Single-arm robotic device with compact joint design and related systems and methods

Abstract

Disclosed herein are various robotic surgical devices and systems that include first and second elongate bodies, first and second drive shafts disposed through the second elongate body, and a coaxial shoulder joint with a robotic arm coupled thereto. In particular embodiments, the coaxial shoulder joint has a differential gimbaling fork and a dual shaft disposed within a gimbaling fork cavity.

Description

[0001] This invention patent application is a divisional application of Chinese invention patent application CN 201980015437.3 (international application number PCT / US2019 / 012507), filed on January 7, 2019, entitled "Single-arm robot device and related system and method with compact joint design".

[0002] Cross-references to related applications

[0003] This application claims the benefit of U.S. Provisional Application 62 / 614,127, filed January 5, 2018, entitled “Single-Manipulator Robotic Device With Compact Joint Design,” filed under 35 USC § 119(e), the entire contents of which are incorporated herein by reference. Technical Field

[0004] The various embodiments described herein relate to a variety of medical devices and related components, including robotic and / or in vivo surgical devices and related components such as arms and end effectors. More specifically, this document discloses robotic surgical devices and systems for use in minimally invasive surgical procedures. Background Technology

[0005] Advances in minimally invasive surgery (MIS) techniques continue to overcome major drawbacks of open surgery, including long recovery times, increased risk of postoperative infection, noticeable surgical scars, and other similar disadvantages. Minimally invasive laparoscopic surgery is a type of MIS technique that involves inserting thin instruments and attachments into an inflated abdominal area, thus eliminating the need for large incisions. However, these procedures also have limitations, including increased operative time, reduced visibility of the surgical site, and greater demands on the surgeon's dexterity. Accordingly, robotic platform integration has been introduced into the field of surgical medicine in an attempt to overcome these limitations.

[0006] Single-site laparoscopic surgery (LESS) (often also known as single-incision laparoscopic surgery (SILS)) is a newer minimally invasive laparoscopic surgical technique that allows access to the abdomen through a single incision. To perform the procedure, the surgeon must pass instruments through the port, resulting in loss of triangulation, a phenomenon known as the "chopsticks effect." In certain cases, the procedure also includes changing the type of access or entry point into the peritoneal cavity from a traditional trocar to a single-port access device.

[0007] Although the single-port access systems currently used in LESS / SILS procedures are still fragile, one increasingly popular device is the GelPort. ® The GelPort system has been adapted to function as a channel for cannulas and robotic platforms.

[0008] In contrast, a conventional trocar is a relatively simple device that consists of two known components: an outer cannula (or “cannulas”) and a tampon. The tubular cannula is the actual passageway into the abdomen, while the tampon is a component with a generally sharp distal end that is positioned through the cannula and forms a passage into the peritoneal cavity through the patient’s skin.

[0009] The industry standard for externally actuated surgical robot platforms is Da Vinci. ® The DaVinci surgical system consists of a master-slave configuration that surgeons can operate from remote consoles. DaVinci is also capable of single-site surgeries. The disadvantages of DaVinci include its cost (the system costs millions of dollars, which is unaffordable for small, poorly-funded hospitals), its large base that occupies a significant portion of the area around the operating table (and various other consoles distributed throughout the operating room), and its highly complex nature requiring extensive training and experience before surgeons can operate on people.

[0010] There is a need in this field for an improved robotic surgical system. Summary of the Invention

[0011] This article discusses embodiments of various single-arm robotic devices with coaxial / in-line shoulder joints.

[0012] In Example 1, the robot device includes: a first elongated device body including a first motor and a second motor; a second elongated device body coupled to a distal end of the first elongated device body; a first drive shaft disposed through the second elongated device body and operatively coupled to the first motor; a second drive shaft disposed through the second elongated device body and operatively coupled to the second motor, the second drive shaft being operatively coupled at its distal end to a first bevel gear; a shoulder joint; and an arm operatively coupled to an output body. The shoulder joint includes a differential yoke rotatably coupled to the first drive shaft, a dual shaft rotatably disposed within the yoke cavity, and an output body rotatably disposed on an extension shaft. The differential yoke includes a yoke body and a yoke cavity defined within the differential yoke, wherein the cavity has a longitudinal axis transverse to the longitudinal axis of the body. Furthermore, the dual shafts include a rotating shaft and an extension shaft. The rotating shaft is rotatably disposed in the universal joint fork cavity and is rotatably coupled to the first bevel gear. The extension shaft extends from the rotating shaft such that the longitudinal axis of the extension shaft is transverse to the longitudinal axis of the rotating shaft.

[0013] Example 2 relates to a robot device according to Example 1, wherein the first drive shaft is rotatably disposed within the second drive shaft and is radially concentric with the second drive shaft.

[0014] Example 3 relates to a robotic device according to Example 1, further comprising a third drive shaft operably coupled to a third motor, the third drive shaft being operably coupled at a distal end to a second bevel gear, wherein the second bevel gear is operably coupled to the output body.

[0015] Example 4 relates to a robot device according to Example 3, wherein the first drive shaft is rotatably disposed within and radially concentric with the third drive shaft, and wherein the third drive shaft is rotatably disposed within and radially concentric with the second drive shaft.

[0016] Example 5 relates to a robotic device according to Example 1, wherein the device has no second arm.

[0017] Example 6 relates to a robotic device according to Example 1, wherein the shoulder joint is an integral shoulder joint.

[0018] Example 7 relates to a robotic device according to Example 1, wherein the cross-sectional diameter of the second elongated device body is smaller than the cross-sectional diameter of the first elongated device body.

[0019] Example 8 relates to a robotic device according to Example 1, wherein the dimensions and structure of the second elongated device body are configured to enable positioning via a standard cannula port.

[0020] Example 9 relates to a robotic device according to Example 1, wherein the shoulder joint is a coaxial joint collinear with the body of the second elongated device.

[0021] In Example 10, the robot device includes: a first elongated device body including a first motor, a second motor, and a third motor disposed within the first elongated device body; a second elongated device body coupled to a distal end of the first elongated device body; a first drive shaft disposed through the second elongated device body and operably coupled to the first motor; a second drive shaft disposed through the second elongated device body and operably coupled to the second motor, the second drive shaft being operably coupled to a first bevel gear at its distal end; a third drive shaft disposed through the second elongated device body and operably coupled to the third motor, the third drive shaft being operably coupled to a second bevel gear at its distal end; a shoulder joint; and an arm operably coupled to an output body. The shoulder joint includes a differential universal joint fork rotatably coupled to the first drive shaft, a T-shaped shaft rotatably disposed within the universal joint fork cavity, and an output body rotatably disposed on an extension shaft, the output body being rotatably coupled to the first bevel gear. The differential universal joint fork includes a universal joint fork body and a universal joint fork cavity defined therein, wherein the universal joint fork cavity has a longitudinal axis transverse to the longitudinal axis of the body. The T-shaped shaft includes a rotating shaft and an extension shaft extending from the rotating shaft, the rotating shaft being rotatably disposed within the universal joint fork cavity and rotatably coupled to the second bevel gear.

[0022] Example 11 relates to a robot device according to Example 10, wherein the first drive shaft is rotatably disposed within and radially concentric with the second drive shaft, and wherein the second drive shaft is rotatably disposed within and radially concentric with the third drive shaft.

[0023] Example 12 relates to a robotic device according to Example 10, wherein the universal joint fork cavity is defined by opposing first universal joint fork cavity walls and second universal joint fork cavity walls, the first universal joint fork cavity wall including a first groove and the second universal joint fork cavity wall including a second groove.

[0024] Example 13 relates to a robotic device according to Example 12, wherein the extension shaft can be disposed within the first slot and the second slot.

[0025] Example 14 relates to a robotic device according to Example 10, wherein the longitudinal axis of the extension shaft is transverse to the longitudinal axis of the rotation shaft.

[0026] Example 15 relates to a robotic device according to Example 10, wherein the cross-sectional diameter of the first elongated device body is larger than the cross-sectional diameter of the second elongated device body.

