Telescoping arm for robotic surgical systems

Abstract

A telescoping arm, such as for a surgical manipulator, includes a first arm portion and a second arm portion. An interior surface of the first arm portion defines a helical groove and a plurality of axial grooves. A drive assembly for the telescoping arm includes a helical drive assembly having a helical member moveably engaging and constrained by the helical groove of the first arm portion and a rotational drive assembly having a plurality of axial members moveably engaging and constrained by the plurality of axial grooves of the first arm portion.

Description

TELESCOPING ARM FOR ROBOTIC SURGICAL SYSTEMSFIELD

[0001] Disclosed embodiments relate to telescoping arms for robotic surgical systems.BACKGROUND

[0002] Minimally invasive medical techniques (e.g., laparoscopy) have been used to reduce the amount of extraneous tissue which may be damaged during diagnostic or surgical procedures, thereby reducing patient recovery time, discomfort, and deleterious side effects. Such techniques were traditionally performed manually via a surgeon manipulating various surgical instruments within the patient’s body but can now by implemented using teleoperated robotic systems that provide telepresence. Performing minimally invasive surgery with teleoperated robotic systems facilitates increased precision and range of motion in manipulating surgical instruments when compared to manual techniques, but also introduces new challenges. One such challenge is the need to position and orient surgical instruments relative to a patient.SUMMARY

[0003] The following presents a simplified summary of various examples described herein and is not intended to identify key or critical elements or to delineate the scope of the claims.

[0004] In accordance with a first aspect, a telescoping arm is described that can include a first arm portion and a second arm portion. The first arm portion can have an annular body elongated along an axis, where an interior surface of the annular body can be cylindrical and defines a helical groove extending along the axis and a plurality of axial grooves extending along the axis. The second arm portion can be configured to be at least partially received within the annular body of the first arm portion. The second arm portion can be elongated along the axis and defines an elongated passageway. The telescoping arm can further include a drive assembly that can include a helical drive assembly and a rotational drive assembly. The helical drive assembly can have a helical member moveably engaging and constrained by the helical groove of the first arm portion. The rotational drive assembly can have a plurality of axial members moveably engaging and constrained by the plurality of axial grooves of the first arm portion. The plurality of axial members can be operably coupled to the helical drive assembly. Rotation of the helical drive assembly relative to the rotational drive assembly can cause the helical drive assembly and thesecond arm portion to axially translate relative to the first arm portion along the axis and rotation of the rotational drive assembly relative to the plurality of axial grooves causes rotation about the axis of at least one of the first arm portion and the second arm portion.

[0005] In some examples, the helical drive assembly can include a housing defining a helical bearing path including an inwardly recessed return path portion, and the helical member can include ball bearings received within the helical bearing path to engage the helical groove of the first arm portion.

[0006] In further examples, the helical drive assembly can include a return path cap coupled to the housing of the helical drive assembly over the return path portion of the helical bearing path. In yet further examples, the return path cap can define one or more portions of external thread configured to fit within the helical groove of the first arm portion and / or the return path cap can include projections extending outwardly over ends of the return path portion to guide movement of the ball bearings into and out of return path portion.

[0007] In further examples, the housing of the helical drive assembly can further define external grooves that continue outside of the helical bearing path and / or the helical bearing path can be sized to hold one turn of the ball bearings.

[0008] In further examples, the helical drive assembly can include a helical drive motor to drive rotation of the housing of the helical drive assembly. In yet further examples, the helical drive motor can include a motor stator coupled to one of the second arm portion or the housing of the helical drive assembly and a motor rotor coupled to the other of the second arm portion or the housing of the helical drive assembly to be rotationally driven by the motor stator.

[0009] In some examples, the rotational drive assembly can include a housing defining a plurality of axial bearing paths, each axial bearing path having an exterior portion and an interior portion; and the axial members comprise bearings received within the axial bearing paths, the bearings moveably engaging and constrained by the plurality of axial grooves of the first arm portion while in the exterior portion of the axial bearing path.

[0010] In further examples, the bearings can be cylindrical roller bearings; the interior surface of the first arm portion can define three or more axial grooves extending along the axis and the rotational drive assembly can include three or more axial members moveably engaging andconstrained by the three or more axial grooves of the first arm portion; the housing of the helical drive assembly and the housing of the rotational drive can define a central passageway through the drive assembly, where the central passageway is connected to the elongated passageway of the second arm portion; and / or the housing of the helical drive assembly and the housing of the rotational drive assembly can be annular.

[0011] In some examples, the rotational drive assembly can include a rotational drive motor to drive rotation of the housing of the rotational drive assembly to drive rotation of the first arm portion about the axis. In further examples, the rotational drive motor can include a motor stator coupled to the second arm portion and a motor rotor coupled to the housing of the rotational drive assembly to be rotationally driven by the motor stator and / or the rotational drive assembly can include differential gearing operably disposed between the motor stator and the housing of the rotational drive assembly for higher torque application to the axial members.

[0012] In some examples, the helical groove of the of the first arm portion can have a gothicarch cross-sectional shape and / or the drive assembly can define a central passageway extending therethrough connecting an interior of the first arm portion to the elongated passageway of the second arm portion providing a continuous path through the telescoping arm.

[0013] In accordance with a second aspect, a robotic surgical system is described that includes an instrument manipulator comprising a plurality of links having joints disposed therebetween, where at least one of the plurality of links can include or can be a telescoping arm according to any of the examples provided herein. The robotic surgical system further can include an instrument carriage disposed on a distal end of the instrument manipulator.

[0014] In accordance with a third aspect, a method of operating a telescoping arm is described. A helical member coupled to a housing of a helical drive assembly can be engaged with an internal groove defined in a first arm portion of the telescoping arm. Rotation can be controlled of the first arm portion with a plurality of axial members of a rotational drive assembly received in a plurality of axial grooves of the first arm portion, where the rotational drive assembly can be operably coupled to the helical drive assembly. Rotation of the housing of the helical drive assembly can be driven relative to the plurality of axial members to cause a second arm portion of the telescoping arm to axially translate relative to the first arm portion.

[0015] In some examples, engaging the helical member with the internal groove defined in the first arm portion can include engaging ball bearings received within a helical bearing path defined in the housing of the helical drive assembly with the internal groove defined in the first arm portion and directing the ball bearings to an adjacent helical height via an inwardly recessed return path portion of the helical bearing path. In further examples, engaging the ball bearings received within the helical bearing path defined in the housing of the helical drive assembly with the internal groove defined in the first arm portion can include engaging one turn of the ball bearings with the internal groove defined in the first arm portion.

[0016] In some examples, controlling rotation of the first arm portion with the plurality of axial members of the rotational drive assembly received in the plurality of axial grooves of the first arm portion can include movably engaging the plurality of axial grooves of the first arm portion with bearings received within exterior portions of a plurality of axial bearing paths defined in a housing of the rotational drive assembly. In further examples, driving rotation of the housing of the helical drive assembly relative to the plurality of splines to cause the second arm portion of the telescoping arm to axially translate relative to the first arm portion can include directing the bearings along an axial path of travel within interior portions of the plurality of axial bearing paths defined in the housing of the rotational drive assembly. In yet further examples, the method can include receiving one or more items through a central passageway defined by the housing of the helical drive assembly and the housing of the rotational drive through the drive assembly.

