Torque sensor for robotic surgical systems

Abstract

A surgical system includes an instrument drive assembly supporting a motor assembly and a torque sensor. The torque sensor is coupled to the motor assembly and includes an output coupler, an input coupler, and a shaft assembly connecting the output coupler to the input coupler. The output coupler is configured to engage a surgical instrument. The input coupler is engaged with the motor assembly. The shaft assembly includes an outer shaft mounted on an inner shaft. The inner shaft is movable relative to the outer shaft to apply a first torque, and the inner shaft is movable with the outer shaft to apply a second torque.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 446,393, filed February 17, 2023, the entire contents of which are incorporated herein by reference. Background Art

[0003] Robotic surgical systems are already used in minimally invasive medical procedures. During such procedures, the robotic surgical system is controlled by a surgeon who interacts with a user interface. The user interface allows the surgeon to manipulate the end effector that acts on the patient. The user interface includes input controls or handles that the surgeon can move to control the robotic surgical system.

[0004] The end effectors of a robotic surgical system are positioned at the end of a robotic arm. Each end effector is manipulated by a control drive unit that supports a motor assembly operable to move the end effector about a corresponding axis or to perform a specific function of the end effector (e.g., approximation, pivoting, etc. of the jaws of the end effector). The motor assembly may include a plurality of drive motors, each associated with a corresponding degree of freedom or function of the end effector. The drive motors may be coupled to torque sensors to measure the force applied by the drive motors. Summary of the Invention

[0005] According to one aspect of the present disclosure, a robotic surgical system includes an instrument drive assembly supporting a motor assembly, a surgical instrument operably coupled to the instrument drive assembly, and a torque sensor. The torque sensor is supported between the motor assembly and the surgical instrument. The torque sensor includes an output coupling, an input coupling, and a shaft assembly connecting the output coupling to the input coupling. The shaft assembly includes an outer shaft mounted on an inner shaft. The inner shaft is movable relative to the outer shaft to apply a first torque and movable together with the outer shaft to apply a second torque.

[0006] In various aspects, the first torque may be lower than the second torque. The inner shaft may include an output arm and an input arm separated by a connecting arm. The diameter of the connecting arm may be smaller than the diameters of the output arm and the input arm. The inner shaft may include a first spline supported on the output arm and a second spline supported on the input arm. The outer shaft may define a first spline groove in which the first spline is seated and a second spline groove in which the second spline is seated. The first spline and the first spline groove may be torsionally locked together. The second spline may be configured to slide through the second spline groove when the inner shaft rotates relative to the outer shaft. When the second spline slides through the second spline groove, the inner shaft may be positioned to be angularly displaced relative to the outer shaft. The second spline may engage with a sidewall of the outer shaft that defines the second spline groove. When the second spline engages the sidewall, the outer shaft and the inner shaft may rotate together.

[0007] In various aspects, the robotic surgical system may further include at least one rotation angle sensor coupled to the shaft assembly.

[0008] According to another aspect, the present disclosure relates to a surgical system. The surgical system includes an instrument drive assembly supporting a motor assembly, and a torque sensor coupled to the motor assembly. The torque sensor includes an output coupling configured to engage with a surgical instrument, an input coupling coupled to the motor assembly, and a shaft assembly connecting the output coupling to the input coupling. The shaft assembly includes an outer shaft mounted on an inner shaft. The inner shaft is movable relative to the outer shaft to apply a first torque, and is movable with the outer shaft to apply a second torque.

[0009] According to yet another aspect, the present disclosure relates to a torque sensor for a robotic surgical system. The torque sensor includes an output coupling configured to engage with a surgical instrument; a first rotational angle sensor coupled to the output coupling; an input coupling configured to engage with a motor assembly; a second rotational angle sensor coupled to the input coupling; and a shaft assembly defining a longitudinal axis and connecting the output coupling to the input coupling. The shaft assembly includes an outer shaft mounted on an inner shaft. The inner shaft is movable relative to the outer shaft through a first angular displacement, and the inner shaft is movable relative to the outer shaft through a second angular displacement greater than the first angular displacement. The first rotational angle sensor and the second rotational angle sensor are configured to cooperate with each other to enable the robotic surgical system to determine a torque applied to the robotic surgical system when the shaft assembly rotates about the longitudinal axis.

[0010] Other aspects, features, and advantages will be apparent from the following description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 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 disclosure given above and the detailed description given below, serve to explain the principles of the disclosure. In the drawings:

[0012] Figure 1 is a perspective view of a robotic surgical system for performing a surgical procedure on a patient in accordance with the principles of the present disclosure;

[0013] Figure 2 yes Figure 1 An enlarged perspective view of a torque sensor of a robotic surgical system viewed from an output end of the torque sensor;

[0014] Figure 3 yes Figure 2A perspective view of the torque sensor as viewed from the input end of the torque sensor;

[0015] Figure 4 Yes Figure 2 A perspective view of a torque sensor arranged in FIG. 1 with its parts separated;

[0016] Figure 5 yes Figure 4 The details shown in the figure indicate an enlarged perspective view of the area;

[0017] Figure 6 is a perspective view of the outer shaft of the torque sensor;

[0018] Figure 7 It is along Figure 2 An enlarged cross-sectional view of the torque sensor taken along section line 7-7 shown in FIG.

