Low-profile robotic surgical devices and related systems and methods

Abstract

A robotic surgical device having an elongate body, a distal section having a distal section diameter and a proximal section having a proximal section diameter greater than the distal section diameter, and a first arm and a second arm operably coupled to a distal end of the device body. In some embodiments, the elongate device body has a first driveline assembly and a second driveline assembly, both of which have pitch and roll drivelines. In other embodiments, the first and second arms each have a forearm with a rotational and roll driveline.

Description

[Technical Field]

[0001] Embodiments disclosed herein relate to various medical devices and associated components that can comprise surgical systems, including robotic and / or in vivo medical devices and associated components. Certain embodiments include various robotic medical devices, including robotic devices that are disposed within a body cavity and that are deployed using a body or support component that is disposed through a hole or opening within the body cavity. Other embodiments relate to various systems having robotic surgical devices and controllers. [Background technology]

[0002] Invasive surgical procedures are essential to address a variety of medical conditions, and where possible, minimally invasive procedures such as laparoscopic surgery are preferred. However, known minimally invasive techniques, such as laparoscopy, are limited in scope and complexity due in part to 1) the limited mobility imposed by the use of rigid tools inserted through access ports, and 2) limited visual feedback. Known robotic systems, such as the da Vinci® Surgical System (available from Intuitive Surgical, Inc., Sunnyvale, Calif.), are not only limited by access ports, but also have the additional disadvantages of being very large, very expensive, unavailable in most hospitals, and having limited sensory and mobility capabilities.

[0003] There is a need in the art for improved surgical methods, systems, and devices. Summary of the Invention

[0004] Discussed herein are various robotic surgical systems having various robotic devices, including low-profile robotic surgical devices for use in minimally invasive procedures.

[0005] In Example 1, a robotic surgical device comprises an elongate device body, a first arm operably coupled to a distal end of the elongate device body via a first shoulder assembly, and a second arm operably coupled to the distal end of the elongate device body via a second shoulder assembly. The elongate device body comprises a distal section having a distal section width in the range of about 28 mm to about 30 mm and a distal section depth in the range of about 22 mm to about 24 mm, and a proximal section having a proximal section diameter greater than the distal section diameter.

[0006] Example 2 relates to the robotic surgical device according to Example 1, in which each of the first arm and the second arm has an arm width ranging from about 13 mm to about 15 mm and an arm depth ranging from about 20 mm to about 26 mm.

[0007] Example 3 relates to a robotic surgical device according to Example 2, with an arm width of about 14 mm and an arm depth of about 23 mm. Example 4 relates to a robotic surgical device according to Example 1, with a distal section width of about 29 mm and a distal section depth of about 23 mm.

[0008] Example 5 relates to a robotic surgical device according to example 1, wherein the proximal section comprises a camera port. Example 6 relates to the robotic surgical device according to Example 1, wherein the elongated device body further comprises a first driveline assembly and a second driveline assembly. The first driveline assembly comprises a first pitch driveline and a first roll driveline. The first pitch driveline comprises a first pitch actuator, a first pitch motor gear rotatably coupled to the first pitch actuator via a first pitch motor drive shaft, and a first pitch driven gear rotatably coupled to the first pitch motor gear, wherein the first pitch driven gear rotates about an axis substantially perpendicular to a longitudinal axis of the first pitch actuator. The first roll drive system includes a first roll actuator disposed proximal to the first pitch actuator, a first roll motor gear rotatably coupled to the first roll actuator, a first roll drive shaft rotatably coupled to the first roll motor gear, the first roll drive shaft disposed radially adjacent to the first pitch actuator, and a first shoulder drive shaft rotatably coupled to the first roll drive shaft, the first shoulder drive shaft rotationally constrained to the first shoulder assembly and having a first lumen defined therethrough, the first pitch motor drive shaft rotatably disposed through the first lumen, and the first pitch driven gear rotatably disposed within the first shoulder assembly. The second drive system assembly includes a second pitch drive system and a second roll drive system. The second pitch drive system includes a second pitch actuator, a second pitch motor gear rotatably coupled to the second pitch actuator via a second pitch motor drive shaft, and a second pitch driven gear rotatably coupled to the second pitch motor gear, wherein the second pitch driven gear rotates about an axis that is substantially perpendicular to the longitudinal axis of the second pitch actuator.The second roll drive system includes a second roll actuator disposed proximal to the second pitch actuator, a second roll motor gear rotatably coupled to the second roll actuator, a second roll drive shaft rotatably coupled to the second roll motor gear, the second roll drive shaft disposed radially adjacent to the second pitch actuator, and a second shoulder drive shaft rotatably coupled to the second roll drive shaft, the second shoulder drive shaft rotationally constrained to the second shoulder assembly, the second shoulder drive shaft having a second lumen defined therethrough, the second pitch motor drive shaft rotatably disposed through the second lumen, and the second pitch driven gear rotatably disposed within the second shoulder assembly.

[0009] Example 7 relates to the robotic surgical device according to Example 1, wherein each of the first arm and the second arm comprises an upper arm including a rotary drive system and a roll drive system. The rotary drive system includes a rotary actuator, a rotary motor gear rotatably coupled to the rotary actuator via a rotary motor drive shaft, and a rotary driven gear rotatably coupled to the rotary motor gear, the rotary driven gear rotating about an axis substantially perpendicular to a longitudinal axis of the rotary actuator. The roll drive system includes a roll actuator disposed adjacent to the rotary actuator, at least one roll gear rotatably coupled to the roll actuator, and an elbow drive shaft rotatably coupled to the at least one roll gear, the elbow drive shaft rotationally constrained to the elbow assembly, the elbow drive shaft having a lumen defined therethrough, the rotary motor drive shaft rotatably disposed through the lumen, and the rotary driven gear rotatably disposed within the elbow assembly.

[0010] Example 8 relates to a robotic surgical device according to Example 7, wherein the upper arm further comprises an upper arm housing and a proximal mounting structure disposed at a proximal end of the upper arm housing, the proximal mounting structure being configured to be connectable to one of the first shoulder assembly and the second shoulder assembly, and the rotational drive system and the roll drive system being disposed within the upper arm housing.

[0011] Example 9 relates to a robotic surgical device according to Example 7, wherein each of the first arm and the second arm comprises a forearm rotatably coupled to the upper arm and an end effector operably coupled to the forearm.

[0012] In Example 10, a robotic surgical device includes an elongated device body, a first arm, and a second arm. The elongated device body includes a first driveline assembly and a second driveline assembly. The first driveline assembly includes a first pitch driveline and a first roll driveline. The first pitch driveline includes a first pitch actuator, a first pitch motor gear rotatably coupled to the first pitch actuator via a first pitch motor drive shaft, and a first pitch driven gear rotatably coupled to the first pitch motor gear, wherein the first pitch driven gear rotates about an axis substantially perpendicular to a longitudinal axis of the first pitch actuator. The first roll drive system includes a first roll actuator disposed proximal to the first pitch actuator, a first roll motor gear rotatably coupled to the first roll actuator, a first roll drive shaft rotatably coupled to the first roll motor gear, the first roll drive shaft disposed radially adjacent to the first pitch actuator, and a first shoulder drive shaft rotatably coupled to the first roll drive shaft, the first shoulder drive shaft rotationally constrained to the first shoulder assembly and having a first lumen defined therethrough, the first pitch motor drive shaft rotatably disposed through the first lumen, and the first pitch driven gear rotatably disposed within the first shoulder assembly. The second drive system assembly includes a second pitch drive system and a second roll drive system. The second pitch drive system includes a second pitch actuator, a second pitch motor gear rotatably coupled to the second pitch actuator via a second pitch motor drive shaft, and a second pitch driven gear rotatably coupled to the second pitch motor gear, wherein the second pitch driven gear rotates about an axis that is substantially perpendicular to the longitudinal axis of the second pitch actuator.The second roll drive system includes a second roll actuator disposed proximal to the second pitch actuator, a second roll motor gear rotatably coupled to the second roll actuator, a second roll drive shaft rotatably coupled to the second roll motor gear, the second roll drive shaft disposed radially adjacent to the second pitch actuator, and a second shoulder drive shaft rotatably coupled to the second roll drive shaft, the second shoulder drive shaft rotationally constrained to the second shoulder assembly and having a second lumen defined therethrough, the second pitch motor drive shaft rotatably disposed through the second lumen, and the second pitch driven gear rotatably disposed within the second shoulder assembly. The first arm is operably coupled to the first shoulder assembly, and the second arm is operably coupled to the second shoulder assembly.

[0013] Example 11 relates to a robotic surgical device according to Example 10, wherein the elongated device body further comprises a distal section having a distal section width in the range of about 28 mm to about 30 mm and a distal section depth in the range of about 22 mm to about 24 mm, and a proximal section having a proximal section diameter larger than the distal section diameter.

[0014] Example 12 relates to a robotic surgical device according to Example 11, wherein the distal section width is about 29 mm and the distal section depth is about 23 mm. Example 13 relates to a robotic surgical device according to example 11, wherein the proximal section comprises a camera port.

[0015] Example 14 relates to the robotic surgical device according to Example 10, wherein each of the first arm and the second arm has an arm width ranging from about 13 mm to about 15 mm and an arm depth ranging from about 20 mm to about 26 mm.

