Variable angle drill

Abstract

An instrument assembly for use with a high-speed surgical instrument for use in cutting bone includes a motor housing having a motor operably disposed therein, the motor including a motor drive shaft. An attachment member is configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof. A proximal end of the flexible drive shaft is configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing. A surgical tool including a tool shaft is configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

Description

VARIABLE ANGLE DRILL

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 693,386, filed 11 September 2024, the entire content of which is incorporated herein by reference. FIELD

[0002] The present disclosure relates to surgical systems for bone cutting or bone shaping, and, more particularly, to surgical instruments for cutting and shaping bone. BACKGROUND

[0003] A surgical instrument for cutting or shaping bone typically includes a motor housing with a grip, a surgical attachment, and a surgical tool. The surgical attachment and the surgical tool may be interchangeable with other surgical attachments and surgical tools. The surgical attachment connects to the motor housing and engages with a motor disposed therein configured to rotate, oscillate or otherwise move the surgical tool upon activation of the motor. The surgical tool typically includes an elongated shaft and a surgical cutting head or bur attached at a distal end thereof (or integrally associated therewith). The elongated shaft extends from the surgical bur, engages with the surgical attachment and is axially rotated, oscillated or otherwise moved upon actuation of the motor.

[0004] Such surgical instruments typically include a straight surgical attachment coupled to a motor to provide torque to the tool to rotate the surgical bur during an operation. An attachment member holds the tool relative to the motor typically by a collet having various gears and connection portions that transfer torque from the motor to the tool. The attachment member may provide various features, such as a bore diameter, length, angle, and the like to allow selecting the tool to be operated by the motor. Further, the attachment member may include stiffness modification and / or damping features such as damping members, thicknesses, and the like to minimize and / or reduce vibration at a tool tip (e.g., surgical bur) and caused by the tool that may be felt and received by a user.

[0005] In surgical instruments which include an angled connection between the motor shaft and the attachment shaft, complex miter gear connections are typically utilized to transfer the torque. Complimentary miter gearing may not be as effective as a straight connection especially under high torque loads, higher rotational speeds or higher angles, may not be as effective in transferring the torque between the motor shaft and the attachment shaft, and may produce unnecessary amount of heat. These can all lead to reduced life of the surgical instrument.

[0006] As a result, manufacturing a surgical instrument with a more effective connection between the motor shaft and the attachment shaft would be an improvement in the field. SUMMARY

[0007] Provided in accordance with aspects of the present disclosure is an instrument assembly for use with a high-speed surgical instrument for use in cutting bone. The instrument assembly includes a motor housing having a motor operably disposed therein, the motor including a motor drive shaft. An attachment member is configured to selectively couple to the housing, and includes a drive assembly having a flexible drive shaft at a proximal end thereof. A proximal end of the flexible drive shaft is configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing. A surgical tool including a tool shaft is configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

[0008] In aspects in accordance with the present disclosure, the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

[0009] In aspects in accordance with the present disclosure, the attachment member is disposed at an angle relative to the motor housing. In other aspects in accordance with the present disclosure, the angle between the motor housing and the attachment member ranges from about zero degrees to about forty (40) degrees. In still other aspects in accordance with the present disclosure, the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

[0010] In aspects in accordance with the present disclosure, the instrument assembly further includes an adjustment assembly configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing. In other aspects in accordance with the presentdisclosure, the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty (40) degrees.

[0011] In aspects in accordance with the present disclosure, the adjustment assembly includes a lead screw disposed atop the motor housing, the lead screw rotatable to selectively adjust the angle of the attachment member relative to the motor housing.

[0012] In aspects in accordance with the present disclosure, a linkage is disposed between the motor housing and the attachment member to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0013] In aspects in accordance with the present disclosure, a body joint is disposed within the attachment member and is configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0014] In aspects in accordance with the present disclosure, a linkage connection is disposed on the attachment member and is configured to operably connect to the linkage about a pivot.