[0019] Figure 8 It is along Figure 7 An enlarged cross-sectional view of the torque sensor taken along section line 8-8 shown in FIG.

[0020] Figure 9 and Figure 10 are progressively enlarged cross-sectional views of the torque sensor taken along respective section lines 9-9 and 10-10;

[0021] Figure 11 yes Figure 1 A longitudinal cross-sectional view of a drive assembly of a robotic surgical system showing a servo drive motor coupled to another torque sensor according to the principles of the present disclosure; and

[0022] Figure 12 It is taken along the section line 12-12 Figure 11 sectional view of . DETAILED DESCRIPTION

[0023] Various aspects of the present disclosure are described in detail with reference to the accompanying drawings in which like reference numerals represent identical or corresponding elements in each of the several views. As used herein, the term "distal" refers to the portion of a structure that is closer to the patient, while the term "proximal" refers to the portion of a structure that is farther from the patient. As used herein, the term "clinician" refers to a physician, nurse, or other care provider, and may include support personnel and / or equipment operators. As used herein in conjunction with torque ranges, the term "approximately" indicates a tolerance limit defined by plus or minus ten percent of each endpoint of the referenced torque range.

[0024] In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

[0025] Robotic surgical systems have been used in minimally invasive medical procedures. Such procedures may be referred to as "tele-surgery." These robotic surgical systems have one or more surgical instruments removably coupled thereto. Such surgical instruments include, for example, endoscopes, electrosurgical forceps, cutting instruments, staplers, graspers, electrocautery devices, or any other endoscopic or open surgical device. Before or during use of the robotic surgical system, various surgical instruments can be selected and coupled to the robotic surgical system for selective operation of the end effector of the coupled surgical instrument.

[0026] refer to Figure 1 , a robotic surgical system is shown generally at 10. The robotic surgical system 10 employs various robotic elements to assist the clinician and allows for remote (or partially remote) operation of surgical instruments 60 of a surgical instrument system 50 of the robotic surgical system 10. Various controllers, circuitry, 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 during a procedure or treatment in conjunction with the surgical system 10. Such robotic systems may include tele-steerable systems, automated flexible surgical systems, teleflexive surgical systems, tele-articulated surgical systems, wireless surgical systems, modular or selectively configurable teleoperated surgical systems, and the like.

[0027] The robotic surgical system 10 includes a workstation 12 and an instrument cart 14. The instrument cart 14 supports a control drive assembly 100 on a mounting arm assembly 15 that is selectively movable relative to the instrument cart 14. The control drive assembly 100 includes one or more surgical instrument systems 50 mounted on a control drive unit 101 that is supported on the mounting arm assembly 15. The control drive unit 101 is movable relative to the cart 14 and houses an instrument drive assembly 103 for manipulating the surgical instrument systems 50 and / or their individual surgical instruments 60 with the assistance of, for example, one or more computing devices or controllers.

[0028] Surgical instrument system 50 further includes surgical portal assembly 16 configured to receive, for example, surgical instruments 60 for accessing a body cavity "BC" of patient "P." In particular, surgical portal assembly 16 can be inserted into the body cavity "BC" of patient "P" through incision "I."

[0029] Workstation 12 includes an input device 22 in communication with control drive unit 101 for use by a clinician to control surgical portal assembly 16 and surgical instrument system 50 (and surgical instruments 60 of surgical instrument system 50) via instrument drive assembly 103, for example, to perform a surgical procedure on patient "P" while patient "P" is supported on operating table 24. Input device 22 is configured to receive input from the clinician and generate input signals. Input device 22 may also be configured to generate feedback to the clinician. This feedback may be visual, auditory, tactile, or the like. Instrument drive assembly 103 includes a motor assembly 105 having a motor 106 and a torque sensor 107 coupled to motor 106 for determining torque delivered to motor 106. Torque sensor 107 may be in the form of an inline rotary shaft torque sensor configured to eliminate noise by isolating the cantilever effect of the drive actuator of motor assembly 105.

[0030] The torque sensor or transducer of the present disclosure is configured to precisely and accurately measure the force applied by the drive motor. The torque sensor can measure torque when the drive motor is activated and deactivated, so that the torque sensor can measure the pretension in the drive cable and can be used to limit the force experienced by the drive cable. It is conceivable that the torque sensor can be used to provide increased fidelity or accuracy to the control of the drive motor of a surgical device and the feedback of the control of the drive motor of the surgical device, including but not limited to: staplers, wrist or cable control devices, energy-based devices, harmonic devices, rod-actuated devices, graspers, knives, scissors, dissectors, drills, saws (linear or orbital), staplers, hernia anchors and clamping devices, and biopsy devices. It is also conceivable that the torque sensor can be part of a sterile interface module (SIM) for driving endoscope rotation, endoscope manipulation, linear drive mechanisms, screw drive mechanisms, capstan-driven cable tensioning mechanisms, linear-driven cable tensioning mechanisms, gear drive mechanisms, and belt drive mechanisms, etc. It should be understood that the SIM maintains a sterile interface while enabling the transmission of rotational and / or translational forces and electrical signals (eg, power, control, feedback, etc.) between the driving mechanism and the driven mechanism.

