Systems and methods for exchanging surgical instruments in an implantable surgical robotic system

Abstract

A robotic arm end effector region device forming part of a surgical robotic system includes an instrument base portion coupled to an end portion of the robotic arm by a linkage, and first and second pulley elements rotatably coupled to the instrument base portion, and further includes first and second instrument elements coupled together and removably and replaceably mountable to the pulley elements.

Description

[Technical Field]

[0001] Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 111,950, entitled "System And Method For Exchanging Surgical Tools In An Implantable Surgical Robotic System," filed November 10, 2020, the contents of which are incorporated herein by reference. [Background technology]

[0002] Since its inception in the early 1990s, the field of minimally invasive surgery has grown rapidly. While minimally invasive surgery significantly improves patient outcomes, this improvement comes at the cost of surgeons' inability to operate precisely and easily. During traditional laparoscopic procedures, surgeons typically insert laparoscopic instruments through multiple small incisions in the patient's abdominal wall. The nature of instrument insertion through the abdominal wall constrains laparoscopic instrument motion because the instruments cannot be moved side-to-side without damaging the abdominal wall. Standard laparoscopic instruments also have limited motion, typically limited to four axes of motion. These four axes of motion are translation of the instrument into and out of the trocar (axis 1), rotation of the instrument within the trocar (axis 2), and angular movement of the trocar in two planes while maintaining a pivoted position at the trocar's entrance into the abdominal cavity (axis 3 and axis 4). For over 20 years, the majority of minimally invasive surgeries have been performed using only these four degrees of motion. Additionally, previous systems require multiple incisions if the surgery needs to address multiple different locations within the abdominal cavity.

[0003] Existing robotic surgical devices have attempted to solve many of these problems. Some existing robotic surgical devices replicate non-robotic laparoscopic surgery with additional degrees of freedom at the end of the instruments. However, even with many costly modifications to the surgical procedure, existing robotic surgical devices have failed to provide improved patient outcomes in the majority of procedures in which they are used. Existing robotic devices also create a large gap between the surgeon and the surgical end effector. This large gap can lead to surgeon misinterpretation of motion and injury due to forces applied by the robotic device. Because the degrees of freedom of many existing robotic devices are unfamiliar to the operator, surgeons must train extensively on a robotic simulator before operating on a patient to minimize the possibility of inadvertent injury.

[0004] To control existing robotic devices, the surgeon typically sits at a console and controls manipulators with their hands and / or feet. Additionally, the robotic camera remains in a semi-fixed location and is moved by combined foot and hand movements from the surgeon. These semi-fixed cameras offer only a limited field of view, making it difficult to visualize the entire surgical field.

[0005] Other robotic devices have two robotic manipulators inserted through a single incision. These devices reduce the number of incisions required for a single incision, often in the navel. However, existing single-incision robotic devices have significant drawbacks due to the design of their actuators. Existing single-incision robotic devices include servo motors, encoders, gearboxes, and all other actuation devices internal to the in-vivo robot, which makes the robotic unit inserted within the patient relatively large. This size significantly limits the robotic unit in terms of mobility and ability to perform various procedures. Furthermore, such large robots typically must be inserted through large incisions, often near the size of open surgery, thereby increasing the risk of infection, pain, and general morbidity.

[0006] Furthermore, in laparoscopic and robotic surgery, a variety of instruments and graspers are required to complete a surgical procedure. Initially inserting all of the necessary instruments used by a surgical robotic system into a patient at once can pose increased risks to the patient due to the potential use of excessive incision sites and the increased complexity inherent in safely storing and manipulating the instruments during the surgical procedure. Therefore, current surgical procedures typically rely on removing and replacing instruments throughout the procedure. This removal and replacement process serves to lengthen the duration of the surgery, increases the likelihood of complications due to instruments being completely removed and new instruments being inserted into the patient, and increases the amount of materials required and, therefore, the potential cost of the surgery. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Patent No. 10,285,765 [Patent Document 2] PCT / US20 / 39203 [Patent Document 3] US Patent Application Publication No. 2019 / 0076199 [Patent Document 4] US Patent Application Publication No. 2018 / 0221102 Summary of the Invention [Means for solving the problem]

[0008] The present invention is directed to the ability to replace instruments that form the end effectors of the robotic arms of the present invention in an easy and efficient manner. The ability to easily replace instruments allows a user, such as a surgeon, to simply remove and replace the end effector portion of the robotic arm rather than replacing the entire robotic arm, which typically has a dedicated instrument attached. Removal and replacement of instrument components can be performed inside or outside of the patient. By not requiring the entire robotic arm to be replaced, the robotic arms of the present invention reduce costs and waste because users do not need to use the entire robotic arm.

[0009] The present invention includes an end effector portion including opposing instrument exchange base segments, pulley elements, electrical contact elements, and a pair of instrument elements, shown as pairs of gripper elements. The instrument base is assembled by mounting pulley elements to their respective instrument base segments by inserting portions of the pulley elements into recesses formed in the instrument element segments. The end effector portion can then be coupled to a robotic arm assembly by a pair of connecting flanges and coupling pins, each with an aperture formed therein. The apertures can be coupled to an appropriate connector formed on an end portion of the robotic arm assembly. The pulley elements can employ surface features, such as embossments, that are complementary in shape to surface features formed in or on the main body of the instrument element. When the pulley element embossments and the apertures formed in the instrument element are oriented in a selected position (e.g., an open instrument exchange position), the instrument element can be easily mounted to or removed from the instrument base portion. The instrument element can be positioned in the open instrument exchange position, where the gripper portions (e.g., working surfaces) are separated from each other by a predetermined set angle, such as approximately 180 degrees. This allows the instrument element to slide easily over the surface features of the pulley element. Once loaded, the pulley element can be actuated by a suitable cable to move the instrument element into one or more use positions where the working surfaces are separated from one another by less than 180 degrees. The use position secures the instrument elements together while incidentally securing the instrument element to the instrument base. To remove the instrument element from the instrument base, the instrument element can be repositioned in the open instrument exchange position.

[0010] The present invention is directed to a method for removing one or more instrument elements forming an instrument from and inserting them into a wrist portion of a robotic arm in a surgical robotic system. The method includes the steps of providing an instrument base portion coupled to an end portion of the robotic arm, rotatably coupling a first pulley element and a second pulley element to the instrument base portion, securing the first pulley element and the second pulley element to the instrument base portion with a shaft element, providing the first and second instrument elements coupled together, and configuring the first and second instrument elements to be positioned in an open instrument exchange position so that they can be loaded onto or removed from the instrument base portion. The instrument base portion is configured with a first instrument base segment and a second instrument base segment, where the first pulley element is rotatably coupled to the first instrument base segment and the second pulley element is rotatably coupled to the second instrument base segment. Thereby, the first and second instrument elements are removably and exchangeably coupled to the instrument base portion when placed in the open instrument exchange position.

[0011] The method of the present invention further includes the steps of configuring a first pulley element to have a first pulley surface feature formed thereon and configuring a second pulley element to have a second pulley surface feature formed thereon; configuring a first equipment element to have a first surface feature formed thereon that is complementary in shape to the first pulley surface feature of the first pulley element; and configuring a second equipment element to have a second surface feature formed thereon that is complementary in shape to the second pulley surface feature of the second pulley element. When the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element are aligned, and when the first surface feature of the first instrument element and the second surface feature of the second instrument element are aligned when placed in the open instrument exchange position, the first instrument element and the second instrument element can be removably and replaceably mounted at the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element, respectively.

[0012] According to one embodiment, the method also includes providing a first instrument element capable of coupling together with a second instrument element, configuring the first instrument element to have a first interlocking surface feature formed thereon, and configuring the second instrument element to have a second interlocking surface feature formed thereon that is complementary in shape to the first interlocking surface feature, such that the first and second instrument elements can be coupled together when the first and second interlocking surface features are aligned. The first interlocking surface feature can include a groove, and the second interlocking surface feature can include a protruding rail-like element. The first and second interlocking surface features in combination form a dovetail coupling. Furthermore, when the first and second instrument elements are assembled, the method includes the step of locking the first and second instrument elements together by selectively rotating one or more of the first and second instrument elements from an open instrument exchange position to one or more use positions by one or more rotational movements of the first and second pulley elements. This allows the device of the present invention, when positioned in a selected position, such as the open instrument exchange position, to easily remove and replace different types of instrument elements from the instrument base portion, while moving the instrument elements from the open instrument exchange position to one or more different use positions locks the instrument elements together to the instrument base portion. The use positions correspond to the positions at which the instrument elements are positioned during the performance of a surgical procedure. According to one implementation, the instrument elements need not be separated by an angular distance approaching or exceeding 180 degrees during use.

[0013] The method also includes providing a first conductive spring element coupled to the first pulley element and a second conductive spring element coupled to the second pulley element, and providing a first conductive contact element coupled to the first instrument element and a second conductive contact element coupled to the second instrument element, The method further includes maintaining direct contact between a portion of the conductive spring element and a portion of the conductive contact element during use regardless of the rotational positions of the first and second pulley elements.

[0014] The present invention is also directed to an end effector area device for a robotic arm in a surgical robotic system, the end effector area device comprising: an instrument base portion coupled to an end portion of the robotic arm by a coupler; a first pulley element rotatably coupled to the instrument base portion; a second pulley element rotatably coupled to the instrument base portion, the first and second pulley elements being fixed to the instrument base portion with a shaft element; and a first instrument element coupled together with the second instrument element. The first and second instrument elements are configured to be positioned in an open instrument exchange position so that they can be loaded onto or removed from the instrument base portion. According to one embodiment, the instrument base portion can comprise a first instrument base segment and a second instrument base segment, wherein the first pulley element is rotatably coupled to the first instrument base segment and the second pulley element is rotatably coupled to the second instrument base segment. The first and second instrument elements are removably and replaceably coupled to the instrument base portion when disposed in the open instrument exchange position.

