustable rails 2250 on a second side of the patient platform 2260, thus providing a system with two arms. The surgical robot 2200 may also include, for example, a controller 2120 (…). Figure 31 The controller is communicatively connected to the command console, allowing the surgeon's input at the command console to be implemented via the controller through the surgical robot 2200.

[0256] Figure 33 A perspective view of the tool driver 2300, also referred to herein as an IDM, is shown. Various aspects of the tool driver 2300 are further described, for example, in U.S. Patent 10,470,830, entitled “SYSTEM AND METHODS FOR INSTRUMENTBASED INSERTION ARCHITECTURES”, published November 12, 2019.

[0257] The tool actuator 2300 can be used with, for example, a robotic surgical system 2100 and a surgical robot 2200. The tool actuator 2300 is configured to attach surgical tools to a robotic arm in a manner that allows the surgical tools to rotate or “roll” continuously about the longitudinal axis of the surgical tool. The tool actuator 2300 includes a base 2302 and a surgical tool holder assembly 2304 coupled to the base 2302. The surgical tool holder assembly 2304 serves as a means of holding surgical tools such as surgical tool 2118 (…). Figure 31 ) or surgical instruments 2218 ( Figure 32 (Tool rack)

[0258] The surgical tool holder assembly 2304 also includes an outer housing 2306, a surgical tool holder 2308, an attachment interface 2310, a channel 2312, and a plurality of torque couplings 2314 having splines 2318. The channel 2312 includes a through-hole extending along an axis 2316 from one face of the tool driver 2300 to the opposite face of the tool driver 2300. The tool driver 2300 can be used with a variety of surgical tools, which may include a handle or housing and an elongated body or shaft, and can be used with laparoscopes, endoscopes, or other types of surgical tools. For example, an exemplary surgical tool 2400 is shown... Figure 34 middle.

[0259] The base 2302 removably or permanently mounts the tool driver 2300 to the robotic surgical arm of the robotic surgical system. Figure 33 In this configuration, base 2302 is fixedly attached to the outer housing 2306 of surgical tool holder assembly 2304. In an alternative embodiment, base 2302 is configured to include a platform adapted to rotatably receive surgical tool holder 2308 on a surface opposite to attachment interface 2310. The platform may include channels aligned with channel 2312 to receive elongated bodies of surgical tools, and in some embodiments, additional elongated bodies of second surgical tools coaxially mounted with a first surgical tool. One or more motors may be housed in base 2302. For example, surgical tool holder 2308 may include a plurality of motors configured to drive (i.e., rotate) torque driver 2314 at torque and rotational speeds controllable by a controller, for example.

[0260] The surgical tool holder assembly 2304 is configured to secure surgical tools to the tool actuator 2300 and allow the surgical tools to rotate relative to the base 2302. Mechanical and electrical connections are provided from the surgical arm to the base 2302 and then to the surgical tool holder assembly 2304 to allow the surgical tool holder 2308 to rotate relative to the outer housing 2306 and to allow power and / or signals to be manipulated and / or delivered from the surgical arm to the surgical tool holder 2308 and ultimately to the surgical tools. Signals may include signals of pneumatic pressure, electrical power, electrical signals, and / or optical signals.

[0261] Attachment interface 2310 is the attachment surface of surgical tool holder 2308 to a surgical tool. Attachment interface 2310 includes a first portion of an attachment mechanism that reciprocally engages with a second portion of the attachment mechanism located on the surgical tool. Attachment interface 2310 is further described, for example, in U.S. Patent 10,470,830, entitled “SYSTEM AND METHODS FOR INSTRUMENTBASED INSERTION ARCHITECTURES,” published November 12, 2019.

[0262] Various tools can be attached to the tool actuator 2300, including tools for laparoscopic surgery, endoscopic surgery, and endoscopic surgery. The tools may include a tool-based insertion architecture that reduces reliance on a robotic arm for insertion. In other words, the design and architecture of the surgical tool can facilitate insertion of the surgical tool (e.g., toward the surgical site). For example, in some cases where the tool includes an elongated shaft and a shank, the tool's architecture allows the elongated shaft to be longitudinally translated relative to the shank along the insertion axis. The various advantages of tool-based insertion architectures are further described in U.S. Patent 10,470,830, entitled "SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES," published November 12, 2019, the entire contents of which are incorporated herein by reference.

[0263] Surgical tool 2400 with tool-based insertion architecture is shown. Figure 34 Various aspects of the surgical tool 2400 are further described, for example, in U.S. Patent 10,470,830 entitled “SYSTEM AND METHODS FOR INSTRUMENT BASEDINSERTION ARCHITECTURES”, published on November 12, 2019.

[0264] Surgical tool 2400 enables translation along an insertion axis (e.g., translation of its shaft 2402 and end effector 2412 relative to the distal end of the tool actuator and / or robotic arm). In such cases, surgical tool 2400 can move along the insertion axis with little or no dependence on the movement of the robotic arm. Surgical tool 2400 includes an elongated shaft 2402, an end effector 2412 connected to the shaft 2402, and a shank 2420 coupled to the shaft 2402, which may also be referred to as an instrument housing or base. The elongated shaft 2402 includes a tubular member having a proximal portion 2404 and a distal portion 2406. The elongated shaft 2402 includes one or more channels or grooves along its outer surface. The grooves are configured to receive one or more wires or cables 2430 passing through them. Cables 2430 extend along the outer surface of the elongated shaft 2402. In other aspects of this disclosure, certain cables 2430 may pass through shaft 2402 and may not be exposed. Manipulation of cables 2430 (e.g., via tool driver 2300) causes actuation of, for example, end effector 2412.

[0265] The end effector 2412 includes, for example, a laparoscopic component, an endoscopic component, or an intracavitary component, and may be designed to provide effects to a surgical site. For example, the end effector 2412 may include a wrist, a gripper, teeth, clamps, scissors, jigs, knives, and / or fasteners. An exemplary surgical end effector is further described herein. A cable 2430 extending along a groove on the outer surface of a shaft 2402 actuates the end effector 2412. The cable 2430 extends from a proximal portion 2404 of the shaft 2402 through a handle 2420 and toward a distal portion 2406 of the shaft 2402, where the cable actuates the end effector 2412.

[0266] The instrument handle 2420 includes an attachment interface 2422 having one or more mechanical inputs 2424 (e.g., jacks, pulleys, or reels), said one or more mechanical inputs being configured to engage with one or more torque couplings 2314 on the attachment interface 2310 of the tool driver 2300. Figure 33 The attachment interface 2422 can be attached to the tool driver 2300 via front mounting, rear mounting, and / or top mounting. When physically connected, latched, and / or coupled together, the engaging mechanical input 2424 of the instrument handle 2420 can share a rotational axis with the torque connector 2314 of the tool driver 2300, thereby allowing torque to be transmitted from the motor in the tool driver 2300 to the instrument handle 2420. In some cases, the torque connector 2314 may include a spline designed to mate with a socket on the mechanical input. The cable 2430 for actuating the end effector 2412 engages a socket, pulley, or reel of the handle 2420, such that the transmission of torque from the tool driver 2300 to the instrument handle 2420 results in actuation of the end effector 2412.

[0267] Surgical tool 2400 may include a first actuation mechanism 2450 that controls the actuation of end effector 2412. Figure 35 The tool 2400 may also include a second actuation mechanism that enables the shaft 2402 to translate relative to the shank 2420 along the insertion axis A. In various cases, the first actuation mechanism 2450 may be disengaged from the second actuation mechanism, such that the actuation of the end effector 2412 is unaffected by the translation of the shaft 2402, and vice versa.

[0268] In various cases, the actuation mechanism may include one or more pulleys mounted on the axis of rotation to change the relative cable length, and in other cases, the pulleys may be mounted on a lever-, gear-, or rail-based system to adjust their position. Additionally or alternatively, a spherical splined rotary shaft traveling along the length of the tool may also be used to transmit force mechanically remotely. Various actuation mechanisms are further described, for example, in U.S. Patent 10,470,830, entitled “SYSTEM AND METHODS FORINSTRUMENT BASED INSERTION ARCHITECTURES,” published November 12, 2019.

[0269] See Figure 35 The first actuation mechanism 2450 provides N+1 wrist movements, where N is the number of degrees of freedom provided by the N+1 cables. The first actuation mechanism 2450 for actuating the end effector 2412 includes at least one cable segment 2430 extending through at least one set of pulleys. Figure 35 In the actuation mechanism, a first cable or cable segment extends through pulley components 2450a, 2450b, and 2450c, while a second cable or cable segment extends through pulley components 2450d, 2450e, and 2450f. Cable 2430 is located at its distal end 2404 of shaft 2402. Figure 34 The cable 2430 is grounded at or near the proximal end 2404 of the shaft 2420, and then extends through a set of pulleys 2450a, 2450b, 2450c, 2450d, 2450e, and 2450f located within the housing 2420, before terminating at or near the end actuator 2412. The total cable path length is kept constant by grounding each cable 2430 at or near the proximal end 2404 of the shaft 2402, and by grounding one or more pulleys (e.g., pulley members 2450b and 2450e) as... Figure 35 The arrows indicate that relative length changes are achieved by moving the end effector 2412 actuated relative to each other. In some cases, the pulleys can be moved via linear or rotary motion of the corresponding mechanical input 2424. The first actuation mechanism 2450 allows the instrument shaft 2402 to move freely relative to the actuating pulleys 2450a, 2450b, 2450c, 2450d, 2450e, and 2450f, thereby allowing the inclusion of additional cables to allow insertion and retraction of the instrument shaft 1202 while the end effector 1212 is actuated.

[0270] Robotic surgical tools with tool-based insertion architecture (such as Figure 34The surgical tool (2400) shown may be subjected to high loads during certain surgical actuation or surgical function. For example, surgical tools used for clamping, cutting, suturing, and / or fastening tissue may be subjected to high clamping and firing loads when clamping certain types of tissue and / or when firing fasteners. In some cases, the clamping and firing loads on a surgical tool may exceed, for example, 300 lbf. The tool-based insertion architecture in the housing of such a surgical tool should be configured to withstand such loads. In some cases, a lead screw may be used to translate the tool housing along an elongated axis that may withstand high clamping and firing loads. However, in some cases, the lead screw arrangement may be bulky and / or expensive.

[0271] Alternatively, in certain situations, a lightweight, dexterous, and / or less expensive translation mechanism than a lead screw may be advantageous. Such a translation mechanism can be robust enough to withstand significant forces during use, such as high forces transmitted during clamping and / or firing. For example, a pulley and cable arrangement can be used in combination with one or more pivot locks configured to resist high clamping and / or firing forces.

[0272] In one aspect of this disclosure, a surgical tool may include: a surgical end effector including opposing jaws; an elongated shaft extending distally to the surgical end effector; and a housing defining a channel therethrough, wherein the elongated shaft extends through the channel. The surgical tool may also include an actuation mechanism configured to selectively move the housing relative to the surgical end effector along the elongated shaft, wherein the actuation mechanism includes a pulley, a cable engaged with the pulley, and a locking arrangement configured to releasably lock the housing relative to the elongated shaft. The locking arrangement may include a washer positioned about the elongated shaft, wherein the cable engages the washer, and wherein the washer is configured to pivot relative to the elongated shaft between a locking orientation and an unlocking orientation. Furthermore, actuation of the pulley may apply tension to the cable to pivot the washer to the unlocking orientation.

[0273] In various cases, this locking arrangement may also include a second washer positioned about an elongated axis, wherein the opposite end of the cable engages with the second washer, and wherein the second washer is configured to pivot relative to the elongated axis between a locking orientation and an unlocking orientation.

