Robotic surgical assembly including surgical instrument with articulatable end effector

Abstract

A surgical instrument for use in a robotic surgical system includes: an end effector; a housing configured to be operably coupled to the instrument drive unit; a shaft extending distally from the housing; and one or more wave spring coils, the one or more wave spring coils movably coupling the end effector to a portion of the shaft. An articulation cable adjusts pitch and yaw of the end effector relative to the shaft.

Description

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 432,764, filed on Dec. 15, 2022, the entire content of which is incorporated herein by reference. BACKGROUND OF THE INVENTION

[0002] Some surgical robotic systems include a console that supports a surgical robotic arm and a surgical instrument or at least one end effector (e.g., a clamp or grasping tool) mounted to the robotic arm. The robotic arm provides mechanical power for the surgical instrument for operation and movement of the surgical instrument. Each robotic arm may include an instrument drive unit that is operatively connected to the surgical instrument and coupled to the robotic arm via a track. During operation, the robotic arm is moved to a position above the patient, and then the surgical instrument is guided through a trocar or a natural orifice of the patient into a small incision to position the end effector at a working site within the patient's body. The instrument drive unit drives rotation of each corresponding driven member of the attached surgical instrument to perform a surgical treatment. The instrument drive unit may be configured to articulate the end effector in multiple directions to adjust the pitch and / or yaw of the end effector within the surgical site, open / close the jaw members, and / or actuate features of the end effector. SUMMARY OF THE INVENTION

[0003] In one aspect of the present disclosure, a surgical instrument for a surgical robotic system is provided. The surgical instrument includes a housing, a shaft extending distally from the housing, an end effector pivotally coupled to a distal portion of the shaft, a first articulation cable and a second articulation cable, and a first wrist assembly. The first articulation cable and the second articulation cable each have a proximal portion operatively coupled to an actuator and a distal portion fixed to the end effector such that the first articulation cable and the second articulation cable articulate the end effector relative to the shaft in a first plane. The first wrist assembly is positioned between the end effector and the distal portion of the shaft. The first wrist assembly includes a first wave spring coil and a bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil. The bead is configured to maintain the first axial gap.

[0004] In various aspects, the bead may be radially offset from the first articulation cable and the second articulation cable.

[0005] In various aspects, the surgical instrument may include a plurality of beads longitudinally aligned with each other along the length of the first wrist assembly.

[0006] In various aspects, the surgical instrument can further include a third articulation cable and a fourth articulation cable configured to articulate the end effector relative to the shaft in a second plane perpendicular to the first plane.

[0007] In various aspects, the surgical instrument can further include a second wrist assembly positioned along the shaft and including a second wave spring coil and at least one bead positioned within a second axial gap and configured to maintain the second axial gap defined between adjacent first and second turns of the second wave spring coil.

[0008] In various aspects, the first wrist assembly and the second wrist assembly can be positioned adjacent to each other.

[0009] In various aspects, the second wrist assembly can be positioned between a first section and a second section of the shaft, and the first wrist assembly can be positioned distally of the second section of the shaft.

[0010] In various aspects, the first wave spring coil can be radially offset from the second wave spring coil.

[0011] In various aspects, the first wave spring coil can have multiple turns, each turn including a first peak and a second peak diametrically opposed. The second wave spring can have multiple turns, each turn including a first peak and a second peak diametrically opposed that are radially offset from the first and second peaks of the first wave spring coil.

[0012] In various aspects, the first peaks of the first wave spring coil can be axially aligned with each other, the second peaks of the first wave spring coil can be axially aligned with each other, the first peaks of the second wave spring coil can be axially aligned with each other, and the second peaks of the second wave spring coil can be axially aligned with each other.

[0013] In another aspect of the present disclosure, a surgical instrument is provided that includes: a shaft; an end effector pivotally coupled to a distal portion of the shaft; a first articulation cable and a second articulation cable that extend through the shaft and are configured to articulate the end effector to adjust the pitch of the end effector; a third articulation cable and a fourth articulation cable that extend through the shaft and are configured to articulate the end effector to adjust the yaw of the end effector; a first wrist assembly positioned between the end effector and the distal portion of the shaft; and a second wrist assembly positioned along the shaft. The first wrist assembly includes a first wave spring coil having multiple turns. The second wrist assembly includes a second wave spring coil that includes multiple turns.

[0014] In various aspects, the first wrist assembly may include a plurality of beads positioned in respective first axial gaps and configured to maintain the first axial gaps, the first axial gaps being defined between adjacent turns of the multiple turns of the first wave spring coil.

