Surgical instrument power cartridge and surgical system

Abstract

This application relates to a surgical instrument power box and a surgical system. The surgical instrument power box includes a housing and multiple power modules disposed within the housing. The power modules are staggered and stacked along the thickness direction of the surgical instrument power box. Each power module includes a stator, a rotor, an output shaft, and a reducer. The rotor and stator are positioned opposite each other, and the reducer is nested within the rotor, drivingly connecting the rotor to the output shaft. The internal structure of this surgical instrument power box is compact, reducing its volume and increasing the movement space of the surgical instruments at the end of the robotic arm, thus facilitating the operation of the entire surgical robot system.

Description

Technical Field

[0001] This application relates to the field of medical device technology, and in particular to a surgical instrument power box and surgical system. Background Technology

[0002] In minimally invasive surgical procedures, surgical systems utilize surgical instruments at the end effector of a robotic arm to perform specific surgical operations. The power source for these instruments is a device mounted on the robotic arm called the surgical instrument power unit. This power unit contains multiple motors, each driving the surgical instruments to perform specific operations such as rotation, pitch, yaw, opening, closing, and cutting. However, existing surgical instrument power units are excessively large, reducing the movement space of the surgical instruments at the end effector of the robotic arm and hindering the overall operation of the surgical robot system. Summary of the Invention

[0003] Therefore, it is necessary to provide a surgical instrument power box and surgical system to address the problem of the excessively large size of existing surgical instrument power boxes.

[0004] A surgical instrument power box includes a box body and a plurality of power modules disposed within the box body, wherein the plurality of power modules are staggered and stacked in the thickness direction of the surgical instrument power box.

[0005] The power module includes a stator, a rotor, an output shaft, and a reducer. The rotor is arranged opposite to the stator, and the reducer is nested inside the rotor and drives the rotor to the output shaft.

[0006] In one embodiment, the reducer includes a first gear and a plurality of second gears, wherein the outer diameter of the first gear is larger than the outer diameter of the second gears;

[0007] The first gear is fixed on the output shaft, and the second gear meshes with the inner circumferential surface of the rotor.

[0008] In one embodiment, the inner circumferential surface of the rotor is provided with two annular grooves spaced apart along the thickness direction of the power module, and the two annular grooves are located on both sides of the thickness direction of the second gear.

[0009] The inner circumferential surface of the rotor is provided with a limiting part, which includes two retaining rings, and the retaining rings are accommodated in the corresponding annular grooves.

[0010] In one embodiment, the stator is cast from a plurality of winding units, wherein the winding units are arranged circumferentially and connected according to phase sequence.

[0011] In one embodiment, the power module further includes: a first end cover, a second end cover, and a housing fixedly connected to the housing body. The first end cover and the second end cover are arranged along the thickness direction of the power module and are both connected to the housing. The stator and the rotor are arranged in the space enclosed by the housing, the first end cover, and the second end cover. The first end of the output shaft is rotatably arranged on the first end cover, and the second end is rotatably arranged on the second end cover, wherein the first end and the second end are arranged opposite to each other.

[0012] In one embodiment, the power module further includes a motor sensor and a joint sensor. The motor sensor is disposed on the axial end face of the rotor and is used to acquire the position information of the rotor. The joint sensor is disposed on the axial end face of the output shaft and is used to acquire the position information of the output shaft.

[0013] In one embodiment, the surgical instrument power box further includes a torque estimation module, which is used to determine the load torque of the power module based on the received position information of the rotor and the position information of the output shaft.

[0014] In one embodiment, the torque estimation module stores the torque deformation coefficient between the rotor and the output shaft in the same power module;

[0015] The torque estimation module includes a first calculation unit and a second calculation unit. The first calculation unit is used to calculate the difference between the rotor and the output shaft after converting them into joint radians based on the position information of the rotor and the position information of the output shaft. The second calculation unit is used to multiply the difference by the torque deformation coefficient to obtain the load torque.