[0016] Example 15 relates to a robotic surgical device according to Example 14, in which the arm width is about 14 mm and the arm depth is about 23 mm. Example 16 relates to the robotic surgical device according to example 10, wherein each of the first and second arms comprises an upper arm, the upper arm comprising a rotary drive system and a roll drive system. The rotary drive system comprises a rotary actuator, a rotary motor gear rotatably coupled to the rotary actuator via a rotary motor drive shaft, and a rotary driven gear rotatably coupled to the rotary motor gear, the rotary driven gear rotating about an axis substantially perpendicular to a longitudinal axis of the rotary actuator. The roll drive system comprises a roll actuator disposed adjacent to the rotary actuator, at least one roll gear rotatably coupled to the roll actuator, and an elbow drive shaft rotatably coupled to the at least one roll gear, the elbow drive shaft rotationally constrained to the elbow assembly, the elbow drive shaft comprising a lumen defined therethrough, the rotary motor drive shaft rotatably disposed through the lumen, and the rotary driven gear rotatably disposed within the elbow assembly.

[0017] Example 17 relates to a robotic surgical device according to Example 16, wherein the upper arm further comprises an upper arm housing and a proximal mounting structure disposed at a proximal end of the upper arm housing, the proximal mounting structure being configured to be connectable to one of the first shoulder assembly and the second shoulder assembly, and the rotational drive system and the roll drive system being disposed within the upper arm housing.

[0018] Example 18 relates to a robotic surgical device according to Example 16, wherein each of the first arm and the second arm comprises a forearm rotatably coupled to the upper arm and an end effector operably coupled to the forearm.

[0019] In Example 19, a robotic surgical device includes an elongated device body, a first arm operably coupled to a first shoulder assembly, and a second arm operably coupled to a second shoulder assembly. The elongated device body includes a device body housing, a first driveline assembly disposed within the device body housing, and a second driveline assembly disposed within the device body housing. The device body housing includes a distal section having a distal section diameter and a proximal section having a proximal section diameter larger than the distal section diameter. The first driveline assembly includes a first pitch driveline and a first roll driveline. The first pitch driveline includes a first pitch actuator, a first pitch motor gear rotatably coupled to the first pitch actuator via a first pitch motor drive shaft, and a first pitch driven gear rotatably coupled to the first pitch motor gear, wherein the first pitch driven gear rotates about an axis substantially perpendicular to a longitudinal axis of the first pitch actuator. The first roll drive system includes a first roll actuator disposed proximal to the first pitch actuator, a first roll motor gear rotatably coupled to the first roll actuator, a first roll drive shaft rotatably coupled to the first roll motor gear, the first roll drive shaft disposed radially adjacent to the first pitch actuator, and a first shoulder drive shaft rotatably coupled to the first roll drive shaft, the first shoulder drive shaft rotationally constrained to the first shoulder assembly and having a first lumen defined therethrough, the first pitch motor drive shaft rotatably disposed through the first lumen, and the first pitch driven gear rotatably disposed within the first shoulder assembly. The second drive system assembly is disposed within the device body housing and includes a second pitch drive system and a second roll drive system.The second pitch drive system includes a second pitch actuator, a second pitch motor gear rotatably coupled to the second pitch actuator via a second pitch motor drive shaft, and a second pitch driven gear rotatably coupled to the second pitch motor gear, wherein the second pitch driven gear rotates about an axis that is substantially perpendicular to the longitudinal axis of the second pitch actuator. The second roll drive system includes a second roll actuator disposed proximal to the second pitch actuator, a second roll motor gear rotatably coupled to the second roll actuator, a second roll drive shaft rotatably coupled to the second roll motor gear, the second roll drive shaft disposed radially adjacent to the second pitch actuator, and a second shoulder drive shaft rotatably coupled to the second roll drive shaft, the second shoulder drive shaft rotationally constrained to the second shoulder assembly, the second shoulder drive shaft having a second lumen defined therethrough, the second pitch motor drive shaft rotatably disposed through the second lumen, and the second pitch driven gear rotatably disposed within the second shoulder assembly.

[0020] While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. As will be understood, the various embodiments are capable of modification in various obvious respects, all without departing from the spirit and scope thereof. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 is a perspective view of a robotic surgical system. [Figure 2] FIG. 1 is a perspective view of a robotic surgical device. [Figure 3A] FIG. 1 is a front view of a robotic surgical device, according to one embodiment. [Figure 3B] FIG. 3B is a side view of the robotic surgical device of FIG. 3A, according to one embodiment. [Figure 4] FIG. 1 is a front view of an arm of a robotic surgical device, according to one embodiment. [Figure 5] FIG. 1 illustrates a side view of a workspace of a robotic surgical device, according to one embodiment. [Figure 6A] FIG. 1 illustrates a perspective view of the workspace of a robotic surgical device with arms disposed at a forward sweep angle, according to one embodiment. [Figure 6B] FIG. 6B is a perspective view of the workspace of the robotic surgical device of FIG. 6A with the arms disposed in a neutral position, according to one embodiment. [Figure 6C] FIG. 6B is a perspective view of the workspace of the robotic surgical device of FIG. 6A with the arms disposed at a rearward sweep angle, according to one embodiment. [Figure 7] FIG. 1 illustrates a perspective view of a housing of an elongated body of a robotic surgical device, according to one embodiment. [Figure 8A] FIG. 10 is a perspective view of some of the internal components of the housing of the elongated body of the robotic surgical device, according to one embodiment. [Figure 8B] 8B is a perspective view of a right drivetrain and a left drivetrain of the elongate body of FIG. 8A according to one embodiment. [Figure 8C] FIG. 8B is a perspective view of a right shoulder roll drive train of the elongated body of FIG. 8A according to one embodiment. [Figure 8D] FIG. 8B is a perspective view of a right shoulder pitch drive train of the elongated body of FIG. 8A according to one embodiment. [Figure 9A] FIG. 1 illustrates a perspective view of the right upper arm, according to one embodiment. [Figure 9B] FIG. 9B is a perspective view of the roll drive train and rotary drive train of the right upper arm of FIG. 9A, according to one embodiment. [Figure 9C] FIG. 9B is a perspective view of the roll drive system of the right upper arm of FIG. 9A, according to one embodiment. [Figure 9D] FIG. 9B is a perspective view of the rotary drive train of the right upper arm of FIG. 9A, according to one embodiment. [Figure 10A] FIG. 1 illustrates a perspective view of a right forearm, according to one embodiment. [Figure 10B] FIG. 10B is a perspective view of some of the internal components of the right forearm of FIG. 10A, according to one embodiment. [Figure 10C] FIG. 10B is a perspective view of the right forearm of FIG. 10A with an end effector attached thereto, according to one embodiment. [Figure 10D] FIG. 10B is a side view of the internal components of the right forearm of FIG. 10A, according to one embodiment. [Figure 10E] FIG. 10B is an opposite side view of the internal components of the right forearm of FIG. 10A, according to one embodiment. [Figure 10F] FIG. 10B is an end view of the internal components of the right forearm of FIG. 10A, according to one embodiment. [Figure 10G] FIG. 10B is a perspective view of a cross-sectional view of the distal end of the right forearm of FIG. 10A with an end effector disposed for insertion therein, according to one embodiment. [Figure 10H] FIG. 10B is a perspective view of some of the internal components of the right forearm of FIG. 10A with an end effector attached thereto, according to one embodiment. [Figure 10I] FIG. 10H is a perspective view of the internal components of FIG. 10H, according to one embodiment. [Figure 10J] FIG. 10B is a perspective view of another internal component of the right forearm of FIG. 10A with an end effector attached thereto, according to one embodiment. [Figure 10K] FIG. 10J is a perspective view of the internal components of FIG. 10J, according to one embodiment. [Figure 10L] FIG. 10B is a perspective view of some of the electrical components of the right forearm of FIG. 10A with an end effector attached thereto, according to one embodiment. [Figure 11A] FIG. 10 is a cross-sectional schematic view of a right upper arm with a motor disposed therein, according to one embodiment. [Figure 11B] FIG. 1 is a cross-sectional schematic view of the right upper arm, according to one embodiment. [Figure 11C] FIG. 10 is another cross-sectional schematic view of the right upper arm, according to one embodiment. [Figure 12] FIG. 1 is a perspective view of a one-arm robotic device, according to one embodiment. [Figure 13A]FIG. 1 is a perspective view of a three-arm robotic device with the arms in a bent configuration, according to one embodiment. [Figure 13B] FIG. 13B is a perspective view of the three-arm robotic device of FIG. 13A with the arms in a straight configuration, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0022] The various systems and devices disclosed herein relate to devices for use in medical procedures and systems. More particularly, various embodiments relate to various medical devices, including robotic devices and related methods and systems.

