Capstan assembly for removal of slack in actuation members, and related systems and methods

Abstract

A capstan assembly includes first and second capstan body parts coupled to each other, the second capstan body part rotatable relative to the first capstan body part; a first actuation member receiving portion fixed in rotation with the first capstan body part and having a surface configured to pay in an actuation member; a second actuation member receiving portion fixed in rotation with the second capstan body part and having a surface configured to pay in an actuation member; and an elastically deformable biasing element coupled between the first capstan body part and the second capstan body part, the elastically deformable biasing element having a compressed state in a first position of rotation of the second capstan body part relative to the first capstan body part and an expanded state in a second position of rotation of the second capstan body part relative to the first capstan body part.

Description

PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304CAPSTAN ASSEMBLY FOR REMOVAL OF SLACK IN ACTUATION MEMBERS, AND RELATED SYSTEMS AND METHODS CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application 63 / 574,554, filed April4, 2024, the entirety of which is incorporated by reference herein. TECHNICAL FIELD

[0002] Aspects of the present disclosure relate to a capstan assembly for tensioning anactuation member used to transmit an actuation force, such as, for example, to actuate movement of a component of an instrument. Related devices, systems and methods also are disclosed. INTRODUCTION

[0003] Various medical and industrial instruments include shafts and have one or morecomponents that impart one or more degrees of freedom of movement to such instruments. Such components can be in the form of end effectors that move in one or more degrees of freedom, such as for example, translating mechanisms, jaws that open and close, etc. Other such components may include articulable structures, such as joint mechanisms, along the shaft that can pivot or otherwise allow bending (e.g., in pitch and / or yaw) of the shaft or of components relative to the shaft. These components that impart one or more degrees of freedom to the instrument can be actuated and controlled via actuation members extending along a length of the shaft. Such actuation members may be in the form of pullable (tension) members such as cables, wires, filaments or the like that are flexible in all directions and generally transmit stronger force by pulling on the actuation member to place it in tension (sometimes referred to as pull-pull actuation members).

[0004] The actuation members extend through the instrument shaft to couple to an actuatablecomponent (e.g., a moveable end effector component and / or an articulable structure) at a relatively distal portion of the shaft and to a drive device of force transmission system at a relatively proximal portion of the instrument shaft. In this way, the actuation members transmit forces from the force transmission system, which can remain at a remote location from the work site (e.g., outside a patient’s body in the case of a medical instrument performing a medicalprocedure) to the actuatable component, which is proximate a worksite (e.g., inside a patient’sbody in the case of a medical instrument performing a medical procedure). Force transmissionPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304systems can have manually-operated inputs for instruments that are manually operated or can include drive input interfaces that are configured to engage with an output drive, such as of part of manipulator system of a teleoperated, computer-assisted system, which manipulator systems comprise motorized output drives that are under control from remote input mechanisms, as would be familiar to those of ordinary skill in the art. Output drive may also include motors or other actuators onboard the force transmission system.

[0005] In some force transmission systems, the drive devices to which pull-pull type actuationmembers are coupled include rotary drive mechanisms, and rotary motion causes the actuation members to be paid in (partially wound around the rotary drive member) and paid out (partially unwound from the rotary drive member). Paying in tensions the actuation member so that it can transmit force to impart movement to the actuatable component. The rotary drive mechanism to which the actuation member couples can include an input drive shaft that receives input either manually or an output drive device, such as an onboard motor or other actuator of the force transmission system, or an output drive device, such as a servo motor and output drive member of a manipulator system to which the force transmission system is coupled.

[0006] In addition, to reduce backlash and facilitate accurate movement and control of theactuatable components, it is desirable to maintain tension in such pull-pull type actuation members and to control slack development that may lead to inaccuracies in movement and positioning of the actuatable component.

[0007] Further, in some applications a pair (or multiple pairs) of pull-pull type actuationmembers may work in tandem through the same rotary drive mechanism such that one actuation member is paid onto the rotary drive member to provide the pulling force (tension) to move an actuatable component in one degree of freedom, while the other actuation member is paid off the rotary drive member, and vice versa to move the actuatable component in a different (or opposite) degree of freedom motion. In such applications, the actuation member being paid out can develop slack that may interfere with the routing of the actuation member through various components of the instrument, such as pulleys or other guide structures along which the actuation member is routed. When the actuation member with slack is paid back in to tension it and actuate the actuatable component in the degree of freedom associated with that actuation member, the removal of slack and repositioning of the actuation member introduces additional time that can negatively impact the responsiveness of the movement of thePCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304actuatable component. In addition, there is a potential for the actuation member to not get routed back to its original position and / or to get caught on various elements during such repositioning. Further, during the repositioning, the actuation member can slide, rub, or otherwise contact against various routing and other elements, thereby potentially damaging the actuation member, such as by causing increased wear over time.

[0008] There exists a need, therefore, to provide the ability to control tension, such as removingslack, in an actuation member that is in a paid out state and not actively generating a pull (tension) force to actuate an actuatable component with which the actuation member is operably coupled. There further exists a need to allow for such control utilizing a mechanism that has a similar size space requirement as mechanisms that may be in use to actuate the actuation member. There further exists a need to provide such mechanisms that are robust in operation and manufacture. SUMMARY

[0009] Embodiments of the present disclosure may solve one or more of the above-mentionedproblems and / or may demonstrate one or more of the above-mentioned desirable features. Other features and / or advantages may become apparent from the description that follows.

[0010] In accordance with at least one aspect of the present disclosure, a drive system forcontrolling tension in an actuation member used to transmit actuation force comprises an input drive shaft having a longitudinal axis, the input drive shaft rotatable about the longitudinal axis; a capstan assembly comprising: a first capstan body part fixed in rotation with the input drive shaft, a second capstan body part coupled with the input drive shaft and the first capstan body part, the second capstan body part rotatable relative to the input drive shaft, a first actuation member receiving part fixed in rotation with the first capstan body part, and a second actuation member receiving part fixed in rotation with the second capstan body part. The drive system may further comprise a first actuation member coupled to the first actuation member receiving portion and configured to be paid relative to the first actuation member receiving portion; and a second actuation member coupled to the second actuation member receiving portion and configured to be paid relative to the second actuation member receiving portion. In a state of tension of the second actuation member in response to being paid in to the second actuation member receiving portion so as to transmit an actuation force, the first and second capstan body parts are rotatable together with the input drive shaft, an in a state of slack of the secondPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304actuation member in response to the second actuation member being paid out from the second actuation member receiving portion and while the first actuation member is paid in to the first actuation member receiving portion and tensioned to transmit an actuation force, the first capstan body part is rotatable with the input drive shaft, and the second capstan body part is rotatable relative to the first capstan body part and the input drive shaft.

[0011] In at least another aspect of the present disclosure, a capstan assembly for controllingtension in actuation members comprises a first capstan body part; a second capstan body part coupled to the first capstan body part and rotatable relative to the first capstan body part; a first actuation member receiving portion fixed in rotation with the first capstan body part and configured to provide a surface to pay in an actuation member; a second actuation member receiving portion fixed in rotation with the second capstan body part and configured to provide a surface to pay in an actuation member; and an elastically deformable biasing element coupled between the first capstan body part and the second capstan body part, the elastically deformable biasing element having a compressed state in a first position of rotation of the second capstan body part relative to the first capstan body part and an expanded state in a second position of rotation of the second capstan body part relative to the first capstan body part.

[0012] In yet another aspect of the present disclosure, a method of controlling tension inactuation members used to transmit actuation force comprises rotating a first capstan body part of a capstan assembly in a first direction, thereby causing a first actuation member to be paid into the capstan assembly so as to tension a first actuation member; causing a second capstan body part of the capstan assembly to rotate in the first direction by rotation of the first capstan body part, thereby causing a second actuation member to paid out from the capstan assembly; and in response to the paying out of the second actuation member and tension in the second actuation member decreasing to a sufficient level, causing the second capstan body part to rotate in a second direction opposite the first and relative to the first capstan body part, thereby causing the second actuation member to be paid in to the capstan assembly first capstan body part.

