Surgical end effector assembly, such as for use in surgical robotic system, and method of manufacturing surgical end effector assembly

Abstract

A method of assembling a surgical end effector, the method comprising: positioning a first proximal identification portion (143a) of a first jaw member (142) between and adjacent to a second and a third proximal identification portion (145a) of a second jaw member (144), such that the cam slots of the first and second indicia portions are partially aligned and define a first channel; inserting the cam head assembly in a first orientation between the first identification portion and the third identification portion wherein a first cam pin portion (818a) extending from a cam block of the cam head assembly is oriented substantially parallel with respect to the identification portions; and rotating the cam head assembly from a first orientation to a second orientation such that the first cam pin portion is oriented substantially perpendicularly relative to the indicia, thereby rotating the first cam pin portion through the first channel and engaging within the cam slots.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 453,771, filed March 22, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to surgical instruments, and more specifically to surgical end effector assemblies for use in surgical robot systems and methods for manufacturing such surgical end effector assemblies. Background Technology

[0004] Robotic surgical systems are increasingly being used in a wide variety of surgical procedures. Some robotic surgical systems include a control console that supports a robotic arm. One or more different surgical instruments can be configured for use with the robotic surgical system and can be selectively mounted onto the robotic arm. The robotic arm provides one or more inputs to the mounted surgical instruments to enable operation of the mounted surgical instruments, such as rotation, articulation, and / or actuation of the mounted surgical instruments.

[0005] End effector assemblies suitable for use with surgical instruments or any other surgical instruments in robotic surgical systems may include gripper-based end effector assemblies. Gripper-based end effector assemblies typically include one or more gripper members that are movable to grip tissue between the gripper member and an opposing structure (e.g., another gripper member). Various actuation mechanisms can be employed to actuate the one or more gripper members, such as cam mechanisms, which involve moving a cam structure through a cam slot to move the one or more gripper members. Summary of the Invention

[0006] As used herein, the term "distal" refers to the portion described as being further away from the operator (whether surgeon or surgical robot), while the term "proximal" refers to the portion described as being closer to the operator. As utilized herein, terms including "generally," "about," "substantially," etc., mean encompassing and including variations of up to and including ±10% (e.g., manufacturing tolerances, material tolerances, usage tolerances and environmental tolerances, measurement variations, design variations, and / or other variations). Furthermore, to the extent consistent, any aspect described herein may be used in conjunction with any or all other aspects described herein.

[0007] According to various aspects of this disclosure, a method for assembling an end effector assembly of a surgical instrument is provided. The method includes positioning a first proximal marking of a first gripper member between and adjacent to a spaced-apart second proximal marking and a third proximal marking of a second gripper member, such that a first cam slot defined through the first proximal marking is partially aligned with a second cam slot defined through the second proximal marking to define a first channel through the first cam slot and the second cam slot. The method further includes inserting a cam head assembly between the first and third proximal markings in a first orientation, wherein a first cam pin portion extending from a cam block of the cam head assembly is oriented substantially parallel to the first, second, and third proximal markings. The method further includes rotating the cam head assembly from the first orientation to a second orientation, in which the first cam pin portion is oriented substantially perpendicular to the first, second, and third proximal markings. This rotation causes the first cam pin portion to rotate through the first channel and engage within the first and second cam slots.

[0008] In one aspect of this disclosure, the first gripper member further includes a fourth proximal marker spaced apart from the first proximal marker. In this aspect, the positioning further includes positioning the fourth proximal marker adjacent to the third proximal marker such that a fourth cam slot defined through the fourth proximal marker is partially aligned with a third cam slot defined through the third proximal marker to define a second channel through the third and fourth cam slots. The cam head assembly includes a second cam pin portion extending from the cam block opposite to the first cam pin portion; and the rotation causes the second cam pin portion to rotate through the second channel and engage within the third and fourth cam slots.

[0009] In another aspect of this disclosure, positioning the fourth proximal sign portion adjacent to the third proximal sign portion includes positioning the fourth proximal sign portion on the inner side of the third proximal sign portion, between the third proximal sign portion and the first proximal sign portion. Alternatively, positioning the fourth proximal sign portion adjacent to the third proximal sign portion includes positioning the fourth proximal sign portion on the outer side of the third proximal sign portion, such that the third proximal sign portion is disposed between the fourth proximal sign portion and the first proximal sign portion.

[0010] In another aspect of this disclosure, the cam block includes a first corner defining a chamfer, and the rotation includes rotating the first corner relative to the first proximal marking portion, with a gap defined by the chamfer between the first corner and the first proximal marking portion.

[0011] In another aspect of this disclosure, the first gripper member includes a first gripper body extending distally from the first proximal marking portion and defining a first tissue contact surface, and the second gripper member includes a second gripper body extending distally from the second proximal marking portion and the third proximal marking portion and defining a second tissue contact surface, and the positioning includes positioning the first tissue contact surface and the second tissue contact surface relative to each other at an angle of about 150 degrees to about 175 degrees.

[0012] In another aspect of this disclosure, after rotation, the method further includes positioning the first proximal marking portion relative to the second and third proximal marking portions such that a first pivot orifice defined by the first proximal marking portion is aligned with a second and third pivot orifice defined by the second and third proximal marking portions. In this aspect, the method further includes inserting a pivot pin through these aligned first, second, and third pivot orifices, thereby pivotally connecting the first and second gripper members to each other.

[0013] In another aspect of this disclosure, the method further includes retaining the pivot pin engaged within the first pivot orifice, the second pivot orifice, and the third pivot orifice, thereby retaining the first jaw member and the second jaw member pivotally engaged with each other.

[0014] In another aspect of this disclosure, the cam head assembly includes a drive tube that engages with the cam block prior to insertion and extends proximally from the cam block.

[0015] In another aspect of this disclosure, the method further includes welding the first cam pin portion to the cam block prior to the insertion.

[0016] In another aspect of this disclosure, the positioning includes inserting the first gripper member and the second gripper member into the fixing device, wherein the insertion and the rotation are performed with the first gripper member and the second gripper member positioned within the fixing device.

[0017] Another method of assembling the end effector assembly of the surgical instrument according to this disclosure includes: positioning a first proximal marking portion and a fourth proximal marking portion of a first gripper member relative to a second proximal marking portion and a third proximal marking portion of a second gripper member such that the first and second proximal marking portions are adjacent to each other and define first channels through corresponding first and second cam slots of the first and second proximal marking portions; and positioning the third and fourth proximal marking portions are adjacent to each other and define second channels through corresponding third and fourth cam slots of the third and fourth proximal marking portions. In this configuration, the two innermost proximal marking portions of the first, second, third, and fourth proximal marking portions define a distance between them. The method further includes inserting a cam head assembly between the two innermost proximal marking portions, the cam head assembly including a cam block and a cam pin engaging the cam block such that a first cam pin portion and a second cam pin portion extend from opposite sides of the cam block. The length defined by the cam pin is greater than the distance between the two innermost proximal marking portions. The method further includes rotating the cam head assembly from a first orientation to a second orientation, thereby rotating the cam pin such that the first cam pin portion and the second cam pin portion move through corresponding first and second channels, wherein the first cam pin portion engages in the first cam slot and the second cam slot, and the second cam pin portion engages in the third cam slot and the fourth cam slot, thereby engaging the first gripper member and the second gripper member with the cam head assembly.

[0018] In one aspect of this disclosure, the cam block defines a first diagonal dimension that is greater than the distance between the two innermost proximal markings, and a corresponding second diagonal dimension that is less than the distance between the two innermost proximal markings, thereby defining a unidirectional rotation direction for rotation.

[0019] In another aspect of this disclosure, the method further includes welding the cam pin into the cam block prior to positioning.

[0020] In another aspect of this disclosure, the positioning includes inserting the first gripper member and the second gripper member into the fixing device, wherein the insertion and the rotation are performed with the first gripper member and the second gripper member positioned within the fixing device.

[0021] In another aspect of this disclosure, the method includes: after rotation, positioning the first gripper member and the second gripper member such that pivot orifices defined by the first gripper member and the second gripper member are aligned with each other, and inserting a pivot pin through the aligned pivot orifices to pivotally connect the first gripper member and the second gripper member to each other.