[0015] Provided in accordance with aspects of the present disclosure is an instrument assembly for use with a high-speed surgical instrument for use in cutting bone. The instrument assembly includes a motor housing having a motor operably disposed therein, the motor including a motor drive shaft. An attachment member is configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof. A proximal end of the flexible drive shaft is configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing. An adjustment assembly is configured to facilitate selective adjustment of the angle of attachment of the attachment member relative to the motor housing, the adjustment assembly including a linkage pivotably connected at a proximal end to the motor housing and pivotably attached at a distal end to the attachment member. A surgical tool is included having a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

[0016] In aspects in accordance with the present disclosure, the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

[0017] In aspects in accordance with the present disclosure, the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty (40 degrees.

[0018] In aspects in accordance with the present disclosure, the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

[0019] In aspects in accordance with the present disclosure, the adjustment assembly includes a lead screw disposed atop the motor housing, the lead screw rotatable to selectively adjust the angle of the attachment member relative to the motor housing.

[0020] In aspects in accordance with the present disclosure, a body joint is disposed within the attachment member and is configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0021] In aspects in accordance with the present disclosure, a linkage connection is disposed on the attachment member and is configured to operably connect to the linkage about a pivot.

[0022] Provided in accordance with aspect of the present disclosure is an instrument assembly for use with a high-speed surgical instrument for use in cutting bone. The instrument assembly includes a motor housing having a motor operably disposed therein, the motor including a motor drive shaft. An attachment member is configured to selectively couple to the housing, the attachment member including a drive assembly having a drive shaft at a proximal end thereof. A proximal end of the drive shaft is configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing. A surgical tool is included and has a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the drive shaft to the tool shaft upon activation of the motor, the tool shaft including proximal and distal portions that pivotably couple to one another about a hinged connection. An adjustment assembly is configured to facilitate selective adjustment of an angle between the distal portion relative to the proximal portion of the tool shaft about the hinged connection.

[0023] In aspects in accordance with the present disclosure, the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty (40) degrees in a first direction and about zero degrees to about forty (40) degrees in an opposite direction.DESCRIPTION OF THE DRAWINGS

[0024] The above and other aspects and features of the present disclosure will become more apparent in view of the following detailed description when taken in conjunction with the accompanying drawings wherein like reference numerals identify similar or identical elements.

[0025] FIG.1 is a perspective view of a prior art micro-burring surgical instrument with an in- line connection between a shaft of an attachment member and a motor;

[0026] FIG. 2 is a side view of an attachment member in accordance with a prior art micro- burring instrument;

[0027] FIG.3A is an enlarged view of the attachment member of FIG.2;

[0028] FIG.3B is an internal, cross-sectional view of the attachment member of FIG.2;

[0029] FIG.4 is an internal, cross-sectional view of the attachment member in accordance with the present disclosure showing a flexible drive shaft;

[0030] FIG. 5 is an internal, cross-sectional view of another embodiment of an attachment member in accordance with the present disclosure showing a flexible drive shaft with an adjustment assembly;

[0031] FIGS. 6A-6C are various side views of an attachment member in accordance with another embodiment of an attachment member and adjustment assembly according to the present disclosure highlighting the range of articulation of the attachment member; and

[0032] FIGS. 7A-7B are enlarged, side views of a surgical tool for use with the adjustment mechanism of FIGS.6A-6C.

[0033] FIG.8 shows a robotic surgical system according to another embodiment of the present disclosure.

[0034] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0035] Example embodiments will now be described more fully with reference to the accompanying drawings and with initial reference to FIGS. 1 and 2, wherein an instrument assembly 10 is illustrated. Instrument assembly 10 can be similar to one or more known instrument assemblies used to resect tissue (e.g., bone or other hard tissue structures), for example the Straightshot®M4 Microdebrider powered handpiece or the Midas Rex® Legend EHS Stylus®High-Speed Surgical Drill, which may be selectively used for ear-nose-throat (ENT) or neurosurgery, sold by Medtronic. Instrument assembly 10 includes a motor housing 16 that extends along an axis 20b and may have various angled or ergonomically shaped portions as described below.

[0036] Housing 16 includes a motor 17 disposed therein having a collet assembly 18 composed of various gears and components to operably connect the motor 17 with a surgical tool, e.g., surgical bur 55 (FIGS.7A-7C). Bur 55 includes a working end 52 and a stem 54. The working end 52 may include a surgical bur, a surgical drill bit, a resection tool, or other appropriate working surgical tool. Motor 17 is configured to regulate torque to the working end 52 through the shaft 54 via an interconnection within the collet 18.