[0016] In one embodiment, the surgical instrument power box further includes a motor drive module, which stores a preset torque of the output shaft of the power module. When the motor drive module receives a fault signal, it obtains the position information of the output shaft of the power module, and then controls the output shaft of the power module to maintain its current position and enable the output shaft to have the preset torque.

[0017] A surgical system comprising a surgical arm and a surgical instrument power unit as described in any of the preceding claims, the surgical instrument power unit being disposed at the end of the surgical arm.

[0018] The aforementioned surgical instrument power box and surgical system, on the one hand, feature a staggered distribution of multiple power modules within the power box along its thickness. This not only reduces the power box's volume, making its internal structure more compact and increasing its power-to-volume ratio (output power to volume), but also allows for an increase in the output shaft diameter while maintaining the same spacing between each output shaft, thus enhancing torque output capability. It also accommodates the installation dimensions of surgical instruments from the older power box version, facilitating assembly. On the other hand, by embedding the reducer within the rotor, the reducer can be integrated into the power module, resulting in higher integration and further reducing the power box's volume. This also enables a modular design of the power module, enhancing its reusability, flexibility in application expansion, and ensuring development cycle and reliability. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a surgical instrument power box after being processed by perspective, as provided in an embodiment of this application.

[0020] Figure 2 This is a schematic diagram of the installation of a surgical instrument power box on the end of a robotic arm, as provided in an embodiment of this application.

[0021] Figure 3 This is a schematic diagram showing the distribution of four power modules within a power box of a surgical instrument, as provided in an embodiment of this application.

[0022] Figure 4 This is a schematic diagram showing the distribution of six power modules within a power box of a surgical instrument, as provided in an embodiment of this application.

[0023] Figure 5 This is a schematic diagram of the structure of a power module provided in an embodiment of this application.

[0024] Figure 6 This is a schematic diagram of a stator structure provided in an embodiment of this application.

[0025] Figure 7 This is a cross-sectional view of a rotor provided in an embodiment of this application.

[0026] Figure 8 A flowchart illustrating the sequential execution logic of a surgical instrument power box provided in this application embodiment.

[0027] Figure 9 This is a flowchart illustrating the implementation of a dual-program torque estimation function in a surgical instrument power box, as provided in an embodiment of this application.

[0028] Figure 10This is a flowchart illustrating the position torque holding function of a surgical instrument power box provided in an embodiment of this application.

[0029] Figure 11 This is a schematic diagram of the operation of the surgical system provided in the embodiments of this application. Detailed Implementation

[0030] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0031] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0032] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0033] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0034] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0035] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0036] See Figure 1 , Figure 1 The surgical instrument power box 10 of one embodiment of this application is shown after being transparently processed. The surgical instrument power box 10 provided in one embodiment of this application includes a box body 100 and a plurality of power modules 200 disposed in the box body 100.

[0037] Among them, see Figure 2 The surgical instrument 20 can be mounted at the end of the surgical arm 30 of the surgical system via the surgical instrument power box 10. The housing 100 of the surgical instrument power box 10 is mounted on the telescopic joint 30a at the end of the surgical arm 30, which allows the surgical instrument power box 10 to reciprocate with the extension and retraction of the telescopic joint 30a, thereby driving the surgical instrument 20 to reciprocate. In addition to driving the surgical instrument 20 to reciprocate, the surgical instrument power box 10 can also provide various forms of operating power to the surgical instrument 20 through multiple power modules 200.

[0038] Further, see Figure 1Multiple power modules 200 are staggered and stacked in the thickness direction of the surgical instrument power box 10, meaning that the power modules 200 are stacked in the thickness direction of the surgical instrument power box 10, and the power modules 200 in adjacent layers are staggered. This arrangement of the multiple power modules 200 within the surgical instrument power box 10 not only reduces the volume of the surgical instrument power box 10, making its internal structure more compact and increasing its power-to-volume ratio (i.e., the ratio of output power to volume), but also allows for an increase in the diameter of the output shafts while maintaining the same spacing between each pair of output shafts, thereby increasing torque output capacity. It also accommodates the installation dimensions of the surgical instruments 20 corresponding to the older version of the surgical instrument power box 10, facilitating the assembly of the surgical instrument power box 10.