[0031] Increased fidelity or precision of control and feedback can be advantageous for controlling the functions of surgical devices, including but not limited to: limiting articulation or positional load limits caused or driven by the system; limiting directional overloads caused or driven by the system; limiting clamping pressure, load, or direction caused or driven by the system; limiting wrist motion or directional load caused or driven by the system; rotating the device, device shaft, or end effector, including driving a belt-driven rotary gear motor; retracting a load by consistent loading or back-driving to confirm proper function; identifying end stops and distal limit positions; limiting driver actuation or load thresholds; firing implantable fasteners, including nails, tacks, or clips, by verifying forming and forming quality; determining anatomical or jaw opening / opening loads; load; determine collision by mechanical shock or heavy load offset or threshold; determine the absence of a reload or implantable object (nail, tack or clip); enable the knife or cutting mechanism back drive; lock the device to prevent firing in the absence of an implantable object; determine the stapler length by the force slope increase corresponding to the device reload length or stroke; the back drive torque enabled by the SIM withdrawal device creates additional resistance on one or more target drives; set staple or cutting load limits to prevent damage or fining to undesirable tissue, bone, ligament, tube suture or other device or implantable fastener; enable harmonic device; monitor for undesirable vibration or inconsistent or irregular back drive load; and calibrate the cannula with the instrument and device. The increase in fidelity or accuracy of control and feedback can be used in various configurations to perform various functions, including but not limited to: confirming that the actuator is properly coupled by axial loads in spring-loaded SIM couplings; identifying proximity to the distal limit of a device or for a mechanical feature or bump; monitoring degradation of actuator efficiency to control or limit device life; limiting load peaks to extend device life; providing additional fidelity for tactile reaction force or vibration feedback for end-user controls; preventing unexpected loads on the device or end effector; limiting tension in belts and cables to extend fatigue life; and providing feedback on devices, rotary encoders, and other components for motor drive current feedback. Initialize, home, calibrate, test, or type confirm a linear encoder, linear encoder, linear load cell, linear switch, or position sensor; monitor vibration or backlash to determine drive coupling wear and degradation; manage end-of-life by monitoring backlash range, belt tensioning backdrive, or belt tensioning vibration; monitor backdrive loads induced on the end effector or device reload; and monitor end effector loads backdriven by the end user or by impact of a patient or other device on the applied load to allow feedback to the end user or to stop the system when load limits are approached or exceeded.

[0032] Now refer to Figures 2 to 10Each torque sensor 107 defines a longitudinal axis "L" and includes an output end portion 107a for coupling to a driven assembly (not explicitly shown) of surgical instrument 60 for operating surgical instrument 60, and an input end portion 107b for coupling to one of the motors 106 of instrument drive assembly 103 for applying a rotational driving force from motor 106 to output end portion 107a of torque sensor 107 via torque sensor 107. Torque sensor 107 is configured to provide fidelity or accuracy regarding control and feedback regarding the driving force from instrument drive assembly 103 to surgical instrument 60. Each torque sensor 107 includes an output ball bearing 108a and an input ball bearing 108b, an output mounting member 110a, an input mounting member 110b, an output coupling 112, an input coupling 114, a primary rotation angle sensor 116, a secondary rotation angle sensor 118 (which may be identical to primary rotation angle sensor 116), and a shaft assembly 120. The primary and secondary rotation angle sensors 116 , 118 are configured to be in electrical communication with one or more controllers (not explicitly shown) of the robotic surgical system 10 for providing angular positioning data from the torque sensor 107 resulting from rotation of the shaft assembly 120 to such controllers.

[0033] The output ball bearing 108a of the torque sensor 107 defines a central opening 108c for receiving the output coupling 112 therethrough. The output ball bearing 108a is configured to facilitate rotation of the output coupling 112 about the longitudinal axis "L" when the shaft assembly 120 rotates about the longitudinal axis "L." Similarly, the input ball bearing 108b of the torque sensor 107 defines a central opening 108d for receiving the input coupling 114 therethrough. Like the output ball bearing 108a, the input ball bearing 108b is configured to facilitate rotation of the input coupling 114 about the longitudinal axis "L" when the input coupling 114 is coupled to the motor assembly 105, thereby rotating the shaft assembly 120 about the longitudinal axis "L."

[0034] Output mounting member 110a defines a central passage 110c therethrough and a plurality of external apertures 110d at spaced locations along the respective outer surfaces of output mounting member 110a and input mounting member 110b. Output mounting member 110a further defines a plurality of internal apertures 110e at spaced locations aligned with, but transversely aligned with, external apertures 110d. The plurality of internal apertures 110e are positioned to communicate with the plurality of external apertures 110d, and each internal aperture is configured to receive a fastener or fastener assembly 111 to secure output mounting member 110a and input mounting member 110b to respective primary and secondary rotational angle sensors 116 and 118. Specifically, angle sensors 116 and 118 are axially and radially secured to the input and output ends of rotating shaft assembly 120, respectively, via mounting members 110b and 110a. The input mounting member 110 b includes the same structure as the output mounting member 110 a and is disposed on an opposite side of each respective torque sensor 107 in a mirrored relationship to the output mounting member 110 a .