[0274] In some cases, the aforementioned arrangement can reliably facilitate translation of the surgical instrument housing along the slender axis of the surgical instrument without requiring highly mechanically efficient linear motion, such as linear motion achieved using a lead screw. Furthermore, the actuation mechanism used to achieve tool-based translation can be, for example, ingenious and lightweight.

[0275] See now Figure 36The image shows a surgical tool 2500. The surgical tool 2500 includes: a housing 2520, also referred to herein as a handle or tool base; an elongated shaft 2530 slidably positioned through a portion of the housing 2520; and a distal end actuator 2512. The housing 2520 may be similar in many respects to housing 2420 (…). Figure 34 For example, housing 2520 may include an attachment interface having one or more mechanical inputs (such as jacks, pulleys, and / or reels) configured to engage with one or more torque couplings 2314 on attachment interface 2310 of tool driver 2300. Figure 33 It reciprocates and receives actuation motion from the robotic system. One or more actuation mechanisms, such as actuation mechanism 2550, may be positioned, for example, in housing 2520 and configured to perform one or more surgical actuations, such as articulation, clamping, and / or firing of end effector 2512.

[0276] Translation of the end effector 2512 can be achieved using an actuation mechanism 2570, which includes a pulley arrangement 2572 and a locking arrangement 2584. The pulley arrangement 2572 includes pulleys 2574, a winch 2576, and a cable 2578 extending from a first end 2580 to a second end 2582. The cable 2578 terminates at both the first and second ends 2580. The first and second ends 2580 are mounted to features within a housing 2520, which will be described further herein. Figure 36 The cable 2578 is not a continuous loop. Instead, cable 2578 comprises a section of cable having ends 2580, 2582, which are configured to move relative to each other in certain circumstances to change the length of the cable loop. Actuation of pulley arrangement 2572 is configured to apply tension to cable 2578 to apply a pulling force on housing 2520 along the length of elongated axis 2530. For example, rotation of winch 2576 applies tension to cable 2578. When actuation mechanism 2570 is unlocked, as further described herein, the pulling force on cable 2578 is configured to pull housing 2520 along the length of elongated axis 2530, causing end effector 2512 to displace along longitudinal axis A of surgical tool 2500.

[0277] The elongated shaft 2530 is grounded at its proximal end 2532 to a component 2502 of a surgical robot, such as the distal end of a robotic arm, which in many respects is similar to, for example, robotic arm 2102. Figure 31 ) and robotic arm 2202 ( Figure 32Similarly, the distal end 2534 of the elongated shaft 2530 is grounded to the distal portion of the surgical tool 2500. More specifically, the distal end 2534 is secured to a bracket 2514 mounted on the end effector 2512. The housing 2520 is configured to move along the elongated shaft 2530 between the component 2502 and the bracket 2514.

[0278] The actuation mechanism 2570 also includes a locking arrangement 2584 combined with the pulley arrangement 2572. The locking arrangement 2584... Figure 36 The locking arrangement 2584 is schematically shown in the figure. The housing 2520 is configured to releasably lock to the elongated shaft 2530 such that the forces applied to the elongated shaft 2530 during certain surgical actuation and / or functions (e.g., clamping and / or firing) do not affect the longitudinal displacement of the housing 2520 relative to the elongated shaft 2530 and do not cause the end effector 2512 to move along the insertion axis A.

[0279] Generally, during clamping and / or firing actuation, the end effector 2512 does not advance or retract along the longitudinal axis of the insertion axis or the elongated shaft 2530. More specifically, for example, when tissue is clamped, cut, and / or sutured, the longitudinal position of the end effector 2512 is typically fixed, which in some cases prevents damage and / or injury to the tissue. To this end, the locking arrangement 2584 may be configured to lock the longitudinal position of the housing 2520 on the elongated shaft 2530 during clamping and / or firing actuation. When in the locked configuration, any forces transmitted between the housing 2520 and the shaft 2530 can be resisted by the locking arrangement 2584 to keep the end effector 2512 fixed relative to, for example, the tissue being clamped, cut, and / or sutured.

[0280] See now Figure 37 The surgical instrument 2600 is shown. For clarity, certain portions of the surgical instrument 2600 are shown from... Figure 37 Removed from. For example, certain parts of housing 2620 are removed from... Figure 37 Removed from the middle. Surgical tool 2600 may be similar to surgical tool 2500 in many respects. For example, surgical tool 2600 includes: a housing 2620, which is also referred to herein as a handle or tool base; an elongated shaft 2630 slidably positioned through housing 2620; and a distal end actuator 2612. Housing 2620 may be similar to housing 2420 in many respects ( Figure 34 The housing 2620 may include an attachment interface having one or more mechanical inputs (such as jacks, pulleys, and / or reels) configured to engage with one or more torque couplings 2314 on the attachment interface 2310 of the tool driver 2300. Figure 33The actuators reciprocate and are configured to receive actuated motions from the robotic system. One or more actuation mechanisms in housing 2620 may be configured to perform one or more surgical actuations, such as articulation, gripping, and / or firing of end effector 2612. For example, housing 2620 may be constructed about an elongated shaft 2630.

[0281] An elongated shaft 2630 extends from the surgical robot to the end effector 2612. For example, the distal end 2632 of the elongated shaft 2630 is mounted to the robotic arm 2602 of the robotic surgical system, and the distal end 2634 of the elongated shaft 2630 is mounted to the distal flange 2614 of the end effector 2612. A housing 2620 is slidably positioned between the distal ends 2632 and 2634 about the elongated shaft 2630.

[0282] Surgical tool 2600 includes an actuation mechanism 2670, which includes a pulley arrangement 2672 and a locking arrangement 2684. The pulley arrangement 2672 is similar in many respects to pulley arrangement 2572. Figure 36 It includes a pulley 2674 mounted to the robotic arm 2602, a winch 2676 mounted to the flange 2614, and a cable 2678 engaging with and extending therebetween the pulley 2674 and the winch 2676. The cable 2678 is mounted to the housing 2620 via a locking arrangement 2684. Furthermore, the pulley arrangement 2672, and more specifically its cable 2678, is configured to allow the locking arrangement 2684 to move between an unlocked configuration and a locked configuration.

[0283] Locking arrangement 2684 is configured to releasably lock housing 2620 relative to elongated shaft 2630. Locking arrangement 2684 includes a first lock 2686 and a second lock 2688. Locks 2686 and 2688 are washer-shaped and have a central hole or through-hole configured to receive the elongated shaft 2630 passing through it. In other words, the first lock 2686 and the second lock 2688 are positioned within housing 2620 about elongated shaft 2630. A first end 2636 of cable 2678 engages with the first lock 2686, and a second end 2638 of cable 2678 engages with the second lock 2688. Locks 2686 and 2688 are configured to pivot relative to elongated shaft 2630 as they move between a locking orientation and an unlocking orientation. More specifically, the actuation of the pulley arrangement 2672 (e.g., rotation of the winch 2767) is configured to apply tension to the cable 2678 to pull the ends 2636, 2638 and pivot the locks 2686, 2688 to the unlocked configuration.

[0284] In the locking configuration, the first lock 2686 and the second lock 2688 are oriented at an angle relative to the longitudinal axis defined by the elongated shaft 2630. More specifically, the axis extending through the central hole in each lock 2686, 2688 is oriented at an angle relative to the longitudinal axis of the elongated shaft 2630. In the unlocking configuration, the first lock 2686 and the second lock 2688 are configured to pivot toward a parallel orientation, wherein the locks 2686, 2688 are parallel or nearly parallel to each other. When the locks 2686, 2688 pivot toward the unlocking configuration, the axis extending through the central hole in each lock 2686, 2688 is configured to move to axial alignment with the longitudinal axis of the elongated shaft 2630. In some cases, the first lock 2686 and the second lock 2688 may be referred to as shielded door locks, or collectively as opposing shielded door locks.

[0285] Locking arrangement 2684 includes a spring 2690 positioned between a first lock 2686 and a second lock 2688. Spring 2690 biases a portion of the first lock 2686 away from a portion of the second lock 2688, causing locks 2686 and 2688 to pivot relative to an angled orientation with respect to elongated shaft 2630. In various configurations, the tension applied by the actuation of pulley arrangement 2672 is configured to overcome the biasing force of spring 2690, causing the first lock 2686 and the second lock 2688 to move from their locked configuration to their unlocked configuration, and thus unlock their actuation mechanism 2670 and locking arrangement 2684. In this arrangement, tension in cable 2678 first overcomes locking arrangement 2684, then pulls elongated shaft 2630 to achieve displacement along insertion axis A.

[0286] See also Figure 37 The housing 2620 includes a body portion 2622 having an internal cavity 2626 that receives at least a portion of the locks 2686 and 2688 and a portion of the elongated shaft 2630. The body portion 2622 includes an inner wall 2624 defining a portion of the internal cavity. Actuation of the pulley arrangement 2672 is configured to push a portion of the first lock 2686 against the inner wall 2624 to pull or drag the housing 2620 along the elongated shaft 2630. In various cases, when tension in the cable 2678 is released, a spring 2690 is configured to return the locks 2686 and 2688 to their locked configuration, wherein clamping and firing loads involving the elongated shaft 2630 are resisted by the locking arrangement 2684.

[0287] In various situations, the locking arrangement 2684 can be integrated with the surgical tool 2500. Figure 36 In, for example, locking arrangement 2584 ( Figure 36 It may include locking arrangement 2684 or a component thereof.

[0288] See now Figure 38The flowchart in the document illustrates the transverse cutting operation 2800. This document describes various surgical tools including end effectors for transverse tissue cutting, and these various surgical tools and / or robotic surgical systems can utilize the transverse cutting operation 2800 to cut tissue and / or fire fasteners. The reader will understand that the transverse cutting operation 2800 can be implemented using various control circuitry, including, for example, located in controller 2120 (…). Figure 31 ) and / or control tower 130 ( Figure 1 The control circuit, controller, and computer processor in the system.

[0289] Used to implement cross-cutting operation 2800 ( Figure 38 Example control circuit 2728 is shown in, for example Figure 39 In the middle. The control circuit 2728 includes a processor 2740 that communicates with a memory 2742, a communication device 2744, a drive system 2752, and input devices 2780, 2782. The processor 2740 includes a clock or timer 2741, which is configured to respond to the transverse operation 2800 ( Figure 38 Timing is performed at each stage or sub-stage of the process, as further described herein.

[0290] Memory 2742 stores program instructions configured to perform various surgical procedures, including clamping operation 2840 and transverse incision operation 2800. Figure 38 ) or their respective stages. Memory 2742 also stores various threshold parameters related to the transitions between the stages in the cross-cutting operation 2800, such as emergency threshold parameters. Additional parameters stored in memory 2742 are further described herein.

[0291] The communication device 2744 is configured to transmit information from the processor 2740 to an external device, such as a graphical user interface (GUI) 2790. Various outputs to the GUI 2790 are further described herein.

[0292] The drive system 2752 includes a motor 2758, an input driver 2760 coupled to the motor 2758, a torque sensor 2732, a rotary encoder / position sensor 2736, and a speed sensor 2738. The drive system 2752 corresponds to a rotary driver in a tool holder or tool driver, as further described herein. The drive system 2752 is configured to provide rotary input to a surgical tool to perform a surgical function. More specifically, the drive system 2752 corresponds to a firing drive system configured to achieve a firing motion of the surgical tool. In various cases, the input driver 2760 may correspond to... Figure 33One of the torque connectors 2314 is used. For example, the output from the motor 2758 can be transmitted to the torque connector 2314 and ultimately to the surgical instrument to achieve a surgical function. More specifically, one of the torque connectors 2314 is configured to transmit output motion from the firing motor 2758 to the surgical instrument to achieve a firing stroke. A torque sensor 2732 can detect, for example, torque from the firing motor 2758 and / or the input driver 2760 coupled thereto, a position sensor 2736 can detect, for example, the rotational position of the input driver 2760, and a speed sensor 2738 can detect, for example, the rotational speed of the input driver 2760.

