Robotic surgical instrument

Abstract

The robotic surgical instrument includes: an instrument cartridge assembly; an elongate shaft assembly extending from the instrument cartridge assembly; and an end effector that is supported on the elongate shaft assembly. The elongate shaft assembly defines a longitudinal axis. The instrument cartridge assembly includes a cable drive assembly, a grip mechanism, a manual release mechanism, and a wrist mechanism. The cable drive assembly includes a drive jaw assembly having a drive jaw pinion, a first rack assembly, and a second rack assembly. The first rack assembly and the second rack assembly translate relative to each other in response to rotation of the drive jaw pinion to move the end effector relative to the longitudinal axis. The grip mechanism and the wrist mechanism are coupled to the end effector, and the manual release mechanism is coupled to the grip mechanism.

Description

Technical Field

[0001] The present disclosure relates to robotic systems and, more particularly, to robotic surgical instruments. Background Art

[0002] Surgical instruments used in laparoscopic and / or robotic surgery typically have a proximal housing and an elongated shaft extending distally from the proximal housing to an end effector. The proximal housing supports an actuation mechanism that can be used to actuate the end effector to perform a surgical task within a patient's body cavity. Such instruments can be used in applications where there is a limited reach area for an operator. The end effector can be inserted into the limited reach area, and the operator can remotely and / or robotically manipulate the instrument via the actuation mechanism. Summary of the invention

[0003] According to one aspect of the present disclosure, a robotic surgical system includes a surgical instrument for a robotic surgical system. The surgical instrument includes an end effector, an elongated shaft assembly, and an instrument box assembly. The elongated shaft assembly defines a longitudinal axis and has a distal portion and a proximal portion. The distal portion includes a dexterous assembly supporting the end effector. The dexterous assembly is movable relative to the longitudinal axis to move the end effector in different planes. The instrument box assembly is supported on the proximal portion of the elongated shaft assembly. The instrument box assembly includes a cable drive assembly, which includes a plurality of drive jaw assemblies. Each of the plurality of drive jaw assemblies includes a drive jaw pinion, a first rack assembly, and a second rack assembly. The first rack assembly includes a first cable, and the second rack assembly includes a second cable. The first rack assembly and the second rack assembly are positioned to translate relative to each other in response to rotation of the drive jaw pinion so that the first cable and the second cable move the end effector relative to the longitudinal axis.

[0004] In various aspects, the first rack assembly can include a first ferrule securing the first cable to a first rack of the first rack assembly.The first rack assembly can include a clamp removably coupled to the first rack to secure the first ferrule to the first rack.

[0005] In various aspects, the instrument box assembly can include a transition block that guides the first cable and the second cable into the elongated shaft assembly. The transition block can include a plurality of shells fixed together to define a cable channel through the transition block, wherein the cable channels define a longitudinal radial pattern configured to guide the first cable and the second cable into a hub assembly supported on a proximal portion of the elongated shaft assembly.

[0006] In various aspects, the instrument box assembly may include a wrist mechanism. The wrist mechanism may include a bilateral rack, a wrist drive pawl pinion and a wrist gear. The wrist drive pawl pinion may be rotatable so that the bilateral rack is translated. The wrist gear may be rotatable in response to the translation of the bilateral rack. The wrist mechanism may further include a composite shaft assembly coupled to the wrist gear. The composite shaft assembly may extend through the elongated shaft assembly and may include one or more flexible sections and one or more rigid sections. The wrist gear may be arranged at an angle relative to the wrist drive pawl pinion.

[0007] In various aspects, the instrument cartridge assembly may include a gripping mechanism actuatable to move the jaw members of the end effector relative to one another and a manual release mechanism coupled to the gripping mechanism.

[0008] According to one aspect, the present disclosure relates to an instrument box assembly for a robotic surgical instrument. The instrument box assembly includes a housing assembly, a cable drive assembly, a gripping mechanism, and a release mechanism. The housing assembly supports a mounting plate. The cable drive assembly is supported in the housing assembly and includes a drive pawl pinion, a first rack assembly, and a second rack assembly. The first rack assembly and the second rack assembly are engaged with the drive pawl pinion and are positioned to translate relative to each other in response to rotation of the drive pawl pinion. The gripping mechanism is supported on the mounting plate, and the release mechanism is coupled to the gripping mechanism.

[0009] In various aspects, the housing assembly may include a cover that is selectively removable from the housing assembly to expose the release mechanism. The release mechanism may include a lock slide, a bracket, a turntable, and a spring. The lock slide may be slidably movable relative to the bracket so that the spring can push the bracket and the turntable from a first position to a second position. The turntable may be rotatable relative to the bracket in the second position to operate the gripping mechanism.

[0010] In various aspects, the gripping mechanism may include a drive dog and a crank operatively associated with the drive dog. The crank may be configured to receive a gripping cable therethrough.

[0011] In various aspects, the instrument cassette assembly can include a high voltage circuit supported within the housing assembly.