[0027] Example 16 relates to a robotic device according to Example 10, wherein the arm includes an upper arm body, a forearm body, an elbow joint coupling the forearm body to the upper arm body, an end effector, and a wrist joint coupling the end effector to the forearm body, wherein the upper arm body is operatively coupled to the output body.

[0028] In Example 17, the robot device includes: a first elongated device body including a first motor, a second motor, and a third motor disposed within the first elongated device body; a second elongated device body coupled to a distal end of the first elongated device body; a first drive shaft disposed through the second elongated device body and operatively coupled to the first motor; a second drive shaft disposed through the second elongated device body and operatively coupled to the second motor; a third drive shaft disposed through the second elongated device body and operatively coupled to the third motor; a shoulder joint; and an arm operatively coupled to an output body. The second drive shaft is operatively coupled at its distal end to a first bevel gear, wherein the first drive shaft is rotatably disposed within the second drive shaft and radially concentric with the second drive shaft. The third drive shaft is operatively coupled at its distal end to a second bevel gear, wherein the second drive shaft is rotatably disposed within the third drive shaft and radially concentric with the third drive shaft. The shoulder joint includes a differential universal joint fork rotatably coupled to the first drive shaft, a T-shaped shaft rotatably disposed within the universal joint fork cavity, and an output body rotatably disposed on an extension shaft, the output body being rotatably coupled to the first bevel gear. The differential universal joint fork includes a universal joint fork body and a universal joint fork cavity defined in the differential universal joint fork by opposing first and second curved housings, wherein the first curved housing includes a first groove and the second curved housing includes a second groove, and wherein the longitudinal axis of the universal joint fork cavity is transverse to the longitudinal axis of the body. The T-shaped shaft includes a rotating shaft and an extension shaft extending from the rotating shaft, the rotating shaft being rotatably disposed within the universal joint fork cavity and rotatably coupled to the second bevel gear.

[0029] Example 18 relates to a robotic device according to Example 17, wherein the extension shaft can be disposed within the first slot and the second slot.

[0030] Example 19 relates to a robotic device according to Example 17, wherein the cross-sectional diameter of the first elongated device body is greater than the cross-sectional diameter of the second elongated device body.

[0031] Example 20 relates to a robotic device according to Example 17, wherein the cross-sectional diameter of the shoulder joint is smaller than or substantially similar to the cross-sectional diameter of the second elongated body.

[0032] While several embodiments have been disclosed, other embodiments of the invention will be apparent to those skilled in the art from the following detailed description showing and describing illustrative embodiments of the invention. As will be appreciated, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative rather than restrictive in nature. Attached Figure Description

[0033] Figure 1A This is a perspective view of a single-arm robot device provided through a cannula port according to one embodiment.

[0034] Figure 1B According to one embodiment Figure 1A A side view of the robotic device.

[0035] Figure 1C According to one embodiment Figure 1A A top view of the robotic device.

[0036] Figure 2A This is a side view of the first and second elongated bodies of a robotic device according to one embodiment.

[0037] Figure 2B According to one embodiment Figure 2A A side cross-sectional view of a portion of the first and second elongated bodies of the robotic device.

[0038] Figure 2C According to one embodiment Figure 2A Partial cross-sectional perspective view of the extensions of the first and second elongated bodies of the robotic device.

[0039] Figure 2D According to one embodiment Figure 2A A partial cross-sectional perspective view of the second slender body and the extension of the shoulder joint of the robotic device.

[0040] Figure 2E According to one embodiment Figure 2A A top view of the cross-section of the shoulder joint of the robotic device.

[0041] Figure 2FAccording to one embodiment Figure 2A An exploded 3D view of the shoulder joint of the robotic device.

[0042] Figure 3 This is a top sectional view of the shoulder joint of a robotic device according to one embodiment.

[0043] Figure 4 This is a perspective view of a portion of the second elongated body and the robot arm of a single-arm robot device according to one embodiment.

[0044] Figure 5A This is a side view of the upper arm of a robot arm of a robot device according to one embodiment.

[0045] Figure 5B According to one embodiment Figure 5A A side sectional view of the elbow joint of the robot arm.

[0046] Figure 6A This is a perspective view of the forearm of a robot arm according to one embodiment.

[0047] Figure 6B According to one embodiment Figure 6A A partial sectional perspective view of the extended portion of the forearm.

[0048] Figure 6C According to one embodiment Figure 6A A partial sectional perspective view of another section of the extended portion of the forearm.

[0049] Figure 7A According to one embodiment Figure 6A Side view of the forearm.

[0050] Figure 7B According to one embodiment Figure 6A A sectional side view of a portion of the forearm and the wrist joint of the forearm.

[0051] Figure 8A This is a perspective view of a laparoscopic cannula according to one embodiment.

[0052] Figure 8B According to one embodiment Figure 8A A side view of the laparoscopic cannula.

[0053] Figure 9A This is an external perspective view of a single-arm robotic device positioned within a target cavity of a patient, according to one embodiment.

[0054] Figure 9B According to one embodiment Figure 9A A schematic diagram of the calculated workspace of a single-arm robot device. Detailed Implementation

[0055] Embodiments of various robotic surgical devices and systems disclosed or envisioned herein include robotic devices having an elongated body and a single robotic arm attached thereto via a coaxial shoulder joint, the elongated body having a minimal cross-sectional profile.

[0056] It should be understood that various embodiments of the robotic devices and related methods and systems disclosed herein can be incorporated into or used with any other known medical devices, systems and methods. For example, the various embodiments disclosed herein can be incorporated into or used with any medical device and system disclosed in the following patent documents: U.S. Patent 7,492,116 (filed October 31, 2007, entitled "Robot for Surgical Applications"), U.S. Patent 7,772,796 (filed April 3, 2007, entitled "Robot for Surgical Applications"), U.S. Patent 8,179,073 (published May 15, 2011, entitled "Robotic Devices with Agent Delivery Components and Related Methods"), U.S. Patent 8,343,171 (published January 1, 2013, entitled "Methods and Systems of Actuation in Robotic Devices"), and U.S. Patent 8,679,096 (published March 25, 2014, entitled "Multifunctional Operational Component for Robotic Devices"). U.S. Patent 8,828,024 (published September 9, 2014, entitled "Methods and Systems of Actuation in Robotic Devices"), U.S. Patent 8,834,488 (published September 16, 2014, entitled "Magnetically Coupleable Surgical Robotic Devices and Related Methods"), U.S. Patent 8,894,633 (published November 25, 2014, entitled "Modular and Cooperative Medical Devices and Related Systems and Methods"), U.S. Patent 8,968,267 (published March 3, 2015, entitled "Methods and Systems for Handling or Delivering Materials for Natural Orifice Surgery"), and U.S. Patent 8,968,US Patents 332 (published March 3, 2015, entitled "Magnetically Coupleable Robotic Devices and Related Methods"), 8,974,440 (published March 10, 2015, entitled "Modular and Cooperative Medical Devices and Related Systems and Methods"), 9,010,214 (published April 21, 2015, entitled "LocalControl Robotic Surgical Devices and Related Methods"), 9,060,781 (published June 23, 2015, entitled "Methods, Systems, and Devices Relating to Surgical EndEffectors"), 9,089,353 (published July 28, 2015, entitled "Robotic Surgical Devices, Systems, and Related Methods"), and 9,179,981 (published November 10, 2015, entitled "Multifunctional Operational...") U.S. Patent 9,498,292 (published November 22, 2016, entitled "Single Site Robotic Devices and Related Systems and Methods"), U.S. Patent 9,579,088 (published February 28, 2017, entitled "Methods, Systems, and Devices for Surgical Visualization and Device Manipulation"), U.S. Patent 9,743,987 (published August 29, 2017, entitled "Methods, Systems, and Devices Relating to Robotic Surgical Devices, End Effectors, and Controllers"), U.S. Patent 9,770,305 (published September 26, 2017, entitled "Robotic Surgical Devices, Systems, and Related Methods"), and U.S. Patent 9,888,966 (published February 13, 2018, entitled "Methods, Systems, and Devices Relating to Force Control Surgical Systems"), all of which are incorporated herein by reference in their entirety.