[0293] The control circuitry 2728 also includes inputs 2780 and 2782, which are configured to transmit signals to the processor 2740 indicative of inputs from a surgeon and / or clinician located at a command console. In various cases, input 2780 may correspond to an active / inactive state of a traversing input (e.g., a traversing pedal at the command console), and input 2782 may correspond to an active / inactive state of a clamping input (e.g., a clamping pedal at the command console).

[0294] See you again Figure 38 The traverse operation 2800 includes emergency detection, graphical user interface (GUI) prompts and / or warnings, stall detection, and various safety faults, as further described herein. The traverse operation 2800 can utilize speed, torque, and / or position sensors to transition between states and continue through transition operation 2800. Various sensors in the robot and / or surgical tool can be configured to detect the speed, torque, and / or position of input components (e.g., input actuators and / or pedals), rotary drive components (e.g., tool drivers and / or motors and / or rotary drives in the tool base), and output components (e.g., firing components and / or cutting blades).

[0295] In various cases, the transverse cutting operation 2800 can follow the clamping step or the clamping operation 2840. During normal, uninterrupted transverse cutting, the transverse cutting operation 2800 can progress from the clamping operation 2840 to the start state 2802, the pre-locked area state 2804, the locked area state 2808, the transverse cutting state 2816, the transverse cutting completion state 2818, the retraction state 2830, and finally to the transverse cutting end state 2834. However, the control circuitry is configured to monitor various parameters during the transverse cutting operation 2800, and certain parameters at certain stages can trigger changes that occur during the normal, uninterrupted transverse cutting operation 2800. For example, the torque and / or speed of the firing member can cause operation 2800 to bypass the flow between the start state 2802 and the transverse cutting end state 2834 as described above. Additional states in operation 2800 may include, for example, pre-lock pause state 2806, lock pause state 2810, lock detection state 2812, lock damage state 2814, cross-cut cancellation state 2820, cross-cut pause state 2822, damage state 2824, cross-cut stall state 2826, stall limit state 2828, retraction stall state 2832, emergency attempt state 2836, and / or unrecoverable state 2838.

[0296] In various scenarios, the transverse cutting operation 2800 involves a clinician activating a transverse cutting input (e.g., a pedal) to transversely cut or slice tissue held between the jaws of an end effector. Tissue cutting typically relies on extending a blade or cutting edge distally through the held tissue. In various aspects of the invention, transverse cutting of tissue is accompanied by nearly simultaneous tissue suturing. For example, the cutting edge may cut the tissue directly after suturing.

[0297] In various scenarios, when a surgical instrument is mounted onto a robotic arm, the surgical robot can initially perform a homing operation, wherein the angular position of the torque connector and / or rotary input is measured at various limits or “bumps” within the range of motion of the surgical instrument and recorded in the memory of the control circuitry (e.g., memory 2742). The homing operation is further described herein and, for example, in U.S. Patent Application 16 / 553,725, filed August 28, 2019, entitled “ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FORARTICULATION AND CALIBRATION.”

[0298] After homing and clamping, the traverse operation 2800 can begin to enter the start state 2802. Upon entering the start state 2802, the control circuitry (e.g., control circuitry 2728) checks condition A, which corresponds to a disabled value (DV) for future firing of the surgical system and / or surgical instrument. Condition A is satisfied when the DV stored in memory (e.g., memory 2742) is false / negative, indicating that future firing of the surgical system and / or surgical instrument has not yet been disabled. If condition A is satisfied, the traverse operation 2800 proceeds from the start state 2802 to the pre-locked area state 2804. Alternatively, if the DV is true / positive, such that condition A is not satisfied, future firing has been disabled and operation 2800 does not proceed from the start state 2802. In various cases, if the DV is true / positive, the control circuitry can, for example, transmit the disabled state to the user via a GUI (e.g., GUI 2790). In various cases, the GUI can be updated throughout operation 2800. For example, the firing component and / or the cutting edge extension function can send update signals to the GUI about the position and / or status of the cutting edge (e.g., before the locking zone, in the locking zone, in the transverse zone, at the end transverse position, etc.) throughout operation 2800.

[0299] When entering the pre-locked region state 2804, the firing motor angle (FMA) from a position sensor (e.g., position sensor 2736), the firing motor speed (FMV) from a speed sensor (e.g., speed sensor 2738), and the firing motor torque (FMT) from a torque sensor (e.g., torque sensor 2732) are set or targeted by a control circuit (e.g., control circuit 2728). The target FMA corresponds to the end-truncation angle (TTA) at which the firing member has reached the end or furthest position within the end effector. The target FMV corresponds to the pre-locked region speed stored in a memory (e.g., memory 2742). The motor associated with firing actuation (e.g., firing motor 2758) is configured to deliver the target FMT. In the pre-locked region state 2804, the target FMT corresponds to the pre-locked region operating torque stored in a memory (e.g., memory 2742). In the pre-locked region state 2804, if the FMA from the position sensor (e.g., position sensor 2736) exceeds a threshold non-opening angle associated with the firing member position to prevent the jaws from loosening or opening, the non-opening code (NOC) is set to positive / true. The threshold non-opening angle can be recorded, for example, during the return operation and stored in memory (e.g., memory 2742). The NOC corresponds to the inability to open the jaws. In various cases, the NOC can remain positive / true until operation 2800 advances to the transverse end state 2834.

[0300] In the pre-locked zone state 2804, the control circuitry (e.g., control circuitry 2728) checks conditions B and C. Condition B corresponds to an FMA from a position sensor (e.g., position sensor 2736) that is equal to or greater than the minimum chamber locking angle stored in a memory (e.g., memory 2742). In such a case, the FMA indicates that the firing member has extended into the locked zone. If condition B is met during the pre-locked zone state 2804, operation 2800 proceeds to the locked zone state 2808, which will be described further herein.

[0301] Condition C corresponds to the inactive state of the traverse pedal (e.g., input 2780). If condition C is met during the pre-locked region state 2804, i.e., the traverse pedal becomes inactive, operation 2800 proceeds to the pre-locked pause state 2806, which will be described further herein.

[0302] During normal, uninterrupted transverse cutting, the firing member can advance from the pre-locked region to the locked region (e.g., condition B is met) without incident. Therefore, operation 2800 advances to the locked region state 2808, during which time the firing member can, for example, pass through the cartridge lock. The locked region may correspond to the area in which a hollow, used, and / or missing cartridge lock is located. In various cases, the cartridge lock includes a mechanical feature in the proximal portion of the end effector and / or cartridge that prevents the cutting edge on the firing member from advancing distally into the tissue when the cartridge (or the absence of a cartridge) will not adequately secure the tissue to be transversely cut.

[0303] Upon entering the locked zone state 2808, FMA, FMV, and FMT are set or targeted by the control circuitry (e.g., control circuitry 2728). The target FMA may again correspond to the end-truncation angle (TTA). The target FMV corresponds to the locked zone speed stored in the memory (e.g., memory 2742), which may differ from the pre-locked zone speed. Furthermore, the target FMT corresponds to the locked zone operating torque also stored in the memory (e.g., memory 2742). In the locked zone state 2808, if the FMA from the position sensor (e.g., position sensor 2736) exceeds a threshold non-opening angle associated with a position preventing the jaws from loosening or opening, the NOC (associated with the inability to open the jaws) is set to positive / true.

[0304] In the locked region state 2808, the control circuitry (e.g., control circuitry 2728) checks conditions G, H, I, and J. Condition G corresponds to an FMA from a position sensor (e.g., position sensor 2736) that is equal to or greater than the maximum magazine locking angle, which may be determined, for example, during a return operation and stored in a memory (e.g., memory 2742). In such cases, the firing motor angle may indicate that the firing member has extended beyond the locked region. If condition G is met during locked region state 2808, operation 2800 proceeds to the transverse state 2816, which will be described further herein.

[0305] Condition H corresponds to (A) the FMT from the torque sensor (e.g., torque sensor 2732) being equal to or greater than the operating torque of the locking region, and (B) the FMV from the speed sensor (e.g., speed sensor 2738) being equal to or less than the locking region speed for a period of time exceeding the locking threshold time stored in the memory (e.g., memory 2742). For example, when the locking member blocks the firing path, the high torque from the motor and applied to the firing member can result in minimal or no displacement of the firing member, in order to, for example, prevent transverse cutting of unsutured tissue. Condition H indicates that chamber locking has occurred. If condition H is met during the locking region state 2808, operation 2800 proceeds to the locking detection state 2812, which will be described further herein.

[0306] Condition I corresponds to an FMT from a torque sensor (e.g., torque sensor 2732) that is equal to or greater than a damage-locking threshold torque, which is stored in a memory (e.g., memory 2742) and indicates that the compartment lock is damaged. In various cases, the damage-locking threshold torque may be greater than the operating torque of the locked area. If condition I is met during locked area state 2808, operation 2800 proceeds to locked damage state 2814.

[0307] Condition J corresponds to the inactive state of the traverse pedal (e.g., input 2780). If condition J is met during the locked region state 2808, i.e., the traverse pedal becomes inactive, the traverse operation 2800 proceeds to the locked pause state 2810, which will be described further herein.

[0308] During normal, uninterrupted traverse cutting, the firing member can advance from the locking region to the traverse cutting region (satisfying condition G) without an accident. Therefore, operation 2800 proceeds to traverse cutting state 2816. Upon entering traverse cutting state 2816, the traverse cutting count stored in the memory of the control circuit (e.g., memory 2742 of control circuit 2728) is incremented by one. Furthermore, the FMA, FMV, and FMT of traverse cutting state 2816 are set or targeted. The target FMA may again correspond to the end traverse cutting angle (TTA), and the target FMV may correspond to the traverse cutting region speed stored in the memory (e.g., memory 2742). In various cases, the traverse cutting region speed may differ from the pre-locked region speed and / or the locked region speed. The target FMT corresponds to the traverse cutting operating torque stored in the memory (e.g., memory 2742).

[0309] In the cross-cut state 2816, the control circuit (e.g., control circuit 2728) checks conditions N, O, P, Q, and R, where condition N corresponds to the inactive state of the cross-cut pedal (e.g., input 2780). If condition N is met during the cross-cut state 2816, i.e., the cross-cut pedal becomes inactive, operation 2800 proceeds to the cross-cut pause state 2822, which will be described further herein.

[0310] Condition O corresponds to an FMT from a torque sensor (e.g., torque sensor 2732) that is equal to or greater than the maximum lateral cutting torque, which is stored in a memory (e.g., memory 2742) and indicates that the firing element (e.g., the blade / cutting edge) has been subjected to high torque and may be damaged during lateral cutting state 2816. If condition O is met during lateral cutting state 2816, operation 2800 proceeds to damage state 2824, which will be described further herein.

[0311] Condition P corresponds to (A) the FMT from the torque sensor (e.g., torque sensor 2732) being equal to or greater than the transverse operating torque, and (B) the FMV from the speed sensor (e.g., speed sensor 2738) being equal to or less than the stall threshold speed, wherein both (A) and (B) are true for a period exceeding the stall threshold time (STT) stored in the memory (e.g., memory 2742). Condition P may indicate that the firing member or blade has stalled during transverse state 2816. Condition Q corresponds to the number of times the firing member has stalled being equal to or less than the maximum number of times the firing member has stalled stored in the memory (e.g., memory 2742). If conditions P and Q are satisfied, operation 2800 proceeds to transverse stall state 2826, which will be further described herein. If condition P is satisfied but condition Q is not satisfied, operation 2800 proceeds to stall limit state 2828, which will be further described herein and indicates that the surgical device has exceeded the stall limit.

