Systems and subsystems for firing surgical instruments

Abstract

A surgical instrument designed to operate in conjunction with a robotic platform is disclosed. The surgical instrument assembly includes a shaft, an end effector, a knife firing subsystem for activating the function of the end effector, an articulation subsystem actuated to articulate the end effector, an articulation joint around which the end effector articulates, a rolling subsystem for rolling the shaft, and a housing coupled to the robotic platform.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 515,020, filed on July 21, 2023 (Attorney Docket No. END9566USPSP1) and U.S. Provisional Patent Application No. 63 / 640,289, filed on April 30, 2024 (Attorney Docket No. END9566USPSP2), the disclosures of which are hereby expressly incorporated by reference herein.

[0002] (Field of the Invention) This disclosure relates to surgical instruments and, in various configurations, to surgical stapling instruments, surgical cutting instruments designed to staple and cut tissue, and staple cartridges for use with them.

Summary of the Invention

Means for Solving the Problems

[0003] The disclosed technology can be for systems, devices, and subsystems for surgical instruments for robotic surgery. The surgical instrument can have several subsystems that can be actuated independently to provide certain operations such as closing and opening of the stapler's end effector, articulation of the end effector, rolling of the end effector, and firing of staples within the end effector.

[0004] The disclosed technology describes a launch subsystem which may be one of several subsystems and / or subcomponents for a surgical instrument. The launch subsystem includes a knife. The launch subsystem includes a thread coupled to or integrated with the knife, configured to move the knife within an end effector. The launch subsystem includes a launch rod configured to drive the thread. The launch subsystem includes a first push rod, comprising a first push rod distal end coupled to the thread and a first push rod proximal end coupled to the launch rod. The launch subsystem includes a second push rod, comprising a second push rod distal end coupled to the thread and a second push rod proximal end coupled to the launch rod. For implementation in a surgical instrument, the launch subsystem may be combined with one or more of the following: an end effector, a joint motion coupling, a cable joint motion subsystem, a roll subsystem, and a housing.

[0005] The disclosed technology describes a control device which may be one of several subsystems and / or subcomponents for a surgical instrument. The control device is configured to read the firing force of a motor-driven knife. The control device is configured to determine whether the firing force exceeds an upper threshold. The control device is configured to calculate an error in response to determining that the firing force exceeds the upper threshold. The control device is configured to calculate a time modulator using the error. The control device is configured to use the time modulator to calculate a new time to move the knife from its current position to the leading edge of the cutting line. The control device is configured to transmit the new time to a motor trajectory generator, which is configured to accelerate or decelerate the motor based on the transmitted new time.

[0006] The disclosed technology describes a surgical instrument. The surgical instrument includes an end effector and a knife launch subsystem. The end effector includes a channel, an anvil coupled to the channel, and a knife launch subsystem, the knife launch subsystem comprising a knife, a thread coupled to or integrated with the knife and configured to move the knife within the end effector, a launch rod configured to drive the thread, a first push rod including a first push rod distal end coupled to the thread and a first push rod proximal end coupled to the launch rod, and a second push rod including a second push rod distal end coupled to the thread and a second push rod proximal end coupled to the launch rod. [Brief explanation of the drawing]

[0007] [Figure 1] This is a schematic perspective view of a surgical system, including surgical instruments, based on the disclosed technology. [Figure 2] These are schematic detail diagrams of the end effector, articulated joint, and parts of the cable articulated subsystem, knife firing subsystem, and roll subsystem, based on the disclosed technology. [Figure 3] This is a schematic detail diagram of an end effector and joint motion coupling based on the disclosed technology. [Figure 4] This is a schematic exploded view of the distal end of a surgical instrument using the disclosed technology. [Figure 5] This is a schematic detail diagram of the knife based on the disclosed technology. [Figure 6] This is a schematic detail front view of the end effector based on the disclosed technology. [Figure 7] This is a schematic detail diagram of an end effector and articulated joint with the anvil removed, as described by the disclosed technology. [Figure 8A] This is a schematic side cross-sectional view of the distal end of a surgical instrument showing the anvil in the open position according to the disclosed technology. [Figure 8B]This is a schematic side cross-sectional view of the distal end of a surgical instrument, showing the anvil with the knife in a partially advanced gripping position, according to the disclosed technology. [Figure 8C] This is a schematic side cross-sectional view of the distal end of a surgical instrument, showing the anvil with the knife partially advanced in a clamped position, according to the disclosed technology. [Figure 8D] This is a schematic side cross-sectional view of the distal end of a surgical instrument, showing the anvil in the fully advanced clamped position according to the disclosed technology. [Figure 9A] This is a schematic side cross-sectional detail view of the distal end of a surgical instrument, showing the anvil in the open position, according to the disclosed technology. [Figure 9B] This is a schematic side cross-sectional detail view of the distal end of a surgical instrument, showing the anvil with the knife in a partially advanced gripping position, as disclosed by the technology. [Figure 9C] This is a schematic side cross-sectional detail view of the distal end of a surgical instrument, showing the anvil in a partially advanced clamped position with the knife, according to the disclosed technology. [Figure 9D] This is a schematic side cross-sectional view of the distal end of a surgical instrument, showing the anvil in the fully advanced clamped position, according to the disclosed technology. [Figure 10] This is a schematic exploded view of a joint motion device based on the disclosed technology. [Figure 11] This is a schematic elevation view of a jointed motion device based on the disclosed technology. [Figure 12] This is a schematic cross-sectional view of a jointed motion device cut along line 12-12 in Figure 11, according to the disclosed technology. [Figure 13] This is a schematic cross-sectional view of a jointed motion device cut along line 13-13 in Figure 11, according to the disclosed technology. [Figure 14] This is a schematic perspective detail of the distal end of a surgical instrument, showing an end effector that pivots vertically and laterally with the anvil open, according to the disclosed technology. [Figure 15]A schematic side detailed view of the distal end of a surgical instrument showing an end effector that pivots vertically with the anvil in a closed state according to the disclosed technology. [Figure 16] A schematic top detailed view of the distal end of a surgical instrument showing an end effector that pivots laterally with the anvil in a closed state according to the disclosed technology. [Figure 17] A schematic exploded view of a surgical instrument showing a cable articulation subsystem, a knife firing subsystem, and a portion of a roll subsystem according to the disclosed technology. [Figure 18] A schematic top view of the proximal end of a surgical instrument showing a cable articulation subsystem, a knife firing subsystem, and a portion of a roll subsystem according to the disclosed technology. [Figure 19] A schematic perspective view of a shaft assembly, a differential, and a firing rod of a surgical instrument according to the disclosed technology. [Figure 20] A schematic side view of a firing subsystem showing an end effector pivoted vertically downward and an anvil in an open position according to the disclosed technology. [Figure 21] A schematic side view of a firing subsystem showing an end effector pivoted vertically upward and an anvil in an open position according to the disclosed technology. [Figure 22] A schematic side view of a firing subsystem showing an end effector pivoted vertically upward, an anvil in a clamped position, and a fully advanced knife according to the disclosed technology. [Figure 23] A schematic detailed view of the proximal end of a surgical instrument showing a portion of a knife firing subsystem according to the disclosed technology. [Figure 24] A schematic exploded detailed view of a rotary joint according to the disclosed technology. [Figure 25] A schematic detailed view of one side of a housing showing a rotary pack engaged with a robotic platform according to the disclosed technology. [Figure 26] A schematic detailed view of another side of the housing according to the disclosed technology. [Figure 27]Schematic exploded view of the housing according to the disclosed technology. [Figure 28] Schematic detailed view of the housing with its upper shroud removed according to the disclosed technology. [Figure 29] Schematic perspective view of the housing with its upper shroud and intermediate frame removed according to the disclosed technology. [Figure 30] Schematic perspective view of the housing with its upper shroud, intermediate frame removed, and specific subsystem components removed according to the disclosed technology. [Figure 31] Schematic detailed view of the rotating pack assembly of the housing according to the disclosed technology. [Figure 32] Schematic elevation view of the housing according to the disclosed technology. [Figure 33] Schematic cross-sectional view of the housing cut along line 33-33 of FIG. 32 according to the disclosed technology. [Figure 34] Schematic cross-sectional view of the housing cut along line 34-34 of FIG. 32 according to the disclosed technology. [Figure 35] Schematic cross-sectional view of the housing cut along line 35-35 of FIG. 32 according to the disclosed technology. [Figure 36] Schematic cross-sectional view of the housing cut along line 36-36 of FIG. 32 according to the disclosed technology. [Figure 37] Schematic top view of the housing with its upper shroud, intermediate frame removed, and specific subsystem components removed according to the disclosed technology. [Figure 38] Schematic top detailed view of an alternative distal end configuration of the end effector with its anvil and cartridge removed according to the disclosed technology. [Figure 39] Schematic bottom detailed view of an alternative distal end configuration of the end effector of FIG. 38 according to the disclosed technology. [Figure 40]Figure 38 shows a schematic cross-sectional detail of an alternative distal end of the end effector, cut along the roll axis of the end effector, according to the disclosed technology. [Figure 41] This is a schematic detail side view of an alternative proximal end configuration for an end effector using the disclosed technology. [Figure 42] This is a flowchart of the adaptive launch process using the disclosed technology. [Figure 43] This is a schematic block diagram of a control device, robotic arm, and surgical instrument based on the disclosed technology. [Modes for carrying out the invention]

[0008] The following detailed description should be read in reference to the drawings, where similar elements in different drawings are numbered identically. The drawings are not necessarily to scale, depict selected embodiments, and are not intended to limit the scope of the invention. The detailed description illustrates the principles of the invention as examples, not as limitations. This specification describes several embodiments, adaptations, modifications, alternatives, and uses of the invention, including those that are currently considered to be the best modes for carrying out the invention, which will make it clear to those skilled in the art that the invention can be made and used.