[0013] Yet another aspect of the present disclosure contemplates An instrument comprising ashaft; an end effector comprising an actuatable component coupled to the shaft; and the drive system discussed above coupled to the shaft. The first actuation member is operably coupled toPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304the actuatable component and configured to actuate movement of the actuatable component in a first degree of freedom in response to the first actuation member being paid in and placed in tension, and the second actuation member is operably coupled to the actuatable component and configured to actuate movement of the actuatable component in a second degree of freedom in response to the second actuation member being paid in and placed in tension.

[0014] Additional objects, features, and / or advantages will be set forth in part in the descriptionwhich follows, and in part will be obvious from the description, or may be learned by practice of the present disclosure and / or claims. At least some of these objects and advantages may be realized and attained by the elements and combinations particularly pointed out in the appended claims.

[0015] It is to be understood that both the foregoing general description and the followingdetailed description are for example and explanatory only and are not restrictive of the claims; rather the claims should be entitled to their full breadth of scope, including equivalents. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present disclosure can be understood from the following detailed description, eitheralone or together with the accompanying drawings. The drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments of the present teachings and together with the description explain certain principles and operation. In the drawings,

[0017] FIG.1 is a perspective view of an embodiment of rotary drive mechanism with a capstanassembly for actuation member slack removal;

[0018] FIG. 2 is a perspective view another embodiment of rotary drive mechanism withcapstan assembly for actuation member slack removal;

[0019] FIG.3 is an exemplary workflow in accordance with aspects of the present disclosure;

[0020] FIG. 4 is a perspective view of a rotary drive mechanism with a capstan assembly foractuation member slack removal in accordance with another implementation.

[0021] FIG.5 is a partial exploded view of FIG.4 showing portions of the capstan assembly andthe input drive shaft;

[0022] FIG.6 is a detailed view of portion 6-6 of FIG.4;PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304

[0023] FIGs. 7A and 7B depict a first state of operation of the rotary drive mechanism andcapstan assembly of FIG.4;

[0024] FIGs.8A and 8B depict a second state of operation of the rotary drive mechanism andcapstan assembly of FIG.4.

[0025] FIG.9 is another exemplary workflow in accordance with aspects of the presentdisclosure;

[0026] FIG.10A is a schematic side view of an instrument in accordance with an aspect of thedisclosure;

[0027] FIG.10B is a plan view of the drive interface of the force transmission system of theinstrument of FIG.10B; and

[0028] FIG.11 is a perspective schematic view of a manipulator system according to an aspectof the present disclosure. DETAILED DESCRIPTION

[0029] The present disclosure relates to devices, systems, and methods for controlling tension,such as for the removal of slack, in an actuation member that is paid in and out relative to a rotary drive mechanism, and which transmits force in the paid in, tensioned state to cause an actuatable component to which the actuation member is operably coupled to move. Such actuation members may also be referred to as a pull-pull type actuation member and can include, but are not limited to, cables, wires, filaments, or the like, and can be manufactured from a variety of metal (e.g., tungsten or stainless steel) or polymer (e.g., high molecular weight polyethylene) materials. Force transmission systems and instruments that utilize such rotary drive mechanisms and actuation members are also contemplated.

[0030] Various implementations can include a capstan assembly as part of a rotary drivemechanism and the capstan assembly can have differing states depending on an amount of force exerted by an actuation member operably coupled and being paid in / out relative to the capstan assembly. For example, a first state can correspond to a paid in state of an actuation member in which tension in the actuation member is exerted on the capstan assembly and a second state can correspond to a paid out state of the actuation member due to development ofPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304slack in the actuation member and consequent release of force on the capstan assembly by the actuation member.

[0031] In various implementations, the capstan assembly can provide differing states of rotationrelative to an input drive shaft that drives the capstan assembly, the differing states of rotation corresponding to the state of slack or tension of the actuation member. For example, in a state of the actuation member being in a tensioned state, the capstan assembly can be in a fixed rotational relationship with the input drive shaft. In a state of the actuation member developing slack, the capstan assembly can be in a differential rotational relationship with the input drive shaft such that it can rotate relative to the shaft. More specifically, the capstan assembly can rotate relative to the drive shaft to pay in the actuation member so as to remove slack from the actuation member.

[0032] In various implementations, a capstan assembly that allows for fixed and differentialstates of rotation relative to an input drive shaft can be utilized in conjunction with a pair of actuation members that work in tandem to transmit force to actuate movement of a movable component. In some configurations, a capstan assembly can comprise multiple capstan body portions to allow one portion to move in a differential manner with respect to another. This can allow a differential motion of actuation members so as to be able to remove slack in one actuation member without affecting the tensioned state of another. While various embodiments described herein use the differential motion of multiple capstan body portions to remove slack in one actuation member without affecting the tensioned state of a second actuation member, those having ordinary skill in the art would appreciate that more than two actuation members may be utilized and slack removed from one or more without affecting others of the plurality of actuation members. For example, a given number of actuation members may be paid in / out respectively relative to different capstan body portions capable of differential rotation. In other embodiments, more than one actuation member may be paid in / out relative a same capstan body portion and moved in a step-wise synchronized manner with the other actuation member, while not exhibiting the same tension state.

[0033] Various implementations further contemplated by the present disclosure includeinstruments comprising a capstan assembly providing differential motion in accordance with various embodiments to actuate pull-pull-type actuation members to actuate a grip DOF (degree of freedom) movement (i.e., opening / closing of opposing jaw members of an end effector of anPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304instrument). Various other implementations and applications will be appreciated from the description and figures set forth herein and the examples shown and described in more detail below are to be considered as illustrative and non-limiting.

[0034] With reference to FIG.1, a rotary drive mechanism that utilizes a capstan assembly fortensioning an actuation member for removal of slack in accordance with one implementation of the present disclosure is illustrated. The rotary drive mechanism 100 includes a capstan assembly 130 operably coupled to a input drive device 140 that is configured to be driven by an external mechanism, as discussed above, such as a manual drive force, a drive force provided by a motor, or a drive force provided by a manipulator system, embodiments of which are described further below. More specifically, the capstan assembly 130 can comprise a shaft portion 136 having a bore that receives a input drive shaft (not shown) coupled to the input drive device 140. The shaft portion 136 can further include an actuation member receiving portion 138. An actuation member 150 can be coupled to the actuation member receiving portion 138 and configured to wrap around the portion 138 as the actuation member 150 is paid in to the capstan assembly 130 and unwrapped therefrom as the actuation member 150 is paid out from the capstan assembly 130.

[0035] In various implementations, as shown, the actuation member receiving portion 138 cancomprise guide features 138’, such as helical grooves to assist with guiding the actuation member 150 onto the actuation member receiving portion 138 as it is paid in so as to, for example, avoid the actuation member 150 wrapping on itself. The actuation member 150 can be secured to the actuation member receiving portion 138 via the use of crimps, fittings, various types of mechanical fasteners, and other techniques (e.g., welding, fusing, over-molding, etc.) suitable for coupling the actuation member to the actuation member receiving portion 138 of the capstan assembly 130. Attachment can also occur through various forms of frictional engagement between the capstan assembly 130 and the actuation member 150, without the use of mechanical fasteners.

[0036] The capstan assembly 130 can have a fixed rotational state relative to the input driveshaft (not shown) in a state of the actuation member 150 being in a paid in, tensioned state in which the actuation member 150 is transmitting force to actuate an actuatable component to which it is operably coupled (not shown in FIG.1). The capstan assembly 130 can have a differential rotational state relative to the input drive shaft in a state of the actuation member 150PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304being in a paid out, slack state in which the actuation member 150 is not transmitting force to actuate the actuatable component.

