Surgical robotic system and method for tissue thickness measurement using a grasping instrument during stapling procedures

Abstract

A surgical robotic system for tissue thickness measurement using a grasping instrument during stapling procedures includes a robotic arm equipped with a grasping instrument operable in a first mode for tissue manipulation and a second mode for measuring tissue thickness. The system utilizes sensors to collect data on jaw position and motor torque during clamping and calculates tissue thickness based on this information. A stapling instrument, controlled by the same or another robotic arm, is then configured to deploy staples according to the measured tissue thickness. The system can select an appropriate stapler cartridge based on pre-set ranges associated with different tissue thicknesses. Additionally, the system may provide feedback to the user through a surgeon console, displaying the recommended stapler cartridge and guiding tissue measurement. This approach aims to improve precision in stapling procedures and optimize patient outcomes.

Description

Attorney Docket No.: A0012438W001SURGICAL ROBOTIC SYSTEM AND METHOD FOR TISSUE THICKNESS MEASUREMENT USING A GRASPING INSTRUMENT DURING STAPLING PROCEDURESCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 712,565 filed October 28, 2024, the entire contents of which is incorporated herein by reference.BACKGROUND

[0002] Surgical robotic systems are currently being used in a variety of surgical procedures, including minimally invasive medical procedures. Some surgical robotic systems include a surgeon console controlling a surgical robotic arm and a surgical instrument having an end effector (e.g., forceps, grasping instrument, surgical stapler, etc.) coupled to and actuated by the robotic arm. In operation, the robotic arm is moved to a position over a patient and then guides the surgical instrument into a small incision via a surgical port or a natural orifice of a patient to position the end effector at a work site within the patient’s body.

[0003] During surgical stapling, surgeons may select an appropriate stapler cartridge, e.g., reload, based on the thickness of the tissue to be stapled. This is often left to the surgeon’s best judgement based on their expertise and experience. But these are typically not as accurate and reliable as being able to measure and confirm the thickness of the tissue to be stapled. Some systems and methods for tissue thickness determination during surgery are known. However, there remains a need for a system and method that can provide tissue- thickness-feedback to a user so they can select an appropriate stapler cartridge (e.g., reload), particularly in robotic assisted surgery, based on feedback from the robotic tools themselves and associated sensors, and stored data related to those tools.SUMMARY

[0004] According to one embodiment of the present disclosure, a surgical robotic system is disclosed. The surgical robotic system includes a first robotic arm having a first instrument drive unit coupled to a grasping instrument that is operable in a first mode and a second mode. The first instrument drive unit includes one or more sensors configured to measure a parameter during operation of the grasping instrument. In the first mode, the grasping instrument is configured to perform a primary function and in the second mode the grasping instrument is configured to grasp tissue and measure tissue thickness. The system alsoAttorney Docket No.: A0012438W001 includes a second robotic arm having a second instrument drive unit coupled to a stapling instrument having a stapling cartridge with a plurality of staples. The system additionally includes a surgeon console including a display screen configured to display a graphical user interface. The system also includes a processor configured to load an attribute of the grasping instrument, switch the grasping instrument to the second mode, and operate the grasping instrument in the second mode to clamp tissue. The processor is further configured to calculate the tissue thickness based on the attribute of the grasping instrument and the measured parameter, select a stapler cartridge suitable for stapling tissue based on the calculated tissue thickness, and display the selected stapler cartridge on the display screen.

[0005] According to another embodiment of the present disclosure, a method for selecting a stapling cartridge is described. The method includes controlling, using a processor, a first robotic arm having a first instrument drive unit coupled to a grasping instrument operable in a first mode and a second mode. The first instrument drive unit includes one or more sensors configured to measure a parameter during operation of the grasping instrument, where in the first mode the grasping instrument is configured to perform a primary function and in the second mode the grasping instrument is configured to grasp tissue and measure tissue thickness. The method also includes controlling, using the processor, a second robotic arm including a second instrument drive unit coupled to a stapling instrument having a stapling cartridge having a plurality of staples, and loading an attribute of the grasping instrument into the processor. The method further includes switching the grasping instrument to the second mode and operating the grasping instrument in the second mode to clamp tissue. The method additionally includes calculating the tissue thickness based on the attribute of the grasping instrument and the measured parameter, selecting a stapler cartridge suitable for stapling tissue based on the calculated tissue thickness, and displaying the selected stapler cartridge on a display screen of a surgeon console.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Various embodiments of the present disclosure are described herein with reference to the drawings wherein:

[0007] FIG. 1 is a schematic illustration of a surgical robotic system including a control tower, a console, and one or more surgical robotic arms each disposed on a movable cart according to an embodiment of the present disclosure;Attorney Docket No.: A0012438W001

[0008] FIG. 2 is a perspective view of an input handle controller according to one embodiment of the present disclosure;

[0009] FIG. 3 is a perspective view of a surgical robotic arm of the surgical robotic system of FIG. 1 according to an embodiment of the present disclosure;

[0010] FIG. 4 is a perspective view of a movable cart having a setup arm with the surgical robotic arm of the surgical robotic system of FIG. 1 according to an embodiment of the present disclosure;

[0011] FIG. 5 is a schematic diagram of a computer architecture of the surgical robotic system of FIG. 1 according to an embodiment of the present disclosure;

[0012] FIG. 6 is a plan schematic view of movable carts of FIG. 1 positioned about a surgical table according to an aspect of the present disclosure;

[0013] FIG. 7 is a perspective view, with parts separated, of an instrument drive unit and a surgical instrument according to an embodiment of the present disclosure;

[0014] FIG. 8 is a top, perspective view of a grasper end effector, according to an embodiment of the present disclosure, for use in the surgical robotic system of FIG. 1;

[0015] FIG. 9 shows the grasper end effector in various configurations according to an embodiment of the present disclosure;

[0016] FIG. 10 is a perspective view of a surgical robotic stapler instrument in an unarticulated position according to an embodiment of the present disclosure;

[0017] FIG. 11 is an enlarged, perspective view of a stapling end effector of the surgical robotic stapler instrument of FIG. 10 in an unarticulated position;

[0018] FIG. 12 is a schematic diagram of a system for determining phases of a surgical procedure according to an embodiment of the present disclosure; and

[0019] FIG. 13 is a flow chart of a method for tissue thickness measurement using a grasping instrument during a stapling procedure according to an embodiment of the present disclosure.DETAILED DESCRIPTION

[0020] Embodiments of the presently disclosed surgical robotic system are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.

[0021] As will be described in detail below, the present disclosure is directed to a surgical robotic system, which includes a surgeon console, a control tower, and one or more movableAttorney Docket No.: A0012438W001 carts having a surgical robotic arm coupled to a setup arm. The surgeon console receives user input through one or more interface devices. The input is processed by the control tower as movement commands for moving the surgical robotic arm and an instrument and / or camera coupled thereto. Thus, the surgeon console enables teleoperation of the surgical arms and attached instrum ents / cam era. The surgical robotic arm includes a controller, which is configured to process the movement commands and to generate a torque commands for activating one or more actuators of the robotic arm, which would, in turn, move the robotic arm in response to the movement commands.