[0009] Numerous specific details are described in order to provide a complete understanding of the overall structure, function, manufacture, and use of the embodiments, as described in the specification and shown in the accompanying drawings. Well-known operations, components, and elements are not described in detail so as not to obscure the embodiments described herein. Readers will understand that the embodiments described and illustrated herein are non-limiting examples, and therefore certain structural and functional details disclosed herein may be representative and illustrative. Modifications and changes thereto may be made without departing from the claims.

[0010] The terms “comprise” (and any form of “comprise,” such as “comprises” and “comprising”), “have” (and any form of “have,” such as “has” and “having”), “include” (and any form of “include,” such as “includes” and “including”), and “contain” (and any form of “contains” and “containing”) are unrestricted linking verbs. As a result, a surgical system, device, or apparatus that “comprises,” “has,” “includes,” or “contains” one or more elements has one or more of those elements, but is not limited to having only one or more of those elements. Similarly, an element of a system, device, or apparatus that “comprises,” “has,” “includes,” or “contains” one or more features has one or more of those features, but is not limited to having only one or more of those features.

[0011] As used herein, the terms “about” or “approximately” for any number or range of numbers indicate a suitable dimensional tolerance that enables some or a set of components to function for the intended purpose described herein. More specifically, “about” or “approximately” may refer to a range of values ​​within ±20% of the enumerated values; for example, “about 90%” may refer to a range of values ​​between 71% and 99%.

[0012] The terms “proximal” and “distal” are used herein in reference to the robotic platform that operates the housing portion of the surgical instrument. “Proximal” refers to the portion closest to the robotic platform, and “distal” refers to the portion located further away from the robotic platform. For convenience and clarity, spatial terms such as “vertical,” “horizontal,” “up,” and “down” may also be used herein in reference to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be restrictive and / or absolute.

[0013] Furthermore, the use of “couple,” “coupled,” or similar phrases should not be interpreted as limiting to a specific number of components or a specific order of components unless the context clearly indicates otherwise.

[0014] Furthermore, when alternative examples of a particular form of a surgical instrument are described, and the same reference numbers as the aforementioned example are used to label the components of the alternative(s) examples, the structure and function of those components are the same unless otherwise specified.

[0015] Various exemplary devices and methods for performing laparoscopic and minimally invasive surgical procedures are provided. However, it will be readily apparent to the reader that the various methods and devices disclosed herein can be used in many surgical procedures and applications, including, for example, those related to incisional surgical procedures. By reading further into the “Modes for Carrying Out the Invention” section of this specification, the reader will further understand that the various instruments disclosed herein can be inserted into the body in any way, for example, through a pre-existing opening, through an incision or puncture hole formed in the tissue, etc. The working portion, or end-effector portion, of these instruments can be inserted directly into the patient’s body, or through an access device having a working passage through which the end-effector and elongated shaft of the surgical instrument can be advanced.

[0016] A surgical stapling system may comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw, although other embodiments can be conceived in which the staple cartridge is not removable from the first jaw, or at least not easily replaceable from the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The anvil is pivotable relative to the first jaw about a closing axis, although other embodiments can be conceived in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulated joint configured to rotate, i.e., articulate, the end effector relative to the shaft. Other embodiments can be conceived in which the articulated joint is not included. In other words, other elements described herein may also be used in embodiments without articulated joints, without departing from the spirit and scope of this disclosure. Similarly, articulated joints may also be used in embodiments in which other elements described herein are omitted.

[0017] I. Overview of Surgical Instruments A surgical instrument 1000 is shown in Figure 1. As will be discussed in more detail below, the surgical instrument 1000 is configured to grasp, clamp, cut, and seal patient tissue. The surgical instrument 1000 comprises an end effector 200, an articulated joint 300, an articulated drive subsystem 400 (Figure 2) configured to articulate the end effector 200 around the articulated joint 300, a knife launch subsystem 500 (Figure 2) configured to move the end effector between various positions (e.g., open position, grasping position, and clamping position) to cut and staple patient tissue, a roll subsystem 600 configured to roll the end effector 200 around a roll axis, and a housing 700.

[0018] II. Overview of End Effectors The end effector 200 comprises a first jaw 202 and a second jaw 204 movable between an open position and a closed position. For clarity, the first jaw 202 is used interchangeably with the “jaw 202” (also referred to as the “channel” in the art) herein, and the second jaw 204 is used interchangeably with the “anvil 204”. The jaw 202 and the anvil 204 may be elongated in form. The jaw 202 defines an elongated channel 208 for receiving a staple cartridge 210. The anvil 204 has a proximal end 204A, a distal end 204B, and an inclined surface 216 defined on the proximal end 204A, which will be described in more detail below with respect to Figures 4 and 9A-9D. The jaw 202 and the anvil 204 are pivotably coupled via pivot pins 212 extending through the jaw 202 and the anvil 204. As shown in Figure 7, one or more biasing springs 214 extend between the jaws 202 and the anvil 204 to bias the anvil 204 to the open position. The inclined surface 216 may be visible through a bean-shaped opening 222 (which may be formed as part of the manufacturing process for creating the inclined surface 216) having a first lateral end 216A and a second lateral end 216B. In other words, the bean-shaped opening may open at its lateral ends 222A, 222B (Figure 3). As shown in Figure 3, the inclined surface 216 forms the lower surface of the bean-shaped opening 222. The inclined surface 216 may be formed in an arc shape. For example, as shown particularly in Figures 4 and 9A-9D, it may be inclined upward at a first angle 218 and tapered in an arc shape to a second angle 220 that is substantially horizontal distally. The inclined surface may include, for example, a single radius curve, a series of multiple radius curves, a series of multiple radius curves having a series of inflection points, and / or may be linearly inclined.

[0019] The anvil 204 further defines an upper knife channel 224 (e.g., Figure 8A) that extends longitudinally. In particular, as shown in Figure 6, the upper knife channel 224 includes a centrally located cylindrical upper knife channel portion 226 and at least one lateral upper knife channel wing 228 extending away from the upper knife channel portion 226. Although the term “cylindrical” is used, the channel portion 226 does not need to resemble a perfect cylinder.

[0020] II.1. End Effector and Launch Subsystem The surgical instrument 1000 further comprises a knife launch subsystem 500 that is operable to close the anvil 204 during a closing stroke. After the end effector 200 is closed, the knife launch subsystem 500 (Figures 2 and 17) is operable during the launch stroke to cut and staple the patient tissue captured between the staple cartridge 210 (held by the jaws 202) and the anvil 204 with staples from the staple cartridge 210.

[0021] The knife launch subsystem 500, described in more detail below, includes a knife 206. The knife 206 is coupled to or integrated with the knife thread 236. The knife thread 236 is a non-cutting element of the knife 206 and is also called an I-beam. The knife thread 236 includes an upper knife tab 238 and a lower knife tab 246. The upper knife tab 238 includes a centrally located cylindrical upper knife tab portion 240 and at least one upper knife tab lateral wing 242 extending away from the upper knife tab portion 240. Although the term “cylindrical” is used, the tab portion does not need to resemble a perfect cylinder. In some embodiments, the upper knife tab 238 includes a pair of lateral wings 242 configured to slide within the upper knife channel 224 in order to move the anvil 204 between an open position, a gripping position, and a clamped position. Each lateral wing 242 may include an inclined surface 242A that engages with the anvil inclined surface 216. The upper knife tab portion 240 defines an upper knife tab opening 244 configured to receive a barrel crimp coupled to a central cable 512, which will be described in more detail below. The lower knife tab 246 includes a centrally located cylindrical lower knife tab portion 248 and at least one lower knife tab lateral wing 250 extending away from the lower knife tab portion 248. Although the term “cylindrical” is used, the lower knife tab portion 248 does not need to resemble a perfect cylinder. In some embodiments, the lower knife tab 246 includes a pair of lateral wings 250. The lower knife tab portion 248 defines a lower knife tab opening 252 configured to receive a barrel crimp coupled to a central cable 514, which will be described in more detail below. The staple cartridge 210 comprises a cartridge body. For use, the staple cartridge is positioned within the channel 208 of the jaws 202 on the first side of the tissue to be stapled, and the anvil 204 is positioned on the second side of the tissue. The anvil 204 is moved toward the staple cartridge 210 to compress and clamp the tissue against the deck of the staple cartridge 210. Staples, which are removably stored within the cartridge body, can then be deployed into the tissue. The cartridge body includes a defined staple cavity, within which the staples are removably stored. In some embodiments, the staple cavity is arranged in six longitudinal rows. In some embodiments, three rows of staple cavities are positioned on the first side of the lower knife channel 230, and three rows of staple cavities are positioned on the second side of the lower knife channel 230.