[0312] Condition R corresponds to the FMA reaching the end-of-cut angle (TTA) from the position sensor (e.g., position sensor 2736), which indicates, for example, that the firing member has traveled to the end of the cut or slit line. If condition R is met, operation 2800 proceeds to the cut completion state 2818.

[0313] During a normal, uninterrupted cross-cut, the firing member can be advanced to the end of the cross-cut area (satisfying condition R) without causing an accident. Therefore, operation 2800 proceeds to the cross-cut completion state 2818. Upon entering the cross-cut completion state 2818, the control circuit (e.g., control circuit 2728) is configured to send GUI feedback indicating the completion of the cross-cut or firing stroke to the GUI (e.g., GUI 2790), thus preparing to transition to the retraction state 2830.

[0314] During a normal, uninterrupted traverse cut, the firing member advances from the traverse cut completion state 2818 to the retraction state 2830 without causing an accident. Upon entering the retraction state 2830, FMA, FMV, and FMT are set or targeted by the control circuit (e.g., control circuit 2728). The target FMA may correspond to the firing angle after return to position, which is stored in a memory (e.g., memory 2742), and the target FMV may correspond to the retraction speed, which is also stored in a memory (e.g., memory 2742). The target FMT may correspond to the retraction operating torque stored in a memory (e.g., memory 2742). In the retraction state 2830, the control circuit (e.g., control circuit 2728) may check conditions Y and Z.

[0315] Condition Y corresponds to (A) the FMT from the torque sensor (e.g., torque sensor 2732) being equal to or greater than the retraction operating torque, and (B) the FMV from the speed sensor (e.g., speed sensor 2738) being equal to or less than the retraction speed, wherein both (A) and (B) are true for a period of time equal to or greater than the stall threshold time (STT) stored in the memory (e.g., memory 2742). Condition Y indicates that the firing member has stalled during retraction. If condition Y is satisfied during retraction state 2830, operation 2800 proceeds to retraction stall state 2832.

[0316] Condition Z corresponds to the return trigger angle from the FMA (e.g., position sensor 2736). Condition Z indicates that the firing member has returned to its return stroke angle before firing. If condition Z is met during the retraction state 2830, operation 2800 proceeds to the traverse end state 2834.

[0317] Upon entering the transverse cut end state 2834, the NOC (associated with the inability to open the jaws) stored in memory (e.g., memory 2742) is set to negative / false, indicating that the firing member has been fully retracted to allow the jaws to open or release. Operation 2800 then proceeds to clamping operation 2840.

[0318] In various situations, operation 2800 can traverse from pre-locked region state 2804 to pre-locked pause state 2806. From pre-locked pause state 2806, operation 2800 can return to pre-locked pause state 2806, or can proceed to traverse cancellation state 2020 or emergency attempt state 2036. Upon entering pre-locked pause state 2806, control circuitry (e.g., control circuitry 2728) is configured to store the FMA corresponding to the pre-locked pause angle from a position sensor (e.g., position sensor 2736). Control circuitry is configured to target the pre-locked pause angle during pre-locked pause state 2806. For example, the pre-locked pause angle can be maintained or sustained during pre-locked pause state 2806.

[0319] In the pre-lock pause state 2806, the control circuit (e.g., control circuit 2728) checks conditions D, E, and F. Condition D corresponds to the active state of the traverse pedal (e.g., input 2780). If condition D is met during the pre-lock pause state 2806, i.e., the traverse pedal becomes active, operation 2800 returns to the pre-lock region state 2804, which will be described further herein.

[0320] Condition E corresponds to the active state of the clamping pedal (e.g., input 2782). If condition E is met during the pre-lock pause state 2806, i.e. the clamping pedal becomes active, operation 2800 proceeds to the cross-cut cancellation state 2820, which will be described further herein.

[0321] Condition F corresponds to (A) the FMT from the torque sensor (e.g., torque sensor 2732) being equal to or greater than the emergency detection torque, and (B) the FMV from the speed sensor (e.g., speed sensor 2738) being equal to or less than the emergency detection speed, wherein both (A) and (B) are true for a time period equal to or greater than the emergency detection time stored in the memory (e.g., memory 2742). Condition F may indicate that a surgeon or clinician is attempting and / or implementing an emergency procedure when the firing member moves through the pre-locked area. For example, during a surgical procedure, a surgeon or clinician may manually manipulate the firing member via an emergency lever or actuator on the housing of a surgical instrument, which may involve, for example, disengaging the firing member from the firing motor and manually retracting the firing member. If condition F is met during the pre-locked pause state 2806, the traverse operation 2800 proceeds to the emergency attempt state 2836, which will be further described herein.

[0322] In various situations, operation 2800 can traverse from locked area state 2808 to locked pause state 2810. From locked pause state 2810, operation 2800 can return to locked area state 2808, or proceed to traverse cancellation state 2020 or emergency attempt state 2036. Upon entering locked pause state 2810, control circuitry (e.g., control circuitry 2728) is configured to store the FMA corresponding to the locked pause angle. Control circuitry is configured to target the locked pause angle during locked pause state 2810. For example, the FMA can be maintained or sustained during locked pause state 2810.

[0323] In the locked pause state 2810, the control circuit (e.g., control circuit 2728) checks conditions K, L, and M. Condition K corresponds to the active state of the traverse pedal (e.g., input 2780). If condition K is met during the locked pause state 2810, i.e., the traverse pedal becomes active, then operation 2800 returns to the locked area state 2808, which will be described further herein.

[0324] Condition L corresponds to the active state of the clamping pedal (e.g., input 2782). If condition L is met during the locked pause state 2810, i.e. the clamping pedal becomes active, operation 2800 proceeds to the cross-cut cancellation state 2820, which will be described further herein.

[0325] Condition M corresponds to (A) the FMT from the torque sensor (e.g., torque sensor 2732) being equal to or greater than the emergency detection torque, and (B) the FMV from the speed sensor (e.g., speed sensor 2738) being equal to or less than the emergency detection speed, where both (A) and (B) are true for a time period equal to or greater than the emergency detection time. In the pre-lock pause state 2806, the emergency detection torque, emergency detection speed, and emergency detection time are the same threshold values. For example, condition M can be the same as condition F. In other cases, different emergency threshold values ​​can be applied during pre-lock pause state 2806 and lock pause state 2810. Condition M may indicate that a surgeon or clinician is attempting and / or implementing an emergency procedure when the firing member moves through the locked area. For example, during surgical procedures, the surgeon or clinician may manually manipulate the firing member, which may involve, for example, disengaging the firing member from the firing motor and manually retracting the firing member. If condition M is met during the locked pause state 2810, the cross-cut operation 2800 proceeds to the emergency attempt state 2836, which will be described further in this document.

[0326] In various scenarios, operation 2800 can traverse from the locked area state 2808 to the lock detection state 2812, and then to the retracted state 2830. Upon entering the lock detection state 2812, control circuitry (e.g., control circuitry 2728) is configured to transmit confirmation of the locked and locked states to the clinician, for example, via a GUI (e.g., GUI 2790). For instance, the control circuitry may issue an error message informing the clinician that a compartment is missing and / or the installed compartment is empty / used. From the lock detection state 2812, operation 2800 can proceed to the retracted state 2830, which will be described further herein.

[0327] Under various conditions, operation 2800 can circumvent from the locked-area state 2808 to the locked-damaged state 2814, and then to the retracted state 2830. Upon entering the locked-damaged state 2814, control circuitry (e.g., control circuitry 2728) is configured to transmit a message to the clinician indicating that damage has been detected and the surgical tool may be damaged or otherwise inoperable. For example, the control circuitry may issue an error message via a GUI (e.g., GUI 2790). Furthermore, the control circuitry may update the DV to true / positive, indicating that future firing of the surgical system and / or surgical tool has been disabled. As further described herein, when the DV is true / positive, condition A is not met, and subsequent operation 2800 will not proceed from the start state 2802. From the locked-damaged state 2814, operation 2800 can proceed to the retracted state 2830, which will be further described herein.

[0328] In various situations, operation 2800 can navigate from various states to a traverse cancellation state 2820, and then to a retraction state 2830. For example, traverse operation 2800 can be cancelled, and thus navigate directly from a pre-lock pause state 2806 (condition E), a lock pause state 2810 (condition L), a traverse pause state 2822 (condition T), or a traverse stall state 2826 (condition V) to traverse cancellation state 2820. For example, actuation of a clamping operation (e.g., actuation of a clamping pedal or other input) can cancel operation 2800, and the operation can proceed directly to traverse cancellation state 2820. Upon entering traverse cancellation state 2820, control circuitry (e.g., control circuitry 2728) is configured to transmit a message to the clinician indicating that traverse operation 2800 has been cancelled. For example, the control circuitry may issue an error message via a GUI (e.g., GUI 2790). From the cross-cut cancellation state 2820, operation 2800 can proceed to the retraction state 2830, which will be described further in this document.

[0329] In various situations, operation 2800 can traverse from the traverse state 2816 to the traverse pause state 2822. For example, deactivating the clamping pedal or other input during traverse state 2816 can pause the traverse operation 2800. Upon entering the traverse pause state 2822, the control circuitry (e.g., control circuitry 2728) is configured to store the FMA corresponding to the traverse pause angle. The control circuitry is configured to target the traverse pause angle during traverse pause state 2822. For example, the traverse pause angle can be maintained or sustained during traverse pause state 2822.

[0330] In the cross-cut pause state 2822, the control circuit (e.g., control circuit 2728) checks conditions S, T, and U. Condition S corresponds to the active state of the cross-cut pedal (e.g., input 2780). If condition S is met during the cross-cut pause state 2822, i.e., the cross-cut pedal becomes active, operation 2800 returns to the cross-cut state 2816, which will be described further herein.

[0331] Condition T corresponds to the active state of the clamping pedal (e.g., input 2782). If condition T is met during the cross-cut pause state 2822, i.e. the clamping pedal becomes active, then operation 2800 proceeds to the cross-cut cancellation state 2820, which will be described further herein.

[0332] Condition U corresponds to (A) the FMT from the torque sensor (e.g., torque sensor 2732) being equal to or greater than the emergency detection torque, and (B) the FMV from the speed sensor (e.g., speed sensor 2738) being equal to or less than the emergency detection speed, where both (A) and (B) are true for a time period equal to or greater than the emergency detection time. In the pre-lock pause state 2806 and the lock pause state 2810, the emergency detection torque, emergency detection speed, and emergency detection time are the same threshold. In other cases, different emergency thresholds may be applied during the pre-lock pause state 2806, the lock pause state 2810, and / or the transverse pause state 2822. For example, condition U may be the same as condition F and / or condition M. In other examples, different emergency thresholds may be applied during the transverse pause state 2822. Condition U may indicate that a surgeon or clinician is attempting and / or implementing an emergency step during a tissue transverse step. For example, during surgical procedures, a surgeon or clinician may manually manipulate the firing mechanism, which may involve, for example, disengaging the firing mechanism from the firing motor and manually retracting the firing mechanism. If condition U is met during the traverse pause state 2822, the traverse operation 2800 proceeds to the emergency attempt state 2836, which will be described further herein.