[0015] The first pulley element has a first pulley surface feature formed thereon, the second pulley element has a second pulley surface feature formed thereon, the first instrument element has a first surface feature formed thereon that is complementary in shape to the first pulley surface feature of the first pulley element, and the second instrument element has a second surface feature formed thereon that is complementary in shape to the second pulley surface feature of the second pulley element. When positioned in an open instrument exchange position, the first surface feature of the first pulley element and the second surface feature of the second pulley element are aligned, and the first surface feature of the first instrument element and the second surface feature of the second instrument element are aligned. In this position, the first and second instrument elements can be removably and replaceably mounted at the first and second pulley surface features of the first and second pulley element, respectively.

[0016] Still further, the first instrument element has a first interlocking surface feature formed on its surface, and the second instrument element has a second interlocking surface feature formed on its surface that is complementary in shape to the first interlocking surface feature such that the first and second instrument elements can be joined together when the first and second interlocking surface features are aligned. The first interlocking surface feature includes a groove, and the second interlocking surface feature includes a protruding rail-like element. The first and second interlocking surface features may be configured to form a dovetail interlock.

[0017] Still further, when the first and second instrument elements are assembled, the first and second instrument elements are locked together by selective rotation of one or more of the first and second instrument elements from an open instrument exchange position to one or more use positions by one or more rotational movements of the first and second pulley elements.

[0018] The device of the present invention may also comprise a first conductive spring element coupled to the first pulley element, a second conductive spring element coupled to the second pulley element, a first conductive contact element coupled to the first instrument element, and a second conductive contact element coupled to the second instrument element, wherein in use, when assembled together, a portion of the conductive spring element is in continuous and direct contact with a portion of the conductive contact element, regardless of the rotational positions of the first and second pulley elements.

[0019] The present invention is also directed to a wrist portion of a robotic arm forming part of a robotic unit of a surgical robotic system, the wrist portion comprising: an instrument base portion coupled to an end portion of the robotic arm by a coupler; a first pulley element rotatably coupled to the instrument base portion, the first pulley element having a main body having a first pulley surface feature formed thereon; a second pulley element rotatably coupled to the instrument base portion, the second pulley element having a main body having a second pulley surface feature formed thereon; a first instrument element having a main body having a first surface feature formed thereon that is complementary in shape to the first pulley surface feature of the first pulley element; and a second instrument element having a main body having a second surface feature formed thereon that is complementary in shape to the second pulley surface feature of the second pulley element, wherein the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element are aligned with each other when positioned in a first open instrument exchange position. In this position, the first and second instrument elements can be removably and interchangeably mounted at the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element, respectively. According to one embodiment, the instrument base portion comprises a first instrument base segment and a second instrument base segment, wherein the first pulley element is rotatably coupled to the first instrument base segment and the second pulley element is rotatably coupled to the second instrument base segment. Furthermore, when the first instrument element is removably mounted to the first pulley element and the second instrument element is removably mounted to the second pulley element, the first surface feature of the first instrument element mates and seats with the first pulley surface feature of the first pulley element and the second surface feature of the second instrument element mates and seats with the second pulley surface feature of the second pulley element. According to one embodiment, each of the first pulley surface feature and the second pulley surface feature are shaped and configured as raised elements, and each of the first surface feature and the second surface feature includes a slot.

[0020] The instrument base segment of the present invention also has a main body having an extension portion at one end and a flange portion at the opposite end. The extension portion has an inner surface and an opposite outer surface, and an opening is formed therein. The inner surface of the extension portion has a recess formed therein. The flange portion of each of the first and second instrument base segments has an opening formed therein for seating a coupling. Furthermore, the first and second pulley elements each have a main body having an inner surface and an opposite outer surface with a coupling element formed thereon that protrudes outwardly from the surface. Pulley surface features are formed on the inner surface of the main body. The main body of each of the first and second pulley elements has a plurality of holes formed therein, at least a portion of the plurality of holes sized and configured to seat a portion of the control cable. Still further, the connecting element of the first pulley element is seated and held in a recess formed in the inner surface of the first instrument base segment, and the connecting element of the second pulley element is seated and held in a recess formed in the inner surface of the second instrument base segment.

[0021] The wrist portion also includes a first conductive spring element coupled to the first pulley element and a second conductive spring element coupled to the second pulley element. Each of the first and second conductive spring elements includes a main body having a central coil element, an upper tab portion coupled to one end of the coil element, and a lower tab portion coupled to the other end of the coil element. The lower tab portion is coupled to an electrical lead housed within the instrument base portion, the coil element is coupled to an outer surface of the pulley element, and at least a portion of the upper tab portion is coupled to an inner surface of the pulley element. During use, the central coil element is configured to expand and contract based on movement of the upper tab portion.

[0022] According to the present invention, the wrist portion comprises a first conductive contact element coupled to the working surface of the first instrument element and a second conductive contact element coupled to the working surface of the second instrument element. Furthermore, at least a portion of the first and second conductive contact elements are configured to contact at least a portion of the upper tab portions of the first and second conductive spring elements, respectively, when mounted on the first and second instrument elements. Still further, the contacting portion of each of the first and second conductive contact elements remains in continuous electrical contact with a portion of the first and second conductive spring elements, respectively, during use.

[0023] These and other features of the present invention will be more fully understood by reference to the following detailed description taken in conjunction with the accompanying drawings, in which like numerals refer to like elements throughout the different views, illustrating the principles of the invention and showing relative dimensions, although not to scale, in which: [Brief explanation of the drawings]

[0024] [Figure 1] FIG. 1 is a schematic diagram of an exemplary surgical robotic system implementing the robotic end effector of the present invention. [Figure 2A] FIG. 2 is a perspective view of a robot arm of a robotic unit in accordance with the teachings of the present invention. [Figure 2B] FIG. 2 is a perspective view of a robot arm of a robotic unit in accordance with the teachings of the present invention. [Figure 3] FIG. 1 is an exploded perspective view of an end effector portion of a robotic arm in accordance with a first embodiment of the present invention. [Figure 4] FIG. 1 is an exploded perspective view of an end effector portion of a robotic arm in accordance with a first embodiment of the present invention. [Figure 5] FIG. 2 is a partial assembly view of a portion of an end effector portion of a robotic arm in accordance with the teachings of the present invention. [Figure 6] FIG. 1 is a perspective view of a fully assembled end effector portion of a robotic arm in accordance with the teachings of the present invention. [Figure 7A] 1 is a perspective view of an instrument base portion of an end effector portion and selected end effector instruments in accordance with the teachings of the present invention. [Figure 7B] 1 is a perspective view of an instrument base portion of an end effector portion and selected end effector instruments in accordance with the teachings of the present invention. [Figure 7C] 1 is a perspective view of an instrument base portion of an end effector portion and selected end effector instruments in accordance with the teachings of the present invention. [Figure 7D] 1 is a perspective view of an instrument base portion of an end effector portion and selected end effector instruments in accordance with the teachings of the present invention. [Figure 8A] 1 is a perspective view of an end effector portion of the present invention showing the loaded instrument elements in selected positions during use. [Figure 8B] FIG. 1 is a perspective view of the end effector portion of the present invention showing a loaded instrument element in an open instrument exchange position where the instrument element can be loaded onto or removed from the instrument base portion. [Figure 8C] FIG. 1 is a perspective view of the end effector portion of the present invention showing a loaded instrument element in an open instrument exchange position where the instrument element can be loaded onto or removed from the instrument base portion. [Figure 8D] 1 is a perspective view of the appliance base of the present invention when assembled. [Figure 9] FIG. 1 is a partial perspective view of an end effector portion of the present invention showing a loaded instrument element in an open instrument exchange position where the instrument element can be loaded onto or removed from the instrument base portion. [Figure 10A] 1 is a partial perspective view of an end effector portion of the present invention showing the loaded instrument elements in selected positions during use. [Figure 10B] 1 is a partial perspective view of an end effector portion of the present invention showing the loaded instrument elements in selected positions during use. [Figure 10C]1 is a partial perspective view of an end effector portion of the present invention showing the loaded instrument elements in selected positions during use. [Figure 11] 1 is a perspective view of an appliance base in accordance with the teachings of the present invention; [Figure 12A] FIG. 1 is a partial perspective view of selected components of the implement base showing the cables for driving the pulley elements of the present invention. [Figure 12B] FIG. 1 is a partial perspective view of selected components of the implement base showing the cables for driving the pulley elements of the present invention. [Figure 12C] FIG. 1 is a partial perspective view of selected components of the implement base showing the cables for driving the pulley elements of the present invention. [Figure 13A] FIG. 10 is a side perspective view of an end effector portion of a robotic arm in accordance with a second embodiment of the present invention. [Figure 13B] FIG. 13B is a front perspective view of an end effector portion of the robotic arm of FIG. 13A in accordance with the teachings of the present invention. [Figure 14A] FIG. 2 is an exploded view of an end effector portion in accordance with the teachings of the present invention. [Figure 14B] FIG. 2 is an exploded view of an end effector portion in accordance with the teachings of the present invention. [Figure 14C] FIG. 2 is an exploded view of an end effector portion in accordance with the teachings of the present invention. [Figure 14D] FIG. 2 is an exploded view of an end effector portion in accordance with the teachings of the present invention. [Figure 14E] FIG. 2 is an exploded view of an end effector portion in accordance with the teachings of the present invention. [Figure 15] FIG. 2 is an exploded perspective view of an end effector portion in accordance with the teachings of the present invention. [Figure 16A] FIG. 1 is a front view of a pulley element of an end effector portion of a robotic arm in accordance with the teachings of the present invention. [Figure 16B] FIG. 1 is a side view of a pulley element of an end effector portion of a robotic arm in accordance with the teachings of the present invention. [Figure 16C]FIG. 10 is a rear view of a pulley element of an end effector portion of a robotic arm in accordance with the teachings of the present invention. [Figure 17A] FIG. 10 is a front view of a conductive spring element of an end effector portion in accordance with the teachings of the present invention. [Figure 17B] FIG. 10 is a side view of a conductive spring element of an end effector portion in accordance with the teachings of the present invention. [Figure 17C] 1 is a front view of a conductive spring element in a first exemplary operating position in accordance with the teachings of the present invention. FIG. [Figure 17D] FIG. 10 is a front view of a conductive spring element in a second exemplary operating position in accordance with the teachings of the present invention. [Figure 18A] FIG. 1 is a front view of a pulley element having a conductive spring element coupled thereto in accordance with the teachings of the present invention. [Figure 18B] FIG. 10 is a rear view of a pulley element having a conductive spring element coupled thereto in accordance with the teachings of the present invention. [Figure 19A] FIG. 1 is a partial cutaway view of an end effector portion of a robotic arm showing the connection between a conductive spring element and an internal electrical wire in accordance with the teachings of the present invention. [Figure 19B] FIG. 10 is an enlarged, partial cutaway view of an end effector portion of a robotic arm showing the connection between a conductive spring element and an internal electrical wire in accordance with the teachings of the present invention. [Figure 20A] FIG. 1 is a front side perspective view of the instrument elements of the present invention showing mating surface features for joining the instrument elements together. [Figure 20B] FIG. 1 is a front side perspective view of the instrument elements of the present invention showing mating surface features for joining the instrument elements together. [Figure 21] 1 is a perspective view of one of the tool elements mounted on a respective pulley element in accordance with the teachings of the present invention. FIG. [Figure 22A] 1 is a perspective view of the instrument elements when coupled together in accordance with the teachings of the present invention; [Figure 22B] 1 is a perspective view of the instrument elements when coupled together in accordance with the teachings of the present invention; [Figure 23A]FIG. 1 is a front perspective view of an implement element when mounted to a embossed element of a pulley element in accordance with the teachings of the present invention. [Figure 23B] FIG. 10 is a rear perspective view of an implement element when mounted to a embossed element of a pulley element in accordance with the teachings of the present invention. [Figure 23C] FIG. 10 is a side view of an implement element when mounted on a embossed element of a pulley element in accordance with the teachings of the present invention. [Figure 24A] FIG. 1 is a front perspective view of an implement element and associated conductive contact elements as mounted to a pulley element in accordance with the teachings of the present invention. [Figure 24B] FIG. 1 is a rear perspective view of an implement element and associated conductive contact elements as mounted to a pulley element in accordance with the teachings of the present invention. [Figure 25] FIG. 1 is a side perspective view of an implement element as mounted to a pulley element of the present invention. [Figure 26A] FIG. 1 is a rear perspective view of an implement element as mounted to a pulley element in accordance with the teachings of the present invention. [Figure 26B] FIG. 1 is a front perspective view of an implement element when mounted to a corresponding pulley element in accordance with the teachings of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0025] In the following description, numerous specific details are set forth with respect to the systems and methods of the present invention, as well as the environments in which the systems and methods may operate, to provide a thorough understanding of the disclosed subject matter. However, it will be apparent to those skilled in the art that the disclosed subject matter can be practiced without such specific details, and that certain features well known in the art have not been described to avoid complexity and enhance clarity of the disclosed subject matter. It is also understood that any examples provided below are merely illustrative and are not to be construed in a limiting manner, and that other systems, devices, and / or methods are contemplated by the inventors to be usable to implement or store the teachings of the present invention and are considered to be within the scope of the present invention.