[0057] Furthermore, the various embodiments disclosed herein can be incorporated into or used with any medical device and system disclosed in the following co-pending U.S. Publications: U.S. Publication 2014 / 0046340 (filed March 15, 2013, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Publication 2014 / 0058205 (filed January 10, 2013, entitled "Methods, Systems, and Devices for Surgical Access and Insertion"), U.S. Publication 2014 / 0303434 (filed March 14, 2014, entitled "Robotic Surgical Devices, Systems, and Related Methods"), and U.S. Publication 2015 / 0051446 (filed July 17, 2014, entitled "Robotic Surgical Devices, Systems, and Related Methods"). Related Methods), U.S. Publication Application 2016 / 0074120 (filed September 14, 2015, entitled "Quick-Release EndEffectors and Related Systems and Methods"), U.S. Publication Application 2016 / 0135898 (filed November 11, 2015, entitled "Robotic Device with Compact Joint Design and Related Systems and Methods"), U.S. Publication Application 2016 / 0157709 (filed February 8, 2016, entitled "Medical Inflation, Attachment, and Delivery Devices and Related Methods"), U.S. Publication Application 2017 / 0035526 (filed August 3, 2016, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Publication Application 2017 / 0354470 (filed May 18, 2017, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Publication Application 2017 / 0354470 (filed May 18, 2017, entitled "Robotic Surgical Devices, Systems, and Related Methods"), SystemsThe following patents are listed: U.S. Publication Application 2018 / 0055584 (filed August 30, 2017, entitled "Robotic Device with Compact Joint Design and an Additional Degree of Freedom and Related Systems and Methods"), U.S. Publication Application 2018 / 0056527 (filed August 25, 2017, entitled "Quick-Release End Effector Tool Interface"), U.S. Publication Application 2018 / 0140377 (filed November 22, 2017, entitled "GrossPositioning Device and Related Systems and Methods"), U.S. Publication Application 2018 / 0147019 (filed November 29, 2017, entitled "User Controller with User Presence Detection and Related Systems and Methods"), and U.S. Publication Application 2018 / 0161122 (filed December 14, 2017, entitled "Releasable"). "Attachment Device for Coupling to Medical Devices and Related Systems and Methods", all of which are incorporated herein by reference in their entirety. Additionally, the various embodiments disclosed herein can be incorporated into or used with any medical device and system disclosed in co-pending U.S. Application 16 / 144,807 (filed September 27, 2018), which is incorporated herein by reference in its entirety.

[0058] The implementations of the specific devices and systems disclosed in the patents and / or applications listed above can be positioned within a patient's body cavity in conjunction with a support component, similar to those disclosed herein and / or with reference to the specific patents and / or applications incorporated above. As used herein, "in-body device" means any device capable of being at least partially positioned, operated, or controlled by a user when positioned within a patient's body cavity, including any device disposed and coupled to a support component (e.g., a rod or other such component) through an opening or orifice of the body cavity; any device placed substantially against or adjacent to the patient's body cavity wall; further including any such device internally actuated (without an external power source); and also including any device that can be used laparoscopically or endoscopically during surgery. As used herein, the terms "robot" and "robot device" should refer to any device capable of performing tasks automatically or in response to commands.

[0059] Specific embodiments provide for inserting the invention into a cavity while maintaining adequate airflow into the cavity. Further embodiments minimize physical contact between the surgeon or surgical user and the invention during insertion. Other embodiments enhance safety for the patient and the insertion process. For example, some embodiments provide visualization of the invention as it is inserted into the patient's cavity to ensure no harmful contact occurs between the system / device and the patient. Additionally, specific embodiments allow for minimization of incision size / length. Further embodiments reduce the complexity of the access / insertion process and / or the steps required for that process. Other embodiments relate to devices with minimal contours, minimal dimensions, or generally minimal functionality and appearance to enhance ease of operation and use.

[0060] Similar to manual laparoscopic surgery, known inflatable systems can be used to pump sterile carbon dioxide (or other gases) into the patient's abdominal cavity. This elevates the abdominal wall from the organs and creates space for the robot. In certain embodiments, the system does not have a direct interface to the inflatable system. Alternatively, the system may have a direct interface to the inflatable system.

[0061] According to various embodiments, the insertion port is a conventional cannula or an improved cannula as described elsewhere herein. In such embodiments, the device embodiments described herein, or a portion thereof, are provided via the cannula of the cannula as described in more detail below. Alternatively, in certain embodiments, the insertion port is a single-port access device, which is a known, commercially available flexible membrane placed over the abdomen to seal and protect the abdominal incision. An example of such a single-port access device is the GelPort discussed above. ®This readily available component is the same device used in the same way for manually operated laparoscopic surgery (HALS). The only difference is that the robotic arm is inserted into the abdominal cavity through an insertion port instead of the surgeon's hand. The robotic body seals the insertion port to maintain inflation pressure. This port is for single use and is disposable. Alternatively, any known port can be used.

[0062] The specific embodiments disclosed herein relate to “combined” or “modular” medical devices that can be assembled in various configurations. For the purposes of this application, “combined device” and “modular device” should refer to any medical device and related system having modular or interchangeable components that can be arranged in a variety of different configurations. The modular components and combined devices disclosed herein also include segmented triangular or quadrilateral combined devices. These devices consist of modular components (also referred to herein as “segments”) connected to form a triangular or quadrilateral configuration, and these devices can provide leverage and / or stability during use, while also providing effective load space within the device for larger or more operating components. As with the various combined devices disclosed and discussed above, according to one embodiment, these triangular or quadrilateral devices can be positioned within a patient’s body cavity in the same manner as those discussed and disclosed above.

[0063] The various system implementations described herein are used to perform robotic surgery. Furthermore, the various implementations disclosed herein can be used minimally invasively for a variety of surgeries typically performed "open" by known techniques, thus having the potential to improve clinical outcomes and healthcare costs, including general intra-abdominal surgical applications such as colectomy and other known procedures. Further, the various implementations disclosed herein can be used instead of known large, mainframe-like laparoscopic surgical robots that are inserted into the body from outside the patient. That is, the low-invasive robotic systems, methods, and apparatus according to the embodiments disclosed herein are characterized by small, complete surgical devices that are inserted integrally through a single incision in the patient's abdomen. By utilizing existing tools and techniques familiar to surgeons, the devices disclosed herein will not require specialized operating rooms or specialized infrastructure, and due to their significantly smaller size, these devices are expected to be much cheaper than existing laparoscopic surgical robot alternatives. Due to these technological advancements, the various implementations herein enable minimally invasive approaches to procedures performed in today's open surgeries. In certain implementations, the various systems described herein are based on and / or utilize techniques used in manual laparoscopic surgery, including abdominal insufflation and the use of ports to insert tools into the abdominal cavity.

[0064] As will be described in detail below, the components of the various system implementations disclosed or conceived herein may include a console and a robot with a minimum cross-sectional profile, as well as a single robotic arm as described herein. As further described in detail herein, the robot implementation is constructed and arranged for insertion into an inflatable abdominal cavity.

[0065] Although the various embodiments described herein are characterized by having a motor, it should be understood that any type of known actuator may be used instead of a motor. Furthermore, while the transmission component that transmits force from the motor within the device is referred to as a shaft coupled by gears, it should be understood that any type of transmission component or mechanism may be used in place of such a shaft and gears, including hydraulic or pneumatic components or other mechanical components such as cables and pulleys or similar components.

[0066] As described herein, various embodiments are disclosed in detail in the accompanying drawings and related discussions.