[0022] The end effector assembly of the surgical instrument provided according to this disclosure includes a first gripper member, a second gripper member, a pivot, and a cam drive assembly. The first gripper member includes a first pair of proximal markings and a distal body extending distally from the first pair of proximal markings and defining a first tissue contact surface. The proximal markings of the first pair of proximal markings define a lateral distance therebetween. The second gripper member includes a second pair of proximal markings and a distal body extending distally from the second pair of proximal markings and defining a second tissue contact surface. The first pair of proximal markings are disposed between the proximal markings of the second pair of proximal markings. The pivot pivotally connects the first pair of proximal markings and the second pair of proximal markings to each other such that at least one of the first tissue contact surface or the second tissue contact surface can pivot relative to the other of the first tissue contact surface between a spaced-apart position and a proximal position to hold tissue therebetween. The cam drive assembly includes a cam block and a cam pin fixed relative to the cam block. A cam block is disposed between the proximal marking portions of the first pair of proximal marking portions, wherein the cam pin operably engages a cam slot defined within the proximal marking portions of the first pair of proximal marking portions and the second pair of proximal marking portions. The cam block has a rectangular configuration defining a first diagonal lateral dimension and a second diagonal lateral dimension opposite to the first diagonal lateral dimension. The first diagonal lateral dimension is greater than the lateral distance, and the second diagonal lateral dimension is less than the lateral distance.

[0023] In another aspect of this disclosure, the first diagonal lateral dimension extends between the first and second corners of the cam block, and the second diagonal lateral dimension extends between the first and second chamfers defined in the cam block.

[0024] In another aspect of this disclosure, the cam pin extends through the cam block, and the cam block defines an orifice extending perpendicularly to the cam pin. The cam pin is welded to the cam block within this orifice.

[0025] In another aspect of this disclosure, the cam drive assembly further includes a proximal extension configured to engage the drive tube with the cam block.

[0026] Another end effector assembly of the surgical instrument provided according to this disclosure includes a first gripper member, a second gripper member, a pivot, and a cam drive assembly. The first gripper member includes a pair of first proximal markings and a distal body extending distally from the pair of first proximal markings and defining a first tissue contact surface. The second gripper member includes at least one second proximal marking and a distal body extending distally from the at least one second proximal marking and defining a second tissue contact surface. The pivot pivotally connects the pair of first proximal markings and the at least one second proximal marking to each other such that at least one of the first or second tissue contact surfaces can pivot relative to the other of the first or second tissue contact surfaces between a spaced-apart position and a proximal position to hold tissue therebetween. The cam drive assembly includes a cam block and a cam pin fixed relative to the cam block. The cam block is disposed between the first proximal markings of the pair of first proximal markings, wherein the cam pin operably engages a cam slot defined within the first proximal markings of the pair of first proximal markings. The cam block includes a first diagonal defined between a pair of chamfered corners opposite each other diagonally.

[0027] In one aspect of this disclosure, the first proximal marking portions of the pair of first proximal marking portions define a lateral distance between them, and the first diagonal defines a diagonal lateral distance smaller than the lateral distance.

[0028] In another aspect of this disclosure, the cam block further includes a second diagonal line opposite to the first diagonal line and defined between a pair of diagonally opposite, chamfer-free corners.

[0029] In another aspect of this disclosure, the at least one second proximal marking portion defines a cam slot. In this respect, the cam pin operatively engages within the cam slot of the at least one second proximal marking portion.

[0030] In another aspect of this disclosure, the at least one second proximal identifier includes a pair of second proximal identifiers. In this aspect, the pair of first proximal identifiers may be disposed between the second proximal identifiers in the pair of second proximal identifiers.

[0031] Details of one or more aspects of this disclosure are set forth in the following figures and description. Other features, objects, and advantages of the technology described in this disclosure will become clear from the specification, figures, and claims. Attached Figure Description

[0032] The various aspects and features of this disclosure are described below with reference to the accompanying drawings, wherein similar reference numerals denote the same or corresponding elements in each of the plurality of views.

[0033] Figure 1 This is a schematic diagram of a surgical robot system based on various aspects of this disclosure, which includes a control tower, a console, and one or more surgical robotic arms;

[0034] Figure 2 Based on all aspects of this disclosure Figure 1 A 3D view of the surgical robotic arm of a surgical robot system;

[0035] Figure 3 This is a perspective view of the installation arm based on various aspects of this disclosure, the installation arm having... Figure 1 Surgical robotic arms in surgical robot systems;

[0036] Figure 4 Based on all aspects of this disclosure Figure 1 A schematic diagram of the computer architecture of a surgical robot system;

[0037] Figure 5 This is a perspective view of a surgical instrument provided in this disclosure, configured for installation in a surgical robot system (e.g., Figure 1 On the robotic arm of a surgical robot system;

[0038] Figure 6A and Figure 6B They are Figure 5 A frontal and rear stereoscopic view of the proximal portion of the surgical instrument, with the outer shell removed;

[0039] Figure 7 yes Figure 5 A frontal stereoscopic view of the proximal portion of the surgical instrument, with the outer shell and additional internal components removed;

[0040] Figure 8A and Figure 8B They are Figure 5 Side and top views of the end effector assembly of a surgical instrument;

[0041] Figure 9A yes Figure 5 A three-dimensional view of the cam drive assembly of a surgical instrument;

[0042] Figure 9B yes Figure 9A Rear view of the cam head assembly of the cam drive assembly;

[0043] Figures 10A to 10D yes Figure 9A Cam drive assembly and Figure 8A and Figure 8B A progressive illustration of the assembly of the gripper components of the end effector assembly;

[0044] Figure 11 This is a flowchart of the assembly method based on this disclosure;

[0045] Figure 12 yes Figure 8A and Figure 8B A top perspective view of the gripper component of the end effector assembly, the gripper component being positioned in a fixing device provided according to this disclosure to facilitate... Figure 9A The assembly of the cam drive assembly and the gripper assembly;

[0046] Figure 13 yes Figure 12 A side view of a portion of the fixing device. Figure 8A and Figure 8B The gripper component of the end effector assembly is positioned within the fixing device to facilitate... Figure 9A The assembly of the cam drive assembly and the gripper assembly; and

[0047] Figure 14 This is a top perspective view of another fixing device provided in this disclosure, which is configured to facilitate... Figure 8A and Figure 8B Assembly of the end effector components. Detailed Implementation

[0048] This disclosure provides surgical end effector assemblies and methods of manufacturing such surgical end effector assemblies. As described in detail below, the surgical end effector assembly of this disclosure can be configured for use with a surgical robotic system, which may include, for example, a surgical console, a control tower, and one or more mobile trolleys having a surgical robotic arm coupled to a mounting arm. The surgical console receives user input via one or more interface devices, which is interpreted by the control tower as movement commands for moving the surgical robotic arm. The surgical robotic arm includes a controller configured to process the movement commands and generate torque commands for actuating one or more actuators of the robotic arm, which in turn move the robotic arm in response to the movement commands. Although described below in conjunction with a surgical robotic system, aspects and features of this disclosure are also suitable for use with handheld surgical instruments (e.g., endoscopic instruments and / or open instruments).

[0049] refer to Figure 1 The surgical robot system 10 includes a control tower 20 connected to components of the surgical robot system 10, including a surgical console 30 and one or more robotic arms 40. Each robotic arm 40 includes surgical instruments 50, 51 removably coupled thereto. Each robotic arm 40 is also coupled to a movable trolley 60.

[0050] One or more surgical instruments 50, 51 may be configured for use in minimally invasive and / or open surgical procedures. In various aspects, one of the surgical instruments 51 may be an endoscope (e.g., an endoscopic camera 51) configured to provide video feed to a clinician. In various aspects, one of the surgical instruments 50 may be a gripper-based surgical instrument, such as an electrosurgical forceps, ultrasonic sealing and cutting instrument, surgical suture instrument, surgical clamp applicator, surgical holder, or any other suitable surgical instrument including an end effector assembly having one or more gripper members. Additionally or alternatively, one of the surgical instruments 50, 51 may include an excitable element configured to treat tissue (e.g., a monopolar element, bipolar element, thermal element, microwave element, etc.). Suction and / or irrigation functions for the surgical instruments 50, 51 are also contemplated. Other suitable surgical instruments 50, 51 may also be provided.