[0015] In various aspects, the second wrist assembly may include a plurality of beads positioned in respective second axial gaps and configured to maintain the second axial gaps, the second axial gaps being defined between adjacent turns of the multiple turns of the second wave spring coil.

[0016] In various aspects, the plurality of beads of the first wrist assembly may be axially aligned with each other, and the plurality of beads of the second wrist assembly may be axially aligned with each other.

[0017] In various aspects, the plurality of beads of the first wrist assembly may be radially offset from the plurality of beads of the second wrist assembly.

[0018] In another aspect according to the present disclosure, a surgical robot system is provided. The surgical robot system includes: a surgical robotic arm; an instrument drive unit configured to be supported on the surgical robotic arm; and a surgical instrument configured to be coupled to and driven by the instrument drive unit. The instrument drive unit includes one or more motors, and the surgical instrument includes: a housing configured to be attached to the instrument drive unit; a shaft extending distally from the housing; an end effector movably coupled to a distal portion of the shaft; a first articulation cable and a second articulation cable, each having a proximal portion operably coupled to the one or more motors of the instrument drive unit and a distal portion fixed to the end effector, such that the first articulation cable and the second articulation cable cause the end effector to articulate relative to the shaft in a first plane in response to actuation of the one or more motors. The surgical instrument further includes a first wrist assembly positioned between the end effector and the distal portion of the shaft. The first wrist assembly includes a first wave spring coil and at least one bead positioned in a first axial gap and configured to maintain the first axial gap defined between adjacent first and second turns of the first wave spring coil.

[0019] In various aspects, the bead(s) may be radially offset from the first articulation cable and the second articulation cable.

[0020] In various aspects, the surgical instrument of the surgical robot system may include a plurality of beads longitudinally aligned with each other along the length of the first wrist assembly.

[0021] In various aspects, the surgical instrument of the surgical robot system may further include a third articulation cable and a fourth articulation cable configured to cause the end effector to articulate relative to the shaft in a second plane perpendicular to the first plane.

[0022] In various aspects, the surgical instrument of the surgical robot system may further include a second wrist assembly positioned along the shaft. The second wrist assembly may include a second wave spring coil and a bead positioned in a second axial gap and configured to maintain the second axial gap defined between adjacent first and second turns of the second wave spring coil.

[0023] Further details and aspects of exemplary embodiments of the present disclosure are described in more detail below with reference to the accompanying drawings.

[0024] As used herein, the terms "parallel" and "perpendicular" are to be understood to include relative configurations that are substantially parallel and substantially perpendicular to true parallelism and true perpendicularity, up to approximately plus or minus 10 degrees. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Embodiments of the present disclosure are described herein with reference to the drawings, in which:

[0026] Figure 1 is a schematic illustration of a robotic surgical system according to the present disclosure;

[0027] Figure 2 is Figure 1 a perspective view of a surgical robotic arm of the robotic surgical system, showing a surgical instrument and an instrument drive unit coupled to the surgical robotic arm;

[0028] Figure 3 shows Figure 2 a side view of a wrist assembly of the surgical instrument shown in

[0029] Figure 4A shows Figure 3 a side view of components of the wrist assembly of

[0030] Figure 4B shows Figure 4A a top view of a spacer of the wrist assembly of

[0031] Figure 4C shows Figure 4A a perspective view of components of the wrist assembly of

[0032] Figure 5A shows Figure 4A a side view of components of a wrist assembly including a plurality of beads of

[0033] Figure 5B shows Figure 2 a side view of another embodiment of a wrist assembly for use with the surgical instrument of

[0034] Figure 6 shows Figure 2 a side view of another embodiment of a wrist assembly incorporated into the surgical instrument of

[0035] Figure 7 shows Figure 2 a side view of a pair of separate wrist assemblies incorporated into the surgical instrument of

[0036] Figure 8 shows Figure 2 a perspective view of two pairs of separate wrist assemblies incorporated into the surgical instrument of

[0037] Figure 9A is a side view showing the wrist assembly of a surgical instrument according to another embodiment; and

[0038] Figure 9B shows Figure 9A a perspective view of the components of the wrist assembly of Detailed Description of the Invention

[0039] Embodiments of the disclosed robotic surgical system and method thereof are described in detail with reference to the accompanying drawings, in which like reference numerals represent the same or corresponding elements in each of the multiple views. As used herein, the term "distal" refers to the part of the robotic surgical system or its components that is further away from the user, while the term "proximal" refers to the part of the robotic surgical system or its components that is closer to the user.