[0067] Figures 1A to 1C An embodiment of a single manipulator device 10 (also referred to herein as a "one-piece manipulator," "single arm," "one-piece arm," "coaxial joint," "coaxial shoulder joint," and "robotic surgical" device) according to one embodiment is shown. In this embodiment, the device 10 has a first body 12 (also referred to herein as an "outer body" or "first support beam"), a second body 14 (also referred to herein as an "inner body" or "second support beam"), a first arm component 16 (also referred to herein as an "upper arm"), a second arm component 18 (also referred to herein as a "forearm"), and an operating component 20 (also referred to herein as an "end effector"). In this described embodiment and various other embodiments herein, the inner body 14 has a smaller cross-sectional diameter than the outer body 12, such that the inner body 14 can be inserted through a port smaller than that that might be used for the outer body 12, such as including a cannula port, as... Figure 1A Port 28 is shown. Note that in... Figure 1A In this configuration, the inner body 14 is disposed and positioned within the cannula port 28, such that the distal end of the inner body 14 extends beyond the distal end of the cannula 30. This positions the distal end of the inner body 14 and the shoulder joint 22 within the patient's internal target cavity. The second body 14 is coupled to the first body 12. In a particular embodiment, the first body 12 and the second body 14 are removably coupled. Alternatively, the first body 12 and the second body 14 are fixedly coupled or integrally formed as a single, integral component. In another alternative, the first body 12 and the second body 14 are movably coupled to each other in a hinged or other non-rigid manner.

[0068] The first arm component 16 is rotatably coupled to the second body 14 via a first joint 22 (also referred to herein as the "shoulder joint"), while the second arm component 18 is rotatably coupled to the first arm component 16 via a third joint 24 (also referred to herein as the "elbow joint"), and the operating component 20 is rotatably coupled to the second arm component 18 via a fourth joint 26 (also referred to herein as the "wrist joint"). Each of these components will be discussed in further detail below according to various embodiments of the robotic surgical apparatus.

[0069] It should be understood that the compact coaxial (or “coaxial”) shoulder joint, as further described in detail in the various embodiments disclosed or contemplated herein, represents less intrusiveness to the insertable portion of the robot compared to devices with non-coaxial shoulder joints (including devices with two shoulder joints). In other words, the coaxial shoulder joint device embodiments described herein have a smaller cross-sectional diameter compared to known non-coaxial or dual shoulder joints.

[0070] Figures 2A to 2F An embodiment of the single-arm device 40 is described in further detail, more specifically its outer body 42, inner body 44, and shoulder joint 46. Like all other embodiments disclosed or contemplated herein, this particular embodiment of the device 40 has a shoulder joint 46 with three degrees of freedom (“DOF”) and a minimum cross-sectional diameter to facilitate insertion via cannulas and other insertion devices. The minimum diameter is achieved through the specific design of the various components within the inner body 44 and joint 46, as described in further detail below.

[0071] Figure 2A A side view of the device 40 is shown, including an outer body 42, an inner body 44, and a shoulder joint 46. More specifically, the figure shows an outer casing or housing 48 of the outer body 42 and an outer casing or housing 50 of the inner body 44.

[0072] Figure 2BA cross-sectional front view of an outer body 42, an inner body 44, and a shoulder joint 46 according to an exemplary embodiment is depicted, wherein certain internal components among these components are visible. In this embodiment and other embodiments disclosed or contemplated herein, the outer body 42 houses actuators (in a particular embodiment, motors) 70A, 70B, 70C that actuate the shoulder joint 46 via drive shafts 52 (also referred to herein as “nested drive shafts”) disposed within the inner body 44. This configuration, having motors 70A, 70B, 70C disposed within the outer body 42 and nested drive shafts 52 disposed in a nested configuration within the inner body 44, results in the inner body 44 having a smaller cross-sectional diameter than the outer body 42, as discussed above with respect to device 10. A set of nested drive shafts 52 are rotatably disposed within the inner body 44. As described herein, the term “nested” is intended to describe concentric components such that at least one component is located inside another of those components, and each component has a common axis of rotation.

[0073] Reference Figure 2B The nested drive shafts 52 consist of a first or outer drive shaft 52A, a second or intermediate drive shaft 52B, and a third or inner drive shaft 52C. As shown, the nested drive shafts 52 extend from the outer body 42 into and through the inner body 44. As shown, the inner drive shaft 52C is rotatably disposed within the intermediate drive shaft 52B and has a driven gear 54C fixedly or integrally attached to its proximal end. The inner drive shaft 52C is coupled at its distal end to or integrally formed with a differential universal joint fork 56C (also referred to herein as a "shoulder housing" or "converter"). As shown, the intermediate drive shaft 52B is rotatably disposed within the outer drive shaft 52A and has a driven gear 54B fixedly or integrally attached to its proximal end. The intermediate drive shaft 52B is coupled at its distal end to a second or inner drive bevel gear 56B. The outer drive shaft 52A is rotatably disposed within the inner body 44 and has a driven gear 54A fixedly or integrally attached to its proximal end. The external drive shaft 52A is coupled at its distal end to the first or external drive bevel gear 56A.

[0074] According to one embodiment, in Figure 2B and Figure 2C The diagram best illustrates various internal components at the proximal end of the inner body 44 and the distal end of the outer body 42, including the proximal ends of drive shafts 52A, 52B, 52C and the associated gears and motors driving these drive shafts 52A, 52B, 52C. Figure 2BAs best shown, the proximal end of the internal drive shaft 52C is rotatably supported in the outer body 42 via a first shaft bearing 60 and a second shaft bearing 62. Furthermore, the proximal end of the intermediate drive shaft 52B (including the driven gear 54B) is rotatably supported in the outer body 42 via a second shaft bearing 62 and a third shaft bearing 64. Additionally, the proximal end of the external drive shaft 52A (including the driven gear 54A) is rotatably supported in the outer body 42 via a third shaft bearing 64.

[0075] like Figure 2B and Figure 2C As best shown, this nested set of drive shafts 52 has three motors operatively coupled to them (although only two of the three motors are visible), with the three motors arranged within the outer body 42 as described above. More specifically, motor 70A has a motor drive gear 72A coupled to driven gear 54A (which is coupled to the outer drive shaft 52A). Furthermore, motor 70C has a motor drive gear 72C coupled to driven gear 54C (which is coupled to the inner drive shaft 52C). Additionally, a third motor (logically identified as 70B, but not visible in the figure due to its viewing angle) has a third motor drive gear (logically identified as 72B, but also not visible) coupled to driven gear 54B (which is coupled to the intermediate drive shaft 52B). Based on the description herein, those skilled in the art will understand the positioning and function of the third motor and the third motor drive gear.

[0076] In one embodiment, motors 70A, 70B, and 70C are 12-volt Faulhaber 1226 series brushless DC motors coupled to a Faulhaber 256:1 planetary gearbox with a rated efficiency of 0.60. Alternatively, any known motor can be used in the external body 42.

[0077] Therefore, in operation, motor 70A can be actuated to drive the external drive shaft 52A to rotate by rotating motor drive gear 72A, which in turn drives the driven gear 54A to rotate. Similarly, motor 70B (not visible in the figure) can be actuated to drive the intermediate drive shaft 52B to rotate by rotating motor drive gear 72B (also not visible), which in turn drives the driven gear 54B to rotate. In a similar manner, motor 70C can be actuated to drive the internal drive shaft 52C to rotate by rotating motor drive gear 72C, which in turn drives the driven gear 54C to rotate.

[0078] Figure 2B , Figure 2D , Figure 2E and Figure 2FA shoulder joint 46 and its various components according to one embodiment are depicted. More specifically, Figure 2D A three-dimensional cross-sectional view of the internal components of joint 46 is depicted, while Figure 2E A top view of the cross-section of joint 46 is depicted, and Figure 2F An exploded view of the internal components of joint 46 is depicted. As described above and as... Figure 2B , Figure 2D and Figure 2F As shown, the external drive shaft 52A is coupled to (or is rotationally constrained by) the external drive bevel gear 56A, while the intermediate drive shaft 52B is coupled to the internal drive bevel gear 56B, and the internal drive shaft 52C is coupled to the differential universal joint fork 56C. Figure 2B As shown in the optimal configuration, at the distal end, the external drive shaft 52A and the external drive bevel gear 56A are supported by a first shoulder bearing 80. Furthermore, the intermediate drive shaft 52B and the internal drive bevel gear 56B are supported by a first shoulder bearing 80 and a second shoulder bearing 82.