[0012] In various aspects, the instrument box assembly may include a latch assembly supported by the housing assembly, and the latch assembly may be actuated to disconnect the sterile adapter assembly from the housing assembly. The latch assembly may include a latch spring coupled to a pair of latches. The pair of latches may be configured to fix the housing assembly to the sterile adapter assembly.

[0013] In various aspects, the instrument cassette assembly can include the sterile adapter assembly.

[0014] According to another aspect, the present disclosure relates to a robotic surgical system. The robotic surgical system includes: an instrument drive assembly; a sterile adapter assembly, the sterile adapter assembly is coupled to the instrument drive assembly; and a robotic surgical instrument, the robotic surgical instrument is coupled to the sterile adapter assembly and can be actuated by the instrument drive assembly. The robotic surgical instrument includes: an instrument box assembly; an elongated shaft assembly, the elongated shaft assembly extending from the instrument box assembly; and an end effector, the end effector supported on a distal portion of the elongated shaft assembly. The elongated shaft assembly defines a longitudinal axis. The instrument box assembly includes a cable drive assembly, a gripping mechanism, a manual release mechanism, and a wrist mechanism. The cable drive assembly includes a plurality of drive jaw assemblies, each of the plurality of drive jaw assemblies including a drive jaw pinion, a first rack assembly, and a second rack assembly. The first rack assembly and the second rack assembly are positioned to translate relative to each other in response to rotation of the drive jaw pinion so that the end effector moves relative to the longitudinal axis. The gripping mechanism is operatively coupled to the end effector and actuatable to move the jaw members of the end effector between an open position, a closed position, and an over-closed position. The manual release mechanism is operatively coupled to the gripping mechanism to enable manual movement of the jaw members relative to each other. The wrist mechanism is operatively coupled to the end effector and actuatable to rotate the end effector.

[0015] Other aspects, features, and advantages will be apparent from the following description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various aspects of the present disclosure and, together with the general description of the present disclosure given above and the detailed description given below, explain the principles of the present disclosure. In the drawings:

[0017] Figure 1 is a stereoscopic view of a robotic surgical system for performing a surgical procedure on a patient in accordance with the principles of the present disclosure;

[0018] Figures 2 to 4 is to demonstrate the manipulation of the patient's body cavity Figure 1 Progressive view of surgical instruments for a robotic surgery system;

[0019] Figure 5 yes Figure 1 A stereoscopic view of a robotic surgical instrument of a robotic surgical system;

[0020] Figure 6 yes Figure 5An enlarged rear stereoscopic view of a proximal portion of a robotic surgical instrument;

[0021] Figure 7 yes Figure 5 A perspective view of an instrument cartridge assembly of a robotic surgical instrument with parts separated, the instrument cartridge assembly shown coupled to a hub assembly of an elongated shaft assembly of the robotic surgical instrument;

[0022] Figure 8 and Fig. 9 yes Figure 7 A front perspective view of an instrument cassette assembly with portions thereof removed for clarity;

[0023] Fig.10 yes Figure 8 A magnified rear stereoscopic view of

[0024] Fig.11 yes Figure 7 An enlarged stereoscopic view of a cable drive assembly of an instrument box assembly;

[0025] Fig.12 yes Fig.11 A three-dimensional view of the part with the parts separated;

[0026] Fig.13 yes Fig.11 An enlarged perspective view of a rack assembly of a cable drive assembly;

[0027] Fig.14 yes Figure 7 An enlarged stereoscopic view of a transition block assembly of an instrument box assembly;

[0028] Fig.15 yes Fig.14 an enlarged front perspective view of a portion of a transition block of the transition block assembly and illustrating an arrangement of distal cable apertures defined by the transition block;

[0029] Fig.16 The cable routing of the transition block assembly is shown Fig.15 Schematic diagram of the cable routing arrangement of the distal cable aperture shown in;

[0030] Fig.17 It shows the connection to Figure 7 The hub assembly Fig.14 A perspective view of a transition block assembly;

[0031] Fig.18 yes Fig.17 A three-dimensional view of the part with the parts separated;

[0032] Figures 19 to 25 It is a display Figure 5Progressive views of movement of a drive jaw of a drive assembly of a robotic surgical instrument causing corresponding movement of an end effector of the robotic surgical instrument;

[0033] Fig.26 It is a display Figure 5 Schematic diagram of a composite shaft assembly within a robotic surgical instrument;

[0034] Fig. 27 yes Figure 5 An enlarged stereoscopic view of a wrist mechanism of a robotic surgical instrument;

[0035] Fig.28 yes Fig. 27 Side view of

[0036] Fig.29 yes Figure 7 A perspective view of an instrument cassette assembly of , wherein the cover thereof is shown separated, and wherein the grip and wrist hub assemblies of the instrument cassette assembly are shown in phantom for clarity;

[0037] Figure 30 to Figure 32 yes Fig.29 an enlarged stereoscopic view of the grip and wrist hub assembly;

[0038] Figure 33 to Figure 39 It is a display Fig.29 Progressive views of the grip and operation of the manual release mechanism of the wrist hub assembly;