[0035] The output coupling 112 of the torque sensor 107 includes a flange 112a disposed at the input end of the output coupling 112 and receivable within a central channel 118a of the secondary rotation angle sensor 118; a first section 112b extending from the flange 112a toward the output end of the output coupling 112 for supporting the output mounting member 110a; and a second section 112c extending from the first section 112b toward the output end of the output coupling 112 and having a smaller diameter than the first section 112b for supporting the output ball bearing 108a. The first section 112b and the second section 112c have smaller diameters than the flange 112a. The outer coupling 112 defines a non-circular channel 112e (e.g., D-shaped) at the output end thereof for receiving a driven member (not shown) of the surgical instrument 60 and for imparting rotation to the driven member when coupled to the driven member. The outer coupling 112 further defines a shaft opening 112f on the input end of the output coupling 112 for receiving the outer coupling end 122h of the shaft assembly 120. The shaft opening 112f can be circular and / or non-circular, but is configured to be fixedly (e.g., non-rotatably) coupled to the outer coupling end 122h of the shaft assembly 120.

[0036] The input connector 114 of the torque sensor 107 includes: a flange 114a, which is on the output end of the input connector 114 and can be received in the central channel 116a of the main rotation angle sensor 116; a first section 114b, which extends from the flange 114a toward the input end of the input connector 114 for supporting the input mounting member 110b; a second section 114c, which extends from the first section 114b toward the input end of the input connector 114 and has a smaller diameter than the first section 114b for supporting the input ball bearing 108b; and a third section 114d, which extends from the second section 114c toward the input end of the input connector 114 and has a smaller diameter than the second section 114c. The input coupling 114 further defines a driver opening 114e (e.g., non-circular) on the input end of the input coupling 114 for receiving the output end of the driver or motor 106, and a shaft opening 114f on the output end of the input coupling 114 for receiving the inner coupling end 122i of the shaft assembly 120. The shaft opening 114f can be circular and / or non-circular, but is configured to be fixedly (e.g., non-rotatably) coupled to the inner coupling end 122i of the shaft assembly 120.

[0037] The shaft assembly 120 of the torque sensor 107 includes an inner shaft 122 and an outer shaft 124 that can be integrated or assembled onto the inner shaft 122. The outer shaft 124 can be a hollow shaft, a sleeve, a tube, or any desired external form that enables the internal form to be matched with the inner shaft 122 or the sensor structure to produce the shaft assembly 120. The shaft assembly 120 provides dual flexure and is configured to provide a wide torque sensing range with a large fatigue torque limit. Advantageously, this dual flexure enables the shaft assembly 120 to be shorter than conventional torque sensors because it eliminates the need to combine the torque sensing range with fatigue torque. In various aspects, the inner shaft 122 can be a one-piece machined component, or it can be a multi-component device joined by any combination of keyed features, a press-fit single flat surface or multiple splines, welding, machined threaded connections, pin connections, or fastened connections (e.g., an array of fasteners). The inner shaft 122 can be machined or manufactured by additive manufacturing. Inner shaft 122 includes an output arm 122a and an input arm 122b coupled together by a connecting arm 122c having a smaller diameter than both output arm 122a and input arm 122b to achieve dual flexure. Specifically, when low-torque flexure is applied to inner shaft 122, connecting arm 122c enables input arm 122b to rotate relative to output arm 122a. Connecting arm 122c is configured to facilitate low-torque flexure along its central portion, where its diameter is smallest, and to facilitate high-torque flexure at its output end, where its diameter is largest and transitions to output arm 122a. Inner shaft 122 further defines an annular channel 122d surrounding the circumference of connecting arm 122c. The output arm 122a further includes a plurality of first splines 122e disposed at spaced locations around the circumference of the output arm 122a and extending longitudinally along the inner shaft 122 for torsionally locking the output arm 122a to the outer shaft 124. The input arm 122b further includes a plurality of second splines 122f disposed at spaced locations around the circumference of the input arm 122b and extending longitudinally along the inner shaft 122. The plurality of first splines 122e and the plurality of second splines 122f are disposed adjacent to the connecting arm 122c at a middle portion 122g of the inner shaft 122, which is disposed between the outer coupling end 122h and the inner coupling end 122i of the inner shaft 122. The outer coupling end 122h and the inner coupling end 122i of the inner shaft 122 may be circular and / or non-circular, but are configured to be fixedly (e.g., non-rotatably) coupled to the shaft opening 112f of the output coupling 112 and the shaft opening 114f of the input coupling 114, for example, via an interference fit, welding, or any other suitable coupling technique. In this regard, the inner shaft 122 is configured to rotate together with the output coupling 112 and the input coupling 114.