[0022] The system uses grasping instruments that are used for tissue manipulation, such as graspers, dissectors, forceps, or vessel sealers, as sensing devices to collect of information about jaw position and motor torque. This information, combined with the jaw dimensions (e.g., surface area) and geometry of the grasping instrument, is then used to calculate the thickness of the tissue being grasped. The current disclosure provides a system and a method for determining tissue thickness based on information available from robotic instruments.

[0023] With reference to FIG. 1, a surgical robotic system 10 includes a control tower 20, which is connected to all of the components of the surgical robotic system 10 including a surgeon console 30 and one or more movable carts 60. Each of the movable carts 60 includes a robotic arm 40 having a surgical instrument 50 coupled thereto. The robotic arms 40 also couple to the movable carts 60. The robotic system 10 may include any number of movable carts 60 and / or robotic arms 40.

[0024] The surgical instrument 50 is configured for use during minimally invasive surgical procedures. In embodiments, the surgical instrument 50 may be configured for open surgical procedures. In further embodiments, the surgical instrument 50 may be an electrosurgical forceps configured to seal tissue by compressing tissue between jaw members and applying electrosurgical current thereto. In yet further embodiments, the surgical instrument 50 may be a surgical stapler including a pair of jaws configured to grasp and clamp tissue while deploying a plurality of tissue fasteners, e.g., staples, and cutting stapled tissue. In yet further embodiments, the surgical instrument 50 may be a surgical clip applier including a pair of jaws configured to apply a surgical clip onto tissue. However, it will be understood that various types of surgical instruments for use during minimally invasive surgical procedures are contemplated and within the scope of this disclosure.Attorney Docket No.: A0012438W001

[0025] One of the robotic arms 40 may include an endoscopic camera 51 configured to capture video of the surgical site. The endoscopic camera 51 may be a stereoscopic endoscope configured to capture two side-by-side (i.e., left and right) images of the surgical site to produce a video stream of the surgical scene. The endoscopic camera 51 is coupled to a video processing device 56, which may be disposed within the control tower 20. The video processing device 56 may be any computing device as described below configured to receive the video feed from the endoscopic camera 51 and output the processed video stream.

[0026] The surgeon console 30 includes a first display 32, which displays a video feed of the surgical site provided by camera 51 disposed on the robotic arm 40, and a second display 34, which displays a user interface for controlling the surgical robotic system 10. The first display 32 and second display 34 may be touchscreens allowing for displaying various graphical user inputs.

[0027] The surgeon console 30 also includes a plurality of user interface devices, such as foot pedals 36 and a pair of input handle controllers 38a and 38b which are used by a user to remotely control robotic arms 40. The surgeon console further includes an armrest 33 used to support clinician’s arms while operating the input controllers 38a and 38b.

[0028] FIG. 2 shows the left-input controller 38b, which is a mirror copy of the right-input controller 38a. The input controllers 38a and 38b may be used to control, i.e., move, activate, etc., tool coupled to the IDU 52 of the robotic arms 40, such as the instrument 50, the laparoscopic camera 51. Each of the input controllers 38a and 38b includes an input 70 and a paddle 72 that is pivotally coupled to the input 70 at one end (e.g., proximal) of the paddle 72. The paddle 72 is configured to actuate a function of the instrument 50. The paddle 72 may include a finger sensor (not shown) configured to detect presence or movement of a finger, such as touch sensors, capacitive sensors, optical sensors, and the like. In embodiments, the finger sensor may be disposed on any portion of the input controllers 38a and 38b. Each of the input controllers 38a and 38b may also include a trigger 74a and one or more buttons 74b for activating various functions of the instrument 50. In addition, each of the input controllers 38a and 38b may include a gimbal assembly 76 allowing for movement and rotation of the input controllers 38a and 38b in a coordinate system of the input controller 38a. The coordinate system is represented by a 3D axis symbol including the X-axis, Y-axis, Z-axis. The gimbal assembly includes a plurality ofAttorney Docket No.: A0012438W001 frames 78a, 78b, 78c interconnected by rotatable joints 77 between each of the frames 78a, 78b, 78c, the input 70, and a support frame 79. The joints include encoders or other sensors suitable for measuring rotation, which is then used as input to control movement (e.g., pitch, roll, yaw, etc.) of the instrument 50. In embodiments, the input controllers 38a and 38b may be any other directional input device, such as an analog joystick, a directional pad, a touchpad, trackball, mouse, and the like.

[0029] The control tower 20 includes a display 23, which may be a touchscreen that may display the graphical user interfaces (GUIs). The control tower 20 also acts as an interface between the surgeon console 30 and one or more robotic arms 40. In particular, the control tower 20 is configured to control the robotic arms 40, such as to move the robotic arms 40 and the corresponding surgical instrument 50, based on a set of programmable instructions and / or input commands from the surgeon console 30, in such a way that robotic arms 40 and the surgical instrument 50 execute a desired movement sequence in response to input from the foot pedals 36 and the input controllers 38a and 38b. The foot pedals 36 may be used to enable and lock the input controllers 38a and 38b, repositioning camera movement and electrosurgical activation / deactivation. In particular, the foot pedals 36 may be used to perform a clutching action on the input controllers 38a and 38b. Clutching is initiated by pressing one of the foot pedals 36, which disconnects (i.e., prevents movement inputs) the input controllers 38a and / or 38b from the robotic arm 40 and corresponding instrument 50 or camera 51 attached thereto. This allows the user to reposition the input controllers 38a and 38b without moving the robotic arm(s) 40 and the instrument 50 and / or camera 51. This is useful when reaching control boundaries of the surgical space.

[0030] Each of the control tower 20, the surgeon console 30, and the robotic arm 40 includes a respective computer 21, 31, 41. The computers 21, 31, 41 are interconnected to each other using any suitable communication network based on wired or wireless communication protocols. The term “network,” whether plural or singular, as used herein, denotes a data network, including, but not limited to, the Internet, Intranet, a wide area network, or a local area network, and without limitation as to the full scope of the definition of communication networks as encompassed by the present disclosure. Suitable protocols include, but are not limited to, transmission control protocol / internet protocol (TCP / IP), datagram protocol / internet protocol (UDP / IP), and / or datagram congestion control protocol (DCCP). Wireless communication may be achieved via one or more wireless configurations, e.g.,Attorney Docket No.: A0012438W001 radio frequency, optical, Wi-Fi, Bluetooth (an open wireless protocol for exchanging data over short distances, using short length radio waves, from fixed and mobile devices, creating personal area networks (PANs), ZigBee® (a specification for a suite of high level communication protocols using small, low-power digital radios based on the IEEE 122.15.4-1203 standard for wireless personal area networks (WPANs)).

[0031] The computers 21, 31, 41 may include any suitable processor (not shown) operably connected to a memory (not shown), which may include one or more of volatile, nonvolatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM), or flash memory. The processor may be any suitable processor (e.g., control circuit) adapted to perform the operations, calculations, and / or set of instructions described in the present disclosure including, but not limited to, a hardware processor, a field programmable gate array (FPGA), a digital signal processor (DSP), a central processing unit (CPU), a microprocessor, and combinations thereof. Those skilled in the art will appreciate that the processor may be substituted by using any logic processor (e.g., control circuit) adapted to execute algorithms, calculations, and / or set of instructions described herein.