[0037] Instrument assembly 10 also includes an attachment member 40 including an attachment base or housing 30 and an attachment shaft / tube 34 including a bore 42 defined therethrough that extends from a proximal end 35 to a distal end 37 (FIG. 6A). The attachment base 30 is selectively removable from motor housing 16 and the attachment shaft / tube 34 is selectively removeable from the base 30 via any known removeable coupling in the art. Attachment member 40 may be disposed at an angle alpha (α) relative to the motor housing 16 defined by an axis 20a extending through shaft / tube 34 and base 30 and an axis 20b extending through motor housing 16. The angle α between the two axes 20a and 20b may be selected based upon a selected procedure and may further include movable interconnections to provide power to the bur 55 from the motor 17 through the angled region.

[0038] As mentioned above, the attachment member 40 may be selectively coupled to the motor housing 16 via any known coupling in the art. Moreover, the surgical tool, e.g., bur 55, may be selectively coupled to the attachment member 40 at distal end of base 30. FIG.2A shows one such connection which includes a first twist lock connection 27a which couples the attachment member 40 to the motor housing 16. A second twist lock connection 27b connects the surgical tool 55 to the attachment member 40. A shaft / tube exposure actuator 27c may be included to regulate the exposure of the tube 34 relative to the attachment member.

[0039] With reference to FIGS. 3A-3B, the attachment member 40 is discussed in greater detail. Attachment member 40 includes the generally cylindrical exterior attachment shaft / tube 34 that is engaged within the attachment base 30. Inner bore 42 (FIG.7A) is formed by an internal annular wall that varies in diameter along the length of the bore 42 at selected regions, e.g.,proximal end 35 may have a greater diameter than distal end 37. The surgical tool shaft 54 is configured to operably couple to a drive assembly 22 disposed within the base 30. Drive assembly 22 includes a proximal end 22a which is configured to operably couple to a motor shaft 19 of motor 17 and a distal end 22b which is configured to operably couple to a proximal end 54a of the shaft 54 of surgical tool 55. Any known coupling method is envisioned.

[0040] More particularly, the motor shaft 19 includes a miter gear 19’ at a distal end thereof which is configured to operably mesh with a corresponding spring-loaded miter gear 23’ disposed at a proximal end of the drive assembly 22. By mitering the two gears 19’ and 23’ at complementary angles, the torque from the motor 17 can be transferred to the drive assembly 22 when base 30 is coupled to the motor housing 16. Since the miter gear 19’ of the motor 17 will likely remain fixed so that the motor housing 16 can accommodate a wide range of angles, miter gear 23’ needs to be appropriately angled to ensure a good mesh between the two gears 19’ and 23’ and to avoid excess heating at higher RPMs. Various lubricants may be employed to mitigate friction and heat between the two gears 19’ and 23’.

[0041] Turning now to FIG.4, an instrument assembly 100 is disclosed in accordance with the present disclosure which incorporates a flexible drive shaft 128 configured to transfer torque from the motor 17 to the drive assembly 122. More particularly, the flexible drive shaft 128 replaces the miter gear arrangement mentioned above and is configured to operably couple to the motor shaft 19 upon coupling the attachment base 130 to the motor housing 16. An opposite end of the flexible drive shaft 128 couples to the drive assembly 122 such that the flexible drive shaft 128 bends to accommodate the appropriate angle α between the attachment member 140 and the motor housing 16. The flexible drive shaft 128 may be solid (e.g., wire-like or cable) or in the form of a tube and may be made from a super-elastic nickel titanium alloy (e.g., Nitinol®) or braided steel. The flexible drive shaft 128 may include various end features, e.g., weld 128’, machined or welded thereon to facilitate interaction with the drive assembly 122 and / or the motor shaft 19.

[0042] Flexible drive shaft 128 allows the attachment member 140 to be variably-angled relative to the motor housing 16, e.g., axis 20a relative to axis 20b. As such, a single attachment member 140 may be utilized for variably-angled procedures. Moreover, the flexible drive shaft 128 reduces the overall number of components and the complexity of manufacturing the miter gears 19’ and 23’ mentioned above. Further, the flexible drive shaft 128 mitigates heat generation between the base 130 and the motor housing 16 which increases the life of the instrument assembly100. It is also envisioned that the flexible drive shaft 128 will reduce so-called “toggle” in the drive assembly, e.g., drive assembly 22, since spacing between complementary gear teeth is removed.