[0333] Under various conditions, operation 2800 can detour from the transverse state 2816 to the damaged state 2824, and then to the retracted state 2830. Detection of high torque on the firing motor and / or firing member during the transverse state (which is associated with damage to the surgical device) (e.g., condition O) can trigger a detour to the damaged state 2824. Upon entering the damaged state 2824, control circuitry (e.g., control circuitry 2728) is configured to transmit a message to the clinician indicating suspected damage and that the surgical instrument may be damaged or otherwise inoperable. For example, the control circuitry may issue an error message via a GUI (e.g., GUI 2790). Furthermore, the control circuitry may update the DV stored in memory (e.g., memory 2742) to true / positive, indicating that future firing of the surgical system and / or surgical instrument has been disabled. As further described herein, when DV is true / positive, condition A is not met, and subsequent operation 2800 will not proceed from the start state 2802. From damaged state 2824, operation 2800 can proceed to retracted state 2830, which will be described further in this document.

[0334] Under various circumstances, operation 2800 can circumvent the transverse stall state 2816 to the transverse stall state 2826. For example, if certain monitoring parameters (such as FMV and FMT) indicate that the firing element has stalled during the transverse state and the total number of times the firing element has stalled is less than a maximum threshold, operation 2800 can enter the transverse stall state 2826.

[0335] Upon entering transverse stall state 2826, the transverse stall count stored in the memory of the control circuit (e.g., memory 2742 of control circuit 2728) is incremented by one. As further described herein, the transverse stall count is compared with the maximum threshold number of firing member stalls stored in memory for condition Q under transverse state 2816. Furthermore, the control circuit is configured to transmit or relay the stall count, and in some cases the transverse stall count, to a clinician. For example, the control circuit may issue GUI feedback via a GUI (e.g., GUI 2790) indicating that operation 2800 has stalled and thus entered transverse stall state 2826.

[0336] Upon entering the lateral stall state 2826, the control circuit (e.g., control circuit 2728) is also configured to store the FMA corresponding to the stall angle from the position sensor (e.g., position sensor 2736), and set the time parameter of the timer and / or internal clock (e.g., clock 2741) to the current time, i.e., the time when the lateral stall state 2826 begins. Furthermore, FMA, MFV, and FMT are set by the control circuit or are targeted. In various cases, the target FMA angle may correspond to the retraction angle, and the target FMV may again correspond to the lateral area speed, which is the same as the target FMV during lateral stall state 2816. In various cases, the target FMT corresponds to the lateral operating torque, which is the same as the target FMT during lateral stall state 2816.

[0337] In the transverse stall state 2826, the control circuit (e.g., control circuit 2728) checks conditions V, W, and X. Condition V corresponds to the active state of the clamping pedal (e.g., input 2782). If condition V is met during the transverse stall state 2826, i.e., the clamping pedal becomes active, operation 2800 proceeds to the transverse cancellation state 2820, which will be described further herein.

[0338] Condition W corresponds to (A) the current time minus the recorded time parameter being equal to or greater than the traverse back time, and (B) the traverse pedal state (e.g., the state of input 2780) changing from inactive to active. Condition W also corresponds to the stall duration being less than a threshold time period stored in memory (e.g., memory 2742), and the traverse pedal returning to the active state. In such cases, condition W is satisfied, and operation returns to the traverse state 2816.

[0339] Condition X corresponds to (A) the FMT from the torque sensor (e.g., torque sensor 2732) starting to equal or exceed the emergency detection torque, and (B) the FMV from the speed sensor (e.g., speed sensor 2738) equaling or less than the emergency detection speed, where (A) and (B) are both true for a period equal to or greater than the emergency detection time. In the pre-lock pause state 2806, the lock pause state 2810, the lateral pause state 2822, and / or the lateral stall state 2826, the emergency detection torque, emergency detection speed, and emergency detection time are the same threshold values. For example, condition X can be the same as condition F, condition M, and / or condition U. In other cases, different emergency threshold values ​​can be applied during the lateral pause state 2826.

[0340] Condition X indicates that a surgeon or clinician is attempting and / or implementing an emergency procedure when the firing member moves through the locking zone. For example, during surgical procedures, the surgeon or clinician may manually manipulate the firing member, which may involve, for example, disengaging the firing member from the firing motor and manually retracting the firing member. If condition X is met during the traverse stall state 2826, the traverse operation 2800 proceeds to the emergency attempt state 2836, which will be described further herein.

[0341] Under various conditions, operation 2800 can detour from the transverse stall state 2816 to the stall limiting state 2828, and then to the transverse cancellation state 2820. For example, if the parameters for entering the transverse stall state 2826 are met, operation 2800 can proceed to the stall limiting state 2828; however, the surgical tool has exceeded the maximum threshold number of times the firing member has stalled. In other words, the surgical tool has stalled more times than reasonably and / or expected. Upon entering the stall limiting state 2828, control circuitry (e.g., control circuitry 2728) is configured to transmit a determination of the stall limit to the clinician, for example, via a GUI (e.g., GUI 2790). Under various conditions, the control circuitry can issue an error message to the GUI informing the clinician that the stall limit has been reached and / or that stall limiting state 2828 has begun. From the stall limiting state 2828, operation 2800 can proceed to the retraction state 2830, which will be described further herein.

[0342] In various situations, operation can circumvent from retracted state 2830 to retracted stall state 2832. For example, the firing mechanism may be jammed by a motor (e.g., firing motor 2758) or otherwise inoperable during retracted state 2830. Upon entering retracted stall state 2832, control circuitry (e.g., control circuitry 2728) may message and / or transmit the status of the surgical tool to the clinician or user. For example, control circuitry may transmit signals to a GUI (e.g., GUI 2790) instructing the clinician on one or more troubleshooting steps. Troubleshooting steps may be configured to remedy mechanically restrained surgical tools and / or their firing systems. Control circuitry may also update the DV stored in memory (e.g., memory 2742) to true / positive, indicating that future firing of the surgical system and / or surgical tool has been disabled. As further described herein, when DV is true / positive, condition A is not met, and subsequent operation 2800 will not proceed from start state 2802. From the retraction stall state 2832, operation 2800 can proceed to the unrecoverable state 2838, which will be described further in this document.

[0343] Under various conditions, operation 2800 can proceed from the pre-locked pause state 2806, the locked pause state 2810, the transverse pause state 2822, and / or the transverse stall state 2826 to the emergency attempt state 2836. The emergency attempt state 2836 may correspond to a higher FMT from a torque sensor (e.g., torque sensor 2732) and a lower FMV from a speed sensor (e.g., speed sensor 2738), as further described herein. Upon entering the emergency attempt state 2836, control circuitry (e.g., control circuitry 2728) provides feedback to the clinician regarding how to handle the emergency surgical device. For example, the control circuitry may signal to the GUI (e.g., GUI 2790) instructions (verbal and / or visual) on how to manually retract the surgical device (e.g., manually retract the firing member so that the jaws can release any tissue held therein). From the emergency attempt state 2836, operation can proceed to the irreversible state 2838.

[0344] For example, operation 2800 can transition from an emergency attempt state 2836 and / or a retraction stall state 2832 to an irreversible state 2838. Upon entering the irreversible state 2838, the surgical instrument may become irreversible. In various situations, control circuitry (e.g., control circuitry 2728) can signal the irreversible condition of the surgical instrument to the GUI (e.g., GUI 2790). In such cases, new clamping operations 2840 and / or new transverse cutting operations 2800 can be prevented. In some circumstances, the surgical instrument may be returned and / or sent back to the manufacturer for inspection and / or repair.

[0345] Example

[0346] Various aspects of the subject matter described herein are set forth in the following numbered embodiments.

[0347] Example 1 - A surgical tool configured to receive rotational input from a robotic surgical system. The surgical tool includes: a distal end effector including jaws for clamping tissue therebetween; an intermediate shaft portion coupled to the distal end effector; and a proximal housing coupled to the intermediate shaft portion. The proximal housing includes a rotary actuator arrangement including a first rotary actuator. The first rotary actuator includes: an input shaft configured to receive rotational input from the robotic surgical system; a transition nut slidably positioned on the input shaft; and an output gear. The first rotary actuator further includes: a high-speed gear configured to selectively drive the output gear; a high-torque gear configured to selectively drive the output gear; and a spring arrangement configured to bias the transition nut along the input shaft from a high-speed operating state to a high-torque operating state when a threshold torque is obtained, wherein the transition nut is driven to engage with the high-speed gear in the high-speed operating state and with the high-torque gear in the high-torque operating state.

[0348] Example 2 - A surgical tool according to Example 1, wherein the transition nut includes a periphery, a first end, and an array of inclined teeth extending around the periphery to the first end.

[0349] Example 3 - A surgical tool according to Example 2, wherein the high-torque gear includes a complementary tilting socket array configured to receive a tilting gear array when the transition nut is in a high-torque operating state.

[0350] Example 4 - A surgical tool according to Example 1, 2 or 3, wherein the transition nut further includes a second end and a first tooth array extending around the periphery to the second end.

[0351] Example 5 - The surgical tool according to Example 4 further includes a gripping gear that engages with a high-speed gear drive, wherein the gripping gear includes a second tooth array configured to receive the first tooth array when the transition nut is in a high-speed operating state.

[0352] Example 6 - A surgical tool according to Example 5, wherein the spring arrangement includes a first spring configured to bias a first tooth array toward a second tooth array.

[0353] Example 7 - A surgical tool according to Examples 1, 2, 3, 4, 5 or 6, wherein the spring arrangement further includes a second spring configured to bias the first end of the transition nut away from the second end of the transition nut.

[0354] Example 8 - The surgical tool according to Example 1, 2, 3, 4, 5, 6 or 7 further includes an output shaft drivenly connected to an output gear, wherein the output shaft is configured to drive a rotating drive screw to achieve jaw closure.

[0355] Example 9 - A surgical tool according to Examples 1, 2, 3, 4, 5, 6, 7 or 8, wherein the first rotary actuator further includes a gear train comprising high-speed gears, and wherein the gear train has a speed ratio greater than one.

[0356] Example 10 - A surgical tool for a robotic surgical system. The surgical tool includes: a distal end effector including jaws for gripping tissue therebetween; an intermediate shaft portion coupled to the distal end effector; and a proximal housing coupled to the intermediate shaft portion. The proximal housing includes: an input shaft configured to receive rotational input from the robotic surgical system; a transition nut slidably positioned on the input shaft; and an output gear. The proximal housing also includes: a first rotary driver configured to selectively drive the output gear; a second rotary driver configured to selectively drive the output gear; and a spring arrangement configured to bias the transition nut along the input shaft based on a threshold torque applied to the transition nut to engage the input shaft with either the first or second rotary driver.

[0357] Example 11 - A surgical tool according to Example 10, wherein the transition nut rotates together with the input shaft.

[0358] Example 12 - A surgical tool according to Example 10 or 11, wherein the spring arrangement includes a first spring configured to bias a transition nut to disengage from a second rotary actuator and engage with a first rotary actuator when a threshold torque is exceeded.

[0359] Example 13 - A surgical tool according to Examples 10, 11, or 12, wherein the transition nut includes a periphery, a first end, and an array of inclined teeth extending around the periphery to the first end. The transition nut also includes a second end, a first array of teeth extending around the periphery to the second end, and a second spring configured to bias the first end away from the second end.

[0360] Example 14 - A surgical tool according to Example 13, wherein the first rotary actuator includes a high-torque gear, the high-torque gear including a complementary tilting jack configured to receive a tilting gear array when the input shaft is engaged with the first rotary actuator, and wherein the surgical tool is in a high-torque operating state when the first rotary actuator is engaged with the input shaft.