[0023] It is understood that various embodiments of the robotic devices and related methods and systems disclosed herein can be incorporated into or used in conjunction with any other known medical devices, systems, and methods. For example, various embodiments disclosed herein may be incorporated into or used in conjunction with any other known medical devices, systems, and methods, including, but not limited to, U.S. Patent No. 8,968,332 (issued March 3, 2015, entitled "Magnetic Coupleable Robotic Devices and Related Methods"), U.S. Patent No. 8,834,488 (issued September 16, 2014, entitled "Magnetic Coupleable Surgical Robotic Devices and Related Methods"), U.S. Patent No. 10,307,199 (issued June 4, 2019, entitled "Robotic Surgical Devices and Related Methods"), U.S. Patent No. 9,579,088 (issued February 28, 2017, entitled "Methods, Systems, and Devices for Surgical Visualization and Device Design"), and U.S. Patent No. 6,834,488 (issued September 16, 2014, entitled "Magnetic Coupleable Surgical Robotic Devices and Related Methods"). No. 61 / 030,588 (filed February 22, 2008), U.S. Patent No. 8,343,171 (issued January 1, 2013, entitled "Methods and Systems of Actuation in Robotic Devices"), U.S. Patent No. 8,828,024 (issued September 9, 2014, entitled "Methods and Systems of Actuation in Robotic Devices"), U.S. Patent No. 9,956,043 (issued May 1, 2018, entitled "Methods and Systems of Actuation in Robotic Devices"), U.S. Patent Application No. 15 / 966,606 (filed April 30, 2018, entitled "Methods, Systems, and Devices for Surgical Access and Procedures"), U.S. Patent Application No. 12 / 192,No. 663 (filed August 15, 2008, entitled "Medical Inflation, Attachment, and Delivery Devices and Related Methods"), U.S. Patent Application No. 15 / 018,530 (filed February 8, 2016, entitled "Medical Inflation, Attachment, and Delivery Devices and Related Methods"), U.S. Patent No. 8,974,440 (issued March 10, 2015, entitled "Modular and Cooperative Medical Devices and Related Systems and Methods"), U.S. Patent No. 8,679,096 (issued March 25, 2014, entitled "Multifunctional Operational Component for Robotic Devices"), U.S. Patent No. 9,179,981 (issued November 10, 2015, entitled "Multifunctional Operational Component for Robotic Devices"), No. 9,883,911 (issued February 6, 2018, entitled "Multifunctional Operational Component for Robotic Devices"), U.S. Patent Application No. 15 / 888,723 (filed February 5, 2018, entitled "Multifunctional Operational Component for Robotic Devices"), U.S. Patent No. 8,894,633 (issued November 25, 2014, entitled "Modular and Cooperative Medical Devices and Related Systems and Methods"), U.S. Patent No. 8,968,267 (issued March 3, 2015, entitled "Methods and Systems for Handling or Delivering Materials for Natural Orifice Surgery"), U.S. Patent No. 9,060,No. 781 (issued June 23, 2015, entitled "Methods, Systems, and Devices Relating to Surgical End Effectors"), U.S. Patent No. 9,757,187 (issued September 12, 2017, entitled "Methods, Systems, and Devices Relating to Surgical End Effectors"), U.S. Patent No. 10,350,000 (issued July 16, 2019, entitled "Methods, Systems, and Devices Relating to Surgical End Effectors"), U.S. Patent Application No. 16 / 512,510 (filed July 16, 2019, entitled "Methods, Systems, and Devices Relating to Surgical End Effectors"), U.S. Patent No. 9,089,353 (issued July 28, 2015, entitled "Robotic Surgical Devices, Systems, and No. 10,111,711 (filed October 30, 2018, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Patent Application No. 16 / 123,619 (filed September 6, 2018, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Patent Application No. 9,770,305 (filed September 26, 2017, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Patent Application No. 15 / 661,147 (filed July 27, 2017, entitled "Robotic Devices with On Board Control & Related Systems & Devices"), U.S. Patent Application No. 13 / 833,605 (filed March 15, 2013, entitled "Robotic Surgical 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November 12, 2019, entitled "Local Control Robotic Surgical Devices and Related Methods"), U.S. Patent Application No. 16 / 596,034 (filed October 8, 2019, entitled "Local Control Robotic Surgical Devices and Related Methods"), U.S. Patent No. 9,743,No. 987 (issued August 29, 2017, entitled "Methods, Systems, and Devices Relating to Robotic Surgical Devices, End Effectors, and Controllers"), U.S. Patent Application No. 15 / 687,787 (filed August 28, 2017, entitled "Methods, Systems, and Devices Relating to Robotic Surgical Devices, End Effectors, and Controllers"), U.S. Patent No. 9,888,966 (issued February 13, 2018, entitled "Methods, Systems, and Devices Relating to Force Control Surgical Systems"), U.S. Patent Application No. 15 / 894,489 (filed February 12, 2018, entitled "Methods, Systems, and Devices Relating to Force Control Surgical Systems"), No. 14 / 212,686 (filed March 14, 2014, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Patent Application No. 14 / 334,383 (filed July 17, 2014, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Patent Application No. 14 / 853,477 (filed September 14, 2015, entitled "Quick-Release End Effectors and Related Systems and Methods"), U.S. Patent Application No. 16 / 504,793 (filed July 8, 2019, entitled "Quick-Release End Effectors and Related Systems and Methods"), U.S. Patent Application No. 10,376,No. 322 (issued August 13, 2019, entitled "Robotic Device with Compact Joint Design and Related Systems and Methods"), U.S. Patent Application No. 16 / 538,902 (filed August 13, 2019, entitled "Robotic Device with Compact Joint Design and Related Systems and Methods"), U.S. Patent Application No. 15 / 227,813 (filed August 3, 2016, entitled "Robotic Surgical Devices, Syst, No. 15 / 599,231 (filed May 18, 2017, entitled "Robotic Surgical Devices, Systems, and Related Methods"), U.S. Patent Application No. 15 / 687,113 (filed August 25, 2017, entitled "Quick-Release End Effector Tool Interface"), U.S. Patent Application No. 15 / 691,087 (filed August 30, 2017, entitled "Robotic Device with Compact Joint Design and an Additional Degree of Freedom and Related Systems and Method"), U.S. Patent Application No. 15 / 821,169 (filed November 22, 2017, entitled "Gross Positioning Device and Related Systems and No. 15 / 826,166 (filed November 29, 2017, entitled "User controller with user presence detection and related systems and methods"), U.S. patent application Ser. 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No. 16 / 241,No. 263 (filed January 7, 2019, entitled "Single-Manipulator Robotic Device With Compact Joint Design and Related Systems and Methods"), U.S. Patent Application No. 16 / 736,329 (filed January 7, 2020, entitled "Robotically Assisted Surgical System and Related Devices and Methods"), U.S. Patent Application No. 17 / 368,255 (filed July 6, 2021, entitled "Surgical Robot Positioning System and Related Devices and Methods"), U.S. Patent Application No. 18 / 064,784 (filed December 12, 2022, entitled "Robotic Arm with Hybrid Actuation Assemblies and Related Devices, Systems, and Methods"), U.S. Patent Application No. 18 / 299,129 (filed April 12, 2023, entitled "Energy Coupling Mitigation Device and Related Systems and No. 6,492,116 (filed October 31, 2007, entitled "Robot for Surgical Applications"), U.S. Patent No. 7,772,796 (filed April 3, 2007, entitled "Robot for Surgical Applications"), and U.S. Patent No. 8,179,073 (filed May 15, 2011, entitled "Robotic Devices with Agent Delivery Components and Related Methods"), all of which are incorporated herein by reference in their entireties.

[0024] Certain device and system implementations disclosed in the above-listed applications can be placed within a patient's body cavity, or portions of the device can be positioned within a body cavity in combination with a support component similar to those disclosed herein. As used herein, "in-vivo device" means any device that can be at least partially positioned, operated, or controlled by a user while positioned within a patient's body cavity, including any device coupled to a support component, such as a rod or other such component, disposed through an opening or aperture in the body cavity, any device positioned substantially against or adjacent to the wall of a patient's body cavity, any such device that operates internally (has no external driving force source), and additionally any device that can be used laparoscopically or endoscopically during a surgical procedure. As used herein, the terms "robot" and "robotic device" refer to any device that can perform a task either automatically or in response to a command.

[0025] Certain embodiments provide for inserting the present invention into a cavity while maintaining sufficient insufflation of the cavity. Further embodiments minimize the surgeon's or surgical user's physical contact with the present invention during the insertion process. Other implementations improve the safety of the insertion process for the patient and the present invention. For example, some embodiments provide visualization of the present invention as it is being inserted into the patient's cavity to ensure no damaging contact occurs between the system / device and the patient. Additionally, certain embodiments allow for minimizing the size / length of the incision. Other implementations include devices that can be inserted into the body through an incision or natural orifice. Further implementations reduce the complexity of the access / insertion procedure and / or the steps required for the procedure. Other embodiments relate to devices with a minimal profile, smallest size, or generally minimal functionality and appearance to improve ease of handling and use.

[0026] As in manual laparoscopic procedures, a known insufflation system can be used to pump sterile carbon dioxide (or other gas) into the patient's abdominal cavity. This lifts the abdominal wall from the organs, creating space for the robot. In certain implementations, the system does not directly interface with an insufflation system. Alternatively, the system can directly interface to an insufflation system.

[0027] In certain implementations in which the device is inserted through an insertion port, the insertion port is a known, commercially available, flexible membrane positioned transversely across the abdomen to seal and protect the abdominal incision. This off-the-shelf component is the same device, or substantially the same device, used in substantially the same manner as in hand-assisted laparoscopic surgery (HALS). The only difference is that the arms of the robotic device according to various embodiments herein are inserted into the abdominal cavity through the insertion port rather than the surgeon's hands. The robotic device body seals against the insertion port when it is positioned through the insertion port, thereby maintaining insufflation pressure. The port is single-use and disposable. Alternatively, any known port can be used. In a further alternative, the device can be inserted through an incision without a port or through a natural orifice.