[0039] The number of power modules 200 depends on the degrees of freedom and functional complexity required by the surgical instrument 20, or in other words, on the type of surgical instrument 20. For example, the surgical instrument power box 10 contains... Figure 3 The four power modules shown are 200, or Figure 4 The six power modules 200 are shown.

[0040] Furthermore, see Figure 5 In this application, the power module 200 includes a stator 210, a rotor 220, an output shaft 230, and a reducer 240. The rotor 220 and stator 210 are arranged opposite to each other. The reducer 240 is nested inside the rotor 220 and drives the rotor 220 and the output shaft 230. Embedding the reducer 240 inside the rotor 220 allows it to be integrated into the motor, resulting in higher integration of the power module 200. This further reduces the size of the surgical instrument power box 10 and enables modular design of the power module 200, making it more reusable, flexible in application expansion, and ensuring development cycle and reliability. It should be noted that the axial direction of the output shaft 230 is consistent with the thickness direction of the power module 200.

[0041] See Figure 1 The power module 200 has a generally flat and thin external shape, which also saves more space.

[0042] It is understandable that the stator 210 can generate a rotating magnetic field that drives the rotor 220 to rotate. See also Figure 6The stator 210 can be molded from multiple winding units 211, which are arranged circumferentially and connected according to phase sequence. The stator 210 is directly molded from multiple winding units 211 without an iron core. This not only reduces the size of the surgical instrument power box 10, but also makes the power module 200 free of cogging force. When the surgical instrument 20 needs to be reverse driven, the reverse drive torque can be reduced, thereby improving the operator's operating experience.

[0043] Among them, the power module 200 is a three-phase torque motor, which is characterized by its large output power. In the complete winding of the motor (i.e., stator 210), UVW (referring to the three phases of the three-phase motor) are distributed adjacently, with the heads and tails of the same phase connected (such as in a star connection), and the tails of the three phases are shorted together to form the neutral point of the three phases.

[0044] The manufacturing process of stator 210 is described below:

[0045] Step 1: Select copper wire with a large effective conductor area and good conductivity as the winding material. At the same time, according to the model and specifications of the power module 200, use metal as the material of the winding mold. The shape and size of the winding mold are matched with the rotor 220 and stator 210 of the power module 200.

[0046] Step 2: Press the copper wire tightly and evenly around the winding mold one turn at a time until the required number of turns are reached. Then, use a small amount of insulating adhesive (such as high-temperature resistant and hard epoxy resin) to pour and shape it. Finally, remove the winding mold, trim and polish it to form the winding unit 211. Repeat this step multiple times until multiple winding units 211 are obtained.

[0047] Step 3: Stack and lay out the multiple winding units 211 as described above. Following the motor design principle of "connecting the beginning and end of each winding unit 211," weld the beginning and end of each winding unit 211 to form the winding of the power module 200. See also... Figure 6 The head end 211a and tail end 211b of the winding unit 211 are both located on the outer peripheral edge of the stator 210. The space of the annular outer peripheral edge is larger than that of the inner peripheral edge, making it easier to realize the welding process of connecting the head and tail of the winding units 211.

[0048] It should be noted that the "head-to-head, tail-to-tail" design principle specifically means that: in the odd-numbered winding unit 211, the head end 211a of the copper wire is connected to the head end 211a of the copper wire in the adjacent next winding unit 211, and the tail end 211b is connected to the tail end 211b of the copper wire in the adjacent previous winding unit 211; in the even-numbered winding unit 211, the head end 211a of the copper wire is connected to the head end 211a of the copper wire in the adjacent previous winding unit 211, and the tail end 211b is connected to the tail end 211b of the copper wire in the adjacent next winding unit 211. The copper wire tail end 211b is connected; or, in the odd-numbered winding unit 211, the copper wire head end 211a is connected to the copper wire head end 211a of the adjacent previous winding unit 211, and the tail end 211b is connected to the copper wire tail end 211b of the adjacent next winding unit 211; in the even-numbered winding unit 211, the copper wire head end 211a is connected to the copper wire head end 211a of the adjacent next winding unit 211, and the tail end 211b is connected to the copper wire tail end 211b of the adjacent previous winding unit 211.