[0026] Although the systems and methods of the present invention can be designed for use with one or more surgical robotic systems used as part of a virtual reality surgical system, the robotic systems of the present invention can be used in connection with any type of surgical system, such as, for example, robotic surgical systems, straight-through surgical systems, laparoscopic systems, etc. The systems of the present invention may also be used in other non-surgical systems where a user needs access to a myriad of information while controlling a device or apparatus.

[0027] The present invention employs a robotic subsystem, including a surgical robotic unit, that can be inserted into a patient through a trocar through a single incision location or site. The robotic unit is small enough to be deployed in vivo at a surgical site and sufficiently maneuverable when inserted to be able to move within the body to perform various surgical procedures at multiple different locations or sites. The surgical robotic unit includes multiple separate robotic arms that are deployable within the patient along different or separate axes. Additionally, a surgical camera assembly can also be deployed along a separate axis. Thus, the surgical robotic unit employs multiple separate components, such as pairs of robotic arms and a surgical or robotic camera assembly, each deployable along a different axis and each independently steerable, steerable, and movable. Robotic arms and camera assemblies that are positionable along separate and steerable axes are referred to herein as split-arm (SA) architectures. The SA architecture is designed to simplify and increase the efficiency of robotic surgical instrument insertion through a single trocar at a single insertion site, while concomitantly assisting in the deployment of surgical instruments to a surgical prep state and subsequent removal of the surgical instruments through the trocar. By way of example, surgical instruments may be inserted through trocars to access and perform surgery in vivo in the patient's abdominal cavity. In some embodiments, a variety of surgical instruments may be used, including but not limited to robotic surgical instruments and other surgical instruments known in the art.

[0028] The systems and methods disclosed herein can incorporate and utilize, for example, the robotic surgical devices and related systems disclosed in U.S. Patent No. 10,285,765 and PCT Patent Application PCT / US20 / 39203, and / or the camera assemblies and systems disclosed in U.S. Patent Application Publication No. 2019 / 0076199, the entire contents and teachings of which are incorporated herein by reference. A surgical robotic unit forming part of the present invention can form part of a surgical robotic system including a surgeon workstation, a user workstation, and a robotic assistance system (RSS) for interacting with and assisting the robotic subsystem of the present invention. The robotic subsystem comprises a motor unit and a surgical robotic unit including one or more robotic arms and one or more camera assemblies. The robotic arms and camera assemblies can form part of a single support axis robotic system or can form part of a split-arm (SA) architecture robotic system. The robotic assistance system can provide multiple degrees of freedom to allow the robotic unit to be maneuvered to a single position or multiple different positions within a patient. In one embodiment, the robotic-assisted system can be mounted directly to the operating table or to the floor or ceiling within the operating room. In other embodiments, mounting is achieved by various fastening means, including but not limited to, clamps, screws, or combinations thereof. In other embodiments, the structure may be freestanding. The robotic-assisted system can include a motor assembly that is coupled to a surgical robotic unit, including a robotic arm and a camera assembly. The motor assembly can include gears, motors, drive trains, electronics, etc., to power the components of the surgical robotic unit.

[0029] The robotic arm and camera assembly can have multiple degrees of freedom of movement. According to one implementation, the robotic arm and camera assembly can move in at least axial, yaw, pitch, and roll directions when inserted into a patient through a trocar. The robotic arm assembly is designed to incorporate and utilize multiple degrees of freedom of movement of the robotic arm, with an end effector mounted at the distal end corresponding to the user's wrist region or joint. In other embodiments, the working end (e.g., end effector end) of the robotic arm is designed to incorporate and utilize other robotic surgical instruments, such as those described in U.S. Patent Application Publication No. 2018 / 0221102, the contents of which are incorporated herein by reference.

[0030] FIG. 1 is a schematic block diagram depiction of a surgical robotic system 10 in accordance with the teachings of the present invention. System 10 includes a display device or display unit 12, a virtual reality (VR) computer unit 14, a sensing and tracking unit 16, a computer unit 18, and a robotic subsystem 20. Display unit 12 can be any selected type of display device for displaying information, images, or videos generated by VR computer unit 14, computer unit 18, and / or robotic subsystem 20. Display unit 12 can include or form part of, for example, a head-mounted display (HMD), a screen or display device, a three-dimensional (3D) screen, or the like. The display unit can also include an optional sensor and tracking unit 16A, such as those found in commercially available head-mounted displays. Sensing and tracking units 16 and 16A can include one or more sensors or detection devices coupled to a user of the system, such as a nurse or surgeon. Sensors can be coupled to the user's arms, and if a head-mounted display is not used, additional sensors can be coupled to the user's head and / or neck area. The sensors in this arrangement are depicted by the sensor and tracking unit 16. If the user uses a head-mounted display, eye, head, and / or neck sensors and associated tracking technology can be incorporated into or employed within that device and thus form part of the optional sensor and tracking unit 16A. The sensors of the sensor and tracking unit 16 coupled to the surgeon's arm may preferably be coupled to selected regions of the arm, such as the shoulder region, elbow region, wrist or hand region, and, if desired, the fingers. According to one implementation, the sensors are coupled to a pair of hand controls operated by the surgeon. The sensors generate position data indicating the position of selected parts of the user. The sensing and tracking unit 16 and / or 16A can be utilized to control the movement of the camera assembly 44 and robotic arm 42 of the robotic subsystem 20.Position data 34 generated by the sensors of the sensor and tracking unit 16 can be transmitted to the computer unit 18 for processing by the processing unit 22. From the position data 34, the computer unit 18 can determine or calculate the position and / or orientation of each part of the surgeon's arm and transmit this data to the robotic subsystem 20. According to an alternative embodiment, the sensing and tracking unit 16 can use sensors coupled to the surgeon's torso or any other body part. Furthermore, in addition to sensors, the sensing and tracking unit 16 can use an inertial momentum unit (IMU) having, for example, an accelerometer, a gyroscope, a magnetometer, and a motion processor. The addition of a magnetometer is standard practice in the field because magnetic heading allows for reduction in sensor drift around the vertical axis. Alternative embodiments also include sensors placed on surgical fabrics such as gloves, surgical gowns, or surgical attire. The sensors can be reusable or disposable. Furthermore, the sensors can be located external to the user, such as in a fixed location in a room, such as an operating room. External sensors can generate external data 36 that can be processed by the computer unit and thus used by the system 10. In other embodiments, there are sensors located on a mechanical linkage that is manipulated by the user. The sensors generate signals that serve as inputs that are processed by the computer unit. According to other embodiments, when the display unit 12 is a head-mounted device that uses an associated sensor and tracking unit 16A, the device generates tracking and position data 34A that is received and processed by the VR computer unit 14. Additionally, the sensor and tracking unit 16 may include a hand controller, if desired. The display device, sensing and tracking unit, VR computer unit, etc., can form part of the surgeon's or a remote workstation.