[0028] Certain implementations disclosed herein relate to "combined" or "modular" medical devices that can be assembled in a variety of configurations. For purposes of this application, both "combined device" and "modular device" shall mean any medical device that has modular or interchangeable components that can be arranged in a variety of different configurations.

[0029] Certain embodiments disclosed or contemplated herein can be used in colectomy, a surgical procedure performed to treat patients with lower gastrointestinal diseases such as diverticulitis, Crohn's disease, inflammatory bowel disease, and colon cancer. Approximately two-thirds of known colectomy procedures are performed via a fully open surgical procedure, involving an 8- to 12-inch incision and a recovery time of up to six weeks. Due to the complex nature of the procedure, existing robotic-assisted surgical devices are rarely used in colectomy procedures, with manual laparoscopic approaches being used in only one-third of cases. In contrast, various implementations disclosed herein can be used in minimally invasive approaches to various procedures typically performed "openly" by known techniques, with the potential to improve clinical outcomes and healthcare costs. Furthermore, various implementations disclosed herein can be used for any laparoscopic surgical procedure, replacing known mainframe-like laparoscopic surgical robots that reach inside the patient from outside the body. That is, the minimally invasive robotic systems, methods, and devices disclosed herein feature small, self-contained surgical devices that are inserted entirely through a single incision in a patient's abdomen. Designed to utilize existing tools and techniques familiar to surgeons, the devices disclosed herein do not require a dedicated operating room or dedicated infrastructure, and due to their much smaller size, are expected to be significantly less expensive than existing robotic-assisted alternatives for laparoscopic surgery. Due to these technological advances, various embodiments herein may enable minimally invasive approaches to procedures performed in open surgery today.

[0030] FIG. 1 illustrates one embodiment of a robotic surgical system 10 having several components, which are described in additional detail below. Components of various system implementations disclosed or contemplated herein may include an external control console 16 and a robotic device 12 having a detachable camera 14, as described in additional detail below. According to the implementation of FIG. 1 , the robotic device 12 is shown attached to an operating table 18 via a known, commercially available support arm 20 and positioned such that a portion of the device 12 is disposed intracavity in a patient 26 through an incision. In certain implementations, the system 10 can be operated by a surgeon 22 at the console 16 and by one surgical assistant 24 positioned at the operating table 18. Alternatively, one surgeon 22 can operate the entire system 10. In a further alternative, three or more people can be involved in the operation of the system 10. It is further understood that the surgeon (or user) 22 can be located remotely relative to the operating table 18, such that the surgeon 22 can be in a different city or country or a different continent from the patient on the operating table 18.

[0031] In this particular implementation, the robotic device 12 with the camera 14 are both connected to the surgeon console 16 via a device cable 28A and a camera cable 28B, which are described in additional detail below. Alternatively, any connection configuration can be used. In certain implementations, the system can also interact with other devices during use, such as an electrosurgical generator, an insertion port, and an auxiliary monitor.

[0032] One known robotic device 30 that can be used in the above-described system 10 is shown in Figure 2. Device 30 has two robotic arms with end effectors coupled thereto that can be used to perform various procedures within a target cavity of a patient (such as patient 26 of Figure 1).

[0033] The various device embodiments disclosed or contemplated herein have several differences compared to known device 30, including drive train configuration, robotic arm configuration, and overall dimensions (e.g., a device body with a smaller radius, as discussed in more detail below).

[0034] 3A and 3B illustrate one exemplary implementation of an improved robotic device 40 that can be incorporated into the exemplary system 10 discussed above or any other system disclosed or contemplated herein. The device 40 has a body (or “torso”) 42 having a distal end 42A and a proximal end 42B, through which an imaging device (or “camera”) 44 is disposed, as mentioned above and described in additional detail below. Briefly, the robotic device 40 has two robotic arms 46, 48 operably coupled thereto, and the camera 44 is removably positionable through the body 42 and disposed between the two arms 46, 48. That is, the device 40 has a first (or “right”) arm 46 and a second (or “left”) arm 48, both of which are operably coupled to the device 40, as discussed in additional detail below. In this embodiment, the body 42 of the illustrated device 40 has an enclosure (also referred to as a “cover” or “casing”) 52 such that the internal components and lumens of the body 42 are disposed within the enclosure 52. The device body 42 has two rotatable bodies (also referred to as “shoulders” or “turrets”) 54A, 54B: a first (or “right”) shoulder 54A and a second (or “left”) shoulder 54B. Each arm 46, 48 in this implementation also has an upper arm (also referred to herein as an “inner arm,” “inner arm assembly,” “inner link,” “inner link assembly,” “upper arm assembly,” “first link,” or “first link assembly”) 46A, 48A, and a forearm (also referred to herein as an “outer arm,” “outer arm assembly,” “outer link,” “outer link assembly,” “forearm assembly,” “second link,” or “second link assembly”) 46B, 48B. The right upper arm 46A is operably coupled to a right shoulder 54A of the main body 42 at a right shoulder joint 46C, and the left upper arm 48A is operably coupled to a left shoulder 54B of the main body 42 at a left shoulder joint 48C. Additionally, for each arm 46, 48, the forearms 46B, 48B are rotatably coupled to the upper arms 46A, 48A at elbow joints 46D, 48D.In various embodiments, the forearms 46B, 48B are configured to receive a variety of removable and interchangeable end effectors 56A, 56B.

[0035] The end effectors 56A, 56B at the distal ends of the arms 46, 48 can be various tools 56A, 56B (scissors, graspers, needle drivers, etc.), as described in additional detail below. In certain implementations, the tools 56A, 56B are designed to be removable, in some cases including by slightly twisting a tool knob coupling the end effectors 56A, 56B to the arms 46, 48. In certain implementations, at least two single-use, replaceable, disposable surgical end effectors can be used with any of the robotic device embodiments herein (including device 40). Such end effectors can include, but are not limited to, a fenestrated grasper that enables bipolar cauterization, scissors that perform monopolar cauterization, a hook that performs monopolar cauterization, and a left / right needle driver set. Tools can be selected for specific surgical tasks. Certain forearm and end effector configurations that allow for end effector removability and interchangeability are disclosed in detail in U.S. Application No. 14 / 853,477, which was previously incorporated by reference. Furthermore, it is understood that any known forearm and end effector combination can be used in any of the robotic device embodiments disclosed or contemplated herein.

[0036] In various implementations, at least one of the links of the body 42 and the arms 46, 48 can house various actuators or motors. In certain implementations, the body 42 does not have a motor disposed therein, but at least one motor is present in each of the arms 46, 48. Alternatively, in other embodiments, the body 42 has at least one motor associated therewith, while the arms 46, 48 do not have a motor. In further alternative implementations, the body 42 and the arms 46, 48 each have at least one motor associated therewith. In one embodiment, any of the motors disclosed or contemplated herein can be brushed or brushless motors. Furthermore, the motors can be, for example, 6 mm, 8 mm, or 10 mm diameter motors. Alternatively, any known size that can be incorporated into a medical device can be used. In a further alternative, the actuators can be any known actuators used in medical devices to actuate component movement or action. Examples of motors that can be used for the motors described herein include the EC10 BLDC+GP10A Planetary Gearhead, the EC8 BLDC+GP8A Planetary Gearhead, or the EC6 BLDC+GP6A Planetary Gearhead, all commercially available from Maxon Motors, located in Fall River, Massachusetts. There are many ways to actuate these movements, including DC motors, AC motors, permanent magnet DC motors, brushless motors, air pressure, cables to remote motors, hydraulics, etc. Thus, the actuation source can be at least one motor, hydraulic source, pneumatic source, or any other actuation source disposed remotely or proximally from device 40, such that a suitable coupling or transmission mechanism (such as at least one cable, at least one hydraulic transmission hose, at least one pneumatic transmission hose, or any other transmission mechanism) is disposed through body 42.

[0037] In one embodiment, the various joints discussed above according to any of the embodiments disclosed or contemplated herein can be driven by electric motors disposed within the device, and in some implementations, disposed near each joint. Other embodiments include incorporating pneumatic or hydraulic actuators into any of the implementations of the devices herein. In additional alternative embodiments, the drive actuators are disposed outside the device and / or body cavity, and a power transmission mechanism is provided to transmit energy from an external source to the various joints of any of the devices herein. Such a transmission mechanism may take the form of, for example, gears, drive shafts, cables, pulleys, or other known mechanisms, or any combination thereof.

[0038] As discussed above and shown in FIG. 4 , the upper arms 46A, 48A are coupled to the body 42 via shoulder joints 46C, 48C. In one embodiment, each shoulder joint 46C, 48C is a joint comprised of a shoulder body 54A, 54B having two axes of rotation. For example, the right shoulder joint 46C can be configured to provide rotation of the upper arm 46A relative to the body 42 as shown by arrow A about axis AA (substantially parallel to the longitudinal axis of the body 42) and also as shown by arrow B about axis BB, which is substantially perpendicular to axis AA. Because the left shoulder joint 48C and left upper arm 48A are substantially identical to the right shoulder joint 46C and right upper arm 46A, the above description also applies to their substantially similar (or identical) components. Alternatively, any known joint can be used to couple the upper arms 46A, 48A to the body 42.