[0040] A robotically controlled surgical instrument may include a wrist assembly that allows the end effector to articulate in multiple directions to change, for example, the pitch or yaw of the end effector. However, the wrist assembly may be prone to wear and tear and may have dead zones. Accordingly, the present disclosure provides a wrist assembly that is implemented as a wave spring coil that allows for reduced joint movement resistance of the end effector, limits wear and tear on the wrist assembly, and reduces dead zones.

[0041] First, referring to Figure 1 and Figure 2 , a robotic surgical system 1 is shown, which generally includes: a plurality of surgical robotic arms 2, 3, each surgical robotic arm having a surgical instrument 10 (e.g., an electrosurgical instrument, a surgical suturing instrument, a surgical clamp, a surgical grasper, etc.) removably coupled thereto; a control device 4 (e.g., a computer); and an operating console 5, which is coupled to the control device 4.

[0042] Continuing to refer to Figure 1 , the operating console 5 includes: a display device 6 that is configured to display two-dimensional and three-dimensional images; and manual input devices 7, 8 that are used to enable a user (e.g., a surgeon) to remotely manipulate the robotic arms 2, 3, as is generally known to those skilled in the art. Each of the robotic arms 2, 3 may include a plurality of members interconnected by joints. The robotic arms 2, 3 may be driven by an electric drive device (not shown) connected to the control device 4. The control device 4 is configured to execute a computer program to activate the electric drive device such that the robotic arms 2, 3 and their instrument drive units 20 and thus the surgical instrument 10 perform movements in accordance with the movements of the manual input devices 7, 8. The control device 4 may also be configured to adjust the movement of the robotic arms 2, 3 and / or the electric drive device.

[0043] The robotic surgical system 1 is configured to perform minimally invasive treatment on a patient "P" lying on an operating table "ST" using a surgical instrument (e.g., surgical instrument 10) coupled to the robotic surgical system 1. In some embodiments of the present disclosure, the robotic surgical system 1 may include more than two robotic arms, which are also coupled to the control device 4 and can be remotely manipulated by the operation console 5. The surgical instrument (e.g., surgical instrument 10) may also be attached to one or more additional robotic arms.

[0044] The surgical instrument 10 includes an end effector 40( Figure 2 ), which is used to grasp tissue and treat the tissue in multiple aspects. The control device 4 can control a plurality of motors (motors 1...n), where each motor is configured to drive the relative rotation of a drive member of a transmission assembly (not labeled) of the surgical instrument 10 to effect the operation and / or movement of the end effector 40 of the surgical instrument 10. It is contemplated that the control device 4 coordinates the enabling of the respective motors (motors 1...n) to coordinate the clockwise or counterclockwise rotation of a drive member (not shown) of the instrument drive unit 20 in order to coordinate the operation and / or movement of the end effector 40. In an embodiment, each motor may be configured to actuate a drive rod or lever arm to effect the operation and / or movement of the end effector 40 of the surgical instrument 10.

[0045] Specifically referring to Figure 2 , the robotic surgical system 1 includes a surgical assembly 12, which includes a robotic arm 2, a surgical instrument 10 coupled to the robotic arm 2, and an instrument drive unit 20 configured to be operably coupled to the surgical instrument 10. The instrument drive unit 20 is configured to provide power to the surgical instrument 10. The instrument drive unit 20 transfers power and actuation force from its motor (not shown) to the transmission assembly of the surgical instrument 10 to ultimately drive the movement of components of the end effector 40, e.g., the movement of a blade 80 (see Figure 4C ) for cutting tissue and the closing and opening of the jaw members of the end effector 40 for grasping tissue, and / or drive the articulation movement of the end effector 40.

[0046] The surgical instrument 10 generally includes a housing 102, a shaft 120 extending distally from the housing 102, and a wrist assembly 30 pivotally coupling an end effector 40 to the shaft 120. The housing 102 is configured to hook, latch, or otherwise attach to a surface of the robotic arm 2, such as the distal end 2a of the robotic arm 2, to secure the surgical instrument 10 to the robotic arm 2. In an embodiment, the housing 102 may be attached to the surgical robotic arm 2 via various fastening engagements (such as clips, latches, friction fit engagements), buttons, various fasteners, and / or bayonet-type connections. The housing 102 houses a transmission assembly that interfaces with the instrument drive unit 20. The transmission assembly converts the motion and torque of the motor of the instrument drive unit 20 into the motion necessary for the following operations: articulating the wrist assembly 30 of the surgical instrument 10, opening and closing the jaw members of the end effector 40, and deploying and retracting the blade 80 to cut tissue grasped between the jaw members of the end effector 40.