[0017] In some examples, the method can include driving rotation of the housing of the rotational drive assembly to cause the first arm portion of the telescoping arm to rotate relative to the second arm portion of the telescoping arm. In further examples, driving rotation of the housing of the rotational drive assembly can include driving rotation of the housing of the rotational drive assembly with a motor stator coupled to the second arm portion via a motor rotor coupled to the housing of the rotational drive assembly. In yet further examples, driving rotation of the housing of the rotational drive assembly with the motor stator coupled to the second arm portion via the motor rotor coupled to the housing of the rotational drive assembly can include increasing a torque application to the plurality of axial members with differential gearing operably disposed between the motor stator and the housing of the rotational drive assembly.

[0018] In some examples, driving rotation of the housing of the helical drive assembly relative to the plurality of axial members to cause the second arm portion of the telescoping arm to axially translate relative to the first arm portion can include driving rotation of the housing of the helical drive assembly with a motor stator coupled to the second arm portion via a motor rotor coupled to the housing of the helical drive assembly; and / or the method can include receiving one or more items through a continuous path through the telescoping arm including an interior of the first arm portion, a central passageway extending through the drive assembly, and a passageway of the second ami portion.

[0019] In accordance with a fourth aspect, an apparatus is described. A first portion can have an annular body elongated along an axis, where an interior surface of the annular body can be cylindrical and define a helical groove extending along the axis and a plurality of axial grooves extending along the axis. A second portion can be at least partially received within the annular body of the first portion. The second portion can be elongated along the axis and define an elongated passageway. A drive assembly can include a helical drive assembly and a rotational drive assembly. The helical drive assembly can have a helical member moveably engaging and constrained by the helical groove of the first portion. The rotational drive assembly can have a plurality of axial members moveably engaging and constrained by the plurality of axial grooves of the first portion, where the plurality of axial members can be operably coupled to the helical drive assembly. Rotation of the helical drive assembly relative to the rotational drive assembly can cause the helical drive assembly and the second portion to axially translate relative to the first portion along the axis. Rotation of the rotational drive assembly can cause rotation about the axis of the first portion.

[0020] It is to be understood that both the foregoing general description and the following detailed description are illustrative and explanatory in nature and are intended to provide an understanding of the present disclosure without limiting the scope of the present disclosure. In that regard, additional aspects, features, and advantages of the present disclosure will be apparent to one skilled in the art from the following detailed description.BRIEF DESCRIPTIONS OF THE DRAWINGS

[0021] FIG. 1 is a schematic diagram for a robotically-assisted manipulator system, according to some examples.

[0022] FIG. 2 is a perspective view of a surgical system according to some embodiments.

[0023] FIG. 3a is a cross-sectional view of a first arm portion for a telescoping arm according to some embodiments.

[0024] FIG. 3b is a perspective view of a helical member and housing of a helical drive assembly for a telescoping arm according to some embodiments.

[0025] FIG. 3c is a perspective view of the helical member and housing of the helical drive assembly of FIG. 3b including a return path cap according to some embodiments.

[0026] FIG. 3d is a perspective view of axial members and a portion of a housing of a rotational drive assembly for a telescoping arm according to some embodiments.

[0027] FIG. 3e is a perspective view of the axial member and the housing of the rotational drive assembly of FIG. 3d according to some embodiments.

[0028] FIG. 3f is a cross-sectional view of a first example telescoping arm including a drive assembly according to some embodiments.

[0029] FIG. 3g is a cross-sectional view of a second example telescoping arm including a drive assembly according to some embodiments.

[0030] FIG. 4 is a cross-sectional view of a third example telescoping arm including a drive assembly according to some embodiments.

[0031] Embodiments of the present disclosure and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures, wherein showings therein are for purposes of illustrating embodiments of the present disclosure and not for purposes of limiting the same.DETAILED DESCRIPTION

[0032] Minimally invasive surgery can be performed by inserting surgical instruments through orifices in a patient’s body (c.g., natural orifices or body-wall incisions) and controlling the surgical instruments via an interface on the outside of the body. In various embodiments of the present disclosure, the surgical instruments are teleoperated by surgeons. Thus, the surgeons do not move the instruments by direct physical contact, but instead control instrument motionfrom some distance away by moving master controllers (“masters”). The operating surgeon is typically provided with a view of the actual surgical site via a visual display, so that the surgeon may remotely perform surgical motions on the masters while viewing the surgical site. A controller of the surgical system causes the surgical instrument to be moved in accordance with movement of the masters.

[0033] Aspects of this disclosure herein can be pail of a computer-assisted teleoperational manipulator system, sometimes referred to as a robotically-assisted manipulator system or a robotic system. The manipulator system can include one or more manipulators that can be operated with the assistance of an electronic controller (e.g., computer) to move and control functions of one or more instruments when coupled to the manipulators.

[0034] The instrument manipulator includes a plurality of manipulator links and joints situated between adjacent manipulator links to facilitate an articulated movement of the manipulator to locate a surgical instrument at a desired location and angular orientation. In addition to the degrees of freedom (e.g., yaw, pitch, and roll) of the joints, in some instances it may be desirable for one or more of the manipulator links to include translation and / or rotation capabilities.

[0035] In one type of conventional telescoping manipulator link, linear motion is driven by a lead screw or a ball screw. Due to size constraints, the screw shaft typically has a small diameter relative to an outer housing of the link to provide space for the lead screw nut / ball screw and drive motor to fit around the screw shaft within the housing. A long screw shaft having a small diameter may have low stiffness in torsion and bending relative to the requirements of the robotic system. Further, additional structure is needed to allow the screw and drive disk to rotate relative to each other rather than spinning together, which is conventionally provided by separate bearings external to the housing.

[0036] Telescoping manipulator links as provided herein advantageously provide a smaller footprint relative to conventional links being able to house the full drive assembly internally, while also being able to provide a central path through the drive assembly for system components and / or air flow. Further, the manipulator links have better stiffness in both torsion and bending per unit mass relative to a conventional solid screw by utilizing an internal helical groove on a base portion of the manipulator link.

[0037] The manipulator link includes first and second arm portions with a drive assembly coupled between the first and second arm portions. The first arm portion includes an annular body, where an interior surface of the body defines the helical groove and a plurality of axial grooves. The drive assembly engages the grooves of the first arm portion to drive axial movement of the first and second arm portions relative to one another and, if desired, drives rotation of the first and second arm portions relative to one another.

[0038] To provide above functionality, the drive assembly includes a helical member configured to engage the helical groove of the first arm portion. With this configuration, rotation of the helical member causes the drive assembly to translate axially relative to the first arm portion. The drive assembly further includes a rotational drive assembly having a plurality of axial members configured to engage the axial grooves of the first arm portion. With this configuration, the rotation control unit can prevent rotation of the first arm portion via the axial members, ensuring that rotation of the helical member is completely translated to axial movement of the second arm portion relative to the first arm portion. If desired, the drive assembly can be further configured to selectively drive rotation of the rotational drive assembly, such that the telescoping arm can include rotational movement in addition to linear movement.