[0361] Example 15 - A surgical tool according to Example 13 or 14, wherein the second rotary drive includes a high-speed gear and a gripping gear droopingly engaged with the high-speed gear, wherein the gripping gear includes a second tooth array configured to receive a first tooth array when the input shaft is engaged with the second rotary drive, and wherein the surgical tool is in a high-speed operating state when the second rotary drive is engaged with the input shaft.

[0362] Example 16 - A surgical tool according to Examples 10, 11, 12, 13, 14 or 15, wherein the second rotary actuator further includes a gear train comprising high-speed gears, and wherein the gear train has a speed ratio greater than one.

[0363] Example 17 - The surgical tool according to Examples 10, 11, 12, 13, 14, 15 or 16 further includes an output shaft drivenly connected to an output gear, wherein the output shaft is configured to drive a rotating drive screw to achieve jaw closure.

[0364] Example 18 - A rotary drive system for driving a drive screw in a rotary robotic surgical tool. The rotary drive system includes: an input shaft configured to receive a rotary input from a robotic surgical system; a transition nut slidably positioned on the input shaft; and an output gear dromatically coupled to the output shaft. The rotary drive system further includes: a first rotary driver configured to selectively drive the output gear; a second rotary driver configured to selectively drive the output gear; and a spring arrangement configured to bias the transition nut along the input shaft to engage with either the first or second rotary driver based on a threshold torque applied to the transition nut.

[0365] Example 19 - A rotary drive system according to Example 18, wherein the first rotary drive includes a high-torque gear, the high-torque gear including a complementary tilting socket configured to receive a tilting tooth array on a transition nut when the input shaft engages with the first rotary drive.

[0366] Example 20 - A rotary drive system according to Example 18 or 19, wherein the second rotary drive includes a high-speed gear and a gripping gear droopingly engaged with the high-speed gear, wherein the gripping gear includes a tooth array configured to engage a transition nut when the input shaft engages with the second rotary drive.

[0367] Example 21 - A robotic surgical system includes a closure system. The closure system includes a first pinion driven to a first motor, a second pinion driven to a second motor, and a closing gear selectively driven by the first and second pinions. The robotic surgical system also includes control circuitry configured to perform motor cross-checking operations. The control circuitry is configured to receive a first parameter indicating a first torque generated by the first motor, receive a second parameter indicating a second torque generated by the second motor, compare the first parameter with the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicates the state of the closure system.

[0368] Example 22 - A robotic surgical system according to Example 21, wherein the control circuit is configured to determine when the closure system reaches a steady state during a motor cross-check operation, and to compare a first parameter with a second parameter after the closure system reaches a steady state.

[0369] Example 23 - A robotic surgical system according to Example 21 or 22, wherein a first pinion and a second pinion simultaneously drive a closed gear to achieve a closed stroke.

[0370] Example 24 - A robotic surgical system according to Examples 21, 22 or 23, wherein when the comparison between the first parameter and the second parameter exceeds a threshold, the state transmitted by the control circuit corresponds to a fault state.

[0371] Example 25 - A robotic surgical system according to Example 24, wherein the robotic surgical system is configured to lock when the state corresponds to a fault state.

[0372] Example 26 - A robotic surgical system according to Examples 21, 22, 23, 24 or 25, wherein, in order to achieve motor cross-examination operation, a first motor is configured to drive a closed gear in a first direction, and wherein a second motor is configured to drive the closed gear in a second direction opposite to the first direction.

[0373] Example 27 - A robotic surgical system according to Examples 21, 22, 23, 24, 25 or 26, wherein a first motor is configured to transmit torque to a second pinion.

[0374] Example 28 - A robotic surgical system according to Examples 21, 22, 23, 24, 25, 26 or 27, wherein a second motor is configured to transmit torque to a first pinion.

[0375] Example 29 - A robotic surgical system according to Examples 21, 22, 23, 24, 25, 26, 27 or 28, wherein the second pinion is configured to move through the backlash region before the closed system reaches a steady state.

[0376] Example 30 - The robotic surgical system according to Example 29, wherein the control circuitry is further configured to record the duration of the interdental region and obtain the duration as a stored value.

[0377] Example 31 - A non-transitory computer-readable medium storing computer-readable instructions that, when executed, cause a machine to receive a first parameter indicating a first torque generated by a first motor of a closed system, receive a second parameter indicating a second torque generated by a second motor of the closed system, and perform a motor cross-check. The first and second motors are configured to simultaneously drive a closed gear. The motor cross-check includes comparing the first and second parameters and transmitting a signal to a communication device, wherein the signal is based on the comparison and indicates the state of the closed system.

[0378] Example 32 - A non-transitory computer-readable medium according to Example 31 that stores computer-readable instructions, when executed, also causes a machine to determine when a closed system reaches a steady state and to compare a first parameter with a second parameter after the closed system has reached a steady state.

[0379] Example 33 - A non-transitory computer-readable medium storing computer-readable instructions according to Example 31 or 32, which, when executed, also causes the machine to enter a fault state when the comparison of a first parameter and a second parameter exceeds a threshold.

[0380] Example 34 - A non-transitory computer-readable medium for storing computer-readable instructions according to Example 33, which, when executed, also causes the machine to enter a locked state when the state corresponds to a fault state.

[0381] Example 35 - A robotic surgical system including a closure system. The closure system includes a first pinion driven to a first motor, a second pinion driven to a second motor, and a closing gear selectively driven by the first and second pinions. The closure system also includes a processor and a memory coupled to the processor. The memory stores instructions executable by the processor to receive a first parameter indicating a first torque from the first motor, a second parameter indicating a second torque from the second motor, and a third parameter indicating a first angular displacement of the first motor. The memory also stores instructions executable by the processor to receive a fourth parameter indicating a second angular displacement of the second motor, and to determine a state of the closure system based on the first, second, third, and fourth parameters. The memory further stores instructions executable by the processor to transmit a signal indicating the state of the closure system to a communication device.

[0382] Example 36 - The robotic surgical system according to Example 35, wherein the memory also stores instructions that can be executed by a processor to perform cross-checking of motors in which the first pinion and the second pinion rotate in opposite directions.

[0383] Example 37 - The robotic surgical system according to Example 35, wherein the memory also stores instructions that can be executed by a processor to perform motor cross-checking in which a first pinion is driven by a first motor and a second pinion is not driven by a second motor.

[0384] Example 38 - A robotic surgical system according to Examples 35, 36 or 37, wherein the memory also stores instructions that can be executed by a processor to measure the backlash angle during motor cross-checking and compare the backlash angle with a backlash value stored in the memory.

[0385] Example 39 - A robotic surgical system according to Examples 35, 36, 37 or 38, wherein the memory further stores instructions that can be executed by a processor to perform a motor cross-check in which the stiffness of a first pinion is calculated from a first torque and a first angular displacement and the stiffness is compared with a threshold.

[0386] Example 40 - A robotic surgical system according to Examples 35, 36, 37, 38 or 39, wherein the memory stores instructions that can be executed by a processor to perform a motor cross-check after at least one of a homing operation or a clamping event of the closure system.

[0387] Example 41 - A control circuit for use with a robotic surgical system. The control circuit is configured to receive parameters indicating the rotational position of an articulated motor. The articulated motor is configured to drive an articulated joint of a robotic surgical tool, wherein the articulated motor is configured to move through a first position range and a second position range. The first and second position ranges are non-overlapping. The control circuit is further configured to realize a first operating state and a second operating state when the parameters correspond to a transition of the articulated motor from the first position range to the second position range. The second operating state differs from the first operating state. The control circuit is further configured to re-realize the first operating state when the parameters correspond to a return of the articulated motor from the second position range to the first position range by a threshold anti-jitter angle.

[0388] Example 42 - The control circuit according to Example 41, wherein the first position range and the second position range are continuous.

[0389] Example 43 - A control circuit according to Example 41 or 42, wherein the second position range includes the mechanical upper limit of the joint motion joint.

[0390] Example 44 - The control circuit according to Example 41, 42 or 43, wherein when the parameter is moving away from the first position range, the maximum permissible speed of the joint motion motor is smaller in the second operating state than in the first operating state.

[0391] Example 45 - The control circuit according to Examples 41, 42, 43 or 44, wherein when the parameters are moving away from the first position range, the maximum permissible torque of the joint motion motor is smaller in the second operating state than in the first operating state.

[0392] Example 46 - The control circuit according to Example 41, 42 or 43, wherein when the parameters are moving away from the first position range, the maximum permissible speed and maximum permissible torque of the joint motion motor are smaller in the second operating state than in the first operating state.

[0393] Example 47 - A control circuit according to Examples 41, 42, 43, 44, 45 or 46, wherein the parameters include a first parameter indicating the rotational position of a first joint motor, and wherein the control circuit is further configured to receive a second parameter indicating a second rotational position of a second joint motor, wherein the second joint motor is configured to drive the joint joint of a robotic surgical tool, wherein the second joint motor is configured to move through a third position range and a fourth position range, and wherein the third position range and the fourth position range are non-overlapping.

[0394] Example 48 - The control circuit according to Example 47 is further configured to realize a third operating state when the second parameter corresponds to the transition of the second joint motion motor from a third position range to a fourth position range, wherein the third operating state is different from the first operating state. The control circuit is further configured to re-realize the first operating state when the second parameter corresponds to the return of the second joint motion motor from the fourth position range to the third position range by a threshold anti-shake angle.

[0395] Example 49 - A control circuit according to Example 47 or 48, wherein the fourth position range includes the mechanical lower limit of the joint motion joint.

[0396] Example 50 - A non-transitory computer-readable medium storing computer-readable instructions, which, when executed, cause a machine to receive a first parameter indicating the rotational position of a first joint motor, receive a second parameter indicating the rotational position of a second joint motor, and achieve a first operating state. The non-transitory computer-readable medium stores computer-readable instructions that, when executed, further cause the machine to transition from the first operating state to a second operating state when the first parameter corresponds to a change in the first joint motor from a first position range to an upper position range, wherein the second operating state is different from the first operating state. The non-transitory computer-readable medium stores computer-readable instructions that, when executed, further cause the machine to return from the second operating state to the first operating state when the first parameter corresponds to a change in the first joint motor from the upper position range to the first position range by a first anti-jitter angle. The non-transitory computer-readable medium stores computer-readable instructions that, when executed, further cause the machine to achieve a third operating state when the second parameter corresponds to a change in the second position range of the second joint motor from a second position range to a lower position range, wherein the third operating state is different from the first operating state. The non-transitory computer-readable medium stores computer-readable instructions that, when executed, also cause the machine to return from a third operating state to a first operating state when the second parameter corresponds to the second joint motion motor returning from the lower position range to the second position range at a second anti-shake angle.

[0397] Example 51 - A robotic surgical tool includes a housing, an end effector, and an elongated shaft extending distally from the housing to the end effector. The robotic surgical tool further includes: an articulation joint configured to articulate the end effector relative to the elongated shaft during articulation; an inner shaft extending distally from the housing through the elongated shaft; and an articulation drive system. The articulation drive system includes an articulation yoke coupled to the inner shaft, an articulation band coupled to the articulation yoke and extending distally along the inner shaft to the articulation joint, and a rolling element located between the inner shaft and the articulation yoke, wherein the articulation yoke is configured to roll along the rolling element during articulation.

[0398] Example 52 - A robotic surgical tool according to Example 51, wherein the rolling element is circumferentially positioned around an inner shaft.

[0399] Example 53 - The robotic surgical tool according to Example 51 or 52 further includes a rolling element pad. The rolling element pad includes a base fixed to an inner shaft and a retainer fixed to the base, wherein the base and the retainer form a continuous annular track between them. The rolling element pad also includes a rolling element, wherein the rolling element includes a ball positioned in the continuous annular track.