[0047] Reference Figure 3 , Figure 4A and Figure 4B , the wrist assembly 30 of the surgical instrument 10 operably couples the end effector 40 to the distal portion 122 of the shaft 120. The wrist assembly 30 may be positioned along the shaft 120 between the distal end 122b and the proximal end 122a of the distal portion 122 of the shaft 120. In various aspects, the wrist assembly 30 may be coupled between the proximal portion of the end effector 40 and the distal end 122b of the shaft 120. The wrist assembly 30 is configured to effect pivotal movement of the end effector 40 relative to the shaft 120 using a series of translatable cables "C1", "C2", "C3", "C4" driven by a motor of the instrument drive unit 20 to adjust the yaw and / or pitch of the end effector 40. The articulation cables "C1", "C2", "C3", "C4" are routed through the wrist assembly 30 and have distal portions fixed to a distal gasket 32 of the wrist assembly 30 and / or proximal portions fixed to an actuator 104 ( Figure 8 ) of the housing 102 of the surgical instrument 10, wherein proximal / distal translation of the articulation cables "C1", "C2", "C3", "C4" results in adjustment of the pitch and yaw of the end effector 40. Each actuator 104 may be connected to a corresponding motor (not shown) of the instrument drive unit 20.

[0048] The wrist assembly 30 includes a pair of adjacent first wrist assemblies 30a and second wrist assemblies 30b, and each wrist assembly includes a respective first wave spring coil 42 and second wave spring coil 44. The first wave spring coil 42 is positioned between the distal gasket 32b and the intermediate gasket 32c, the distal gasket being fixed to the distal end 122b of the shaft 120, and the intermediate gasket being positioned between the first wave spring coil 42 and the second wave spring coil 44. The second wave spring coil 44 is positioned between the proximal gasket 32a and the intermediate gasket 32c, the proximal gasket being fixed to the proximal end 122a of the distal portion 122 of the shaft 120.

[0049] The first wave spring coil 42 can be an integrally formed multi-turn wave spring having multiple turns, each turn having a diametrically opposed first peak 45 and second peak (only the first peak is marked), and a diametrically opposed first valley 47 and second valley (only the first valley is marked). It is contemplated that the first wave spring coil 42 can have more than two peaks and two valleys. The first wave spring coil 42 is configured to compress or deform along a longitudinal axis "A1" extending through the first peak 45 of each turn during proximal translation of the first cable "C1", or along a longitudinal axis (not explicitly marked) extending through the second peak of each turn during proximal translation of the second cable "C2". On the other hand, the first wave spring coil 42 is configured to resist compression or deformation along a longitudinal axis "B1" extending through the first valley 47 of each turn and along a longitudinal axis "B2" extending through the second valley of each turn during proximal translation of the first cable "C1" or the second cable "C2".

[0050] The second wave spring coil 44 may be an integrally formed multi-turn wave spring having a plurality of turns, each turn having diametrically opposed first and second crests 50, 52 and diametrically opposed first and second troughs (only the first trough is labeled). It is contemplated that the second wave spring coil 44 may have more than two crests and two troughs. The second wave spring coil 44 is configured to compress or deform along a longitudinal axis "B1" extending through the first crest 50 of each turn during proximal translation of the third cable "C3", or along a longitudinal axis "B2" extending through the second crest 52 of each turn during proximal translation of the fourth cable "C4". On the other hand, the second wave spring coil 44 is configured to resist compression or deformation along a longitudinal axis "A1" extending through the first trough 54 of each turn and along a longitudinal axis extending through the second trough of each turn during proximal translation of the third cable "C3" or the fourth cable "C4". Thus, the first and second crests of the first wave spring 42 are radially offset (e.g., 90 degrees) from the first and second crests 50, 52 of the second wave spring coil 44 and are coaxial with the corresponding first and second troughs 54 of the second wave spring coil 44. That is, the first wave spring coil 42 and the second wave spring coil 44 are rotationally or radially offset from each other (e.g., 90 degrees) about a central longitudinal axis defined through the first and second wrist assemblies 30a, 30b.

[0051] The distal spacer 32b ( Figure 4B ) defines four channels 46a, 46b, 46c, 46d therethrough that are equidistantly spaced from each other about the circumference of the distal spacer 32b. The intermediate spacer 32c and the proximal spacer 32a also define corresponding channels (not explicitly labeled) therethrough. The first pair of first articulation cables "C1" and the second articulation cable "C2" are slidably positioned in the respective first and second channels 46a, 46b, and the second pair of first articulation cables "C3" and the second articulation cable "C4" are slidably positioned in the respective third and fourth channels 46c, 46d. Each of the cables "C1", "C2", "C3", "C4" is positioned within a central passage 48 defined through the first and second wave spring coils 42, 44.