[0043] FIG. 5 shows one envisioned embodiment of an instrument assembly 200 having a variable angle adjustment assembly 275 configured to selectively allow adjustment of the attachment member 240 relative to the motor housing 16. Many of the features of instrument assembly 200 are similar to instrument assembly 100 and, for the purposes of brevity, only those features pertinent to instrument assembly 200 will be described in detail.

[0044] Instrument assembly 200 includes a flexible drive shaft 228 configured to transfer torque from the motor 17 to the drive assembly 222. Similar to instrument assembly 100, the flexible drive shaft 228 replaces the miter gear arrangement and is configured to operably couple to the motor shaft 19 upon coupling the attachment base 230 to the motor housing 16. Since the attachment member 240 may be selectively adjusted to affect any desired angle, the attachment base 230 may be permanently coupled to or integrally associated with the motor 17 depending upon a particular purpose. In embodiments where it is not desirable to integrally associate the motor 17 and the attachment base 230, a more sophisticated coupling arrangement may be utilized since the surgeon will not have to swap out differently-angled attachment members 240.

[0045] Similar to above, flexible drive shaft 228 may be solid (e.g., wire-like or cable) or in the form of a tube and may be made from super-elastic nickel titanium alloy (Nitinol®) or single or multi-layer braided steel. The flexible drive shaft 228 may include various end features, e.g., weld 128’, machined or welded thereon to facilitate interaction with the drive assembly 222 and / or the motor shaft 19.

[0046] The adjustment assembly 275 includes a lead screw assembly 277 operably disposed atop the motor housing 16 which is selectively translatable relative to the motor housing 16 upon rotation thereof. Lead screw assembly 277 includes an engagement sleeve 277a and a thumb actuator 277b. In embodiments, a simple lead screw arrangement may be employed or a lead screw collar may also be employed. Other types of screw assemblies are also envisioned, e.g., ball screw, or other linear motion mechanism, e.g., translating sleeve with detents at a particular angle may be utilized. Engagement sleeve 277a of lead screw assembly 277 is operably coupled to a linkage 278 about a first pivot 281a proximate to and in general registry with a movable body portion 235 disposed at the proximal end of the attachment base 230. Linkage 278 is configuredto span generally across the movable body joint 235 of attachment base 230 and is pivotably attached at a distal end thereof via a second pivot 281b to a linkage connection 279 which is disposed on the proximal end of attachment base 230. Linkage 278 is configured to allow attachment member 240 to selectively pivot relative to housing 16 about a body joint 229 disposed within a proximal end of the attachment base 230.

[0047] In use, a surgeon rotates the thumb actuator 277b of the lead screw assembly 277 to distally translate the engagement sleeve 277a which, in turn, forces linkage 278 to rotate about pivot 281a and forces the attachment member 240 to rotate about body joint 229 and change the angle α of the attachment member 240 relative to motor housing 16. The further the thumb actuator 277b of the lead screw assembly 277 is rotated, the greater the angle α. As can be appreciated, a user can selectively vary the angle α of the attachment member 240 without having to switch between preset angled attachment members, e.g., attachment member 40, 140, as described above. Moreover, during the course of the procedure, the user can vary the angle α as needed and change out surgical tools 20 without having to worry about the relative angle α of the attachment member 240.

[0048] In embodiments, the angle α may be selectively adjusted from about zero degrees to about forty (40) degrees depending upon a particular purpose. Moreover, the angle α may be changed intraoperatively increasing a surgeon’s flexibility and reducing manufacturing costs. As can be appreciated, this eliminates the need for additional attachment members 40, 140 in a given instrument portfolio.

[0049] Turning now to FIGS. 6A-6C, another embodiment of an instrument assembly 300 having a variable angle adjustment assembly 375 according to the present disclosure is shown. Adjustment assembly 375 is configured to selectively allow adjustment of a distal portion 37 of the instrument attachment shaft / tube 34 relative to a proximal portion 35 of the attachment shaft / tube 34. Many of the features of instrument assembly 300 are similar to instrument assembly 100 and, for the purposes of brevity, only those features pertinent to instrument assembly 300 will be described in detail.