[0022] Referring particularly to Figure 6, the lower knife channel 230 includes a centrally located cylindrical lower knife channel portion 232 and at least one lateral lower knife channel wing 234 extending away from the lower knife channel portion 232. Although the term “cylindrical” is used, the channel portion 232 does not need to resemble a perfect cylinder. Other configurations of the staple cavity and staples may also be possible. For example, in some embodiments, the lower knife channel 230 may be defined within the jaws 202.

[0023] The staples are supported by a staple driver within the cartridge body. The driver is movable between a first, i.e., non-firing position and a second, i.e., firing position, to eject staples from the staple cavity. The driver is held within the cartridge body by a retainer extending around the lower perimeter of the cartridge body and includes an elastic member configured to grip the cartridge body and hold the retainer relative to the cartridge body. The drivers are indirectly movable between their non-firing positions and their firing positions by threads 236. More specifically, the knife threads 236 are movable between a proximal position adjacent to the proximal end and a distal position adjacent to the distal end. A portion of the knife threads 236 (see, for example, Figures 8C–8D) engages with the cartridge threads 210A, which slide beneath the driver, lifting the driver and the staples supported above it toward the anvil 204. It is desirable that the knife 206 be positioned at least partially proximal to the inclined surface such that the staple is in a second position in front of the knife 206, i.e., the firing position (i.e., the ejection position).

[0024] In addition to the above, the thread 236 is moved distally and proximal by the launch rod 502. The launch rod 502 is configured to directly engage with the thread 236 (discussed in more detail below) and to apply an indirect force to the thread 236 via push coils 508, 510 that push the thread 236 toward the distal end of the end effector 200. As the launch rod 502 is advanced distally, the thread 236 rides on the lower knife channel 230 and the upper knife channel 224. At the start of the movement, the upper knife tab 238 rides along the anvil inclined surface 216. Specifically, as seen in particular in the sequences of Figures 8A-8D and 9A-9D, the distal movement of the thread 236 causes the upper knife tab inclined surface 242A to slide along the anvil inclined surface 216. This movement first biases the anvil 204 toward a position where sufficient compressive force is applied to the tissue to grasp it (e.g., Figures 8B and 9B) (referred to as the gripping position). Compressive force is applied to the tissue as the thread 236 moves continuously upward along the inclined surface 216 (see e.g., Figures 8C and 9C) (referred to as the clamping position). As the anvil inclined surface 216 moves toward its substantially horizontal angled surface 218 (see e.g., Figures 8D and 9D), the upper knife tab 238 can slide within the upper knife channel 224 to drive stapling and cutting of the tissue.

[0025] III. Overview of Housing and Shaft Assembly The surgical instrument 1000 further comprises a housing 700 and a shaft assembly 600A extending from the housing 700. The housing is configured to engage with a robot platform 2000. In some embodiments, the housing 700 may be configured as a handle (e.g., it may have a gripping portion for a clinician). The shaft assembly 600A comprises a rotatable outer shaft 602 and an inner shaft 604, the outer shaft 602 being rotatably mounted to the housing around a rotary joint 606 (which may include one or more bearings). The inner shaft 604 is rotatably fixed to the outer shaft 602 and is configured so that articulation cables 402, 404, 406, and 408, which will be discussed in more detail below, can be partially wound around it without entanglement. As will be discussed in more detail below, the housing 700 further comprises (1) a launch pack assembly 712 as part of a knife launch subsystem 500 that is operable to close the end effector 200, fire staples, and cut across tissue; (2) a set of articulation pack assemblies 702, 704, 706, and 708 as part of an articulation subsystem 400 that is operable to articulate the end effector 200 relative to the shaft assembly 600A; and (3) a shaft roll pack assembly 710 as part of a roll subsystem 600 configured to roll the outer shaft 602.

[0026] IV. Overview of the Joint Movement Subsystem IV.1. Joint Movement Couplings Referring to Figure 10, the articular joint 300 comprises a plurality of concentric disks 302 and a central beam assembly 306. Each concentric disk further includes a concentric central opening 304. The central beam assembly 306 has a proximal end 306A and a distal end 306B. As shown in Figures 12 and 13, a portion of the central beam assembly 306 extends through the central opening 304 of each concentric disk 302, and the central beam assembly 306 applies compressive force to the concentric disks 302. The concentric disks 302 are nested on the central beam assembly 306 such that adjacent concentric disks 302 interface with each other. As seen in Figure 7, the distal end 306B of the central beam assembly 306 is coupled to the plurality of concentric disks 302 (via one or more fasteners 322) to the proximal end of the end effector 200 of the surgical instrument 1000. As shown in Figure 10, the distal end 306B includes a distal end retaining disk 334 that defines a plurality of cable retaining openings 334A. Furthermore, the proximal end 306A of the central beam assembly 306 includes a second disk retaining bearing 332 that is nested within and / or coupled to the shaft assembly 600A so as to connect a concentric disk 302 to the shaft assembly 600A. In some embodiments, the distal end 306B of the central beam assembly 306 abuts against a knife thread 236.

[0027] In particular, as shown in Figures 10, 12, and 13, each concentric disk 302 includes an articular socket 308, an articular pin 310 protruding outward from the articular socket 308, a first push coil opening 312A defined through the articular socket 308 and configured to receive a first push coil 508 through its interior, a second push coil opening 312B defined through the articular socket 308 and configured to receive a second push coil 510 through its interior, and through the articular socket 308 The concentric disk openings 304 include a plurality of articular cable openings 314A to 314D (e.g., first articular cable opening 314A, second articular cable opening 314B, third articular cable opening 314C, and fourth articular cable opening 314D) defined and configured to receive individual articular cable openings 402, 404, 406, 408 (e.g., first articular cable opening 402, second articular cable opening 404, third articular cable opening 406, and fourth articular cable opening 408), which will be discussed in more detail below. As shown in Figures 12 and 13, the concentric disk openings 304 are defined on the articular pins 310 of each concentric disk 302. In some embodiments, three joint movement cable openings 314A, 314B, and 314C are provided to correspond to three joint movement cables 402, 404, and 406, while in other embodiments, four joint movement cable openings 314A, 314B, 314C, and 314D are provided to correspond to four joint movement cables 402, 404, 406, and 408.

[0028] Each concentric disk 302 further includes a rounded proximal end 310A of an articular pin and a hemispherical pin receiving opening 316 defined in the articular socket 308. In particular, as shown in Figures 12 and 13, each rounded proximal end 310A of an articular pin pivotably engages with an adjacent pin receiving opening 316 of an adjacent concentric disk 302, except for the nearest end 310A that engages with a second disk retaining bearing 332. The proximal end 310A of the articular pin and the pin receiving opening 316 interface in a manner similar to that of a swivel bearing. Furthermore, the articular socket 308 includes a socket disk 318 and a pin retaining socket 320. A pair of pins 336 are used to provide rotational coupling from one disk 302 to the next disk, around the principal axis of the shaft assembly 600A. In other words, the pin restricts the rotational degrees of freedom between the instrument 1000 and adjacent concentric disks 302) around the roll axis RA. In alternative embodiments, this feature may be integrated with the disks 302, as opposed to a separate pin 336 as shown, for example, in Figure 10.

[0029] Referring particularly to Figure 10, the distal end 306B of the central beam assembly 306 includes a first disc retaining bearing 324 that defines a plurality of clearance pockets 326. The central beam assembly 306 also further includes a central beam 328 extending through each of the concentric discs 302, a jack screw 330, and a second disc retaining bearing 332. The jack screw 330 is screw-connected to the second disc retaining bearing 332 to adjust the compressive force of the central beam 328 (i.e., the jack screw may be used to adjust the pre-tension of the articulated joint 300). The central beam assembly 326 holds the discs 302 together and also responds to launch loads, and as a result the launch loads do not respond to the articulated cables (discussed in more detail below).

[0030] The central beam 328 further includes a nitinol core 328A and stainless steel 328B wound around the nitinol core, which allows the central beam 328 to bend elastically in response to the pivoting of one, some, or all of the concentric disks 302. The wound stainless steel 328B has clockwise and counterclockwise braiding to prevent it from unraveling.

[0031] The articular joint 300 described above forms part of a cable articular joint subsystem 400 that enables precise 360° movement of the end effector 200 around the articular joint 300 with at least two degrees of freedom. In some embodiments, the articular joint is capable of rolling approximately 320 degrees within the entire system, as determined by the roll subsystem 600 and as it is necessary to limit the amount of winding of the articular joint cables 402, 404, 406, and 408. The cable articular joint subsystem 400 also includes a plurality of articular joint cables 402, 404, 406, and 408, each having distal ends 402A, 404A, 406A, and 408A, which are coupled to the distal end 306B of the central beam assembly 306, and proximal ends 402B, 404B, 406B, and 408B. More specifically, each distal end 402A, 404A, 406A, 408A may include a crimp that engages with the cable holding opening 334A of the distal end holding disk 334 to maintain its position.

[0032] IV.2. Joint Movement Cables Each articulation cable 402, 404, 406, and 408 comprises a stainless steel material having clockwise and counterclockwise braiding to prevent unraveling. In other embodiments, other materials may be used, such as polymer threads and / or filaments, various metal cables (e.g., tungsten), and combinations thereof. Each articulation cable is individually operable to cause rotation of the articulation joint 300 and the end effector 200 about at least one of the pitch axis PA and the yaw axis YA.