[0051] As described above, the endoscopic camera 51 can be configured to capture video of the surgical site. In this respect, the surgical console 30 includes a first display 32 and a second display 34, the first display showing the video feed of the surgical site provided by the endoscopic camera 51, and the second display showing a user interface for controlling the surgical robot system 10. The first display 32 and the second display 34 can be touchscreen graphical user interface (GUI) displays that allow receiving various user inputs.

[0052] The surgical console 30 also includes multiple user interface devices, such as a foot pedal 36 and a pair of handle controllers 38a and 38b, which are used by clinicians to remotely control the robotic arm 40. The surgical console further includes an armrest 33 for supporting the clinician's arm when operating the handle controllers 38a and 38b.

[0053] The control tower 20 includes a display 23, which may be a touchscreen GUI and provide output to various GUIs. The control tower 20 also serves as an interface between the surgical console 30 and one or more robotic arms 40. Specifically, the control tower 20 is configured to control the robotic arms 40, for example, to move the robotic arms 40 and corresponding surgical instruments 50, 51 based on a set of programmable instructions and / or input commands from the surgical console 30, in such a way that the robotic arms 40 and surgical instruments 50, 51 perform a desired sequence of movements in response to inputs from the foot pedal 36 and / or the handle controllers 38a and 38b.

[0054] Each of the control tower 20, surgical console 30, and robotic arm 40 includes a corresponding computer 21, 31, or 41. Computers 21, 31, and 41 are interconnected using any suitable communication network based on wired or wireless communication protocols. As used herein, the term "network," whether plural or singular, refers to a data network, including but not limited to the Internet, intranet, wide area network, or local area network, and is not limited to the full range of communication networks as defined in this disclosure. Suitable protocols include, but are not limited to, Transmission Control Protocol / Internet Protocol (TCP / IP), Datagram Protocol / Internet Protocol (UDP / IP), and / or Datagram Congestion Control Protocol (DCCP). Wireless communication can be implemented via one or more wireless configurations, such as radio frequency, optical, Wi-Fi, etc. (An open wireless protocol for exchanging data from fixed and mobile devices over short distances using short-length radio waves, creating personal area networks (PANs), and / or (A set of specifications for advanced communication protocols using small, low-power digital radios based on the IEEE 122.15.4-2003 standard for Wireless Personal Area Networks (WPANs).)

[0055] Computers 21, 31, and 41 may include any suitable processor operatively connected to memory, which may include one or more of volatile, non-volatile, magnetic, optical, quantum, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM), or flash memory. The processor may be any suitable processor (e.g., control circuitry) adapted to perform operations, calculations, and / or instruction sets, including but not limited to hardware processors, field-programmable gate arrays (FPGAs), digital signal processors (DSPs), central processing units (CPUs), microprocessors, quantum processors, and combinations thereof. Those skilled in the art will understand that a processor may be replaced by any logical processor (e.g., control circuitry) adapted to perform algorithms, calculations, and / or instruction sets.

[0056] refer to Figure 2 Each robotic arm 40 may include multiple links 42a, 42b, 42c, which are interconnected at joints 44a, 44b, 44c. Joint 44a is configured to secure the robotic arm 40 to a movable trolley 60 and define a first longitudinal axis. (Reference) Figure 3The movable trolley 60 includes a lift 61 and a mounting arm 62 that provides a base for mounting the robotic arm 40. The lift 61 allows vertical movement of the mounting arm 62. The movable trolley 60 also includes a display 69 for displaying information about the robotic arm 40. The mounting arm 62 includes a first link 62a, a second link 62b, and a third link 62c that provide lateral maneuverability of the robotic arm 40. The links 62a, 62b, and 62c are interconnected at joints 63a and 63b, each joint including an actuator (not shown) for rotating links 62a and 62b relative to each other and relative to link 62c. In particular, links 62a, 62b, and 62c are movable in their corresponding parallel lateral planes, thereby allowing the robotic arm 40 to extend relative to a patient (e.g., an operating table). In various respects, the robotic arm 40 can be coupled to an operating table (not shown). The mounting arm 62 includes a control device 65 for adjusting the movement of the connecting rods 62a, 62b, 62c and the elevator 61.

[0057] The third link 62c includes a rotatable base 64 having two degrees of freedom. Specifically, the rotatable base 64 includes a first actuator 64a and a second actuator 64b. The first actuator 64a is rotatable about a first fixed arm axis perpendicular to the plane defined by the third link 62c, and the second actuator 64b is rotatable about a second fixed arm axis transverse to the first fixed arm axis. The first actuator 64a and the second actuator 64b allow for full three-dimensional orientation of the robotic arm 40.

[0058] Same reference Figure 2 The robotic arm 40 also includes a holder 46 that defines a second longitudinal axis and is configured to receive an instrument drive unit (IDU) 52. Figure 1 IDU 52 is configured as an actuation mechanism coupled to surgical instrument 50 and camera 51 and is configured to move (e.g., rotate) and actuate instrument 50 and / or camera 51. IDU 52 transmits actuating force from its actuator to surgical instrument 50 to actuate components of surgical instrument 50 (e.g., end effector). Holder 46 includes sliding mechanism 46a configured to move IDU 52 along a second longitudinal axis defined by holder 46. Holder 46 also includes joint 46b that rotates holder 46 relative to link 42c.

[0059] The robotic arm 40 further includes multiple manual override buttons 53, which are located in the IDU 52 (see [link]). Figure 1 It is mounted on arm 62 and can be used in manual mode. For example, a clinician can press one of these buttons 53 to move the component associated with that button 53. Figure 1 ).

[0060] Joints 44a and 44b include actuators 48a and 48b, which are configured to drive joints 44a, 44b, and 44c relative to each other via a series of belts 45a and 45b or other mechanical linkages (such as drive rods, cables, levers, etc.). In particular, actuator 48a is configured to rotate the robotic arm 40 about a longitudinal axis defined by link 42a.

[0061] Actuator 48b of joint 44b is connected to joint 44c via belt 45a, and joint 44c is in turn connected to joint 46c via belt 45b. Joint 44c may include a transfer case connecting belts 45a and 45b, such that actuator 48b is configured to rotate each of links 42b, 42c and retainer 46 relative to each other. More specifically, links 42b, 42c and retainer 46 are passively connected to actuator 48b, which forces rotation about a distal center point “P” located at the intersection of a first axis defined by link 42a and a second axis defined by retainer 46. Thus, actuator 48b controls the angle “θ” between the first and second axes, thereby allowing orientation of surgical instrument 50. Since the links 42a, 42b, 42c and the retainer 46 are interconnected via belts 45a and 45b, the angle between the links 42a, 42b, 42c and the retainer 46 is also adjusted to achieve the desired angle "θ". In various respects, some or all of the joints 44a, 44b, 44c may include actuators to eliminate the need for mechanical linkages.

[0062] refer to Figure 4 , combined Figures 1 to 3Each of the computers 21, 31, and 41 of the surgical robot system 10 may include multiple controllers, which may be implemented in hardware and / or software. The computer 21 of the control tower 20 includes a controller 21a and a safety observer 21b. The controller 21a receives data from the computer 31 of the surgical console 30 regarding the current position and / or orientation of the handle controllers 38a and 38b, as well as the state of the foot pedal 36 and / or other inputs. The controller 21a processes these input positions to determine desired drive commands for each joint of the robotic arm 40 and / or the IDU 52, and transmits these desired drive commands to the computer 41 of the robotic arm 40. The controller 21a also receives the actual joint angles and uses this information to determine force feedback commands, which are transmitted back to the computer 31 of the surgical console 30 to provide tactile feedback or other feedback via the handle controllers 38a and 38b. The handle controllers 38a and 38b include one or more tactile feedback vibration devices that output tactile feedback, although visual feedback, auditory feedback, and / or other feedback are also envisioned. The safety observer 21b performs validity checks on the data entering and exiting the controller 21a, and if an error is detected in the data transmission, it notifies the system fault handler to put the computer 21 and / or the surgical robot system 10 into a safe state.