[0039] Fig.40 yes Figure 7 A stereoscopic view of the various parts of the instrument box assembly and its high voltage circuit is shown;

[0040] Fig.41 yes Fig.40 Schematic diagram of the high voltage circuit;

[0041] Fig.42 It is shown Figure 5 A stereoscopic view of a robotic surgical instrument attached to a sterile adapter assembly;

[0042] Fig.43 yes Figure 7 A rear perspective view of a proximal portion of an instrument cassette assembly and showing a latch assembly thereof;

[0043] Fig.44 yes Fig.43 a perspective view of a latch assembly; and

[0044] Fig.45 yes Fig.42 An enlarged stereoscopic view of the indicated area of ​​detail is shown. DETAILED DESCRIPTION

[0045] Various aspects of the present disclosure are described in detail with reference to the accompanying drawings, in which the same reference numerals represent the same or corresponding elements in each of the several views. As used herein, the term "distal" refers to a portion of a structure that is farther from a user (e.g., a clinician), while the term "proximal" refers to a portion of a structure that is closer to a user. As used herein, the term "clinician" refers to a doctor, nurse, or other care provider, and may include support personnel and / or equipment operators. As used herein, the term "cable" refers to one or more wires or fibers that may include a metal or non-metal material, may have one or more protective shells or insulating portions thereon (e.g., a polymer material, such as rubber or plastic), and / or may be twisted together. In some aspects, a cable may include one or more nitinol wires.

[0046] In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

[0047] Robotic surgical systems have been used in minimally invasive medical procedures and may include a robotic arm assembly. Such procedures may be referred to as what is commonly known as "tele-surgery". Some robotic arm assemblies include one or more robotic arms to which surgical instruments may be coupled. Such surgical instruments include, for example, endoscopes, electrosurgical forceps, cutting instruments, staplers, graspers, electrocautery devices, or any other endoscopic or open surgical devices. Prior to or during use of the robotic surgical system, various surgical instruments may be selected and connected to the robotic arm for selectively actuating the end effector of the connected surgical instrument.

[0048] refer to Figures 1 to 4 , a robotic surgical system is generally shown at 10. The robotic surgical system 10 employs various robotic elements to assist the clinician and to allow for remote operation (or partial remote operation) of surgical instruments 100 of a surgical instrument system 50 of the robotic surgical system 10. Various controllers, circuit systems, robotic arms, gears, cams, pulleys, electric and mechanical motors, and the like may be used for this purpose and may be designed to assist the clinician in the operation or treatment process in conjunction with the surgical system 10. Such robotic systems may include tele-steerable systems, automated flexible surgical systems, tele-flexible surgical systems, tele-articulated surgical systems, wireless surgical systems, modular or selectively configurable tele-operated surgical systems, and the like.

[0049] The robotic surgical system 10 includes a workstation 12 and an instrument cart 14. The instrument cart 14 includes one or more surgical instrument systems 50 mounted on a mobile drive unit 18, which houses an instrument drive assembly 20 for manipulating the surgical instrument system 50 and / or its individual surgical instruments 100 with the assistance of, for example, one or more computing devices or controllers. The surgical instruments 100 may include, for example, graspers or forceps 26 (which may be electrosurgical forceps), an endoscope 28, and / or any other suitable instrument that may be driven by one or more associated tool drivers (not shown) of the instrument drive assembly 20. For example, in addition to the grasper 26 and the endoscope 28, the one or more surgical instruments 100 may include a dexterous tool for performing a surgical procedure, such as a needle driver, a stapler, a dissector, a cutter, a hook, a scissors, a coagulator, an irrigator, a suction device, the like, or a combination thereof.

[0050] The surgical instrument system 50 includes an insertion tube 16 that defines a plurality of separate conduits, channels, or lumens 16a therethrough that are configured to receive, for example, a surgical instrument 100 for accessing a body cavity "BC" of a patient "P". In other aspects, the insertion tube 16 may define a single conduit, channel, or lumen therethrough that is configured to receive, for example, a surgical instrument 100 for accessing a body cavity "BC" of a patient "P". In particular, the insertion tube 16 may be inserted and enter the body cavity "BC" of the patient "P" through the incision "I" and / or access devices 17a, 17b (e.g., a surgical portal that may include one or more seals to facilitate sealed insertion through the tissue "T" of the patient "P"). With the insertion tube 16 positioned in the patient "P", the surgical instrument 100 may be advanced through the insertion tube 16 into the body cavity "BC" of the patient "P". In some aspects, the insertion tube 16 can be in the form of an access device (such as access device 17a), and the movable drive unit 18 can include a support arm 19 that can be selectively attached to the access device 17a so that when the access device 17a is connected to the distal portion of the support arm 19, the surgical instrument 100 can be advanced through the access device 17a.

[0051] Further, the workstation 12 includes an input device 22 for use by a clinician to control the surgical instrument system 50 and its surgical instruments 100 via the instrument drive assembly 20, so as to perform a surgical operation on a patient "P" when, for example, the patient "P" is supported on an operating table 24. The input device 22 is configured to receive input from the clinician and generate input signals. The input device 22 can also be configured to generate feedback to the clinician. The feedback can be visual, auditory, tactile, etc.