[0052] Although the wrist assembly 30 is shown as including spacers 32a, 32b, 32c, it is contemplated and envisioned that the wrist assembly may be configured to have more or fewer than three spacers, and as Figure 9A and Figure 9B shown, it is contemplated that the wrist assembly 30 may be configured to have no spacers at all.

[0053] In operation, to cause the end effector 40 to be in theFigure 3 The joint movement is performed in the first direction indicated by arrow "A" to adjust the pitch of the end effector 40 relative to the shaft 120. The first joint movement cable "C1" can be translated proximally or distally, and the second joint movement cable "C2" can be translated in the other of proximally or distally. The translation of the joint movement cables "C1", "C2" can be actuated by one or more motors of the instrument drive unit 20( Figure 2 ). The translation of the cables "C1", "C2" in opposite directions causes the first peak 45 of the first wave spring coil 42 to compress, thereby reducing the axial distance between the peaks, and causes the second peak of the first wave spring coil 42 to expand, thereby increasing the axial distance between the peaks. The first valley 47 and the second valley of the first wave spring coil 42 can be configured to resist axial compression therebetween to facilitate joint movement of the end effector 40 only in the first direction.

[0054] To cause the end effector 40 to perform joint movement in the second direction about the pivot axis indicated by arrow "B" in Figure 3 to adjust the yaw of the end effector 40 relative to the shaft 120, the third joint movement cable "C3" can be translated proximally or distally, and the fourth joint movement cable "C4" can be translated in the other of proximally or distally. The translation of the joint movement cables "C3", "C4" can be actuated by one or more motors of the instrument drive unit 20( Figure 2 ). The translation of the cables "C3", "C4" in opposite directions causes the first peak 50 or the second peak 52 of the second wave spring coil 44 to compress, thereby reducing the axial distance between the peaks, and causes the other of the first peak 50 or the second peak 52 of the second wave spring coil 44 to expand, thereby increasing the axial distance between the peaks. The first valley 54 and the second valley of the second wave spring coil 44 can be configured to resist axial compression therebetween to facilitate joint movement of the end effector 40 only in the second direction. Thus, the first wrist assembly 30a is responsible for adjusting the pitch of the end effector 40, and the second wrist assembly 30b is responsible for adjusting the yaw of the end effector 40. In various aspects, the second wrist assembly 30b can be responsible for adjusting the pitch of the end effector 40, and the first wrist assembly 30a can be responsible for adjusting the yaw of the end effector 40.

[0055] Refer to Figure 4A and Figure 5A, the distal wrist assembly 30a of the surgical instrument 10 may further include a first set of beads 60 respectively positioned in the axial gaps 66 defined between adjacent first peaks 45 of the first wave spring coil 42, and a second set of beads (not clearly labeled) respectively positioned in the axial gaps 66 defined between adjacent second peaks of the first wave spring coil 42. The first set of beads 60 and the second set of beads are incompressible or substantially incompressible to prevent compression / deformation between the first peak 45 and the second peak, thereby maintaining the axial gap 66. However, there are no beads 60 in the axial gap 68 defined between adjacent valleys 47 of the first wave spring coil 42, thereby allowing axial compression / deformation between the axial gaps 68. It is contemplated that the beads 60 may be made of any suitable material such as rubber, plastic, or metal, and may take any suitable shape sufficient to fill or substantially fill the axial gap 66, such as rectangular, square, circular, triangular, etc. As Figure 3 , Figure 4A , Figure 7 and Figure 8 shown, the wrist assembly of the present disclosure may be completely free of beads 60.

[0056] The proximal wrist assembly 30b of the surgical instrument 10 may also include a first set of beads 62 respectively positioned in the axial gaps 70 defined between adjacent first peaks 50 of the second wave spring coil 44, and a second set of beads 64 respectively positioned in the axial gaps 72 defined between adjacent second peaks 52 of the second wave spring coil 44. Thus, the first set of beads 62 and the second set of beads 64 of the proximal wrist assembly 30b prevent compression / deformation between the first peak 50 and the second peak 52 to maintain the axial gaps 70, 72 between the peaks. However, there are no beads in the axial gap 76 defined between adjacent valleys 54 of the second wave spring coil 44, thereby allowing axial compression / deformation between the axial gaps 76. The first set of beads 62 and the second set of beads 64 of the second wave spring coil 44 are radially or rotationally offset (e.g., 90 degrees) from the first set of beads 60 and the second set of beads of the first wave spring coil 42 about the central longitudinal axis. In this way, the distal wrist assembly 30a facilitates articulation of the end effector 40 in a first direction, and the proximal wrist assembly 30b facilitates articulation of the end effector 40 in a second direction.