[0032] With reference to FIG. 4, each of the robotic arms 40 may include a plurality of links 42a, 42b, 42c, which are interconnected at joints 44a, 44b, 44c, respectively. Other configurations of links and joints may be utilized as known by those skilled in the art. The joint 44a is configured to secure the robotic arm 40 to the movable cart 60 and defines a first longitudinal axis. With reference to FIG. 4, the movable cart 60 includes a lift 67 and a setup arm 61, which provides a base for mounting of the robotic arm 40. The lift 67 allows for vertical movement of the setup arm 61. The movable cart 60 also includes a display 69 for displaying information pertaining to the robotic arm 40. In embodiments, the robotic arm 40 may include any type and / or number of joints.

[0033] The setup arm 61 includes a first link 62a, a second link 62b, and a third link 62c, which provide for lateral maneuverability of the robotic arm 40. The links 62a, 62b, 62c are interconnected at joints 63a and 63b, each of which may include an actuator (not shown) for rotating the links 62b and 62b relative to each other and the link 62c. In particular, the links 62a, 62b, 62c are movable in their corresponding lateral planes that are parallel to each other, thereby allowing for extension of the robotic arm 40 relative to the patient (e.g.,Attorney Docket No.: A0012438W001 surgical table). In embodiments, the robotic arm 40 may be coupled to the surgical table (not shown). The setup arm 61 includes controls 65 for adjusting movement of the links 62a, 62b, 62c as well as the lift 67. In embodiments, the setup arm 61 may include any type and / or number of joints.

[0034] The third link 62c may include a rotatable base 64 having two degrees of freedom. In particular, the rotatable base 64 includes a first actuator 64a and a second actuator 64b. The first actuator 64a is rotatable about a first stationary arm axis which is perpendicular to a plane defined by the third link 62c and the second actuator 64b is rotatable about a second stationary arm axis which is transverse to the first stationary arm axis. The first and second actuators 64a and 64b allow for full three-dimensional orientation of the robotic arm 40.

[0035] The actuator 48b of the joint 44b is coupled to the joint 44c via the belt 45a, and the joint 44c is in turn coupled to the joint 46b via the belt 45b. Joint 44c may include a transfer case coupling the belts 45a and 45b, such that the actuator 48b is configured to rotate each of the links 42b, 42c and a holder 46 relative to each other. More specifically, links 42b, 42c, and the holder 46 are passively coupled to the actuator 48b which enforces rotation about a pivot point “P” which lies at an intersection of the first axis defined by the link 42a and the second axis defined by the holder 46. In other words, the pivot point “P” is a remote center of motion (RCM) for the robotic arm 40. Thus, the actuator 48b controls the angle 9 between the first and second axes allowing for orientation of the surgical instrument 50. Due to the interlinking of the links 42a, 42b, 42c, and the holder 46 via the belts 45a and 45b, the angles between the links 42a, 42b, 42c, and the holder 46 are also adjusted in order to achieve the desired angle 9. In embodiments, some or all of the joints 44a, 44b, 44c may include an actuator to obviate the need for mechanical linkages.

[0036] The joints 44a and 44b include an actuator 48a and 48b configured to drive the joints 44a, 44b, 44c relative to each other through a series of belts 45a and 45b or other mechanical linkages such as a drive rod, a cable, or a lever and the like. In particular, the actuator 48a is configured to rotate the robotic arm 40 about a longitudinal axis defined by the link 42a.

[0037] With reference to FIG. 3, the holder 46 defines a second longitudinal axis and configured to receive an instrument drive unit (IDU) 52 (FIG. 1). The IDU 52 is configured to couple to an actuation mechanism of the surgical instrument 50 and the camera 51 and is configured to move (e.g., rotate) and actuate the instrument 50 and / or the camera 51. IDU 52 transfers actuation forces from its actuators to the surgical instrument 50 to actuateAttorney Docket No.: A0012438W001 components of an end effector 49 of the surgical instrument 50. The holder 46 includes a sliding mechanism 46a, which is configured to move the IDU 52 along the second longitudinal axis defined by the holder 46. The holder 46 also includes a joint 46b, which rotates the holder 46 relative to the link 42c. During endoscopic procedures, the instrument 50 may be inserted through an endoscopic access port 55 (FIG. 4) held by the holder 46. The holder 46 also includes a port latch 46c for securing the access port 55 to the holder 46 (FIG. 3).

[0038] The IDU 52 is attached to the holder 46, followed by a sterile interface module (SIM) 43 being attached to a distal portion of the IDU 52. The SIM 43 is configured to secure a sterile drape (not shown) to the IDU 52. The instrument 50 is then attached to the SIM 43. The instrument 50 is then inserted through the access port 55 by moving the IDU 52 along the holder 46. The SIM 43 includes a plurality of drive shafts configured to transmit rotation of individual motors of the IDU 52 to the instrument 50 thereby actuating the instrument 50. In addition, the SIM 43 provides a sterile barrier between the instrument 50 and the other components of robotic arm 40, including the IDU 52.

[0039] The robotic arm 40 also includes a plurality of manual override buttons 53 (FIG. 1) disposed on the IDU 52 and the setup arm 61, which may be used in a manual mode. The user may press one or more of the buttons 53 to move the component associated with the one or more buttons 53.

[0040] With reference to FIG. 5, each of the computers 21, 31, 41 of the surgical robotic system 10 may include a plurality of controllers, which may be embodied in hardware and / or software. The computer 21 of the control tower 20 includes a controller 21a and safety observer 21b. The controller 21a receives data from the computer 31 of the surgeon console 30 about the current position and / or orientation of the input controllers 38a and 38b and the state of the foot pedals 36 and other buttons. The controller 21a processes these input positions to determine desired drive commands for each joint of the robotic arm 40 and / or the IDU 52 and communicates these to the computer 41 of the robotic arm 40. The controller 21a also receives the actual joint angles measured by encoders of the actuators 48a and 48b and uses this information to determine force feedback commands that are transmitted back to the computer 31 of the surgeon console 30 to provide haptic feedback through the input controllers 38a and 38b. The safety observer 21b performs validity checks on the data going into and out of the controller 21a and notifies a system fault input if errors in the dataAttorney Docket No.: A0012438W001 transmission are detected to place the computer 21 and / or the surgical robotic system 10 into a safe state.

[0041] The computer 41 includes a plurality of controllers, namely, a main cart controller 41a, a setup arm controller 41b, a robotic arm controller 41c, and an instrument drive unit (IDU) controller 4 Id. The main cart controller 41a receives and processes joint commands from the controller 21a of the computer 21 and communicates them to the setup arm controller 41b, the robotic arm controller 41c, and the IDU controller 4 Id. The main cart controller 41a also manages instrument exchanges and the overall state of the movable cart 60, the robotic arm 40, and the IDU 52. The main cart controller 41a also communicates actual joint angles back to the controller 21a.