[0049] Step 4: Make an external casting mold according to the dimensional requirements such as outer diameter, inner diameter, and height. Use an insulating adhesive (such as high-temperature resistant and hard epoxy resin) to cast and shape the winding. After demolding, perform grinding, carving, machine tool cleaning and other processes until it is processed into a standard split stator 210.

[0050] The rotor 220 may include a turntable and a plurality of magnets, which are arranged circumferentially on the end face of the turntable near the stator 210, with gaps between the magnets and the stator 210. It is understood that the magnets are arranged opposite to the stator 210.

[0051] The reducer 240 can be disposed between the inner circumferential surface of the turntable and the outer circumferential surface of the output shaft 230. See also... Figure 5 As shown, the reducer 240 may include a first gear 241 and several second gears 242. The outer diameter of the first gear 241 is larger than the outer diameter of the second gears 242. The first gear 241 is fixed on the output shaft 230, and the second gears 242 mesh with the inner circumferential surface of the rotor 220. It is understood that the inner circumferential surface of the turntable is provided with a tooth structure 220a adapted to the second gears 242 (see...). Figure 7 When the rotor 220 rotates under the drive of the stator 210, it drives the second gear 242 to revolve around the first gear 241 as the center. The first gear 241 also rotates accordingly, thereby driving the output shaft 230 to rotate. The reducer 240 of this structure can reduce the back drive force of the output shaft 230 and improve the transmission efficiency.

[0052] To prevent the second gear 242 from affecting its revolution due to wobbling in the thickness direction of the surgical instrument power box 10, see [reference needed]. Figure 7The inner circumferential surface of the rotor 220 is provided with a limiting part 221, which is used to limit the range of movement of the second gear 242 in the thickness direction of the power module 200.

[0053] Specifically, the inner circumferential surface of the rotor 220 is provided with two annular grooves spaced apart along the thickness direction of the power module 200, and the two annular grooves are located on both sides of the second gear 242 in the thickness direction; see also Figure 7 The limiting part 221 includes two retaining rings 2211, which are accommodated in corresponding annular grooves. After the second gear 242 and the first gear 241 are assembled, the retaining rings 2211 are pressed and inserted into the corresponding annular grooves. Then, the retaining rings 2211 are released and reset. The inner circumferential surface of the retaining rings 2211 can protrude from the inner circumferential surface of the rotor 220, thereby blocking the second gear 242 in the thickness direction of the power module 200 and preventing the second gear 242 from moving in the thickness direction of the power module 200.

[0054] See Figure 5 In this application, the power module 200 further includes: a first end cover 251, a second end cover 252, and a housing (not shown in the drawings) fixedly connected to the housing 100. The first end cover 251 and the second end cover 252 are arranged along the thickness direction of the power module 200 and both are connected to the housing. The stator 210 and the rotor 220 are arranged in the space enclosed by the housing, the first end cover 251, and the second end cover 252. The first end of the output shaft 230 is rotatably mounted on the first end cover 251, and the second end is rotatably mounted on the second end cover 252, wherein the first end and the second end are arranged opposite to each other. The first end cover 251, the second end cover 252, and the housing can enclose the stator 210 and the rotor 220, providing protection, and also making the power module 200 a complete body, facilitating the assembly and disassembly of the power module 200.

[0055] A first bearing 261 is provided between the first end of the output shaft 230 and the first end cover 251, and a second bearing 262 is provided between the second end of the output shaft 230 and the second end cover 252. The first bearing 261 and the second bearing 262 not only provide axial positioning for the output shaft 230, but also facilitate the rotation of the output shaft 230.