[0400] Example 54 - A robotic surgical tool according to Example 53, wherein the retainer includes a window, and wherein a set of rolling elements protrudes through the window and contacts the articular yoke.

[0401] Example 55 - A robotic surgical tool according to Example 53 or 54, wherein a rolling element is press-fitted into a recess in an inner shaft.

[0402] Example 56 - A robotic surgical tool according to Examples 53, 54 or 55, wherein the continuous circular track includes a first continuous circular track, and wherein the base and retainer form a second continuous circular track, the second continuous circular track being configured to receive a plurality of rolling elements therein.

[0403] Example 57 - The robotic surgical tool according to Example 56, wherein the articulation yoke includes a first articulation yoke configured to slidably engage a rolling element positioned in a first continuous annular track during joint movement, wherein the joint movement drive system further includes a second articulation yoke coupled to an inner shaft at a location remote from the first articulation yoke, and wherein the second articulation yoke is configured to slidably engage a rolling element positioned in a second continuous annular track during joint movement.

[0404] Example 58 - A robotic surgical tool according to Example 57, wherein the articulation band includes a first articulation band attached to a first articulation yoke and extending along an inner axis to an articulation joint, and wherein the articulation drive system further includes a second articulation band attached to a second articulation yoke and extending along an inner axis to an articulation joint.

[0405] Example 59 - A robotic surgical tool according to Example 57 or 58, wherein the joint motion drive system is configured to enable a first joint yoke and a second joint yoke to move relative to each other and along an inner axis to achieve joint motion.

[0406] Example 60 - A surgical tool comprising: a surgical end effector including opposing jaws; an elongated shaft extending distally to the surgical end effector; and a housing defining a channel therethrough, wherein the elongated shaft extends through the channel. The surgical tool further includes an actuation mechanism configured to selectively move the housing relative to the surgical end effector along the elongated shaft. The actuation mechanism includes a pulley, a cable engaging the pulley, and a locking arrangement configured to releasably lock the housing relative to the elongated shaft. The locking arrangement includes a washer positioned about the elongated shaft. The cable engages the washer. Actuation of the pulley is configured to apply tension to the cable to pivot the washer relative to the elongated shaft from a locking orientation to an unlocking orientation.

[0407] Example 61 - A surgical tool according to Example 60, wherein the washer includes a first washer, wherein the locking arrangement further includes a second washer positioned about an elongated axis, wherein the cable engages with the second washer, and wherein the second washer is configured to pivot relative to the elongated axis between a locking orientation and an unlocking orientation.

[0408] Example 62 - A surgical tool according to Example 61, wherein, in its locking orientation, the first washer and the second washer are inclined relative to the longitudinal axis of the elongated shaft, and wherein the first washer and the second washer are configured to pivot toward the parallel orientation when they move to their unlocking orientation.

[0409] Example 63 - A surgical tool according to Example 61 or 62, wherein the locking arrangement further includes a spring located between the first washer and the second washer, and wherein the spring biases a portion of the first washer away from a portion of the second washer.

[0410] Example 64 - A surgical tool according to Example 63, wherein the tension applied by the actuation of the pulley is configured to overcome the biasing force of the spring to move the first washer and the second washer from their locking orientation to their unlocking orientation.

[0411] Example 65 - A surgical tool according to Examples 61, 62, 63 or 64, wherein tension applied to a cable by actuation of a pulley is configured to pivot the first and second washers to an unlocking orientation, and then pull an elongated shaft to move the housing along the elongated shaft.

[0412] Example 66 - A surgical tool according to Examples 60, 61, 62, 63, 64 or 65, wherein the housing includes a body having an inner wall, wherein the inner wall defines a portion of an internal cavity in the body, and wherein a gasket extends at least partially into the internal cavity.

[0413] Example 67 - The surgical tool according to Example 68, wherein the actuation of the pulley is configured to push the washer against the inner wall to pull the housing along the elongated axis.

[0414] Example 68 - A surgical tool according to Examples 60, 61, 62, 63, 64, 65, 66 or 67, wherein the surgical end effector further includes a firing member configured to cut tissue positioned between opposing jaws.

[0415] Example 69 - A surgical tool according to Examples 60, 61, 62, 63, 64, 65, 66, 67 or 68, wherein the surgical end effector further includes a staple cartridge containing staples.

[0416] Example 70 - A surgical tool includes a surgical end effector, an elongated shaft extending distally to the surgical end effector, and a housing defining a channel therethrough, wherein the elongated shaft extends through the channel. The surgical tool also includes an actuation mechanism configured to selectively move the housing relative to the surgical end effector along the elongated shaft. The actuation mechanism includes a pulley, a winch, and a cable engaging with the pulley and the winch. The actuation mechanism also includes a locking arrangement configured to releasably lock the housing relative to the elongated shaft. The locking arrangement includes a first washer positioned about the elongated shaft. A first end of the cable engages the first washer. The first washer is configured to pivot relative to the elongated shaft between a locking orientation and an unlocking orientation. The locking arrangement also includes a second washer positioned about the elongated shaft. A second end of the cable engages the second washer. The second washer is configured to pivot relative to the elongated shaft between a locking orientation and an unlocking orientation. The locking arrangement also includes a spring located between the first and second washers, wherein the spring is configured to bias a portion of the first washer away from a portion of the second washer to pivot the first and second washers to a locking orientation. Rotation of the winch is configured to apply tension to the cable to pivot the first and second washers to their unlocking orientation.

[0417] Example 71 - A surgical tool according to Example 70, wherein, in a locking orientation, the first washer and the second washer are inclined relative to the longitudinal axis of the elongated shaft, and wherein the first washer and the second washer are configured to pivot parallel to their unlocking orientation from their locking orientation.

[0418] Example 72 - A surgical tool according to Example 70 or 71, wherein the tension applied by the rotation of a winch is configured to overcome the biasing force of a spring to move the first and second washers from their locking orientation to their unlocking orientation.

[0419] Example 73 - A surgical tool according to Examples 70, 71 or 72, wherein the housing includes a body having an inner wall, wherein the inner wall defines a portion of an internal cavity within the body, and wherein a first washer extends at least partially into the internal cavity.

[0420] Example 74 - A surgical tool according to Example 73, wherein the rotation of the winch is configured to push the first washer against the inner wall to pull the housing along an elongated axis.

[0421] Example 75 - A surgical tool according to Examples 70, 71, 72, 73 or 74, wherein the tension applied to the cable by the rotation of the winch is configured to pivot the first and second washers to their unlocking orientation and pull the housing along the elongated axis.

[0422] Example 76 - A surgical tool includes an elongated shaft and a housing defining a channel therethrough, wherein the elongated shaft extends through the channel. The surgical tool also includes an actuation mechanism configured to selectively move the housing along the elongated shaft. The actuation mechanism includes a pulley arrangement and a locking arrangement configured to releasably lock the housing relative to the elongated shaft. The locking arrangement includes a lock positioned about the elongated shaft. Actuation of the pulley arrangement is configured to move the lock from a locked orientation to an unlocked orientation.

[0423] Example 77 - A surgical tool according to Example 76, wherein the lock is configured to pivot from a locking orientation to an unlocking orientation.

[0424] Example 78 - A surgical tool according to Example 76 or 77, wherein, in a locking orientation, the lock is tilted relative to the longitudinal axis of the elongated shaft.

[0425] Example 79 - A surgical tool according to Examples 76, 77 or 78, wherein the locking arrangement further includes a spring configured to bias the lock to a locking orientation.

[0426] Although several forms have been illustrated and described, the applicant does not intend to limit or restrict the scope of the appended claims to such details. Many modifications, variations, alterations, substitutions, combinations, and equivalents of these forms can be made without departing from the scope of this disclosure, and those skilled in the art will recognize such modifications, variations, alterations, substitutions, combinations, and equivalents. Furthermore, alternatively, the structure of each element associated with a described form can be described as a device for providing the function performed by said element. Additionally, where materials for certain components are disclosed, other materials may also be used. Therefore, it should be understood that the foregoing detailed descriptions and the appended claims are intended to cover all such modifications, combinations, and variations falling within the scope of the forms disclosed in this invention. The appended claims are intended to cover all such modifications, variations, alterations, substitutions, modifications, and equivalents.

[0427] The specific embodiments described above have illustrated various forms of apparatus and / or methods using block diagrams, flowcharts, and / or examples. Wherever such block diagrams, flowcharts, and / or examples contain one or more functions and / or operations, those skilled in the art will understand that each function and / or operation in such block diagrams, flowcharts, and / or examples can be implemented individually and / or collectively by various hardware, software, firmware, or virtually any combination thereof. Those skilled in the art will recognize that some aspects of the forms disclosed herein can be equivalently implemented in an integrated circuit, wholly or partially, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or as any combination thereof, and that designing circuit systems and / or writing software and / or hardware code according to this disclosure will be within the skill of those skilled in the art. Furthermore, those skilled in the art will recognize that the mechanisms of the subject matter described herein can be distributed as one or more program products in various forms, and that the exemplary forms of the subject matter described herein apply regardless of the specific type of signal-bearing medium used for actual distribution.

[0428] Instructions used for programming logic to execute various disclosed aspects may be stored in the system's memory, such as dynamic random access memory (DRAM), cache, flash memory, or other memory. Furthermore, the instructions may be distributed via a network or through other computer-readable media. Therefore, machine-readable media may include any means for storing or transmitting information in a machine-readable (e.g., computer-readable) form, but are not limited to floppy disks, optical disks, optical disc read-only memory (CD-ROM), and magneto-optical disks, read-only memory (ROM), random access memory (RAM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic cards or optical cards, flash memory, or tangible machine-readable storage devices used for transmitting information over the Internet via electrical signals, optical signals, acoustic signals, or other forms of propagation signals (e.g., carrier waves, infrared signals, digital signals, etc.). Therefore, non-transitory computer-readable media include any type of tangible machine-readable medium suitable for storing or transmitting electronic instructions or information in a machine-readable (e.g., computer-readable) form.

[0429] As used in any aspect of this document, the term "control circuitry" may refer to, for example, hardwired circuitry systems, programmable circuitry systems (e.g., computer processors including one or more individual instruction processing cores, processing units, processors, microcontrollers, microcontroller units, controllers, digital signal processors (DSPs), programmable logic devices (PLDs), programmable logic arrays (PLAs), field-programmable gate arrays (FPGAs)), state machine circuitry systems, firmware storing instructions executed by the programmable circuitry system, and any combination thereof. Control circuitry can be implemented collectively or individually as part of a larger system, such as integrated circuits (ICs), application-specific integrated circuits (ASICs), system-on-a-chip (SoCs), desktop computers, laptop computers, tablet computers, servers, smartphones, etc. Therefore, as used herein, "control circuit" includes, but is not limited to, electronic circuits having at least one discrete circuit, electronic circuits having at least one integrated circuit, electronic circuits having at least one application-specific integrated circuit, electronic circuits forming a general-purpose computing device configured by a computer program (e.g., a general-purpose computer configured by a computer program that at least partially implements the methods and / or devices described herein, or a microprocessor configured by a computer program that at least partially implements the methods and / or devices described herein), electronic circuits forming a memory device (e.g., forming a random access memory), and / or electronic circuits forming a communication device (e.g., a modem, a communication switch, or an optoelectronic device). Those skilled in the art will recognize that the subject matter described herein can be implemented in analog or digital modes, or some combination thereof.

[0430] As used in any aspect of this document, the term "logic" can refer to an application, software, firmware, and / or circuit system configured to perform any of the foregoing operations. Software can be embodied as a software package, code, instructions, instruction sets, and / or data recorded on a non-transitory computer-readable storage medium. Firmware can be embodied as hard-coded (e.g., non-volatile) code, instructions, or instruction sets and / or data in a memory device.