[0042] Each of joints 63a and 63b and the rotatable base 64 of the setup arm 61 are passive joints (i.e., no actuators are present therein) allowing for manual adjustment thereof by a user. The joints 63a and 63b and the rotatable base 64 include brakes that are disengaged by the user to configure the setup arm 61. The setup arm controller 41b monitors slippage of each of joints 63 a and 63b and the rotatable base 64 of the setup arm 61, when brakes are engaged or can be freely moved by the operator when brakes are disengaged, but do not impact controls of other joints. The robotic arm controller 41c controls each joint 44a and 44b of the robotic arm 40 and calculates desired motor torques required for gravity compensation, friction compensation, and closed loop position control of the robotic arm 40. The robotic arm controller 41c calculates a movement command based on the calculated torque. The calculated motor commands are then communicated to one or more of the actuators 48a and 48b in the robotic arm 40. The actual joint positions are then transmitted by the actuators 48a and 48b back to the robotic arm controller 41c.

[0043] The IDU controller 41d receives desired joint angles for the surgical instrument 50, such as wrist and jaw angles, and computes desired currents for the motors in the IDU 52. The IDU controller 41d calculates actual angles based on the motor positions and transmits the actual angles back to the main cart controller 41a.

[0044] The robotic arm 40 is controlled in response to a pose of the input controller controlling the robotic arm 40, e.g., the input controller 38a, which is transformed into a desired pose of the robotic arm 40 through a hand eye transform function executed by the controller 21a. The hand eye function, as well as other functions described herein, is / are embodied in software executable by the controller 21a or any other suitable controllerAttorney Docket No.: A0012438W001 described herein. The pose of one of the input controllers 38a may be embodied as a coordinate position and roll-pitch-yaw (RPY) orientation relative to a coordinate reference frame, which is fixed to the surgeon console 30. The desired pose of the instrument 50 is relative to a fixed frame on the robotic arm 40. The pose of the input controller 38a is then scaled by a scaling function executed by the controller 21a. In embodiments, the coordinate position may be scaled down and the orientation may be scaled up by the scaling function. In addition, the controller 21a may also execute a clutching function, which disengages the input controller 38a from the robotic arm 40. In particular, the controller 21a stops transmitting movement commands from the input controller 38a to the robotic arm 40 if certain movement limits or other thresholds are exceeded and in essence acts like a virtual clutch mechanism, e.g., limits mechanical input from effecting mechanical output.

[0045] The desired pose of the robotic arm 40 is based on the pose of the input controller 38a and is then passed by an inverse kinematics function executed by the controller 21a. The inverse kinematics function calculates angles for the joints 44a, 44b, 44c of the robotic arm 40 that achieve the scaled and adjusted pose input by the input controller 38a. The desired angles are then passed to the robotic arm controller 41c, which includes a joint axis controller having a proportional-derivative (PD) controller, the friction estimator module, the gravity compensator module, and a two-sided saturation block, which is configured to limit the commanded torque of the motors of the joints 44a, 44b, 44c. In aspects, input controller 38a may be substituted for and / or employed in conjunction with input controller 38b. While reference is made above to input controller 38a, input controller 38b may also be used in a similar manner.

[0046] With reference to FIG. 6, the surgical robotic system 10 is setup around a surgical table 90. The system 10 includes movable carts 60a-d, which may be numbered “1” through “4.” During setup, each of the carts 60a-d are positioned around the surgical table 90. Position and orientation of the carts 60a-d depends on a plurality of factors, such as placement of a plurality of access ports 55a-d, which in turn, depends on the surgery being performed. Once the port placements are determined, the access ports 55a-d are inserted into the patient, and carts 60a-d are positioned to insert instruments 50 and the endoscopic camera 51 into corresponding ports 55a-d.

[0047] During use, each of the robotic arms 40a-d is attached to one of the access ports 55a- d that is inserted into the patient by attaching the latch 46c (FIG. 4) to the access port 55Attorney Docket No.: A0012438W001(FIG. 4). The IDU 52 is attached to the holder 46, followed by the SIM 43 being attached to a distal portion of the IDU 52. Thereafter, the instrument 50 is attached to the SIM 43. The instrument 50 is then inserted through the access port 55 by moving the IDU 52 along the holder 46.

[0048] With reference to FIG. 7, the IDU 52 is shown in more detail and is configured to transfer power and actuation forces from its motors 152a, 152b, 152c, 152d to the instrument 50 to drive movement of components of the instrument 50, such as articulation, rotation, pitch, yaw, clamping, cutting, etc. The IDU 52 may also be configured for the activation or firing of an electrosurgical energy-based instrument or the like (e.g., cable drives, pulleys, friction wheels, rack and pinion arrangements, etc.).

[0049] The IDU 52 includes a motor pack 150 and a sterile barrier housing 130. Motor pack 150 includes motors 152a, 152b, 152c, 152d for controlling various operations of the instrument 50. The instrument 50 is removably couplable to IDU 52. As the motors 152a, 152b, 152c, 152d of the motor pack 150 are actuated, rotation of the drive transfer shafts 154a, 154b, 154c, 154d of the motors 152a, 152b, 152c, 152d, respectively, is transferred to the drive assemblies of the instrument 50. The instrument 50 is configured to transfer rotational forces / movement supplied by the IDU 52 (e.g., via the motors 152a, 152b, 152c, 152d of the motor pack 150) into longitudinal movement or translation of the cables or drive shafts to effect various functions of an end effector 200 (FIG. 8).

[0050] Each of the motors 152a, 152b, 152c, 152d includes a current sensor 153, a torque sensor 155, and a position sensor 157. For conciseness only operation of the motor 152a is described below, however, it will be understood that motors 152b-d may operate in a similar manner. The sensors 153, 155, 157 monitor the performance of the motor 152a. The current sensor 153 is configured to measure the current draw of the motor 152a and the torque sensor 155 is configured to measure motor torque. The torque sensor 155 may be any force or strain sensor including one or more strain gauges configured to convert mechanical forces and / or strain into a sensor signal indicative of the torque output by motor 152a. Position sensor 157 may be any device that provides a sensor signal indicative of the number of rotations of the motor 152a, such as a mechanical encoder or an optical encoder. Parameters which are measured and / or determined by position sensor 157 may include speed, distance, revolutions per minute, position, and the like. The sensor signals from sensors 153, 155, 157 are transmitted to the IDU controller 4 Id, which then controls the motors 152a, 152b, 152c,Attorney Docket No.: A0012438W001152d based on the sensor signals. In particular, the motors 152a, 152b, 152c, 152d are controlled by an actuator controller 159, which controls torque outputted and angular velocity of the motors 152a, 152b, 152c, 152d. In embodiments, additional position sensors may also be used, which include, but are not limited to, potentiometers coupled to movable components and configured to detect travel distances, Hall Effect sensors, accelerometers, and gyroscopes. In embodiments, a single controller can perform the functionality of the IDU controller 41d and the actuator controller 159.

[0051] With reference to FIG. 7, a grasping instrument 50’ is coupled to one of the robotic arms 40a-d, e.g., a first robotic arm 40a, and includes an adapter 160 having a housing 162 at a proximal end portion thereof and an elongated shaft 164 that extends distally from housing 162. Housing 162 of instrument 50’ is configured to selectively couple to IDU 52, to enable motors 152a, 152b, 152c, 152d of IDU 52 to operate the end effector 200 of the instrument 50’. Housing 162 of instrument 50’ supports a drive assembly that mechanically and / or electrically cooperates with motors 152a, 152b, 152c, 152d of IDU 52. Drive assembly of instrument 50’ may include any suitable electrical and / or mechanical component to effectuate driving force / movement.