[0056] The surgical instrument power box 10, as an actuator, receives control commands from the upper controller in the surgical system, thereby providing corresponding power to the surgical instrument 20. The surgical instrument power box 10 includes a position information acquisition module and a motor drive module. These modules interact with the upper controller to achieve closed-loop control of the power module 200. The workflow is roughly as follows: the position information acquisition module acquires the position information of the output shaft 230 of the power module 200 in real time; the upper controller generates corresponding control commands based on the position information of the output shaft 230 fed back by the position information acquisition module; and the motor drive module, upon receiving the control command, drives the power module 200 to perform corresponding operations, such as increasing or decreasing the speed of the output shaft 230, increasing or decreasing the torque of the output shaft 230, or turning the unit on or off. Data interaction between the position information acquisition module, the motor drive module, and the upper controller can utilize an industrial Ethernet EtherCat bus and necessary external I / O device interfaces. The position information acquisition module can be a position information acquisition circuit board, and the motor drive module can be a motor drive circuit board.

[0057] The position of the output shaft 230 of the power module 200 can be obtained by a sensor; see details below. Figure 5 The power module 200 also includes a joint sensor 272, which is disposed on the axial end face of the output shaft 230 and used to acquire the position information of the output shaft 230. In this application, in addition to the joint sensor 272, the power module 200 also includes a motor sensor 271, which is disposed on the axial end face of the rotor 220 and used to acquire the position information of the rotor 220. By setting the joint sensor 272 and the motor sensor 271, the position information acquisition module can acquire the position information of the output shaft 230 and the rotor 220. The dual position feedback of the power module 200 can provide the sensor data support required by the algorithm for reverse drive compliance, and can also improve the safety of the surgical robot system using this dual-encoder redundancy design. The joint sensor 272 can be a joint encoder, and the motor sensor 271 can be a motor encoder; it can be understood that each power module 200 has two position encoder acquisition channels.

[0058] The motor drive module is also used to receive multiple control commands and control the corresponding power modules 200 to perform corresponding operations based on the control commands, wherein the control commands correspond one-to-one with the power modules 200. This configuration allows the motor drive module to control multiple power modules 200, achieving a "one-board-multiple-drive" function. Compared to the existing method where one power module 200 corresponds to one motor drive module, the "one-board-multiple-drive" approach of this application not only further reduces the size of the surgical instrument power box 10, but also allows the power modules 200 to interact with each other through the motor drive module. When the surgical robot malfunctions, such as when the upper controller fails, a safer and more timely protection mechanism can be provided. See below for the specific process.

[0059] In addition to providing power to the surgical instruments 20, the surgical instrument power box 10 also has the following functions:

[0060] EtherCat bus transceiver function: multi-slave coordinated operation. The EtherCat bus has the advantages of large data processing capacity, strong real-time performance, high synchronization between slaves, and short communication cycle. Therefore, this bus is used in the surgical instrument power box 10.

[0061] Instrument encryption function: The surgical instrument power box 10 can prevent the use of uncertified surgical instruments 20 during the operation, which could lead to unsafe consequences.

[0062] Dual-stitch torque estimation function: By measuring the deviation value of the dual stitches (i.e., the positional deviation between the output shaft 230 and the rotor 220) and the transmission characteristics, the load force of the power module 200 is estimated. It can be used as a control feedback signal, especially in compliant control, and can improve the sensitivity when manually dragging.

[0063] Position torque holding function: During surgical procedures, there are some scenarios where the surgical instrument 20 needs to maintain a certain torque to ensure safety. This torque holding function is preset and will be activated when a malfunction occurs to prevent accidents during the operation.

[0064] Status monitoring and uploading function: Monitoring and uploading the status of the power module 200 and other peripheral devices to confirm that the system is operating in a safe state. Specifically, for the power module 200, this can be achieved by monitoring the position information of the output shaft 230 and the rotor 220. If the deviation between the position of the output shaft 230 and the preset position is too large, or the deviation between the position of the rotor 220 and the preset position is too large, or the positional deviation between the output shaft 230 and the rotor 220 is too large, it can be considered that the power module 200 has malfunctioned, for example, the surgical instrument 20 is not securely installed.