[0052] The workstation 12 may further include a computing device and / or controller, such as a master processor circuit 22a in communication with the input device 22 for receiving input signals and generating control signals for controlling the robotic surgical system 10, which may be transmitted to the instrument cart 14 via an interface cable 22b. In some cases, the transmission may be wireless, and the interface cable 22b may not be present. The input device 22 may include right-hand and left-hand control devices (not shown) and / or foot pedals (not shown) that are moved / operated to generate input signals at the input device 22 and / or control the robotic surgical system 10. The instrument cart 14 may include a slave processor circuit 20a that receives control signals from the master processor circuit 22a and generates slave control signals that are operable to control the surgical instrument system 50 during a surgical procedure. The workstation 12 may also include a user interface, such as a display (not shown) in communication with the master processor circuit 22a, for displaying information (e.g., body cavity images) and other information to the clinician about an area or region of interest (e.g., a surgical site, a body cavity, etc.). Although both a master processor circuit and a slave processor circuit are shown, in other aspects a single processor circuit may be used to perform both master and slave functions.

[0053] The surgical instrument system 50 of the robotic surgical system 10 may include a plurality of surgical instruments 100. Each surgical instrument 100 may be selectively attached to and selectively removed from the movable drive unit 18 ( Figure 1 ) removed. Although Figure 3 Only four surgical instruments 100 are shown, for example, surgical instrument system 50 may include any number and / or type of surgical instruments.

[0054] refer to Figure 5 and Figure 6, each surgical instrument 100 of the surgical instrument system 50 defines a longitudinal axis "A" and includes: an instrument cartridge assembly 102 at a proximal portion thereof, an elongated shaft assembly 104 extending distally from the instrument cartridge assembly 102, and an end effector 106 supported on a distal portion of the elongated shaft assembly 104. The end effector 106 may include portions (e.g., distal portions) of the elongated shaft assembly 104 (e.g., dexterous assembly 106a) that connect the elongated shaft assembly 104 to jaw members 107a, 107b of the end effector 106 via a wrist 106b and facilitate movement of the end effector 106 (e.g., when manipulating one or more cables of a drive assembly of the surgical instrument 100). The end effector 106 may be actuated by the instrument cartridge assembly 102 to implement a surgical procedure. In practice, actuating the end effector 106 may cause the end effector 106 to articulate, pivot, clamp, rotate, etc., e.g., relative to the longitudinal axis "A" of the surgical instrument 100, for repositioning the end effector 106 and / or for treating tissue "T" of the patient "P", as described above (see Figures 2 to 4 ). Smart assembly 106 includes spine stack 106c that creates an alternating set of orthogonal joints such that every other joint allows bending in the XZ plane and every other joint allows bending in the YZ plane. Spine stack 106c includes segments 106d, 106e, and 106f.

[0055] like Figure 7 As seen in FIG. 1 , the instrument cassette assembly 102 includes a housing assembly 110 , a transition block assembly 120 , a hub assembly 130 , a cable drive assembly 140 , a grip and wrist hub assembly 150 , and a latch assembly 160 .

[0056] The housing assembly 110 of the instrument box assembly 102 includes an upper housing portion 110a, a lower housing portion 110b, and a rear housing portion 110c that are coupled together to support various components within the housing assembly 110. The housing assembly 110 further includes a cover 110d that is removably attached to a manual release opening 110e defined in the upper housing portion 110a. The housing assembly 110 further includes a first support 110f and a second support 110g that are configured to support various internal components of the instrument box assembly 102. The housing assembly 110 further includes a flushing port 110m and a socket for an electrosurgical cable 110n.

[0057] See also Fig.14 , Fig.15 , Fig.16 , Fig.17 and Fig.18, the transition block assembly 120 of the instrument box assembly 102 includes a transition block 122 and supports a plurality of cables 99 passing therethrough. The transition block 122 of the transition block assembly 120 includes an outer shell 124a and an inner shell 124b, which are coupled together via fasteners (not explicitly shown) to define a cable channel 126 passing therethrough for routing the cables 99 through the hub assembly 130 in a longitudinal radial pattern at a first end 122a of the transition block 122, and into the housing assembly 110 in a radial fan-shaped pattern toward the cable drive assembly 140 at a second end 122b of the transition block 122 (see Figures 14 to 16 In practice, the cable pairs are routed through the cable channel 126 in a diametrically opposed relationship (e.g., 180 degrees apart). Fig.16 As can be seen, cable pair "d1" cooperates with each other, cable pair "P1" cooperates with each other, cable pair "d2" cooperates with each other, and cable pair "P2" cooperates with each other. Fig.16 Each of the cable pairs shown in FIG. 1 corresponds to Fig.15 124a and the inner shell 124b may include or be formed of a low friction coefficient polyphenylene sulfide, for example, to minimize drive train losses. The transition block 122 may have one or more bends therein to facilitate routing of cables therethrough and to help reduce load distribution (e.g., friction forces acting on such cables as they translate therethrough).