[0079] like Figure 2D and Figure 2F As best shown, the differential universal joint fork 56C has a cylindrical body 90 and a universal joint fork opening or partial cavity 93 defined at the distal end of the body 90. In one embodiment shown, the cavity 93 is defined by two opposing curved shells (or "curved walls") 92A, 92B extending from the body 90 and defining the universal joint fork cavity 93 located between the two shells 92A, 92B. In one embodiment, each of the two shells 92A, 92B is a set of two forks, such that the first shell 92A is a first set of two curved forks 92A, and the second shell 92B is a second set of two curved forks 92B. Furthermore, shaft grooves 94A, 94B are defined in the two shells 92A, 92B. Thus, in those embodiments where the shells 92A, 92B are fork pairs 92A, 92B, the shaft grooves 94A, 94B are defined between every two forks in each set of forks 92A, 92B. A cylindrical body 90 is disposed in the joint 46 such that its longitudinal axis is parallel to and concentric with the longitudinal axis of the inner body 44. Conversely, the longitudinal axis of the universal joint fork cavity 93, defined by the two shells 92A and 92B, is transverse to the longitudinal axis of the cylindrical body 90.

[0080] Furthermore, joint 46 has a dual shaft 96 (also referred to herein as a "T-bar" or "T-axis") rotatably disposed within the universal joint fork opening 93. The dual shaft 96 has a rotation shaft 96A (also referred to herein as a "main shaft" or "pitch shaft") and an extension shaft 96B (also referred to herein as a "roll shaft"). The extension shaft 96B has a longitudinal axis transverse to the longitudinal axis of the rotation shaft 96A. The pitch shaft 96A is connected by a third shoulder bearing 84 and a fourth shoulder bearing 86 (e.g., ...). Figure 2B(best shown) and the fifth shoulder bearing 88 and the sixth shoulder bearing 89 (also as shown) Figure 2B (Best shown) The pitch shaft 96A is rotatably supported within the universal joint fork opening 93, allowing rotation about a longitudinal axis transverse to the longitudinal axis of the inner body 44 (and thus also the longitudinal axis of a set of nested drive shafts 52). Further, the pitch shaft 96A is coupled to or rotatably constrained to a first shoulder bevel gear 100, such that rotation of the first shoulder gear 100 causes rotation of the rotation shaft 96A. The first shoulder gear 100 is rotatably coupled to an external drive bevel gear 56A, such that rotation of the external drive bevel gear 56A causes rotation of the first shoulder gear 100. The bevel gear 100, the pitch shaft 96A, and the bearings 84, 86, 88, 89 are coupled together and “preloaded” by a screw 102 coupled to the pitch shaft 96A. Alternatively, any known attachment could be used to couple these components together and preload them. Thus, the rotation of motor 70A causes the rotation of rotating shaft 96A, which in turn causes the extension shaft 96B to move about the longitudinal axis of rotating shaft 96A, as described in further detail below.

[0081] Continue to refer to Figure 2B , Figure 2D and Figure 2F The extension shaft 96B is coupled to or integral with the rotating shaft 96A, and extends radially from the rotating shaft 96A such that the longitudinal axis of the extension shaft 96B is transverse to the longitudinal axis of the rotating shaft 96A, resulting in the T-shaped structure of the T-shaped shaft 96. As described above, when the pitch shaft 96A is rotatably disposed within the universal joint fork opening 93, such as Figure 2F As shown in the optimal configuration, the extension shaft 96B extends from the rotation shaft 96A, such that the extension shaft 96B is positioned in either of the shaft grooves 94A or 94B between the fork assembly 92A and 92B, depending on the rotational position of the rotation shaft 96A. That is, as the rotation shaft 96A rotates, the extension shaft 96B rotates about the longitudinal axis of the rotation shaft 96A along a path including the two shaft grooves 94A and 94B, allowing the extension shaft 96B to rotate at least 180° about the rotation shaft 96A.

[0082] Continue to refer to Figure 2FThe shoulder joint 46 also has a second shoulder bevel gear 104, which is rotatably disposed at the end of the rotation shaft 96A opposite to the first shoulder bevel gear 100, so that the second shoulder gear 104 can rotate relative to the rotation shaft 96A. The second shoulder bevel gear 104 is rotatably coupled to an internal drive bevel gear 56B, such that rotation of the internal drive bevel gear 56B causes rotation of the second shoulder bevel gear 104. Further, the second shoulder bevel gear 104 is also rotatably coupled to an output body (also referred to as a "roller") bevel gear 108, such that rotation of the second shoulder gear 104 causes rotation of the output body bevel gear 108. Thus, rotation of the internal drive bevel gear 56B causes rotation of the output body 106, as will be described in detail below.

[0083] An output body 106 with an output bevel gear 108 is rotatably mounted on an extension shaft 96B, allowing the output gear 108 and the output body 106 to rotate relative to the extension shaft 96B. Therefore, the rotation of the output bevel gear 108 about the extension shaft 96B caused by the rotation of the second shoulder bevel gear 104 also causes the output body 106 to rotate. Furthermore, the rotation of the extension shaft 96B about the rotation axis of the rotation shaft 96A causes both the extension shaft 96B and the output body 106 mounted thereon to rotate about the rotation axis of shaft 96A, resulting in pitch movement of the arm attached thereto (e.g., such as arm 130 or upper arm 150).

[0084] In use, the external drive bevel gear 56A is rotatably coupled to the first shoulder bevel gear 100 as described above, such that rotation of the external drive bevel gear 56A causes rotation of the first shoulder bevel gear 100. This rotation of the first shoulder bevel gear 100 causes rotation of the rotation shaft 96A, which in turn causes radial movement of the extension shaft 96B and the output body 106 coupled thereto about the longitudinal axis of the rotation shaft 96A, thereby causing pitch.

[0085] Furthermore, as described above, the internal drive bevel gear 56B is rotatably coupled to the second shoulder bevel gear 104, such that rotation of the internal drive bevel gear 56B causes rotation of the second shoulder bevel gear 104. This rotation of the second shoulder bevel gear 104 causes rotation of the output body bevel gear 108, which in turn causes the output body 106 to rotate about the extension shaft 96B, resulting in roll.

[0086] Furthermore, as described above, the internal drive shaft 52C is coupled to or integrated with the differential universal joint fork 56C, such that rotation of the internal drive shaft 52C causes rotation of the differential universal joint fork 56C, thereby resulting in yaw.

[0087] Therefore, the shoulder joint 46 provides three degrees of freedom. The construction of the shoulder joint 46 provides these three degrees of freedom while minimizing its cross-sectional dimensions. Figure 2EThe maximum cross-sectional diameter of the shoulder joint 46 is depicted, which is also the maximum cross-sectional diameter of the internal components of device 40 and any other device embodiments disclosed or contemplated herein. Therefore, according to a particular embodiment, the cross-sectional diameter of the second or internal body (e.g., internal body 44) is not greater than (or substantially not greater than) the cross-sectional diameter of the shoulder joint (e.g., shoulder joint 46), such as... Figure 2B The example shown is best illustrated. In one embodiment, the maximum diameter of the shoulder joint 46 is about 15 mm, which means that the internal body 44, the shoulder joint 46, and the robotic arm (not shown) coupled thereto can be inserted by any cannula or other insertion device with a minimum inner diameter of about 15 mm.

[0088] Figure 3 Another embodiment of a shoulder joint 120 with a similar construction to the joint 46 described above and a maximum diameter of about 13.5 mm is shown. This means that any device embodiment with such a joint 120 can have an internal body, a shoulder joint 120 and a coupled robotic arm, which can be inserted by any cannula or other insertion device with a minimum inner diameter of 13.5 mm.