[0039] In some examples, the helical member can be ball bearings disposed within a helical bearing path defined in an exterior surface of a housing. The helical bearing path can include a return path portion for directing the ball bearings from one end of the helical bearing path back to another end of the helical bearing path, thereby moving the ball bearings out of one turn of the helical groove of the first arm portion and into an adjacent turn of the helical groove of the first arm portion. This allows the ball bearings to have a continuous path during rotation. Given the large diameter of the first arm portion and the correspondingly high number of bearings disposed within the helical groove, a single turn of bearings - meaning the bearings collectively resemble / constitute a single external thread - may provide sufficient axial stiffness for intended axial loads. However, additional turns of bearings (e.g., additional threads) can be provided for added axial stiffness and / or added axial load capacity, and / or the helical groove can have a gothic-arch cross-sectional shape to create a four-point contact on each bearing.

[0040] In some examples, the rotational drive assembly can include a housing defining axial bearing paths, and the axial members can be bearings disposed within axial bearing paths. Eachof the axial bearing paths has an exterior portion where the bearings engage the axial grooves of the first arm portion and an interior, return portion. The rotational drive assembly can include two, three, four, or more axial members arrayed therearound to provide a desired rigidity of the bearing arrangement to bending loads in multiple directions. Further, the axial length of the rotational drive assembly, and therefore the number of bearings engaging the axial grooves of the first arm portion, can be tailored to provide a sufficient bending load capacity for intended uses.

[0041] FIG. 1 illustrates an embodiment of a robotically-assisted manipulator system for use with the tools described herein. The manipulator system can be used, for example, in surgical, diagnostic, therapeutic, biopsy, or non-medical procedures, and is generally indicated by the reference numeral 100. As shown in FIG. 1 , a robotically-assisted manipulator system 100 can include one or more manipulator assemblies 102 for operating one or more medical instrument systems 104 in performing various procedures on a patient P positioned on a table T in a medical environment 101. For example, the manipulator assembly 102 can drive catheter or end effector motion, can apply treatment to target tissue, and / or can manipulate control members. The manipulator assembly 102 can be teleoperated, non-teleoperated, or a hybrid teleoperated and non-teleoperated assembly with select degrees of freedom of motion that can be motorized and / or teleoperated and select degrees of freedom of motion that can be non-motorized and / or non-teleoperated. An operator input system 106, which can be inside or outside of the medical environment 101, generally includes one or more control devices for controlling manipulator assembly 102. Manipulator assembly 102 supports medical instrument system 104 and can optionally include a plurality of actuators or motors that drive inputs on medical instrument system 104 in response to commands from a control system 112. The actuators can optionally include drive systems that when coupled to medical instrument system 104 can advance medical instrument system 104 into a naturally or surgically created anatomic orifice. Other drive systems can move the distal end of medical instrument in multiple degrees of freedom, which can include three degrees of linear motion (e.g., linear motion along the X, Y, Z Cartesian axes) and in three degrees of rotational motion (e.g., rotation about the X, Y, Z Cartesian axes). The manipulator assembly 102 can support various other systems for irrigation, treatment, or other purposes. Such systems can include fluid systems (including, for example, reservoirs, heating / cooling elements, pumps, and valves), generators, lasers, interrogators, and ablation components.

[0042] Robotically-assisted manipulator system 100 also includes a display system 110 for displaying an image or representation of the surgical site and medical instrument system 104 generated by an imaging system 109 which can include an imaging system, such as an endoscopic imaging system. Display system 110 and operator input system 106 can be oriented so an operator O can control medical instrument system 104 and operator input system 106 with the perception of telepresence. A graphical user interface can be displayable on the display system 110 and / or a display system of an independent planning workstation.

[0043] In some examples, the endoscopic imaging system components of the imaging system 109 can be integrally or removably coupled to medical instrument system 104. However, in some examples, a separate imaging device, such as an endoscope, attached to a separate manipulator assembly can be used with medical instrument system 104 to image the surgical site. The endoscopic imaging system 109 can be implemented as hardware, firmware, software, or a combination thereof which interact with or are otherwise executed by one or more computer processors, which can include the processors of the control system 112.

[0044] Robotically-assisted manipulator system 100 can also include a sensor system 108. The sensor system 108 can include a position / location sensor system (e.g., an actuator encoder or an electromagnetic (EM) sensor system) and / or a shape sensor system (e.g., an optical fiber shape sensor) for determining the position, orientation, speed, velocity, pose, and / or shape of the medical instrument system 104. The sensor system 108 can also include temperature, pressure, force, or contact sensors or the like.

[0045] Robotically-assisted manipulator system 100 can also include a control system 112. Control system 112 includes at least one memory 116 and at least one computer processor 114 for effecting control between medical instrument system 104, operator input system 106, sensor system 108, and display system 110. Control system 112 also includes programmed instructions (e.g., a non-transitory machine-readable medium storing the instructions) to implement a procedure using the robotically-assisted manipulator system including for navigation, steering, imaging, engagement feature deployment or retraction, applying treatment to target tissue (e.g., via the application of energy), or the like.

[0046] Control system 112 can optionally further include a virtual visualization system to provide navigation assistance to operator O when controlling medical instrument system 104during an image-guided surgical procedure. Virtual navigation using the virtual visualization system can be based upon reference to an acquired pro-operative or intra-operative dataset of anatomic passageways. The virtual visualization system processes images of the surgical site imaged using imaging technology such as computerized tomography (CT), magnetic resonance imaging (MRI), fluoroscopy, thermography, ultrasound, optical coherence tomography (OCT), thermal imaging, impedance imaging, laser imaging, nanotube X-ray imaging, and / or the like. The control system 112 can use a pre-operative image to locate the target tissue (using vision imaging techniques and / or by receiving user input) and create a pre-operative plan, including an optimal first location for performing treatment. The pre-operative plan can include, for example, a planned size to expand an expandable device, a treatment duration, a treatment temperature, and / or multiple deployment locations.

[0047] FIG. 2 depicts a patient-side portion 200 of a surgical system in accordance with one or more embodiments of the present disclosure. The patient-side portion 200 is a robotic system for performing minimally invasive surgery on a patient P positioned on an operating table T. The patient-side portion 200 includes a support assembly 202, a manipulator 204, and an instrument carriage 206. In this example, the support assembly 202 anchors the patient-side portion 200 to a base B of the operating table T. In other embodiments, however, the patient-side portion 200 may be mounted to a floor via a column or the like, a wall, to the ceiling, or to other operating room equipment. In some embodiments, the manipulator 204 and instrument carriage 206 is interchangeable with, or a variation of, the manipulator assembly 102 of FIG. 1.

[0048] The support assembly 202 branches radially outward from the base B of the operating table T to couple with the manipulator 204. The instrument carriage 206 is coupled to a distal end of the manipulator 204. The instrument carriage 206 supports a detachable surgical instrument (not shown). Accordingly, the instrument carriage 206 includes various actuators and control connections for actively controlling a functionality of the surgical instrument within the patient P during a surgical procedure. For example, teleoperated actuators housed in the instrument carriage 206 can provide a number of controller motions that the surgical instrument translates into a corresponding variety of movements of the instrument’s end effector.