[0065] Fault alarm detection function: When a fault is detected, an alarm signal is generated, which can promptly remind the operator.

[0066] When the surgical instrument power box 10 has the above-mentioned multiple functions, the entire sequential execution logic of the surgical instrument power box 10 can be as follows: Figure 8 As shown. Among them, Figure 8 The upper-level control mode refers to the mode in which the drive of the power module 200 is controlled by the upper-level controller when the entire system is in a safe operating state.

[0067] Specifically, regarding the dual-axis torque estimation function, before or during surgery, it is sometimes necessary to manually adjust the workspace of the surgical instrument 20. The amount of force applied and the flexibility of this adjustment determine the patient's experience. Therefore, the dual-axis torque estimation function can be used to estimate the amount of force applied by the hand as feedback, which can effectively optimize the control effect. The torque estimation module can be formed by embedding a logic algorithm on the motor drive circuit board to realize the dual-axis torque estimation function. This torque estimation module is used to determine the load torque of the power module 200 based on the received position information of the rotor 220 and the output shaft 230. The host controller can provide feedback on the load torque of the power module 200, allowing the operator to adjust the dragging force of the surgical instrument 20 according to the feedback from the host controller.

[0068] Specifically, the torque estimation module stores the torque deformation coefficient between the rotor 220 and the output shaft 230 in the same power module 200. The torque estimation module includes a first calculation unit and a second calculation unit. The first calculation unit calculates the difference between the rotor 220 and the output shaft 230 after converting them into joint radians based on the position information of the rotor 220 and the real-time position information of the output shaft 230. The second calculation unit multiplies the difference by the torque deformation coefficient to obtain the load torque. The entire dual-program torque estimation process can be described as follows: Figure 9 As shown.

[0069] Regarding the position and torque holding function, certain surgical procedures require the surgical instrument 20 to maintain its position or torque in the event of a malfunction to prevent accidents. This is necessary when clamping an artery. The power module 200 used to clamp the blood vessel can be configured to maintain its torque. This position and torque holding function can be implemented by embedding a logic algorithm into the motor drive module. Specifically, the motor drive module stores the preset torque of the output shaft 230 of the power module 200. Upon receiving a fault signal, it acquires the position information of the output shaft 230 of the power module 200, and then controls the output shaft 230 to maintain its current position and provide the preset output torque. The preset torque of the output shaft 230 can be set empirically. Figure 10A flowchart illustrating the position torque holding function when the host controller malfunctions is provided. It should be noted that... Figure 10 The control modes of the clamping motor involved can include two control modes: upper-level control mode and lower-level control mode. The upper-level control mode is controlled by the upper-level controller, while the lower-level control mode is controlled by the motor drive module in the surgical instrument power box 10. When in the lower-level control mode, the motor drive module interacts with the position information acquisition module, enabling the motor drive module to control multiple power modules 200 accordingly. That is, the power modules 200 can interact with each other through the motor drive module.

[0070] On the other hand, another embodiment of this application provides a surgical system including a surgical arm 30 and a surgical instrument power box 10 as described in any of the above claims, the surgical instrument power box 10 being disposed at the end of the surgical arm 30.

[0071] The aforementioned surgical system, on the one hand, features multiple power modules 200 staggered along the thickness of the surgical instrument power box 10. This not only reduces the volume of the surgical instrument power box 10, making its internal structure more compact and increasing its power-to-volume ratio (i.e., the ratio of output power to volume), but also allows for an increase in the diameter of the output shafts while maintaining the same spacing between them, thereby increasing torque output capacity. It also accommodates the installation dimensions of the surgical instruments 20 corresponding to the older version of the surgical instrument power box 10, facilitating assembly. On the other hand, by embedding the reducer 240 within the rotor 220, the reducer 240 can be integrated into the power module 200, resulting in higher integration of the power module 200. This further reduces the volume of the surgical instrument power box 10 and enables modular design of the power module 200, making it more reusable, flexible in application expansion, and ensuring development cycle and reliability.