[0031] In embodiments in which the display device is an HMD, the display unit 12 may be a virtual reality head-mounted display, such as an Oculus Rift, Varjo VR-1, or HTC Vive Pro Eye. The HMD may provide the user with a display device coupled to or worn on the user's head, lenses that enable a focused field of view of the display device, and a sensor and / or tracking system 16A for providing tracking of the position and orientation of the display device. The position and orientation sensor system may include, for example, an accelerometer, a gyroscope, a magnetometer, a motion processor, infrared tracking, eye tracking, computer vision, emitting and sensing alternating magnetic fields, any other method of tracking at least one of position and orientation, or any combination thereof. As is known, the HMD may provide image data from a camera assembly 44 to the surgeon's right and left eyes. To maintain a virtual reality experience for the surgeon, the sensor system may track the position and orientation of the surgeon's head and relay the data to the VR computer unit 14 and, if desired, to the computer unit 18. The computer unit 18 can further adjust the pan and tilt of the robot's camera assembly 44 to follow the user's head movements.

[0032] Sensor or position data 34A generated by the sensors can be communicated to the computer unit 18, either directly or via the VR computer unit 14, if associated with an HMD, e.g., associated with the display unit 12 and / or tracking unit 16A. Similarly, tracking and position data 34 generated by other sensors in the system, such as from the sensing and tracking unit 16, which may be associated with the user's arms and hands, can be communicated to the computer unit 18. The tracking and position data 34, 34A can be processed by the processing unit 22 and stored, for example, in the storage unit 24. The tracking and position data 34, 34A can be used by the control unit 26, which can responsively generate control signals for controlling the movement of one or more parts of the robotic subsystem 20. The robotic subsystem 20 can include a user workstation, a robotic assistance system (RSS), a motor unit 40, and an implantable surgical robot unit 50 including one or more robotic arms 42 and one or more camera assemblies 44. According to one embodiment, the motor unit 40 can form part of the robotic assistance system. The implantable robotic arm 42 and camera assembly 44 can form part of a single assist axis robotic unit, such as that disclosed and described in U.S. Pat. No. 10,285,765, or can form part of a split-arm (SA) architecture robotic system, such as that disclosed and described in PCT patent application PCT / US20 / 39203.

[0033] The control signals generated by the control unit 26 can be received by the motor unit 40 of the robot subsystem 20. The motor unit 40 can include a series of servo motors and gears configured to separately drive the robot arm 42 and camera assembly 44 of the robot unit 50. The robot arm 42 can be controlled to follow the scaled-down movements or motions of the surgeon's arm as sensed by associated sensors. The robot arm 42 can have portions or regions that can be associated with the movements associated with the user's shoulder, elbow, and wrist joints, as well as the fingers. For example, the robot's elbow joint can follow the position and orientation of a person's elbow, and the robot's wrist joint can follow the position and orientation of a person's wrist. The robot arm 42 can also be associated with end regions that can terminate in an end effector or grasper that follow the movement of one or more of the user's fingers, such as the index finger when the user pinches together with the index finger and thumb. The position of the robot's shoulder is fixed while the robot's arm follows the movement of the user's arm. In one embodiment, the position and orientation of the user's torso is subtracted from the position and orientation of the user's arm. This subtraction allows the user to move their torso without the robotic arm moving.

[0034] The robotic camera assembly 44 is configured to provide the surgeon with image data 48, such as a live video feed of the surgical site or surgical site, and to allow the surgeon to operate and control the cameras forming part of the camera assembly 44. The camera assembly 44 preferably includes a pair of cameras whose optical axes are axially spaced a selected distance, known as the inter-camera distance, to provide a stereoscopic view or image of the surgical site. The surgeon can control the movement of the cameras through movement of a head-mounted display or via sensors coupled to the surgeon's head, using hand controls or sensors that track the user's head or arm movements, thereby allowing the surgeon to obtain a desired view of the surgical site in an intuitive and natural manner. The cameras are movable in multiple directions, including, for example, yaw, pitch, and roll, as is known. The stereoscopic camera components can be configured to provide a user with a natural and comfortable experience. In some embodiments, the inter-axis distance between the cameras can be varied to adjust the user's perceived depth of the surgical site.

[0035] According to one embodiment, the camera assembly 44 can be activated by the surgeon's head movement. For example, if during surgery the surgeon wishes to view an object located above the current field of view (FOV), the surgeon's upward gaze will cause the stereoscopic camera to rotate upward about the pitch axis from the user's perspective. Image or video data 48 generated by the camera assembly 44 can be displayed on the display unit 12. If the display unit 12 is a head-mounted display, the display device can include an internal tracking sensor system 16A that obtains raw orientation data for the HMD's yaw, pitch, and roll directions, as well as position data in the HMD's Cartesian coordinate space (x, y, z). However, alternative tracking systems may be used to provide supplemental position and orientation tracking data for the display device instead of or in addition to the HMD's internal tracking system.

[0036] Image data 48 generated by the camera assembly 44 can be transmitted to the virtual reality (VR) computer unit 14 and processed by the VR or image rendering unit 30. The image data 48 can include still photograph or image data and video data. The VR rendering unit 30 can include appropriate hardware and software for processing the image data and then rendering the image data for display by the display unit 12. Furthermore, the VR rendering unit 30 can combine the image data received from the camera assembly 44 with information associated with the position and orientation of the cameras in the camera assembly, as well as information associated with the position and orientation of the surgeon's head, as is known in the art. With this information, the VR rendering unit 30 can generate an output video or image rendering signal and send this signal to the display unit 12. That is, the VR rendering unit 30 renders the hand control device position and orientation readings and the surgeon's head position for display on the display unit, such as in an HMD worn by the surgeon.

[0037] The VR computer unit 14 may also include a virtual reality (VR) camera unit 38 for generating one or more virtual reality (VR) cameras for use or placement in the VR world displayed on the display unit 12. The VR camera unit 38 can generate one or more virtual cameras in the virtual world and can be used by the system 10 to render images for the head-mounted display. This ensures that the VR camera always renders the same field of view as a user wearing the head-mounted display would see the cubemap. In one embodiment, a single VR camera can be used, while in other embodiments, separate left-eye and right-eye VR cameras can be used to render separate left-eye and right-eye cubemaps to the display device to provide a stereoscopic field of view. The VR camera's FOV setting can self-configure to the FOV exposed by the camera assembly 44. In addition to providing a context for the live camera field of view or image data, the cubemap can be used to generate dynamic reflections in virtual objects. This effect allows the reflective surfaces of virtual objects to acquire reflections from the cubemap, making these objects appear to the user as if they were actually reflecting their real-world environment.

[0038] The robotic subsystem 20 may employ multiple different robotic arms 42 that are deployable along different or separate axes. Furthermore, a camera assembly 44 that may employ multiple different camera elements may also be deployed along a common, separate axis. Thus, a surgical robotic unit employs multiple different components, such as separate pairs of robotic arms and camera assemblies 44 that are deployable along different axes. Furthermore, the robotic arms 42 and camera assemblies 44 are independently operable, steerable, and movable. The robotic subsystem 20, including the robotic arms and camera assemblies, may be arranged along separate steerable axes to form an SA architecture. The SA architecture is designed to simplify and increase the efficiency of robotic surgical instrument insertion through a single trocar at a single insertion point or site, while concomitantly assisting in the deployment of the surgical instruments to a surgical prep state and subsequent removal of the surgical instruments through the trocar. For example, surgical instruments may be inserted through a trocar to access and perform surgery in a patient's body cavity. In some embodiments, various surgical instruments may be used, including but not limited to robotic surgical instruments and other surgical instruments known in the art.

[0039] In one embodiment, the robotic subsystem 20 of the present invention is supported by a structure with multiple degrees of freedom, allowing the robotic arm 42 and camera assembly 44 (e.g., robotic unit 50) to be maneuvered to a single position or multiple different positions within a patient. In one embodiment, the robotic subsystem 20 can be mounted directly to an operating table, to the floor or ceiling in an operating room, or to any other type of support structure. In other embodiments, mounting is achieved by various fastening means, including, but not limited to, fasteners, screws, or a combination thereof. In yet a further embodiment, the support structure may be freestanding. The support structure is referred to herein as a robotic-assisted system (RSS). The RSS can form part of an overall surgical robotic system 10, which may include a virtual station that allows a surgeon to perform a virtual surgery within a patient.

[0040] In one embodiment, the RSS of the surgical robotic system 10 may optionally include a motor unit 40 coupled at one end to the robot unit 50 and at the opposite end to an adjustable support member or element. Alternatively, as shown herein, the motor unit 40 may form part of the robot subsystem 20. The motor unit 40 may include gears, one or more motors, a drive train, electronics, and the like for powering and driving one or more components of the robotic arm and camera assembly (e.g., the robotic unit 50). The robotic unit 50 may be selectively coupled to the motor unit 40. According to one embodiment, the RSS may include a support member having the motor unit 40 coupled to a distal end. The motor unit 40 may further be coupled to the camera assembly 44 and each of the robotic arms 42. The support member may be configured and controlled to move one or more components of the robotic unit 50 linearly or in any other selected direction or orientation.

[0041] The motor unit 40 may also provide mechanical power, electrical power, mechanical transmission, and electrical communication to the robotic unit 50 and may further include an optional controller for processing input data from one or more of the system components (e.g., the display device 12, the sensing and tracking unit 16, the robotic arm 42, and the camera assembly 44) and for generating control signals in response to the input data. The motor unit 40 may also include a storage element for storing data. Alternatively, the motor unit 40 may be controlled by the computer unit 18. Thus, the motor unit 40 may generate signals for controlling one or more motors, which may further control and drive the robotic arm 42, including the position and orientation of each articulation joint of each arm, and the camera assembly 44, for example. The motor unit 40 may further provide translational or linear degrees of freedom that are initially used to insert and remove each component of the robotic unit 50 through an appropriate medical device, such as a trocar 108. The motor unit 40 can also be used to adjust the insertion depth of each robotic arm 42 as it is inserted into the patient 100 through the trocar 108 .

