Joint structures, related devices and methods for articulated mechanisms

Abstract

A joint structure configured to provide articulation between two links connected by a joint structure includes a pair of complementary joint features. One of the pair of complementary joint features includes an elongated slot defined by a pair of protrusions extending in the extension direction of the slot and defining sidewalls of the slot. The other of the pair of complementary joint features includes a convex gear feature terminating in a circular head. The circular head is received in the slot and is movable relative to the slot, and is held in position within the slot defined by the pair of protrusions by the articulated range of motion of the joint structure.

Description

[0001] Cross-references to related applications This application claims the benefit of U.S. Provisional Application No. 63 / 592,978, filed October 25, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to joint structures for articulated mechanisms, and related apparatus and methods. Specifically, this disclosure relates to instruments having joint structures capable of articulating in response to forces transmitted by an actuating element extending through a link joined together at the joint structure. Background Technology

[0003] Various instruments (such as medical (e.g., surgical) or other industrial instruments) include articulated mechanisms that include joint structures that give such instrument one or more degrees of freedom of movement. These articulated mechanisms may include one or more joint structures, each of which can articulate in one or more degrees of freedom, which may be the same or different.

[0004] The articulation can be controlled by one or more actuating elements (e.g., cables) coupled to a manipulator system via various components. This manipulator system receives input from a user (e.g., a surgeon or other operator) to orient parts of the instrument as needed. Such a manipulator system may include a remotely controlled (e.g., computer-controlled) manipulator system. In other applications, the instrument and articulated mechanism can be manually actuated. In some cases, it is desirable for the articulated mechanism to exhibit relatively high stiffness at any given articulated position to facilitate the instrument's ability to maintain a given position under reaction forces, such as those generated by the operation of the instrument's end effectors or working end components.

[0005] The device may include one or more articulated mechanisms for attaching an end effector to a distal portion of the device's axis to provide orientation of the end effector in one or two degrees of freedom, such as pitch and yaw. Other articulated mechanisms may be provided along the length of the axis to achieve various orientations of the device's axis. The one or more actuating elements extend from a transmission mechanism attached proximally to the axis of the articulated mechanism through the device axis and into a connecting rod of the articulated mechanism's joint structure. Forces transmitted by the one or more actuating elements apply to the connecting rods with respect to each other articulated about the joint structure, thereby allowing remote "steering" of the articulated mechanism. For example, the actuating elements may transmit force through selective tension / tensioning of flexible, cable-like actuating elements and / or through push / pull forces of more rigid, compressive rod-like actuating elements. Various types of actuating elements for transmitting force to articulate articulated mechanisms are familiar to those skilled in the art.

[0006] Some articulated mechanisms may include a joint structure with a joint feature that provides transmission-type movement and thus allows two opposing links connected by the joint structure to have a relative angular orientation that varies depending on the fixing relationship, and this relative angular orientation prevents the links from sliding relative to each other during articulation. However, such articulated mechanisms can be prone to dislocation if excessive rotation occurs, where the joint feature disengages and slides out of their fixing relationship. Therefore, dislocation can become problematic when the joint structure has a larger angular orientation (i.e., when the links are articulated at a larger angle). For example, pin-driven and involute-driven joint structures have previously been used to strengthen rolling constraints between links in articulated mechanisms. However, such joint structures can have more complex meshing gear features, which are more prone to dislocation.

[0007] There is a need for articulated mechanisms with appropriate strength and precision, designed for ease of manufacture and with a simplified design. There is also a need for articulated mechanisms that address the problem of joint misalignment. Summary of the Invention

[0008] The exemplary embodiments disclosed herein are capable of solving one or more of the problems described above and / or exhibiting one or more of the desired features described above. Other features and / or advantages will become apparent from the following description.

[0009] According to at least one exemplary embodiment, a joint structure configured to provide a hinge between two links connected by a joint structure includes a pair of complementary joint features. One of the pair of complementary joint features includes an elongated slot defined by a pair of protrusions extending in the extension direction of the slot and defining a sidewall of the slot. The other of the pair of complementary joint features includes a convex gear feature terminating in a circular head. The circular head is received in the slot and is movable relative to the slot, and is held in a position within the slot defined by the pair of protrusions by the hinged range of motion of the joint structure.

[0010] According to at least another exemplary embodiment, the connector structure is configured to provide a hinge between two links connected by a connector structure comprising a pair of complementary connector features. One of the pair of complementary connector features includes an elongated slot defined by a pair of protrusions extending in the extension direction of the slot and defining a sidewall of the slot. The other of the pair of complementary connector features includes a cam feature terminating in a circular head. The cam feature has a recessed region adjacent to the circular head. The circular head is received in the slot and is movable relative to the slot. Through a hinged range of motion of the connector structure from a neutral position in a first direction, the circular head is held within the elongated slot defined by the pair of protrusions, and one of the pair of protrusions is respectively received in the recessed region and moves along the recessed region. Through a hinged range of motion of the connector structure from a neutral position in a second direction, the circular head is held within the elongated slot and defined by the pair of protrusions, and the other of the pair of protrusions is respectively received in the recessed region and moves along the recessed region.

[0011] According to at least another exemplary embodiment, the articulated mechanism includes a first link and a second link connected to each other by a pair of complementary joint features. The pair of complementary joint features are configured to allow the first link and the second link to hinge relative to each other about a pivot axis. The pair of complementary joint features includes a pair of protrusions extending from the first link in a direction perpendicular to the pivot axis and defining an elongated slot between the protrusions. The pair of complementary joint features further includes a pin extending from the second link and received in the elongated slot. The pin and the pair of protrusions are rotatable relative to each other to cause the first link and the second link to hinge relative to each other. Through the range of motion of the first link and the second link relative to each other, the pin is translatably movable relative to the slot and retained within the slot defined by the pair of protrusions.