[0057] Referring to Figure 5B , another embodiment of a wrist assembly 130 for incorporation into the surgical instrument 10 is shown. The wrist assembly 130 is substantially similar to Figure 5A the wrist assembly 30. Accordingly, only the selected differences between the wrist assembly 130 and the wrist assembly 30 will be described in detail herein.

[0058] The wrist assembly 130 includes a single multi-turn wave spring coil 142 positioned between a proximal spacer 132a and a distal spacer 132b. The wrist assembly 130 further includes a first set of beads 160 that are axially aligned with each other and are positioned in alternating first axial gaps defined between adjacent turns of the wave spring coil 142. A second set of beads (not explicitly labeled) is provided that are axially aligned with each other and are positioned in the alternating first axial gaps defined between adjacent turns of the wave spring coil 142. The second set of beads is diametrically opposed to the first set of beads 160.

[0059] The wrist assembly 130 further includes a third set of beads 162 that are axially aligned with each other and are positioned in alternating second axial gaps defined between adjacent turns of the wave spring coil 142. A fourth set of beads 164 is provided that are axially aligned with each other and are positioned in the alternating second axial gaps defined between adjacent turns of the wave spring coil 142. The fourth set of beads 164 is diametrically opposed to the third set of beads 162. The third set of beads 162 and the fourth set of beads 164 are radially or rotationally offset (e.g., 90 degrees) from the first set of beads 160 and the second set of beads about a central longitudinal axis.

[0060] Although the beads 60, 62, 64, 160, 162, 164 are shown as rectangular, it is contemplated and within the scope of the present disclosure that the beads can have any profile, including but not limited to circular, oval, triangular, ovoid, etc.

[0061] Reference Figure 6 , shows Figure 2 an alternative embodiment of the surgical instrument 10 incorporating the wrist assembly 230. The wrist assembly 230 includes two pairs of Figure 5A wrist assemblies 30a, 30b stacked on top of each other.

[0062] Reference Figure 7 , shows Figure 2 the surgical instrument 10 incorporating Figure 3 a first wrist assembly 30a and a second wrist assembly 30b. However, Figure 7The wrist assemblies 30a, 30b of the surgical instrument 10 are separated from each other along the axis 120 and radially offset from each other. More specifically, the first wrist assembly 30a is positioned between the proximal section 125 of the axis 120 and the intermediate section 123 of the axis 120, and the second wrist assembly 30b is positioned between the intermediate section 123 of the axis 120 and the distal end 122b of the axis 122. Thus, the end effector 40 is configured to articulate relative to the intermediate section 123 about the second wrist assembly 30b to adjust one of the pitch or yaw of the end effector 40, and the end effector 40 together with the intermediate section 123 is configured to articulate relative to the proximal section 125 about the first wrist assembly 30a to adjust the other of the pitch or yaw of the end effector 40.

[0063] Reference Figure 8 , shows Figure 2 of the surgical instrument 10 in combination with Figure 3 two pairs of first wrist assemblies 30a and second wrist assemblies 30b. The first or proximal pair of first wrist assemblies 30a and second wrist assemblies 30b are positioned between the proximal section 125 of the axis 120 and the intermediate section 123 of the axis 120, and the second or distal pair of first wrist assemblies 30a and second wrist assemblies 30b are positioned between the intermediate section 123 of the axis 120 and the distal end 122b of the axis 120. Thus, the end effector 40 is configured to articulate relative to the intermediate section 123 about the distal pair of wrist assemblies 30a, 30b to adjust the pitch and / or yaw of the end effector 40, and the end effector 40 together with the intermediate section 123 is configured to articulate relative to the proximal section 125 about the proximal pair of first wrist assemblies 30a and second wrist assemblies 30b to adjust the pitch and / or yaw of the end effector 40.

[0064] According to one aspect of the present disclosure, there is provided a surgical instrument for a surgical robot system, the surgical instrument comprising: a housing; a shaft extending distally from the housing; an end effector pivotally coupled to a distal portion of the shaft; a first articulation cable and a second articulation cable, each having a proximal portion operatively coupled to an actuator and a distal portion secured to the end effector such that the first articulation cable and the second articulation cable articulate the end effector relative to the shaft in a first plane; and a first wrist assembly positioned between the end effector and the distal portion of the shaft. The first wrist assembly includes: a first wave spring coil; and at least one bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil and configured to maintain the first axial gap.