[0037] For example, the capstan assembly 130 can be fixed in rotation with the input drive shaft(and consequently the input drive device 140) in a first direction of rotation (shown as arrow A in FIG.1) about the longitudinal axis ALof the input drive shaft and the capstan assembly 130. The first direction of rotation A can correspond to the actuation member 150 being paid in to the capstan assembly 130 and tensioned so as to cause actuation of the actuatable component to which it is operably coupled. In a second direction of rotation (shown by arrow B in FIG.1) opposite the first direction of rotation A, the capstan assembly 130 can provide a differential rotation relative to the input drive shaft such that the capstan assembly 130 or at least the actuation member receiving portion 138 can rotate relative to the input drive shaft. In this state, the input drive shaft may be initially driven to pay out the actuation member 150 from the capstan assembly 130. Upon sufficient tension on the actuation member 150 as such paying out occurs, the capstan assembly 130 can rotate in a fixed manner with the input drive shaft. However, if slack develops in the actuation member 150 and tension reduced to a sufficient level, a release of the force of the actuation member 150 acting on the capstan assembly 130 can allow the capstan assembly 130 to become rotatable relative to the input drive shaft. This can allow the capstan assembly 130 to rotate in an opposite direction (i.e., back in direction A) relative to the input drive shaft (which can continue to rotate in direction B or remain stationary), thus paying in the actuation member 150 and taking up slack developed in the actuation member 150.

[0038] In various implementations, a limit is provided on the differential rotation of the actuationmember receiving portion 138 of the capstan assembly 130 relative to the input drive shaft, and consequent amount of paying in of the actuation member 150 in the slack condition, so as to avoid tensioning the actuation member 150 to an amount that would actuate the actuatable component. Rather, the amount of slack removal that is desirable by the differential rotational state of the capstan assembly 130 is to maintain desired routing paths and avoid “derailing” the actuation member 150 from guide components and routing paths the actuation member 150 is configured to follow in its tensioned state, without tensioning it to a level that is intended to transmit force to actuate the actuatable component.PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304

[0039] As noted above, the capstan assembly 130 can be configured such that the shaft portion136 and the actuation member receiving portion 138 are fixed together in rotation in both states of rotation, or the actuation member receiving portion 138 can be rotatable relative to the shaft portion 136 and the input drive shaft in the differential rotational state of the capstan assembly 130, with the shaft portion 136 being fixed in rotation with the input drive shaft in both states.

[0040] Referring now to FIG.2, another implementation of a rotary drive mechanism utilizing acapstan assembly for tensioning an actuation member to remove slack is illustrated. In FIG.2, a rotary drive mechanism 200 is operably coupled with a pair of actuation members 250, 251 that are utilized to transmit force to an actuatable component (not depicted) to which the actuation members 250, 251 are operably coupled. More specifically, the actuation member 250 is used to transmit force to actuate the actuatable component to move in a first degree of freedom and the actuation member 251 is used to transmit force to actuate the actuatable component to move in a second degree of freedom. The actuation members 250, 251 operate in tandem such that the one that is being used to transmit the force to the actuatable component is tensioned, while tension is released from the other.

[0041] The implementation of FIG.2 has similar parts as those in the implementation of FIG.1,with similar parts being labeled with the series 2xx instead of 1xx, but the last two digits remaining the same for the similar parts. In particular, as in FIG.1, the rotary drive mechanism 200 of FIG.2 includes a capstan assembly 230 operably coupled to a drive input 240 that is configured to be driven by an external mechanism, such as a manual drive force, a drive force provided by a motor, or a drive force provided by a manipulator system. More specifically, the capstan assembly 230 can comprise a shaft portion 236 having a bore that receives a input drive shaft 241 (a portion of which is visible in FIG.2) coupled to the input drive device 240. The capstan assembly 230 can further include an actuation member receiving portion 238 configured to be coupled to and provide a surface for wrapping (paying in) and unwrapping (paying out) an actuation member 250 coupled to the actuation member receiving portion 238, as described above with reference to FIG.1. The actuation member receiving portion 238 can comprise guide features 238’, such as helical grooves to assist with guiding the actuation member 250 onto the actuation member receiving portion 238 as it is paid in, as also described with reference to FIG.1. The actuation member 250 can be secured to the actuation member receiving portion via any of the ways discussed above with reference to FIG.1PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304

[0042] In the embodiment of FIG. 2, in addition to the actuation member receiving portion 238,the capstan assembly 230 includes a second actuation receiving member portion 239 operably coupled to another actuation member 251, using any of the securing techniques described above. Actuation member receiving portion 239 also provides a surface for wrapping (paying in) and unwrapping (paying out) of the actuation member 251, and can include guide features 239’, such as helical grooves, to assist with guiding the actuation member 251 onto the actuation member receiving portion 239, as discussed above.

[0043] As can be seen in FIG.2, the actuation members 250, 251 pay in and pay out relative tothe capstan assembly 230 and respective actuation member receiving portions 238, 239 in opposite directions of rotation. Specifically, when actuation member receiving portion 238 rotates in direction A, actuation member 238 is paid out from actuation member receiving portion 238 and tension is released. When actuation member receiving portion 238 rotates in direction B, actuation member 250 is paid in to the actuation member receiving portion 238 and placed in tension. Actuation member 251 behaves in the opposite manner. That is, when the actuation member receiving portion 239 rotates in direction A, actuation member 251 is paid in and placed in tension, whereas when actuation member receiving portion 239 rotates in direction B, actuation member 251 is paid out.

[0044] As with the embodiment of FIG.1, in FIG.2, actuation member receiving portion 238 canhave a fixed rotational state relative to the input drive shaft 241 in a state of the actuation member 250 being in a paid in, tensioned state in which the actuation member 250 is transmitting force to actuate an actuatable component to which it is operably coupled (not shown in FIG.2). The actuation member receiving portion 238 can have a differential rotational state relative to the input drive shaft 241 in a state of the actuation member 250 being in a paid out, slack state in which the actuation member 250 is not transmitting force to actuate the actuatable component.

[0045] For example, the actuation member receiving portion 238 can be fixed in rotation withthe input drive shaft 241 (and with the input device 240 and actuation member receiving portion 239) in a first direction of rotation (shown as arrow B in FIG.2) about the longitudinal axis ALof the input drive shaft 241 and the capstan assembly 230, which corresponds to the actuation member 250 being paid in. In a second direction of rotation (shown by arrow A in FIG.2) opposite the first direction of rotation B, the capstan assembly 230 can provide a differentialPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304rotation of at least the actuation member receiving portion 238 relative to the input drive shaft 241 such that the actuation member receiving portion 238 can rotate relative to the input drive shaft 241. In this state, the input drive shaft 241 may be initially driven to rotate the capstan assembly 230, including actuation member receiving portions 238, 239, in direction A, thereby paying out the actuation member 250 while paying in actuation member 251. Upon sufficient tension in the actuation member 250 as such paying out occurs, the capstan assembly 230 including both portions 238, 239 can rotate with the input drive shaft 251. However, upon sufficient slack development in the actuation member 250, a reduction in tension of the actuation member 250 results in reducing force acting on the actuation member receiving portion 238 of the capstan assembly 230. This reduction of force by the actuation member 250 can allow the actuation member receiving portion 238 to become decoupled from rotation with the input drive shaft 241, allow the actuation member receiving portion 238 to rotate in an opposite direction (i.e., back in direction B) relative to the input drive shaft 241 (which can continue to rotate in direction A or remain stationary depending on whether the input drive shaft continues to drive it in rotation or not). Rotation of actuation member receiving portion 238 in direction B relative to the input drive shaft 241 thus pays in the actuation member 250 and takes up slack developed in the actuation member 250.

[0046] To avoid affecting the tensioned state of actuation member 251 as it is being tensionedby the capstan assembly 230, in an implementation, the actuation member receiving portion 239 has a fixed rotational state relative to the input drive shaft 241 in both directions of rotation A and B of the input drive shaft 241. By fixing the rotation of the actuation member receiving portion 239 relative to the input drive shaft 241, tension can be maintained in the actuation member 251 as it is being paid in due to the rotation in direction A, even while slack is removed by paying in the actuation member 250. In other words, because the actuation member receiving portion 239 is fixed rotationally to the input drive shaft 241, the actuation member receiving portion 238 exhibits a differential rotational motion relative to the actuation member receiving portion 239 as well as the input drive shaft 241.