[0042] The present invention is directed to the ability to replace instruments that form the end effectors of the robotic arms of the present invention in an easy and efficient manner. The ability to easily replace instruments allows a user, such as a surgeon, to simply remove and replace the end effector portion of the robotic arm rather than replacing the entire robotic arm, which typically has a dedicated instrument attached. Removal and replacement of instrument components can be performed inside or outside the patient. By not requiring the entire robotic arm to be replaced, the robotic arms of the present invention reduce costs and waste because users do not need to use the entire robotic arm and associated instruments.

[0043] 2A and 2B illustrate the general design of selected components of a robotic arm 42 of a surgical robotic unit 50 according to a first embodiment of the present invention, which allows a user to replace the end effector of the robotic arm without requiring replacement of the entire robotic arm. As such, the end effector region of the robotic arm of the present invention provides a highly functional and easy-to-use mechanical linkage that allows for easy removal and replacement of instruments. For simplicity, only one robotic arm is shown, but second or subsequent robotic arms can be similar or identical in form and function. The illustrated robotic arm 42 can include a series of joint segments 52 that form articulation zones corresponding to the joints of a human arm. As such, the joint segments 52 can be constructed and combined to provide rotational and / or bending movement to mimic different portions of a human arm, such as, for example, a shoulder joint or region, an elbow joint or region, and a wrist joint or region 58. The joint segments 52 of the robotic arm 42 can be constructed to provide, for example, cable-driven rotational movement within reasonable rotational limit constraints. The articulation segments 52 are configured to provide maximum torque and speed with minimal magnitude. The articulation segments 52 are mechanically coupled together and terminate in an end effector portion or segment 54. The end effector portion 54 includes an instrument base portion 56 that can incorporate any selected surgical instrument used to perform a desired or selected procedure. For example, the instrument base portion 56 can mount a pair of instrument elements 80, 82. In this example, the instrument elements are grippers, but one skilled in the art will readily recognize that any selected type of surgical instrument can be used. As shown in FIG. 2B, the end effector portion 54 and the adjacent arm segment 52 form a wrist portion or joint 58 of the robotic arm. The end effector portion 54 is shown in detail, for example, in FIGS. 3-12C.

[0044] As shown in FIGS. 2A-6 , the end effector portion 54 includes opposing instrument base segments 60 and 62, pulley elements 70 and 72, and instrument elements 80 and 82, which are shown as a pair of gripper or grasper elements. The instrument base portion 56 is assembled by mounting the pulley element 70 to the instrument base segment 60 via a protrusion, such as a post. Similarly, the pulley element 72 is mounted to the instrument base segment 62 via a similar post. In one embodiment, the instrument element 80 is mounted or coupled to the pulley element 70 via a mechanical interference connection to minimize play and form a tighter connection, such as by an interlocking configuration as shown in FIGS. 5 , 7A-7D , 9 , and 10A-10C . Similarly, the instrument element 82 is mounted to the pulley element 72 via a similar arrangement. The assembled instrument base with the instrument elements 80 and 82 is shown in FIG. 6 . Each of the instrument base segments 60, 62 may include a connecting flange 64, 66 having an opening formed therein that may be coupled to a suitable connector formed on the end portion of the robotic arm 42.

[0045] As shown, the instrument base portion 56 can include two independently driven rotating pulley elements 70, 72. When the pulley elements are positioned to open the instrument elements at a wider angle than required in surgery (e.g., an open instrument exchange position), mechanical features on the pulley elements align, allowing the instrument element to be easily removed, such as by sliding the instrument from the instrument base or gently pushing it, depending on the selected open configuration. Specifically, each of the rotatable pulley elements 70, 72 has a raised element configured to engage with a complementary shaped groove or notch formed in the corresponding instrument element 80, 82. When an instrument element is placed in the empty instrument exchange base of FIG. 11, the mechanical interface formed by the raised element on the pulley element and the notch on the instrument element self-aligns with the funnel-shaped ramp (FIGS. 4 and 10) so that it can be precisely positioned within the base by a pin-like alignment feature. This funnel and pin combination design allows for less precise alignment and always results in the instrument element locking or mounting itself in the instrument base after any small actuation movement away from the open instrument exchange position. This precise mechanical alignment also aligns any required electrical contacts without additional work or complexity, thereby allowing the instrument element to be immediately operational and ready for use.

[0046] By using the same actuation motion used during normal instrument movement to also release the instrument when the instrument elements (e.g., graspers) are overextended to the open instrument exchange position, the interlocking feature of the instrument elements is added without the need for additional actuation cables or motors. By mechanically interlocking each instrument element, both sides of the instrument can be oriented to a specific position to release the instrument. Thus, the instrument mounting designs herein can still move the instrument elements through their full range of motion in closed or semi-closed positions, which is where the surgeon needs to use the instrument during surgery.

[0047] Conventional surgical robotic systems require the complete removal of the associated arm or laparoscopic instrument from the patient to replace it with another instrument during surgery. The present invention allows this replacement to occur within the patient, if desired, without requiring additional degrees of freedom in the arm or limiting the usable range of the instrument. Instrument replacement can be performed by inserting an instrument introducer into the patient to deploy the appropriate instrument replacement device. According to other implementations, instrument components can be removed either by using an opposing robotic arm or by sliding the instrument component during instrument removal. Moving the instrument exchange within the patient can make the surgical procedure faster, more automated, and less material-intensive. Alternatively, instrument replacement or exchange can occur outside the patient.

[0048] 7A-7D show instrument elements 80, 82 positioned in various positions relative to one another. For example, as shown in FIG. 7A, instrument elements 80, 82 can be positioned relative to one another in an open instrument exchange position such that mechanical features (e.g., slot or wedge elements) on the instrument elements are aligned with corresponding surface features (e.g., embossments) on the respective pulley elements 70, 72. When positioned in the open instrument exchange position, the instrument elements can be separated by a predetermined angular distance. According to one embodiment, the angular distance is approximately 180 degrees, although other angular distances may also be used. The angular distance between the instrument elements when positioned in the open instrument exchange position preferably does not resemble or resemble the usual or typical angular separation between the instrument elements during use in surgery. Thus, instrument elements 80, 82 can easily slide into the appropriate loading position. FIGS. 7B and 7C show the mating features of the instrument and pulley elements during loading. As the instrument elements 80, 82 are slid or pushed downward onto the corresponding pulley elements 70, 72, the funnel-like fit of the slots and embossments automatically engages and aligns the instrument elements into an initial, open instrument exchange position, as shown. Figure 7D shows that as the instrument elements 80, 82 begin to move toward each other via the pulley elements, they lock into place thanks to their pin-like alignment features and shared axis (e.g., post or pin).

[0049] Figures 8A-8D, 9, 10A-10C, and 11 illustrate the movement and operation of instrument elements 80, 82 during use of the end effector segment as part of the robotic arm 42 of the present invention. Specifically, Figures 8A and 10A-10C show instrument elements 80, 82 in one of many different operating positions in which instrument elements 80, 82, shown as graspers, are locked to instrument base portion 56 and can be used as part of the robotic arm to grasp, pull, or push any selected device or tissue within a patient during surgery. As shown in Figures 8B, 8C, and 9, when a different instrument element is required to be attached to the instrument base, the pulley element can drive the instrument element to a full open instrument exchange position (Figure 7A) to permit or enable the instrument element to be removed from the base. As previously mentioned, instrument exchange can be performed within the patient using separate instrument instruments positioned by an instrument introducer or by using opposing robotic arms. When properly configured, as shown in Figures 7B and 8B, for example, instrument elements 80, 82 can be removed by simply lifting the elements relative to the base, which can be stored at the surgical site or removed from the patient, as desired. Figures 8D and 11 show the instrument base when an instrument element is removed or prior to placement of the instrument element. As such, the instrument base portion 56 is ready to accept the instrument element.

[0050] Figures 12A-12C show an actuation mechanism associated with pulley elements 70, 72 of the instrument base portion 56 for moving instrument elements 80, 82. As shown, a single pulley element is driven by an actuation mechanism that may include a pair of cables 90, 92. The cables 90, 92 enter the pulley from below, wrap around selected portions of the pulley to actuate it, and continue to wrap inside the pulley to create greater friction. Finally, the cables are each terminated at a knot or in some other manner (as indicated by an area of ​​increased diameter), with the remaining ends tucked into pockets. Figure 12B shows the other side of the pulley of Figure 12A. Figure 12C shows the instrument base portion 56 with a total of four drive cables, one pair on each side, connected to each pulley element.

[0051] 13A and 13B show the general design of selected components of a robotic arm 42 of a surgical robotic unit 50 according to a second embodiment of the present invention. Like numerals refer to like parts throughout the various views. For simplicity, only one robotic arm is shown, but a second or subsequent robotic arm can be similar or identical in form and function. As with the previous embodiment, the robotic arm 42 can include a series of joint segments 52 forming joint regions corresponding to the joints of a human arm. As such, the joint segments 52 can be constructed and combined to provide rotational and / or bending movement to mimic different portions of a human arm, such as, for example, a shoulder joint or region, an elbow joint or region, and a wrist joint or region 58. The joint segments of the robotic arm 42 can be constructed to provide, for example, cable-driven rotational movement within reasonable rotational limit constraints. The joint segments are configured to provide maximum torque and speed with minimal magnitude. The joint segments can be mechanically coupled together and can terminate in an end effector portion or segment 54. The end effector portion 54 includes an instrument base portion 56 that can incorporate any selected surgical instrument used to perform a desired or selected procedure. For example, the instrument base portion 56 can mount a pair of instrument elements 102, 104. In this example, the instrument elements are grippers or graspers, but one skilled in the art will readily recognize that any selected type of surgical instrument can be used. As shown in FIG. 13B, the end effector portion 54 and the adjacent arm segment 52 form a wrist portion or joint 58 of the robotic arm. The end effector portion 54 is shown in detail, for example, in FIGS. 14A-26B.