[0049] An entry guide 208 (e.g., a cannula) serves as a surgical port to an orifice of the patient P that receives the surgical instrument to guide the instrument into the patient P. Theentry guide 208 may perform various other functions, such as allowing fluids and other materials to pass into or out of the patient P, and reducing trauma at the surgical site by isolating at least some motion (e.g., translating movement along an insertion axis and axial rotation of the instrument shaft) of the surgical instrument from the body wall.

[0050] The term “surgical instrument” is used herein to describe a medical device for insertion into a patient's body and use in performing surgical or diagnostic procedures. A surgical instrument can include an end effector associated with one or more surgical tasks, such as forceps, a needle driver, a shears, a bipolar cauterizer, a tissue stabilizer or retractor, a clip applier, an anastomosis device, an imaging device (e.g., an endoscope or ultrasound probe), and the like. Some surgical instruments used with embodiments of the present disclosure further provide an articulated support (sometimes referred to as a “wrist”) for the end effector so that the position and orientation of the end effector can be manipulated with one or more mechanical degrees of freedom in relation to the instrument's shaft. Further, many surgical end effectors include a functional mechanical degree of freedom, such as jaws that open or close, or a knife that translates along a path. Surgical instruments may also contain stored information (e.g., on a semiconductor memory inside the instrument) that may be permanent or may be updatable by the surgical system. Accordingly, the system may provide for either one-way or two-way information communication between the instrument and one or more system components.Surgical instruments appropriate for use in one or more embodiments of the present disclosure may control their end effectors (surgical tools) with one or more rods and / or flexible cables. In some examples, rods, which may be in the form of tubes, may be combined with cables to provide a “push / pull” control of the end effector, with the cables providing flexible sections as required. A typical elongate shaft for a surgical instrument is small, perhaps five to eight millimeters in diameter. The diminutive scale of the mechanisms in the surgical instrument creates unique mechanical conditions and issues with the construction of these mechanisms that are unlike those found in similar mechanisms constructed at a larger scale, because forces and strengths of materials do not scale at the same rate as the size of the mechanisms. The rods and cables must fit within the elongate shaft and be able to control the end effector through the wrist joint.

[0051] Referring to FIG. 2, the manipulator 204 may be provided in a variety of forms that allow the surgical instrument to move with one or more mechanical degrees of freedom (e.g., allsix Cartesian degrees of freedom, five or fewer Cartesian degrees of freedom, etc.). Typically, the instrument manipulator 204 is controlled to move the surgical instrument around a particular remote center of motion that remains stationary with reference to the patient P. This remote center of motion is typically located proximate where the surgical instrument enters the patient P (e.g., at some point along the entry guide 208, such as the midpoint of the body wall).

[0052] In this example, the manipulator 204 includes a plurality of manipulator links 210, joints 212 situated between adjacent manipulator links 210, and an elongated spar 214. The spar 214 carries and supports the instrument carriage 206 and the entry guide 208. The instrument carriage 206 is mounted to ride along the length of spar 214, while the entry guide 208 is held fixed at the distal end of the spar 214. Movement of the instrument carriage 206 effects identical translating movement of the surgical instrument through the stationary entry guide 208 along an insertion axis relative to the patient P.

[0053] The joints 212 facilitate the articulated movement of the manipulator links 210 to locate the surgical instrument at a desired angular orientation with multiple degrees of freedom (e.g., yaw, pitch, and roll) about the remote center of motion. Furthermore, as described above, the translating movement of the instrument carriage 206 along the spar 214 locates the surgical instrument at a desired insertion point through the remote center of motion. Thus, the various teleoperated actuators of the manipulator 204 move the surgical instrument as a whole, while the actuators housed within the instrument carriage 206 move only the instrument’s end effector or other individual instrument components. In some examples, movement of the joints 212 is constrained to maintain the remote center of motion of the manipulator 204 by fixed intersecting axes (hardware-centering). In some other examples, movement of the joints 212 is constrained by software-controlled motors (software-centering). As noted above, implementations employing the software-centering motor-driven joints may especially benefit from embodiments described below that enhance heat dissipation along the manipulator 204.

[0054] In the illustrated form, the manipulator 204 includes three manipulator links 210, including a distal manipulator link, an intermediate manipulator link, and a proximal manipulator link, connected by two joints 212. One or more of the manipulator links 210 can include first and second arm portions 210a, 210b, such as the intermediate manipulator link 210 as shown, that move relative to one another to provide additional mechanical degrees of freedom. For example,the first and second arm portions 210a, 210b can translate relative to one another along a longitudinal axis of the manipulator link 210 and / or can rotate relative to one another about the longitudinal axis of the manipulator link 210.

[0055] FIGS. 3a-3g depict a telescoping arm 300 (e.g., for a manipulator of a surgical system) in accordance with one or more embodiments of the present disclosure. In some embodiments, the telescoping arm 300 is interchangeable with, or a variation of, one or more of the manipulator links 210 of the manipulator 204 of FIG. 2.

[0056] The telescoping arm 300 includes two arm portions that are movable relative to one another to provide one or more additional mechanical degrees of freedom for a manipulator. An example first ami portion 302 is shown in FIG. 3a that has an annular body 304 elongated along an axis L (e.g., a longitudinal axis). The annular body 304 has cylindrical interior and exterior surfaces 306, 308. As shown, the interior surface 306 defines both a helical groove 310 extending along the axis L and a plurality (e.g., two, three, four, five, or more) of axial grooves 312 extending along the axis L. The helical and axial grooves 310, 312 can have any suitable cross-section. For example, the grooves 310, 312 can have a cross-section corresponding to a shape of the member received therein (e.g., curved, half-circle, slot, etc.). In another example, the grooves 310, 312 can have a cross-section to emphasize a functionality of groove (e.g., gothic-arch cross-section to provide four points of contact to accommodate high axial stiffness requirements or reduce backlash).

[0057] Helical and rotational components for a drive assembly 314 for the telescoping arm 300 are shown in FIGS. 3b-3e. The drive assembly 314 interacts with the arm portions of the telescoping arm 300 to drive movement thereof relative to one another. For example, portions of a helical drive assembly 316 of the drive assembly 314 are shown in FIGS. 3b and 3c and portions of a rotational drive assembly 318 are shown in FIGS. 3d and 3e.

[0058] The helical drive assembly 316 includes a helical member 320 that is configured to moveably engage and be constrained by the helical groove 310 of the first arm portion 302. As such, the helical member 320 has a pitch and circumference configured to seat the helical member 320 at least partially within the helical groove 310. In one example, the helical member 320 can be an external thread. In another example, the helical member 320 can be a plurality of ball bearings, i.e., helical member 320 can be formed by ball bearings 320a as shown in FIGS. 3band 3c. In some embodiments, implementation of the helical member 320 as a plurality of bearings, or by some other low-friction interface, can enable the telescoping arm 300 to be back drivable because of a relatively low friction coefficient between moving parts. With back driving capability, the arm portions of the telescoping arm 300 can be moved using external forces (e.g., manipulated using human arms) to extend, rotate, or retract the telescoping arm 300. Back driving capability can be useful for moving the telescoping arm 300 when power is not available to operate the telescoping arm 300

[0059] The helical drive assembly 316 can further include a housing 322 sized to fit within the first arm portion 302. The housing 322 can be configured to receive the helical member 320 (e.g., the ball bearings 320a) or have the helical member 320 coupled thereto or be integral therewith (e.g., the external thread). So configured, as the housing 322 is rotated relative to the first arm portion 302, the housing 322 and first arm portion 302 translate relative to one another. In some examples, the housing 322 can have an annular configuration that defines a central aperture 324.