[0033] In some embodiments, three articular movement cables may be provided instead of the four cables 402, 404, 406, and 408 shown herein. However, the four articular movement cables 402, 404, 406, and 408, spaced approximately 90 degrees apart from each other in the circumferential direction (as illustrated), provide load distribution. In addition, in alternative embodiments, three and fourth articular movement cable configurations may be arranged asymmetrically spaced apart from each other.

[0034] The shaft assembly 600A and housing 700 also form part of the cable joint motion subsystem 400. More specifically, each joint motion cable 402, 404, 406, and 408 extends from the joint motion joint 300 through the shaft assembly 600A to the housing 700. The proximal ends 402B, 404B, 406B, and 408B of each joint motion cable (402, 404, and 406) are movably mounted within the housing 700, thereby causing the aforementioned rotation of the joint motion joint 300 and the end effector 200. In some embodiments, the housing 700 includes articular motion pack assemblies 702, 704, 706, and 708 having rotatable capstans 702B, 704B, 706B, and 708B, which are discussed in more detail below, and the corresponding proximal ends 402B, 404B, 406B, and 408B of the articular motion cables 402, 404, 406, and 408 are mounted so as to be wrapable around the rotatable capstans. As shown in Figures 35 and 36, the capstans 702B, 704B, 706B, and 708B may be offset perpendicularly to each other (for example, capstans 702B and 704B may be positioned proximal to one portion 700A of the housing 700, and capstans 706B and 708B may be positioned proximal to the other portion 700B of the housing 700).

[0035] The articular movement cables 402, 404, 406, and 408 are positioned between the outer shaft 602 and the inner shaft 604 and routed through the shaft assembly 600A so that the articular movement cables 402, 404, 406, and 408 can partially wrap around it without entanglement. The inner shaft 604 also prevents the articular movement cables 402, 404, 406, and 408 from interfering with other components that run down the center of the device 1000 (through the inner shaft 604).

[0036] IV.3. Connection / Operation of Joint Motion Couplings and Joint Motion Cables The articular motion cables 402, 404, 406, and 408 are routed and connected to the end effector 200 via the articular motion joint 300, so that their proximal movement (by winding around the capstans 702B, 704B, 706B, and 708B) causes the end effector 200 to pivot around the articular motion joint 300 in a predetermined manner. For example, proximal movement of the first articular motion cable 402 causes upward and leftward rotation of the end effector 200, proximal movement of the second articular motion cable 404 causes upward and rightward rotation of the end effector 200, proximal movement of the third articular motion cable 406 causes downward and leftward rotation of the end effector 200, and proximal movement of the fourth articular motion cable 408 causes downward and rightward rotation of the end effector 200. Similarly, simultaneous movement of the two articular motion cables will result in mixed movement of the end effector 200. For example, movement of both the first articular motion cable 402 and the second articular motion cable 404 at the same speed will cause only upward pivoting of the end effector 200 (i.e., little to no horizontal component relative to rotation). As will be understood by those skilled in the art, this configuration provides the aforementioned precise 360-degree movement of the end effector around the articular motion joint 300 with at least two degrees of freedom and a roll of about 320 degrees.

[0037] V. Overview of the Launch Subsystem Referring mainly to Figures 2, 8A-8D, 9A-9D, 17, and 23, the knife launch subsystem 500 includes the aforementioned knife 206, the aforementioned thread 236, a launch rod 502 that drives the knife 206 and / or thread 236, a first push rod 504, and a second push rod 506. The launch rod 502 includes a launch rod rack 530 and is driven by a launch pack assembly 712, which will be described in more detail below. The first push rod 504 has a first push rod distal end 504A coupled to the thread 236 and a first push rod proximal end 504B coupled to the launch rod 502. Similarly, the second push rod has a second push rod distal end 506A coupled to the thread 236 and a second push rod proximal end 506B coupled to the launch rod 502. The distal ends 504A and 506A are connected to the upper and lower parts of the thread 236, respectively (e.g., the upper knife tab 238 and the lower knife tab 246), thereby enabling the knife 206 to be pushed evenly at both ends. In some embodiments, the proximal ends 504B and 506B of the push rods 504 and 506 are connected to the launch rod via a differential 520, which will be discussed in more detail below.

[0038] The knife launch subsystem 500 is configured to allow articulation of the end effector 200 while still enabling the proper functioning of the knife 206. To this end, the first push rod 504 includes a first flexible section 508, and the second push rod 506 includes a second flexible section 510. As shown in particular in Figures 20 to 22, the flexible sections 508 and 510 pass through the articulation joint 300 via their respective push coil openings 312A and 312B, and the push rods 504 and 506 engage with their respective tab openings 244 and 252 in the thread 236. More specifically, the first flexible section 508 includes a first push coil 508, and a first central cable 512 extends through the first push coil 508 and engages with the thread 236 via a barrel crimp; the second flexible section 510 includes a second push coil 510, and a second central cable 514 extends through the second push coil 510 and engages with the thread 236 via a barrel crimp. The push coils 508, 510 provide the rods 504, 506 with sufficient stability to deliver firing force to the knife 206, while not being too rigid to hinder articulation in the joint 300. As described above (see, for example, Figure 8A), the cables 512, 514 engaged with the thread 236 prevent the coils 508, 510 from stretching and / or elongating, and function as retractable cables when the rods 504, 506 are retracted toward the proximal end of the surgical instrument 1000.

[0039] Continuing to refer to Figures 20-22, the entirety of the push rods 504, 506 does not need to bend during use and / or extend through the articulated joint 300, and therefore does not need to be flexible. Accordingly, the proximal section of each push rod 504, 506 includes rigid rods 516, 518. The term “rigid” as used herein refers to a structure that is less flexible than the push coils 508, 510 and cables 512, 514 described. Specifically, the first push rod 504 includes a first rigid rod 516 that is coaxial with and coupled to the first push coil 508 and the first central cable 512, and the second push rod 506 includes a second rigid rod 518 that is coaxial with and coupled to the second push coil 510 and the second central cable 514.

[0040] In addition to the above, the bending radii of the first push coil 508 and the second push coil 510 may differ depending on how the end effector 200 is pivoted around the articulated joint 300. For example, in the configuration shown in Figure 21 (i.e., when the end effector 200 is pivoted upward), the first push coil 508 has a smaller bending radius than the second push coil 510, and the amount of the second push coil 510 extending through the articulated joint 300 is greater than that of the first push coil 508. The differential gear 520 is provided to take these different bending radii into account and to balance the difference in loads, ensuring an even distribution of the firing force delivered to the push rods 504, 506.

[0041] More specifically, the differential 520 connects the proximal ends 504B of the first pushrod and the proximal end 506B of the second pushrod to the launch rod 502, and the differential 520 allows relative axial movement between the first pushrod 504 and the second pushrod 506 (as depicted, for example, in Figures 20 to 21). The differential 520 includes a first rack 522 connected to the first pushrod 504, a second rack 524 connected to the second pushrod 506, a pinion rod 526 connected to the launch rod 502, and a pinion 528 rotatably mounted on the pinion rod 526 and meshing with the first rack 522 and the second rack 524.

[0042] In addition to the above, as particularly illustrated in Figures 20 and 21, the first rack 522 and the second rack 524 are movable in opposite axial directions relative to each other in accordance with the rotation of the thread 236 around the pitch axis PA, taking into account the aforementioned different bending radii of the push coils 508 and 510.

[0043] Furthermore, as shown in Figure 22, the first rack 522 and the second rack 524 are each movable in the same axial direction (e.g., the first axial direction) in response to the movement of the launch rod 502 in the first axial direction due to the launch force. As described above, this launch force is delivered to the knife 206 through the push coils 508, 510, thereby closing the anvil 204 to the gripping and / or clamping position. As shown in the sequence in Figures 9A to 9D, the distal movement of the push coils 508, 510 results in them resting on the central upper knife channel portion 226 of the upper knife channel 224 and the central lower knife channel portion 232 of the lower knife channel 224, respectively. Further movement of the launch rod 502 in the first axial direction continues the movement of the knife 206, which, as described above, launches the staple and crosses the tissue. The contraction of the knife 206 and the opening of the anvil are achieved by moving the launch rod 502 in the opposite second direction. As demonstrated in Figures 21 and 22, the independent cable joint motion system 400 and knife launching system 500 allow the knife 206 and thread 236 to be oriented and translated non-parallel to the orientation and movement of the launching rod 502.

[0044] To enable the rolling of the outer shaft 602, which will be discussed in detail below, the differential 520 is attached to the shaft assembly 600A and coupled to the launch rod 502 so as to be rotatable about the roll axis RA. As a result, the pinion rod 526 is axially constrained to the launch rod 502 and freely rotatable relative to it.

[0045] VI. Overview of the Role Subsystem Referring here to the roll subsystem 600, the roll subsystem includes the shaft assembly 600A, the rotary coupling 606, and the shaft roll pack assembly 710, which will be discussed in more detail below. As discussed in the preceding paragraph, the rotatable nature of the differential 520 is also a feature of the roll subsystem. The shaft assembly 600A includes the rotatable outer shaft 602 and inner shaft 604 discussed earlier. As shown in the exploded view of Figure 19, the inner shaft 604 may be a split clamshell of design, coupled to each other and housing certain components of the surgical instrument 1000, such as the differential 520 and the distal portion of the firing rod 502. In addition, the clamshell inner shaft 604 may provide support for certain portions of the push coils 508, 510. The inner shaft 604 is fixedly coupled to the outer shaft 602, and as a result they are coupled in the rotational direction. The outer shaft 602 is coupled to the housing via a swivel coupling 606, which may include one or more bearings (see, for example, Figures 24 and 27). The bearings engage with the housing 700 and allow relative rotation between the outer shaft 604 and the housing 700 during the operation of the shaft roll pack assembly, which will be described in more detail below. One or both of the shafts 602, 604 are provided with various channels for which cables 402, 404, 406, 408, push rods 504, 506, differential gears 520, etc., are mounted. Furthermore, lugs are rotatably fixed to the outer shaft and are configured to reach the bottom of a cavity in the housing to indicate when the outer shaft 602 is in the home position.