[0431] As used in any part of this document, the terms “component,” “system,” “module,” etc., can refer to computer-related entities, hardware, combinations of hardware and software, software, or software in execution.

[0432] As used in any aspect of this document, "algorithm" refers to a systematic sequence of steps that leads to a desired result, where "step" refers to the manipulation of physical quantities and / or logical states, which may (but not necessarily) take the form of electrical or magnetic signals that can be stored, transferred, combined, compared, and otherwise manipulated. These signals are commonly referred to as bits, values, elements, symbols, characters, terms, numbers, etc. These and similar terms may be associated with appropriate physical quantities and are merely convenient labels applied to these quantities and / or states.

[0433] The network may include a packet-switched network. Communication devices may be able to communicate with each other using a selected packet-switched network communication protocol. An exemplary communication protocol may include an Ethernet communication protocol that may allow communication using Transmission Control Protocol / Internet Protocol (TCP / IP). The Ethernet protocol may conform to or be compatible with the Ethernet standard entitled "IEEE 802.3 Standard" published by the Institute of Electrical and Electronics Engineers (IEEE) in December 2008 and / or a higher version of this standard. Alternatively or additionally, communication devices may be able to communicate with each other using the X.25 communication protocol. The X.25 communication protocol may conform to or be compatible with standards published by the International Telecommunication Union Telecommunication Standardization Sector (ITU-T). Alternatively or additionally, communication devices may be able to communicate with each other using the Frame Relay communication protocol. The Frame Relay communication protocol may conform to or be compatible with standards published by the International Telegraph and Telephone Consultative Committee (CCITT) and / or the American National Standards Institute (ANSI). Alternatively or additionally, transceivers may be able to communicate with each other using the Asynchronous Transfer Mode (ATM) communication protocol. The ATM communication protocol may conform to or be compatible with the ATM standard entitled "ATM-MPLS Network Interworking 2.0" and / or a higher version of that standard, published by the ATM Forum in August 2001. Of course, this document also envisions different and / or subsequently developed connectivity-oriented network communication protocols.

[0434] Unless otherwise expressly stated in the foregoing disclosure, it is understood that in the foregoing disclosure, discussions using terms such as “processing,” “estimating,” “calculating,” “determining,” and “displaying” refer to the actions and processes of a computer system or similar electronic computing device that manipulate data represented as physical (electronic) quantities in the registers and memories of the computer system and convert them into other data similarly represented as physical quantities in the memory or registers of the computer system or other such information storage, transmission, or display devices.

[0435] One or more components may be referred to herein as “configured to be,” “configurable to be,” “operable / operationally,” “suitable / adaptable,” “capable,” “adaptable / fittable,” etc. Those skilled in the art will recognize that, unless the context otherwise requires, “configured to be” generally encompasses components in an active state and / or in an inactive state and / or in a standby state.

[0436] The terms "proximal" and "distal" are used herein in relation to the clinician manipulating the handle portion of the surgical instrument. "Proximal" refers to the portion closest to the clinician, and "distal" refers to the portion furthest from the clinician's position. It should also be understood that, for brevity and clarity, spatial terms such as "vertical," "horizontal," "upper," and "lower" may be used in conjunction with accompanying drawings. However, surgical instruments are used in many orientations and locations, and these terms are not restrictive and / or absolute.

[0437] Those skilled in the art will recognize that, in general, the terminology used herein, and particularly in the appended claims (e.g., the text of the appended claims), is typically intended to be “open” terms (e.g., the term “comprising” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “at least having,” the term “including” should be interpreted as “comprising but not limited to,” etc.). Those skilled in the art will also understand that if a specific number of statements in the introduced claims is intended, such an intention will be explicitly stated in the claims, and if no such statement is present, such an intention does not exist. For example, to aid understanding, the appended claims below may contain the use of the introductory phrases “at least one” and “one or more” to introduce the claims. However, the use of such phrases should not be construed as implying that introducing a claim statement with the indefinite article "a" or "an" limits any particular claim containing such an introductory claim statement to a claim containing only one such statement, even when the same claim includes the introductory phrase "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and / or "an" should generally be interpreted as meaning "at least one" or "one or more"); this also applies to the use of definite articles used to introduce a claim statement.

[0438] Furthermore, even when a specific number of claims is explicitly stated, those skilled in the art should recognize that such a statement should generally be interpreted as referring to at least the number stated (e.g., in the absence of other modifiers, a bare statement of "two statements" generally means at least two statements, or two or more statements). Moreover, in cases where conventions such as "at least one of A, B, and C" are used, such constructions are generally intended to have a meaning that those skilled in the art will understand (e.g., "a system having at least one of A, B, and C" will include, but is not limited to, systems having only A, only B, only C, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In cases where conventions such as "at least one of A, B, or C" are used, such constructions are generally intended to have a meaning that those skilled in the art will understand (e.g., "a system having at least one of A, B, or C" should include, but is not limited to, systems having only A, only B, only C, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Those skilled in the art should also understand that, generally, unless the context otherwise indicates, any transitional words and / or phrases presenting two or more alternative terms in the detailed description, claims, or drawings should be understood to cover the possibility of including one of the terms, any one of the terms, or both of the terms. For example, the phrase "A or B" will generally be understood to include the possibility of "A" or "B" or "A and B".

[0439] With respect to the appended claims, those skilled in the art will understand that the operations described herein can generally be performed in any order. Furthermore, although various operation flowcharts are shown in one or more sequences, it should be understood that the various operations may be performed in other orders than those shown, or may be performed simultaneously. Unless the context otherwise requires, examples of such alternative orderings may include overlapping, interleaving, interruption, reordering, incremental, preparatory, supplementary, simultaneous, reverse, or other altered orderings. Moreover, unless the context otherwise requires, terms such as “in response to,” “related,” or other past tense adjectives are generally not intended to exclude such variations.

[0440] It is worth noting that any reference to "one aspect," "one aspect," "one example," or "one example" means that the specific feature, structure, or characteristic described in connection with said aspect is included in at least one aspect. Therefore, the phrases "in one aspect," "in one aspect," "in one example," and "in one example" appearing in various places throughout the specification do not necessarily refer to the same aspect. Furthermore, specific features, structures, or characteristics may be combined in one or more aspects in any suitable manner.

[0441] Any patent application, patent, non-patent publication, or other public material mentioned in this specification and / or listed in any application data sheet is incorporated herein by reference, provided that the incorporated material is inconsistent with this specification. Therefore, and to the extent necessary, the disclosures expressly listed herein replace any conflicting material incorporated herein by reference. Any material or portion thereof allegedly incorporated herein by reference that conflicts with existing definitions, statements, or other public materials listed herein will be incorporated only to the extent that the incorporated material does not conflict with existing public materials.

[0442] In summary, many beneficial effects resulting from employing the concepts described herein have been described. For illustrative and descriptive purposes, one or more of the specific embodiments described above have been provided. These embodiments are not intended to be exhaustive or limited to the precise forms disclosed in the invention. Modifications or variations may be made to the invention in accordance with the teachings above. The one or more forms chosen and described are intended to illustrate the principles and practical applications, thereby enabling those skilled in the art to utilize various forms and modifications suitable for the intended particular use. The claims filed herein are intended to define the full scope.

Claims

1. A robotic surgical system, comprising: A closed system, the closed system comprising: The first pinion is drivenly connected to the first motor; A second pinion, which is droopingly connected to a second motor; and A closed gear, which is selectively driven by a first pinion and a second pinion; and A control circuit configured to perform a motor cross-check operation, wherein the control circuit is configured to: Receive a first parameter indicating the first torque generated by the first motor; and Receive a second parameter indicating the second torque generated by the second motor; The motor cross-check operation includes: Compare the first parameter with the second parameter; and Transmit a signal to a communication device, wherein the signal is based on the comparison and indicates the state of the closed system; The control circuit is further configured to: Determine when the closed system reaches a steady state during the motor cross-check operation; and After the closed system reaches the steady state, the first parameter is compared with the second parameter.

2. The robotic surgical system according to claim 1, wherein, The first pinion and the second pinion simultaneously drive the closed gear to achieve a closed stroke.

3. The robotic surgical system according to claim 1, wherein, When the comparison between the first parameter and the second parameter exceeds a threshold, the state transmitted by the control circuit corresponds to a fault state.

4. The robotic surgical system according to claim 3, wherein, The robotic surgical system is configured to lock when the state corresponds to the fault state.

5. The robotic surgical system according to claim 1, wherein, In order to perform the motor cross-check operation, the first motor is configured to drive the closed gear in a first direction, and the second motor is configured to drive the closed gear in a second direction opposite to the first direction.

6. The robotic surgical system according to claim 5, wherein, The first motor is configured to transmit torque to the second pinion.

7. The robotic surgical system according to claim 6, wherein, The second motor is configured to transmit torque to the first pinion.

8. The robotic surgical system according to claim 5, wherein, The second pinion is configured to move through the backlash region before the closed system reaches a steady state.

9. The robotic surgical system according to claim 8, wherein, The control circuit is further configured to record the duration of the tooth gap region and obtain the duration as a stored value.

10. The robotic surgical system of claim 1, wherein, The control circuit includes: Processor; and A memory, coupled to the processor, stores instructions executable by the processor, to: Receive a first parameter indicating a first torque from the first motor; Receive a second parameter indicating the second torque from the second motor; Receive a third parameter indicating the first angular displacement of the first motor; Receive a fourth parameter indicating the second angular displacement of the second motor; and The state of the closed system is determined based on the first parameter, the second parameter, the third parameter, and the fourth parameter.

11. The robotic surgical system of claim 10, wherein, The memory also stores instructions that can be executed by the processor to perform cross-checking of the motor in which the first pinion and the second pinion rotate in opposite directions.

12. The robotic surgical system of claim 10, wherein, The memory also stores instructions that can be executed by the processor to perform motor cross-checking in which the first pinion is driven by the first motor and the second pinion is not driven by the second motor.

13. The robotic surgical system of claim 12, wherein, The memory also stores instructions that can be executed by the processor, to: The backlash angle was measured during the motor cross-check; and The backlash angle is compared with the backlash value stored in the memory.

14. The robotic surgical system of claim 10, wherein, The memory also stores instructions executable by the processor to perform motor cross-checking, wherein: The stiffness of the first pinion is calculated from the first torque and the first angular displacement; and The stiffness is compared with a threshold.

15. The robotic surgical system of claim 10, wherein, The memory stores instructions that can be executed by the processor to perform a motor cross-check after at least one of the homing operation or clamping event of the closing system.

16. A non-transitory computer-readable medium storing computer-readable instructions, which, when executed, cause a machine to: Receive a first parameter indicating the first torque generated by the first motor of the closed system; Receive a second parameter indicating a second torque generated by a second motor of the closed system, wherein the first motor and the second motor are configured to drive the closed gear simultaneously; Implement motor cross-checking, the motor cross-checking includes: Compare the first parameter with the second parameter; Transmit a signal to a communication device, wherein the signal is based on the comparison and indicates the state of the closed system; Determine when the closed system reaches a steady state during the motor cross-check operation; and After the closed system reaches the steady state, the first parameter is compared with the second parameter.

17. The non-transitory computer-readable medium for storing computer-readable instructions according to claim 16, wherein the computer-readable instructions, when executed, also cause the machine to enter a fault state when the comparison between the first parameter and the second parameter exceeds a threshold.

18. The non-transitory computer-readable medium of claim 17 storing computer-readable instructions, wherein the computer-readable instructions, when executed, also cause the machine to enter a locked state when the state corresponds to the fault state.

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