[0052] The grasping instrument 50’ also includes an end effector 200 coupled to the elongated shaft 164. The end effector 200 may include any number of degrees of freedom allowing the end effector 200 to articulate, pivot, etc., relative to the elongated shaft 164. The end effector 200 may be any suitable surgical end effector configured to treat tissue, such as a dissector, grasper, sealer, stapler, etc.

[0053] The adapter 160 includes a storage device 163 configured to store attributes pertaining to the grasping instrument 50’, such as jaw dimensions (e.g., surface area) and geometry, a factor and / or function for calculating jaw force as a function of torque, a factor and / or function for calculating jaw angle as a function of motor position, tissue thickness ranges or values and corresponding stapler cartridges. The IDU controller 41d may obtain the attributes automatically by reading the attributes from the storage device 163 and / or the attributes may be set manually by the user by selecting either the type of the adapter 160 and / or the loading unit 240. Some or all of the attributes, such as various values, factors, functions, etc. may be stored in the memory of the system 10 or a remote server accessible by the system 10. The storage device 163 may be any suitable device configured to storeAttorney Docket No.: A0012438W001 data, e.g., flash memory. The adapter 160 may also include a torque or force sensor (not shown) in addition or in lieu of the torque sensors 155 of the IDU 52.

[0054] As shown in FIGS. 8 and 9, the end effector 200 may include a pair of opposing jaws 120 and 122 that are movable relative to each other. In embodiments, the end effector 200 may include a proximal portion 112 having a first pin 113 and a distal portion 114. Although the jaws 120 and 122 are shown as gripping jaws, it should be understood that the jaws may be any suitable type of jaw, such as shears, etc. The end effector 200 may be actuated using a plurality of cables 201a-d routed through proximal and distal portions 112 and 114 around their respective pulleys 112a, 112b, 114a, 114b, which are integrally formed as arms of the proximal and distal portions 112 and 114. Each of the cables 201a-d is actuated by a respective motor 152a-d via corresponding couplers disposed in adapter 160. In embodiments, the end effector 200, namely, the distal portion 114 and the jaws 120 and 122, may be articulated about the axis “A-A” to control a yaw angle of the end effector with respect to a longitudinal axis “X-X”. The distal portion 114 includes a second pin 115 with a pair of jaws including a first jaw 120 and a second jaw 122 pivotably coupled to the second pin 115. The jaws 120 and 122 are configured to pivot about an axis “B-B” defined by the second pin 115 allowing for controlling a pitch angle of the jaws 120 and 122 as well as opening and closing the jaws 120 and 122. The yaw, pitch, and jaw angles between the jaws 120 and 122 as they are moved between open and closed positions are controlled by adjusting the tension and / or length and direction (e.g., proximal or distal) of the cables 201a- d as shown in FIG. 8. The end effector 200 also includes a cable displacement sensor 116 configured to measure position of the cables 201. Thus, the end effector 200 may have three degrees of freedom, yaw, pitch, and jaw angle between jaws 120 and 122.

[0055] Wristed end effector 200 utilizes for drive cables 201a-d to articulate pitch, yaw, and jaw degrees of freedom. The cables responsible for closing the jaws are called high-side cables 201b and 201c and those responsible for opening the jaws are called low-side cables 201a and 20 Id. Thus, the high-side cable 201c and low-side cable 201a actuate the second jaw 122, and high-side cable 201b and the low-side cable 201d actuate the first jaw 120. During closure, the high-side cables 201b and 201c are tensioned while minimum tension is applied to the low-side cables 201a and 20 Id. During opening, the tension is applied to the cables in reverse, i.e., higher tension to the low-side cables 201a and 201d and minimal tension to the high-side cables 201b and 201c. The cables 201a-d are controlled by theirAttorney Docket No.: A0012438W001 respective motors 152a-d. Thus, the motors 152b and 152c are high-side motors as they actuate high-side cables 201b and 201c and the motors 152a and 152d are low-side motors as they actuate low-side cables 201a and 20 Id.

[0056] With reference to FIG. 10, a surgical stapling instrument 50” is coupled to one of the robotic arms 40a-d, e.g., second robotic arm 40b, and includes some common components as the grasping instrument 50’, such as an adapter 160 having a housing 162 at a proximal end portion thereof and an elongated shaft 164 that extends distally from housing 162. Housing 162 of adapter 160 is configured to selectively couple to IDU 52, to enable motors 152a-d of IDU 52 to operate the loading unit 240 coupled to the stapling instrument 50”. Housing 162 of adapter 160 supports a drive assembly that mechanically and / or electrically cooperates with motors 152a-d of IDU 52. Drive assembly 250 of stapling instrument 50” may include any suitable electrical and / or mechanical component to effectuate driving force / movement.

[0057] Elongated shaft 164 is configured to couple to the loading unit 240 having an end effector 244. With reference to FIGS. 10 and 11, the loading unit 240 includes a proximal body portion 242 and the end effector 244. Proximal body portion 242 is releasably attached to a distal end portion of the stapling instrument 50”, and end effector 244 is pivotally attached to a distal end of proximal body portion 242. End effector 244 includes an anvil assembly 246 and a cartridge assembly 248. Anvil assembly 246 is pivotable in relation to the cartridge assembly 248 and is movable between an open or unclamped position and a closed or clamped position. Proximal body portion 242 includes a drive assembly 250.

[0058] Drive assembly 250 includes a drive shaft 254, which may be flexible, and having a distal end portion 254a and a proximal engagement section 254b. The distal end portion 254a includes an I-beam 255 having a knife 255a. The I-beam 255 is configured to travel through the anvil assembly 246 and the cartridge assembly 248, thereby pushing the anvil assembly 246 toward the cartridge assembly 248 to clamp tissue. The proximal engagement section 254b includes diametrically opposed inwardly extending fingers 254c that engage a drive member (not shown) of the stapling instrument 50” to fixedly secure drive member to the proximal end of flexible drive shaft 254. Drive member is actuated by the IDU 52. The end effector 244 is pivotally coupled to a base 243 and is articulated via an articulation link 245, which longitudinally movable by one of the motors 152a-d of the IDU 52.Attorney Docket No.: A0012438W001

[0059] Cartridge assembly 248 of end effector 244 includes a staple cartridge 258 removably supported in a carrier 260. Staple cartridge 258 defines a central longitudinal slot 258a, and a plurality of linear rows of staple retention slots 258b positioned on each side of the central longitudinal slot 258a. Each of the staple retention slots 258b receives a staple 262 and a portion of a staple pusher 264. During operation, drive assembly 250 abuts an actuation sled 266 and pushes actuation sled 266 through the staple cartridge 258. As the actuation sled 266 moves through staple cartridge 258, cam wedges of the actuation sled 266 sequentially engage staple pushers 264 to move staple pushers 264 vertically within staple retention slots 258b and sequentially eject the staples 262 therefrom for formation against an anvil plate 246a of anvil assembly 246. In addition, the drive shaft 254 closes the anvil assembly 246 and the cartridge assembly 248 and simultaneously advances the knife 255a and the actuation sled 266. Once clamping, cutting, and stapling is completed, the drive shaft 254 is retracted in a reverse (i.e., proximal) direction.