[0046] VII. Overview of Housing Pack Assemblies and Integration with Surgical Instrument Subsystems Referring primarily to Figures 23 to 35, the housing 700 is configured to engage with a robotic platform 2000 controlled by a clinician. Proximal mechanisms are provided to interface with the robotic platform in order to control the subsystems 400, 500, and 600 described above. More specifically, the outer shell of the housing, including an upper shroud 700A, a lower frame 700B, and an intermediate frame 700C, houses at least (1) a plurality of articulation pack assemblies 702, 704, 706, and 708 for the articulation of the end effector 200, (2) a shaft roll pack assembly 710 for rolling the outer shaft 602, (3) a launch pack assembly for translating the knife 206, and (4) a near-field radio-frequency identification (RFID) board 724 for communicating information about the surgical instrument 1000 to the robotic platform 2000.

[0047] VII.1. Housing and Joint Movement Subsystems In addition to the above, the housing includes four articular movement pack assemblies 702, 704, 706, and 708, the four articular movement cables 402, 404, 406, and 408 used in the surgical instruments described herein. The first articular movement pack assembly 702 is used in cooperation with the first articular movement cable 402. Similarly, the second articular movement pack assembly 704 is used in cooperation with the second articular movement cable 404, the third articular movement pack assembly 706 is used in cooperation with the third articular movement cable 406, and the fourth articular movement pack assembly 708 is used in cooperation with the first articular movement cable 408. During use, the first joint movement cable 402 wraps around and unwraps the first joint movement pack assembly 702, the second joint movement cable 404 wraps around and unwraps the second joint movement pack assembly 704, the third joint movement cable 406 wraps around and unwraps the third joint movement pack assembly 706, and the fourth joint movement cable 408 wraps around and unwraps the first joint movement pack assembly 708.

[0048] The first articular motion pack assembly 702 includes a first articular motion pack 702A, a first capstan 702B, and a first torsion spring 702C. The first articular motion pack 702A is mounted on the outer surface of the lower frame 700B and engages directly with the robot platform 2000. The first capstan 702B is connected to the first articular motion pack 702A and wraps the first articular motion cable 402 around it. The first capstan 702B is rotatably mounted to a first pivot pin 726 (integrated with the first articular motion pack 702A). The first capstan 702B is biased in the contraction direction by the first torsion spring 702C to maintain a minimum level of tension in the first articular motion cable 402, such as when it is disconnected from the robot platform 2000. Since the first joint movement pack assembly 702 does not contain any gears, the mechanical advantages achieved are determined by the diameter of the first capstan 702B.

[0049] During use, for example, rotation of the first capstan 702B by the robot platform 2000 causes the first articulation cable 402 to wrap around the first capstan 702B in a first direction via the first articulation pack 702A, resulting in the end effector 200 pivoting upward and to the left around the articulation joint 300. As previously discussed, this upward movement of the end effector 200 is compensated by the differential gear 520 in the knife firing subsystem. Rotation in the opposite direction by the first articulation pack 702A unwinds the first articulation cable 402, returning the end effector 200 to a position substantially coaxial with the shaft assembly 600A (e.g., coaxial with the roll axis RA).

[0050] The second articular movement pack assembly 704 includes a second articular movement pack 704A, a second capstan 704B, and a second torsion spring 704C. The second articular movement pack 704A is mounted on the outer surface of the lower frame 700B and engages directly with the robot platform 2000. The second capstan 704B is connected to the second articular movement pack 704A and the second articular movement cable 404 is wound around it. The second capstan 704B is rotatably mounted to a second pivot pin 728 (integrated with the second articular movement pack 704A). The second capstan 704B is biased in the contraction direction by the second torsion spring 704C to maintain a minimum level of tension in the second articular movement cable 404. Since the second joint movement pack assembly 704 does not contain any gears, the mechanical advantages achieved are determined by the diameter of the second capstan 704B.

[0051] During use, for example, rotation of the second capstan 704B by the robot platform 2000 causes the second articulation cable 404 to wrap around the second capstan 704B in a first direction via the second articulation pack 704A, resulting in the end effector 200 pivoting upward and to the right around the articulation joint 300. As previously discussed, this upward movement of the end effector 200 is compensated by the differential gear 520 in the knife firing subsystem. Rotation in the opposite direction by the second articulation pack 704A unwinds the second articulation cable 404, returning the end effector 200 to a position substantially coaxial with the shaft assembly 600A (e.g., coaxial with the roll axis RA).

[0052] The third articular movement pack assembly 706 includes a third articular movement pack 706A, a third capstan 706B, and a third torsion spring 706C. The third articular movement pack 706A is mounted on the outer surface of the lower frame 700B and engages directly with the robot platform 2000. The third capstan 706B is connected to the third articular movement pack 706A and wraps the third articular movement cable 406 around it. The third capstan 706B is rotatably mounted to a third pivot pin 730 (integrated with the third articular movement pack 706A). The third capstan 706B is biased in the contraction direction by the third torsion spring 706C to maintain a minimum level of tension in the third articular movement cable 406. Since the third joint movement pack assembly 706 does not contain any gears, the mechanical advantages achieved are determined by the diameter of the third capstan 706B.

[0053] During use, for example, rotation of the third capstan 706B by the robot platform 2000 causes the third articulation cable 406 to wrap around the third capstan 706B in a first direction via the third articulation pack 706A, resulting in the end effector 200 pivoting downward and to the left around the articulation joint 300. As previously discussed, this downward movement of the end effector 200 is compensated by the differential gear 520 in the knife firing subsystem. Rotation in the opposite direction by the third articulation pack 706A unwinds the third articulation cable 406, returning the end effector 200 to a position substantially coaxial with the shaft assembly 600A (e.g., coaxial with the roll axis RA).

[0054] The fourth articular movement pack assembly 708 includes a fourth articular movement pack 708A, a fourth capstan 708B, and a fourth torsion spring 708C. The fourth articular movement pack 708A is mounted on the outer surface of the lower frame 700B and engages directly with the robot platform 2000. The fourth capstan 708B is connected to the fourth articular movement pack 708A and wraps the third articular movement cable 408 around it. The fourth capstan 708B is rotatably mounted to a fourth pivot pin 732 (integrated with the fourth articular movement pack 708A). The fourth capstan 708B is biased in the contraction direction by the fourth torsion spring 708C to maintain a minimum level of tension in the third articular movement cable 408. Since the fourth joint movement pack assembly 708 does not contain any gears, the mechanical advantages achieved are determined by the diameter of the fourth capstan 708B.

[0055] During use, for example, rotation of the fourth capstan 708B by the robot platform 2000 causes the fourth articulation cable 408 to wrap around the fourth capstan 708B in a first direction via the fourth articulation pack 708A, resulting in the end effector 200 pivoting downward and to the right around the articulation joint 300. As previously discussed, this downward movement of the end effector 200 is compensated by the differential gear 520 in the knife firing subsystem. Rotation in the opposite direction by the fourth articulation pack 708A unwinds the fourth articulation cable 408, returning the end effector 200 to a position substantially coaxial with the shaft assembly 600A (e.g., coaxial with the roll axis RA).

[0056] Naturally, as discussed above, the synchronized movement of various combinations of pack assemblies 702, 704, 706, and 708 allows clinicians to position the end effector 200 in any orientation (via the robotic platform 2000).

[0057] In addition, as shown in particular in Figure 37, the housing 700 (for example, the lower frame 700B as shown in Figure 37) may be provided with a number of static redirects 714, 716, 718, 720, each having a surface that engages with an individual articular motion cable 402, 404, 406, 408 and redirects it within the housing 700. These redirects 714, 716, 718, 720 ensure proper routing of the articular motion cables 402, 404, 406, 408.

[0058] VII.2. Housing and Roll Subsystems In addition to the above, the shaft roll pack assembly 710 includes a shaft roll pack 710A, a first screw gear 710B, and a second screw gear 710C. The shaft roll pack 710A is mounted on the outer surface of the lower frame 700B and is integrated with a fifth pivot pin 734, and engages directly with the robot platform 2000. The first screw gear 710B is coaxial with the shaft roll pack 710A and is rotatable together with the shaft roll pack 710A. The second screw gear 710C meshes with the first screw gear 710B and is coupled to the rotatable outer shaft 602.

[0059] During use, for example, as discussed in more detail above, the rotation of the first screw gear 710B by the robot platform 2000 causes the second screw gear 710C to roll in a first direction via the shaft roll pack 710A, thereby causing the outer shaft 602 to roll (for example, clockwise around the roll axis RA). The rotation of the first screw gear in the opposite second direction causes the outer shaft 602 to roll in the opposite direction (for example, counterclockwise around the roll axis RA).