[0089] Alternatively, the maximum diameter of any shoulder joint (e.g., joint 46 or 120) according to any embodiment disclosed or contemplated herein may range from about 13.5 mm to any desired larger diameter. In another embodiment, the maximum diameter of any such shoulder joint may be about 18 mm.

[0090] exist Figures 1A to 3In certain embodiments and various other embodiments disclosed or contemplated herein, one advantage of a coaxial, three-degree-of-freedom (“3 DOF”) shoulder joint is the resulting reduced cross-sectional profile. In other words, the overall cross-sectional diameter (transverse to the longitudinal axis of the body and the single arm) of the device (e.g., device 40 or other embodiments herein) is smaller compared to known devices (including those with two arms) that have motors (and other such actuators) in their body. Known two-arm devices have two arms attached to a single body, such that these arms have mirror-symmetric functionality. This known mirror-symmetric configuration of the two arms results in a larger cross-sectional profile. In contrast, the single-arm devices of the embodiments disclosed or contemplated herein have a smaller cross-sectional profile and can therefore be incorporated into a system of two or more such devices, allowing for the positioning of two or more devices in various locations within the patient's abdomen through various incisions at different locations. Given the differences in human anatomy between patients, the positioning of surgical instruments and accessories can vary significantly, thus providing an advantage for the use of a single-arm device. Furthermore, using two or more separate single-arm devices can provide spatial and operational independence between the two or more robotic arms, thereby achieving independent overall positioning capability. Thus, the device (e.g., device 40 or any other embodiment disclosed or contemplated herein) can be inserted through a smaller opening used in medical procedures (e.g., a cannula port, other known ports, or incisions), or two or more such devices can be inserted through two or more openings, resulting in less invasive surgery compared to known devices.

[0091] Furthermore, as stated above, the maximum diameter of the coaxial, 3DOF shoulder joint embodiment described herein (such as, for example, joint 46 or 120) is smaller than that of most separate shoulder joints in known bi-arm devices. This reduced cross-sectional diameter is caused by the coaxial shoulder joint construction consisting of a differential universal joint fork (e.g., universal joint fork 16C) and a dual shaft (e.g., dual shaft 96), and by how these two components are placed together with various gears within the shoulder to minimize the diameter. Taking shoulder joint 46 as an example, the arrangement of the rotatable dual shaft 96 within the differential universal joint fork 16C, combined with (1) the rotatable coupling of the internal drive shaft 52C and the differential universal joint fork 56C, and with (2) the rotatable coupling of the external drive bevel gear 56A with the first shoulder bevel gear 100 and thus with the rotational shaft 96A of the dual shaft 96, results in a minimized profile of shoulder joint 46. In other words, unlike most known shoulder joints, the outermost radial portion of shoulder joint 46 is the first shoulder bevel gear 100. In other words, the component driven by the first shoulder bevel gear 100 is positioned radially inside the gear 100, rather than radially outside the gear 100 relative to the midpoint of the cross-section of the shoulder 46. In contrast, in the most known / existing shoulder joints, such an outer bevel gear would be coupled to a component positioned radially outside the bevel gear, resulting in a larger cross-sectional diameter compared to the shoulder joints disclosed and envisioned herein.

[0092] The "coaxial" or collinear feature of the DOF shoulder joint 46 arises from the rotational coupling of the differential universal joint fork 56C, with a dual axis 96 rotatably disposed therein, to the internal drive shaft 52C. Therefore, when the dual axis 96 is configured such that the rotation axis 96A extends away from the internal body 44 and is parallel and concentric with the longitudinal axis of the internal body 44 (so that the upper arm of the robot arm (not shown) coupled thereto is also parallel and concentric with the longitudinal axis of the internal body 44), rotation of the internal drive shaft 52C results in a directly corresponding rotation of the differential universal joint fork 56C (and thus a directly corresponding rotation of the upper arm to which it is attached).

[0093] In certain embodiments, such as Figure 4 As best shown, a single-arm device 130 similar to the above embodiment has an outer body (not shown), an inner body 132, a shoulder joint 134, and a single robotic arm 136 coupled to the single shoulder joint 134. Furthermore, according to some embodiments, the arm 136 has two parts: a first arm part 136A (also referred to herein as the "upper arm") and a second arm part 136B (also referred to herein as the "forearm"). Additionally, some embodiments have an operating component 138 (also referred to herein as an "end effector") coupled to the arm 136.

[0094] Figure 5A and Figure 5BAn embodiment of an upper arm 150 according to one embodiment is depicted. The upper arm 150 of this embodiment can be fixedly coupled to an output body (e.g., output body 106 discussed above) of a joint (such as joint 46), such that rolling of the output body causes the upper arm 150 to rotate about its longitudinal axis. More specifically, the arm 150 has an opening 152 defined in its proximal end, in which the output body (e.g., output body 106) can be disposed and thereby attached to the arm 150. Alternatively, any coupling mechanism, feature, or method can be used to couple the upper arm 150 to the output body.

[0095] The upper arm 150 also has an arm joint 154 (referred to herein as an "elbow joint") at its distal end, which allows for joint coupling with the forearm (e.g., the forearm 180 described below). The elbow joint 154 has two opposing supports 156A, 156B (or "protrusions") extending from or at the distal end of the upper arm 150, defining a space in which a coupling body 158 is rotatably disposed. Each support 156A, 156B has bearings 160A, 160B disposed on its inner wall. The coupling body 158 has two rotating protrusions 162A, 162B, a coupling member 164, and a body bevel gear 166. According to one embodiment, as... Figure 5B As best shown, two rotating protrusions 162A and 162B are respectively disposed within and rotatably coupled to two bearings 160A and 160B, such that the coupling body 158 is rotatable relative to the supports 156A and 156B. In this embodiment, the coupling member 164 is an opening 164 defined in the coupling body 158, which is configured to receive a portion of a forearm (e.g., forearm 180), such that the forearm portion is disposed within the opening 164, and the forearm is thereby coupled to the coupling body 158. Alternatively, the coupling member 164 can be any coupling mechanism, feature, or method for coupling the upper arm 150 to the forearm.

[0096] Furthermore, joint 154 includes an elbow joint bevel gear 168 coupled to or rotatably constrained to upper arm motor 170, such that actuation of motor 170 causes elbow joint bevel gear 168 to rotate. Elbow joint bevel gear 168 is rotatably coupled to body bevel gear 166, such that rotation of elbow joint bevel gear 168 causes body bevel gear 166 to rotate, thereby causing coupling body 158 to rotate relative to supports 156A, 156B, thereby causing the forearm (e.g., forearm 180) coupled thereto to rotate relative to upper arm 150. Thus, actuation of upper arm motor 170 can cause forearm (e.g., forearm 180) to rotate relative to upper arm 150 at elbow joint 154.

[0097] In one embodiment, the upper arm 150 has additional space within the arm 150 (in addition to the space occupied by the upper arm motor 170) to accommodate additional components as needed. For example, in one embodiment, one or more controllers (not shown) for controlling various components (including motors) of the arm or robotic device may be provided within the upper arm 150.

[0098] Figures 6A to 6C An embodiment of a forearm 180 according to one embodiment is depicted. In this embodiment, the forearm 180 can be securely coupled to a coupling member 164 of a coupling body 158 at a coupling protrusion 188 at the proximal end of the forearm 180. It should be understood that any coupling mechanism or method can be used for this attachment.

[0099] In this embodiment, the forearm 180 has a wrist joint 182 at its distal end, to which an actuating component 184 (“end effector”) is coupled. In this specific embodiment, the end effector 184 is a gripper 184; however, it is understood that the end effector 184 is removable, and therefore various known, interchangeable end effectors 184 can be used with it. Further, as... Figure 6B and Figure 6C As shown in the best embodiment, the forearm 180 has three motors disposed within the body 190 of the forearm 180: a first motor 186A, a second motor 186B, and a third motor 186C.