[0050] Similar to instrument assembly 100, a flexible drive shaft, e.g., flexible drive shaft 228 may be utilized to replace the mitered gear arrangement of instrument assembly 100. The flexible drive shaft, e.g., flexible drive shaft 228, is configured to operably couple to the motor shaft 19 upon coupling the attachment base 330 to the motor housing 16. Since instrument assembly 300may be actuated to selectively adjust the angle α, the attachment member 340 may be permanently coupled to or integrally associated with the motor 17 and motor housing 16 depending upon a particular purpose. In embodiments where is not desirable to integrally associate the motor 17 and the attachment member 340, a more sophisticated coupling arrangement may be utilized since the surgeon will not have to swap out differently-angled attachment members 340.

[0051] The adjustment assembly 375 includes a lead screw 380 operably disposed atop attachment shaft / tube 34 which is selectively translatable relative to the attachment member 340 upon rotation thereof. Lead screw 380 is operably engaged to an engagement sleeve 377 which, upon translation of lead screw 380, correspondingly translates the engagement sleeve 377. Engagement sleeve 377, in turn, is operably coupled to a linkage 378 about a first pivot 381a proximate to and in general registry with a proximal end of a hinged portion 39 disposed proximate the distal portion 37 of the attachment shaft / tube 34. Linkage 378 is configured to span to the movable hinged portion 39 and is pivotably attached at a distal end thereof via a second pivot 381b to a linkage connection 379 which is disposed on the proximal end of hinged portion 39. Linkage 378 is configured to allow hinged portion 39 to selectively pivot relative to attachment shaft / tube 34 about a body joint 329 disposed within a proximal end of the hinged portion 39.

[0052] In use, a surgeon rotates lead screw 380 to distally translate the engagement sleeve 377 which, in turn, forces linkage 378 distally to rotate the hinged portion 39 about pivot 381a and change the angle α of the hinged portion 39 relative to attachment shaft / tube 34. The further lead screw 380 is rotated, the greater the angle α. As can be appreciated, a user can selectively vary the angle α of the hinged portion 39 without having to switch between preset angled attachment members, e.g., attachment member 40, 140, as described above. Moreover, during the course of the procedure, the user can vary the angle α as needed and change out surgical tools 20 without having to worry about the relative angle α of the attachment member 40, 140.

[0053] FIGS.6B and 6C show the various angles α that the hinged portion may be articulated depending on the rotation of the lead screw 380. More particularly, if the lead screw 380 is rotated in a counter-clockwise direction, the lead screw 380 will move proximally and, in turn, pull the engagement sleeve 377 proximally (FIG. 6B). When the engagement sleeve 377 moves proximally, the engagement sleeve 377 pulls the linkage 378 proximally which, in turn, pulls the linkage connection 379 proximally causing the hinged portion 39 to articulate in a first direction about body joint 329 relative to proximal portion 35, e.g., angle upwards. If the lead screw 380 isrotated in a clockwise direction, the lead screw 380 will move distally and, in turn, push the engagement sleeve 377 distally. When the engagement sleeve 377 moves distally, the engagement sleeve 377 pushes the linkage 378 distally which, in turn, pushes the linkage connection 379 distally causing the hinged portion 39 to articulate in a second direction about body joint 329 relative to proximal portion 35, e.g., angle downwards (FIG.6C).

[0054] In embodiments, the angle α may be selectively adjusted from about zero degrees to about forty (40) degrees in either direction (i.e., upwards or downwards) depending upon a particular purpose. Moreover, the angle α may be changed intraoperatively increasing a surgeon’s flexibility and reducing manufacturing costs. As can be appreciated, this eliminates the need for additional attachment members 40, 140 in a given instrument portfolio.

[0055] FIGS.7A and 7B show a surgical shaft / tube 54 for use with the adjustment assembly shown in FIGS.6A-6C. More particularly, shaft / tube 54 includes a shank configured to operably couple to the drive assembly, e.g., drive assembly 222, at a proximal portion 54a thereof and a surgical tool 55 configured to operably couple to a distal portion 54b thereof. A flexible portion 59 is disposed between the proximal portion 54a and distal portion 54b of the shank 54 and is pivotable about a body joint 59’ to facilitate movement of the distal portion 54b relative to the proximal portion 54a of shank 54.