[0039] Continuing with reference to FIG. 4 , according to one implementation, the upper arms 46A, 48A are coupled to the forearms 46B, 48B, respectively, at elbow joints 46D, 48D such that each of the forearms 46B, 48B can rotate. For example, the right forearm 46B can rotate relative to the upper arm 46A around an axis CC (substantially parallel to the longitudinal axis of the upper arm 46A) as indicated by arrow C, and can also rotate relative to the upper arm 46A around an axis DD (substantially perpendicular to axis CC) as indicated by arrow D. Because the left elbow joint 48D and left forearm 48B are substantially identical to the right elbow joint 46D and right forearm 46B, the above description also applies to substantially similar (or identical) components. Alternatively, any known joint can be used to couple the forearms 46B, 48B to the upper arms 46A, 48A.

[0040] Additionally, the right end effector 56A can also rotate relative to the forearm 46B, as indicated by arrow E about axis E-E (substantially parallel to the longitudinal axis of the forearm 46B), thereby allowing the end effector 56A to “roll” relative to the forearm 46B. Furthermore, in those embodiments in which the end effector 56A has a rotating component (e.g., a grasper jaw), the jaw of the end effector 56A can be actuated to move between at least two configurations, such as an open configuration and a closed configuration, as indicated by arrow F about axis F-F (substantially perpendicular to axis E-E). The left end effector 56B and left forearm 48B can be substantially identical to the right end effector 56A and right forearm 46B, and therefore the above description also applies to those substantially similar (or identical) components. Alternatively, the end effectors 56A, 56B can be coupled to the forearms 46B, 48B, respectively, such that the end effectors 56A, 56B can be moved or actuated in any known manner.

[0041] In one embodiment, the upper arms 46A, 48A have a length of approximately 80 to 100 mm. Alternatively, the upper arms 46A, 48A have a length of approximately 90 mm. In certain implementations, the forearms 46B, 48B have a length of approximately 60 to 80 mm. Alternatively, the forearms 46B, 48B have a length of approximately 70 mm. According to some embodiments, the end effectors 56A, 56B can be attached to the ends of the forearms 46B, 48B with a length of approximately 15 to 25 mm, or alternatively, a length of approximately 20 mm. Furthermore, each of the arms 46, 48 has a width ranging from approximately 13 to 15 mm, or alternatively, a width of approximately 14 mm. Additionally, each of the arms 46, 48 has a depth of approximately 20 to 26 mm, or alternatively, a depth of approximately 23 mm.

[0042] 5-6C show schematic diagrams of the overall workspace 60 of the arms 46, 48 of the robotic device 40, according to certain embodiments. In these embodiments, the "workspace" 60 refers to the space 60 around the robotic device 40 within which either arm 46, 48 and / or end effector 56A, 56B can move, access, and perform its function.

[0043] More specifically, FIG. 5 shows a side view of the entire device 40 and workspace 60, including the full range of motion of the arms 46, 48 from their forward point 62 at +90° to their rear point 64 at −90° of the workspace 60. Additionally, FIG. 5 also shows a forward sweep angle (66) of +75°, a neutral angle (68) of 0°, and a rearward sweep angle (70) of −75°. Similarly, FIG. 6A shows the arms 46, 48 at a forward sweep angle, FIG. 6B shows the arms 46, 48 in a neutral position, and FIG. 6C shows the arms at a rearward sweep angle. Thus, each arm 46, 48 has a range of motion and corresponding workspace 60 that extends from the front of the device 40 to the rear of the device 40. Thus, both arms 46, 48 move equally forward and rearward through a space of approximately 180° relative to the axis of the device body 42. This workspace 60 allows the robotic device 40 to work equally well at the front and rear without having to reposition the body 42 .

[0044] FIG. 7 illustrates one embodiment of the device body 42 with the outer casing or housing 52. The body 42 has a proximal camera port or nest 80 at its proximal end 42B, left and right shoulder housings 54A, 54B rotatably coupled to its distal end 42A, and a groove 82 defined in the outer periphery of the housing 52 distal to the camera port 80, as shown. Additionally, the body 42 has a reduced diameter section or length 84 extending distally from a location distal to the groove 82 to the distal end 42A of the body 42. The reduced diameter section 84 has a width ranging from about 28 mm to about 30 mm. Alternatively, the reduced diameter section 84 has a width of about 29 mm. Additionally, the reduced diameter section 84 has a depth ranging from about 22 mm to about 24 mm. Alternatively, the reduced diameter section 84 has a depth of about 23 mm. In other words, the reduced diameter section can have a cross-sectional perimeter in the range of about 100 mm to about 108 mm. In contrast, the proximal end 42B of the body 42 has a diameter in the range of about 50 mm to about 70 mm, or alternatively, has a diameter of about 60 mm. Furthermore, the reduced diameter length 84 has a length in the range of about 150 mm to about 250 mm. Alternatively, the reduced diameter section 84 has a length of about 200 mm. As noted above, in this particular implementation, the drive train configuration within the housing 52 (as described in detail below) enables the radius of the reduced diameter length 84 to be smaller than the radius of the proximal end 42B, and in certain implementations, to be at least 20 mm smaller, and in some cases, at least 30 mm or even 37 mm smaller than the diameter of the proximal end 42B.

[0045] 8A-8D show the internal components of body 42, which are shown in these figures without its casing 52, according to one embodiment. More specifically, FIG. 8A shows internal support structure 90, such that internal drive trains 92, 94 and camera lumen 140, as best shown in FIG. 8B, are disposed within or associated with internal structure 90. In contrast, FIGS. 8B-8D show the internal actuation and control components of body 42 without showing any housing or support components (such as outer housing 52 and internal support structure 90) in order to better display drive trains 92, 94. Each of these drive trains 92, 94 is configured to provide two degrees of freedom to shoulders 54A, 54B.

[0046] Figure 8B shows right drive train 92 and left drive train 94 coupled to right shoulder housing 54A and left shoulder housing 54B, respectively. Additionally, Figures 8C and 8D show separate pitch drive train 100 and roll drive train 102 of right drive train 92. The components of left drive train 94 that operate / control / actuate left shoulder housing 54B are substantially the same as those shown and described herein with respect to right drive train 92 and right shoulder housing 54A, and it is understood that the descriptions provided below apply equally to those components.

[0047] 8C and 8D, right shoulder drive system 92 is comprised of two separate drive systems: a shoulder roll drive system 100 and a shoulder pitch drive system 102. As shown in FIGURE 8C, shoulder roll drive system 100 is comprised of a first or roll actuator 110, a first or roll motor gear 112 operably coupled to actuator 110, a first driven gear 114 rotatably coupled to roll motor gear 112, a drive shaft 116 fixedly attached to the first driven gear at a proximal end thereof, a second driven gear 118 fixedly attached to drive shaft 116 at a distal end thereof, and a shoulder gear 120 rotatably coupled to second driven gear 118, with shoulder gear 120 fixedly attached (rotationally constrained) to right shoulder 54A via a shoulder drive shaft 122.

[0048] In operation, actuation of actuator 110 causes rotation of drive shaft 116 (via motor gear 112 and first driven gear 114), which causes roll rotation of right shoulder 54A (via second driven gear 118, shoulder gear 120, and shoulder drive shaft 122). Thus, roll actuator 110 causes roll rotation of shoulder 54A about an axis that is substantially parallel to the longitudinal axis of device body 42.

[0049] 8D , the shoulder pitch drive system 102 of the right shoulder drive system 92 is comprised of a second or pitch actuator 130, an elongated motor shaft 132 operably coupled to the actuator 130 and disposed through a lumen (not shown) in the shoulder gear 120 and shoulder drive shaft 122, a drive gear 134 attached (and rotationally constrained) to the motor shaft 132, and a driven gear 136 rotatably coupled to the drive gear 134. In one embodiment, the drive gear 134 is a worm gear 134 and the driven gear 136 is a worm wheel 136. Alternatively, any combination of known gears can be used.

[0050] In operation, actuation of actuator 130 causes rotation of motor shaft 132, which causes pitch rotation of shoulder 54A via drive gear 134 and driven gear 136. Thus, pitch actuator 130 causes pitch rotation of shoulder 54A about an axis that is substantially perpendicular to the axis of roll rotation.

[0051] The left drivetrain 94 is substantially the same as the right drivetrain 92, and therefore the above description also applies to those substantially similar (or identical) components. Alternatively, any known drivetrain can be used to actuate the two rotational axes of the shoulders 54A, 54B.

[0052] 9A-9D show the right upper arm 46A in more detail, according to one embodiment. More specifically, FIG. 9A shows the right upper arm 46A with its external housing 140 and proximal mounting structure 142, while FIGS. 9B-9D show the upper arm 46A without its housing so that the internal actuator and drivetrain are visible. The components of the left upper arm 48A are substantially the same as those shown and described herein with respect to the right upper arm 46A, and the descriptions provided below will be understood to apply equally to those components.

[0053] 9A, the proximal mounting structure 142 is comprised of two mounting arms 142A, 142B extending from the proximal end of the housing 140. Each of the two arms 142A, 142B has a shoulder mounting opening 144 defined therein such that the opening 144 receives the rotatable shaft of the driven gear 136 discussed above. Alternatively, the mounting structure 142 can be any known mounting mechanism or device for coupling the upper arm 46A to the shoulder 54A.