[0060] VII.3. Housing and Launch Subsystem In addition to the above, the launch pack assembly includes a launch pack 712A, a drive gear 712A1, a gear train 712B, and a driven gear or pinion 712C. The launch pack 712A is mounted on the outer surface of the lower frame 700B and is integrated with a sixth pivot pin 736, and engages directly with the robot platform 2000. The drive gear 712A1 rotates directly with the launch pack 712A. As shown particularly in Figure 23, the gear train 712B is rotatable with the launch pack 712A and the drive gear 712A1. In some embodiments, the gear train 712B includes a first idler gear 712B1 meshed with the drive gear 712A1, a second idler gear 712B2 coaxial with and rotatably mounted to the first idler gear 712B1, and a third idler gear 712B3 meshing with the second idler gear 712B2. The pinion 712C is coaxial with the third idler gear 712B3 and rotatably mounted to the third idler gear 712B3. Furthermore, the pinion 712C meshes with the rack 530 of the launch rod 502 to produce its translational motion (for launching and retracting the knife 206 as discussed above).

[0061] During use, for example, the rotation of the launch pack 712A by the robot platform 2000 causes the drive gear 712A1 to rotate, which in turn drives the gear train 712B to rotate the pinion 712C. Depending on the direction of rotation of the launch pack 712A, the launch rod 502 is either moved distally (i.e., toward the end effector 200) to close the anvil 204 and / or fire the knife 206, or moved proximal (i.e., toward the rear of the housing 700) to retract the knife 206 and / or open the anvil 204.

[0062] VIII. Operational Algorithms Figure 43 shows an exemplary control device 1110 for controlling a robotic arm 1200 and a surgical device 1000 via a handle 700. As shown, the control device 1110 may include a processor 1112, an input / output device 1114, an operating system (OS) 1118, a memory 1116 containing a storage device 1120 which may be any suitable storage location for data, and a program 1122. The input / output device may be configured to receive and output commands for controlling the robotic arm 1200 and the surgical device 1000. The control device 1110 may include a user interface (U / I) 1124 device for receiving user input data (e.g., from a physician, technician, etc.), such as data representing clicks, scrolls, taps, presses, movement of a control lever, or typing on an input device which can detect tactile input. The control device 1110 may include a display.

[0063] The control device 1110 may include a peripheral interface, which may include hardware, firmware, and / or software that enables communication with various peripheral devices such as media drives (e.g., magnetic disk, solid-state, or optical disk drives), other processing devices, or any other input sources used in connection with this technology. The peripheral interface may include serial ports, parallel ports, general-purpose input and output (GPIO) ports, game ports, universal serial bus (USB), micro USB ports, high-definition multimedia (HDMI) ports, video ports, audio ports, Bluetooth® ports, WiFi ports, near-field communication (NFC) ports, other similar communication interfaces, or any combination thereof, which can communicate with other devices via wired or wireless connections or networks, whether local area or wide area, private or public, as known in the art. The power supply may be configured to provide power to the components by providing appropriate alternating current (AC) or direct current (DC).

[0064] The processor 1112 may include one or more application-specific integrated circuits (ASICs), programmable logic devices, microprocessors, microcontrollers, digital signal processors, coprocessors, etc., or combinations thereof, that can execute stored instructions and operate based on stored data. Memory 1116 may include one or more suitable types of memory (e.g., volatile or non-volatile memory, random access memory (RAM), read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic disk, optical disk, floppy disk, hard disk, removable cartridge, flash memory, redundant array of independent disk (RAID), etc.) for storing files containing the operating system 1118, application programs 1122 (e.g., web browser applications, widget or gadget engines, and / or other applications as needed), executable instructions, and data.

[0065] The processor 1112 may be one or more known processing devices, such as microprocessors from the Pentium® family manufactured by Intel®, the Turion® family manufactured by AMD®, or the Cortex® family or SecurCore® manufactured by ARM®, to name just a few examples. The processor 1112 may be a single-core processor or a multi-core processor that performs parallel processing simultaneously. For example, the processor 1112 may be a single-core processor configured with virtual processing technology. Those skilled in the art will understand that other types of processor configurations that provide the capabilities disclosed herein may be implemented.

[0066] The control device 1110 may include one or more storage devices 1120 configured to store information used by the processor 1112 (or other components) to perform at least some of the functions disclosed herein. For example, the control device 1110 may include a memory 1116 containing instructions that enable the processor 1112 to execute one or more applications, network communication processes, and any other type of application or software known to be available on a computer system. Alternatively, instructions, application programs, or other software may be stored in external storage and / or available from remote memory via a network. The one or more storage devices may be volatile or non-volatile, magnetic, semiconductor, tape, optical, removable, non-removable, or other types of storage devices or tangible computer-readable media.

[0067] The control device 1110 may include a memory 1116 containing instructions that, when executed by the processor 1112, perform one or more processes consistent with the functions disclosed herein. Methods, systems, and products consistent with the disclosed embodiments are not limited to separate programs or computers configured to perform dedicated tasks. For example, the control device 1110 may include a memory 1116 containing one or more programs 1122 for performing one or more functions of the disclosed technology. For example, the control device 1110 may have access to one or more programs 1122 that, when executed, perform at least one of the functions disclosed herein. One or more programs 1122 may receive input from a user (e.g., a doctor, a technician, etc.) and cause the control device 1110 to output one or more control signals to the robot arm 1200. One or more programs 1122 may be configured to display images on the user interface 1124 that indicate a function or state associated with the robot arm 1200.

[0068] The memory 1116 of the control device 1110 may include one or more memory devices for storing data and instructions used to implement one or more of the methods and features disclosed herein. The memory 1116 may include software components that, when executed by the processor 1112, execute one or more processes consistent with those disclosed herein. The control device 1110 may include any number of hardware and / or software applications that are executed to facilitate any operation. One or more I / O interfaces 1114 may be used to receive or collect data and / or user instructions from a wide variety of input devices. The received data may be processed by one or more computer processors 1112 and / or stored in one or more memory devices, as desired in various implementations of the technology of this disclosure.

[0069] While control devices 1110 for implementing the techniques described herein have been described above, those skilled in the art will understand that other functionally equivalent techniques can be used. For example, as is known in the art, some or all of the functions implemented via executable instructions can be implemented using firmware and / or hardware devices such as application-specific integrated circuits (ASICs), programmable logic arrays, and state machines. Furthermore, control devices 1110 may include more or fewer components than those illustrated and / or described above.

[0070] As those skilled in the art will understand, the control device 1110 described above may be implemented within the robot platform 2000 or any other structure (for example, a computing system separate from the robot platform 2000).

[0071] Furthermore, the control device 1110 communicates with one or more sensors 1300 integrated with the surgical instrument 1000, or with a pack encoder 1300 integrated with the robot platform 2000. For example, one or more sensors 1300 may include one or more magnetic rotary position encoders configured to identify the motor 1202 of the robot arm 1200, the shaft assembly 600A (e.g., the roll angle of the outer shaft 602), and / or the rotational position of the end effector 200 of the surgical instrument 1000. In some examples, the magnetic rotary position encoder may be coupled to the processor 1112. The sensors 1300 may also include current sensors, velocity sensors, and other forms of position sensors as necessary to perform the following processes:

[0072] VIII.1 Adaptive launch with planned period modulation Adaptive firing of a surgical instrument (e.g., an endocutter) is a process of changing the knife firing speed in real time to relax the tissue. When relaxation occurs, the firing force decreases, allowing the knife to cut through thicker tissue. This firing speed can be actuated directly or indirectly. In a direct approach, the motor speed is the output of a controller that takes input from the system and calculates the optimal firing speed. In an indirect approach, the change in knife speed is a result of changing other parameters in the system, such as the motor's acceleration or the time it takes to move from point A to point B. In this current embodiment of planned target period modulation, the output of the control system is the time it takes for the motor to move from its current position to the target position, thereby such a time is calculated in proportion to the torque the firing motor is receiving during cutting.

[0073] Most adaptive firing processes employ a stop / start approach (also known as pulsation), where the motor stops when the force exceeds a certain threshold. The controller waits for a certain amount of time, and then re-accelerates the motor. The process repeats when the force again exceeds the threshold. The problem with this method is that the knife experiences static friction each time it stops, thereby creating a force spike each time it transitions from static to dynamic motion. The process described below keeps the knife 206 of the surgical instrument 1000 moving when the force exceeds a certain threshold, and only stops completely if there is no solution to keep the knife 206 moving forward at a lower speed.

[0074] Figure 42 shows a logic flow diagram of the adaptive launch process 800, which is controlled by the control device 1110 and implemented by the launch subsystem 500.

[0075] In summary, process 800 expands and contracts the time to reach the end of the cut in proportion to the launch force when the force exceeds a certain threshold. To do this, a planning period parameter is calculated as an output to a proportional-integral controller that takes the launch force as input and outputs a planning period. This planning period is passed at a constant speed via a trajectory interpolator to the launch motor 1202 (e.g., the motor 1202 that controls the launch pack assembly 712). The trajectory interpolator then calculates the motor acceleration for moving from the current position to the end of the cut in a given time frame. This effect is demonstrated by the modulation of the motor acceleration in proportion to the launch force; that is, the motor decelerates as the launch force increases and accelerates as the launch force decreases.