[0063] Computer 41 includes multiple controllers: a trolley main controller 41a, an arm mounting controller 41b, a robotic arm controller 41c, and an IDU controller 41d. The trolley main controller 41a receives and processes joint commands from controller 21a on computer 21 and transmits them to the arm mounting controller 41b, robotic arm controller 41c, and IDU controller 41d. The trolley main controller 41a also manages instrument exchanges and the overall status of the movable trolley 60, robotic arm 40, and IDU 52. The trolley main controller 41a transmits the actual joint angles back to controller 21a.

[0064] The mounting arm controller 41b controls each of joints 63a and 63b, as well as the rotatable base 64 of the mounting arm 62, and calculates the desired motor movement command (e.g., motor torque) for the pitch axis. The mounting arm controller 41b also controls the brakes. The robotic arm controller 41c controls each joint 44a and 44b of the robotic arm 40 and calculates the desired motor torque required for gravity compensation, friction compensation, and closed-loop position control of the robotic arm 40. The robotic arm controller 41c calculates the movement command based on the calculated torque. The calculated motor command is then transmitted to one or more of the actuators 48a and 48b in the robotic arm 40. The actual joint position is transmitted back to the robotic arm controller 41c by the actuators 48a and 48b.

[0065] IDU controller 41d receives the desired joint angles (such as wrist angle and gripper angle) from surgical instrument 50 and calculates the desired current of the motor in IDU 52. IDU controller 41d calculates the actual angles based on the motor position and transmits these actual angles back to trolley main controller 41a.

[0066] Regarding the control of the robotic arm 40, firstly, the posture of the handle controller (e.g., handle controller 38a) controlling the robotic arm 40 is transformed into the desired posture of the robotic arm 40 via a hand-eye transformation function executed by controller 21a. The hand-eye function is implemented in software that can be executed by controller 21a or any other suitable controller of the surgical robot system 10. The posture of handle controller 38a can be implemented as a coordinate position and roll-pitch-yaw (“RPY”) orientation relative to a coordinate reference system (fixed to the surgical console 30). The desired posture of the instrument 50 is relative to a fixed system on the robotic arm 40. The posture of handle controller 38a is then scaled by a scaling function executed by controller 21a. In various respects, the scaling function reduces the coordinate position and enlarges the orientation. Furthermore, controller 21a also executes a clutch function, thus disengaging handle controller 38a from the robotic arm 40. Specifically, if certain movement limits or other thresholds are exceeded, controller 21a will stop transmitting movement commands from handle controller 38a to robotic arm 40, and essentially acts like a virtual clutch mechanism, for example, limiting the mechanical input from affecting the mechanical output.

[0067] The desired posture of the robotic arm 40 is based on the posture of the handle controller 38a and then transmitted via an inverse kinematics function executed by the controller 21a. The inverse kinematics function calculates the angles of the joints 44a, 44b, and 44c of the robotic arm 40, realizing the scaled and adjusted posture input from the handle controller 38a. The calculated angles are then transmitted to the robotic arm controller 41c, which includes a joint axis controller with a proportional-derivative (PD) controller, a friction estimator module, a gravity compensator module, and a dual-sided saturation block configured to limit the command torque of the motors of joints 44a, 44b, and 44c.

[0068] Go to Figures 5 to 7 The surgical instrument 110 provided in this disclosure is configured to work with the surgical robot system 10. Figure 1 Used together, the surgical instrument generally includes a housing 120, a shaft 130 extending distally from the housing 120, an end effector assembly 140 extending distally from the shaft 130, and an actuation assembly 1100 disposed within the housing 120 and operatively associated with the end effector assembly 140. The instrument 110 is detailed herein as being configured to work with a surgical robot system (e.g., surgical robot system 10). Figure 1 Articulated electrosurgical forceps used together. However, the aspects and features of the device 110 provided in accordance with this disclosure, as detailed below, are equally applicable to use with other suitable surgical instruments (e.g., clamps, sutures, clamp applicators) and / or for use in other suitable surgical systems (e.g., motorized systems, other power-driven systems, and / or manually actuated surgical systems (including handheld instruments)).

[0069] For details, please refer to the following: Figure 5 The housing 120 of the device 110 includes a first body portion 122a and a second body portion 122b, and a proximal panel 124, which cooperate to enclose the actuation assembly 1100 therein. The proximal panel 124 includes a through-hole defined therein, through which the input connectors 1110 to 1140 of the actuation assembly 1100 are located. Figure 6B ) extends through these through-holes. A pair of latch levers 126 extend outward from opposite sides of the housing 120. Figure 5 Only one of them is shown in the image) enables the housing 120 to be integrated with a surgical robot system (e.g., surgical robot system 10). Figure 1 The robotic arm can be releasably engaged. A window 128 defined through housing 120 allows thumbwheel 1440 to extend through so that thumbwheel 1440 can be manually operated from outside housing 120, thereby allowing manual opening and closing of end effector assembly 140.

[0070] Also refer to Figures 6A to 7 Multiple electrical contacts 190 extend through one or more orifices defined by the proximal panel 124 to engage the instrument 110 with the surgical robot system 10. Figure 1 Electrical communication is achieved between the instrument 110 and the surgical robot system via the robotic arm, thereby enabling communication of data, control, and / or power signals between them, for example. As an alternative to the electrical contacts 190 extending through the proximal panel 124, other suitable transmitter, receiver, and / or transceiver components capable of enabling communication of data, control, and / or power signals are also envisioned, for example, through the use of RFID, Alternatively, it may be communicated via any other suitable wired, wireless, contact, or contactless communication method. At least some of the electrical contacts 190 are electrically connected to electronic devices 192 mounted on the inner side of the proximal panel 124, for example, within the housing 120. Electronic devices 192 may include, for example, storage devices, communication devices (including suitable input / output components), and a CPU containing memory and a processor. Electronic devices 192 may be mounted on a circuit board or otherwise configured, such as as a chip.

[0071] The storage device of electronic device 192 stores information related to the surgical instrument, such as: part number, e.g., SKU number; manufacturing date; manufacturing location, e.g., location code; serial number; batch number; usage information; setting information; adjustment information; calibration information; security information such as encryption keys; and / or other suitable additional or alternative data. The storage device of electronic device 192 may be, for example, a disk, flash memory, optical disk, or other suitable data storage device.

[0072] Instead of or attached to the storage device storing the aforementioned information in the electronic device 192, some or all of such information (e.g., usage information, calibration information, setting information, and / or adjustment information) may be stored in conjunction with the surgical robot system 10. Figure 1 ), remote servers, cloud servers, etc., and can be connected via instrument 110 and / or surgical robot system 10 ( Figure 1 The information can be accessed via a storage device. In such a configuration, the information can be updated, for example, through updates provided by the manufacturer, and / or can be applied to individual instruments, instrument units (e.g., units from the same manufacturing location, manufacturing cycle, batch number, etc.), or applied to all instruments. Furthermore, even where the information is stored locally on each instrument, the information can also be accessed via a storage device connected to the surgical robot system 10. Figure 1 Then update manually or automatically through the updates provided by the manufacturer.

[0073] Refer again Figure 5 The shaft 130 of the device 110 includes a distal segment 132 (which may at least partially define the U-shaped clamp of the end effector assembly 40), a proximal segment 134, and an articulated section 136 disposed between the distal segment 132 and the proximal segment 134. The articulated section 136 includes one or more articulated elements 137, such as links, joints, etc. A plurality of articulated motion cables 138 (e.g., four (4) articulated motion cables) or other suitable actuators extend through the articulated section 136. More specifically, the articulated motion cables 138 are operatively coupled at their distal ends to the distal segment 132 of the shaft 130 and extend proximally from the distal segment 132 of the shaft 130, through the articulated section 136 and the proximal segment 134 of the shaft 130, and into the housing 120, wherein the articulated motion cables 138 are connected to the actuation assembly 1100 ( Figure 6AThe articulated motion subassembly 1200 is operatively coupled to enable selective articulation of the distal segment 132 (and therefore the end effector assembly 140) relative to the proximal segment 134 and the housing 120, for example, with respect to at least two axes of articulation (e.g., yaw and pitch articulation movements). The articulated motion cable 138 is arranged in a generally rectangular configuration, but other suitable configurations are also contemplated. In some configurations, as an alternative, the shaft 130 is significantly rigid, extendable, or flexible and is not configured for active articulation movement. The articulated motion subassembly 1200 is described in more detail below.