[0012] According to at least another exemplary embodiment, the link of the articulated mechanism includes a first end, a second end, a transverse surface extending between the first and second ends, and a longitudinal axis extending between the first and second ends. The link further includes first mating joint features extending from the first end in a first axial direction and positioned diametrically opposite each other, and second mating joint features extending from the second end in a second axial direction and positioned diametrically opposite each other. Each of the first mating joint features includes an elongated groove defined by a pair of protrusions extending in the extension direction of the groove and defining a sidewall of the groove. Each of the second mating joint features includes a semi-circular recessed region adjacent to a circular pin, the circular pin projecting radially outward from the semi-circular recessed region. The first mating joint features are configured to engage a third mating joint feature on another link having the same configuration as the second mating joint features, and the second mating joint features are configured to engage a fourth mating joint feature on another link having the same configuration as the first mating joint features. Attached Figure Description

[0013] This disclosure may be made alone or in conjunction with the appendix. Figure 1 The present disclosure is understood from the following detailed description. The accompanying drawings are included to provide a further understanding of the disclosure, and they are included in and form part of this specification. The drawings illustrate one or more exemplary embodiments of the present disclosure and, together with the specification, explain certain principles and operations. In the drawings, Figure 1 This is a schematic diagram of an embodiment of a device including a hinged mechanism; Figure 2 It employs robotics technology and includes Figure 1 A schematic diagram of an embodiment of a computer-aided medical system for medical devices; Figure 3 and Figure 4 This is a partial perspective view of an embodiment of a device including a hinged mechanism at its distal end. Figure 5 This is an independent perspective view of an embodiment of a hinged mechanism including multiple links; Figure 6 yes Figure 5 An independent perspective view of a hinged mechanism, illustrating how the links of the hinged mechanism are hinged relative to each other; Figure 7A This is a side view of an embodiment of a hinged mechanism, which includes a first link and a second link connected by a joint structure, in a neutral state where the first link and the second link rotate relative to each other about the joint structure. Figure 7B yes Figure 7AA side view of the articulated mechanism shows the first and second links partially rotating about the joint structure relative to each other. Figure 7C yes Figure 7A A side view of the articulated mechanism shows the first and second links rotating fully relative to each other about the joint structure. Figure 8A yes Figure 7A A side view of the articulated mechanism shows the support surfaces of the first and second links, in a neutral state where the first and second links rotate relative to each other about the joint structure; Figure 8B yes Figure 7A A side view of the articulated mechanism, showing the support surfaces of the first and second links when the first and second links partially rotate relative to each other about the joint structure; Figure 8C yes Figure 7A A side view of the articulated mechanism, showing the support surfaces of the first and second links when the first and second links are fully rotated about the joint structure relative to each other; Figure 9 yes Figure 7A A side view of the articulated mechanism, showing the pivot axis of the joint structure when the first link and the second link are fully rotated about the joint structure relative to each other; Figure 10 yes Figure 5 An independent enlarged perspective view of the first link of the articulated mechanism; Figure 11 yes Figure 5 An independent enlarged perspective view of the second link of the articulated mechanism; Figure 12 This is a partial perspective view of another embodiment of the distal portion of an instrument including multiple articulated mechanisms; and Figure 13 This is a schematic diagram illustrating the motion aspects of an articulated mechanism according to various embodiments. Detailed Implementation

[0014] Various technical solutions, objectives, and / or advantages will be set forth in part in the description which follows, and will be apparent in part from the description, or may be learned by practice of this disclosure and / or the claims. At least some of these may be realized and obtained by means of the elements and combinations particularly pointed out in the appended claims.

[0015] It should be understood that the foregoing general description and the following detailed description are merely exemplary and explanatory and do not limit the claims; rather, the claims should enjoy their full scope, including equivalents.

[0016] This disclosure contemplates articulated mechanisms, such as, but not limited to, for various remotely actuated instruments, such as, for example, medical devices. Articulated mechanisms may include one or more joint structures that connect pairs of links together, said joint structures including joint features that provide the desired stiffness and predictable movement (e.g., during hinged engagement of the connected links around the joint structure), while also providing more robust misalignment tolerances (i.e., providing a greater range of hinged engagement before link misalignment, thus making the joint structures less likely to misalign with each other). Various embodiments of this disclosure contemplate joint features that interact to simulate the movement of pin-in-slot joints or revolute joint pairs, enabling the provision of the desired precision and control over joint movement (e.g., reducing slippage or unwanted movement), while utilizing relatively simple surface profile geometry for ease of manufacture. Various embodiments of this disclosure may utilize the joint feature profile simulating a pin-in-slot joint to control the positioning / timing of the joint structure hinge. With this configuration, the joint structure can provide relatively large tolerances, making it unlikely that the joint features will misalign with each other during the articulation of the articulated mechanism.

[0017] As described above, by utilizing the arrangement of mating joint features that simulate the movement of a pin-groove joint, the considered joint structure can provide a single-degree-of-freedom kinematic pair that constrains the motion of the links connected by the joint structure to roll on each other. This kinematically results in rotation about two parallel axes, or in some embodiments, rotation about a pivot axis that varies with the contact position of the joint features, as further explained below.

[0018] Therefore, as Figure 13 The illustrations illustratively demonstrate that the joint features considered according to various embodiments can allow the link to roll on each other in a manner similar to the contact of rolling surfaces of two cylindrical shapes C1 and C2, thereby articulating the joint around two “virtual” pivot points p1 and p2 located at the centers of each cylindrical shape C1 and C2, respectively. Thus, the pivot points p1 and p2 can be considered to lie on two parallel axes approximately 2R apart, where R is the radius of each cylindrical shape C1 and C2.

[0019] Figure 13Point P represents the center of the "simulated pin," which is associated with cylindrical shape C2 at a distance L from the center of the cylindrical shape (which is at pivot point p2). Point P is shown on the X-axis (e.g., the X-axis represents the center of the "simulated groove," which is associated with cylindrical shape C1), but in practical applications it may not actually exist on the X-axis and may be arranged along different paths. While it is not desirable to be bound by a particular theory, it is determined that the parameter L / R can be used to design the joint feature to determine the "L" dimension of the pin position such that when C2 rolls on C1, point P (i.e., the "simulated pin") will remain approximately on or very close to the X-axis (i.e., constrained within the "simulated groove"). In various embodiments, as will be further described below, the parameter L / R (where R is the radius of C2 and L is the distance between the center of C2 and the pin position P) can range between 1.00 and 1.30, with L / R closer to 1.00 used for a smaller range of motion (i.e., with a smaller error potential), and L / R closer to 1.30 used for a larger range of motion, such as, for example, up to about 90 degrees (i.e., with a larger error potential). In some embodiments, for example, when R = .067 inches (where R is the radius of C2) and L = .0774 inches (where L is the distance between the center of C2 and the pin position P), such that L / R = 1.155, the joint features experience very small deviations at a joint angle θ of about 60 degrees (i.e., the joint has very small errors when hinged from a neutral position through a range of about + / - 60 degrees).