[0047] As with the implementation of FIG. 1, in the implementation of FIG.2, a limit can beprovided on the differential rotation of the actuation member receiving portion 238 relative to the input drive shaft 241, and consequent amount of paying in of the actuation member 250 in the slack condition, so as to avoid tensioning the actuation member 250 to an amount that would actuate the actuatable component. Rather, the amount of slack removal that is desirable by thePCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304differential rotational state of the actuation member receiving portion 238 is to maintain desired routing paths and avoid “derailing” the actuation member 250 from guide components and routing paths the actuation member is configured to follow in its tensioned state as it traverses from the rotary drive mechanism to the actuatable component, without tensioning it to a level that is intended to transmit force to actuate the actuatable component.

[0048] As noted above, the capstan assembly 230 can be configured such that the shaft portion236 and the actuation member receiving portion 239 are fixed together in rotation in both states of rotation, or the actuation member receiving portion 239 can be rotatable relative to the shaft portion 236 and the input drive shaft in the differential rotational state of the capstan assembly 230, with the shaft portion 236 being fixed in rotation with the input drive shaft 241 in both states.

[0049] FIG.3 represents one example workflow 300 for removal of slack from an actuationmember which can be implemented using various of the implementations of rotary drive mechanisms described herein, including the implementations of FIGs.1 and 2 discussed above. At action 302 of workflow 300, an input rotary drive device, which can include any of the input drive shafts described herein, is driven in rotation in a first direction, and this in turn causes an actuation member receiving portion of a capstan assembly (such as actuation member receiving portion 138 or 238) to rotate in a first direction in a fixed rotational manner with the input rotary drive device, causing pay in of an actuation member operably coupled to the actuation member receiving portion. At action 304, driving the input rotary drive device in a second direction of rotation, opposite the first direction of rotation, can cause the actuation member receiving portion of the capstan assembly to rotate in the second direction and pay out the actuation member coupled to the actuation member receiving portion. At action 306, in response to decreasing the tension (slack developing) in the paid out state of the actuation member, the workflow can include rotating the actuation member receiving portion relative to the input rotary drive device to pay in the actuation member.

[0050] In various of the implementations described herein, the slack development that occurs inthe actuation member can trigger the actuation member receiving portion of the capstan assembly to be released from fixed rotation with the input rotary drive device. In this sense, slack development or a state of slack or other similar references of an actuation member as used herein can correspond to the tension in the actuation member being decreased to aPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304sufficiently low level that it does not hold the actuation member receiving portion to which the actuation member is operably coupled in a fixed rotational state relative to the rotary drive input mechanism. By way of non-limiting example, force to pull out the slack may be about 1 pound- force (lbf) so as to reduce the slack by about 30 degrees of angular rotation around the capstan or about 0.05 in. of length of the actuation member. As discussed above, the rotation of the actuation member receiving portion to pay in the actuation member at action 306 to remove slack can be limited so as to not cause an over tensioning of the actuation member that might trigger an actuation of the actuation component to which it is operably coupled. Moreover, due to the decoupling of the rotation of the actuation member receiving portion and input rotary drive device, the input rotary drive device may continue to be driven in rotation in the second direction without impacting and causing the rotation of the actuation member receiving portion in that direction.

[0051] Referring now to FIGs.4-8B, yet another implementation of a rotary drive mechanismutilizing a capstan assembly that provides differential motion for tensioning an actuation member to remove slack is illustrated. The capstan assembly of FIG.4 provides a relatively simple construction of a differential capstan assembly and illustrates one example of a mechanism for decoupling and allowing the differential rotational motion of one actuation member receiving portion of the capstan assembly relative to the input drive shaft and to another actuation member receiving portion of the capstan assembly. The mechanism implemented in this embodiment of the capstan assembly could be utilized in the embodiments of FIGs.1 and 2 described above.

[0052] FIGs.4-6 respectively illustrate a perspective view of the rotary drive mechanism 400comprising a capstan assembly 430, input drive device 440 drive, and input drive shaft 441, with corresponding actuation members 450, 451 operably coupled to the capstan assembly 430; a partial exploded view of FIG.4 showing portions of the capstan assembly and the input drive shaft; and a detailed view of portion 6-6 of FIG.4. In each of FIGs.4-6, a portion of the capstan assembly 430 also is shown transparent to allow internal components to be seen. Parts of the rotary drive mechanism 400 that are similar to those described above in FIGs.1 and 2 are labeled with similar reference numerals as 4xx, with the last two digits changing from the 1xx and 2xx numbering in FIGs.1 and 2.PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304

[0053] The rotary drive mechanism of FIGs. 4-6 includes a capstan assembly 430 operablycoupled to an input drive device 440 that is configured to be driven by an external mechanism, such as a manual drive force, a drive force provided by a motor, or a drive force provided by a manipulator system, as with other implementations described herein. More specifically, the capstan assembly 430 can comprise a shaft portion 436 having a bore that receives an input drive shaft 441 coupled to and configured to rotate with the input drive device 440. The capstan assembly 430 further has two actuation member receiving portions 438, 439, similar to those described above with reference to FIG.2, and which are respectively operably coupled to actuation members 450, 451 in the same manner as described above with reference to FIG.2. The actuation members 450, 451 are also operably coupled to and configured to drive actuation of an actuatable component (not shown) in differing degrees of freedom, as described above.

[0054] To provide the differential motion of actuation member receiving portion 438 relative torotation of the input drive shaft 441 upon slack developing in actuation member 450, allowing the actuation member receiving portion 438 to be rotated relative to the input drive shaft 441 and pay in (so as to tension and remove slack from) the actuation member 450, the capstan assembly 430 utilizes a decoupling mechanism 460. Decoupling mechanism 460 enables the actuation member receiving portion 438 to be placed in a fixed rotational state with the input drive shaft 441 and the actuation member receiving portion 439, or in a decoupled, differentially rotational state with the input drive shaft 441 and actuation member receiving portion 439.

[0055] The decoupling mechanism 460 comprises a two-part device comprising a fixed capstanbody part 469 coupled in a fixed relationship with the input drive shaft 441 and a rotatable capstan body part 468 rotatably coupled to the input drive shaft 441. Both parts 468, 469 coupled together form an annular, cylindrical end piece of the capstan assembly 430 that secures the capstan assembly 430 in a fixed axial position on the input drive shaft 441, as will be explained further below.

[0056] Because the fixed capstan body part 469 is fixed in rotation with the input drive shaft441, it is also fixed in rotation with the actuation member receiving portion 439 that is fixed to the input drive shaft 441. The rotatable capstan body part 468 is fixedly coupled (or integrally formed with) actuation member receiving portion 438, and both parts are rotatably coupled to the input drive shaft 441. In other words, the rotatable capstan body part 468 coupled with the actuation member receiving portion 438 are rotationally floating relative to the input drive shaftPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304441, and accordingly relative to the fixed capstan body part 469 and actuation member receiving portion 439.

[0057] The fixed capstan body part 469 and the rotatable capstan body part 468 are configuredto fit together such that they form two portions of an overall annular cylindrical structure. More specifically, the fixed capstan body part 469 has a split ring configuration that includes an annular plate defining an annular end face 471 configured to extend around the entire circumference of the input drive shaft 441. Extending from the annular end face 471 is a partial annular arc segment 473 having a thickness along the longitudinal axial direction of the fixed capstan body part 469 and terminating at ends of the arc defined by the segment 473 in radially inwardly extending surfaces 473’, 473’’ which can function as stop surfaces as described further below.

[0058] The rotatable capstan body part 468 includes an annular plate defining an annular endface 470 configured to extend around the circumference of the input drive shaft 441. Extending longitudinally in one direction from the annular end face 470 is the actuation member receiving portion 438 and in the opposite direction an arc-shaped outer lateral wall 472 that extends partially along the peripheral edge of the annular end face 470. For example, the wall 472 can have an angular extent ranging from about 0 degrees to about 30 degrees. A radially extending surface 474 can extend radially inwardly from one end of the lateral wall 472.