[0052] 14A and 14B are exploded views of the end effector portion 54 of the robotic arm 42 in accordance with the teachings of the present invention. The illustrated end effector portion 54 comprises an instrument base portion 56 including a pair of instrument base segments 106, 108 that may be coupled together via a shaft or axle element 110. The axle element may be formed from any selected material, and is preferably formed from a non-conductive material such as ceramic. The end effector portion 54 also includes a pair of pulley elements 120, 122 coupled to the instrument base segments 106, 108, respectively. The end effector portion 54 further comprises a pair of conductive spring elements for coupling electrosurgical energy to the instrument elements 102, 104 via a pair of conductive contact elements 160, 162. The conductive contact elements 160, 162 are coupled to the instrument elements 102, 104, respectively.

[0053] As shown in FIG. 15 , the illustrated instrument base portion 56 includes a pair of opposing instrument base segments 106, 108. Each of the instrument base segments includes a main body 112A, 112B including a flange portion 114A, 114B that can be configured to couple to an adjacent arm segment 52 of the robotic arm 42. The main body includes an extension portion 118A, 118B extending upwardly from the respective flange portion 114A, 114B. Each of the flange portions includes a recess 204 formed therein for receiving a corresponding portion of the pulley elements 120, 122. Specifically, the coupling elements 132 of the pulley elements 120, 122 seat within the recess 204. The extension portions 118A, 118B also include an opening 206A, 206B, respectively, for receiving and seating the shaft element 110. Additionally, flange portions 114A, 114B have openings 208 formed therein for connection to the distal end of a robotic arm.

[0054] 16A-16C illustrate pulley element 120 of end effector portion 54 of the present invention. For brevity, pulley element 122 has identical features, and therefore only pulley element 120 will be described here. Pulley element 120 has a main body 124 with an inner surface 126A and an opposing outer surface 126B. Main body 124 has a central opening 128 for seating shaft element 110 and also has a plurality of holes 136 for seating portions of respective cables 90, 92 to control the circular or rotational movement of the pulley element. Holes 136 can have the same or different shapes and can have different sizes. Inner surface 126A is formed with surface features, preferably raised or protruding embossed elements 130. Embossed elements 130 can have any selected shape or configuration and can have any selected size. The raised element 130, as described herein, is preferably shaped in a complementary manner to a receiving portion of one of the instrument elements. The outer surface 126B of the pulley element also has surface features formed thereon, preferably formed as raised or protruding connecting elements 132. The connecting elements 132 can have any selected shape or size, preferably having a rounded or circular shape. The connecting elements 132 may include a thinner base portion joined to the outer surface 126B to form a groove 134. The groove 134 is configured to receive a portion of the distal ends of the cables 90, 92 to store the distal end portions of the cables during use. The connecting elements 132 are adapted to seat within the main body 124. The main body 124 also includes a slot 138 configured to seat a portion of a conductive spring element 140 to secure the spring element. Pulley elements 120, 122 are cable driven components that can control the orientation or rotational position of instrument elements 102, 104 based on the cable position.

[0055] Conductive spring element 140 is shown, for example, in FIGS. 17A-19B. For simplicity, conductive spring element 142 has identical features, so only conductive spring element 140 will be described here. The illustrated conductive spring element 140 has a main body 144 with a central coil element 146 having one coil end 148A coupled to an upper tab portion 150 and an opposing coil end 148B coupled to an opposite or lower tab portion 152. Central coil element 146 can extend and retract based on the position of one or more of the tab portions. Lower tab portion 152, as seen in FIG. 17B, has a bent end portion 154. Upper tab portion 150 includes a connecting element 156 for coupling to pulley element 120. 18B, the central coil element 146 seats within a central portion of the outer surface 126B of the pulley element 120, and the upper tab portion 150 advances through a central slot 158 ​​formed in the main body 124 of the pulley element 120 to the inner surface 126A of the pulley element. The tab portion 150 then advances along the inner surface 126A until the connecting element 156 seats within the slot 138. The bent portion 154 of the lower tab portion 152 contacts and connects to a portion of the instrument base segment 106. The lower tab portion 152 also connects to the end of a power supply wire 170 that advances through the robotic arm 42 to the wrist portion 58. The tab portion 152 can be fastened to the wire 170 by any known means, such as, for example, by brazing or by known wire connectors. Thus, the lower tab portion 152 is positioned in a fixed position relative to the main body 124. The tab portion 150 rotates with the pulley element 120. Furthermore, when the embossed element 130 is positioned in the open instrument exchange position, the instrument element 102 can slide onto and off the embossed element 130, as shown, for example, in Figures 16A and 18A. In this position, the upper and lower tab portions 152 are oriented in opposite directions and are disposed at approximately 180 degrees, as shown in Figure 17C. When the pulley element 120 is rotated away from the open instrument exchange position by the cables 90, 92, the upper tab portion 150 moves relative to the fixed lower tab portion 152.When pulley element 120, and thus embossing element 130, is rotated approximately 90 degrees from the open instrument exchange position, upper tab portion 152 is also rotated an additional 90 degrees and positioned perpendicular to lower tab portion 152, as shown in FIG. 17D. Conductive spring element 140 can be made from any electrically conductive material, such as, for example, metal. Conductive spring element 140 allows for electrical connection or communication of different types of electrical energy (or monopolar and bipolar electrical energy) to the instrument element, such as during electrosurgical and electrocautery type procedures.

[0056] The illustrated instrument elements 102, 104 are shown in further detail in FIGS. 20A-25. The illustrated instrument elements can have any selected shape and size and can include, for example, graspers or grippers, suturing devices, scissors, etc. The illustrated instrument elements 102, 104 are configured to be coupled to form a combined surgical instrument. The instrument element 102 includes a main body 180 having an engagement end 182 for engaging, for example, another device or tissue, and a fixation end 184 for securing the instrument element 102 to a corresponding pulley element, such as pulley element 120. The engagement end 182 can include any selected type of surface and can provide any selected type of functionality based on the intended use and purpose of the instrument. For example, in this example, the grasper can include a serrated or serrated working surface 116A to enhance the gripping capabilities of the instrument. Additionally, the engagement end 182 can optionally include a conductive contact element 160 for providing surgical energy to a surgical site, if desired. Fixed end 184 includes surface features formed thereon, such as, for example, slots 186 that are complementary in shape to embossed elements 130 formed on inner surface 126A of pulley element 120. The interlocking and mating engagement of slots 186 and embossed elements 130 rotationally secures instrument element 102 to pulley element 120. Instrument elements 102, 104 can be secured or coupled together by any selected coupling technique, and are preferably coupled together using a dovetail joint configuration. The dovetail joint secures instrument elements 102, 104 together in a manner that makes it difficult to pull the instrument elements apart because the joint has a relatively high tensile strength. For example, instrument element 102 has surface features formed on a first, inward-facing surface 188A of fixed end 184. Fixed end 184 also includes an opposite, outward-facing surface 188B. The surface features may include, for example, grooves or sockets 190 sized and configured to receive a rail or tail portion. The grooves 190 have an undercut configuration to properly seat the corresponding rail portion. The grooves 190 also include one or more widened areas 192 that seat the corresponding portions of the rail portion.

[0057] Similarly, instrument element 104 comprises a main body 180 having an engagement end 182 for engaging other devices or tissue at a surgical site and an opposed fixed end 184 for securing instrument element 104 to a corresponding pulley element, such as, for example, pulley element 122. Fixed end 184 also has surface features formed therein, such as, for example, a slot 186 that is complementary in shape to a raised element 130 formed on inner surface 126A of pulley element 122. The interlocking and mating engagement of slot 186 and raised element 130 rotationally secures instrument element 104 to pulley element 122. The illustrated instrument element 104 also has surface features formed on a first, inwardly facing surface 188A of fixed end 184. The surface feature may comprise, for example, a rail or tail portion 196 sized and configured to seat in groove 190. The rail portion 196 also includes one or more widened portions or sections 198 that are complementary in shape and size to the widened sections 192 of the groove 190. As shown in Figures 22A and 22B, the instrument elements 102 and 104 can be locked together by aligning the widened sections 192 of the groove 190 with the widened sections 198 of the rail 196. In this initial configuration, the engagement ends 182, 182 are positioned relative to one another to form an angle greater than 180 degrees, as shown. This initial position of the engagement ends places them beyond the 180-degree open instrument exchange position, in which the instrument elements 102, 104 are locked together. When aligned, the rail 196 can be inserted into the groove 190 and rotated to move the widened sections 198 into the groove 190. For example, the instrument engagement ends 182, 182 can be moved to a normal, closed position, as shown in Figure 22B.

[0058] Figures 23A-25 illustrate the mounting of instrument elements 102, 104 onto a pulley element, such as pulley element 120. Figures 23A-23C illustrate the positioning of instrument elements 102, 104 relative to embossed element 130 of pulley element 120 such that slot 186 aligns with embossed element 130 and then instrument elements 102, 104 are slid into a mounted or engaged position. Similarly, Figures 24A and 24B illustrate conductive contact element 160 secured to instrument element 102 by known techniques. For example, conductive contact element 160 can be secured to the instrument element by soldering, adhesive, or mechanical fastening techniques such as crimping. Slot 186 formed in fixed end 184 is aligned with embossed element 130, and then instrument element 102 is slid or pushed into a mounted or engaged position. In the engaged position, contact portion 164 of conductive contact element 160 is placed in electrical contact with upper tab portion 150 of conductive spring element 140. Additionally, shaft element 110 locks or secures together the various components of end effector portion 56. When the instrument element is removed from the embossing element, tab portion 150 and contact portion 164 are frictionally engaged, helping to keep their respective contact surfaces clean.