[0020] In other words, the joint features of this disclosure are used to constrain the rotation of the joint structure to closely approximate this rolling motion, while preventing translational or sliding linear motion (e.g., sliding or translation of one link relative to another). In this way, the joint features allow the joint structure to have substantially repeatable movement, which allows the links to substantially return to their initial positions, also referred to herein as the “timing” of the joint structure.

[0021] Furthermore, the misalignment tolerance of the joint can be increased by utilizing the mating joint features that simulate the movement of the pin and groove joint, since the depth of the simulated pin and groove can be optimized to constrain the translation of the joint structure (e.g., using the parameter L / R), thereby preventing misalignment of the joint features even at larger angular orientations of the joint structure.

[0022] In various exemplary embodiments, the articulated mechanism includes a first link and a second link joined to each other at a joint structure. The joint structure, for example, includes a pair of complementary joint features, also referred to herein as gear features. The pair of complementary joint features are configured to allow the first link and the second link to hinge relative to each other about a pivot axis. One of the pair of complementary joint features may, for example, include an elongated slot defined by a pair of protrusions extending in the extension direction of the slot and defining sidewalls of the slot (e.g., a concave gear feature). The other of the pair of complementary joint features may include a convex gear feature terminating in a rounded head. Thus, when arranged in the articulated mechanism (to form the joint structure), the rounded head is received in the slot and is movable relative to the slot to cause the first link and the second link to hinge relative to each other. In various embodiments, the rounded head can be held in the position within the slot defined by the pair of protrusions by the joint structure from a neutral position through a hinged range of motion, for example, + / - 60 degrees.

[0023] In some embodiments, for example, the cam gear feature may have a recessed region adjacent to the circular head. In this embodiment, the circular head is held within the elongated groove defined by the pair of protrusions by the articulated range of movement from the neutral position in a first direction via the joint structure, and one of the pair of protrusions is respectively received in the recessed region and moves along the recessed region. Similarly, the circular head is held within the elongated groove defined by the pair of protrusions by the articulated range of movement from the neutral position in a second direction via the joint structure, and the other of the pair of protrusions is respectively received in the recessed region and moves along the recessed region.

[0024] Therefore, the joint structure is configured to mimic the movement of a pin-and-groove joint structure while also providing a design to resist misalignment. With this structure, for example, the considered joint structure can allow controlled and relatively wide-range articulation of the connecting rods relative to each other via a relatively simple manufacturing gear arrangement, while also reducing the possibility of joint misalignment during relatively wide-range articulation.

[0025] As will be explained in further detail below with respect to various embodiments, the corresponding complementary joint features are configured to engage and interact with each other in a manner that constrains the rotational movement of the joint structure as a pin-and-groove type of joint movement (which also resembles a rotating gear, as understood by those skilled in the art). Therefore, for ease of reference, the convex joint features and concave joint features or gear features mentioned herein are also referred to herein as pins and grooves, respectively.

[0026] Now for reference Figure 1 A schematic side view of an embodiment of device 100 (such as a medical device) is shown. The directions “proximal” and “distal” are used herein to define, for example, Figure 1 The directions shown generally indicate the distal end, which is typically along a further direction of the moving arm or the direction closest to the working part in the intended operational use of the instrument 100. While aspects of this disclosure are discussed in the context of medical or surgical instruments with a joint structure (where the joint structure takes the form of a wrist supporting an end effector or other working end component of the instrument), embodiments of this disclosure can be used with a wide variety of instruments used in medical procedures. For example, such instruments include those for diagnosis, treatment, and sensing, including, for example, imaging instruments such as endoscopes and other imaging devices. Therefore, medical instruments as used herein include a wide range of instruments used in surgical, diagnostic, and therapeutic applications. Furthermore, aspects of this disclosure can have non-surgical applications, such as other remotely actuated instruments for examination, as well as other industrial uses, general robotic uses, manipulation of non-tissue workpieces, etc.

[0027] The device 100 includes a shaft 104 having a transmission mechanism 102 at a proximal portion of the shaft 104 and a working end member 106 at a distal portion 107 of the shaft. In an exemplary embodiment, the transmission mechanism 102 is configured to work in conjunction with an operating system (as described below). Figure 2 The control system shown is docked. Optionally, the transmission mechanism 102 can be configured for manual operation, such as for manual laparoscopic instruments, and may have a handle or other arrangement configured for direct operation by the user.

[0028] The working end component 106 is connected at the distal portion 107 of the shaft 104 via a hinged mechanism 105. The hinged mechanism 105 may include one or more hinged joint structures to give the working end component 106 one or more degrees of freedom of movement relative to the shaft 104 (e.g., to move the working end component 106 in one or more of pitch and yaw). Therefore, the hinged mechanism 105 may include two links joined together by joint structures, or a series of more than two links joined together by a series of joint structures. For simplicity and simplification, the embodiments discussed below illustrate two links and a single joint structure (hereinafter referred to as the hinged mechanism), but the principles disclosed herein can be applied to hinged mechanisms having more than two links and more than one joint structure, as is well known to those skilled in the art. Furthermore, the hinged mechanism according to exemplary embodiments may include a series of links connected to joint structures, wherein one or more joint structures have the same or different axes about which the connected links are hinged.

[0029] Certain coordinated movements of multiple joint structures can be achieved, for example, by hinged working end component 106 relative to the axis, longitudinal translation, combined movement in the pitch and yaw directions, or other complex movements of working end component 106 relative to the instrument axis 104 in multiple degrees of freedom. Although combined Figure 1 A single actuating element 108 is shown, but other additional actuating elements may also be operatively coupled between the transmission mechanism 102 and the articulated mechanism 105 to actuate the articulation D of the articulated mechanism 105 along various degrees of freedom associated with the individual joint structure.