[0059] As illustrated in FIGs. 4 and 6, the fixed capstan body part 469 and the rotatable capstanbody part 468 are configured to be fit together to form an overall generally annular cylindrical structure with the end faces 470, 471 forming the end faces of the annular, cylindrical structure that are transverse (perpendicular) to the longitudinal axis of the structure and axis of rotation AL when assembled on the input drive shaft 441. The partial annular segment 473 is received between the ends of the lateral wall 472. In the fit together configuration, the annular segment 473 and lateral wall 472 form an outer lateral wall of the overall annular cylindrical structure. The relative circumferential lengths of the lateral wall 472 and the outer surface of the annular segment 473 are such that a gap is provided allowing the wall 472 space to move to some degree around the longitudinal axis ALas the rotatable capstan body part 468 rotates. This gap and the rotation of the rotatable capstan body part 468 and lateral wall 472 is explained in further detail below.PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304

[0060] An elastically deformable biasing element 480, such as a compression spring shown,can extend generally radially inwardly of and along the lateral wall 472 of the rotatable capstan body part 468 such that one end of the spring-biased element presses against the radially inwardly extending surface 474 and the other against the radially inwardly extending surface 473’. The biasing element 480 has a relaxed (uncompressed), resting state in the configuration shown in FIGs.4 and 6, such that the end of the lateral wall 472 is spaced from the radially inwardly extending surface 473’. The biasing element 480 can have a compressed state by rotating the rotatable capstan body part 468 relative to the input drive shaft 441 and the fixed capstan body part 469 such that the radially extending surface 474 moves toward radially extending surface 473’ and a distance between those two surfaces is decreased.

[0061] As can be best seen in FIG. 6, the radially inwardly extending surface 473’ has arecessed region 473’r that captures the end of the biasing element 480 (compression spring). This recessed region helps to prevent the spring from escaping as a result of the gap between 468 and 469 that can occur, such as in the state of those elements shown in FIGs.4 and 6. Because the biasing element 480 is completely captured (no gaps) between rotatably capstan body part 468 and input drive shaft 441 at the end where it meets radially inwardly extending surface 474, no similar recessed region is needed to capture that end of the biasing element 480.

[0062] A variety of elastically deformable biasing elements can be used other than a coiledcompression spring, such as, but not limited to, for example, a torsion spring in the same location as element 480 or nested between rotatable capstan body part 468 and fixed capstan body part 469, with location hard stops external to the torsion spring; an extension spring, which could be wrapped and affixed on external surfaces of the between rotatable capstan body part 468 and fixed capstan body part 469; a constant force coil spring nested between rotatable capstan body part 468 and fixed capstan body part 469. Various other types and arrangements of elastically deformable biasing elements would be appreciated by those of ordinary skill in the art.

[0063] The split ring configuration of the fixed capstan body part 469 allows for ease inassembly of the parts 468, 469 and the biasing element 480 with each other and with the input drive shaft 441. As perhaps best shown in FIG.6, a through hole 475 can be tunneled through the annular segment 473 and across a separation gap 477 of the split ring configuration to allowPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304a securing device (not shown), such as a bolt or the like, to be received and tightened to clamp and fix the fixed capstan body part 469 to the input drive shaft 441. The through hole 475 can terminate in opposite openings 475’, 475’’ in the outer lateral side wall portions of the annular segment 473 to allow access to the securing device, for example, via a tool to tighten and loosen the same.

[0064] Tightening and securing the fixed capstan body part 469 to the input drive shaft 441 putsthe capstan body part 469 in a fixed rotational and axial relationship with the input drive shaft 441. Due to the fit of the fixed capstan body part 469 with the rotatable capstan body part 468, with the lateral portions 472, 473 sandwiched between the end faces 470, 471, tightening and fixing the fixed capstan body part 469 to the input drive shaft 441 also axially fixes the rotatable capstan body part 468 to the shaft 441, while leaving it rotationally floating relative to the shaft 441.

[0065] The rotatable capstan body part 468 is limited in the extent of its rotation by theabutment of the lateral wall 472 and inwardly extending surface 474 with the radially inwardly extending stop surfaces 473’, 473’’, respectively, of the annular segment 473. In various implementations, the rotatable capstan body part 468 can rotate over a range of about + / - 0-30 degrees around the longitudinal axis between the surfaces 473’ and 473’’. Thus, surfaces 473’, 473’’ function as stop surfaces to limit the range of rotation of the rotatably capstan body part 468. As discussed above, limiting the range of rotation of the rotatable capstan body part 468 can assist with limiting the paying in of the actuation member 450 to the degree needed to remove slack without tensioning the actuation member to a degree at which it would transmit force to actuate the actuatable component to which it is operably coupled.

[0066] With reference to FIGs.7A-8B, operation of the capstan assembly 430 and decouplingmechanism 460 to remove slack in the actuation member 450, during a state when the actuation member 450 is not being actively tensioned, so as to transmit force to actuate an actuatable component will now be described.

[0067] FIGs.7A and 8A are perspective views of the rotary drive mechanism 400 and actuationmembers 450, 451 showing the capstan assembly 430 with the rotatable capstan body part 469 in differing states, as further described below. FIG.7B and 8B are sectional views taken through section 7B-7B of FIG.7A and 8B-8B of FIG.8A, respectively, to show the differing states of the rotatable capstan body part 469 and elastically deformable biasing element 480.PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304

[0068] FIGs.7A and 7B depict the capstan assembly 430 and decoupling mechanism 460 in astate in which the actuation member 450 is in tension (paid in) to actuate an actuatable component to which it is coupled. In this state the elastically deformable biasing element 480 is compressed and the distance between the radially inwardly extending surfaces 474 and 473’ is at a minimum separation distance. As can be seen with reference to FIG.7A, the end of the lateral wall 472 abuts surface 473’ (is bottomed out) in this state as well, as reflected by arrow S1. The opposite end of lateral wall 472 where the radially inwardly extending surface 474 is, on the other hand, is spaced by a gap G from the radially inwardly extending surface 473’’ of the arc segment 473.

[0069] In the state of FIGs. 7A and 7B, the rotatable capstan body portion 468 is held in theposition shown due to tension in the actuation member 450. Rotation of the input drive shaft 441 in direction C shown in FIG.7B, causes rotation of fixed capstan body part 469 in the same direction. Due to the abutment between the stop surface 473’ and lateral wall 472, rotation of the fixed capstan body part 469 in turn drives rotation of the rotatable capstan body part 468 in direction C, which causes actuation member 450 to be further paid in in the tensioned state, thereby enabling it to transmit force to the actuatable component (not shown). As fixed capstan body part 469 rotates in direction C, actuation member 451 is paid out and not actively transmitting force to actuate the actuatable component. Thus, in the state of FIGs.7A and 7B, the rotatable capstan body part 468 is in a fixed rotational relationship with the input drive shaft 441, the fixed capstan body part 469, and actuation member receiving portion 439.

[0070] FIGs.8A and 8B depict the capstan assembly 430 and decoupling mechanism 460 in astate in which the actuation member 451 is in tension and being paid in to actuate the actuatable component to which it is coupled. In this state, the direction of rotation of the input drive shaft 441, and thus the fixed rotatable capstan body part 469 and actuation member receiving portion 439, is in the direction reflected by arrow D, which is opposite to direction C in FIGs.7A and 7B. In this direction of rotation, due to tension still exerted by the actuation member 450, the rotatable capstan body part 468 and actuation member receiving portion 438 can rotate at least initially in direction D, which pays out the actuation member 450.

[0071] As such paying out of actuation member 450 occurs, tension is released on theactuation member 450, which can lead to a slack condition. Upon the slack condition occurring (a reduction in tension in actuation member 450 to a sufficient level), the force exerted by thePCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304actuation member 450 acting to keep the elastically deformable biasing element 480 and the rotatable capstan body part 468 in the position of FIGs.7A and 7B is released. This causes the biasing element 480 to return to its biased, relatively uncompressed, elongated state. In so doing, the biasing element 480 exerts a force on the surface 474 pushing it away from surface 473 and thereby causing rotatable capstan body part 468 to rotate differentially in direction C again (opposite direction D) relative to the input drive shaft 441, fixed capstan body part 469, and actuation member receiving portion 439.

[0072] The biasing element 480 can rotate rotatable capstan body part 468 in direction C untilthe surface 474 abuts and bottoms out at surface 473’’ as shown by arrow S2. In this state the distance between the radially inwardly extending surfaces 474 and 473’ is at a maximum separation distance (as measured in the direction C). As can be seen with reference to FIGs.8A and 8B, the end of the lateral wall 472 is spaced by the gap G from the radially inwardly extending surface 473’ of the arc segment 473.