[0074] Regarding the articulated movement of the end effector assembly 140 relative to the proximal segment 134 of the shaft 130, the actuation of the articulated motion cables 138 can be performed in pairs. More specifically, to pitch the end effector assembly 140, the upper cable pair 138 is actuated in a similar manner, while the lower cable pair 138 is actuated in a manner similar to each other but opposite to that of the upper cable pair 138. Regarding the yaw articulated movement, the right cable pair 138 is actuated in a similar manner, while the left cable pair 138 is actuated in a manner similar to each other but opposite to that of the right cable pair 138. Other configurations of the articulated motion cables 138 or other articulated motion actuators are also contemplated.

[0075] Continue to refer to Figure 5 The end effector assembly 140 accordingly includes a first gripper member 142 and a second gripper member 144. Each gripper member 142, 144 includes a pair of proximal markings 143a, 145a and distal bodies 143b, 145b extending from the corresponding pair of proximal markings 143a, 145a, respectively. The distal bodies 143b, 145b define opposing tissue contact surfaces 146, 148, respectively. Pairs of proximal markings 143a, 145a are pivotally connected to each other about a pivot 150 (e.g., a pivot pin) and operably connected to each other via a cam assembly 152 (which includes a cam pin, described in more detail below, slidably received in a cam slot defined in the pair of proximal markings 143a, 145a in gripper members 142, 144, respectively) to allow gripper member 142 to pivot relative to gripper member 144 and distal segment 132 of shaft 130 between a spaced-apart position (e.g., an open position of end effector assembly 140) and a proximal position (e.g., a closed position of end effector assembly 140) for holding tissue between tissue contact surfaces 146, 148. As an alternative to this unilateral configuration, a bilateral configuration may be provided, wherein the two gripper members 142, 144 are pivotable relative to each other and relative to distal segment 132 of shaft 130.

[0076] In all aspects, a longitudinally extending blade channel 149 (only the blade channel 149 of the gripper member 144 is illustrated; the blade channel of the gripper member 142 is configured in a similar manner) is defined by the tissue contact surfaces 146, 148 of one or both gripper members 142, 144. In such aspects, a blade assembly is provided that includes a blade shank 149a extending from the housing 120 through the shaft 130 to the end effector assembly 140. Figures 8A to 8B ) and the blade 149b disposed within the end effector assembly 140 between the gripper members 142, 144. Figures 8A to 8B Blade 149b Figures 8A to 8B The blade selectively translates through the blade channel 149 and correspondingly between the gripper members 142 and 144, thereby cutting the tissue held between the tissue contact surfaces 146 and 148 of the gripper members 142 and 144. The blade shank 149 ( Figures 8A to 8B ) is operably coupled to the actuation assembly 1100 at its proximal end. Figures 6A to 6B ) knife drive sub-assembly 1300 ( Figure 7 ), so that the tool holder 149a ( Figures 8A to 8B ) can be selectively actuated, thereby causing the blade 149b ( Figures 8A to 8B The device reciprocates between gripper components 142 and 144, thereby cutting the tissue held between tissue contact surfaces 146 and 148. As an alternative to longitudinally advancing mechanical cutters, other suitable mechanical cutters are also envisioned, such as guillotine-type cutters, and energy-based cutters, such as RF electrical cutters and ultrasonic cutters in static or dynamic configurations.

[0077] Still referencing Figure 5 The drive tube 1484 is operatively coupled to the cam slot assembly 152 of the end effector assembly 140, for example, engaging with its cam pin, such that longitudinal actuation of the drive tube 1484 causes the gripper member 142 to pivot relative to the gripper member 144 between a spaced-out position and a proximal position. More specifically, pushing the drive tube 1484 proximally causes the gripper member 142 to pivot relative to the gripper member 144 toward the proximal position, while pushing the drive tube 1484 distally causes the gripper member 142 to pivot relative to the gripper member 144 toward a spaced-out position. However, other suitable mechanisms and / or configurations are also contemplated for pivoting the gripper member 142 relative to the gripper member 144 between a spaced-out position and a proximal position in response to selective actuation of the drive tube 1484. A drive tube 1484 extends proximally from the end effector assembly 140 and is coupled to a drive rod 1486 that extends through the shaft 130 and enters the housing 120, wherein the drive rod 1486 is connected to the actuation assembly 1100. Figures 6A to 6BThe gripper drive subassembly 1400 is operatively coupled to enable selective actuation of the end effector assembly 140 to clamp tissue therebetween and apply gripper force within an appropriate gripper force range.

[0078] The tissue contact surfaces 146 and 148 of the gripper members 142 and 144 are each at least partially formed of a conductive material and can be excited to different potentials so that RF electrical energy can be conducted through the tissue held therebetween. However, the tissue contact surfaces 146 and 148 can alternatively be configured to supply any suitable energy (e.g., heat, microwave, light, ultrasound, ultrasonic waves, etc.) through the tissue held therebetween for energy-based tissue processing. The instrument 110 defines a conduction path (not shown) through the housing 120 and shaft 130 to the end effector assembly 140. This conduction path may include leads, contacts, and / or conductive components to electrically connect the tissue contact surfaces 146 and 148 of the gripper members 142 and 144 to an energy source (not shown), such as an electrosurgical generator, for supplying energy to the tissue contact surfaces 146 and 148 to process (e.g., seal) the tissue held between the tissue contact surfaces 146 and 148.

[0079] For further reference Figures 6A to 7 As described above, the actuation assembly 1100 is disposed within the housing 120 and includes an articulated motion subassembly 1200, a blade drive subassembly 1300, and a gripper drive subassembly 1400. The articulated motion subassembly 1200 is correspondingly operably connected to the first input connector 1110 and the second input connector 1120 of the actuation assembly 1100 and the articulated motion cable 138. Figure 5 Between, such that after receiving appropriate input in the first input connector 1110 and / or the second input connector 1120, the articulated motion subassembly 1200 manipulates the cable 138 ( Figure 5 This allows the end effector assembly 140 to articulate in a desired direction, such as pitching and / or yawing. The articulated motion subassembly 1200 is described in more detail below.

[0080] The tool drive sub-assembly 1300 is operatively connected to the third input connector 1130 of the actuation assembly 1100 and the tool holder 149a. Figures 8A to 8B Between, such that after the third input connector 1130 receives appropriate input, the tool drive subassembly 1300 manipulates the tool holder 149a ( Figures 8A to 8B ) to make the blade 149b ( Figures 8A to 8B The device reciprocates between the gripper components 142 and 144, thereby cutting the tissue held between the tissue contact surfaces 146 and 148.

[0081] The gripper drive subassembly 1400 is operatively coupled between the fourth input connector 1140 of the actuation assembly 1100 and the drive rod 1486, such that upon receiving appropriate input from the fourth input connector 1140, the gripper drive subassembly 1400 pivots the gripper members 142, 144 between a spaced-apart position and a proximal position to hold tissue therebetween and apply a gripper force within an appropriate gripper force range.

[0082] Actuation component 1100 is configured to activate when instrument 110 is mounted on surgical robot system (e.g., system 10). Figure 1 When the surgical robot system 10 is mounted on the robotic arm, it is operatively docked with the surgical robot system so that the robotic operation of the actuation component 1100 can provide the functions detailed above. That is, the surgical robot system 10 Figure 1 Inputs, such as rotational inputs, can be selectively provided to the input connectors 1110 to 1140 of the actuation assembly 1100 to cause the end effector assembly 140 to articulate, clamp tissue between the gripper members 142, 144, and / or cut the tissue clamped between the gripper members 142, 144. However, as described above, it is also contemplated that the actuation assembly 1100 may be configured to interface with any other suitable surgical system (e.g., a manual surgical handpiece, a motorized surgical handpiece, etc.).