[0076] If the firing force continues to increase as the firing motor 1202 decelerates, the firing motor 1202 asymptotically approaches a complete stop, waiting for the tissue to relax. Once relaxation is achieved, the motor accelerates back to full speed and resumes monitoring the firing force. When the force again exceeds the threshold, the time modulator activates again, modulating the duration in proportion to the firing force. In this way, the firing motor 1202 does not come to a complete stop every time the threshold is exceeded. Instead, the control device 1110 attempts to find an intermediate solution to keep the knife 206 moving forward, albeit at a slower pace, and only asymptotically approaches a complete stop if no solution can be found. This minimizes the opportunity for the knife 206 to experience static friction. It also minimizes smart firing time by maintaining the speed of the knife 206 at a certain level on thick tissue.

[0077] Referring specifically to Figure 42, process 800 includes certain defined parameters, including (1) proportional-integral-derivative (PID) parameters (kp, ki) (where kp is the proportional gain and ki is the integral gain), (2) end_position, which is the leading edge of the cut line, and (3) firing_speed, which in this example is set to 9-10 millimeters / second but can be set to other values.

[0078] Furthermore, the process includes determining that clamping is complete (802). For example, this may be determined based on feedback from a position sensor 1300 and / or a pack encoder 1300 that measures the position of the knife 206 as it moves along the anvil inclined surface 216. In a non-limiting example, clamping may be considered complete when the knife 206 has reached a predetermined position from its "home," where the knife's "home" is its collision with the anvil pin during tool homing. The control device 1110 then initiates the firing of the knife 206 (804). The firing motor 1202 is accelerated to a target speed (806) and maintained at the target speed. The firing force of the knife 206 is then read (808) and / or calculated. For example, the firing force may be determined based on the current of the firing motor 1202 (e.g., measured by a current sensor 1300) or by a torque cell.

[0079] In determination block 810, it is determined whether the knife position is greater than (i.e., exceeds) the position associated with the leading edge of the cutting end. If the position value is not greater than the leading edge of the cutting end value, process 800 proceeds to determination block 812, where it is determined whether the firing force (read in block 808) is greater than the upper threshold. As an unrestricted example, in the force domain, the upper threshold may be approximately 140 pounds, and in the torque domain, the upper threshold may be approximately 0.4 to 0.45 Newton meters (Nm). These values ​​may be generated through system calibration. If the firing force is not greater than the upper threshold, process 800 maintains the motor speed (814), checks the position of the knife 206, and loops back to determination block 810 to continue process 800. If the knife position value evaluated in determination block 810 is greater than / once greater than the leading edge of the cutting end value, adaptive firing ends (816) and the cutting line detection process begins (816). After the end of the cut is detected (818), the forward movement of the knife 206 is stopped (820), contraction is initiated, and thus the execution of process 800 is completed.

[0080] In the determination block 812, if it is determined that the firing force of the knife 206 exceeds the upper threshold, the error is calculated by subtracting the upper threshold from the currently read firing force (822). Next, the time modulator is calculated using the following formula (824).

[0081]

number

[0082]

number

[0083] The planned period is passed to the motor trajectory generator / interpolator 1202A of the launch motor 1202 (828). The trajectory generator / interpolator 1202A calculates the motor acceleration required to move from current_knife_position to end_position within a given time frame, i.e., the planned period. This effect is demonstrated by the modulation of the motor acceleration proportional to the launch force. That is, the motor 1202 decelerates as the launch force increases, and otherwise accelerates as the launch force decreases.

[0084] Following the modulation of the motor acceleration, the determination block 830 determines whether the firing force is below the lower threshold. The lower threshold is necessary to eliminate vibrations near the upper threshold. If the system described herein has only an upper threshold, the PID controller decelerates the motor as soon as the firing force exceeds the threshold, and accelerates the motor as soon as the firing force falls below the upper threshold. The lower threshold forms a "dead zone" below the upper threshold, and thus can eliminate vibrations near the upper threshold.

[0085] If the firing force is below the lower threshold, the motor 1202 is re-accelerated (832) back to a preset firing speed (e.g., 9 millimeters / second), and process 800 loops back to block 808, continuing to monitor the upper threshold for firing force until the knife position is greater than the leading edge of the cutting end (determined as "yes" in block 812), at which point adaptive firing is terminated.

[0086] If the firing force is above the lower threshold, the determination block 834 determines whether the current firing velocity (measured / calculated after the motor has finished accelerating, as described in step 828) is below a predetermined minimum velocity (e.g., less than 0.5 millimeters / second). Note that this value may be adjusted over time. For practical purposes, in this example, velocities below the predetermined minimum velocity are considered to be 0.

[0087] If the firing rate determined in block 834 is greater than or equal to a predetermined minimum speed, the current motor speed (after acceleration / deceleration in step 828) is maintained, and process 800 loops back to block 808 and continues to monitor the upper threshold for firing force until the knife position is greater than the leading edge of the cutting end (determined as "yes" in determination block 812), at which point adaptive firing is terminated.

[0088] If the firing velocity determined in block 834 falls below a predetermined minimum velocity, the motor is stopped (836). The control device 1110 waits for tissue relaxation (838) (for example, a predetermined time such as about 2 seconds after the motor has completely stopped). After tissue relaxation occurs, the motor 1202 is re-accelerated to return to firing velocity (832), and process 800 loops back to block 808 and continues to monitor the upper threshold for firing force until the knife position is greater than the leading edge of the cutting end (yes in determination block 812), at which point adaptive firing is terminated.

[0089] The adaptive firing described herein allows for a significant reduction in peak firing force (e.g., by approximately 15 percent or more) compared to firing modes in which adaptive firing is not used. High peak firing force can stall the motor 1202. Therefore, the adaptive firing process 800 described herein can enable less failure and more consistent performance of the surgical instrument 1000 compared to non-adaptive firing.

[0090] IX. Clause The technologies of this disclosure described herein can be further understood in accordance with the following provisions. Clause 1. A knife launch subsystem (500) for a surgical instrument, comprising a knife (206), a thread (236) coupled to or integrated with the knife (206) and configured to move the knife (206) within an end effector (200), a launch rod (502) configured to drive the thread (236), and a first push rod (504) coupled to the thread (236) A knife firing subsystem (500) comprises a first push rod (504) having a rod distal end (504A) and a first push rod proximal end (504B) coupled to a firing rod (502), and a second push rod (506) having a second push rod distal end (506A) coupled to a thread (236) and a second push rod proximal end (506B) coupled to a firing rod (502). Clause 2. The knife launch subsystem (500) according to Clause 1, wherein the first push rod (504) comprises a first flexible section (508), and the second push rod (504) comprises a second flexible section (510). Clause 3. The knife firing subsystem (500) according to Clause 2, wherein the first flexible section (508) comprises a first push coil (508), and the second flexible section (510) comprises a second push coil (510). Clause 4. The knife firing subsystem (500) according to Clause 3, further comprising a first central cable (512) extending through a first push coil (508) and a second central cable (514) extending through a second push coil (510). Clause 5. The knife launch subsystem (500) according to any one of Clauses 2 to 3, wherein the first push rod (504) further comprises a first rigid rod (516) axially aligned with the first flexible section (508) and coupled to the first flexible section (508), and the second push rod (506) further comprises a second rigid rod (518) axially aligned with the second flexible section (510) and coupled to the second flexible section (510). Clause 6. A knife launch subsystem (500) according to any one of Clauses 1 to 5, further comprising a differential (520) coupling a first pushrod proximal end (504B) and a second pushrod proximal end (506B) to a launch rod (502), wherein the differential (520) enables relative axial movement between the first pushrod (504) and the second pushrod (506). Clause 7. The knife launch subsystem (500) according to Clause 6, further comprising: a differential gear; a first rack (522) coupled to a first push rod (504); a second rack (524) coupled to a second push rod (506); a pinion rod (526) coupled to a launch rod (502); and a pinion (528) rotatably mounted on the pinion rod (526) and meshing with the first rack (522) and the second rack (524). Clause 8. The knife firing subsystem (500) as described in Clause 7, wherein the first rack (522) and the second rack (524) are movable in opposite directions relative to each other in accordance with the rotation of the thread (240) about the pitch axis (PA). Clause 9. The knife launch subsystem (500) according to any one of Clauses 7 to 8, wherein the first rack (522) and the second rack (524) are each movable in the first axial direction in response to the movement of the launch rod (502) in the first axial direction. Clause 10. A knife firing subsystem (500) according to any one of Clauses 6 to 9, further comprising a shaft assembly (600A) and a differential (520) mounted on the shaft assembly (600A). Clause 11. A differential (520) is rotatably coupled to a launch rod (502) in the knife launch subsystem (500) as described in any one of Clauses 6 to 10. Clause 12. The knife launch subsystem (500) according to any one of Clauses 7 to 10, wherein the pinion rod (526) is axially constrained with respect to the launch rod (502) and freely rotatable with respect to it. Clause 13. A knife firing subsystem (500) as described in any one of Clauses 1 to 12, wherein a first push rod (504) is coupled to the upper end of the thread (236) and a second push rod (506) is coupled to the lower end of the thread (236). Clause 14. The knife firing subsystem (500) described in any one of Clauses 1 to 13, wherein the firing rod (502) is configured to indirectly drive the thread (236). Clause 15. A control device (1100) configured to read (808) the firing force of a knife (206) driven by a motor (1202), determine (812) whether the firing force exceeds an upper threshold, calculate an error in accordance with the determination that the firing force exceeds an upper threshold, calculate a time modulator using the error (824), calculate a new time using the time modulator to move the knife (206) from its current position to the leading edge of the end of the cutting line (826), and transmit the new time to a motor trajectory generator (1202A), the motor trajectory generator (1202A) configured to accelerate or decelerate the motor (1202) based on the transmitted new time. Clause 16. The error is calculated by subtracting the upper threshold from the read firing force, as described in Clause 15a of the control device. Article 17 is,

[0091]

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[0092]

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[0093] The embodiments described above are for illustrative purposes only, and the present invention is not limited to those specifically illustrated and described herein. Rather, the scope of the present invention includes both combinations and secondary combinations of the various features described and illustrated above, as well as variations and modifications thereof not disclosed in the prior art, which would be recalled by those skilled in the art by reading the foregoing description.