[0030] It can be done manually or by manipulating the system (e.g., Figure 2 The operation of the working end member 106 is controlled by the operation of the transmission mechanism 102, which is the actuation of the control system shown. The transmission mechanism 102 includes various mechanical and / or electromechanical devices that transmit motion, energy, and / or signals, for example, from the control system or from inputs / input devices at the user-operable transmission mechanism 102, to the working end member 106. For example, one or more actuating elements (such as...) Figure 1 An actuating element 108 shown may extend from the transmission mechanism 102, through the shaft 104, and into the working end member 106 to operatively couple the transmission mechanism 102 (or a component thereof) to the working end member 106. The force applied by the transmission mechanism 102 to the actuating element 108 may actuate (e.g., close, open, or otherwise control) the working end member 106.

[0031] Although Figure 1 The working end effector 106 shown includes a jaw mechanism (which includes a pair of opposing jaw members), but other working end effector configurations, such as staplers, clamp applicators, ligation tools, and other tools, are contemplated within the scope of this disclosure. Furthermore, as... Figure 3 and Figure 4 In one embodiment, the exemplary device 200 may similarly include a working end-effector component in the form of an imaging device, such as, for example, an endoscope camera 206, which is connected to the distal portion 207 of the axis 204 of the device 200 via a hinged mechanism 205. In this way, the device 200 can similarly operate to position the distal camera 206 for observing working sites within a patient's body and for manipulating surgical instruments.

[0032] Furthermore, more than one articulated mechanism can be incorporated into the device 100. For example... Figure 12 In one embodiment, the exemplary device 300 may similarly include a jaw mechanism 306, which is connected to the distal portion 307 of the axis 304 of the device 300 via hinged mechanisms 305 and 309.

[0033] In various embodiments, the actuating element may include a flexible member, such as a polymer or a metal (e.g., tungsten); a solid or braided actuating element, such as a cable. Selective tension of the actuating element can cause force to be transmitted to the linkage of the articulated mechanism to result in articulation in a given direction. Such components are generally well known to those skilled in the art and therefore will not be described in detail herein.

[0034] In various embodiments, the transmission mechanism 102 is configured to be operatively coupled to and receive drive inputs from a manipulator system of a remotely operable computer-assisted medical system (sometimes referred to as a robotic surgical system) that is at least partially operated using robotics. One embodiment of such a computer-assisted medical system... Figure 2 The schematic diagram illustrates a manipulator system 1000 comprising multiple manipulator arms 1002, to which a transfer mechanism 102 of an instrument 100 is operably coupled; and a surgeon-side console 2000 comprising various main inputs 52 and a surgeon's observer 2006, the surgeon's observer including endoscopic imaging devices (such as, for example...). Figure 3 and Figure 4 The device 200 of the embodiment captures video images and / or other graphic information of a remote working part by a camera 206; and may also have a vision / control console 4000 with a display 4006 that presents images similar to those of the observer 2006 or other information related to the program.

[0035] In some embodiments, the vision / control console 4000 may further include components that supply assistive functions to the instrument via an auxiliary unit 80, which may be, for example, a blow-in gas, a vacuum for evacuation, electrosurgical energy, and similar flux supply unit. Such a unit may be controlled by a controller integrated with the system and / or may be controlled independently at a separate input unit 90, rather than via the surgeon's console 2000. Non-limiting embodiments of computer-aided, remotely operated medical systems that can utilize the instrument 100 described herein and various instrument embodiments are commercially available from da Vinci® Surgical Systems, Intuitive Surgical, Inc., Sunnyvale, California.

[0036] In various other embodiments considered within the scope of this disclosure, the medical device 100, 200, or 300 may be configured for manual actuation, wherein the proximal transmission mechanism 102 has an input configured for manual actuation rather than being coupled to a manipulator arm. However, other embodiments contemplate that the device may have both a manually actuated input and an input configured to be driven by a drive output of a manipulator system.

[0037] Turn again Figure 3 and Figure 4 An exemplary embodiment of the joint structure 210 of the articulated mechanism (e.g., elbow) 205 of the surgical instrument 200 is shown. For clarity, Figure 3 and Figure 4 The example only describes the distal portion 207 of the shaft 204 of the instrument 200, which includes a hinged mechanism 205 connected thereto. This hinged mechanism 205 comprises multiple joint structures, one of which, 210, is labeled and will be further described below. Other joint structures may have similar or different configurations. Figure 3 and Figure 4 A further example is a working end-effector component in the form of an endoscope camera 206, which is attached to the elbow 205 of the instrument 200. Figure 4 An embodiment of the device 200 is also exemplified, which further includes a protective cap 209 positioned over the articulated mechanism 205. As discussed above, for example, the device 200 can be used to insert the end of the camera 206 through a cannula into a small incision within a patient undergoing a medical procedure, and to operate the elbow 205 at a working site within the patient. However, those skilled in the art will understand that the connector structures according to the various embodiments described further in detail below can be used with other working end component configurations (as referenced above). Figure 1 and Figure 12 The apparatus of any configuration discussed in apparatus 100 and 300.

[0038] The lateral dimensions (e.g., diameter) of the shaft 204, the articulation mechanism (e.g., elbow) 205, and the working end component of the device 200 are typically selected based on the size of the sleeve to be used with the device. In an exemplary embodiment, the maximum lateral dimensions of the working end component, the articulation mechanism 205, and the shaft 204 can be in the range of about 3 mm to about 13 mm, for example, about 4 mm, about 5 mm, or about 8 mm, to match the dimensions of some existing sleeve systems. Due to the dimensional constraints of these components, it is advantageous for the connector structure (e.g., connector structure 210) to save as much internal cross-sectional area as possible so as not to interfere with the laying of conduits, cables, and / or other components (e.g., actuating elements for supplying energy, light, etc. as described above) and / or the central cavity.