[0083] Turning Figure 8A and Figure 8B As mentioned above (refer to the reference) Figure 5In detail, the first gripper member 142 and the second gripper member 144 of the end effector assembly 140 each include a pair of proximal markings 143a, 145a and distal bodies 143b, 145b extending from the corresponding pair of proximal markings 143a, 145a. The proximal markings in each pair of proximal markings 143a, 145a are spaced apart from each other. Further, the pairs of proximal markings 143a, 145a can be arranged in a defined nested configuration (as shown), in which the proximal markings of one of the gripper members (e.g., the proximal marking 143a of gripper member 142) are disposed between (e.g., nested therein) the proximal markings of the other gripper member (e.g., the proximal marking 145a of gripper member 145). Alternatively, the pairs of proximal markings 143a, 145a can be arranged in an offset configuration, in which one proximal marking from each pair of proximal markings 143a, 145a is disposed between the proximal markings of the other pair of proximal markings 143a, 145a, and the other proximal marking from each pair of proximal markings 143a, 145a is disposed outside the proximal markings of the other pair of proximal markings 143a, 145a. In other configurations, one of the gripper members 142, 144 includes only a single proximal marking, which is disposed adjacent to one of the proximal markings of a pair of proximal markings of the other gripper member 142, 144. Additionally or alternatively, the proximal marking associated with one of the gripper members 142, 144 can be attached to, or formed together with, a U-shaped clamp or other gripper support structure. Regardless of the specific arrangement of the proximal marking portions 143a and 145a, the innermost proximal marking portions (e.g., proximal marking portion 143a (as shown in the figure)) are laterally spaced apart by a distance "d" (see also...) Figures 10A to 10D ).

[0084] Continue to refer to Figure 8A and Figure 8B As mentioned above, please also refer to Figure 5 In detail, the paired proximal markings 143a and 145a surround the pivot 150 ( Figure 5 The pivots are pivotally connected to each other, for example, by pivot pins 802 extending through laterally aligned pivot orifices 804, 806 defined by a pair of proximal markings 143a, 145a. Pivot pins 802 may be welded in place (e.g., welded to one or both of the proximal markings 145a), or may be held in place in any other suitable manner (e.g., via a U-shaped clip (not shown) or other suitable support structure arranged around the proximal markings 145a to capture the pivot pins 802 therein), as detailed below.

[0085] The paired proximal markings 143a and 145a are connected via cam assembly 152 ( Figure 5 They are operably connected to each other. More specifically, each of the proximal markings 143a of the gripper member 142 further defines a cam slot 808 of the cam assembly 152. Figure 5 Similarly, each of the pair of proximal markings 145a of the gripper member 144 further defines the cam slot 810 of the cam assembly 152. Figure 5 The cam slots 810 of the proximal marking portion 145a of the gripper member 144 are aligned with each other and can extend in a linear longitudinal orientation, while the cam slots 808 of the proximal marking portion 143a of the gripper member 142 are aligned with each other and can be bent (as shown) or angled relative to the cam slots 810 of the proximal marking portion 145a of the gripper member 144. In this way, the cam pin 816 translates through the cam slots 808, 810, causing the gripper member 142 to pivot about the pivot pin 802 and relative to the gripper member 142, for example, pivoting between a spaced-apart position and a proximal position.

[0086] Drive tube 1484 is operatively coupled to cam slot assembly 152. Figure 5 More specifically, as described above, the drive tube 1484 engages with the drive rod 1486, which in turn connects to the actuation assembly 1100 via the cam head assembly 812. Figures 6A to 6B The gripper drive subassembly 1400 is operatively coupled to enable the gripper member 142 to selectively pivot relative to the gripper member 144, for example, to hold tissue therebetween. The drive tube 1484 and the cam head assembly 812 (and in some respects, the drive rod 1486) may be collectively referred to herein as the cam drive assembly.

[0087] For further reference Figure 9A and Figure 9BThe cam head assembly 812 includes a cam block 814 and a cam pin 816 fixed relative to the cam block 814, such that a first cam pin portion 818a and a second cam pin portion 818b project laterally from opposite sides of the cam block 814. The cam pin 816 may be fixed relative to the cam block 814 by welding, by integrally forming the cam pin 816 and the cam block 814 into a single component (in the same or multiple steps), or by any other suitable means. Furthermore, the cam pin 816 need not be continuous; that is, the cam pin 816 need not extend through (or completely through) the cam block 814, but may be formed by separate cam pin portions 818a, 818b projecting laterally from the cam block 814. In the aspect where the cam pin 816 is continuous and welded to the cam block 814, the cam block 814 may include a welding orifice 815 extending through and intersecting the cam pin to provide passage to the cam pin 816 within the cam block 814, thereby facilitating the welding of the cam pin 816 to the cam block 814. The welding orifice 815 may extend substantially perpendicular to the cam pin 816 and may be defined through the top surface of the cam block 814, but other configurations are also contemplated.

[0088] Continue to refer to Figures 8A to 9B The cam block 814 defines a diagonal dimension “D” between its relative (actual or possible) corners. In all respects, each diagonal dimension “D” is greater than the distance “d” between the proximal markings 143a of the gripper members 142, such that if the cam block 814 defines a perfectly square rectangle, and the cam block 814 is positioned in a first orientation between the proximal markings 143a of the gripper members 142 (in which the cam pin 816 is substantially parallel to the proximal markings 143a), then rotation of the cam block 814 to a second orientation (in which the cam pin 816 is substantially perpendicular to the proximal markings 143a) will be suppressed, or at least contact between the cam pin 816 and the proximal markings 143a is required. Therefore, at least one corner of the cam block 814 defines a chamfer 820, which can be an angled surface (as shown), a rounded corner, or other suitable cut to reduce at least one diagonal dimension of the cam block 814 to a distance less than the distance "d", thereby enabling the cam block 814 to rotate from a first orientation to a second orientation. In various aspects (such as...) Figure 9B As shown), a chamfer 820 is defined at either end or both ends of one diagonal, while the other diagonal does not include a chamfer. This configuration allows the cam block 814 to rotate from the first orientation to the second orientation in only one direction, thereby preventing the cam block 814 from being incorrectly installed between the gripper members 142, 144. Alternatively (as shown) Figures 10A to 10DAs shown), the chamfer 820 may be defined at either end or both ends of the two diagonals. In each respect, the cam block 814 defines at least one diagonal dimension “D” between its opposing (actual or possible) corners, which is smaller than the distance “d” between the proximal markings 143a, such that the cam block 814 can rotate from a first orientation to a second orientation without chamfering.

[0089] The cam block 814 further includes a proximal extension 822 configured to at least partially receive the drive tube 1484 to engage the drive tube 1484 with the cam block 814, for example, by welding the drive tube 1484 to the proximal extension 822, crimping the proximal extension 822 around the distal portion of the drive tube 1484, etc. The drive rod 1486 engages with the drive tube 1484 and may extend partially through the drive tube 1484, for example, wherein the drive rod 1486 engages within the proximal portion of the drive tube 1484, or may extend completely through the drive tube 1484, for example, wherein the drive rod 1486 engages within the distal portion of the drive tube 1484 and / or engages with the proximal extension 822 of the cam block 814.

[0090] Turning Figures 10A to 10D and Figure 11 , combined Figure 8A and Figure 8B The assembly of the cam head assembly 812 and the gripper members 142 and 144 is described in detail, for example, in combination method 900. Figure 11 Before assembling the cam head assembly 812 with the gripper members 142, 144, the cam pin 816 passes through the weld orifice 815, for example, by welding. Figure 8B The drive tube 1484 engages with the proximal extension 822 of the cam block 814 before the cam head assembly 812 is assembled with the gripper members 142, 144. The drive rod 1486 may also engage with the drive tube 1484 before the cam head assembly 812 is assembled with the gripper members 142, 144, but the drive tube 1484 and / or the drive rod 1486 may alternatively engage after the cam head assembly 812 is assembled with the gripper members 142, 144.