[0059] During assembly, cables 90 and 92 are coupled to each of pulley elements 120 and 122. Cable elements 90, 92 facilitate movement of each of the pulley elements in any selected rotational direction. As such, embossed elements 130 formed on the inner surface 126A of the pulley elements are further rotated in the opposite rotational direction. The instrument base section 56 of the end effector portion 54 can be assembled by forcing the connecting elements 132 of the pulley elements 120 into corresponding recesses formed along the inner surface of the instrument base segment 106. Similarly, the connecting elements 132 of the pulley elements 122 can be forced into corresponding recesses formed along the inner surface of the instrument base segment 108. The instrument elements 102, 104 can be coupled together by placing rails 196 into grooves 190 of the instrument elements to form a dovetail joint. The instrument elements can also be coupled together using other known coupling methods that provide both axial and radial mechanical constraints to the movement of the instrument elements relative to one another. The engagement ends 182, 182 of the instrument elements 102, 104 can be positioned to be separated by approximately 180 degrees to the open instrument exchange position. In this position, the slots 186, 186 are aligned. The embossed elements 130 of the pulley elements 120, 122 can also be aligned and positioned to seat in the slots 186, 186 of the instrument elements when placed in the open instrument exchange position. This position is the maximum angular distance or separation between the engagement ends 182, 182 of the instrument elements that is allowed during use. The cables 90, 92 can be actuated to rotate each pulley element 120, 122 independently. The engagement ends 182, 182 of the instrument elements can be moved individually or separately to subsequent rotational positions such that when placed in the open instrument exchange position, the engagement ends relative to each other are separated by an angle less than the 180-degree position of the instrument elements. In itself, each pulley element moves the respective instrument element mounted thereto. For example, pulley element 120 rotates or moves instrument element 102, and pulley element 122 rotates or moves instrument element 104. Thus, the pulley elements are cable-driven components that control the rotational position or orientation of the instrument elements.The instrument base portion 56 can only accept or release the instrument elements 102, 104 when the embossment elements 130, 130 are similarly aligned, such as when placed in an open instrument exchange position. When the embossment elements 130, 130 are moved out of alignment with one another, a vertically outwardly displaced movement force applied to the instrument elements cannot remove or detach the instrument elements from the instrument base portion 56 and, therefore, from the pulley elements 120, 122.

[0060] During surgery, the robotic arm 42 can be equipped with surgical instruments, such as graspers, hooks, scissors, etc., either inside or outside the patient. Regardless of the instrument exchange location, the instrument elements 102, 104 can be mounted or coupled to the instrument base 56 by aligning the embossed elements 130, 130 of the pulley elements 120, 122 into aligned mounting positions and then aligning the slots 186, 186 of the instrument elements. When the slots of the instrument elements are aligned, in one embodiment, the engagement ends 182, 182 of the instrument elements are separated by a selected angular distance, such as about 180 degrees, thereby placing the ends in an open instrument exchange position, and thus the instrument elements in an open instrument exchange position. The angular distance can be any selected angular amount, provided that it is not typically used or performed during surgery or normal use. The slots 186, 186 of the instrument elements are then slid or pushed into the embossments 130, 130 of the pulley elements 120, 122, as shown in Figures 21, 23A, and 24. The pulley elements 120, 122 can then be actuated to move the instrument elements 102, 104 to one or more surgical use positions where the instrument elements are separated by an angular amount or distance of less than 180 degrees. One example of many surgical use positions is shown, for example, in Figures 26A and 26B, where the instrument elements 102, 104 are separated by an angular amount or distance of less than 180 degrees. Furthermore, if one or more of the pulley elements 120, 122 rotate their corresponding embossment elements 130 away from the vertical mounting position, as shown, the instrument elements 102, 104 cannot be slid or removed from the embossment elements and, therefore, from the instrument base 56.

[0061] Additionally, conductive contact elements 160, 162 are coupled to the instrument elements 102, 104, respectively. The conductive contact elements can conduct energy, such as electricity, to any material, e.g., tissue, or device that contacts the exposed portion of the conductive contact element. The conductive contact elements preferably cover selected portions of the working surfaces 116A, 116B of the instrument elements 102, 104. For example, the working surfaces 116A, 116B of the instrument elements can carry the conductive contact elements. The conductive contact elements are electrically coupled to the conductive spring elements 140, 142 via continuous, persistent contact between the upper tab portions 150 of the conductive spring elements and the contact portions 164, 164 of the conductive contact elements. The lower tab portions 152 of the conductive spring elements 140, 142 are then placed in contact with a power supply line 170. Computer unit 18 can couple power supply 170 to a monopolar power source that delivers relatively high voltage monopolar electrocautery energy or power to the conductive contact elements. Alternatively, computer unit 18 can couple power supply 170 to a bipolar power source that delivers relatively high current bipolar electrocautery energy or power to the conductive contact elements.

[0062] The pulley elements 120, 122 can be independently driven and rotated by the cables 90, 92. When the raised elements of the pulley elements 120, 122 move from their mounted positions, the upper tab portion 150 of the conductive spring element 140 moves relative to the stationary lower tab portion 152, as shown in FIG. 22B. The central coil element 146 can expand and contract to permit or enable relative movement between the tab portions 150, 152 without damaging or destroying the conductive spring elements. Furthermore, the tab element mounting arrangement forms a static electrosurgical connection between the upper tab portion 150 and the conductive contact element, as well as between the lower tab portion 152 and the power supply line 170, even when the instrument element is rotated between various rotational positions. This static mounting configuration reduces the risk of arcing between the contacts.

[0063] The ability of pulley elements to be driven independently of each other provides an additional degree of freedom to current robotic arms. Specifically, pulleys provide two additional degrees of freedom because each pulley element can be driven separately and independently by a cable.

[0064] Those skilled in the art will readily recognize that the wrist portion or joint of the robotic arm can be formed in different ways and thus can have different mechanical configurations. Clearly, the instrument base portion of the robotic arm can have any selected configuration. According to an alternative embodiment, the instrument base portion of the robotic arm can be configured to form a ball-and-socket joint. [Explanation of symbols]

[0065] 10. Surgical Robot System 12 Display devices, display units, display devices 14 Virtual Reality (VR) Computer Unit 16 Sensor and Tracking Unit, Sensing and Tracking Unit 16A Sensor and Tracking Unit, Sensing and Tracking Unit, Built-in Tracking Sensor System 18 Computer Unit 20 Robot Subsystem 22 Processing equipment 24 Storage Units 26 Control Unit 30 VR or Image Rendering Units 34, 34A Sensor data, location data, tracking data 36 External Data 38 Virtual Reality (VR) Camera Unit 40 Motor unit 42 Robot Arm 44 Camera Assembly 48 Image data, video data 50 Implantable Surgical Robotic Unit 52 joint segments, arm segments 54 end effector portion, end effector segment 56 Equipment basic part 58 Wrist joint, wrist region 60, 62 Instrument base segments 64, 66 Connecting flange 70, 72 Pulley elements 80, 82 Instrument elements 90, 92 Cable 100 patients 102, 104 Instrument elements 106, 108 Instrument base segment 108 Trocar 110 Shaft, axial element 112A, 112B main body 114A, 114B flange part 116A, 116B working surface 118A, 118B extension part 120, 122 Pulley elements 124 Main body 126A Inner surface 126B External surface 128 Center opening 130 Raised Elements 132 Connected Elements 134 Groove 136 holes 138 Slots 140, 142 Conductive spring elements 144 Main body 146 central coil element 148A coil end 148B coil end 150 Upper tab part 152 Lower tab part 154 Bent end 156 Connected Elements 160, 162 Conductive contact elements 164 Contact part 180 Main body 182 Engagement end 184 Fixed end 186 Slots 188A Inward facing surface 188B Outward facing surface 190 Groove, socket 192 Wide Area 196 Rail section, tail section 198 Wide section, wide area 204 Recess 206A, 206B opening 208 Aperture

Claims

1. 1. An end region device for a robotic arm in a surgical robotic system, comprising: an instrument base connected to an end portion of the robotic arm by a link; a first pulley element rotatably coupled to the instrument base; a second pulley element rotatably coupled to the instrument base, the first pulley element and the second pulley element being fixed to the instrument base with a shaft element; a first tool element coupled together with a second tool element; Equipped with An end region device configured to be positioned in an open instrument exchange position such that the first instrument element and the second instrument element can be mounted to or removed from the instrument base portion.

2. 10. The device of claim 1, wherein the instrument base portion comprises a first instrument base segment and a second instrument base segment, the first pulley element being rotatably coupled to the first instrument base segment and the second pulley element being rotatably coupled to the second instrument base segment.

3. 10. The device of claim 1, wherein the first instrument element and the second instrument element are removably and replaceably coupled to the instrument base portion when disposed in the open instrument exchange position.

4. the first pulley element having a first pulley surface feature formed thereon, the second pulley element having a second pulley surface feature formed thereon, the first implement element having a first surface feature formed thereon that is complementary in shape to the first pulley surface feature of the first pulley element, and the second implement element having a second surface feature formed thereon that is complementary in shape to the second pulley surface feature of the second pulley element; 10. The device of claim 1, wherein when the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element are aligned, and when the first surface feature of the first instrument element and the second surface feature of the second instrument element are aligned when disposed in the open instrument exchange position, the first instrument element and the second instrument element can be removably and interchangeably mounted at the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element, respectively.

5. 5. The device of claim 4, wherein the first instrument element has a first interlocking surface feature formed on a surface thereof and the second instrument element has a second interlocking surface feature formed on a surface thereof that is complementary in shape to the first interlocking surface feature such that the first and second instrument elements can be joined together when the first and second interlocking surface features are aligned.

6. The device of claim 5 , wherein the first interlocking surface feature comprises a groove and the second interlocking surface feature comprises a protruding rail-like element.

7. The device of claim 5 , wherein the first interlocking surface feature and the second interlocking surface feature are configured to form a dovetail interlock.

8. 6. The device of claim 5, wherein when the first and second instrument elements are assembled, the first and second instrument elements are locked together by selective rotation of one or more of the first and second instrument elements from the open instrument exchange position to one or more use positions by one or more rotational movements of the first and second pulley elements.

9. a first conductive spring element coupled to the first pulley element and a second conductive spring element coupled to the second pulley element; a first conductive contact element coupled to the first instrument element, and a second conductive contact element coupled to the second instrument element; The device of claim 4 further comprising:

10. 10. The device of claim 9, wherein during use, a portion of the conductive spring element is in continuous and direct contact with a portion of the conductive contact element regardless of the rotational positions of the first pulley element and the second pulley element.

11. 5. The end region device of claim 4, wherein each of the first pulley surface feature and the second pulley surface feature is shaped and configured as a raised element, and each of the first surface feature and the second surface feature includes a slot.