[0065] The at least one bead can be radially offset from the first articulation cable and the second articulation cable.

[0066] The at least one bead can be a plurality of beads longitudinally aligned with each other along the length of the first wrist assembly.

[0067] The surgical instrument can further include a third articulation cable and a fourth articulation cable configured to articulate the end effector relative to the shaft in a second plane perpendicular to the first plane.

[0068] The surgical instrument can further include a second wrist assembly positioned along the shaft. The second wrist assembly can include: a second wave spring coil; and at least one bead positioned in a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.

[0069] The first wrist assembly and the second wrist assembly can be positioned adjacent to each other.

[0070] The second wrist assembly can be positioned between a first section of the shaft and a second section of the shaft, and the first wrist assembly is positioned distally of the second section of the shaft.

[0071] The first wave spring coil can be radially offset from the second wave spring coil.

[0072] The first wave spring coil can have a plurality of turns, each including a first peak and a second peak diametrically opposed, and the second wave spring has a plurality of turns, each including a first peak and a second peak diametrically opposed that are radially offset from the first peak and the second peak of the first wave spring coil.

[0073] The first peaks of the first wave spring coil can be axially aligned with each other, the second peaks of the first wave spring coil can be axially aligned with each other, the first peaks of the second wave spring coil can be axially aligned with each other, and the second peaks of the second wave spring coil can be axially aligned with each other.

[0074] In another aspect of the present disclosure, a surgical instrument is provided, the surgical instrument comprising: a shaft; an end effector pivotally coupled to a distal portion of the shaft; a first articulation cable and a second articulation cable extending through the shaft and configured to articulate the end effector to adjust the pitch of the end effector; a third articulation cable and a fourth articulation cable extending through the shaft and configured to articulate the end effector to adjust the yaw of the end effector; a first wrist assembly positioned between the end effector and the distal portion of the shaft and including a first wave spring coil having a plurality of turns; and a second wrist assembly positioned along the shaft and including a second wave spring coil having a plurality of turns.

[0075] The first wrist assembly may include a plurality of beads positioned in respective first axial gaps and configured to maintain the first axial gaps, the first axial gaps being defined between adjacent turns of the plurality of turns of the first wave spring coil, and the second wrist assembly includes a plurality of beads positioned in respective second axial gaps and configured to maintain the second axial gaps, the second axial gaps being defined between adjacent turns of the plurality of turns of the second wave spring coil.

[0076] The plurality of beads of the first wrist assembly may be axially aligned with each other, and the plurality of beads of the second wrist assembly may be axially aligned with each other.

[0077] The plurality of beads of the first wrist assembly may be radially offset from the plurality of beads of the second wrist assembly.

[0078] The first wrist assembly and the second wrist assembly may be positioned adjacent to each other along the shaft or separated from each other along the shaft.

[0079] In another aspect of the present disclosure, a surgical robot system is provided, the surgical robot system comprising: a surgical robotic arm; an instrument drive unit configured to be supported on the surgical robotic arm, the instrument drive unit including at least one motor; and a surgical instrument configured to be coupled to and driven by the instrument drive unit, the surgical instrument wherein a housing is configured to be attached to the instrument drive unit; proximal portions of each of the first articulation cable and the second articulation cable are operatively coupled to the at least one motor of the instrument drive unit, wherein the first articulation cable and the second articulation cable articulate the end effector relative to the shaft in response to actuation of the at least one motor of the instrument drive unit.

[0080] It will be understood that various modifications can be made to the embodiments disclosed herein. Accordingly, the above description should not be construed as restrictive, but merely as illustrative of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the appended claims.

Claims

1. A surgical instrument for a surgical robot system, the surgical instrument comprising: A housing; A shaft extending distally from the housing; An end effector pivotally coupled to a distal portion of the shaft; A first joint motion cable and a second joint motion cable, each having a proximal portion operably coupled to an actuator and a distal portion fixed to the end effector such that the first joint motion cable and the second joint motion cable cause the end effector to articulate relative to the shaft in a first plane; And A first wrist assembly positioned between the end effector and the distal portion of the shaft, the first wrist assembly comprising: A first wave spring coil; And At least one bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil and configured to maintain the first axial gap.

2. The surgical instrument according to claim 1, wherein, The at least one bead is radially offset from the first joint motion cable and the second joint motion cable.

3. The surgical instrument according to claim 2, wherein, The at least one bead is a plurality of beads longitudinally aligned with each other along the length of the first wrist assembly.

4. The surgical instrument according to claim 1, further comprising a third joint motion cable and a fourth joint motion cable configured to cause the end effector to articulate relative to the shaft in a second plane perpendicular to the first plane.