[0060] The adapter 160 includes a storage device 203 configured to store attributes pertaining to the stapling instrument 50”. The IDU controller 41d may obtain the attributes automatically by reading the attributes from the storage device 203 and / or the attributes may be set manually by the user by selecting either the type of the stapling instrument 50” and / or the loading unit 240. The storage device 203 may be any suitable device configured to store data, e.g., flash memory. The adapter 160 may also include a torque or force sensor (not shown) in addition or in lieu of the torque sensors 155 of the IDU 52.

[0061] The loading unit 240 may also include a storage device 303 (FIG. 11) configured to store attributes pertaining to the loading unit 240. Such attributes may include, for example, a maximum torque and / or maximum current that may be used during retraction of the drive shaft 254 to open anvil assembly 246 and the cartridge assembly 248 to release stapled and cut tissue. Additional attributes may include staple cartridge 258 length, staple size, number of staples, articulation state. The handle may further include a position sensor for measuring position of the motor. The loading unit may include a storage device storing a maximum threshold value and the offset value, the storage device being accessible by the controller. The storage device 303 may be connected to the IDU controller 41 d using a wireless or a wired connection enabling for communication therebetween. The IDU controller 41d may obtain the attributes automatically by reading the attributes from the storage device 303 and / or the attributes may be set manually by the user by selecting either the type of theAttorney Docket No.: A0012438W001 adapter 160 and / or the loading unit 240. The storage device 303 may be substantially similar to the storage device 203 and may be any suitable device configured to store data, e.g., flash memory.

[0062] In embodiments, the staple cartridge 258 may be removable from the loading unit 240, which itself may be removable or formed as part of the adapter 160. In this embodiment, a storage device 403, which is substantially similar to the storage devices 203 and 303, and is configured to store attributes pertaining the staple cartridge 258, such as staple cartridge 258 length, staple size, number of staples, etc. The staple cartridge 258 may be inserted into the carrier 260.

[0063] With reference to FIG. 12, the surgical robotic system 10 may include an AI / ML processing system 310 that processes the surgical data using one or more ML models to identify one or more features, such as surgical phase, instrument, anatomical structure, etc., in the surgical data. The ML processing system 310 includes a ML training system 325, which may be a separate device (e.g., server) that stores its output as one or more trained ML models 330. The ML models 330 are accessible by a ML execution system 340. The ML execution system 340 may be separate from the ML training system 325, namely, devices that “train” the models are separate from devices that “infer,” i.e., perform real-time processing of surgical data using the trained ML models 330.

[0064] System 10 includes a data reception system 305 that collects surgical data, including the video data and surgical instrumentation data. The data reception system 305 can include one or more devices (e.g., one or more user devices and / or servers) located within and / or associated with a surgical operating room and / or control center. The data reception system 305 can receive surgical data in real-time, i.e., as the surgical procedure is being performed.

[0065] The ML processing system 310, in some examples, may further include a data generator 315 to generate simulated surgical data, such as a set of virtual or masked images, or record the video data from the image processing device 56, to train the ML models 330 as well as other sources of data, e.g., user input, arm movement, etc. Data generator 315 can access (read / write) a data store 320 to record data, including multiple images and / or multiple videos.

[0066] The ML processing system 310 also includes a phase detector 350 that uses the ML models to identify a phase within the surgical procedure. Phase detector 350 uses a particular procedural tracking data structure 355 from a list of procedural tracking dataAttorney Docket No.: A0012438W001 structures. Phase detector 350 selects the procedural tracking data structure 355 based on the type of surgical procedure that is being performed. In one or more examples, the type of surgical procedure is predetermined or input by user. The procedural tracking data structure 355 identifies a set of potential phases that may correspond to a part of the specific type of surgical procedure.

[0067] In some examples, the procedural tracking data structure 355 may be a graph that includes a set of nodes and a set of edges, with each node corresponding to a potential phase. The edges may provide directional connections between nodes that indicate (via the direction) an expected order during which the phases will be encountered throughout an iteration of the surgical procedure. The procedural tracking data structure 355 may include one or more branching nodes that feed to multiple next nodes and / or may include one or more points of divergence and / or convergence between the nodes. In some instances, a phase indicates a procedural action (e.g., surgical action) that is being performed or has been performed and / or indicates a combination of actions that have been performed. In some instances, a phase relates to a biological state of a patient undergoing a surgical procedure. For example, the biological state may indicate a complication (e.g., blood clots, clogged arteries / veins, etc.), pre-condition (e.g., lesions, polyps, etc.). In some examples, the ML models 330 are trained to detect an “abnormal condition,” such as hemorrhaging, arrhythmias, blood vessel abnormality, etc.

[0068] The phase detector 350 outputs the phase prediction associated with a portion of the video data that is analyzed by the ML processing system 310. The phase prediction is associated with the portion of the video data by identifying a start time and an end time of the portion of the video that is analyzed by the ML execution system 340. The phase prediction that is output may include an identity of a surgical phase as detected by the phase detector 350 based on the output of the ML execution system 340. Further, the phase prediction, in one or more examples, may include identities of the structures (e.g., instrument, anatomy, etc.) that are identified by the ML execution system 340 in the portion of the video that is analyzed. The phase prediction may also include a confidence score of the prediction. Other examples may include various other types of information in the phase prediction that is output. The predicted phase may be used by the controller 21 a to determine when to execute various software modules and other features of the system 10, such as whenAttorney Docket No.: A0012438W001 to enable use of the grasping instrument 50’ for measuring thickness of the tissue as part of a stapling procedure.

[0069] FIG. 13 shows a flow chart of a method 400 for tissue thickness measurement using the grasping instrument 50’ during a stapling procedure with the stapling instrument 50”. The method may be embodied as software instructions stored in memory and executed by a processor, e.g., controller 21a. At step 402, once the grasping instrument 50’ is coupled to the IDU 52, the system 10 receives and loads attributes pertaining to the grasping instrument 50’ from the storage device 163. Attributes may include jaw dimensions (e.g., surface area) and geometry, a factor and / or function for calculating jaw force as a function of torque, a factor and / or function for calculating jaw angle as a function of motor position, tissue thickness ranges or values and corresponding stapler cartridges.

[0070] The grasping instrument 50’ may be operated in two or more modes. In embodiments, any jaw instrument may be used as the grasping instrument 50’ such as vessel sealers, etc. In a first mode (e.g., grasping, vessel sealing, etc.), the grasping instrument 50’ is controllable by the surgeon console 30 to open and close the jaw members 120 and 122 to perform its primary function, e.g., to grasp objects, seal tissue, etc. Controlling the grasping instrument 50’ may be done by moving the input controllers 38a and 38b, moving the paddle 72 to actuate the jaw members 120 and 122 to grasp tissue. In a second mode (e.g., measurement), the grasping instrument 50’ is also controlled via the surgeon console 30 to grasp tissue to measure tissue thickness. The first mode may be a default operating mode and the system 10 may be switched between the first and second modes.