12. 3. The end region device of claim 2, wherein the first and second instrument base segments each have a main body having an extension portion at one end and a flange portion at an opposite end, the extension portion having an inner surface and an opposite outer surface, the inner surface of the extension portion having an opening formed therein, and the inner surface of the extension portion having a recess formed therein.

13. 5. The end region device of claim 4, wherein the first pulley element and the second pulley element each have a main body having an inner surface and an opposing outer surface having connecting elements formed thereon that protrude outwardly from the surface, and the pulley surface features are formed on the inner surface of the main body.

14. 14. The end region device of claim 13, wherein the main body of each of the first pulley element and the second pulley element defines a plurality of holes, at least a portion of the plurality of holes sized and configured to seat a portion of a control cable.

15. An end region device as described in claim 13, wherein the instrument base portion comprises a first instrument base segment and a second instrument base segment, the connecting element of the first pulley element being seated and held in a recess formed in the inner surface of the first instrument base segment, and the connecting element of the second pulley element being seated and held in a recess formed in the inner surface of the second instrument base segment.

16. 1. A wrist portion of a robotic arm forming part of a robotic unit of a surgical robotic system, comprising: an instrument base connected to an end portion of the robotic arm by a link; a first pulley element rotatably coupled to the tool base portion, the first pulley element having a main body with a first pulley surface feature formed thereon; a second pulley element rotatably coupled to the tool base portion, the second pulley element having a main body with second pulley surface features formed thereon; a first tool element having a main body having a first surface feature formed thereon that is complementary in shape to the first pulley surface feature of the first pulley element; a second tool element having a main body having a second surface feature formed thereon that is complementary in shape to the second pulley surface feature of the second pulley element; Equipped with A wrist portion, wherein when the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element are aligned with each other when positioned in a first open instrument exchange position, the first instrument element and the second instrument element can be removably and replaceably mounted at the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element, respectively.

17. 17. The wrist portion of claim 16, wherein the instrument base portion comprises a first instrument base segment and a second instrument base segment, the first pulley element being rotatably coupled to the first instrument base segment and the second pulley element being rotatably coupled to the second instrument base segment.

18. 18. The robotic arm wrist portion of claim 17, wherein when the first instrument element is removably mounted to the first pulley element and the second instrument element is removably mounted to the second pulley element, the first surface feature of the first instrument element mates and seats with the first pulley surface feature of the first pulley element and the second surface feature of the second instrument element mates and seats with the second pulley surface feature of the second pulley element.

19. 20. The wrist portion of claim 18, wherein each of the first pulley surface feature and the second pulley surface feature is shaped and configured as a raised element, and each of the first surface feature and the second surface feature includes a slot.

20. 20. The robotic arm wrist portion of claim 18, wherein the first instrument base segment and the second instrument base segment each have a main body having an extension portion at one end and a flange portion at an opposite end, the extension portion having an inner surface and an opposite outer surface with an opening formed therein, and the inner surface of the extension portion having a recess formed therein.

21. 21. The wrist portion of a robotic arm of claim 20, wherein the flange portion of each of the first and second instrument base segments defines an opening for seating the coupling.

22. 21. The robotic arm wrist portion of claim 20, wherein the first pulley element and the second pulley element each have a main body having an inner surface and an opposing outer surface having connecting elements formed thereon that project outwardly from the surface, the pulley surface features formed on the inner surface of the main body.

23. 23. The robotic arm wrist portion of claim 22, wherein the main body of each of the first pulley element and the second pulley element defines a plurality of holes, at least a portion of the plurality of holes sized and configured to seat a portion of a control cable.

24. 23. A robotic arm wrist portion as described in claim 22, wherein the connecting element of the first pulley element is seated and retained in the recess formed in the inner surface of the first instrument base segment and the connecting element of the second pulley element is seated and retained in the recess formed in the inner surface of the second instrument base segment.

25. 25. The robotic arm wrist portion of claim 24, further comprising a first conductive spring element coupled to the first pulley element and a second conductive spring element coupled to the second pulley element.

26. 26. The robotic arm wrist portion of claim 25, wherein the first conductive spring element and the second conductive spring element each comprise a main body having a central coil element, an upper tab portion coupled to one end of the central coil element, and a lower tab portion coupled to the other end of the central coil element.

27. 27. The robotic arm wrist portion of claim 26, wherein the lower tab portion is coupled to an electrical lead housed within the instrument base portion, the central coil element is coupled to the outer surface of the pulley element, and at least a portion of the upper tab portion is coupled to the inner surface of the pulley element.

28. 28. A robotic arm wrist portion according to claim 27, wherein, in use, the central coil element is configured to expand and contract based on movement of the upper tab portion.

29. each of the first and second tool elements having an active surface for contacting a workpiece; and a first conductive contact element coupled to the working surface of the first instrument element; a second conductive contact element coupled to the working surface of the second instrument element; Equipped with 28. The robotic arm wrist portion of claim 27, wherein at least a portion of the first conductive contact element and the second conductive contact element are configured to contact at least a portion of the upper tab portions of the first conductive spring element and the second conductive spring element, respectively, when mounted on the first instrument element and the second instrument element, respectively.

30. 30. The robotic arm wrist portion of claim 29, wherein the portion of each of the first conductive contact element and the second conductive contact element remains in continuous electrical contact with the portion of each of the first conductive spring element and the second conductive spring element during use.

31. 30. A robotic arm wrist portion as described in claim 29, wherein the first instrument element has a main body having an outer surface and an opposing inner surface with a first instrument surface feature associated therewith, and the second instrument element has a main body having an outer surface and an opposing inner surface with a second instrument surface feature associated therewith, the second instrument surface feature being complementary in shape to the first instrument surface feature.

32. 32. The robotic arm wrist portion of claim 31 , wherein the first instrument surface feature of the first instrument element is a groove and the second instrument surface feature of the second instrument element is a protrusion.

33. 33. The robotic arm wrist portion of claim 32, wherein the groove and the protrusion are configured to form a dovetail connection.

34. 33. The wrist portion of claim 32, wherein each of the grooves and protrusions has a selected width, and each of the grooves and protrusions has one or more narrow sections and one or more wide sections.

35. 35. A robotic arm wrist portion according to claim 34, wherein the first and second instrument elements are assembled together by positioning the first and second instrument elements relative to one another such that the widened section of the protrusion is aligned with the widened section of the groove, and when the protrusion is inserted into the groove and the first and second instrument elements are rotated relative to one another, the first and second instrument elements are coupled to one another.

36. a first conductive spring element coupled to the first pulley element; a second conductive spring element coupled to the second pulley element; a first conductive contact element coupled to the first instrument element; a second conductive contact element coupled to the second instrument element; and 20. The robotic arm wrist portion of claim 17, further comprising:

37. 37. The robotic arm wrist portion of claim 36, wherein each of the first instrument base segment, the second instrument base segment, the first pulley element, the second pulley element, the first instrument element, and the second instrument element has an opening formed therein for seating a shaft element for securing the first instrument base segment, the second instrument base segment, the first pulley element, the second pulley element, the first instrument element, and the second instrument element together when aligned together.

38. 1. A method for removing and inserting one or more instrument elements into a wrist portion of a robotic arm in a surgical robotic system, comprising: providing an instrument base coupled to an end portion of the robotic arm; rotatably coupling a first pulley element to the implement base; rotatably coupling a second pulley element to the implement base; securing the first pulley element and the second pulley element to the tool base with a shaft element; providing a first tool element that can be coupled together with a second tool element; configuring the first and second instrument elements to be positioned in an open instrument exchange position so that they can be mounted on or removed from the instrument base portion; A method comprising:

39. configuring the implement base portion to include a first implement base segment and a second implement base segment; rotatably coupling the first pulley element to the first implement base segment; rotatably coupling the second pulley element to the second implement base segment; 39. The method of claim 38, further comprising:

40. 40. The method of claim 39, further comprising configuring the first instrument element and the second instrument element to be removably and replaceably coupled to the instrument base portion when disposed in the open instrument exchange position.

41. configuring the first pulley element to have a first pulley surface feature formed thereon and configuring the second pulley element to have a second pulley surface feature formed thereon; configuring the first tool element to have a first surface feature formed thereon that is complementary in shape to the first pulley surface feature of the first pulley element, and configuring the second tool element to have a second surface feature formed thereon that is complementary in shape to the second pulley surface feature of the second pulley element; further comprising 40. The method of claim 39, wherein when the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element are aligned, and when the first surface feature of the first instrument element and the second surface feature of the second instrument element are aligned when placed in the open instrument exchange position, the first instrument element and the second instrument element can be removably and replaceably mounted at the first pulley surface feature of the first pulley element and the second pulley surface feature of the second pulley element, respectively.

42. The step of providing a first tool element that can be coupled together with a second tool element comprises: configuring the first tool element to have a first interlocking surface feature formed thereon; configuring the second instrument element to have a second interlocking surface feature formed thereon that is complementary in shape to the first interlocking surface feature, such that the first and second instrument elements can be joined together when the first and second interlocking surface features are aligned; 42. The method of claim 41, further comprising:

43. 43. The method of claim 42, further comprising configuring the first interlocking surface feature to include a groove and configuring the second interlocking surface feature to include a protruding rail-like element.

44. 43. The method of claim 42, further comprising configuring the first interlocking surface feature and the second interlocking surface feature to form a dovetail interlock.

45. 43. The method of claim 42, further comprising the step of locking the first and second instrument elements together when the first and second instrument elements are assembled by selectively rotating one or more of the first and second instrument elements from the open instrument exchange position to one or more use positions by one or more rotational movements of the first and second pulley elements.

46. providing a first conductive spring element coupled to the first pulley element and a second conductive spring element coupled to the second pulley element; providing a first conductive contact element coupled to the first instrument element and a second conductive contact element coupled to the second instrument element; 43. The method of claim 42, further comprising:

47. 47. The method of claim 46, further comprising the step of maintaining direct contact between a portion of the conductive spring element and a portion of the conductive contact element during use regardless of the rotational positions of the first pulley element and the second pulley element.

Images