[0094] [Implementation Method] (1) A knife launching subsystem (500) for surgical instruments, Knife (206) and, A thread (236) coupled to or integrated with the knife (206), configured to move the knife (206) within the end effector (200), A firing rod (502) configured to drive the aforementioned thread (236), The first push rod (504), The distal end (504A) of the first push rod is connected to the thread (236), A first push rod (504) comprises a first push rod proximal end (504B) coupled to the launch rod (502), The second push rod (506), The distal end (506A) of the second push rod is connected to the thread (236), A knife firing subsystem (500) comprises a second push rod (506) having a second push rod proximal end (506B) coupled to the firing rod (502), and a second push rod (506). (2) The knife launch subsystem (500) according to Embodiment 1, wherein the first push rod (504) comprises a first flexible section (508) and the second push rod (504) comprises a second flexible section (510). (3) The knife firing subsystem (500) according to Embodiment 2, wherein the first flexible section (508) comprises a first push coil (508) and the second flexible section (510) comprises a second push coil (510). (4) A first central cable (512) extending through the first push coil (508), The knife firing subsystem (500) according to Embodiment 3 further comprises a second central cable (514) extending through the second push coil (510). (5) The knife launch subsystem (500) according to any of embodiments 2 to 3, wherein the first push rod (504) further comprises a first rigid rod (516) which is axially aligned with the first flexible section (508) and coupled to the first flexible section (508), and the second push rod (506) further comprises a second rigid rod (518) which is axially aligned with the second flexible section (510) and coupled to the second flexible section (510).

[0095] (6) A knife launch subsystem (500) according to any one of embodiments 1 to 5, further comprising a differential device (520) that couples the proximal end (504B) of the first push rod and the proximal end (506B) of the second push rod to the launch rod (502), wherein the differential device (520) enables relative axial movement between the first push rod (504) and the second push rod (506). (7) The differential device is A first rack (522) coupled to the first push rod (504), A second rack (524) coupled to the second push rod (506), The pinion rod (526) is connected to the launch rod (502), The knife launch subsystem (500) according to embodiment 6 further comprises a pinion (528) rotatably mounted on the pinion rod (526) and meshing with the first rack (522) and the second rack (524). (8) The knife firing subsystem (500) according to Embodiment 7, wherein the first rack (522) and the second rack (524) are movable in opposite directions relative to each other in accordance with the rotation of the thread (240) about the pitch axis (PA). (9) The knife launch subsystem (500) according to any one of embodiments 7 to 8, wherein the first rack (522) and the second rack (524) are each movable in the first axial direction in response to the movement of the launch rod (502) in the first axial direction. (10) A knife firing subsystem (500) according to any of embodiments 6 to 9, further comprising a shaft assembly (600A), wherein the differential (520) is mounted on the shaft assembly (600A).

[0096] (11) A knife launch subsystem (500) according to any one of embodiments 6 to 10, wherein the differential (520) is rotatably coupled to the launch rod (502). (12) The knife launch subsystem (500) according to any one of embodiments 7 to 10, wherein the pinion rod (526) is axially constrained to the launch rod (502) and freely rotatable with respect to it. (13) A knife firing subsystem (500) according to any one of embodiments 1 to 12, wherein the first push rod (504) is coupled to the upper end of the thread (236) and the second push rod (506) is coupled to the lower end of the thread (236). (14) The knife launch subsystem (500) according to any one of embodiments 1 to 13, wherein the launch rod (502) is configured to indirectly drive the thread (236). (15) A control device (1100), Reading the firing force (808) of the knife (206) driven by the motor (1202), (812) Determining whether the firing force exceeds the upper threshold, In accordance with the determination that the firing force exceeds the upper threshold, the error is calculated, Using the aforementioned error, calculate the time modulator (824), Using the time modulator, calculate a new time (826) for moving the knife (206) from its current position to the leading edge of the cutting line. A control device (1100) is configured to transmit the new time to a motor trajectory generator (1202A), the motor trajectory generator (1202A) being configured to accelerate or decelerate the motor (1202) based on the transmitted new time.

[0097] (16) The control device according to embodiment 15, wherein the error is calculated by subtracting the upper threshold from the read firing force. (17) The time modulator is

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Claims

1. A knife launching subsystem (500) for surgical instruments, Knife (206) and, A thread (236) coupled to or integrated with the knife (206), configured to move the knife (206) within the end effector (200), A firing rod (502) configured to drive the aforementioned thread (236), The first push rod (504) is, The distal end (504A) of the first push rod is connected to the thread (236), A first push rod (504) comprises a first push rod proximal end (504B) coupled to the launch rod (502), The second push rod (506) is, The distal end (506A) of the second push rod is connected to the thread (236), A knife launch subsystem (500) comprises a second push rod (506) having a second push rod proximal end (506B) coupled to the launch rod (502), and a second push rod (506).

2. The knife launch subsystem (500) according to claim 1, wherein the first push rod (504) comprises a first flexible section (508), and the second push rod (504) comprises a second flexible section (510).

3. The knife firing subsystem (500) according to claim 2, wherein the first flexible section (508) comprises a first push coil (508), and the second flexible section (510) comprises a second push coil (510).

4. A first central cable (512) extends through the first push coil (508), The knife firing subsystem (500) according to claim 3, further comprising a second central cable (514) extending through the second push coil (510).

5. The knife launch subsystem (500) according to any one of claims 2 to 3, wherein the first push rod (504) further comprises a first rigid rod (516) which is axially aligned with the first flexible section (508) and coupled to the first flexible section (508), and the second push rod (506) further comprises a second rigid rod (518) which is axially aligned with the second flexible section (510) and coupled to the second flexible section (510).

6. The knife launch subsystem (500) according to claim 1, further comprising a differential (520) that connects the proximal end (504B) of the first push rod and the proximal end (506B) of the second push rod to the launch rod (502), wherein the differential (520) enables relative axial movement between the first push rod (504) and the second push rod (506).

7. The differential device is A first rack (522) coupled to the first push rod (504), A second rack (524) is coupled to the second push rod (506), The pinion rod (526) is connected to the launch rod (502), The knife launch subsystem (500) according to claim 6, further comprising a pinion (528) rotatably mounted on the pinion rod (526) and engaging with the first rack (522) and the second rack (524).

8. The knife firing subsystem (500) according to claim 7, wherein the first rack (522) and the second rack (524) are movable in opposite axes relative to each other in accordance with the rotation of the thread (240) about the pitch axis (PA).

9. The knife launch subsystem (500) according to any one of claims 7 to 8, wherein the first rack (522) and the second rack (524) are each movable in the first axial direction in accordance with the movement of the launch rod (502) in the first axial direction.

10. The knife firing subsystem (500) according to claim 6, further comprising a shaft assembly (600A), wherein the differential (520) is attached to the shaft assembly (600A).

11. The knife launch subsystem (500) according to claim 6, wherein the differential (520) is rotatably coupled to the launch rod (502).

12. The knife launch subsystem (500) according to claim 7, wherein the pinion rod (526) is axially constrained with respect to the launch rod (502) and freely rotatable with respect to it.

13. The knife firing subsystem (500) according to claim 1, wherein the first push rod (504) is connected to the upper end of the thread (236), and the second push rod (506) is connected to the lower end of the thread (236).

14. The knife launch subsystem (500) according to claim 1, wherein the launch rod (502) is configured to indirectly drive the thread (236).

15. A control device (1100), Reading (808) the firing force of the knife (206) driven by the motor (1202), (812) Determining whether the firing force exceeds the upper threshold, In accordance with the determination that the firing force exceeds the upper threshold, the error is calculated, Using the aforementioned error, the time modulator is calculated (824), Using the time modulator, calculate a new time (826) for moving the knife (206) from its current position to the leading edge of the cutting line. A control device (1100) is configured to transmit the new time to a motor trajectory generator (1202A), the motor trajectory generator (1202A) being configured to accelerate or decelerate the motor (1202) based on the transmitted new time.

16. The control device according to claim 15, wherein the error is calculated by subtracting the upper threshold from the read firing force.

17. The aforementioned time modulator is [Math 1] A control device according to any one of claims 15 to 16, calculated using the formula, where kp is the proportional gain, ki is the integral gain, error is the calculated error, and dt is the delta time.

18. The aforementioned new time is [Math 2] The control device according to claim 15, calculated using the formula, where firing_speed is the target knife velocity, end_position is the leading edge of the end of the cutting line, and current_knife_position is the current position of the knife (206).

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