[0058] Continue to refer Fig.18 The hub assembly 130 of the instrument box assembly 102 includes a hub 132 (e.g., polyetheretherketone) that supports a cable seal 134 (e.g., silicone) in its proximal portion for sealing the cable 99 and guiding it through the hub 132. The hub assembly 130 further includes a distal shaft 136 (e.g., stainless steel) that extends distally from the hub 132 and receives the cable 99 therethrough.

[0059] Now go to Figures 6 to 13 The cable drive assembly 140 of the instrument box assembly 102 includes a plurality of drive jaw assemblies 142. The plurality of drive jaw assemblies 142 include a proximal drive jaw assembly 142p and a distal drive jaw assembly 142d configured to impart movement to the cable 99. Figures 11 to 13As seen in FIG. 1 , each drive pawl assembly 142 includes a drive pawl pinion 144, a first rack assembly 146, and a second rack assembly 148, which are movably coupled together and positioned to impart movement to the cable 99 coupled thereto. The drive pawl pinion 144 includes a drive pawl 144a (e.g., made of polyetheretherketone) and a pinion 144b (e.g., made of stainless steel) extending distally from the drive pawl 144a. The drive pawl 144a is pinned to the proximal portion of the pinion 144b by a pin 144c. The pinion 144b includes a plurality of teeth 144d around the circumference of the distal portion of the pinion 144b. Each of the first rack assembly 146 and the second rack assembly 148 (e.g., made of polyetheretherketone) includes a rack 147a on a first side thereof and a retaining portion 147b on a second side thereof opposite to the first side. The retaining portion 147b defines a ferrule opening 147c, a clamp opening 147d, and a cable channel 147e therein. The ferrule opening 147c supports a ferrule 147f that holds an end of a cable 99 (e.g., a cable 99 crimped by the ferrule 147f with, for example, a preload of about 0.8 mm applied) therein. The cable channel 147e communicates with the ferrule opening 147c and supports the cable 99 therein. The clamp 149 is selectively received in the clamp opening 147d and removably secured to the retaining portion 147b (e.g., snap fit) to secure the ferrule 147f and the cable 99 in the cable channel 147e and the ferrule opening 147c, respectively.

[0060] As in Figure 7 As best shown in FIG. 1 , the first rack assembly 146 and the second rack assembly 148 of the proximal drive dog assembly 142p are supported in a rack cavity 110j defined in the first support body 110f of the housing assembly 110. The rack cavity 110j is closed by a cover assembly 110k. The first rack assembly 146 and the second rack assembly 148 of the distal drive dog assembly 142d are supported in and disposed between the first support body 110f and the second support body 110g.

[0061] As in Figure 20 to Figure 25 As seen in FIG. 1 , rotation of each drive dog pinion 144 causes the first rack 146 and the second rack 148 to move (e.g., translate relative to each other before striking a hard stop, e.g., up to 9 mm of travel), as indicated by arrow “R”, thereby causing the first cable 99a and the second cable 99b coupled to the racks 146, 148, respectively, to translate relative to each other to generate a push-pull force for imparting motion / force to the end effector 106. The relative movement of the racks 146, 148 and the first and second cables 99a, 99b causes the end effector 106 to move relative to the longitudinal axis “A”, as shown in FIG. Fig.21 and Fig.25 It is worth noting that when the racks 146, 148 are substantially aligned with each other (e.g., arranged in a mirror-image relationship with each other), the end effector 106 is arranged to be aligned with the longitudinal axis "A", as shown in FIG. Fig.23 As seen in Fig.19 As seen in FIG. 1 , the drive dog pinions 144 of the proximal drive dog assembly 142p and the distal drive dog assembly 142d are configured to rotate up to about 155 degrees in a clockwise and / or counterclockwise direction relative to the respective tilted center lines “ACL1” to “ACL4” for moving the end effector 106 through Fig.19 The proximal plane and / or distal plane "PP1" (e.g., rotation of the first proximal drive jaw assembly), "PP2" (e.g., rotation of the second proximal drive jaw assembly), "DP1" (e.g., rotation of the first distal drive jaw assembly) and "DP2" (e.g., rotation of the second distal drive jaw assembly) shown in and / or relative to these proximal planes and / or distal planes. In particular, the translational movement of the end effector 106 relative to / through the proximal planes "PP1", "PP2" can reach 60 mm in the proximal and / or distal directions, and the rotational movement of the end effector 106 through / relative to the distal planes "DP1" and "DP2" can reach 108 degrees in the clockwise and / or counterclockwise direction.

[0062] refer to Figure 6 , Figure 7 , Fig.19 , Figures 26 to 39 , the grip and wrist hub assembly 150 includes a wrist mechanism 170 and a grip mechanism 180 supported by a mounting plate 152 within the housing assembly 110. The grip and wrist hub assembly 150 further includes a manual release mechanism 190 coupled to the grip mechanism 180 and a linear wiper 187 of a high voltage circuit supported on the mounting plate 152.