[0073] In the state of FIGs. 8A and 8B, the rotatable capstan body part 468 is free todifferentially rotate about the input drive shaft 441 and relative to the fixed capstan body part 469 and actuation member receiving portion 439. Rotation of the actuation member receiving portion 438 in direction C in this state allows the actuation member 450 to be paid in, thereby removing slack, without affecting additional paying in or the state of tension of actuation member 451. In other words, in the state of FIGs.8A and 8B, the decoupling mechanism 460 decouples the rotation of rotatable capstan body part 468 from the input drive shaft 441, the fixed capstan body part 469, and actuation member receiving part 439. This decoupling of the rotation allows for slack removal in the actuation member 450 not actively transmitting force to actuate the actuatable component without affecting the ability of the actuation member 451 to be paid in to transmit the force to actuate the actuatable component in the degree of freedom associated with that actuation member 451.

[0074] As discussed above, limiting the overall rotation of the rotatable capstan body part 468and actuation member receiving portion 438 in direction C, e.g., through use of the stop surface 473’’, provides a limit on the paying in and amount of tension that will be applied to actuation member 450 so as to not affect actuation of the actuatable component based on force transmitted by the actuation member 450.PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304

[0075] Upon rotating input drive shaft 441 in direction C again, when it is desired to actuate theactuatable component in the second degree of freedom movement via tensioning actuation member 450 and paying out actuation member 451, the fixed capstan body part 469 will rotate in direction C to cause surface 473’ to abut lateral wall 472. The paying in of tension member 450 to actuation member receiving portion 438 will again increase the tension of the actuation member 450 to a level that will cause rotatable capstan body part 468 and fixed capstan body part 469 to rotate together, with a force sufficient to keep the elastically deformable element 480 compressed, as in the state in FIGs.7A and 7B.

[0076] Referring now to FIG.9, another example workflow 900 for removal of slack in anactuation member using various of the implementations of rotary drive mechanisms described herein, including the implementations of FIGs.4-8B and instruments and systems utilizing the same, is illustrated. The workflow 900 of FIG.9 includes at action 902 rotation of a first capstan body part of a capstan assembly operably coupled to an input rotary drive device in a first direction, causing a first actuation member to be paid in and be placed in tension. At action 904, a second capstan body part of the capstan assembly is rotated in the first direction by the first capstan body part, causing a second actuation member to be paid out from the capstan assembly. At action 906, in response to the paying out of the second actuation member, tension in the second actuation member is decreased. Upon decreasing of the tension to a sufficient level (slack developing), the second capstan body part is caused to rotate in a second direction opposite the first direction and relative to the first capstan body part, thereby causing the second actuation member to be paid in to the capstan assembly. In various implementations, as noted above, the paying in of the second actuation member at action 906 is limited to an amount that will not increase the tension of the second actuation member to a level for transmission of an actuation force to the actuate an actuatable component.

[0077] While the various rotary drive mechanisms and capstan assemblies can be utilized in avariety of applications for the removal of slack, one such application includes an instrument in which the rotary drive mechanism is part of an overall force transmission mechanism configured to transmit actuation forces along a shaft of the instrument to one or more actuatable components located distally along the shaft, such as one or more articulable segments along the shaft and / or an end effector of the instrument. Instruments of this type can be configured for remote actuation of the actuatable components via the force applied to drive inputs of the force transmission mechanism, whether manually or via a computer-assisted manipulator system, asPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304described further below. Instruments of this type can be medical instruments configured for minimally invasive surgical, diagnostic, or therapeutic procedures, or can be other types of industrial instruments that perform a variety of procedures, such as inspection or other procedure, at a worksite.

[0078] Referring now to FIGs.10A and 10B, a schematic, side view of an instrument 1000according to some embodiments of the disclosure is shown in FIG.10A, with a plan view showing an implementation of a drive interface of a force transmission system 1010 shown in FIG.10B. Instrument 1000 can be or include an instrument used to perform medical (e.g., surgical, diagnostic, and / or therapeutic) or non-medical procedures (e.g., industrial inspection applications). The instrument 1000 includes a shaft 1024 elongated along a longitudinal axis AL, between proximal end portion 1001 and distal end portion 1002. In implementations in which the instrument is a medical instrument, such as for use in minimally-invasive medical procedures, the shaft 1024 is on the order of a few millimeters in diameter, for example from five to eight millimeters in diameter. Those having ordinary skill in the art would appreciate that the scale of the mechanisms in such a medical instrument can create 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.

[0079] The instrument 1000 further includes an end effector 1020 coupled to the distal endportion 1002 and a force transmission system 1008 (only the exterior housing portion of which is depicted) coupled to the proximal end portion 1001. The end effector 1020 is configured to carry out a medical or non-medical (such as industrial) procedure. For example, the end effector 1020 can include one or more tools such as gripping tools, staplers, shears, ligation clip appliers, electrosurgical tools, ultrasonic tools, suturing tools, translating sleds, translating cutting tools, or other types of tools. While the illustration of FIG. 10A depicts an end effector 1020 having jawmembers 1028 configured to move toward and away from each other (either by one or both jaw members pivoting about a pivot axis), such a configuration is exemplary and non-limiting and those of ordinary skill in the art would appreciate the instrument 1000 can have any of a variety of end effectors without departing from the scope of the present disclosure.

[0080] In FIG.10A, the instrument 1000 further optionally includes an articulable component1030 coupling the end effector 1020 to the shaft 1024. As shown in FIG.1, the articulablePCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304structure 1030 can be positioned along the distal end portion 1002 of the shaft 1024. But the disclosure is not so limited and the articulable structure 1030 can be positioned at any location along the shaft 1024 without limitation. In addition, the instrument 1000 can include more than one articulable structure 1030, such as two, three, or more articulable structures located in series or at multiple spaced apart locations along the length of the shaft 1024. The articulable structure 1030 can be controlled and actuated via actuation members (not illustrated in FIG. 10A), such as pull-pull type or push-pull type actuation members as described herein, operably coupled to one or more drive components of the force transmission system 1008, and thus able to be actuated via a manipulator through the force transmission system. In various embodiments, as those having ordinary skill in the art would be familiar with, an articulable structure can serve as a wrist mechanism supporting and coupling the end effector 1020 to the shaft 1024 so as to allow orientation of the end effector 1020 relative to the shaft in pitch and / or yaw.

[0081] In the embodiment of FIGs.10A and 10B, the force transmission system 1008 is coupledto the proximal end portion 1001 of the shaft 1024. In other embodiments, the force transmission system 1008 may be coupled at various locations along the shaft 1024, and in some cases moveable along the shaft, but generally in a position such that it remains external to a remote site (such as a patient’s body) at which the end effector 1020 and a distal end portion 1002 of the shaft 1024 are inserted to perform a procedure, thereby permitting access to manipulate inputs on the force transmission system 1008.

[0082] Force transmission system 1008 includes a housing 1025 supporting an input driveportion 1026. Input drive portion 1026 includes a drive interface 1027. Drive interface 1027 provides mechanical connections to the other control features of force transmission system 1008, such as various output drives configured to be operated to transmit force to control the moveable components and operations at the distal end portion 1002 of the instrument 1000. In the implementation of FIGs.10A and 10B, drive interface 1027 is configured to couple to a manipulator system, such as those described further below.

[0083] As shown in FIG.10B, drive interface 1027 includes a plurality of input drive devices1032, each of which can control a different aspect of movement of the movable components (e.g., articulable structures, end effector components) of the instrument 1000. Of course, more or less input drive devices 1032 can be provided in different implementations. When drivePCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304interface 1027 is coupled to a manipulator of a manipulator system, each of drive input devices 1032 interfaces with an actuator that drives the steering input. In this example, drive input devices 1032 are configured to form a direct mechanical engagement with respective rotary actuators (e.g., servo motors) of a manipulator of a manipulator system. However, other suitable configurations for power transmission can also be used (e.g., indirect mechanical couplings including speed and / or torque converters, fluid couplings, and / or electrical couplings).