[0056] Flexible portion 59 is configured to register and align with the body joint 329 shown when the surgical tool 55 is loaded into the distal end 42 of the shaft / tube 34 and engaged to the drive assembly (e.g., in a manner similar to above with respect to drive assembly 222 of FIG.5) and described above with respect to the embodiment shown in FIGS.6A and 6B. As such, when the hinged portion 39 is articulated relative to the proximal portion 35 of attachment shaft / tube 34, the of flexible portion 59 correspondingly articulates the distal portion 54b of the surgical tool 55 relative to the proximal portion 54a about the body joint 59’. This enables the surgeon to articulate the head, e.g., surgical bur 57, disposed at the end of the distal portion 54b as needed before or during surgery.

[0057] In aspects according to the present disclosure the distal end may be selectively angled to a desired orientation. Embodiments may include a flexible drive shaft portion (not shown) as part of the tool 55. Some of the above-described embodiments are configured to replace the miter gears but are not adjustable in angle and / or do not allow for the angle to be selected at the originallocation of the miter gears. A flexible drive shaft portion (not shown) would allow angular orientation at any desired angle. .

[0058] Robotic surgical system 1000 generally includes a plurality of robot arms 1002, 1003; a control device 1004; and an operating console 1005 coupled with control device 1004. Operating console 1005 may include a display device 1006, which may be set up in particular to display three-dimensional images; and manual input devices 1007, 1008, by means of which a clinician, e.g., a clinician, may be able to telemanipulate robot arms 1002, 1003 in a first operating mode. Robotic surgical system 1000 may be configured for use on a patient 1013 lying on a patient table 1012 to be treated in a minimally invasive manner. Robotic surgical system 1000 may further include a database 1014, in particular coupled to control device 1004, in which are stored, for example, pre-operative data from patient 1013 and / or anatomical atlases.

[0059] Each of the robot arms 1002, 1003 may include a plurality of members, which are connected through joints, and a mounted device which may be, for example, a surgical tool “ST.” The surgical tools “ST” may include, for example, the micro-burring instrument assemblies 100, 200 and 300 of the present disclosure, thus providing any of the above-detailed functionality on a robotic surgical system 1000.

[0060] Robot arms 1002, 1003 may be driven by electric drives, e.g., motors, connected to control device 1004. The motors, for example, may be rotational drive motors configured to provide rotational inputs to accomplish a desired task or tasks. Control device 1004, e.g., a computer, may be configured to activate the motors, in particular by means of a computer program, in such a way that robot arms 1002, 1003, and, thus, their mounted surgical tools “ST” execute a desired movement and / or function according to a corresponding input from manual input devices 1007, 1008, respectively. Control device 1004 may also be configured in such a way that it regulates the movement of robot arms 1002, 1003 and / or of the motors.

[0061] Control device 1004, more specifically, may control one or more of the motors based on rotation, e.g., controlling to rotational position using a rotational position encoder (or Hall effect sensors or other suitable rotational position detectors) associated with the motor to determine a degree of rotation output from the motor and, thus, the degree of rotational input provided.Alternatively or additionally, control device 1004 may control one or more of the motors based on torque, current, or in any other suitable manner.

[0062] Provided in accordance with the present disclosure is an instrument assembly for use with a high-speed surgical instrument for use in cutting bone, comprising: a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof, a proximal end of the flexible drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; and a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

[0063] In aspects in accordance with the present disclosure, the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

[0064] In aspects in accordance with the present disclosure, the attachment member is disposed at an angle relative to the motor housing.

[0065] In aspects in accordance with the present disclosure, the angle between the motor housing and the attachment member ranges from about zero degrees to about forty degrees.

[0066] In aspects in accordance with the present disclosure, the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

[0067] In aspects in accordance with the present disclosure, the instrument assembly further comprises an adjustment assembly configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0068] In aspects in accordance with the present disclosure, the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty degrees.

[0069] In aspects in accordance with the present disclosure, the adjustment assembly includes a lead screw disposed atop the motor housing, the lead screw rotatable to selectively adjust the angle of the attachment member relative to the motor housing.