[0039] refer to Figure 3 and Figure 4The articulated mechanism may include a first link 212 and a second link 214 connected at a joint structure 210. The joint structure 210 may be a two-piece joint, wherein the first link 212 and the second link 214 are in direct contact with each other via a joint feature or gear feature of the joint structure 210. The joint structure 210 including links 212, 214 may be provided in an instrument's toggle or other articulated mechanism, such as a toggle 105, 205 supporting a working end component or along the length of an axis, as in... Figure 12 As shown at position 309 in the device 300. Links 212 and 214 can be connected together by an actuator 202, which controls the movement of links 212 and 214 about the joint structure 210 (as described above for...). Figure 1 As discussed in the exemplary embodiments, and for pressing links 212, 214 against each other to hold them together, as is well known to those skilled in the art. According to embodiments, each link 212, 214 may include one or more channels 203 within the transverse walls 233, 235 (e.g., see...). Figure 11 (Separate enlarged view of link 214) to accommodate a corresponding number of actuating elements 202, such as cables, as described below, passing through links 212 and 214. Figure 5 The hinged mechanism 205 is further shown in a separate view.

[0040] According to embodiments, the linkage may include more than one channel to accommodate various numbers of actuators and / or allow selection of actuator placement paths. For example, the linkage may include two actuator channels, three channels, four channels, or more tendon channels. As will be understood by those skilled in the art, actuators may be arranged in pairs on opposite (e.g., diametrically opposite) sides of the linkage and operate in a concerted manner to rotate the linkage in opposite directions relative to the pivot PA about the joint structure 210, wherein one cable (or a portion thereof, if a shared cable is used) is released while the other cable (or a portion thereof) is retracted. Furthermore, as... Figure 5 As an example, in various embodiments, some actuating elements may be arranged in a generally straight path (e.g., for cables used to drive the connector structure), and some actuating elements may be arranged in a helical path (e.g., for cables used to constrain the connector structure), as will be understood by those skilled in the art or of ordinary skill.

[0041] As in Figure 5 A further example is shown, illustrating a hinged mechanism 205 consisting of multiple joint structures, wherein two different such joint structures 210 are marked, and... Figure 10In the enlarged, independent view, each link 212 has oppositely facing end faces 232, 232' and a transverse wall 233 extending between the end faces 232, 232'. Similarly, further reference... Figure 11 An enlarged, independent view shows that each link 214 has oppositely facing end faces 234, 234' and a transverse wall 235 extending between end faces 234, 234'. Longitudinal axis. Each link extends centrally through each of the links 212, 214. In various embodiments, each of the first and second links 212, 214 is configured to be generally annular, having a central opening 236, 237 surrounded by corresponding transverse walls 233, 235 (see also...). Figure 6 (where the actuating element is removed for ease of illustration). Although as... Figure 10 and Figure 11 As shown in the independent enlarged view, in some embodiments, links 212 and 214 may have similar structures, but as Figure 5 and Figure 6 As further shown, links 212 and 214 may also have different structures—for example, depending on their placement in the articulated mechanism 205, as will be understood by those skilled in the art.

[0042] Furthermore, while the links can have a generally annular configuration, the central openings 236, 237 are not limited to circular shapes and can have various forms. In various embodiments, each central opening 236, 237 can be perpendicular to or parallel to the pivot axis PA of the first and second links 212, 214 around the joint structure 210 relative to each other (see...). Figure 9 Extend in the direction of ).

[0043] The term "link" is used in a broad sense herein because it is often used to describe chain-like or spine-like structures. Those skilled in the art will understand that the link components of an articulated mechanism can have a variety of shapes and configurations, not limited to ring shapes.

[0044] To control the positioning / timing of the hinges of links 212 and 214 relative to each other, while also providing relatively large tolerances for misalignment of links 212 and 214 relative to each other, as described above, various embodiments of this disclosure consider the joint feature profile simulating a pin-groove joint between links 212 and 214. For example, in Figures 5-11 As best illustrated in the enlarged, independent view, the joint structure 210 connecting links 212, 214 can therefore include corresponding joint features 222, 224 that mesh with each other. For example, refer to Figure 5 and Figure 10Each first link 212 may include a first mating feature 222, which is diametrically opposed to each other and extends away from the end face 232 in a first axial direction A1. Each second link 214 may include a second mating feature 224, which is diametrically opposed to each other and extends away from the end face 234 in a second axial direction A2. As will be further described below and Figures 7A-7C and Figure 9 As shown, connector features 222 and 224 are complementary and are configured to engage with each other by means of the range of rotational movement of links 212 and 214 relative to each other.

[0045] like Figures 7A-7C , Figure 10 and Figure 11 As illustrated in the independent views, in various embodiments, each of the first pair of connector features 222 includes an elongated groove 223 defined by a pair of protrusions 225 extending in the extension direction of the groove 223 and defining a sidewall 223' of the groove 223. Each of the second pair of connector features 224 includes a convex gear feature 224 terminating in a rounded head 227. In this way, the first pair of connector features 222 and the second pair of connector features 224 can engage with each other to form a connector structure 210, such that the first link and the second link 212, 214 can rotate relative to each other about the connector structure 210 and the pivot axis PA (see [link]). Figure 9 ).

[0046] In various embodiments, each of the first link and the second links 212 and 214 may further include, for example, an additional joint feature extending from another of their respective end faces 232', 234'. For example, refer to... Figure 5 and Figure 10 For the corresponding joint structure 210, the first connecting rod 212 may further include a third pair of joint features 242, which extends from the end face 232' in an axial direction A2 opposite to the direction A1 of the first pair of joint features. In some embodiments, such as Figure 10 and Figure 11 As shown, the second and third connector features 224 and 242 can have the same configuration. Similarly, as Figure 5 and Figure 11As shown, the second link 214 may further include a fourth mating feature 244, which extends from end face 234' in an axial direction A1 opposite to the direction A2 in which the second mating feature 224 extends, and the first mating features and the fourth mating features 222, 244 may have the same configuration. In various embodiments, as shown, the paired mating features on opposite end faces of the link may be offset by 90 degrees relative to each other to provide an orthogonal axis of rotation of the link relative to the mating link of the connecting link at the mating structure, while in other embodiments, the mating features may be aligned and not rotated offset.