[0054] Figure 9B shows separate roll drive train 150 and rotary drive train 152 coupled to right elbow housing 154. Additionally, Figure 9C shows roll drive train 150 and Figure 9D shows elbow rotary drive train 152. The components and drive trains of left upper arm 48A are substantially the same as those shown and described herein, and the descriptions provided below will be understood to apply equally to those components.

[0055] 9B and 9C, the roll drive train 150 is comprised of a first or roll actuator 160, a first or roll motor gear 162 operably coupled to the actuator 160, a first driven gear 164 rotatably coupled to the roll motor gear 162, an elbow gear 166 rotatably coupled to the first driven gear 164, and an elbow drive shaft 168 fixedly attached to the elbow gear 166, which in turn is fixedly attached (rotationally constrained) to the elbow housing (or "elbow assembly") 154 via the elbow drive shaft 168. In one embodiment, the first drive gear 164 is a single gear 164 as shown. Alternatively, the first drive gear 164 can be comprised of two gears (not shown) that are rotationally constrained to one another.

[0056] In operation, actuation of the actuator 160 causes rotation of the drive shaft 168 (via the motor gear 162, the first driven gear 164, and the elbow gear 166), which in turn causes roll rotation of the right elbow housing 154 (and the forearm 46B attached thereto). Thus, the roll actuator 160 causes roll rotation of the elbow housing 154 (and the forearm 46B) about an axis that is substantially parallel to the longitudinal axis of the upper arm 46A.

[0057] 9B and 9D, the elbow rotary drivetrain 152 is comprised of a second or rotary actuator 180, an elongated motor shaft 182 operably coupled to the actuator 180 and disposed through lumens (not shown) in the elbow gear 166 and elbow drive shaft 168, a drive gear 184 attached to (and rotationally constrained by) the motor shaft 182, and a driven gear 186 rotatably coupled to the drive gear 184. In one embodiment, the drive gear 184 is a worm gear 184 and the driven gear 186 is a worm wheel 186. Alternatively, any combination of known gears can be used.

[0058] In operation, actuation of actuator 180 causes rotation of motor shaft 182, which causes rotation of forearm 46B via drive gear 184 and driven gear 186. Elbow rotation actuator 180 therefore causes rotation of elbow shaft 188 about an axis that is substantially perpendicular to the axis of roll rotation.

[0059] FIGS. 10A-10L illustrate various embodiments of the right forearm 46B and right end effector 56A. FIGS. 10A-10C illustrate the right forearm 46B with most / all of its external housing 200, while FIGS. 10D-10F and 10H-10K illustrate the interior portions and / or components of the forearm 46B without its housing 200. Various implementations disclosed and illustrated herein include actuators, drive components, and electronics that can be used to achieve both tool roll and tool drive (opening and closing actions), as described in further detail below. As described below, the right forearm 46B also includes at least one electrically isolated cauterization circuit, enabling a cauterizing end effector. Certain embodiments are configured to allow for easy removal and replacement of end effectors, such as end effector 56A ("quick change" configuration). Further embodiments include sealing elements that help prevent fluid ingress into the mechanism. The components of the left forearm 48B and left end effector 56B are substantially the same as those shown and described herein with respect to the right forearm 46B and right end effector 56A, and the descriptions provided below will be understood to apply equally to those components.

[0060] 10A, according to one embodiment, the forearm 46B has a proximal mounting structure 202 for mounting to the elbow housing 154, an end effector coupling structure 206, and an end effector lumen 208 defined within a rotatable end effector tube ("roll tube") 212. The end effector coupling structure 206 in this specific embodiment is a coupling collar 206 with female coupling features for receiving male features of the end effector 56A, as discussed in detail below. The proximal mounting structure 202 is comprised of two mounting arms 202A, 202B extending from the proximal end of the housing 200. Each of the two arms 202A, 202B has an elbow mounting opening 210 defined therein such that the opening 210 receives the rotatable shaft 188 of the elbow housing 154, as discussed above. Alternatively, the attachment structure 202 can be any known attachment mechanism or device for coupling the forearm 46B to the elbow 154.

[0061] 10B, a processor or controller 204 is disposed within the forearm housing 200 and is coupled to and controls the motors and other components therein (as discussed in detail below). In one embodiment, the processor 204 is a printed circuit board. Alternatively, any known processor or controller 204 can be used.

[0062] FIG. 10C shows forearm 46B with end effector 56A attached thereto. Figures 10D and 10E show opposite sides of the internal components of forearm 46B, with Figure 10D showing the right side and Figure 10E showing the left side. Figure 10F shows an end view of those internal components. Figure 10G shows a cross-sectional view of the distal end of forearm 46B with end effector 56A positioned for insertion into or removal from end effector lumen 208.

[0063] According to one implementation, certain of the internal components shown in Figures 10D-10F and 10H-10I are configured to actuate rotation of the end effector tube 210 (and the end effector 56A disposed therein) about an axis EE (as best shown in Figures 4 and 10I) that is parallel to the longitudinal axis of the right forearm 46B. This rotation about axis EE is also referred to as "tool roll."

[0064] Rotation, in one aspect, is created as follows. As best shown in FIGS. 10G-10I, a roll actuator 220 is provided, which in this implementation is a motor assembly 220. The actuator 220 is operably coupled to a motor gear 222, which in this embodiment is a spur gear 222. The motor gear 222 is coupled to a driven gear 224 such that rotation of the motor gear 222 causes rotation of the driven gear 224. The driven gear 224 is rotatably coupled to a tube gear 226, which is fixedly coupled to the roll tube (or hub) 212. The lumen 208 of the roll tube 212 has an end effector coupling feature 230 defined in an inner wall of the lumen 208 (as best shown in FIG. 10G) such that the tube 212 is rotationally constrained to the end effector 56A when the end effector 56A is positioned within the lumen 208.

[0065] In operation, actuation of roll actuator 220 causes rotation of roll tube 212 via motor gear 222, driven gear 224, and tube gear 226, which causes rotation of end effector 56A about axis EE (as best shown in FIG. 10I).

[0066] According to one implementation, certain of the internal components shown in Figures 10D-10F and 10J-10K are configured to actuate the end effector 56A to open and close about an axis FF that transverses the longitudinal axis of the right forearm 46B (as best shown in Figures 4 and 10J). This rotation about axis FF is also referred to as the "tool drive."

[0067] 10J and 10K, a tool actuator 240 is provided, which in this implementation is a motor assembly 240. The actuator 240 is operably coupled to a motor gear 242, which in this embodiment is a spur gear 242. The motor gear 242 is coupled to a driven gear 244 such that rotation of the motor gear 242 causes rotation of the driven gear 244. The driven gear 244 is rotatably coupled to an interface gear 246 such that rotation of the driven gear 244 causes rotation of the interface gear 246. The interface gear 246 is fixedly coupled to a female drive interface 248, which in one embodiment is a Torx interface 248. The female drive interface 248 is mateable with a male drive interface 250 disposed at the proximal end of the end effector 56A (as best shown in FIG. 10G), such that the female drive interface 248 is rotationally constrained to the male drive interface 250 when the end effector 56A is positioned within the lumen 208.

[0068] In operation, actuation of tool actuator 240, via motor gear 242, driven gear 244, and interface gear 246, causes rotation of female drive interface 246, which in turn causes rotation of male drive interface 248, which is operably coupled to the gripper of end effector 56A. Thus, depending on the particular end effector 56A and its configuration, rotation of female drive interface 248 can cause rotation of male drive interface 250, which can cause rotation of the gripper about axis FF.

[0069] As mentioned above, forearm 46B (and, in certain embodiments, forearm 48B) also includes at least one electrically isolated cauterization circuit, thereby enabling a cauterization end effector. As best shown in FIG. 10L , according to one embodiment, electrical contacts 260A, 260B are provided within forearm 46B and positioned such that outer contact rings 262A, 262B disposed around roll tube 212 remain in contact with corresponding contacts 260A, 260B during rotation of tube 212. More specifically, first electrical contact 260A is disposed within forearm 46B adjacent to and in contact with first outer contact ring 262A, while second electrical contact 260B is disposed adjacent to and in contact with second outer contact ring 262B. Thus, the rings 262A, 262B are in contact with the contacts 260A, 260B, respectively, and can receive current from the contacts 260A, 260B while the roll tube 212 is rotating or stationary.

[0070] 10G, each of the outer contact rings 262A, 262B has an inner contact surface 263A, 263B disposed within the lumen 208 of the roll tube 212. That is, each ring 262A, 262B extends radially through the roll tube such that the inner contact surface 263A, 263B is disposed along and flush with the inner wall of the roll tube 212. As such, the inner contact surfaces 263A, 263B are disposed within the lumen 208 such that the surfaces 263A, 263B remain in contact with corresponding tool contacts 264A, 264B disposed on the outer surface of the end effector 56A when the end effector is coupled to the forearm 46B. More specifically, when the end effector 56A is coupled to the forearm 46B, the first inner contact surface 263A is disposed at a point along the length of the lumen 208 so as to be adjacent to and in contact with the first tool contact 264A, while the second inner contact surface 263B is disposed at a point along the length of the lumen 208 so as to be adjacent to and in contact with the second tool contact 264B.