[0091] Initially, as indicated in 910, the gripper members 142, 144 are positioned to have proximal marking portions 143a disposed between proximal marking portions 145a, such that the cam slots 808, 810 of adjacent pairs of proximal marking portions 143a, 145a ( Figure 8A ) are partially aligned with each other, thereby defining the extension through the pair of cam slots 808, 810 ( Figure 8A Channel 811 (only one of them is shown) Figure 13 Channel 811 ( Figure 13The cam pin 816 (when positioned between the proximal marking portions 143a and 145a) is elongated enough to allow it to rotate into contact with the cam slots 808 and 810. Figure 8A The cam head assembly 812 is engaged, although the length defined by the cam pin 816 is greater than the distance "d" between the proximal markings 143a. Once the adjacent pairs of proximal markings 143a, 145a are aligned as detailed above or partially aligned prior to this, the cam head assembly 812 is inserted between the proximal markings 143a of the gripper member 142 in a first orientation in which the cam pin 816 is substantially parallel to the proximal markings 143a, as shown below. Figure 10A As shown and indicated at 920. More specifically, the cam head assembly 812 is positioned between the proximal markings 143a such that the cam pin 816 is configured to align with the pair of cam slots 808, 810 (through portions). Figure 8A Limited channel 811 ( Figure 13 Basically, they are aligned horizontally.

[0092] With the cam head assembly 812 positioned as detailed above, the cam head assembly 812 can then rotate about its longitudinal axis (e.g., substantially perpendicular to the longitudinal axis extending from the cam pin 816), whereby the chamfer 820 allows the cam head assembly 812 to rotate from a first orientation to a second orientation without contacting the proximal marking portion 143a, in which the cam pin 816 is substantially perpendicular to the proximal marking portion 143a. More specifically, as indicated at 930 and as... Figures 10A to 10D As shown, rotation of the cam head assembly 812 from a first orientation to a second orientation causes the cam pin portions 818a, 818b to move through the cam slots 808, 810 extending through the pair of cam slots. Figure 8A Channel 811 () Figure 13 ), and enter the final position, in which the cam pin portion 818a extends substantially vertically through the cam slots 808, 810 of the gripper members 142, 144 on the first side of the cam block 814. Figure 8A ), and wherein the cam pin portion 818b extends substantially vertically through the cam slots 808, 810 of the gripper members 142, 144 on the opposite second side of the cam block 814. Figure 8A (See also) Figure 10D Although cam block 814 is shown as included in Figures 10A to 10D The chamfers 820 on the two diagonals are as described above. It is also envisioned that the cam block 814 includes chamfers 820 on only one diagonal so that the cam block 814 can rotate in only one direction, such as unidirectional rotation.

[0093] Return to reference Figure 8A and Figure 8B And continue to refer to Figure 11 After the assembly of the cam head assembly 812 with the gripper members 142, 144 is completed as detailed above, the assembly of the end effector assembly 140 can proceed. More specifically, as indicated in 940, with the cam head assembly 812 operably engaged with the gripper members 142, 144 as detailed above, the gripper members 142 and / or 144 can be moved (e.g., rotated) relative to each other to align with the pivot orifices 804, 806. This rotation of the gripper members 142 and / or 144 causes the cam slots 808, 810 to move relative to each other to prevent the cam head assembly 812 from being disassembled from the gripper members 142, 144, for example, to prevent disassembly in the reverse manner of the assembly detailed above.

[0094] As indicated in 950, with the pivot holes 804 and 806 of the proximal marking portions 143a and 145a aligned with each other, the pivot pin 802 can be inserted through the aligned pivot holes 804 and 806, thereby pivotally engaging the gripper members 142 and 144 with each other. The pivot pin 802 can then be held in place, as indicated in 960, thereby maintaining the gripper members 142 and 144 pivotally engaged with each other and maintaining the cam head assembly 812 operatively engaged with the gripper members 142 and 144. The pivot pin 802 can be held in place by welding the pivot pin 802 to either or both of the proximal marking portion 145a (or the proximal marking portion 143a). Alternatively, the pivot pin 802 may be kept in a “floating” engagement with the proximal marking portions 143a, 145a, for example, by positioning a U-shaped clamp (not explicitly shown) or other support structure at least partially around the proximal marking portion 145a, thereby preventing the pivot pin 802 from retraction from the pivot orifices 804, 806 and maintaining the gripper members 142, 144 in a pivotable engagement without directly securing the pivot pin 802 to the proximal marking portion 145a (or proximal marking portion 143a).

[0095] Turning Figure 12 and Figure 13According to various aspects of this disclosure, a securing device 1000 is provided, configured to facilitate the assembly of the cam head assembly 812 with the gripper members 142, 144 as detailed above. More specifically, the securing device 1000 includes a base 1010, a first gripper retainer 1020, a second gripper retainer 1040, and a support block 1050. The first gripper retainer 1020 and the second gripper retainer 1040 may be formed as recesses on either side of the support block 1050, within corresponding first side portions 1012 and second side portions 1014 of the base 1010, or may be formed and / or positioned in any other suitable manner. The recess or other suitable gripper retainers 1020, 1040 can be configured such that the distal body 143b of the gripper member 142 can be positioned only within the gripper retainer 1020 and / or such that the distal body 145b of the gripper member 144 can be positioned only within the gripper retainer 1040. The first gripper retainer 1020 and the second gripper retainer 1040 are configured to receive the gripper members 142, 144, wherein the tissue contact surfaces 146, 148 of the gripper members 142, 144 ( Figure 8A The face is downward toward the base 1010, but other configurations are also conceivable.

[0096] As described above, the support block 1050 is disposed between the first side portion 1012 and the second side portion 1014 of the base 1010. The support block 1050 includes a first angled surface 1053 and a second angled surface 1055, which are configured to support pairs of proximal marking portions 143a and 145a of the corresponding first gripper member 142 and second gripper member 144, respectively. More specifically, the second angled surfaces 1053, 1055 are oriented relative to each other such that the distal bodies 143b, 145b of the gripper members 142, 144 are disposed within the respective gripper holders 1020, 1040, and the proximal markings 143a, 145a of the gripper members 142, 144 are supported on the respective angled surfaces 1053, 1055. The cam slots 808, 810 of adjacent pairs of proximal markings 143a, 145a are partially aligned with each other to define channels 811 through which the cam pin 816 can rotate, as detailed above. In various respects, the angled surfaces 1053, 1055 can be arranged at an angle "A" relative to each other, such that the tissue contact surfaces 146, 148 ( Figure 8A The angles “A” relative to each other are set from about 150 degrees to about 175 degrees in some aspects; from about 155 degrees to about 170 degrees in others; from about 160 degrees to about 165 degrees in still others; and about 163 degrees in yet another others.

[0097] The fixing device 1000 may further include markings 1060 that indicate, for example, the correct insertion orientation of the cam head assembly 812 (e.g., the orientation of the reference weld orifice 815). Figure 8B The correct rotation direction of the cam head assembly 812 and / or the cam head assembly 812.

[0098] Figure 14 Another retaining device 2000, arranged according to various aspects of this disclosure, is shown. This retaining device is configured to facilitate the assembly of the cam head assembly 812 with the gripper members 142, 144 as detailed above. Retaining device 2000 can be configured to be similar to and include, as detailed above, retaining device 1000. Figure 12 and Figure 13 Any or all features of the fixture 2000 and fixture 1000 are described in detail below; therefore, only the fixture 2000 and fixture 1000 are described in detail below. Figure 12 and Figure 13 The differences between them are described, while the similarities are briefly described or omitted entirely.

[0099] The fixation device 2000 includes markings 2070 on a first side portion 2012 and a second side portion 2014 of the base 2010, indicating which side portion 2012, 2014 corresponds to the respective gripper members 142, 144. Markings 2080 may also be provided to indicate the lead cap color of electrical leads configured to contact the tissue contact surfaces 146, 148 of the gripper members 142, 144, respectively. Figure 8A The device is connected to an energy source (not shown) (e.g., an electrosurgical generator). For example, a gripper member 142, which may be designated as "gripper b", may include a white cap on its lead wire, while a gripper member 144, which may be designated as "gripper a", may include a red cap on its lead wire. Further, the side portions 2012, 2014 of the base 2010 of the fixing device 2000 may include lead wire retainers 2016, 2018 (e.g., orifices (as shown), slots, tortuous passages, recesses, channels, etc.) configured to receive the gripper leads associated with the respective gripper members 142, 144 so that the gripper leads remain unobstructed during assembly.