[0063] The wrist mechanism 170 of the grip and wrist hub assembly 150 provides a wrist rolling function, which is achieved by a composite shaft assembly 172 extending through the elongated shaft assembly 104. The composite shaft assembly 172 includes a proximal flexible section 172a, a rigid middle section 172b, and a distal flexible section 172c fixed together by, for example, laser welding. The composite shaft assembly 172 can be tubular. The distal flexible section 172c is disposed in the smart portion 106a of the end effector 106 for transmitting rotation through the smart portion 106a. The distal flexible section 172c can include a three-layer stainless steel braided component that flexes radially while effectively transmitting torque axially to the wrist 106b of the end effector 106.

[0064] The wrist mechanism 170 further includes a drive dog pinion 174 (e.g., The wrist mechanism 170 is made of polyphenylene sulfide (e.g., polyphenylene sulfide), the drive pawl pinion has a drive pawl 174a on its first end and a shaft 174b extending distally from the drive pawl 174a. The shaft 174b supports the pinion 174c on the distal end portion of the shaft 174b. The pinion 174c acts as an input gear. The wrist mechanism 170 further includes a double-sided rack 176 (made of, for example, polyetheretherketone), which has a first side rack 176a on a first side of the double-sided rack 176 and a second side rack 176b on a second side of the double-sided rack 176. The wrist mechanism 170 further includes a wrist gear 175 (made of, for example, stainless steel), which is connected to the first end of the proximal flexible section 172a of the composite shaft assembly 172. The wrist gear 175, which functions as an output gear, meshes with the second side rack 176b, and the pinion 174c of the drive dog pinion 174 meshes with the first side rack 176a, wherein rotation of the drive dog pinion 174 rotates the pinion 174c and causes the double-sided rack 176 to translate relative to the drive dog pinion 174 and the wrist gear 175, as indicated by arrow "T". As the double-sided rack 176 translates, the double-sided rack 176 rotates the wrist gear 175 via a gear ratio of, for example, 2:1, thereby rotating the composite shaft assembly 172 and imparting wrist rolling movement to the end effector 106. The first side rack 176a is parallel to the pinion 174c, and the second side rack 176b is disposed at an angle (e.g., 15 degrees, although any suitable angle may be provided) relative to the first side rack 176a. The wrist gear 175 further supports a rotating contact wiper 177 for the high voltage circuit, and the rotating contact wiper may comprise a gold plated stainless steel high voltage material. Fig.19 As seen in FIG. 1 , the drive dog pinion 174 can be rotated up to about 140.4 degrees in a clockwise and / or counterclockwise direction relative to the centerline “CL” of the instrument cartridge assembly 102 to achieve a wrist rotation “WR” of up to about 250 degrees in a clockwise and / or counterclockwise direction of the end effector 106 .

[0065] The gripping mechanism 180 of the gripping and wrist hub assembly 150 includes a drive jaw 182 and a crank 184 supported about the drive jaw 182, both of which may include or be formed of polyetheretherketone. The drive jaw 182 is configured to receive a motor input during manual grip release and to engage with the sterile adapter assembly 300 ( Fig.42) engagement / disengagement. The drive claw 182 includes a drive claw shaft 182a which supports a manual release mechanism 190 thereon. The gripping mechanism 180 further includes a gripping cable 99g which extends through the crank 184. The gripping cable 99g is fixed to the crank 184 by a pin 186 (e.g., stainless steel) and a set screw 186a such that rotation of the drive claw 182 rotates the crank 184 and imparts movement to the gripping cable 99g to achieve a gripping movement "G" of the jaw members 107a, 107b. The gripping mechanism 180 further includes a wire routing cap 188 which is fixed to the mounting plate 152 and constrains the gripping cable 99g and supports the gripping cable 99g within a channel 152a defined in the mounting plate 152. Reference Fig.19 and Fig.33 , when applying high grip load, gripping mechanism 180 provides significant additional stroke due to cable stretching.In fact, driving jaw 182 can rotate (for example, open) up to 20.4 degrees in the counterclockwise direction relative to the center line " CL " of instrument box assembly 102, and rotate up to 29.3 degrees in the clockwise direction (for example, pull the closed direction), to realize the gripping movement " G " of jaw member 107a, 107b.When driving jaw 182 was set to be in zero degree, jaw member 107a, 107b closed, and when driving jaw 182 rotated clockwise beyond zero degree position (up to 29.3 degrees), jaw member 107a, 107b was set to be in over-closed position.In this over-closed position, grip cable 99g stretches.