[0071] During operation, when electrical current is desired in a cauterizing end effector (such as end effector 56A), the current can be applied to one or both of electrical contacts 260A, 260B as needed. This current is transferred from one or both of contacts 260A, 260B to one or both of outer contact rings 262A, 262B electrically coupled thereto. As a result, the current passes through one or both of inner contact surfaces 263A, 263B, and thus, when an end effector such as end effector 56A is coupled to forearm 46B, the current is then transferred to one or both of tool contacts 264A, 264B on forearm 46B and can thus be used to perform cauterization as needed in the cauterizing end effector (such as end effector 56A).

[0072] One unique aspect of this device configuration that allows for a reduction in the overall axial diameter of both the device body 42 and arms 46, 48 is the two-degree-of-freedom driveline module used in both the body 42 and upper arms 46A, 48A. For purposes of this discussion, the driveline module in the right upper arm 46A will be used, but it will be understood that the same general driveline configuration is used in the device body 42 as well. That is, the general configuration of the two drivelines (e.g., as shown in FIGS. 8B-8D and 9B-9D) includes a first driveline (e.g., driveline 100 and driveline 150) that drives the roll joint and a second driveline (e.g., driveline 102 and driveline 152) that drives the pitch movement. In both the body 42 and upper arms 46A, 48A, the two drivelines are strategically positioned relative to one another so that the radius of the body / arms is minimized, thereby minimizing the size of the incision or port required to place the device in a patient.

[0073] Given that the motors (actuators) in device embodiments herein are cylindrical and therefore have circular radial cross-sections, their adjacent placement, as shown in FIG. 11A , is the closest placement of two circles to minimize the radial profile. Using the specific example of the right upper arm 46A, the two circles in FIG. 11A represent the pitch drive motor 180 and roll drive motor 160 as discussed above, and thus the oval shape 140 containing both motors 160, 180 with the minimum amount of space represents the upper arm housing 140. Similarly, the motors 110, 130 of the drivetrain 92 within the device body 42 as discussed above are positioned in a similar manner (except that the roll motor 110 is positioned proximal to the pitch motor 130).

[0074] 11C, the gear arrangement for motors 160, 180 results in the gears being disposed within a radial cross section of motors 160, 180 (when the device is in the straight insertion configuration). More specifically, driven gear(s) 164 of the roll drive train and motor gear 184 and driven gear 186 of the pitch drive train, along with any other gears in the drive train, are disposed within upper arm housing 140.

[0075] Thus, as discussed in detail above, the configuration of motors 160, 180 and associated gears within upper arm 46A causes roll motor 160 to cause rotation of shoulder 54A about a roll axis parallel to the axis of motor 160 (and motor 180), and further causes pitch motor 180 to cause rotation of shoulder rotatable shaft 138 about an axis that is substantially perpendicular to the axis of motor 180 (and motor 160).

[0076] This basic drivetrain configuration is used in both the body 42 and the upper arm 46A. For the body 42 configuration, an additional drive shaft 116 is used in the roll drivetrain to maintain the same cross section (or further reduce the cross section) at the expense of length. This allows a larger motor to be used in the device body 42 while maintaining the same cross section.

[0077] According to certain implementations, another advantage of the device configurations herein is that the shoulder housings (such as right shoulder housing 54A) and elbow housings (such as right elbow housing 154) and the joints created by those housings are either radially symmetrical or mirror images. Furthermore, the left and right sides (arms and drivetrains) operate independently of each other. As a result, the arms 46, 48 are modular in nature, meaning that various device embodiments contemplated herein can have one arm, two arms, three arms, four arms, or any additional number of arms.

[0078] For example, an embodiment of a one-arm robotic device 280 is shown in FIG. 12. Device 280 can be used independently or in cooperation with other surgical devices. Arm 282 of device 280 operates in a manner similar to the individual arms described herein (such as right arm 36, as discussed in detail above). As such, arm 282 can be positioned in a straight configuration (such as for insertion or removal) or any other configuration possible based on the components described above.

[0079] In another example, a three-arm robotic device 290 according to a further implementation is shown in FIGS. 13A and 13B. The device 290 can be used independently or in cooperation with other surgical devices. According to one embodiment, the device 290 can have three arms 294A, 294B, 294C permanently attached to a device body 292, as shown. Alternatively, the arms 294A, 294B, 294C can be modular, allowing them to be easily and quickly attached to or detached from the body 292 in various numbers and configurations. Additionally, according to certain embodiments, the elongated body 292 has one or more movable sections to which one or more of the arms 294A-C are attached, such that one or more of the arms 294A-C can be movable relative to the other arms, thereby allowing each arm to be positioned deeper or shallower relative to the other arms.

[0080] Additionally, although grasping end effectors 296A, 296B, 296C are shown, it is understood that any end effector may be used with this device 290. Arms 294A-C of device 290 operate in a manner similar to the individual arms described herein (such as right arm 36, as discussed in detail above), and thus arms 294A-C can be positioned in a straight configuration (such as for insertion or removal) as shown in FIG. 13B, or in any other configuration possible based on the components described above.

[0081] Although the various systems described above are separate implementations, any of the individual components, mechanisms, or devices, and associated features and functionality within the various system embodiments described in detail above, may be incorporated into any of the other system embodiments herein.

[0082] As used herein, the term "about" refers to variations in quantities that may occur with typical measurement techniques and equipment for any quantifiable variable, including, but not limited to, mass, volume, time, distance, wavelength, frequency, voltage, current, and electromagnetic fields. Additionally, there are certain real-world, incidental errors and variations that may occur due to differences in the manufacture, source, or precision of components used to make various components or perform methods, etc. The term "about" also encompasses these variations. The term "about" can include any variation of 5% or 10%, or any amount between 0% and 10%, including any integer. Furthermore, whether modified by the term "about," the claims include the equivalent of the quantity or amount.

[0083] Numerical ranges recited herein are inclusive of the numbers defining the range and include each integer within the defined range. Throughout this disclosure, various aspects of the disclosure are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all possible subranges, fractions, and individual numbers within that range. For example, the description of a range such as 1 to 6 should be considered to have specifically disclosed subranges such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., as well as individual numbers within that range, e.g., 1, 2, 3, 4, 5, and 6, as well as decimals and fractions, e.g., 1.2, 3.8, 1 1 / 2, and 4 3 / 4. This applies regardless of the breadth of the range.

[0084] Although various embodiments have been described with reference to preferred implementations, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope thereof.

Claims

1. 1. A robotic surgical device comprising: (a) an elongate device body, the body comprising: (i) a distal section having a distal section width in the range of about 28 mm to about 30 mm and a distal section depth in the range of about 22 mm to about 24 mm; (ii) a proximal section having a proximal section diameter greater than a distal section diameter; and (b) a first arm operably coupled to a distal end of the elongate device body via a first shoulder assembly; (c) a second arm operably coupled to the distal end of the elongate device body via a second shoulder assembly; A robotic surgical device comprising:

2. The robotic surgical device of claim 1 , wherein the first arm and the second arm each have an arm width ranging from about 13 mm to about 15 mm and an arm depth ranging from about 20 mm to about 26 mm.

3. The robotic surgical device of claim 2 , wherein the arm width is approximately 14 mm and the arm depth is approximately 23 mm.

4. The robotic surgical device of claim 1 , wherein the distal section width is approximately 29 mm and the distal section depth is approximately 23 mm.

5. The robotic surgical device of claim 1 , wherein the proximal section comprises a camera port.

6. the elongated device body comprising: (a) a first driveline assembly, (i) a first pitch drive system, (A) a first pitch actuator; (B) a first pitch motor gear rotatably coupled to the first pitch actuator via a first pitch motor drive shaft; (C) a first pitch driven gear rotatably coupled to the first pitch motor gear; Equipped with a first pitch drive train, the first pitch driven gear rotating about an axis substantially perpendicular to a longitudinal axis of the first pitch actuator; (ii) a first roll drive train assembly, (A) a first roll actuator disposed proximal to the first pitch actuator; (B) a first roll motor gear rotatably coupled to the first roll actuator; (C) a first roll drive shaft rotatably coupled to the first roll motor gear, the first roll drive shaft being disposed radially adjacent to the first pitch actuator; (D) a first shoulder drive shaft rotatably coupled to the first roll drive shaft, the first shoulder drive shaft rotationally constrained to the first shoulder assembly, the first shoulder drive shaft including a first lumen defined therethrough; the first pitch motor drive shaft is rotatably disposed through the first lumen; a first roll drive train assembly, the first pitch driven gear being rotatably disposed within the first shoulder assembly; a first driveline assembly comprising: (b) a second driveline assembly, (i) a second pitch drive system, (A) a second pitch actuator; (B) a second pitch motor gear rotatably coupled to the second pitch actuator via a second pitch motor drive shaft; (C) a second pitch driven gear rotatably coupled to the second pitch motor gear; Equipped with a second pitch drive train, the second pitch driven gear rotating about an axis substantially perpendicular to the longitudinal axis of the second pitch actuator; (ii) a second roll drive train assembly, (A) a second roll actuator disposed proximal to the second pitch actuator; (B) a second roll motor gear rotatably coupled to the second roll actuator; (C) a second roll drive shaft rotatably coupled to the second roll motor gear, the second roll drive shaft being disposed radially adjacent to the second pitch actuator; and (D) a second shoulder drive shaft rotatably coupled to the second roll drive shaft, the second shoulder drive shaft rotationally constrained to the second shoulder assembly, the second shoulder drive shaft including a second lumen defined therethrough; the second pitch motor drive shaft is rotatably disposed through the second lumen; a second roll drive train assembly, the second pitch driven gear being rotatably disposed within the second shoulder assembly; a second driveline assembly comprising: The robotic surgical device of claim 1 , further comprising:

7. Each of the first arm and the second arm comprises an upper arm, the upper arm comprising: (a) a rotary drive system comprising: (i) a rotary actuator; (ii) a rotary motor gear rotatably coupled to the rotary actuator via a rotary motor drive shaft; (iii) a rotary driven gear rotatably coupled to the rotary motor gear; a rotary drive train, wherein the rotary driven gear rotates about an axis that is substantially perpendicular to a longitudinal axis of the rotary actuator; (b) a roll drive train assembly, (i) a roll actuator disposed adjacent to the rotary actuator; (i) at least one roll gear rotatably coupled to the roll actuator; (i) an elbow drive shaft rotatably coupled to the at least one roll gear, the elbow drive shaft rotationally constrained to the elbow assembly, the elbow drive shaft having a lumen defined therethrough; the rotary motor drive shaft is rotatably disposed through the lumen; the rotary driven gear is rotatably disposed within the elbow assembly; The robotic surgical device of claim 1 .