[0038] The outer shaft 124 of the shaft assembly 120 includes an output end 124a and an input end 124b, and defines a central lumen 124c. The outer shaft 124 includes a plurality of first spline grooves 124d at spaced locations around the inner surface of the outer shaft 124 at the output end 124a of the outer shaft 124 for receiving the plurality of first splines 122e of the inner shaft 122 and torsionally locking the output end 124a of the outer shaft 124 to the output arm 122a of the inner shaft 122. The outer shaft 124 further includes a plurality of second spline grooves 124e at spaced locations around the inner surface of the outer shaft 124 at the input end 124b of the outer shaft 124. The plurality of second spline grooves 124e are larger than the plurality of first spline grooves 124d, such that the arc length of each of the plurality of second spline grooves 124e around the circumference of the central lumen 124c is greater than the arc length of each of the plurality of first spline grooves 124d around the circumference of the central lumen. The inner shaft 122 and the outer shaft 124 have a non-circular mating profile. Specifically, the outer shaft 124 is configured to receive the inner shaft 122 such that the plurality of first spline grooves 124 d receive the plurality of first splines 122 e of the shaft assembly 120 via an interference fit, and the plurality of second spline grooves 124 e slidably receive the plurality of second splines 122 f via a close fit, sliding fit, to enable partial angular deflection between the inner shaft 122 and the outer shaft 124 for low torque output, and to enable partially locked engagement between the inner shaft 122 and the outer shaft 124 for high torque output.

[0039] The plurality of second splines 122f of the inner shaft 122 are configured to rotate through the plurality of second spline grooves 124e of the outer shaft 124, as indicated by arrow "A," causing the inner shaft 122 to rotate relative to the outer shaft 124 until the sidewalls 122g of the plurality of second splines 122f rotate into engagement with the sidewalls 124g of the plurality of second spline grooves 124e. Notably, this motion is bidirectional, as this rotation can occur in a clockwise and / or counterclockwise direction within a given amount of play (e.g., fatigue-limited deflection) defined by the difference between the arc length of one of the plurality of second spline grooves 124e of the outer shaft 124 and the arc length of one of the plurality of second splines 122f of the inner shaft 122. This relative rotational motion between the inner shaft 122 and the outer shaft 124 provides low-torque deflection, such that the deflection is within a low-torque range. This range can be configured by design. As an example, the low torque range can be set to less than 200mNm. The amount of angular play is determined based on the fatigue strength of the low torque flexure. After the side walls 122h of the plurality of second splines 122f engage the side walls 124g of the plurality of second spline grooves 124e of the outer shaft 124 (engaged on either side of the second spline grooves 124e, depending on the direction of rotation), the inner shaft 122 and the outer shaft 124 rotate together, as indicated by arrow "B", to provide high torque flexure so that the flexure deflection is within the high torque range. Similar to the low torque range, the higher range can be set to, for example, equal to or greater than 200mNm and less than or equal to 1000mNm. Advantageously, the low torque flexure can be more sensitive and more precise without having to worry about plastic deformation or fatigue life issues due to overload. In particular, this dual concentric shaft assembly 120 provides low-range torque measurement and high-range torque measurement with higher fatigue limits. When the inner shaft 122 and / or the outer shaft 124 rotate, the primary rotation angle sensor 116 and / or the secondary rotation angle sensor 118 determine the rotation angle of the inner shaft 122 and / or the outer shaft 124 to determine the amount of rotation and / or torque applied to the torque sensor 107, the amount of torque output from the motor 106, and / or the amount of torque input to the surgical instrument 60. In particular, the primary rotation angle sensor 116 and the secondary rotation angle sensor 118 measure torque by determining the difference in angular deflection measured between the primary rotation angle sensor 116 and the secondary rotation angle sensor 118.

[0040] In various aspects, the outer shaft 124 and / or the inner shaft 122 can further define one or more pin holes 124 f therethrough for receiving one or more locking pins (not shown) for coupling the outer shaft 124 to the inner shaft 122 and / or for providing a fatigue torque lock pin. These locking pins can be provided in addition to or in lieu of the plurality of second splines 122 f and the plurality of second spline grooves 124 e. In various aspects, the inner shaft 122 and / or the outer shaft 124 do not include any pin holes 124 f. The one or more pin holes defined through the inner shaft 122 and / or the outer shaft 124 near the second splines 122 f can be circular and / or elongated (e.g., elliptical) in a clockwise and / or counterclockwise direction around the inner shaft 122 and / or the outer shaft 124 (e.g., having approximately the same arc length as one of the plurality of second spline grooves 124 e) to enable relative rotation between the inner shaft 122 and the outer shaft 124 and low-torque flexure similar to that described above. The outer shaft 124 , which may be in the form of a tube, enables a more precise level of sensor accuracy and sensitivity to the inner shaft by protecting the inner shaft 122 from high torsional load fatigue or plastic deformation overload damage.

[0041] In various aspects, lubrication may be provided between the inner shaft 122 and the outer shaft 124 , such as between the splines 122 f of the inner shaft 122 and the grooves 124 e of the outer shaft 124 , to reduce any friction variation factor between the inner shaft 122 and the outer shaft 124 .