[0071] At step 404, the system 10 switches to the tissue thickness mode, which may be done manually by the user through the surgeon console 30 or automatically using the phase detector 350. This mode can be toggled from the first, default operational mode of the grasping instrument 50’ where it is used as a standard tissue manipulator (e.g., dissector or vessel sealer) to the second mode where the grasping instrument 50’ measures tissue thickness. Automatic switching to the second mode may be done in response to detection that stapling is about to be performed by the stapling instrument 50”, e.g., reaching a certain phase of the specific surgical procedure, manipulating the stapling instrument 50” in proximity of the tissue, etc.

[0072] At step 406, while in the second mode, the grasping instrument 50’ is used to grasp target tissue to measure its thickness. The surgeon, through the input controllers 38a, 38b,Attorney Docket No.: A0012438W001 manipulates the grasping instrument 50’, positioning the end effector 200 to grasp the target tissue. Grasping may be guided by the system 10 by providing instructions on the surgeon console 30 as well as highlighting tissue to be grasped on a video feed provided by the camera 51. Identification of tissue structures being stapled and measured may be done using any suitable image processing algorithm and highlighting the region using an augmented reality overlay on the video feed.

[0073] Once identified, the grasping instrument 50’ is used to apply pressure on the tissue. The user engages the paddle 72 to close the jaw members 120 and 122 on the tissue. The system 10 may guide the clamping process indicating to the user when the jaw members 120 and 122 are sufficiently clamped for the system 10 be able to determine tissue thickness. Once clamped, the sensors of the IDU 52 actuating the grasping instrument 50’ (e.g., current sensor 153, torque sensors 155, position sensors 157, etc.) collect data on jaw position and applied force and provide the sensor data to the controller 2 Id.

[0074] At step 408, the controller 21a calculates the tissue thickness based on the attributes pertaining to the grasping instrument 50’ and the sensor data collected during clamping. The controller 21a calculates the jaw force as a function of motor torque and the jaw angle (e.g., gap) between the jaw members 120 and 122 as a function of motor position. The jaw force and angle are used along with the jaw attributes (e.g., dimensions, geometry, surface area) to calculate tissue thickness.

[0075] To determine tissue thickness using a robotic grasper instrument, the controller 21a performs several calculations based on jaw geometry, jaw angle, and sensor measurements of torque and position. First, the controller 21a measures the compressed tissue thickness by calculating the distance between the jaw members 120 and 122 when they are closed around the tissue, which depends on the jaw length and the angle between the jaws. Next, the controller 21a calculates the force applied to the tissue by converting the torque measured at one or more of motors 152a-d, based on the mechanical advantage of the jaw linkage and the effective lever arm length that changes with the jaw angle. The contact area between the jaw members 120 and 122 and the tissue is determined using the dimensions (e.g., width and length) of the jaw surfaces in contact with the tissue, which also varies with the jaw angle.

[0076] With the force and contact area known, the controller 21a computes the stress exerted on the tissue. The controller 21a may receive the tissue’s mechanical properties,Attorney Docket No.: A0012438W001 such as its stiffness or elasticity (often characterized by Young's modulus) and relates the applied stress to the strain (i.e., compression) experienced by the tissue. Tissue mechanical properties may be estimated by using imaging from the camera 51 by analyzing deformation of tissue during compression. Finally, using the relationship between stress, strain, and the compressed thickness, the controller 21a estimates the uncompressed (i.e., original) tissue thickness.

[0077] At step 410, the controller 21a evaluates the calculated thickness and compares it to pre-set ranges for various stapler cartridges, such as vascular, medium, thick, or extra-thick reloads. This step involves accessing stored data (either in the system 10 or an external server) on tissue thickness ranges for different stapler cartridges. The identified tissue thickness is compared to a plurality of tissue thickness ranges, each of which corresponds to a specific stapler cartridge 258. The system 10 then selects the stapler cartridge 258 that matches the measured tissue thickness, namely, where the measured tissue thickness is within the operating tissue thickness range of the selected stapler cartridge 258. The system 10 the displays the selected stapler cartridge 258 on one of the displays screens 32 or 34 of the surgeon console 30. For example, the system may recommend a vascular medium reload if the tissue falls within a particular range. After the reload recommendation, the system 10 may also configure the IDU 52 for stapling, adjusting its settings based on the measured tissue thickness to ensure optimal performance during the stapling procedure. The grasping instrument 50’ is switched from the tissue thickness measurement mode to the primary mode, and the stapling instrument 50” is actuated to perform the stapling based on the measured thickness. The stapling instrument 50” clamps the tissue and deploys the staples according to the selected reload configuration.

[0078] Further aspects and embodiments of the present disclosure are set out in the below numbered clauses:1. A surgical robotic system comprising: a first robotic arm including a first instrument drive unit coupled to a grasping instrument operable in a first mode and a second mode, the first instrument drive unit including at least one sensor configured to measure a parameter during operation of the grasping instrument, wherein in the first mode the grasping instrument is configured to perform a primary function and in the second mode the grasping instrument is configured to grasp tissue and measure tissue thickness;Attorney Docket No.: A0012438W001 a second robotic arm including a second instrument drive unit coupled to a stapling instrument including a stapling cartridge having a plurality of staples; and a surgeon console including a display screen configured to display a graphical user interface; and a processor configured to: load an attribute of the grasping instrument; switch the grasping instrument to the second mode; operate the grasping instrument in the second mode to clamp tissue; calculate the tissue thickness based on the attribute of the grasping instrument and the measured parameter; select a stapler cartridge suitable for stapling tissue based on the calculated tissue thickness; and display the selected stapler cartridge on the display screen.2. The surgical robotic system according to clause 1, wherein the grasping instrument is one of a grasper, a dissector, a forceps, or a vessel sealer.3. The surgical robotic system according to any of clauses 1 or 2, wherein the grasping instrument includes a storage device storing the attribute that is accessible by the processor.4. The surgical robotic system according to any of clauses 1 to 3, wherein the display screen is configured to display instructions during the second mode to grasp the tissue to measure the tissue thickness.5. The surgical robotic system according to any of clauses 1 to 4, wherein selecting the stapler cartridge includes selecting the suitable stapler cartridge from a plurality of stapler cartridges each of which corresponds to a range of tissue thicknesses based on the calculated tissue thickness being within one of the ranges.Attorney Docket No.: A0012438W0016. The surgical robotic system according to any of clauses 1 to 5, wherein the processor is further configured to identify and highlight a region of the tissue for measuring the tissue thickness.7. The surgical robotic system according to any of clauses 1 to 6, wherein the attribute of the grasping instrument is one of jaw dimension, jaw geometry, or surface area.8. The surgical robotic system according to any of clauses 1 to 7, wherein the first instrument drive unit includes at least one motor and the parameter is a motor parameter measured by the at least one sensor which is one of a current sensor, a torque sensor, or a position sensor.9. The surgical robotic system according any of clauses 1 to 8, wherein the processor is further configured to: detect a phase of a surgical procedure during which the stapling instrument is being used; and switch the grasping instrument to the second mode based on the detected phase.10. The surgical robotic system according to any of clauses 1 to 9, wherein the processor is further configured to adjust operation of the second instrument drive unit based on the calculated tissue thickness.11. A method for selecting a stapling cartridge comprising: controlling, using a processor, a first robotic arm including a first instrument drive unit coupled to a grasping instrument operable in a first mode and a second mode, the first instrument drive unit including at least one sensor configured to measure a parameter during operation of the grasping instrument, wherein in the first mode the grasping instrument is configured to perform a primary function and in the second mode the grasping instrument is configured to grasp tissue and measure tissue thickness;Attorney Docket No.: A0012438W001 controlling, using the processor, a second robotic arm including a second instrument drive unit coupled to a stapling instrument including a stapling cartridge having a plurality of staples; loading an attribute of the grasping instrument into the processor; switching the grasping instrument to the second mode; operating the grasping instrument in the second mode to clamp tissue; calculating the tissue thickness based on the attribute of the grasping instrument and the measured parameter; selecting a stapler cartridge suitable for stapling tissue based on the calculated tissue thickness; and displaying the selected stapler cartridge on a display screen of a surgeon console.12. The method according to clause 11, wherein operating the grasping instrument comprises operating one of a grasper, a dissector, a forceps, or a vessel sealer.13. The method according to any of clauses 11 or 12, wherein loading an attribute of the grasping instrument into the processor includes retrieving, by the processor, the grasping instrument attribute from a storage device in the grasping instrument storing the attribute.14. The method according to any of clauses 11 to 13, further comprising: displaying a graphical user interface on the display screen of the surgeon console, wherein the display screen is configured to display instructions during the second mode to grasp the tissue to measure the tissue thickness.15. The method according to any of clauses 11 to 14, wherein selecting the stapler cartridge includes selecting the suitable stapler cartridge from a plurality of stapler cartridges each of which corresponds to a range of tissue thicknesses based on the calculated tissue thickness being within one of the ranges.Attorney Docket No.: A0012438W00116. The method according to any of clauses 11 to 15, further comprising: identifying and highlighting a region of the tissue for measuring the tissue thickness.17. The method according to any of clauses 11 to 16, wherein calculating the tissue thickness based on the attribute of the grasping instrument includes calculating the tissue thickness based on one or more of a jaw dimension, a jaw geometry, or a surface area of the grasping instrument.18. The method according to any of clauses 11 to 17, wherein the first instrument drive unit includes at least one motor and measuring a parameter during operation of the grasping instrument includes measuring a motor parameter using at least one sensor which is one of a current sensor, a torque sensor, or a position sensor.19. The method according to any of clauses 11 to 18, further comprising: detecting a phase of a surgical procedure during which the stapling instrument is being used; and switching the grasping instrument to the second mode based on the detected phase.20. The method according to any of clauses 11 to 19, further comprising: adjusting operation of the second instrument drive unit based on the calculated tissue thickness.