[0060] In embodiments with the ball bearings 320a as the helical member 320, the housing 322 defines a helical bearing path 326 sized to receive the ball bearings 320a therein. The helical bearing path 326 is at least partially defined in an external surface of the housing 322 to radially position the ball bearings 320a within the helical groove 310 of the first arm portion 302. The helical bearing path 326 can have any suitable cross-section. For example, the helical bearing path 326 can have a cross-section corresponding to a shape of the bearings 320a received therein (e.g., curved, half-circle, etc.). To reduce a total weight of the housing 322 and / or ease manufacturing of the housing 322 due to formation of the helical bearing path 326, the housing 322 can further define external helical grooves 328 (FIG. 3f) that continue outside of the helical bearing path 326 (e.g., do not receive the ball bearings 320a therein).

[0061] In some examples, the helical bearing path 326 can include an inwardly (e.g., radially inwardly) recessed return path portion 326a so that the ball bearings 320a form a continuous path around the housing 322. As shown, the return path portion 326a guides the ball bearings 320a to an adjacent thread height (e.g., a lower thread or upper thread depending on clockwise or counterclockwise rotation of the housing 322).

[0062] The helical drive assembly 316 can further include a return path cap 330 that couples to the housing 322 over the return path portion 326a. The return path cap 330 contains the ball bearings 320a within the return path portion 326a and prevents any slippage that may occur due to the inward recess of the return path portion 326a or due to the external helical grooves 328. An interior surface (not shown) of the return path cap 330 can define a groove complementary to the return path portion 326a or can otherwise be spaced from the return path portion 326a a sufficient distance to have clearance for the ball bearings 320a to move within the return path portion 326a.

[0063] In some examples, the return path caps 330 can include portions of external thread 332 that correspond to a helical shape of the ball bearings 320a, such that the external threads 332 are received within the helical groove 310 of the first arm portion 302. Further, the return path cap 330 can include projections 334 that extend outwardly from the external threads 332 over ends of the return path portion 326a to guide movement of the ball bearings 320a out of and into the return path portion 326a.

[0064] The helical member 320 can include one, two, or more turns depending on desired functionality. Accordingly, in embodiments having the ball bearings 320a, the housing 322 can define multiple bearing paths 326 or the bearing path 326 can be sized to receive multiple rows of ball bearings 320a. In some examples, the multiple rows or ball bearings 320a can be axially preloaded together.

[0065] As shown in FIGS. 3d and 3e, the rotational drive assembly 318 includes a plurality of axial members 336 (e.g., two, three, four, five, or more) that are configured to moveably engage and be constrained by the axial grooves 312 of the first arm portion 302, where each axial member 336 is received in one of the axial grooves 312. In one example, the axial members 336 can be ribs or protrusions. In another example, the axial members 336 can be formed by bearings 336a as shown in FIGS. 3d and 3e.

[0066] With this configuration, the axial members 336 can restrict rotation of the first arm portion 302 about the axis L. Further, the axial members 336 are operably coupled to the helical drive assembly 316, such that if the helical drive assembly 316 is rotated relative to the rotational drive assembly 318, the drive assembly 314 will translate along the axis L relative to the firstarm portion 302. Conversely, if the rotational drive assembly 318 is rotated, the first arm portion 302 is rotated accordingly.

[0067] The rotational drive assembly 318 can further include a housing 338 sized to fit within the first arm portion 302. The housing 338 can be configured to receive the axial members 336 (e.g., the bearings 336a) or have the axial members 336 coupled thereto or be integral therewith (e.g., ribs or protrusions extending from the housing 338). So configured, as the housing 338 is rotated, the first arm portion 302 is driven to rotate along therewith. In some examples, the housing 338 can have an annular configuration that defines a central aperture 340.

[0068] In embodiments with the bearings 336a as the axial members 336, the housing 338 defines a plurality of axial bearing paths 342 sized to receive the bearings 336a therein. The axial bearing paths 342 are at least partially defined in an external surface of the housing 338 to radially position the bearings 336a within the axial grooves 312 of the first arm portion 302. The axial bearing paths 342 can have any suitable cross-section. For example, the axial bearing paths 342 can have a cross-section corresponding to a shape of the bearings 336a received therein (e.g., curved, half-circle, slot, etc.). The bearings 336a can be ball bearings 336a as shown in FIGS. 3d and 3e or can be other suitable shapes, such as cylindrical rollers as discussed below.

[0069] In some examples, each axial bearing path 342 can include an exterior portion 342a exposed along the exterior surface of the housing 338 and an interior portion 342b spaced inwardly from the exterior surface of the housing 338. Each axial bearing path 342 in these examples further includes ends 342c joining the exterior and interior portions 342a, 342b. With this configuration, the bearings 336a are disposed in a continuous loop traveling through the axial bearing path 342 with the direction depending on the direction of translation along the first arm portion along the axis L and bearings 336a disposed in the exterior portion 342a moveably engage and are constrained by the respective axial groove 312 of the first arm portion 302. As shown in the illustrated example, the exterior and interior portions 342a, 342b can be radially misaligned to reduce a required radial thickness of the housing 338.

[0070] For assembly, the housing 338 can include a main portion 338a defining the exterior and interior portions 342a, 342b of the axial bearing paths 342 and end portions 338b defining the ends 342c of the axial bearing paths 342. So configured, the bearings 336a can be loaded intothe axial bearing paths 342 with the housing 338 at least partially disassembled and then the end portions 338b and the main portion 338a can be fully assembled.

[0071] The telescoping arm 300 is shown at least partially assembled in FIGS. 3f and 3g. As depicted, the drive assembly 314, including the helical drive assembly 316 and the rotational drive assembly 318, is coupled to the first arm portion 302. With the housings 322, 338 of the helical and rotational drive assemblies 316, 318 being annular, a central passageway P is defined through the drive assembly 314.

[0072] In some examples, the housing end portion 338b adjacent to the helical drive assembly 316 can include an elongated wall 343 that extends along the axis L to rotatably couple to the housing 322 of the helical drive assembly 316, such a via a bearing 344 disposed therebetween. The bearing 344 can be mounted between the helical and rotational drive assemblies 316, 318, such that the assemblies 316, 318 are coupled together for translation along the axis L. For example, an annular cap 346 can be coupled to the elongated wall 343 to capture a portion of the bearing 344 between the cap 346 and housing end portion 338b. Other suitable connections or couplings can be utilized.

[0073] Additional components for the telescoping ami 300 are shown in FIG. 3g. As depicted, the drive assembly 314, (e.g., the helical drive assembly 316) can include an end cap 348 coupled to a second arm portion 350 of the telescoping arm 300. The second arm portion 350 is elongated along the axis L and at least partially received within the annular body 304 of the first arm portion 302. In the illustrated example, the second arm portion 350 extends back through the passageway P of the drive assembly 314. So configured, the second arm portion 350 translates and rotates along with the helical drive assembly 316. As such, rotation of the helical drive assembly 316 relative to the rotational drive assembly 318 causes the helical drive assembly 316 and the second arm portion 350 to axially translate relative to the first arm portion 302 along the axis L. Further, rotation of the rotational drive assembly 318 causes rotation about the axis L of the first arm portion 302 via the coupling to the plurality of axial grooves 312. Depending on movement constraints, the helical drive assembly 316 and the second arm portion 350 can also be driven to rotate by rotation of the rotational drive assembly 318.