[0042] In various aspects, the primary rotation angle sensor 116 and / or the secondary rotation angle sensor 118 may include any suitable high-resolution angle sensing structure, such as an optical rotary encoder, a magnetic rotary encoder, or the like.

[0043] In various aspects, any of the splines and / or grooves of the disclosed torque sensor 107 can have any suitable mating form, including non-circular shapes and / or configurations, regardless of concentricity, and in some aspects, the splines and / or grooves can be concentric and mirrored in shape and / or configuration. These mating forms can be, but are not limited to, any one or more of a flat surface, a straight knurl, a star form, a leaf form, an elliptical form, a cloverleaf form, a sinusoidal form, a spiral form, a single form, and / or a multi-key form, or a combination thereof.

[0044] refer to Figure 11 and Figure 12In various aspects, a drive assembly 200 for a robotic surgical system 10 includes a torque sensor assembly 201 coupled to a servo drive motor 202. Motor 202 has a servo drive output drive shaft 204. Torque sensor 201 includes a hollow reaction torque sensor 206. Hollow reaction torque sensor 206 includes a proximal reaction torque sensor mounting flange 208 and a distal reaction torque sensor mounting flange 210, which support and enable sliding of a structural sleeve 211 over proximal and distal reaction torque sensor mounting flanges 208, 210. Torque sensor 201 further includes a sensitive and fragile strain gauge structural member region "R." Structural sleeve 211 provides torsional overload protection for the sensitive and fragile strain gauge structural member "R." Torque sensor 201 further includes a motor plate distal mount 214. The torque sensor 201 further includes a device output drive coupling 215 coupled to the servo drive output drive shaft 204. The output drive coupling 215 is further supported by a ball bearing assembly 216.

[0045] The disclosed structures may include any suitable mechanical, electrical and / or chemical components for operating the disclosed systems or components thereof. For example, such electrical components may include, for example, any suitable electrical and / or electromechanical and / or electrochemical circuit systems, which may include or be coupled to one or more printed circuit boards. As will be appreciated, the disclosed computing devices (and / or servers) may include, for example, "controllers," "processors," "digital processing devices," and similar terms, and these terms are used to indicate a microprocessor or central processing unit (CPU). A CPU is an electronic circuit system within a computer that executes the instructions of a computer program by performing basic arithmetic, logic, control, and input / output (I / O) operations specified by the instructions, and includes, by way of non-limiting example, a server computer. In some aspects, the controller includes an operating system configured to execute executable instructions. An operating system is software, for example, including programs and data, that manages the hardware of the disclosed devices and provides services for executing applications used with the disclosed devices. Those skilled in the art will recognize that, by way of non-limiting example, suitable server operating systems include FreeBSD, OpenBSD, Linux, Mac OS X Windows and In some aspects, the operating system is provided by cloud computing.

[0046] In some aspects, the term "controller" may be used to refer to devices that control the transfer of data from a computer or computing device to a peripheral or separate device (and vice versa), and / or mechanical and / or electromechanical devices (e.g., joysticks, knobs, etc.) that mechanically operate and / or actuate peripheral or separate devices.

[0047] In many aspects, the controller includes a storage and / or memory device. A storage and / or memory device is one or more physical devices for temporarily or permanently storing data or programs. In some aspects, the controller includes volatile memory and requires power to maintain the stored information. In various aspects, the controller includes non-volatile memory and retains the stored information when it is not powered. In some aspects, the non-volatile memory includes flash memory. In some aspects, the non-volatile memory includes dynamic random access memory (DRAM). In some aspects, the non-volatile memory includes ferroelectric random access memory (FRAM). In various aspects, the non-volatile memory includes phase change random access memory (PRAM). In some aspects, by way of non-limiting example, the controller is a storage device including a CD-ROM, a DVD, a flash memory device, a disk drive, a tape drive, an optical drive, and cloud computing-based storage. In various aspects, the storage and / or memory device is a combination of devices such as those disclosed herein.

[0048] In various aspects, the memory can be a random access memory, a read-only memory, a magnetic disk memory, a solid-state memory, an optical disk memory and / or another type of memory. In various aspects, the memory can be separated from the controller and can communicate with the processor through a communication bus of a circuit board and / or through a communication cable (such as a serial ATA cable or other type of cable). The memory includes computer-readable instructions that can be executed by the processor to operate the controller. In various aspects, the controller can include a wireless network interface to communicate with other computers or servers. In various aspects, the storage device can be used to store data. In various aspects, the processor can be, but is not limited to, for example, a digital signal processor, a microprocessor, an ASIC, a graphics processing unit ("GPU"), a field programmable gate array ("FPGA") or a central processing unit ("CPU").

[0049] The memory stores suitable instructions and / or applications to be executed by the processor for receiving sensory data (e.g., sensory data from sensor 107). Although shown as part of the disclosed structure, it is also contemplated that the controller can be remote from the disclosed structure (e.g., on a remote server) and accessible to the disclosed structure via a wired or wireless connection. In aspects where the controller is remote, it is contemplated that the controller can be accessible by and connected to multiple structures and / or components of the disclosed system.