[0047] As described above, this disclosure considers the mating joint features of the joint structure, enabling cooperation and interaction in a manner similar to a pin-and-groove joint. In this way, as... Figures 7A-7C and Figures 9-11 As shown, each considered joint structure 210 includes a pair of complementary joint features 222, 224 or gear features, such that one of the pair of complementary joint features 222, 224 includes an elongated slot 223, and the other of the pair of complementary joint features includes a rounded head 227. As described above, the elongated slot is defined by a pair of protrusions 225 extending in the extension direction of the slot 223, each of the pair of protrusions 225 including a terminal portion 225'. Thus, the pair of protrusions serve to define sidewalls 223' of the slot 223, such that the elongated slot 223 opens at one end and closes at the opposite end, wherein the closed end of the slot 223 has a surface profile complementary to the rounded head 227.

[0048] In this way, the circular head 227 can be received in the slot 223 and can move relative to the slot 223 to provide a pin-and-groove hinge for the joint structure 210, which also increases the misalignment tolerance of the joint structure 210. For example, as in Figure 7A , Figure 7B and Figure 7C As illustrated in the step-by-step example, from the neutral position via joint structure 210 (see...) Figure 7A ) through the angular limit θ of the range of motion (see Figure 7C Within the articulated range of motion, the round head 227 will remain in position within the groove 223 defined by the pair of protrusions 225. Although in Figures 7A to 7C The example illustrates movement only in the first rotational direction D1, but it should be understood that the circular head 227 can also move from... Figure 7A The neutral position moves relative to the slot 223 in the second opposite rotation direction D2 through the opposite angular limit θ of the range of motion (see Figure 9This allows the connector structure 210 to move between a first end and a second end within a relative range of rotation. In some embodiments, for example, the round head 227 can be held in position within the groove 223 defined by the pair of protrusions 225 by the connector structure 210 from the neutral portion through a hinged range of movement of + / -60 degrees.

[0049] like Figure 9 In the example, when the joint structure 210 moves through the hinged range of motion, the joint structure 210 pivots about the pivot axis PA, which varies with the contact position on the radius of curvature of the pivot radius PR. Figure 9 The pivot axis PA is shown at the 60-degree joint locking position (i.e., at the end of the relative rotation range of the links). However, the pivot axis PA should be understood as moving along the contact point of links 212, 214, which is set by the pivot radius PR shared by links 212, 214 (i.e., the contact angle to which joint 210 is set).

[0050] In various embodiments, for example, to help hold the circular head 227 in position within the slot 223, the convex gear feature 224 may include a recessed region 228 adjacent to the circular head 227, such that the circular head 227 protrudes radially outward relative to the recessed region 228. In this way, throughout the entire articulation range of the connector structure 210 (e.g., from neutral to + / - 60 degrees), the recessed region 228 can receive and guide a corresponding protrusion 225 of the pair of protrusions 225. In other words, through the articulation range of the connector structure 210 from its neutral position in a first direction D1, the circular head 227 is held within the slot 223 and defined by the pair of protrusions 225, and one of the pair of protrusions 225 is respectively received in the recessed region 228 and moves along the recessed region 228. The circular head 227 is held within the groove 223 and defined by the pair of protrusions 225, and the other of the pair of protrusions 225 is received in the recessed region 228 and moves along the recessed region 228, through the hinged range of movement from the neutral position in the second direction D2 via the joint structure 210.

[0051] In various embodiments, at both the first and second ends of the articulated range of motion of the joint structure 210, the corresponding outer peripheral portions 253 and 255 of the joint features 222 and 224, which face each other, also contact each other (e.g., see...). Figure 7C In one exemplary embodiment, the outer peripheral portions 253, 255 may be angled (in other words, tilted or angular) relative to the inner peripheral portions of the end faces 232, 234 of the connecting rods 212, 214.

[0052] As is known in the art, the configuration in which the actuating element is held together by links connected by a joint structure results in compressive loads being applied between the links. To address these compressive loads, the proposed joint structure 210 may further include one or more features configured to provide load-bearing surfaces to accommodate compressive loads. Figures 8A-8C The best view shown in the independent view (which is similar to) Figures 7A-7C An example of connector structure 210 from a neutral position (see...) Figure 8A ) through the angular limit θ of the range of motion (see Figure 8C (As the joint structure 210 gradually moves through the articulated range of motion), the links 212, 214 may include corresponding support surfaces 252, 254 configured to roll into contact with each other throughout the articulated range of motion. In various embodiments, for example, the corresponding support surfaces 252, 254 may be positioned radially inward of each joint feature 222, 224. For example, the support surfaces 252, 254 may each include a protruding surface profile such that the support surfaces 252, 254 can interact and roll along each other as the rounded head 227 moves relative to the groove 223. Reference is made to U.S. Patent Nos. 6,817,974 and 11,518,048, which are incorporated herein by reference and describe the configuration of the rolling support surfaces and the interaction of this configuration with the emanation position of the actuating element and its kinematic effects on the overall articulation.

[0053] As described above, because the circular heads 227 of the slot 223 and the cam feature 224 are configured to cooperate and move relative to each other in a manner similar to a pin-and-groove joint, the circular heads 227 of the cam feature 224 can also be considered as pins engaging with the slot 223, which are formed by a pair of protrusions 225 of the concave gear feature 222. Furthermore, since the joint features 222, 224 of the joint structure 210 simulate the movement of a pin-and-groove, rotary joint, the joint structure 210 can provide a controlled and “timing” range of articulated motion between the first link 212 and the second link 214. For example, the joint structure 210 can provide a repeatable maximum range of motion up to the angular limit θ (at the first and second ends of the articulated range of motion) while also preventing the first link 212 from misaligning from the second link 214. In various embodiments, the angular limit θ can be increased to approximately 60 degrees without increasing the risk of misalignment of the links 212, 214.

[0054] Those skilled in the art will understand that, without departing from the scope of this disclosure and the claims, the above discussion and... Figures 3-11The joint structure 210 and associated links 212, 214 shown in the examples are merely non-limiting and exemplary, and the articulated mechanisms, joint structures, and links according to this disclosure may have various configurations and / or shapes of joint features 222, 224. Furthermore, the articulated mechanisms, joint structures, and links contemplated may include various other design features different from those discussed in the exemplary embodiments above.