[0084] In an implementation, one of the input drive devices 1032 can be an input drive device(such as 140, 240, 440 of the rotary drive mechanisms described herein) and that drives rotation of an input drive shaft (such as input drive shaft 241, 441) so as to pay in / pay out an actuation member (such as actuation member 150, 250, 251, 450, 451) and thereby control movement of end effector 1020 or other moveable component of the instrument 1000.

[0085] In one implementation, the present disclosure contemplates the various rotary drivemechanisms of the embodiments described above, such as the embodiment of FIGs.4-8B, operably coupled to drive the opening / closing movement of the jaws 1028 to provide a gripping force. For example, the actuation member operably coupled to the rotatable capstan body parts and corresponding actuation member receiving portion (such as actuation member 250, 450) can be coupled to the jaws 1028 to actuate a grip open degree of freedom movement (pivoting of the jaw members away from each other) of the jaws 1028, and the actuation member operably coupled to the fixed capstan body part and corresponding actuation member receiving portion (such as actuation member 251, 451) can be coupled to the jaws 1028 to actuate a grip close degree of freedom movement (pivoting of the jaw members toward each other).

[0086] In using the various rotary drive mechanisms described herein, and the capstanassemblies that allow for differential motion, such as capstan assemblies 230, 430, slack can be removed from the actuation member configured to actuate the grip open degree of freedom motion (e.g., actuation members 250, 450) when the actuation member controlling the grip closed degree of freedom motion is being actuated (e.g., actuation members 251, 451), without impacting the grip closure even though the actuation receiving member portions of the capstan assembly are operably coupled to the same input drive device.

[0087] The various implementations herein that provide the ability to selectively couple anddecouple the movement of the actuation member receiving portion that pays the actuation member associated with actuation of the grip open degree of freedom motion allows for aPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304reduced number of parts, ease of manufacture, and a relatively minimal space requirement than may be used in other arrangements. Further, the ability to remove the slack from the actuation member can reduce wear and tear on the actuation member, responsiveness of actuation of grip open, and / or prevent misrouting or other undesirable interference of the actuation member with other components.

[0088] Various implementations provide the selective decoupling and slack removal on a gripopen actuation member (actuation member controlling the grip open degree of freedom) because the grip closed actuation member (actuation member controlling the grip closed degree of freedom) may be stretched and over driven so as to provide a high grip force, thereby leading to the generation of slack in the grip open cable. Such overdrive on the grip open cable may not be needed and thus there may be no need to provide slack removal on the grip close actuation member, however, in other embodiments such slack removal may be desirable and one having ordinary skill in the art would understand how to modify embodiments described herein to achieve the same based on the principles of operation described herein.

[0089] As discussed above, in accordance with various embodiments, force transmissionsystems of the present disclosure are configured for use in teleoperated, computer-assisted surgical systems employing robotic technology (sometimes referred to as robotic surgical systems). Referring now to FIG.11, an embodiment of a manipulator system 1100 of a computer-assisted surgical system, to which surgical instruments are configured to be mounted for use, is shown. Such a surgical system may further include a user control system, such as a surgeon console (not shown) for receiving input from a user to control instruments coupled to the manipulator system 1100, as well as an auxiliary system, such as auxiliary systems associated with the da Vinci® systems noted above.

[0090] As shown in the embodiment of FIG.11, the manipulator system 1100 includes a base1120, a main column 1140, and a main boom 1160 connected to the main column 1140. Manipulator system 1100 also includes a plurality of manipulator arms 1110, 1111, 1112, 1113, which are each connected to the main boom 1160. Manipulator arms 1110, 1111, 1112, 1113 each include an instrument mount portion 1122 to which an instrument 1000 may be mounted, which is illustrated as being attached to the manipulator arm 1110. While the manipulator system 1100 of FIG.11 is shown and described having a main boom 1160 to which the plurality of manipulator arms 1110, 1111, 1112, 1113 are coupled and supported thereby, in otherPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304embodiments, the plurality of manipulator arms 1110, 1111, 1112, 1113 can be coupled and supported by other structures, such as an operating table, a ceiling, wall, or floor of an operating room, etc.

[0091] Instrument mount portion 1122 comprises a drive output assembly 1123 and a cannulamount 1124, with a transmission mechanism 1108 (which may generally correspond to the force transmission system 1008 discussed in connection with FIGs.10A and 10B of the instrument 1000 connecting with the drive output assembly 1123, according to an embodiment. Cannula mount 1124 is configured to hold a cannula 1136 through which a shaft of instrument 1130 may extend to a surgery site during a surgical procedure. Drive output assembly 1123 contains a variety of drive and other mechanisms that are controlled to respond to input commands at the surgeon console and transmit forces to the transmission mechanism 1134 to actuate the instrument 1130. Although the embodiment of FIG.13 shows an instrument 1130 attached to only manipulator arm 1010 for ease of viewing, an instrument may be attached to any and each of the manipulator arms 1110, 1111, 1112, 1113.

[0092] Other configurations of surgical systems, such as surgical systems configured for single-port surgery, are also contemplated.

[0093] Embodiments described herein may be used, for example, with remotely operated,computer-assisted systems (such, for example, teleoperated surgical systems) such as those described in, for example, U.S. Patent No.9,358,074 (filed May 31, 2013) to Schena et al., entitled “Multi-Port Surgical Robotic System Architecture”, U.S. Patent No.9,295,524 (filed May 31, 2013) to Schena et al., entitled “Redundant Axis and Degree of Freedom for Hardware- Constrained Remote Center Robotic Manipulator”, and U.S. Patent No.8,852,208 (filed August 12, 2010) to Gomez et al., entitled “Surgical System Instrument Mounting”, each of which is hereby incorporated by reference in its entirety. Further, embodiments described herein may be used, for example, with various da Vinci® Surgical Systems, commercialized by Intuitive Surgical, Inc., of Sunnyvale, California.

[0094] The embodiments described herein are not limited to the surgical systems noted above,and various other teleoperated, computer-assisted surgical and manipulator system configurations may be used with the embodiments described herein. Further, although various embodiments described herein are discussed in connection with a manipulating system of a teleoperated surgical system, the present disclosure is not limited to use with a teleoperatedPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304surgical system. Various embodiments described herein can optionally be used in conjunction with hand-held, manual instruments.

[0095] Other configurations of manipulator systems that can be used in conjunction with thepresent disclosure can use several individual manipulator arms. In addition, individual manipulator arms may include a single instrument or a plurality of instruments. Further, as discussed above, an instrument may be a surgical instrument with an end effector or may be a camera instrument or other sensing instrument utilized during a surgical procedure to provide information, (e.g., visualization, electrophysiological activity, pressure, fluid flow, and / or other sensed data) of a remote surgical site.

[0096] This description and the accompanying drawings that illustrate various embodimentsshould not be taken as limiting. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the scope of this description and the invention as claimed, including equivalents. In some instances, well-known structures and techniques have not been shown or described in detail so as not to obscure the disclosure. Like numbers in two or more figures represent the same or similar elements. Furthermore, elements and their associated features that are described in detail with reference to one embodiment may, whenever practical, be included in other embodiments in which they are not specifically shown or described. For example, if an element is described in detail with reference to one embodiment and is not described with reference to another embodiment, the element may nevertheless be claimed as included in the other embodiment.

[0097] For the purposes of this specification and appended claims, unless otherwise indicated,all numbers expressing quantities, percentages, or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about,” to the extent they are not already so modified. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0098] It is noted that, as used in this specification and the appended claims, the singular forms“a,” “an,” and “the,” and any singular use of any word, include plural referents unless expresslyPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

[0099] Further, this description’s terminology is not intended to limit the invention. For example,spatially relative terms—such as “beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, and the like—may be used to describe one element’s or feature’s relationship to another element or feature as illustrated in the figures. These spatially relative terms are intended to encompass different positions (i.e., locations) and orientations (i.e., rotational placements) of a device in use or operation in addition to the position and orientation shown in the figures. For example, if a device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be “above” or “over” the other elements or features. Thus, the exemplary term “below” can encompass both positions and orientations of above and below. A device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0100] Further modifications and alternative embodiments will be apparent to those of ordinaryskill in the art in view of the disclosure herein. For example, the devices and methods may include additional components or steps that were omitted from the diagrams and description for clarity of operation. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the present teachings. It is to be understood that the various embodiments shown and described herein are to be taken as exemplary. Elements and materials, and arrangements of those elements and materials, may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the present teachings may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of the description herein. Changes may be made in the elements described herein without departing from the spirit and scope of the present teachings and following claims.