[0074] In some examples, the telescoping arm 300 can further include connected tubular members disposed radially outwardly of (e.g., at least partially concentrically around) the secondarm portion 350. For example, the connected tubular members can include a first tubular member 352 coupled to and extending away from the end portion 338b of the rotational drive assembly housing 338. The connected tubular members can further include a second tubular member 354 and a third tubular member 356 that capture two bearings 358 therebetween that rotationally engage the rotational drive assembly housing 338. The second and third tubular members 354, 356 can be threadingly connected together to tighten onto the bearings 358, such that the second and third tubular members 354, 356 rotate relative to the housing 338.

[0075] FIG. 4 depicts a telescoping arm 400 (e.g., for a manipulator of a surgical system) in accordance with one or more embodiments of the present disclosure. In some embodiments, the telescoping arm 400 is interchangeable with, or a variation of, one or more of the manipulator links 210 of the manipulator 204 of FIG. 2. Additionally, components of the telescoping arm 400 (e.g., motors, bearings, differentials, etc.) can be added to or interchangeable with the telescoping arm 300 of FIGS. 3a-3f.

[0076] The telescoping arm 400 includes first and second arm portions 402, 450 that are movable relative to one another to provide one or more additional mechanical degrees of freedom (e.g., for a manipulator). The first arm portion 402 has an annular body 404 elongated along an axis L (e.g., a longitudinal axis). The annular body 404 has a cylindrical interior surface 406 that defines both a helical groove 410 extending along the axis L and a plurality (e.g., two, three, four, five, or more) of axial grooves 412 extending along the axis L. The helical and axial grooves 410, 412 can have any suitable cross-section, as discussed above. The second arm portion 450 is configured to be at least partially received within the annular body 404 of the first arm portion 402 and is elongated along the axis L.

[0077] A drive assembly 414 for the telescoping arm 400 includes a helical drive assembly 416 and a rotational drive assembly 418. The helical drive assembly 416 includes a helical member (not shown), such as a thread or ball bearings as discussed above, configured to moveably engage and be constrained by the helical groove 410 of the first arm portion 402. The helical drive assembly 416 can further include a housing 422 sized to fit within the first arm portion 402. The housing 422 can be configured to receive ball bearings or have an external thread be coupled thereto or be integral therewith. So configured, as the housing 422 is rotated,the housing 422 and the first arm portion 402 translate relative to one another. In some examples, the housing 422 can have an annular configuration that defines a central aperture 424.

[0078] In embodiments utilizing ball bearings, the housing 422 defines a helical bearing path 426 sized to receive the ball bearings therein, which can be configured similarly to the helical bearing path 326 discussed above to include an inwardly recessed return path portion, a return path cap, and so forth. In the illustrated example, the helical bearing path 426 includes three turns, but other numbers (e.g., one, two, or more than three) are suitable or the helical bearing path 426 can be sized to receive multiple rows of ball bearings, as discussed above.

[0079] The rotational drive assembly 418 includes a plurality of axial members 436 (e.g., two, three, four, five, or more) that are configured to moveably engage and be constrained by the axial grooves 412 of the first arm portion 402, where each axial member 436 is received in one of the axial grooves 412. Similar to the above example, the axial members 436 can be ribs or protrusions or can be formed by bearings 436a as shown. With this configuration, the axial members 436 can restrict rotation of the first arm portion 402 about the axis L. Further, the axial members 436 are operably coupled to the helical drive assembly 416, such that if the helical drive assembly 416 is rotated relative to the rotational drive assembly 418, the drive assembly 414 will translate along the axis L relative to the first arm portion 402. Conversely, if the rotational drive assembly 418 is rotated, the first arm portion 402 is rotated accordingly.

[0080] The rotational drive assembly 418 can further include a housing 438 sized to fit within the first arm portion 402. The housing 438 can be configured to receive the bearings 436a or can have ribs or protrusions coupled thereto or be integral therewith. So configured, as the housing 438 is rotated, the first arm portion 402 is driven to rotate along therewith. In some examples, the housing 438 can have an annular configuration that defines a central aperture 440.

[0081] In embodiments with the bearings 436a as the axial members 436, the housing 438 defines a plurality of axial bearing paths 442 sized to receive the bearings 436a therein. The axial bearing paths 442 are at least partially defined in an external surface of the housing 438 to radially position the bearings 436a within the axial grooves 412 of the first arm portion 402. The axial bearing paths 442 can have any suitable cross-section. For example, the axial bearing paths 442 can have a cross-section corresponding to a shape of the bearings 436a received therein (e.g.,curved, half-circle, slot, etc.). The hearings 436a can be cylindrical roller bearings 436a as shown in FIG. 4 or can be other suitable shapes, such as ball bearings as discussed above.

[0082] In some examples, each axial bearing path 442 can include an exterior portion 442a exposed along the exterior surface of the housing 438 and an interior portion 442b spaced inwardly from the exterior surface of the housing 438 joined by curved ends. With this configuration, the bearings 436a are disposed in a continuous loop traveling through the axial bearing path 442 with the direction depending on the direction of translation along the first arm portion 402 along the axis L and bearings 436a disposed in the exterior portion 442a moveably engage and arc constrained by the respective axial groove 412 of the first arm portion 402. As shown in the illustrated example, the exterior and interior portions 442a, 442b can be radially aligned, imparting an oval track shape to the axial bearing paths.

[0083] The telescoping arm 400 is shown assembled in FIG. 4. As depicted, the drive assembly 414, including the helical drive assembly 416 and the rotational drive assembly 418, is coupled to between the first arm portion 402 and the second arm portion 450. With the housings 422, 438 of the helical and rotational drive assemblies 416, 418 being annular', a central passageway P is defined through the drive assembly 414. As such, rotation of the helical drive assembly 416 relative to the rotational drive assembly 418 causes the helical drive assembly 416 and the second arm portion 450 to axially translate relative to the first arm portion 402 along the axis L. Further, rotation of the rotational drive assembly 418 relative to the plurality of axial grooves 412 causes rotation about the axis L of at last one of the first arm portion 402 and the second arm portion 450.

[0084] In some examples, the second arm portion 450 can define a proximal, outwardly opening annular cavity 452 and a distal, inwardly opening annular cavity 454. A helical drive motor 456 of the helical drive assembly 416 is disposed within the proximal cavity 452 to drive rotation of the housing 422. As shown, the helical drive motor 456 includes a motor stator 458 coupled to the second arm portion 450 and a motor rotor 460 coupled to the housing 422. A bearing 461 can be mounted between the housing 422 and the second arm portion 450 to ease the relative rotation therebetween.