[0055] In practice, due to considerations of reducing complexity regarding surface profiles, joint structures and articulated mechanisms including such joint structures (e.g., instrument elbows and other instrument joints and combinations thereof) can be designed to provide the required amount of constrained rolling motion in a more efficient manner with fewer parts. As a result, the manufacturing cost and complexity of articulated mechanisms including one or more such joint structures (such as articulated elbows or other instruments) can be reduced while still achieving the required control over the articulation.

[0056] The embodiments described herein are well-suited for use in medical applications. Specifically, some embodiments are suitable for procedures such as surgery, remote surgery, diagnostic, therapeutic, and / or biopsy. Such procedures can be performed on, for example, human patients, animal patients, human cadavers, animal cadavers, and human or animal anatomy. Some embodiments are also suitable for procedures such as non-surgical diagnostics, cosmetic procedures, imaging of human or animal anatomy, data collection from human or animal anatomy, training medical or non-medical personnel, and procedures on tissue removed from human or animal anatomy (without returning the human or animal anatomy). Even when suitable for such medical procedures, the embodiments can be used for procedures on non-living materials and forms that are not part of a human or animal anatomy. Furthermore, some embodiments are also suitable for non-medical applications, such as industrial robotics uses. In non-limiting embodiments, the techniques, methods, and apparatus described herein can be used in or as part of computer-assisted surgical systems employing robotic technology, such as da Vinci® surgical Systems, commercially available from Intuitive Surgical, Inc., Sunnyvale, California. However, those skilled in the art will understand that the aspects disclosed herein can be embodied and implemented in various ways and systems, including manually operated instruments and computer-aided remotely operated systems, in both medical and non-medical applications. References to daVinci® surgical systems are exemplary and are not intended to limit the scope of the disclosure herein.

[0057] As used herein and in the claims, terms such as computer-aided or remotely operable in the reference manipulator system should be understood broadly to refer to any system comprising one or more controllable kinematic structures (“manipulators”) that are at least partially movable and controllable with the assistance of an electronic controller (with or without human input). Such systems may occasionally be referred to in the art as robot-assisted systems or robotic systems, and are commonly referred to as such. Such systems include those controlled by a user (e.g., via remote operation), automatically controlled by a computer (so-called autonomous control), or a combination of these. In examples where the user controls at least some operations of the manipulator, the electronic controller (e.g., a computer) may facilitate or assist the operation. The term “computer” as used in “computer-aided manipulator system” broadly refers to any electronic control device used to control or assist the user in controlling the operation of the manipulator, and is not intended to be limited to things formally defined or colloquially referred to as “computers.” For example, the range of electronic control devices in computer-aided manipulator systems can range from a traditional “computer” (e.g., a general-purpose processor plus memory storing instructions for processor execution) to low-level special-purpose hardware devices (analog or digital), such as discrete logic circuits or application-specific integrated circuits (ASICs), or anything in between. Furthermore, manipulator systems can be implemented in a variety of contexts to perform a variety of programs, including medical and non-medical procedures. Therefore, while some examples described in more detail herein may focus on a medical context, the devices and principles described herein can also be applied to other contexts, such as industrial manipulator systems.

[0058] The accompanying drawings of this specification and the various aspects and embodiments should not be considered limiting—the claims define the scope of protection. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the spirit and scope of this specification and the claims. In some cases, well-known structures, components, and techniques have not been shown or described in detail so as not to obscure this disclosure. Identical numbers ending with the same two numerals but beginning with different series, such as 8xx, 10xx, etc., in two or more drawings are preferably used to denote the same or similar elements.

[0059] Elements and related aspects described in detail with reference to one embodiment may be included in other embodiments where they are not specifically shown or described, wherever feasible. For example, if an element is described in detail with reference to one embodiment but not with reference to a second embodiment, that element may still be required to be included in the second embodiment.

[0060] Furthermore, the terminology used in this specification is not intended to be limiting. For example, spatially relative terms such as “below,” “under,” “lower,” “above,” “upper,” “near,” “far,” etc., may be used to describe the relationship of one element or feature to another element or feature as illustrated in the examples in the figures. These spatially relative terms are intended to include different positions (i.e., locations) and orientations (i.e., rotational placement) of the device in use or operation, in addition to the positions and orientations shown in the figures. For example, if the device in the figures is flipped, an element described as “below other elements or features” or “below other elements or features” will be “above other elements or features” or “on top of other elements or features.” Thus, the term “below” can include both above and below positions and orientations. The device may be oriented in other ways (e.g., rotated 90 degrees or otherwise), and the spatially relative descriptors used herein are interpreted accordingly. Similarly, descriptions of movement along and about various axes include various specific device positions and orientations. Furthermore, unless the context otherwise requires, the singular forms “a,” “an,” and “the” are also intended to include the plural forms. Furthermore, the terms "comprises," "comprising," and "includes," etc., specify the presence of the described features, steps, operations, elements, components, etc., but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, or groups. Components described as connected may be electrically or mechanically directly connected, or they may be indirectly connected via one or more intermediate components. Unless the context of the specification otherwise requires, mathematical and geometric terms are not necessarily used according to their strict definitions, as those skilled in the art will understand that, for example, substantially similar elements that function in substantially similar ways may readily fall within the scope of descriptive terms, even if those terms also have strict definitions.

[0061] Other embodiments according to this disclosure will be apparent to those skilled in the art from consideration of the specification and drawings, and from the practice of the embodiments disclosed herein. The specification and embodiments are intended to be considered exemplary only, and the appended claims shall enjoy the widest scope, including equivalents, in accordance with applicable law.

Claims

1. A joint structure configured to provide a hinge between two links connected by the joint structure, the joint structure comprising: A pair of complementary joint features, wherein: One of the pair of complementary joint features includes an elongated groove defined by a pair of protrusions extending in the elongation direction of the groove and defining a sidewall of the groove. The other of the pair of complementary joint features includes a convex gear feature terminating in a rounded head. The circular head is received in the groove and is movable relative to the groove, and The circular head is held in position within the groove defined by the pair of protrusions by the hinged range of motion of the joint structure.

2. The connector structure according to claim 1, wherein the elongated groove opens at one end and closes at the opposite end, the closed end having a surface profile complementary to the circular head.