5. The surgical instrument according to claim 4, further comprising a second wrist assembly positioned along the shaft, the second wrist assembly comprising: A second wave spring coil; And At least one bead positioned in a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.

6. The surgical instrument according to claim 5, wherein, The first wrist assembly and the second wrist assembly are positioned adjacent to each other.

7. The surgical instrument according to claim 5, wherein, The second wrist assembly is positioned between a first section and a second section of the shaft, and the first wrist assembly is positioned distally of the second section of the shaft.

8. The surgical instrument according to claim 5, wherein, The first wave spring coil is radially offset from the second wave spring coil.

9. The surgical instrument according to claim 8, wherein, The first wave spring coil has a plurality of turns, each turn including a first peak and a second peak diametrically opposed, and the second wave spring has a plurality of turns, each turn including a first peak and a second peak diametrically opposed and radially offset from the first peak and the second peak of the first wave spring coil.

10. The surgical instrument according to claim 8, wherein, The first peaks of the first wave spring coil are axially aligned with each other, the second peaks of the first wave spring coil are axially aligned with each other, the first peaks of the second wave spring coil are axially aligned with each other, and the second peaks of the second wave spring coil are axially aligned with each other.

11. A surgical instrument, comprising: A shaft; An end effector pivotally coupled to a distal portion of the shaft; A first joint motion cable and a second joint motion cable, the first joint motion cable and the second joint motion cable extending through the shaft and configured to cause the end effector to perform joint motion to adjust the pitch of the end effector; A third joint motion cable and a fourth joint motion cable, the third joint motion cable and the fourth joint motion cable extending through the shaft and configured to cause the end effector to perform joint motion to adjust the yaw of the end effector; A first wrist assembly, the first wrist assembly being positioned between the end effector and the distal portion of the shaft and including a first wave spring coil, the first wave spring coil including multiple turns; And A second wrist assembly, the second wrist assembly being positioned along the shaft and including a second wave spring coil, the second wave spring coil including multiple turns.

12. The surgical instrument according to claim 11, wherein, The first wrist assembly includes a plurality of beads positioned in respective first axial gaps and configured to maintain the first axial gaps, the first axial gaps being defined between adjacent turns of the multiple turns of the first wave spring coil, and the second wrist assembly includes a plurality of beads positioned in respective second axial gaps and configured to maintain the second axial gaps, the second axial gaps being defined between adjacent turns of the multiple turns of the second wave spring coil.

13. The surgical instrument according to claim 12, wherein, The plurality of beads of the first wrist assembly are axially aligned with each other, and the plurality of beads of the second wrist assembly are axially aligned with each other.

14. The surgical instrument according to claim 13, wherein, The plurality of beads of the first wrist assembly are radially offset from the plurality of beads of the second wrist assembly.

15. The surgical instrument according to claim 11, wherein, The first wrist assembly and the second wrist assembly are positioned adjacent to each other along the shaft or are separated from each other along the shaft.

16. A surgical robot system, comprising: A surgical robotic arm; An instrument drive unit configured to be supported on the surgical robotic arm, the instrument drive unit including at least one motor; And A surgical instrument configured to be coupled to and driven by the instrument drive unit, the surgical instrument including: A housing configured to be attached to the instrument drive unit; A shaft extending distally from the housing; An end effector movably coupled to the distal portion of the shaft; A first joint motion cable and a second joint motion cable, the first joint motion cable and the second joint motion cable each having a proximal portion operably coupled to the at least one motor of the instrument drive unit and a distal portion fixed to the end effector such that the first joint motion cable and the second joint motion cable cause the end effector to perform joint motion relative to the shaft in a first plane in response to actuation of the at least one motor of the instrument drive unit; and A first wrist assembly positioned between the end effector and the distal portion of the shaft, the first wrist assembly including: A first wave spring coil; and At least one bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil and configured to maintain the first axial gap.

17. The surgical robot system according to claim 16, wherein, The at least one bead is radially offset from the first articulation cable and the second articulation cable.

18. The surgical robot system according to claim 17, wherein, The at least one bead is a plurality of beads longitudinally aligned with each other along the length of the first wrist assembly.

19. The surgical robot system according to claim 17, wherein, The surgical instrument further includes a pair of third articulation cables and fourth articulation cables configured to articulate the end effector relative to the shaft in a second plane perpendicular to the first plane.

20. The surgical robot system according to claim 19, wherein, The surgical instrument further includes a second wrist assembly positioned along the shaft, the second wrist assembly including: A second wave spring coil; and At least one bead positioned within a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.

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