[0066] The manual release mechanism 190 of the instrument cassette assembly 102 includes a bracket 192, a lock slide 194, a turntable 196, and a spring 198. The lock slide 194 is slidably coupled to the bracket 192 to enable the manual release mechanism 190 to be moved from a first or normal state ( Fig.34 ) moves to the second or released state ( Fig.36 ). To achieve manual release, cover 110d is removed from instrument box assembly 102 to access manual release mechanism 190. Then, lock carriage 194 is pulled out from manual release mechanism 190, as indicated by arrow "D", so that turntable 196, drive claw 182 and bracket 192 are pushed upward by spring 198, as indicated by arrow "F", so that drive claw 182 is recessed in instrument box assembly 102 and disengaged from the motor of instrument drive assembly 20 to prevent low torque actuation of gearbox backdrive and manual release. Turntable 196 then rotates relative to bracket 192, as indicated by arrow "K" (e.g., about 20 degrees), to open the grip of the jaw members 107a, 107b of end effector 106, whereby drive claw 182 rotates concomitantly, as indicated by arrow "H".

[0067] refer to Figure 41 to Figure 45 , the instrument box assembly 102 of the robotic surgical instrument 100 further includes a high voltage circuit 200, which includes a bipolar connector 202, a grip wiper 187, a wrist wiper 177 and sterile adapter bridge contacts 204a, 204b connected together via wires 206 and 208. The high voltage circuit 200 is configured to deliver a high voltage to the end effector 106, for example, to achieve tissue sealing. The sterile adapter bridge contacts 204a, 204b are configured to engage with a sterile adapter bridge 302 supported on a sterile adapter assembly 300, so that electrical energy can be transmitted from, for example, the instrument drive assembly 20 of the removable drive unit 18 through the sterile adapter assembly 300 and to the surgical instrument 100.

[0068] The sterile adapter assembly 300 of the robotic surgical system 10 is configured to be coupled to the proximal portion of the instrument cassette assembly 102 via a latch assembly 160. The latch assembly 160 includes a latch 162 and a latch spring 164 that couples the latches 162 together. The latch 162 includes hooks 162a that are pivotally mounted in the instrument cassette assembly 102 and are positioned to releasably lock the instrument cassette assembly 102 to the sterile adapter assembly 300 via a latch fixture 304 of the sterile adapter assembly 300. Actuation of the latch assembly 1600 causes the latch 162 to pivot, as indicated by arrow "J", thereby releasing the instrument cassette assembly 102 from the sterile adapter assembly 300. Sterile adapter assembly 300 further includes XY locating pins 306 received in locating pin apertures 102 x defined in instrument cartridge assembly 102 , and retaining ribs 308 engaging rotational constraint channels 102 y defined by instrument cartridge assembly 102 to facilitate interface between sterile adapter assembly 300 and surgical instrument 100 .

[0069] The phrases “in one aspect,” “in various aspects,” “in various aspects,” “in some aspects,” or “in other aspects” may each refer to one or more of the same or different aspects according to the present disclosure. A phrase in the form “A or B” means “(A), (B), or (A and B).” A phrase in the form “at least one of A, B, or C” means “(A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).”

[0070] The various aspects disclosed herein may be combined in combinations different from those specifically presented in the specification and drawings. It should also be understood that, according to the examples, certain actions or events of any process or method described herein may be performed in a different order, may be added, combined, or omitted entirely (e.g., all described actions or events may not be necessary to implement these techniques).

[0071] Certain aspects of the present disclosure may include some, all, or none of the advantages described above and / or one or more other advantages apparent to those skilled in the art from the drawings, descriptions, and claims included herein. In addition, although specific advantages have been listed above, various aspects of the present disclosure may include all, some, or none of the listed advantages and / or other advantages not specifically listed above.

[0072] The aspects disclosed herein are examples of the present disclosure and may be embodied in various forms. For example, although some aspects herein are described as being separate, each aspect herein may be combined with one or more of the other aspects herein. The specific structural and functional details disclosed herein should not be interpreted as restrictive, but should be interpreted as the basis of the claims and as a representative basis for teaching those skilled in the art to adopt the present disclosure in various ways in any appropriately detailed structure. Throughout the description of the drawings, the same reference numerals may refer to similar or identical elements.

[0073] Fixing of any components of the disclosed device may be achieved using known fixing techniques, such as welding, crimping, gluing, fastening, etc.

[0074] Those skilled in the art will appreciate that the structures and methods specifically described herein and shown in the accompanying drawings are non-limiting exemplary aspects, and the description, disclosure, and drawings should be understood only as examples of various aspects. Therefore, it should be understood that the present disclosure is not limited to the precise aspects described, and that various other changes and modifications may be achieved by those skilled in the art without departing from the scope or spirit of the present disclosure. In addition, without departing from the scope of the present disclosure, the elements and features shown or described in conjunction with certain aspects may be combined with the elements and features of certain other aspects, and such modifications and variations are also included within the scope of the present disclosure. Therefore, the subject matter of the present disclosure is not limited by the content that has been specifically shown and described.