3. The connector structure according to claim 2, wherein each of the pair of protrusions includes a terminal portion.

4. The joint structure according to any one of claims 1-3, wherein the circular head of the convex gear feature is movable relative to the slot to provide a pin-and-groove hinge of the joint structure.

5. The joint structure according to any one of claims 1-3, wherein the cam gear feature has a recessed region adjacent to the circular head, the circular head protruding radially outward relative to the recessed region.

6. The joint structure according to claim 5, wherein, Through the hinged travel range of the joint structure, the recessed area receives and guides the corresponding protrusion of the pair of protrusions.

7. The joint structure according to any one of claims 1-3, wherein the hinge movement range of the joint structure is from the neutral position through + / -60 degrees.

8. A joint structure configured to provide a hinge between two links connected by the joint structure, the joint structure comprising: A pair of complementary joint features, wherein: One of the pair of complementary joint features includes an elongated groove defined by a pair of protrusions that extend in the extension direction of the groove and define the sidewalls of the groove. Another of the pair of complementary joint features includes a convex gear feature terminating in a circular head, wherein the convex gear feature has a recessed region adjacent to the circular head. The circular head is received in the groove and is movable relative to the groove, and The circular head is held within the elongated groove defined by the pair of protrusions within a hinged range of motion in a first direction from a neutral position via the joint structure, and one of the pair of protrusions is respectively received in the recessed region and moves along the recessed region. The circular head is held within the elongated groove and defined by the pair of protrusions, which are respectively received in the recessed region and move along the recessed region via the joint structure from the neutral position in the second direction.

9. The connector structure according to claim 8, wherein the elongated groove opens at one end and closes at the opposite end, the closed end having a surface profile complementary to the circular head.

10. The connector structure according to claim 9, wherein each of the pair of protrusions includes a terminal portion.

11. The connector structure according to any one of claims 8-10, wherein the circular head protrudes radially outward relative to the recessed region.

12. The joint structure according to any one of claims 8-10, wherein the hinge movement range of the joint structure from the neutral position in the first direction and from the neutral position in the second direction is + / - 60 degrees.

13. A hinged mechanism, comprising: A first link and a second link are connected to each other by a pair of complementary joint features configured to allow the first link and the second link to hinge relative to each other about a pivot axis, the pair of complementary joint features including: A pair of protrusions extending from the first link in a direction perpendicular to the pivot axis and defining an elongated slot between the pair of protrusions, and A pin, extending from the second link and received in the elongated slot, The pin and the pair of protrusions are rotatable relative to each other to cause the first link and the second link to hinge relative to each other, and The pin is able to translate relative to the groove and remain within the groove defined by the pair of protrusions through the articulated range of motion of the first link and the second link relative to each other.

14. The articulated mechanism of claim 13, wherein the pair of complementary joint features comprises a first joint feature and a second joint feature, the first joint feature extending from the first link in a first axial direction and positioned diametrically opposite to each other, and the second joint feature extending from the second link in a second axial direction and positioned diametrically opposite to each other.

15. The articulated mechanism according to claim 14, Each of the first link and the second link further includes oppositely facing end faces, a transverse wall extending between the end faces, and a longitudinal axis extending between the end faces. The first pair of joint features extends from one of the end faces of the first connecting rod, and The second connector feature extends from one of the end faces of the second link.

16. The articulated mechanism of claim 15, wherein each of the first link and the second link includes a central opening surrounded by the transverse wall.

17. The articulated mechanism of claim 16, wherein the central opening of each of the first link and the second link extends in a direction perpendicular to or parallel to the pivot axis of the hinge of the first link and the second link relative to each other.

18. The articulated mechanism according to any one of claims 14-17, wherein each of the first pair of joint features comprises a pair of protrusions extending from the first link in a direction perpendicular to the pivot axis and defining an elongated groove between the pair of protrusions, each of the pair of protrusions comprising a terminal portion.

19. The articulated mechanism of claim 18, wherein each of the second joint features comprises a pin extending from the second link in a direction perpendicular to the pivot axis, the pin comprising a rounded head projecting radially outward from a recessed region.

20. The articulated mechanism of claim 19, wherein, from a neutral position via the first link and the second link, through a range of articulated movement of + / -60 degrees relative to each other, in a first direction from the neutral position, one of the pair of protrusions is received in the recessed region and moves along the recessed region, and in a second direction from the neutral position, the other of the pair of protrusions is received in the recessed region and moves along the recessed region.

21. The articulated mechanism according to any one of claims 14-17, wherein the first link further includes a third mating joint feature extending from the first link in the second axial direction.

22. The articulated mechanism of claim 21, wherein the first and third joint features are offset from each other by 90 degrees about the first link and are positioned diametrically opposite each other.

23. The articulated mechanism of claim 13, further comprising at least one drive traction cable connecting the first link and the second link.

24. The articulated mechanism of claim 23, wherein the at least one drive traction cable is configured to apply a force to at least one of the first link and the second link to cause the first link and the second link to articulate relative to each other.

25. A medical device comprising: axis; The hinged mechanism according to claim 13 is connected to the shaft; as well as Working end component.

26. The medical device of claim 25, wherein the working end component includes an imaging device.

27. The medical device of claim 25, wherein the working end component includes a clamping mechanism.

28. The medical device according to any one of claims 25-27, wherein the hinged mechanism is coupled to the end portion of the shaft.

29. The medical device of claim 28, wherein the working end component is coupled to the hinged mechanism.

30. A link in a hinged mechanism, the link comprising: A first end, a second end, a transverse surface extending between the first end and the second end, and a longitudinal axis extending between the first end and the second end; The first pair of connector features extend from the first end in a first axial direction and are positioned diametrically opposite each other; and The second pair of connector features extend from the second end in the second axial direction and are positioned opposite each other diametrically. Each of the first pair of connector features includes an elongated groove defined by a pair of protrusions that extend in the extension direction of the groove and define a sidewall of the groove. Each of the second pair of connector features includes a semi-circular recessed area adjacent to the circular pin, the circular pin protruding radially outward from the semi-circular recessed area. The first pair of connector features is configured to engage with a third pair of connector features on another link, having the same configuration as the second pair of connector features, and The second connector feature is configured to engage with a fourth connector feature on another link having the same configuration as the first connector feature.

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