[0070] In aspects in accordance with the present disclosure, a linkage is disposed between the motor housing and the attachment member facilitates selective adjustment of the angle of the attachment member relative to the motor housing.

[0071] In aspects in accordance with the present disclosure, a body joint is disposed within the attachment member and is configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0072] In aspects in accordance with the present disclosure, a linkage connection is disposed on the attachment member and is configured to operably connect to the linkage about a pivot.

[0073] Provided in accordance with the present disclosure is an instrument assembly for use with a high-speed surgical instrument for use in cutting bone, comprising: a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof, a proximal end of the flexible drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; an adjustment assembly configured to facilitate selective adjustment of an angle of attachment of the attachment member relative to the motor housing, the adjustment assembly including a linkage pivotably connected at a proximal end to the motor housing and pivotably attached at a distal end to the attachment member; and a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

[0074] In aspects in accordance with the present disclosure, the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

[0075] In aspects in accordance with the present disclosure, the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty degrees.

[0076] In aspects in accordance with the present disclosure, the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

[0077] In aspects in accordance with the present disclosure, the adjustment assembly includes a lead screw disposed atop the motor housing, the lead screw rotatable to selectively adjust the angle of the attachment member relative to the motor housing.

[0078] In aspects in accordance with the present disclosure, a body joint is disposed within the attachment member and is configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0079] In aspects in accordance with the present disclosure, a linkage connection is disposed on the attachment member and is configured to operably connect to the linkage about a pivot.

[0080] Provided in accordance with the present disclosure is an instrument assembly for use with a high-speed surgical instrument for use in cutting bone, comprising: a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a drive shaft at a proximal end thereof, a proximal end of the drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the drive shaft to the tool shaft upon activation of the motor, the tool shaft including proximal and distal portions pivotably couple to one another about a hinged connection; and an adjustment assembly configured to facilitate selective adjustment of an angle α between the distal portion of the tool shaft relative to the proximal portion of the tool shaft about the hinged connection.

[0081] In aspects in accordance with the present disclosure, the adjustment assembly is configured to adjust an angle between the motor housing and the attachment member from about zero degrees to about forty degrees in a first direction and about zero degrees to about forty degrees in an opposite direction.

[0082] While several aspects of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particularaspects. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

[0083] The techniques of this disclosure may also be described in the following examples:

[0084] Example 1. An instrument assembly for use with a high-speed surgical instrument for use in cutting bone, comprising:a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof, a proximal end of the flexible drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; and a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

[0085] Example 2. The instrument assembly according to example 1, wherein the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

[0086] Example 3. The instrument assembly according to example 1, wherein the attachment member is disposed at an angle relative to the motor housing.

[0087] Example 4. The instrument assembly according to example 3, wherein the angle between the motor housing and the attachment member ranges from about zero degrees to about forty degrees.

[0088] Example 5. The instrument assembly according to example 3, wherein the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

[0089] Example 6. The instrument assembly according to example 3, further comprising an adjustment assembly configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0090] Example 7. The instrument assembly according to example 6, wherein the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty degrees.

[0091] Example 8. The instrument assembly according to example 6, wherein the adjustment assembly includes a lead screw disposed atop the motor housing, the lead screw rotatable to selectively adjust the angle of the attachment member relative to the motor housing.

[0092] Example 9. The instrument assembly according to example 6, wherein a linkage is disposed between the motor housing and the attachment member facilitates selective adjustment of the angle of the attachment member relative to the motor housing.

[0093] Example 10. The instrument assembly according to example 6, wherein a body joint is disposed within the attachment member and is configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0094] Example 11. The instrument assembly according to example 6, wherein a linkage connection is disposed on the attachment member and is configured to operably connect to the linkage about a pivot.

[0095] Example 12. An instrument assembly for use with a high-speed surgical

[0096] instrument for use in cutting bone, comprising: a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof, a proximal end of the flexible drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; an adjustment assembly configured to facilitate selective adjustment of an angle of attachment of the attachment member relative to the motor housing, the adjustment assembly including a linkage pivotably connected at a proximal end to the motor housing and pivotably attached at a distal end to the attachment member; and a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

[0097] Example 13. The instrument assembly according to example 12, wherein the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

[0098] Example 14. The instrument assembly according to example 12, wherein the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty degrees.