[0101] It is to be understood that the particular examples and embodiments set forth herein arenon-limiting, and modifications to structure, dimensions, materials, and methodologies may be made without departing from the scope of the present teachings.

[0102] Other embodiments in accordance with the present disclosure will be apparent to thoseskilled in the art from consideration of the specification and practice of the invention disclosedPCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304herein. It is intended that the specification and examples be considered as exemplary only, with the following claims being entitled to their fullest breadth, including equivalents, under the applicable law.

Claims

PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304CLAIMS WHAT IS CLAIMED IS:

1. A drive system for controlling tension in an actuation member used to transmit actuation force, the drive system comprising: an input drive shaft having a longitudinal axis, the input drive shaft rotatable about the longitudinal axis; a capstan assembly comprising: a first capstan body part fixed in rotation with the input drive shaft, a second capstan body part coupled with the input drive shaft and the first capstan body part, the second capstan body part rotatable relative to the input drive shaft, a first actuation member receiving part fixed in rotation with the first capstan body part, and a second actuation member receiving part fixed in rotation with the second capstan body part; a first actuation member coupled to the first actuation member receiving portion and configured to be paid relative to the first actuation member receiving portion; and a second actuation member coupled to the second actuation member receiving portion and configured to be paid relative to the second actuation member receiving portion, wherein in a state of tension of the second actuation member in response to being paid in to the second actuation member receiving portion so as to transmit an actuation force, the first and second capstan body parts are rotatable together with the input drive shaft, and wherein in a state of slack of the second actuation member in response to the second actuation member being paid out from the second actuation member receiving portion and while the first actuation member is paid in to the first actuation member receiving portion and tensioned to transmit an actuation force, the first capstan body part is rotatable with thePCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304input drive shaft, and the second capstan body part is rotatable relative to the first capstan body part and the input drive shaft.

2. The drive system of claim 1, wherein in the state of slack of the second actuationmember, the second capstan body part is rotatable in a direction opposite the first capstan body part and the input drive shaft.

3. The drive system of claim 1, wherein the state of slack of the second actuation member,the second capstan body part is rotatable in a direction to pay in the second actuation member.

4. The drive system of claim 1, wherein the capstan assembly further comprises anelastically deformable biasing element coupled between the first capstan body part and the second capstan body part.

5. The drive system of claim 4, wherein the elastically deformable biasing element appliesa biasing force on the second capstan body part against a force applied by the second actuation member in the state of tension.

6. The drive system of claim 5, wherein the biasing force is sufficient to rotate the secondcapstan body part relative to the first capstan body part and the input drive shaft in the state of slack of the second actuation member.

7. The drive system of claim 1, wherein the first capstan body part comprises stop surfacesarranged to limit rotation of the second capstan body part relative to the first capstan body part.

8. The drive system of claim 1, wherein the first and second actuation members are pull-pull type actuation members.

9. The drive system of claim 1, wherein the first and second actuation members are chosenfrom cables, filaments, or wires.

10. The drive system of claim 1, wherein the first and second actuation member receiving portions comprise helical grooves configured to guide paying in the first and second actuation members, respectively.

11. A capstan assembly for controlling tension in actuation members, the capstan assembly comprising: a first capstan body part;PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304a second capstan body part coupled to the first capstan body part and rotatable relative to the first capstan body part; a first actuation member receiving portion fixed in rotation with the first capstan body part and configured to provide a surface to pay in an actuation member; a second actuation member receiving portion fixed in rotation with the second capstan body part and configured to provide a surface to pay in an actuation member; and an elastically deformable biasing element coupled between the first capstan body part and the second capstan body part, the elastically deformable biasing element having a compressed state in a first position of rotation of the second capstan body part relative to the first capstan body part and an expanded state in a second position of rotation of the second capstan body part relative to the first capstan body part.

12. The capstan assembly of claim 11, wherein the first capstan body part comprises stop surfaces defining a range of rotation of the second capstan body part relative to the first capstan body part.

13. The capstan assembly of claim 11, wherein the first capstan body part and the second capstan body part form a generally annular, cylindrical structure configured to receive a rotatable drive shaft.

14. The capstan assembly of claim 13, wherein the elastically deformable biasing element is a coil spring extending at least partially around a longitudinal axis of the annular, cylindrical structure.

15. The capstan assembly of claim 13, wherein the first capstan body part has a split ring configuration.

16. The capstan assembly of claim 15, wherein the first capstan body part comprises a through hole configured to receive a securing device to secure the first capstan body part to a rotatable drive shaft received by the annular, cylindrical structure.

17. The capstan assembly of claim 16, wherein the first capstan body part fixes an axial position of the second capstan body part in a secured position of the first capstan body part to the rotatable drive shaft received by the annual, cylindrical structure.PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.0030418. A method of controlling tension in actuation members used to transmit actuation force, the method comprising: rotating a first capstan body part of a capstan assembly in a first direction, thereby causing a first actuation member to be paid into the capstan assembly so as to tension a first actuation member; causing a second capstan body part of the capstan assembly to rotate in the first direction by rotation of the first capstan body part, thereby causing a second actuation member to paid out from the capstan assembly; and in response to the paying out of the second actuation member and tension in the second actuation member decreasing to a sufficient level, causing the second capstan body part to rotate in a second direction opposite the first and relative to the first capstan body part, thereby causing the second actuation member to be paid in to the capstan assembly.

19. The method of claim 18, further comprising limiting a range of rotation of the second capstan body part relative to the first capstan body part.

20. The method of claim 18, wherein rotating the first capstan body part occurs via rotation of an input drive shaft in a fixed rotational relationship with the first capstan body part.

21. The method of claim 20, wherein rotating the second capstan body part in the second direction comprises rotating the second capstan body part relative to the input drive shaft.

22. The method of claim 18, further comprising: rotating the first capstan body part in the second direction thereby causing the first actuation member to be paid out from the capstan assembly and tension to decrease in the first actuation member; and rotating the second capstan body part in the second direction with rotation of the first capstan body part thereby causing the second actuation member to be paid in and be placed in tension.

23. The method of claim 22, wherein:PCT PATENT APPLICATIONATTORNEY DOCKET NUMBER: P06850-WOJONES ROBB DOCKET NO.1084.0242.00304rotating the first capstan body part in the first direction tensions the first actuation member thereby actuating movement of an actuatable component in a first degree of freedom; and rotating the second capstan body part in the second direction with rotation of the first capstan body part in the second direction tensions the second actuation member thereby actuating movement of an actuatable component in a second degree of freedom.

24. The method of claim 23, wherein rotating the second capstan body part in the second direction relative to the first capstan body part tensions the actuation member to remove slack.

25. An instrument comprising: a shaft; an end effector comprising an actuatable component coupled to the shaft; and the drive system of claim 1 coupled to the shaft, wherein the first actuation member is operably coupled to the actuatable component and configured to actuate movement of the actuatable component in a first degree of freedom in response to the first actuation member being paid in and placed in tension, and wherein the second actuation member is operably coupled to the actuatable component and configured to actuate movement of the actuatable component in a second degree of freedom in response to the second actuation member being paid in and placed in tension.

26. The instrument of claim 25, wherein the actuatable component comprises jaws, and the first degree of freedom is opening movement of the jaws and the second degree of freedom is closing movement of the jaws.

27. The instrument of claim 25, wherein the drive system comprises an input rotary drive device.

28. The instrument of claim 27, wherein the input drive device is configured to engage with and receive a rotary drive force from a drive output of a manipulator.

29. The instrument of claim 28, further comprising a drive interface comprising the input drive device, the drive interface configured to removably mount the instrument to the manipulator.

Images