[0100] One embodiment of the wrist joint 182 is in Figure 7A and Figure 7B This is shown in more detail below. More specifically, Figure 7BA cross-sectional front view of the distal portion of a forearm body 190 and a wrist joint 182 according to an exemplary embodiment is depicted, wherein certain internal components are visible. The forearm body 190 has a set of nested drive shafts 192 rotatably disposed within the body 190 and extending into the wrist joint 182. This set of nested drive shafts 192 comprises a first or outer drive shaft 192A, a second or intermediate drive shaft 192B, and a third or inner drive shaft 192C. As shown, this set of nested drive shafts 192 extends from the forearm body 190 into the wrist joint 182. As shown, the inner drive shaft 192C is rotatably disposed within the intermediate drive shaft 192B and has a driven gear 194C fixedly or integrally attached to its proximal end. The inner drive shaft 192C is rotatably coupled at its distal end to a first or inner drive bevel gear 196C. As shown in the figure, an intermediate drive shaft 192B is rotatably disposed within an outer drive shaft 192A and has a driven gear 194B fixedly or integrally attached to its proximal end. The intermediate drive shaft 192B is coupled at its distal end to a second or intermediate drive bevel gear 196B. The outer drive shaft 192A is rotatably disposed within a forearm body 190 and a wrist joint 182 and has a driven gear 194A fixedly or integrally attached to its proximal end. The outer drive shaft 192A is coupled at its distal end to a first or outer drive bevel gear 196A.

[0101] Continue to refer to Figure 7B The proximal end of the internal drive shaft 192C is rotatably supported in the forearm body 190 via a first shaft bearing 198 and a second shaft bearing 200. Further, the proximal end of the intermediate drive shaft 192B, including the driven gear 194B, is rotatably supported via a second shaft bearing 200 and a third shaft bearing 202. Additionally, the proximal end of the external drive shaft 192A, including the driven gear 194A, is rotatably supported via a third shaft bearing 202.

[0102] The nested drive shafts 192 have three motors operatively coupled to them. More specifically, ( Figure 6C The motor 186B has a motor drive gear 204A coupled to a driven gear 194A (which is coupled to an external drive shaft 192A). Figure 7A As shown in, but in Figure 7B (Not visible in the text). Furthermore, ( Figure 6C The motor 186A has a motor drive gear 204C coupled to the driven gear 194C (which is coupled to the internal drive shaft 192C). Additionally, Figure 6C The motor 186C has a motor drive gear 204B (also not shown in the figure) coupled to the driven gear 194B (which is coupled to the intermediate drive shaft 192B).

[0103] Therefore, in operation, motor 186B can be actuated to drive the external drive shaft 192A to rotate by rotating motor drive gear 204A (which drives the rotation of driven gear 194A). Similarly, motor 186C can be actuated to drive the intermediate drive shaft 192B to rotate by rotating motor drive gear 204B (also not shown) (which drives the rotation of driven gear 194B). In a similar manner, motor 186A can be actuated to drive the internal drive shaft 192C to rotate by rotating motor drive gear 204C (which drives the rotation of driven gear 194C).

[0104] At the distal end, the external drive shaft 192A and the external drive bevel gear 196A are supported by the first wrist bearing 210. Additionally, the intermediate drive shaft 192B and the intermediate drive bevel gear 196B are supported by the first wrist bearing 210 and the second wrist bearing 212.

[0105] An internal drive bevel gear 196C is rotatably coupled to a differential universal joint fork 220, which has two rotating protrusions 222A and 222B, an extension shaft 224 extending into the end effector body 244, and a universal joint fork bevel gear 226. The differential universal joint fork 220 is similar to the differential universal joint fork 56C of the shoulder joint 46 discussed above, thus producing the same or similar coaxial advantages as the universal joint fork 56C, including a minimal cross-sectional profile and coaxial construction as discussed in detail above. The internal drive bevel gear 196C is rotatably coupled to the universal joint fork bevel gear 226. Thus, rotation of the internal drive bevel gear 196C causes the differential universal joint fork 220 to rotate about the rotating protrusions 222A and 222B, resulting in rotation of the extension shaft 224 about the longitudinal axis of the universal joint fork 220 extending from the first rotating protrusion 222A to the second rotating protrusion 222B.

[0106] An intermediate drive bevel gear 196B is rotatably coupled to a first wrist bevel gear 230, which is rotatably mounted on a first internal rotating protrusion 222A. Additionally, the first wrist bevel gear 230 is rotatably mounted on a first external rotating protrusion 246A extending from a first wrist support frame 246. The first wrist support frame 246 extends from the distal end of the forearm body 190. Thus, the first wrist bevel gear 230 is rotatably supported by the first internal rotating protrusion 222A and the first external rotating protrusion 246A. Further, the first wrist bevel gear 230 is rotatably coupled to an end effector output bevel gear 232, which is coupled to or integrated with the end effector output body 234. Therefore, rotation of the intermediate drive bevel gear 196B causes rotation of the first wrist bevel gear 230, which in turn causes rotation of the end effector output bevel gear 232, which in turn causes rotation of the end effector output body 234. In a particular embodiment, depending on the type of end effector, the output body 234 is operatively coupled to the end effector to actuate the end effector in some way.

[0107] An external drive bevel gear 196A is rotatably coupled to a second wrist bevel gear 240, which is rotatably mounted on a second internal rotating protrusion 222B. Additionally, the second wrist bevel gear 240 is also rotatably mounted on a second external rotating protrusion 248A extending from a second wrist support 248. The second wrist support 248 extends from the distal end of the forearm body 190 in a manner similar to the first wrist support 246. Thus, the second wrist bevel gear 240 is rotatably supported by the second internal rotating protrusion 222B and the second external rotating protrusion 248A. Further, the second wrist bevel gear 240 is rotatably coupled to an end effector rotating bevel gear 242, which is coupled to or integrated with the end effector body 244. Therefore, the rotation of the external drive bevel gear 196A causes the second wrist bevel gear 240 to rotate, which in turn causes the end effector rotating bevel gear 242 to rotate, which in turn causes the end effector body 244 to rotate, thereby causing the end effector to rotate about its longitudinal axis.

[0108] The wrist joint 182 described in the above embodiment is a compact and dexterous wrist joint. The dexterity of the wrist joint in a robotic arm is important considering the unpredictability of patient anatomy, the importance of providing surgeons with as much control as possible to complete surgical tasks, and the importance of tool dexterity during surgery. Several known devices provide seven degrees of freedom for the wrist joint, but these devices have arm and end effector actuation via actuators (typically motors) located outside the patient's body, such as the EndoWrist® of the Da Vinci® system. Using mechanical (cable, etc.), pneumatic, hydraulic, or other such force transmission systems allows EndoWrist and other such devices to maintain a small profile while possessing high dexterity. In contrast, known devices to date with actuators (e.g., motors) located inside the patient's body or within openings for positioning devices have not been able to achieve this degree of freedom or corresponding dexterity. However, the wrist embodiment (e.g., wrist joint 182) offers additional dexterity compared to other devices with internal actuators. That is, due to the construction of joint 182, wrist joint 182 provides three degrees of freedom while minimizing its cross-sectional profile. More specifically, as described above, the wrist joint 182 has a differential universal joint fork 220 construction similar to the differential universal joint fork 56C of the shoulder joint 46, resulting in similar features and functions, including a minimal cross-sectional diameter and coaxial configuration.

[0109] Figure 8A and Figure 8B An example of a cannula 250 according to one embodiment is depicted, the cannula being sized and configured to allow reception of various robotic device embodiments disclosed or contemplated herein. The cannula 250 has a port 252 (or “seal”) and a cannula 254 extending from the port 252. The port 252 and the cannula 254 define a lumen 256 with a diameter sufficiently large to receive any arm and internal body of any device embodiment disclosed or contemplated herein. Further, the length of the cannula 254 is such that the shoulder joint of the robotic device positioned therethrough extends through and is positioned lateral to the distal end 258 of the cannula 254, thereby allowing the arm coupled to the shoulder joint to move in any desired direction without being obstructed or interfered with by the cannula 254. As described elsewhere herein, in addition to the cannula 250 and any other known laparoscopic cannulas, it should be understood that any appropriately sized insertion device (including any type of port) or appropriately sized incision can be used with the devices of the various embodiments disclosed or contemplated herein.