[0072] See Figure 11 The surgical system also includes a control terminal 40, an operating terminal 50, and an energy generator. The control terminal 40 is electrically connected to the operating terminal 50 and the energy generator. The operating terminal 50 is used to mount the surgical arm 30. During the operation, the operator uses the control terminal 40 to manipulate the surgical instruments 20 at the operating terminal 50 to perform surgical operations on the patient's affected area. The control terminal 40 can control the spatial orientation adjustment of the surgical instruments 20 through the connection line with the operating terminal 50, and can control the energy activation through the connection line with the energy generator.

[0073] See Figure 11The surgical system may also include a tool cart 60, an imaging cart 70, and auxiliary equipment 80. The tool cart 60 is used to store surgical instruments 20, and the imaging cart 70 is used to display information such as the spatial orientation of the surgical instruments 20 and the condition of the patient's lesion.

[0074] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0075] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A surgical instrument power box, characterized in that, It includes a housing and multiple power modules disposed within the housing, wherein the multiple power modules are staggered and stacked in the thickness direction of the surgical instrument power box; The power module includes a stator, a rotor, an output shaft, and a reducer. The rotor is arranged opposite to the stator, and the reducer is nested inside the rotor and drives the rotor to the output shaft. The surgical instrument power box also includes a motor drive module, which stores a preset torque of the output shaft of the power module. When the motor drive module receives a fault signal, it controls the output shaft of the power module to maintain its current position and enable the output shaft to have the preset torque.

2. The surgical instrument power box according to claim 1, characterized in that, The reducer includes a first gear and several second gears, wherein the outer diameter of the first gear is larger than the outer diameter of the second gears; The first gear is fixed on the output shaft, and the second gear meshes with the inner circumferential surface of the rotor.

3. The surgical instrument power box according to claim 2, characterized in that, The inner circumferential surface of the rotor is provided with two annular grooves spaced apart along the thickness direction of the power module, and the two annular grooves are located on both sides of the thickness direction of the second gear. The inner circumferential surface of the rotor is provided with a limiting part, which includes two retaining rings, and the retaining rings are accommodated in the corresponding annular grooves.

4. The surgical instrument power box according to claim 1, characterized in that, The stator is formed by casting multiple winding units, wherein the winding units are arranged circumferentially and connected according to phase sequence.

5. The surgical instrument power box according to claim 1, characterized in that, The power module further includes: a first end cover, a second end cover, and a housing fixedly connected to the box body. The first end cover and the second end cover are arranged along the thickness direction of the power module and are both connected to the housing. The stator and the rotor are arranged in the space enclosed by the housing, the first end cover, and the second end cover. The first end of the output shaft is rotatably arranged on the first end cover, and the second end is rotatably arranged on the second end cover, wherein the first end and the second end are arranged opposite to each other.

6. The surgical instrument power box according to any one of claims 1 to 5, characterized in that, The power module also includes a motor sensor and a joint sensor. The motor sensor is disposed on the axial end face of the rotor and is used to obtain the position information of the rotor. The joint sensor is disposed on the axial end face of the output shaft and is used to obtain the position information of the output shaft.

7. The surgical instrument power box according to claim 6, characterized in that, The surgical instrument power box also includes a torque estimation module, which is used to determine the load torque of the power module based on the received position information of the rotor and the position information of the output shaft.

8. The surgical instrument power box according to claim 7, characterized in that, The torque estimation module stores the torque deformation coefficient between the rotor and the output shaft in the same power module. The torque estimation module includes a first calculation unit and a second calculation unit. The first calculation unit is used to calculate the difference between the rotor and the output shaft after converting them into joint radians based on the position information of the rotor and the position information of the output shaft. The second calculation unit is used to multiply the difference by the torque deformation coefficient to obtain the load torque.

9. The surgical instrument power box according to claim 6, characterized in that, When the motor drive module receives a fault signal, it also obtains the position information of the output shaft of the power module.

10. A surgical system, characterized in that, The surgical system includes a surgical arm and a surgical instrument power unit as described in any one of claims 1 to 9, wherein the surgical instrument power unit is disposed at the end of the surgical arm.

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