[0085] A rotational drive motor 462 of the rotational drive assembly 418 is disposed within the distal cavity 454 to drive rotation of the housing 438. As shown, the rotational drive motor462 includes a motor stator 464 coupled to the second arm portion 450 and a motor rotor 466. In some examples, the motor rotor 466 can be coupled to the housing 438. In other examples, differential gearing 468 can be operably disposed between the motor rotor 466 and the housing 438. In the illustrated embodiment, the motor rotor 466 can be coupled to an interior tubular member 470 and the tubular member 470 can be coupled to the housing 438 via the differential gearing 468 (e.g., strain wave gearing, planetary gearbox, etc.). Bearings 472 can be coupled to either end of the tubular member 470 to ease the rotation thereof. A first one of the bearings 472 is disposed between the tubular member 470 and the second arm portion 450 and a second one of the bearings 472 is disposed between the tubular member 470 and a distal end cap 474. Another bearing 476 can be disposed between the second arm portion 450 and the rotational drive housing 438 to aid relative rotation therebetween. Any suitable bearing can be utilized, including a cross roller bearing as shown.

[0086] As shown, the components of the telescoping arm 400 combine to form a continuous path C through the telescoping arm 400. The continuous path C includes the passageway P of the drive assembly 414 (e.g., defined by the tubular member 470), an elongated passageway P2 of the second arm portion 450, and an elongated passageway P3 of the first arm portion 402.

[0087] In the above examples, the helical drive assembly 316, 416 can be configured such that the helical member 320, 420 does not operably engage the axial grooves 312, 412 of the first arm portion 302, 402 (i.e., enter the axial grooves 312, 412 outside of intersections therebetween). The rotational drive assembly 318, 418 can also or alternative be configured such that the axial members 336, 436 do not operably engage the helical groove 310, 410 of the first arm portions 302, 402 (i.e., enter the helical groove 310, 410 outside of intersections therebetween).

[0088] In some examples, one or both of the first and second arm portions 302, 402, 350, 450 can be rotationally and / or translationally fixed. In some examples, one or both of the first and second arm portions 302, 402, 350, 450 can be rotationally and / or translationally braked.

[0089] Although some disclosure as provided herein refers to telescoping arms (e.g., telescoping arms 300, 400) with regard to surgical manipulators and manipulator assemblies (e.g., manipulator 204, manipulator assembly 102, etc.), it will be understood that any of the provided examples can be equally applicable to other fields and systems. Accordingly,telescoping arms are not limited to arms of a surgical manipulator and can represent structural elements utilized in mechanical actuation systems. Such mechanical actuation systems can be related to transmissions, manufacturing systems, assembly systems, material or pail handling, and so forth. Suitable other fields include, without limitation, automotive, transportation, transmission, etc.

[0090] One or more components of the embodiments discussed in this disclosure, such as control system 112, may be implemented in software for execution on one or more processors of a computer system. The software may include code that when executed by the one or more processors, configures the one or more processors to perform various functionalities as discussed herein. The code may be stored in a non-transitory computer readable storage medium (e.g., a memory, magnetic storage, optical storage, solid-state storage, etc.). The computer readable storage medium may be part of a computer readable storage device, such as an electronic circuit, a semiconductor device, a semiconductor memory device, a read only memory (ROM), a flash memory, an erasable programmable read only memory (EPROM); a floppy diskette, a CD-ROM, an optical disk, a hard disk, or other storage device. The code may be downloaded via computer networks such as the Internet, Intranet, etc. for storage on the computer readable storage medium. The code may be executed by any of a wide variety of centralized or distributed data processing architectures. The programmed instructions of the code may be implemented as a number of separate programs or subroutines, or they may be integrated into a number of other aspects of the systems described herein. The components of the computing systems discussed herein may be connected using wired and / or wireless connections. In some examples, the wireless connections may use wireless communication protocols such as Bluetooth, near-field communication (NFC), Infrared Data Association (IrDA), home radio frequency (HomeRF), IEEE 802.11, Digital Enhanced Cordless Telecommunications (DECT), and wireless medical telemetry service (WMTS).

[0091] Various general-purpose computer systems may be used to perform one or more processes, methods, or functionalities described herein. Additionally or alternatively, various specialized computer systems may be used to perform one or more processes, methods, or functionalities described herein. In addition, a variety of programming languages may be used to implement one or more of the processes, methods, or functionalities described herein.

[0092] In the following description, specific details are set forth describing some embodiments consistent with the present disclosure. Numerous specific details arc set forth in order to provide a thorough understanding of the embodiments. It will be apparent, however, to one skilled in the art that some embodiments may be practiced without some or all of these specific details. The specific embodiments disclosed herein are meant to be illustrative but not limiting. One skilled in the art may realize other elements that, although not specifically described here, are within the scope and the spirit of this disclosure. In addition, to avoid unnecessary repetition, one or more features shown and described in association with one embodiment may be incorporated into other embodiments unless specifically described otherwise or if the one or more features would make an embodiment non-functional. In some instances, well known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0093] This disclosure describes various instruments and portions of instruments in terms of their state in three-dimensional space. As used herein, the term “position” refers to the location of an object or a portion of an object in a three-dimensional space (e.g., three degrees of translational freedom along Cartesian x-, y-, and z-coordinates). As used herein, the term “orientation” refers to the rotational placement of an object or a portion of an object (e.g., one or more degrees of rotational freedom such as, roll, pitch, and yaw). As used herein, the term “distal” refers to a position that is closer to a procedural site and the term “proximal” refers to a position that is further from the procedural site. Accordingly, the distal portion or distal end of an instrument is closer to a procedural site than a proximal portion or proximal end of the instrument when the instrument is being used as designed to perform a procedure.

[0094] While certain embodiments and examples have been described above and shown in the accompanying drawings, it is to be understood that such embodiments and examples are merely illustrative and are not limited to the specific constructions and arrangements shown and described, since various other alternatives, modifications, and equivalents will be appreciated by those with ordinary skill in the art.

Claims

What is claimed is:

1. A telescoping arm comprising: a first arm portion comprising an annular body elongated along an axis, an interior surface of the annular body being cylindrical and defining a helical groove extending along the axis and a plurality of axial grooves extending along the axis; a second arm portion configured to be at least partially received within the annular body of the first arm portion, the second arm portion being elongated along the axis and defining an elongated passageway; and a drive assembly comprising: a helical drive assembly having a helical member moveably engaging and constrained by the helical groove of the first arm portion; and a rotational drive assembly having a plurality of axial members moveably engaging and constrained by the plurality of axial grooves of the first arm portion, the plurality of axial members operably coupled to the helical drive assembly, wherein rotation of the helical drive assembly relative to the rotational drive assembly causes the helical drive assembly and the second arm portion to axially translate relative to the first ami portion along the axis, wherein rotation of the rotational drive assembly causes rotation about the axis of the first arm portion.

2. The telescoping arm of claim 1, wherein the helical drive assembly comprises a housing defining a helical bearing path including an inwardly recessed return path portion, and the helical member comprises ball bearings received within the helical bearing path to engage the helical groove of the first arm portion.

3. The telescoping arm of claim 2, wherein the helical drive assembly further comprises a return path cap coupled to the housing of the helical drive assembly over the return path portion of the helical bearing path.

4. The telescoping arm of claim 3, wherein the return path cap defines one or more portions of external thread configured to fit within the helical groove of the first arm portion.

5. The telescoping arm of claim 3, wherein the return path cap includes projections extending outwardly over ends of the return path portion to guide movement of the ball bearings into and out of return path portion.