[0079] It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto.

Claims

Attorney Docket No.: A0012438W001WHAT IS CLAIMED IS:

1. A surgical robotic system (10) comprising: a first robotic arm (40a) including a first instrument drive unit (52) coupled to a grasping instrument (50’) operable in a first mode and a second mode, the first instrument drive unit including at least one sensor (153, 155, 157) configured to measure a parameter during operation of the grasping instrument, wherein in the first mode the grasping instrument is configured to perform a primary function and in the second mode the grasping instrument is configured to grasp tissue and measure tissue thickness; a second robotic arm (40b) including a second instrument drive unit (52) coupled to a stapling instrument (50”) including a stapling cartridge (248) having a plurality of staples (262); and a surgeon console (30) including a display screen (32, 34) configured to display a graphical user interface; and a processor (21a) configured to: load an attribute of the grasping instrument; switch the grasping instrument to the second mode; operate the grasping instrument in the second mode to clamp tissue; calculate the tissue thickness based on the attribute of the grasping instrument and the measured parameter; select a stapler cartridge suitable for stapling tissue based on the calculated tissue thickness; and display the selected stapler cartridge on the display screen.

2. The surgical robotic system according to claim 1, wherein the grasping instrument is one of a grasper, a dissector, a forceps, or a vessel sealer.

3. The surgical robotic system according to any of claims 1 or 2, wherein the grasping instrument includes a storage device (163) storing the attribute that is accessible by the processor.Attorney Docket No.: A0012438W0014. The surgical robotic system according to any of claims 1 to 3, wherein the display screen is configured to display instructions during the second mode to grasp the tissue to measure the tissue thickness.

5. The surgical robotic system according to any of claims 1 to 4, wherein selecting the stapler cartridge includes selecting the suitable stapler cartridge from a plurality of stapler cartridges each of which corresponds to a range of tissue thicknesses based on the calculated tissue thickness being within one of the ranges.

6. The surgical robotic system according to any of claims 1 to 5, wherein the processor is further configured to identify and highlight a region of the tissue for measuring the tissue thickness.

7. The surgical robotic system according to any of claims 1 to 6, wherein the attribute of the grasping instrument is one of jaw dimension, jaw geometry, or surface area.

8. The surgical robotic system according to any of claims 1 to 7, wherein the first instrument drive unit includes at least one motor and the parameter is a motor parameter measured by the at least one sensor which is one of a current sensor (153), a torque sensor (155), or a position sensor (157).

9. The surgical robotic system according any of claims 1 to 8, wherein the processor is further configured to: detect a phase of a surgical procedure during which the stapling instrument is being used; and switch the grasping instrument to the second mode based on the detected phase.

10. The surgical robotic system according to any of claims 1 to 9, wherein the processor is further configured to adjust operation of the second instrument drive unit based on the calculated tissue thickness.Attorney Docket No.: A0012438W00111. A method for selecting a stapling cartridge comprising: controlling, using a processor (21), a first robotic arm (40a) including a first instrument drive unit (52) coupled to a grasping instrument (50’) operable in a first mode and a second mode, the first instrument drive unit including at least one sensor (153, 155, 157) configured to measure a parameter during operation of the grasping instrument, wherein in the first mode the grasping instrument is configured to perform a primary function and in the second mode the grasping instrument is configured to grasp tissue and measure tissue thickness; controlling, using the processor, a second robotic arm (40b) including a second instrument drive unit (52) coupled to a stapling instrument (50”) including a stapling cartridge (246) having a plurality of staples (262); loading an attribute of the grasping instrument into the processor; switching the grasping instrument to the second mode; operating the grasping instrument in the second mode to clamp tissue; calculating the tissue thickness based on the attribute of the grasping instrument and the measured parameter; selecting a stapler cartridge suitable for stapling tissue based on the calculated tissue thickness; and displaying the selected stapler cartridge on a display screen (32, 34) of a surgeon console (30).

12. The method according to claim 11, wherein operating the grasping instrument comprises operating one of a grasper, a dissector, a forceps, or a vessel sealer.

13. The method according to any of claims 11 or 12, wherein loading an attribute of the grasping instrument into the processor includes retrieving, by the processor, the grasping instrument attribute from a storage device in the grasping instrument storing the attribute.Attorney Docket No.: A0012438W00114. The method according to any of claims 11 to 13, further comprising: displaying a graphical user interface on the display screen of the surgeon console, wherein the display screen is configured to display instructions during the second mode to grasp the tissue to measure the tissue thickness.

15. The method according to any of claims 11 to 14, wherein selecting the stapler cartridge includes selecting the suitable stapler cartridge from a plurality of stapler cartridges each of which corresponds to a range of tissue thicknesses based on the calculated tissue thickness being within one of the ranges.

Images