[0050] The term "application" may include a computer program designed to perform a function, task, or activity for the benefit of a user. An application may refer to, for example, software that runs locally or remotely, software that runs as a standalone program or in a web browser, or other software that would be understood by those skilled in the art to be an application. An application may run on the disclosed controller or on a user device, including, for example, a mobile device, an IoT device, or a server system.

[0051] In some aspects, the controller includes a display for sending visual information to the user. In various aspects, the display is a cathode ray tube (CRT). In various aspects, the display is a liquid crystal display (LCD). In some aspects, the display is a thin film transistor liquid crystal display (TFT-LCD). In many aspects, the display is an organic light emitting diode (OLED) display. In some aspects, the OLED display is a passive matrix OLED (PMOLED) or an active matrix OLED (AMOLED) display. In many aspects, the display is a plasma display. In some aspects, the display is a video projector. In various aspects, the display is interactive (e.g., has a touch screen) that can detect user interactions / gestures / responses, etc. In some aspects, the display is a combination of devices such as those disclosed herein.

[0052] The controller may include or be coupled to a server and / or a network. As used herein, the term "server" includes "computer server," "central server," "host server," and similar terms to indicate a computer or device on a network that manages the disclosed apparatus, its components, and / or its resources. As used herein, the term "network" may include any network technology, including, for example, a cellular data network, a wired network, a fiber optic network, a satellite network, and / or an IEEE 802.11a / b / g / n / ac wireless network.

[0053] In various aspects, the controller can be connected to a mesh network. As used herein, a "mesh network" is a network topology in which each node relays data for the network. All mesh nodes collaborate to distribute data within the network. This can be applied to both wired and wireless networks. Wireless mesh networks can be considered a type of "wireless ad hoc" network. Therefore, wireless mesh networks are closely related to mobile ad hoc networks (MANETs). Although MANETs are not limited to a specific mesh network topology, wireless ad hoc networks or MANETs can adopt any form of network topology. Mesh networks can use either flooding or routing techniques to relay messages. With routing, a message travels along a path, hopping from one node to another until it reaches its destination. To ensure that all its paths are available, the network must allow continuous connectivity and must use self-healing algorithms (such as shortest path bridging) to reconfigure itself around broken paths. Self-healing allows routing-based networks to operate even when nodes are disconnected or connections become unreliable. As a result, the network is generally very reliable because there is typically more than one path between a source and a destination in the network. This concept can also be applied to wired networks and software interactions. A mesh network in which all nodes are connected to each other is a fully connected network.

[0054] In some aspects, the controller may include one or more modules. As used herein, the term "module" and similar terms are used to refer to a self-contained hardware component of a central server, which in turn includes a software module. In software, a module is a portion of a program. A program is composed of one or more independently developed modules that are not combined until the program is linked. A single module may contain one or more routines or program parts that perform a specific task.

[0055] As used herein, a controller includes a software module for managing various aspects and functions of the disclosed system or components thereof.

[0056] The disclosed structure may also utilize one or more controllers to receive various information and transform the received information to generate an output. The controller may include any type of computing device, computing circuit, or any type of processor or processing circuit capable of executing a series of instructions stored in a memory. The controller may include multiple processors and / or multi-core central processing units (CPUs), and may include any type of processor such as a microprocessor, a digital signal processor, a microcontroller, a programmable logic device (PLD), a field programmable gate array (FPGA), etc. The controller may also include a memory for storing data and / or instructions that, when executed by one or more processors, cause the one or more processors to execute one or more methods and / or algorithms.

[0057] Phrases such as “in one aspect,” “in aspects,” “in various aspects,” “in some aspects,” “in other aspects,” etc. may respectively refer to one or more of the same or different aspects according to the present disclosure. Phrases of the form “A or B” mean “(A), (B), or (A and B).” Phrases of the form “at least one of A, B, or C” mean “(A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).”

[0058] The various aspects disclosed herein may be combined in combinations different from those specifically presented in the description and drawings. It should also be understood that, according to 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., not all described actions or events may be required to implement these techniques).

[0059] 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 one skilled in the art from the drawings, description, and claims included herein. Furthermore, while specific advantages have been enumerated above, various aspects of the present disclosure may include all, some, or none of the enumerated advantages and / or other advantages not specifically enumerated above.

[0060] The various aspects disclosed herein are examples of the present disclosure and can be embodied in various forms. For example, although some aspects herein are described as being separate, each aspect herein can 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 teaching those skilled in the art to adopt the representative basis of the present disclosure in various ways in any appropriately detailed structure. Throughout the description of the figures, the same reference numerals may refer to similar or identical elements.

[0061] Any method, program, algorithm or code described herein can be converted into or expressed as a programming language or computer program. As used herein, the terms "programming language" and "computer program" each include any language for specifying instructions to a computer, and include (but are not limited to) the following languages ​​and their derivatives: Assembler, Basic, Batchfiles, BCPL, C, C+, C++, Delphi, Fortran, Java, JavaScript, machine code, operating system command language, Pascal, Perl, PL1, scripting languages, Visual Basic, the metalanguage that specifies the program itself, and all first, second, third, fourth, fifth or next generation computer languages. Also included are databases and other data models, and any other metalanguages. No distinction is made between languages ​​that are interpreted, compiled, or use compiled and interpreted methods simultaneously. No distinction is made between compiled and source versions of a program. Therefore, reference to a program (wherein a programming language may exist in multiple states (such as source, compiled, object or linked)) is reference to all of these states. Reference to a program may encompass actual instructions and / or the intent of those instructions.