6. The telescoping arm of claim 2, wherein the housing of the helical drive assembly further defines external grooves that continue outside of the helical bearing path.

7. The telescoping arm of claim 2, wherein the helical bearing path is sized to hold one turn of the ball bearings.

8. The telescoping arm of claim 2, wherein the helical drive assembly further comprises a helical drive motor to drive rotation of the housing of the helical drive assembly.

9. The telescoping arm of claim 8, wherein the helical drive motor comprises a motor stator coupled to one of the second arm portion or the housing of the helical drive assembly and a motor rotor coupled to the other of the second arm portion or the housing of the helical drive assembly to be rotationally driven by the motor stator.

10. The telescoping arm of any one of claims 2 to 8, wherein the rotational drive assembly comprises a housing defining a plurality of axial bearing paths, each axial bearing path having an exterior portion and an interior portion; and the axial members comprise bearings received within the axial bearing paths, the bearings moveably engaging and constrained by the plurality of axial grooves of the first arm portion while in the exterior portion of the axial bearing path.

11. The telescoping arm of claim 10, wherein the bearings comprise cylindrical roller bearings.

12. The telescoping arm of claim 10, wherein the interior surface of the first arm portion defines three or more axial grooves extending along the axis; and the rotational drive assembly comprises three or more axial members moveably engaging and constrained by the three or more axial grooves of the first arm portion.

13. The telescoping arm of claim 10, wherein the housing of the helical drive assembly and the housing of the rotational drive define a central passageway through the drive assembly, the central passageway connected to the elongated passageway of the second arm portion.

14. The telescoping arm of claim 10, wherein the housing of the helical drive assembly and the housing of the rotational drive assembly are annular.

15. The telescoping arm of claim 10, wherein the rotational drive assembly further comprises a rotational drive motor to drive rotation of the housing of the rotational drive assembly to drive rotation of the first arm portion about the axis.

16. The telescoping arm of claim 15, wherein the rotational drive motor comprises a motor stator coupled to the second arm portion and a motor rotor coupled to the housing of the rotational drive assembly to be rotationally driven by the motor stator.

17. The telescoping arm of claim 16, wherein the rotational drive assembly further comprises differential gearing operably disposed between the motor stator and the housing of the rotational drive assembly for higher torque application to the axial members.

18. The telescoping arm of any one of claims 1 to 9, wherein the helical groove of the of the first arm portion has a gothic-arch cross-sectional shape.

19. The telescoping arm of any one of claims 1 to 9, wherein the drive assembly defines a central passageway extending therethrough connecting an interior of the first arm portion to the elongated passageway of the second arm portion providing a continuous path through the telescoping arm.

20. The telescoping arm of any one of claims 1 to 9, wherein the second arm portion is back drivable relative to the first arm portion via the coupling of the helical member of the helical drive assembly with the helical groove defined in the first arm portion.

21. A robotic surgical system comprising: an instrument manipulator comprising a plurality of links having joints disposed therebetween, at least one of the plurality of links comprising a telescoping arm according to any one of claims 1 to 9; and an instrument carriage disposed on a distal end of the instrument manipulator.

22. A method of operating a telescoping arm, the method comprising: engaging a helical member coupled to a housing of a helical drive assembly with an internal groove defined in a first arm portion of the telescoping arm; controlling rotation of the first arm portion with a plurality of axial members of a rotational drive assembly received in a plurality of axial grooves of the first arm portion, the rotational drive assembly operably coupled to the helical drive assembly; and driving rotation of the housing of the helical drive assembly relative to the plurality of axial members to cause a second arm portion of the telescoping arm to axially translate relative to the first arm portion.

23. The method of claim 22, wherein engaging the helical member with the internal groove defined in the first arm portion comprises: engaging ball bearings received within a helical bearing path defined in the housing of the helical drive assembly with the internal groove defined in the first arm portion; and directing the ball bearings to an adjacent helical height via an inwardly recessed return path portion of the helical bearing path.

24. The method of claim 23, wherein engaging the ball bearings received within the helical bearing path defined in the housing of the helical drive assembly with the internal groove defined in the first arm portion comprises engaging one turn of the ball bearings with the internal groove defined in the first arm portion.

25. The method of claim 22, wherein driving rotation of the housing of the helical drive assembly relative to the plurality of axial members to cause the second arm portion of the telescoping arm to axially translate relative to the first arm portion comprises driving rotation ofthe housing of the helical drive assembly with a motor stator coupled to the second arm portion via a motor rotor coupled to the housing of the helical drive assembly.

26. The method of claim 22, wherein controlling rotation of the first arm portion with the plurality of axial members of the rotational drive assembly received in the plurality of axial grooves of the first arm portion comprises movably engaging the plurality of axial grooves of the first arm portion with bearings received within exterior portions of a plurality of axial bearing paths defined in a housing of the rotational drive assembly.

27. The method of claim 26, wherein driving rotation of the housing of the helical drive assembly relative to the plurality of axial members to cause the second arm portion of the telescoping arm to axially translate relative to the first arm portion comprises directing the bearings along an axial path of travel within interior portions of the plurality of axial bearing paths defined in the housing of the rotational drive assembly.

28. The method of claim 27, further comprising receiving one or more items through a central passageway defined by the housing of the helical drive assembly and the housing of the rotational drive through the drive assembly.

29. The method of any one of claims 22 to 28, further comprising driving rotation of the housing of the rotational drive assembly to cause the first arm portion of the telescoping arm to rotate relative to the second arm portion of the telescoping arm.

30. The method of claim 29, wherein driving rotation of the housing of the rotational drive assembly comprises driving rotation of the housing of the rotational drive assembly with a motor stator coupled to the second arm portion via a motor rotor coupled to the housing of the rotational drive assembly.

31. The method of claim 30, wherein driving rotation of the housing of the rotational drive assembly with the motor stator coupled to the second arm portion via the motor rotor coupled to the housing of the rotational drive assembly further comprises increasing a torque application tothe plurality of axial members with differential gearing operably disposed between the motor stator and the housing of the rotational drive assembly.

32. The method of any one of claims 22 to 28, further comprising receiving one or more items through a continuous path through the telescoping arm including an interior of the first arm portion, a central passageway extending through the drive assembly, and a passageway of the second arm portion.

33. The method of any one of claims 22 to 28, further comprising back driving the second arm portion relative to the first arm portion via the coupling of the helical member of the helical drive assembly with the internal groove defined in the first arm portion.

34. An apparatus comprising: a first portion comprising an annular body elongated along an axis, an interior surface of the annular body being cylindrical and defining a helical groove extending along the axis and a plurality of axial grooves extending along the axis; a second portion configured to be at least partially received within the annular body of the first portion, the second portion being elongated along the axis and defining an elongated passageway; and a drive assembly comprising: a helical drive assembly having a helical member moveably engaging and constrained by the helical groove of the first portion; and a rotational drive assembly having a plurality of axial members moveably engaging and constrained by the plurality of axial grooves of the first portion, the plurality of axial members operably coupled to the helical drive assembly, wherein rotation of the helical drive assembly relative to the rotational drive assembly causes the helical drive assembly and the second portion to axially translate relative to the first portion along the axis, wherein rotation of the rotational drive assembly causes rotation about the axis of the first portion.

Images