Claims

1. A surgical instrument for a robotic surgery system, the surgical instrument comprising: End effector; an elongated shaft assembly defining a longitudinal axis and having a distal portion and a proximal portion, the distal portion including a dexterous assembly supporting the end effector, the dexterous assembly being movable relative to the longitudinal axis to move the end effector in different planes; as well as An instrument box assembly is supported on the proximal portion of the elongated shaft assembly, the instrument box assembly includes a cable drive assembly, the cable drive assembly includes a plurality of drive jaw assemblies, each of the plurality of drive jaw assemblies includes a drive jaw pinion, a first rack assembly and a second rack assembly, the first rack assembly includes a first cable, the second rack assembly includes a second cable, the first rack assembly and the second rack assembly are positioned to translate relative to each other in response to rotation of the drive jaw pinion so that the first cable and the second cable move the end effector relative to the longitudinal axis.

2. The surgical instrument according to claim 1, wherein: The first rack assembly includes a first ferrule securing the first cable to a first rack of the first rack assembly.

3. The surgical instrument according to claim 2, wherein: The first rack assembly includes a clamp removably coupled to the first rack to secure the first ferrule to the first rack.

4. The surgical instrument according to claim 1, wherein: The instrument cartridge assembly includes a transition block that directs the first cable and the second cable into the elongated shaft assembly.

5. The surgical instrument according to claim 4, wherein: The transition block includes a plurality of shells secured together to define cable channels therethrough, wherein the cable channels define a longitudinal radial pattern configured to guide the first cable and the second cable into a hub assembly supported on a proximal portion of the elongated shaft assembly.

6. The surgical instrument according to claim 1, wherein: The instrument box assembly includes a wrist mechanism including a double-sided rack, a wrist drive pawl pinion, and a wrist gear. The wrist drive pawl pinion can rotate to translate the double-sided rack, and the wrist gear can rotate in response to the translation of the double-sided rack.

7. The surgical instrument according to claim 6, wherein: The wrist mechanism further includes a composite shaft assembly coupled to the wrist gear.

8. The surgical instrument according to claim 7, wherein: The composite shaft assembly extends through the elongated shaft assembly and includes at least one flexible section and at least one rigid section.

9. The surgical instrument according to claim 6, wherein: The wrist gear is disposed at an angle relative to the wrist drive pawl pinion.

10. The surgical instrument according to claim 1, wherein: The instrument cartridge assembly includes a gripping mechanism actuatable to move the jaw members of the end effector relative to one another and a manual release mechanism coupled to the gripping mechanism.

11. An instrument box assembly for a robotic surgical instrument, the instrument box assembly comprising: a housing assembly supporting the mounting plate; a cable drive assembly supported in the housing assembly and including a drive pawl pinion, a first rack assembly and a second rack assembly meshing with the drive pawl pinion and positioned to translate relative to each other in response to rotation of the drive pawl pinion; a gripping mechanism supported on the mounting plate; as well as A release mechanism is coupled to the gripping mechanism.

12. The instrument box assembly according to claim 11, wherein: The housing assembly includes a cover that is selectively removable from the housing assembly to expose the release mechanism.

13. The instrument box assembly according to claim 12, wherein: The release mechanism includes a lock slide, a bracket, a turntable and a spring, wherein the lock slide is slidably movable relative to the bracket so that the spring can push the bracket and the turntable from a first position to a second position.

14. The instrument box assembly according to claim 13, wherein: The turntable is rotatable relative to the bracket in the second position to operate the gripping mechanism.

15. The instrument box assembly according to claim 11, wherein: The gripping mechanism includes a drive dog and a crank operatively associated with the drive dog, the crank being configured to receive a gripping cable therethrough.

16. The instrument cassette assembly of claim 11, further comprising a high voltage circuit supported within the housing assembly.

17. The instrument cassette assembly of claim 11, further comprising a latch assembly supported by the housing assembly, the latch assembly actuatable to disconnect the sterile adapter assembly from the housing assembly.

18. The instrument cassette assembly of claim 17, wherein: The latch assembly includes a latch spring coupled to a pair of latches configured to secure the housing assembly to the sterile adapter assembly.

19. The instrument cassette assembly of claim 18, further comprising the sterile adapter assembly.

20. A robotic surgery system, comprising: Device drive components; a sterile adapter assembly coupled to the instrument drive assembly; as well as A robotic surgical instrument coupled to the sterile adapter assembly and actuable by the instrument drive assembly, the robotic surgical instrument comprising: an instrument cartridge assembly; an elongated shaft assembly extending from the instrument cartridge assembly; and an end effector supported on a distal end portion of the elongated shaft assembly, the elongated shaft assembly defining a longitudinal axis, the instrument cartridge assembly comprising: a cable drive assembly including a plurality of drive dog assemblies, each of the plurality of drive dog assemblies including a drive dog pinion, a first rack assembly, and a second rack assembly, the first rack assembly and the second rack assembly being positioned to translate relative to each other in response to rotation of the drive dog pinion to move the end effector relative to the longitudinal axis; a gripping mechanism operatively coupled to the end effector and actuatable to move a jaw member of the end effector between an open position, a closed position, and an over-closed position; a manual release mechanism operatively coupled to the gripping mechanism to enable manual movement of the jaw members relative to each other; and A wrist mechanism is operatively coupled to the end effector and is actuatable to rotate the end effector.

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