[0099] Example 15. The instrument assembly according to example 12, wherein the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

[0100] Example 16. The instrument assembly according to example 12, wherein the adjustment assembly includes a lead screw disposed atop the motor housing, the lead screw rotatable to selectively adjust the angle of the attachment member relative to the motor housing.

[0101] Example 17. The instrument assembly according to example 12, wherein a body joint is disposed within the attachment member and is configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

[0102] Example 18. The instrument assembly according to example 12, wherein a linkage connection is disposed on the attachment member and is configured to operably connect to the linkage about a pivot.

[0103] Example 19. An instrument assembly for use with a high-speed surgical instrument for use in cutting bone, comprising: a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a drive shaft at a proximal end thereof, a proximal end of the drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the drive shaft to the tool shaft upon activation of the motor, the tool shaft including proximal and distal portions pivotably couple to one another about a hinged connection; and an adjustment assembly configured to facilitate selective adjustment of an angle α between the distal portion of the tool shaft relative to the proximal portion of the tool shaft about the hinged connection.

[0104] Example 20. The instrument assembly according to example 19, wherein the adjustment assembly is configured to adjust an angle between the motor housing and the attachment member from about zero degrees to about forty degrees in a first direction and about zero degrees to about forty degrees in an opposite direction.

Claims

WHAT IS CLAIMED:

1. An instrument assembly for use with a high-speed surgical instrument for use in cutting bone, comprising: a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof, a proximal end of the flexible drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; and a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

2. The instrument assembly according to claim 1, wherein the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

3. The instrument assembly according to claims 1 or 2, wherein the attachment member is disposed at an angle relative to the motor housing.

4. The instrument assembly according to claim 3, wherein the angle between the motor housing and the attachment member ranges from about zero degrees to about forty degrees.

5. The instrument assembly according to claims 3 or 4, wherein the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

6. The instrument assembly according to claims 3, 4 or 5 further comprising an adjustment assembly configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

7. The instrument assembly according to claim 6, wherein the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty degrees.

8. The instrument assembly according to claims 6 or 7 wherein the adjustment assembly includes a lead screw disposed atop the motor housing, the lead screw rotatable to selectively adjust the angle of the attachment member relative to the motor housing.

9. The instrument assembly according to claims 6, 7 or 8 wherein a linkage is disposed between the motor housing and the attachment member facilitates selective adjustment of the angle of the attachment member relative to the motor housing.

10. The instrument assembly according to claims 6, 7, 8, or 9 wherein a body joint is disposed within the attachment member and is configured to facilitate selective adjustment of the angle of the attachment member relative to the motor housing.

11. The instrument assembly according to claims 6, 7, 8, 9 or 10 wherein a linkage connection is disposed on the attachment member and is configured to operably connect to the linkage about a pivot.

12. An instrument assembly for use with a high-speed surgical instrument for use in cutting bone, comprising: a motor housing including a motor operably disposed therein, the motor including a motor drive shaft; an attachment member configured to selectively couple to the housing, the attachment member including a drive assembly having a flexible drive shaft at a proximal end thereof, a proximal end of the flexible drive shaft configured to selectively couple to the motor drive shaft upon engagement of the attachment member to the housing; an adjustment assembly configured to facilitate selective adjustment of an angle of attachment of the attachment member relative to the motor housing, the adjustment assemblyincluding a linkage pivotably connected at a proximal end to the motor housing and pivotably attached at a distal end to the attachment member; and a surgical tool including a tool shaft configured to selectively couple to a distal end of the drive assembly such that torque from the motor is transferred through the flexible drive shaft to the tool shaft upon activation of the motor.

13. The instrument assembly according to claim 12, wherein the flexible drive shaft is manufactured from at least one of a braided stainless-steel cable or a nickel titanium cable.

14. The instrument assembly according to claims 12 or 13 wherein the adjustment assembly is configured to adjust the angle between the motor housing and the attachment member from about zero degrees to about forty degrees.

15. The instrument assembly according to claims 12, 13 or 14 wherein the flexible drive shaft is configured to bend to accommodate the angle between the motor housing and the attachment member.

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