[0100] Continue to refer to Figure 14 In various aspects, the fixing device 2000 further includes an additional gripper retainer 2090, which is configured for use during the assembly of other parts. For example, the additional gripper retainer 2090 can be used to hold the gripper member 144 therein (where the tissue contact surface 148 faces upward away from the base 2010) to facilitate the blade 149b ( Figures 8A to 8B ) and operable connection with gripper member 144.

[0101] It should be understood that various modifications can be made to the aspects and features disclosed herein. Therefore, the above description should not be construed as limiting, but merely as illustrative of various configurations. Other modifications within the scope and spirit of the appended claims will be contemplated by those skilled in the art.

Claims

1. A method for assembling an end effector assembly of a surgical instrument, the method comprising: The first proximal marking portion of the first gripper member is positioned between and adjacent to the spaced-apart second proximal marking portion and third proximal marking portion of the second gripper member, such that the first cam slot defined by the first proximal marking portion is partially aligned with the second cam slot defined by the second proximal marking portion to define a first channel through the first cam slot and the second cam slot. The cam head assembly is inserted between the first proximal marking portion and the third proximal marking portion in a first orientation, wherein a first cam pin portion extending from the cam block of the cam head assembly is oriented substantially parallel to the first proximal marking portion, the second proximal marking portion and the third proximal marking portion; as well as The cam head assembly is rotated from the first orientation to a second orientation in which the first cam pin portion is oriented substantially perpendicularly to the first proximal marking portion, the second proximal marking portion, and the third proximal marking portion, thereby causing the first cam pin portion to rotate through the first channel and engage within the first cam slot and the second cam slot.

2. The assembly method according to claim 1, wherein, The first gripper member further includes a fourth proximal marking portion spaced apart from the first proximal marking portion, and wherein: The positioning further includes positioning the fourth proximal marker adjacent to the third proximal marker such that the fourth cam slot defined through the fourth proximal marker is partially aligned with the third cam slot defined through the third proximal marker to define a second channel through the third cam slot and the fourth cam slot. The cam head assembly includes a second cam pin portion that extends from the cam block opposite to the first cam pin portion; and The rotation causes the second cam pin portion to rotate through the second channel and engage within the third cam slot and the fourth cam slot.

3. The assembly method according to claim 2, wherein, Positioning the fourth proximal sign portion adjacent to the third proximal sign portion includes positioning the fourth proximal sign portion on the inner side of the third proximal sign portion, between the third proximal sign portion and the first proximal sign portion.

4. The assembly method according to claim 2, wherein, Positioning the fourth proximal sign portion adjacent to the third proximal sign portion includes positioning the fourth proximal sign portion on the outside of the third proximal sign portion, such that the third proximal sign portion is disposed between the fourth proximal sign portion and the first proximal sign portion.

5. The assembly method according to claim 1, wherein, The cam block includes a first corner defining a chamfer, and the rotation includes rotating the first corner relative to the first proximal marking portion, with a gap defined by the chamfer between the first corner and the first proximal marking portion.

6. The assembly method according to claim 1, wherein, The first gripper member includes a first gripper body extending distally from the first proximal marking portion and defining a first tissue contact surface, wherein the second gripper member includes a second gripper body extending distally from the second proximal marking portion and the third proximal marking portion and defining a second tissue contact surface, and wherein the positioning includes positioning the first tissue contact surface and the second tissue contact surface relative to each other at an angle of about 150 degrees to about 175 degrees.

7. The assembly method according to claim 1, further comprising: After the rotation: The first proximal marking portion is positioned relative to the second proximal marking portion and the third proximal marking portion such that the first pivot opening defined by the first proximal marking portion is aligned with the second pivot opening and the third pivot opening defined by the second proximal marking portion and the third proximal marking portion; as well as A pivot pin is inserted through these aligned first pivot holes, second pivot holes, and third pivot holes, thereby pivotally connecting the first jaw member and the second jaw member to each other.

8. The assembly method according to claim 7, further comprising: The pivot pin is held in engagement within the first pivot orifice, the second pivot orifice, and the third pivot orifice, thereby holding the first jaw member and the second jaw member pivotally engaged with each other.

9. The assembly method according to claim 1, wherein, The cam head assembly includes a drive tube that engages with the cam block prior to insertion and extends proximally from the cam block.

10. The assembly method according to claim 1, further comprising: The first cam pin portion is welded to the cam block prior to insertion.

11. The assembly method according to claim 1, wherein, The positioning includes inserting the first gripper member and the second gripper member into the fixing device, wherein the insertion and the rotation are performed with the first gripper member and the second gripper member positioned within the fixing device.

12. An end effector assembly for a surgical instrument, the end effector assembly comprising: A first gripper member includes a first pair of proximal marking portions and a distal body, the distal body extending distally from the first pair of proximal marking portions and defining a first tissue contact surface, the proximal marking portions of the first pair of proximal marking portions defining a lateral distance therebetween. The second gripper member includes a second pair of proximal marking portions and a distal body, the distal body extending distally from the second pair of proximal marking portions and defining a second tissue contact surface, wherein the first pair of proximal marking portions are disposed between the proximal marking portions in the second pair of proximal marking portions; A pivot that pivotally connects the first pair of proximal markings and the second pair of proximal markings to each other, such that at least one of the first tissue contact surface or the second tissue contact surface can pivot relative to the other of the first tissue contact surface or the second tissue contact surface between a spaced-apart position and a proximal position to hold tissue therebetween; and A cam drive assembly includes a cam block and a cam pin fixed relative to the cam block, the cam block being disposed between proximal marking portions in a first pair of proximal marking portions, wherein the cam pin operably engages a cam slot defined within the proximal marking portions of the first pair of proximal marking portions and the second pair of proximal marking portions. The cam block has a rectangular configuration that defines a first diagonal lateral dimension and a second diagonal lateral dimension opposite to the first diagonal lateral dimension. The first diagonal lateral dimension is greater than the lateral distance, and the second diagonal lateral dimension is less than the lateral distance.

13. The end effector assembly of claim 12, wherein, The first diagonal lateral dimension extends between the first corner and the second corner of the cam block, and the second diagonal lateral dimension extends between the first chamfer and the second chamfer defined in the cam block.

14. The end effector assembly of claim 12, wherein, The cam pin extends through the cam block, wherein the cam block defines an orifice extending perpendicularly relative to the cam pin, and wherein the cam pin is welded to the cam block within the orifice.

15. The end effector assembly of claim 12, wherein, The cam drive assembly further includes a proximal extension configured to engage the drive tube with the cam block.

16. An end effector assembly for a surgical instrument, the end effector assembly comprising: A first gripper member includes a pair of first proximal markings and a distal body, the distal body extending distally from the pair of first proximal markings and defining a first tissue contact surface; The second gripper member includes at least one second proximal identifier and a distal body, the distal body extending distally from the at least one second proximal identifier and defining a second tissue contact surface; A pivot that pivotally connects the pair of first proximal markings and the at least one second proximal marking to each other, such that at least one of the first tissue contact surface or the second tissue contact surface can pivot relative to the other of the first tissue contact surface or the second tissue contact surface between a spaced-apart position and a proximal position to hold tissue therebetween. as well as A cam drive assembly includes a cam block and a cam pin fixed relative to the cam block, the cam block being disposed between the first proximal marking portions of the pair of first proximal marking portions, wherein the cam pin operably engages a cam slot defined within the first proximal marking portions of the pair of first proximal marking portions, wherein the cam block includes a first diagonal defined between a pair of diagonally opposite chamfered corners.

17. The end effector assembly of claim 16, wherein, The first proximal marking portions of the pair define a lateral distance between them, and the first diagonal defines a diagonal lateral distance smaller than the lateral distance.

18. The end effector assembly of claim 16, wherein, The cam block further includes a second diagonal that is opposite to the first diagonal and is defined between a pair of diagonally opposite, chamfer-free corners.

19. The end effector assembly of claim 16, wherein, The at least one second proximal marking portion defines a cam slot, and wherein the cam pin is operatively engaged within the cam slot of the at least one second proximal marking portion.

20. The end effector assembly of claim 19, wherein, The at least one second proximal marking portion includes a pair of second proximal marking portions, wherein the pair of first proximal marking portions is disposed between the second proximal marking portions in the pair of second proximal marking portions.

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