8. 8. The robotic surgical device of claim 7, wherein the upper arm further comprises an upper arm housing and a proximal mounting structure disposed at a proximal end of the upper arm housing, the proximal mounting structure configured to be couplable to one of the first shoulder assembly and the second shoulder assembly, and the rotational drive train and the roll drive train disposed within the upper arm housing.

9. 8. The robotic surgical device of claim 7, wherein the first arm and the second arm each comprise a forearm rotatably coupled to the upper arm and an end effector operably coupled to the forearm.

10. 1. A robotic surgical device comprising: (a) an elongate device body, the body comprising: (i) a first driveline assembly, (A) a first pitch drive system, (I) a first pitch actuator; (II) a first pitch motor gear rotatably coupled to the first pitch actuator via a first pitch motor drive shaft; (III) a first pitch driven gear rotatably coupled to the first pitch motor gear; a first pitch drive train, the first pitch driven gear rotating about an axis that is substantially perpendicular to a longitudinal axis of the first pitch actuator; (B) a first roll drive train assembly, (I) a first roll actuator disposed proximal to the first pitch actuator; (II) a first roll motor gear rotatably coupled to the first roll actuator; (III) a first roll drive shaft rotatably coupled to the first roll motor gear, the first roll drive shaft being disposed radially adjacent to the first pitch actuator; (IV) a first shoulder drive shaft rotatably coupled to the first roll drive shaft, the first shoulder drive shaft rotationally constrained to a first shoulder assembly, the first shoulder drive shaft including a first lumen defined therethrough; the first pitch motor drive shaft is rotatably disposed through the first lumen; a first roll drive train assembly, the first pitch driven gear being rotatably disposed within the first shoulder assembly; a first driveline assembly comprising: (ii) a second driveline assembly, (A) a second pitch drive system, (I) a second pitch actuator; (II) a second pitch motor gear rotatably coupled to the second pitch actuator via a second pitch motor drive shaft; (III) a second pitch driven gear rotatably coupled to the second pitch motor gear; a second pitch drive train, the second pitch driven gear rotating about an axis substantially perpendicular to the longitudinal axis of the second pitch actuator; (B) a second roll drive train assembly, (I) a second roll actuator disposed proximal to the second pitch actuator; (II) a second roll motor gear rotatably coupled to the second roll actuator; (III) a second roll drive shaft rotatably coupled to the second roll motor gear, the second roll drive shaft being disposed radially adjacent to the second pitch actuator; and (IV) a second shoulder drive shaft rotatably coupled to the second roll drive shaft, the second shoulder drive shaft rotationally constrained to a second shoulder assembly, the second shoulder drive shaft comprising a second lumen defined therethrough; the second pitch motor drive shaft is rotatably disposed through the second lumen; a second roll drive train assembly, the second pitch driven gear being rotatably disposed within the second shoulder assembly; a second driveline assembly comprising: an elongated device body comprising: (b) a first arm operably coupled to the first shoulder assembly; (c) a second arm operably coupled to the second shoulder assembly; A robotic surgical device comprising:

11. the elongated device body comprising: (a) a distal section having a distal section width in the range of about 28 mm to about 30 mm and a distal section depth in the range of about 22 mm to about 24 mm; The robotic surgical device of claim 10 , further comprising: (b) a proximal section having a proximal section diameter greater than a distal section diameter.

12. The robotic surgical device of claim 11 , wherein the distal section width is approximately 29 mm and the distal section depth is approximately 23 mm.

13. The robotic surgical device of claim 11 , wherein the proximal section includes a camera port.

14. The robotic surgical device of claim 10, wherein the first arm and the second arm each have an arm width ranging from about 13 mm to about 15 mm and an arm depth ranging from about 20 mm to about 26 mm.

15. The robotic surgical device of claim 14 , wherein the arm width is approximately 14 mm and the arm depth is approximately 23 mm.

16. Each of the first arm and the second arm comprises an upper arm, the upper arm comprising: (a) a rotary drive system comprising: (i) a rotary actuator; (ii) a rotary motor gear rotatably coupled to the rotary actuator via a rotary motor drive shaft; (iii) a rotary driven gear rotatably coupled to the rotary motor gear; a rotary drive train, wherein the rotary driven gear rotates about an axis that is substantially perpendicular to a longitudinal axis of the rotary actuator; (b) a roll drive train assembly, (A) a roll actuator disposed adjacent to the rotary actuator; (B) at least one roll gear rotatably coupled to the roll actuator; (C) an elbow drive shaft rotatably coupled to the at least one roll gear, the elbow drive shaft rotationally constrained to the elbow assembly, the elbow drive shaft including a lumen defined therethrough; the rotary motor drive shaft is rotatably disposed through the lumen; a roll drive train assembly, the rotary driven gear being rotatably disposed within the elbow assembly; The robotic surgical device of claim 10 , comprising:

17. 17. The robotic surgical device of claim 16, wherein the upper arm further comprises an upper arm housing and a proximal mounting structure disposed at a proximal end of the upper arm housing, the proximal mounting structure configured to be couplable to one of the first shoulder assembly and the second shoulder assembly, and the rotational drive train and the roll drive train disposed within the upper arm housing.

18. 17. The robotic surgical device of claim 16, wherein the first arm and the second arm each comprise a forearm rotatably coupled to the upper arm and an end effector operably coupled to the forearm.

19. 1. A robotic surgical device comprising: (a) an elongate device body, (i) a device body housing, comprising: (A) a distal section having a distal section diameter; (B) a proximal section having a proximal section diameter greater than the distal section diameter; (ii) a first drive train assembly disposed within the device body housing, the first drive train assembly comprising: (A) a first pitch drive system, (I) a first pitch actuator; (II) a first pitch motor gear rotatably coupled to the first pitch actuator via a first pitch motor drive shaft; (III) a first pitch driven gear rotatably coupled to the first pitch motor gear; a first pitch drive train, the first pitch driven gear rotating about an axis that is substantially perpendicular to a longitudinal axis of the first pitch actuator; (B) a first roll drive train assembly, (I) a first roll actuator disposed proximal to the first pitch actuator; (II) a first roll motor gear rotatably coupled to the first roll actuator; (III) a first roll drive shaft rotatably coupled to the first roll motor gear, the first roll drive shaft being disposed radially adjacent to the first pitch actuator; (IV) a first roll drivetrain assembly comprising: a first shoulder drive shaft rotatably coupled to the first roll drive shaft, the first shoulder drive shaft rotationally constrained to a first shoulder assembly, the first shoulder drive shaft comprising a first lumen defined therethrough; Equipped with the first pitch motor drive shaft is rotatably disposed through the first lumen; a first driveline assembly, the first pitch driven gear being rotatably disposed within the first shoulder assembly; (ii) a second drive train assembly disposed within the device body housing, (A) a second pitch drive system, (I) a second pitch actuator; (II) a second pitch motor gear rotatably coupled to the second pitch actuator via a second pitch motor drive shaft; (III) a second pitch driven gear rotatably coupled to the second pitch motor gear; a second pitch drive train, the second pitch driven gear rotating about an axis substantially perpendicular to the longitudinal axis of the second pitch actuator; (B) a second roll drive train assembly, (I) a second roll actuator disposed proximal to the second pitch actuator; (II) a second roll motor gear rotatably coupled to the second roll actuator; (III) a second roll drive shaft rotatably coupled to the second roll motor gear, the second roll drive shaft being disposed radially adjacent to the second pitch actuator; and (IV) a second shoulder drive shaft rotatably coupled to the second roll drive shaft, the second shoulder drive shaft rotationally constrained to the second shoulder assembly, the second shoulder drive shaft comprising a second lumen defined therethrough; the second pitch motor drive shaft is rotatably disposed through the second lumen; a second roll drive train assembly, the second pitch driven gear being rotatably disposed within the second shoulder assembly; a second driveline assembly comprising: an elongated device body comprising: (b) a first arm operably coupled to the first shoulder assembly; (c) a second arm operably coupled to the second shoulder assembly; A robotic surgical device comprising:

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