[0062] Fixing of any component of the disclosed device may be achieved using known fixing techniques such as welding, crimping, gluing, fastening, etc.

[0063] Those skilled in the art will appreciate that the structures and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary aspects, and that the specification, 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 can be achieved by those skilled in the art without departing from the scope or spirit of the present disclosure. Additionally, the elements and features illustrated or described in conjunction with certain aspects may be combined with elements and features of certain other aspects without departing from the scope of the present disclosure, 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 what has been specifically illustrated and described.

Claims

1. A robotic surgical system comprising: an instrument drive assembly supporting the motor assembly; a surgical instrument operably coupled to the instrument drive assembly; as well as a torque sensor supported between the motor assembly and the surgical instrument, the torque sensor comprising: Output connector; input connector; and A shaft assembly connects the output coupling to the input coupling, the shaft assembly including an outer shaft mounted on an inner shaft, the inner shaft movable relative to the outer shaft to apply a first torque, and the inner shaft movable with the outer shaft to apply a second torque.

2. The robotic surgery system according to claim 1, wherein: The first torque is lower than the second torque.

3. The robotic surgery system according to claim 2, wherein: The inner shaft includes an output arm and an input arm separated by a connecting arm.

4. The robotic surgery system according to claim 3, wherein: The diameter of the connecting arm is smaller than the diameters of the output arm and the input arm.

5. The robotic surgery system according to claim 2, wherein: The inner shaft includes a first spline supported on the output arm and a second spline supported on the input arm.

6. The robotic surgery system according to claim 5, wherein: The outer shaft defines a first spline groove in which the first spline is seated and a second spline groove in which the second spline is seated.

7. The robotic surgery system according to claim 6, wherein: The first spline and the first spline groove are torsionally locked together, and wherein the second spline is configured to slide through the second spline groove when the inner shaft rotates relative to the outer shaft.

8. The robotic surgery system according to claim 7, wherein: When the second spline slides through the second spline groove, the inner shaft is positioned to be angularly displaced relative to the outer shaft.

9. The robotic surgery system according to claim 8, wherein: The second spline is engageable with a side wall of the outer shaft defining the second spline groove, and wherein the outer shaft and the inner shaft rotate together when the second spline engages the side wall.

10. The robotic surgical system of claim 1, further comprising at least one rotation angle sensor coupled to the shaft assembly.

11. A surgical system comprising: an instrument drive assembly supporting the motor assembly; as well as a torque sensor coupled to the motor assembly and comprising: an output coupling configured to engage a surgical instrument; an input coupling engaged with the motor assembly; and A shaft assembly connects the output coupling to the input coupling, the shaft assembly including an outer shaft mounted on an inner shaft, the inner shaft movable relative to the outer shaft to apply a first torque, and the inner shaft movable with the outer shaft to apply a second torque.

12. The surgical system of claim 11, wherein: The first torque is lower than the second torque.

13. The surgical system of claim 12, wherein: The inner shaft includes an output arm and an input arm separated by a connecting arm.

14. The surgical system of claim 13, wherein: The diameter of the connecting arm is smaller than the diameters of the output arm and the input arm.

15. The surgical system of claim 12, wherein: The inner shaft includes a first spline supported on the output arm and a second spline supported on the input arm.

16. The surgical system of claim 15, wherein: The outer shaft defines a first spline groove in which the first spline is seated and a second spline groove in which the second spline is seated.

17. The surgical system of claim 16, wherein: The first spline and the first spline groove are torsionally locked together, and wherein the second spline is configured to slide through the second spline groove when the inner shaft rotates relative to the outer shaft.

18. The surgical system of claim 17, wherein: When the second spline slides through the second spline groove, the inner shaft is positioned to be angularly displaced relative to the outer shaft.

19. The surgical system of claim 18, wherein: The second spline is engageable with a side wall of the outer shaft defining the second spline groove, and wherein the outer shaft and the inner shaft rotate together when the second spline engages the side wall.

20. A torque sensor for a robotic surgery system, the torque sensor comprising: an output coupling configured to engage a surgical instrument; a first rotation angle sensor coupled to the output coupler; an input coupling configured to engage the motor assembly; a second rotation angle sensor coupled to the input coupler; as well as a shaft assembly defining a longitudinal axis and connecting the output coupling to the input coupling, the shaft assembly comprising an outer shaft mounted on an inner shaft, the inner shaft movable through a first angular displacement relative to the outer shaft, the inner shaft movable through a second angular displacement greater than the first angular displacement relative to the outer shaft, wherein the first rotational angle sensor and the second rotational angle sensor are configured to cooperate with each other to enable the robotic surgical system to determine a torque applied to the robotic surgical system when the shaft assembly is rotated about the longitudinal axis.

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