[0110] Cannula ports, such as the aforementioned cannula 250 and other known cannulas, may offer specific advantages over known single-site entry ports. For example, due to the physical contact between the port and the device, insertion of certain known robotic devices via single-site entry ports can lead to structural damage to the robotic device. Additionally, such known single-site entry ports require larger incisions within the patient compared to standard cannulas.

[0111] In use, Figure 9A and Figure 9B An embodiment of a single-arm robotic device 270 in a surgical setting is shown. More specifically, Figure 9A An external view of device 270 is provided, which is positioned in patient 272 via cannula 274 such that device 270 is in its operational configuration. That is, device 270 is positioned within a target cavity (not shown) of patient 272, allowing a robotic arm (not shown) to be used therein to perform the desired surgical procedure. In this embodiment, device 270 is stabilized and / or held in the desired operational position via a known external support 276 coupled to the external body 278 of device 270.

[0112] Furthermore, Figure 9B This is a schematic diagram of device 270 and a visual illustration of the workspace 280 in which device 270 can operate. More specifically, workspace 280 is a visual representation of the entire area accessible to end effector 284 coupled to single arm 282. Thus, device 270 can be positioned at the patient (e.g., ...). Figure 9B The internal body 286 extends into the target cavity of the patient (272), thereby positioning the robotic arm 282 therein. In this specific embodiment, means having components and functions similar to those disclosed or contemplated herein in various other device embodiments can manipulate or otherwise position the arm 282 such that the end effector 284 can extend to all areas defined by the workspace 280. Thus, the end effector 284 can be used to perform surgery at any location within the workspace 280.

[0113] Although the invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes in form and detail may be made without departing from the spirit and scope of the invention.

Claims

1. A robotic device, comprising: (a) An elongated device body, the elongated device body comprising: (i) The proximal portion having a proximal portion diameter; (ii) a distal portion having a distal portion diameter, wherein the distal portion diameter is smaller than the proximal portion diameter; and (iii) A first motor and a second motor disposed within the device body; (b) Operablely coupled to the first drive shaft of the first motor; (c) Operablely coupled to a second drive shaft of the second motor, the second drive shaft being operably coupled to a first bevel gear at a distal end; (d) The shoulder joint, comprising: (i) A differential universal joint fork rotatably coupled to the first drive shaft, the differential universal joint fork including a universal joint fork body and a universal joint fork cavity defined in the differential universal joint fork, wherein the universal joint fork cavity has a longitudinal axis transverse to the longitudinal axis of the universal joint fork body; and (ii) A dual shaft rotatably disposed within the universal joint fork cavity, the dual shaft comprising: (A) A rotating shaft, rotatably disposed within the universal joint fork cavity, the rotating shaft being rotatably coupled to the first bevel gear; and (B) An extension shaft extending from the rotation shaft such that the longitudinal axis of the extension shaft is transverse to the longitudinal axis of the rotation shaft; and (iii) an output body rotatably disposed about the extension shaft such that the extension shaft is rotatably disposed within a cavity of the output body; and (e) An arm operatively coupled to the output body.

2. The robot device according to claim 1, wherein, The extension shaft is fixedly attached to the rotating shaft.

3. The robot device of claim 1 further includes a third drive shaft operably coupled to a third motor, the third drive shaft being operably coupled at a distal end to a second bevel gear, wherein the second bevel gear is operably coupled to the output body.

4. The robot device according to claim 1, wherein, The differential universal joint fork rotates around the first rotation axis. The rotation axis rotates about the second rotation axis, and The output body rotates around the third rotation axis.

5. The robot device according to claim 4, wherein, The first axis of rotation, the second axis of rotation, and the third axis of rotation intersect at a single point.

6. The robot device according to claim 1, wherein, The shoulder joint is a one-piece shoulder joint.

7. The robot device according to claim 1, wherein, The distal portion is sized and structured to allow for positioning via the cannula port.

8. The robot device according to claim 1, wherein, The shoulder joint is a coaxial joint that is collinear with the distal portion.

9. A robotic device, comprising: (a) An elongated device body, comprising a first motor, a second motor and a third motor disposed within the elongated device body; (b) A first drive shaft, which is disposed via the elongated device body and operatively coupled to the first motor; (c) A second drive shaft, which is disposed via the elongated device body and operatively coupled to the second motor, and operatively coupled at its distal end to a first shoulder gear; (d) A third drive shaft, which is disposed through the elongated device body and operably coupled to the third motor, and the third drive shaft is operably coupled at its distal end to a second shoulder gear; (e) A shoulder joint, said shoulder joint comprising: (i) a differential universal joint fork, the differential universal joint fork being rotatably coupled to the first drive shaft, the differential universal joint fork including a universal joint fork cavity defined therein; and (ii) A T-shaped shaft, rotatably disposed within the universal joint fork cavity, the T-shaped shaft comprising: (A) A rotating shaft, rotatably disposed within the universal joint fork cavity, the rotating shaft being rotatably coupled to the first shoulder gear; and (B) An extension shaft extending from the rotation axis; (iii) An output body rotatably mounted on the extension shaft, the output body being rotatably coupled to the second shoulder gear, wherein the first shoulder gear is the radially outermost component of the shoulder joint; and (f) An arm operatively coupled to the output body.

10. The robot device according to claim 9, wherein, The universal joint fork cavity is defined by opposing first universal joint fork cavity walls and second universal joint fork cavity walls, the first universal joint fork cavity wall including a first groove and the second universal joint fork cavity wall including a second groove.

11. The robotic device according to claim 10, wherein, The extension shaft can be positioned within the first groove and the second groove.

12. The robot device according to claim 9, wherein, The longitudinal axis of the extension shaft is transverse to the longitudinal axis of the rotation shaft.

13. The robot device according to claim 9, wherein, The elongated device body includes a proximal portion and a distal portion, wherein the proximal portion has a cross-sectional diameter larger than that of the distal portion.

14. The robot device according to claim 9, wherein, The arm includes an upper arm body; a forearm body; an elbow joint coupling the forearm body to the upper arm body; and an end effector. The end effector is coupled to the wrist joint of the forearm body, wherein the upper arm body is operatively coupled to the output body.

15. The robot device according to claim 9, wherein, The first drive shaft is disposed within the third drive shaft, and the third drive shaft is disposed within the second drive shaft.

16. A robotic device, comprising: (a) An elongated device body, the elongated device body including a first motor and a second motor disposed therein; (b) A first drive shaft, which is disposed through the device body and operatively coupled to the first motor; (c) A second drive shaft, which is disposed through the device body and operably coupled to the second motor, and is operably coupled at its distal end to the first bevel gear; (d) The shoulder joint, comprising: (i) a differential universal joint fork, the differential universal joint fork being fixedly attached to the first drive shaft, the differential universal joint fork including a universal joint fork cavity defined therein; and (ii) A dual-axis rotatably disposed within the universal joint fork cavity, the dual-axis comprising: (A) A rotating shaft, rotatably disposed within the universal joint fork cavity, the rotating shaft being rotatably coupled to the first bevel gear; and (B) An extension shaft extending from the rotation axis; and (iii) an output body rotatably disposed about the extension shaft such that the extension shaft is rotatably disposed within a cavity of the output body; and (e) An arm operatively coupled to the output body.

17. The robotic device according to claim 16, wherein, The extension shaft can be positioned within the first and second slots of the differential universal joint fork.

18. The robotic device according to claim 16, wherein, The elongated device body includes a proximal portion and a distal portion, wherein the proximal portion has a cross-sectional diameter larger than that of the distal portion.

19. The robotic device according to claim 18, wherein, The shoulder joint has a smaller or substantially similar cross-sectional diameter than the distal portion.

20. The robotic device according to claim 18, wherein, The shoulder joint is a coaxial joint that is collinear with the proximal portion and the distal portion.

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