Systems and methods for control of a surgical instrument

Abstract

Systems and methods are provided for control of the surgical system. The surgical system includes drive assemblies, a medical instrument, and a controller operably coupled between the drive assemblies, and a sensor unit. The controller is configured to perform operations that include, causing a tensile load to be applied to a first tension member and a second tension member via the drive assemblies on a condition that the first tension member is in the intact state. The operations also include detecting, based on the output of the sensor unit, a transition of the first tension member from the intact state towards the at least partially broken state and affecting an operation of the second drive assembly to mitigate a non‑commanded movement of an end effector of the instrument.

Description

Attorney Docket No. P06879-WOSYSTEMS AND METHODS FOR CONTROL OF A SURGICAL INSTRUMENTCross-Reference to Related Applications

[0001] This application claims priority to and the filing date benefit of U. S. Provisional Patent Application No. 63 / 734,913, entitled “Systems for Control of a Surgical Instrument,” filed December 17, 2024, and U. S. Provisional Patent Application No. 63 / 734,914, entitled “Systems and Methods for Control of a Surgical Instrument,” filed December 17, 2024, each of which is incorporated herein by reference in its entirety’.Background

[0002] The embodiments described herein relate to medical devices, and more specifically to endoscopic tools. More particularly, the embodiments described herein relate to medical devices that include systems for control of a surgical system in response to a reduction or loss of tension member integrity7.

[0003] Known techniques for Minimally Invasive Surgery (MIS) employ instruments to manipulate tissue that can be either manually controlled or controlled via computer-assisted teleoperation. Many known MIS instruments include a therapeutic or diagnostic end effector (e.g., forceps, a cutting tool, or a cauterizing tool) mounted on a wrist mechanism at the distal end of a shaft. During an MIS procedure, the end effector, wrist mechanism, and the distal end of the shaft are inserted into a small incision or a natural orifice of a patient to position the end effector at a work site within the patient’s body.

[0004] To enable the desired movement of the wrist mechanism and end effector, known instruments include drive assemblies (e.g., motors and capstans) and cables. The cables extend through the shaft that connects the w rist mechanism to a mechanical structure. For teleoperated systems, the proximal mechanical structure is ty pically motor driven and is operably coupled to a computer processing system to provide a user interface for a clinical user (e.g.. a surgeon) to control the instrument as a whole, as well as the instrument’s components and functions. Some teleoperated systems include a manual control separate from the motor driven aspects allowing a user some level of manual interaction with the medical device.

[0005] In some known systems, the cables can be arranged as cable pairs that operate in opposition to produce the desired movement of the distal wrist mechanism and / or end effector. The movement of the distal wrist mechanism and / or end effector is in response to energy7storedAttorney Docket No. P06879-WOin the cable pair (e.g., potential energy resulting from a tensile load placed upon the cable pair). For example, in some known systems, each cable of the cable pair can have a different tensile load, and the distal wrist mechanism and / or end effector moves in response to the difference in magnitudes between the tensile load in each cable of the cable pair.

[0006] During the lifecycle of the instrument, the cables can be subjected to wearing or other forces that can reduce the strength and / or integrity of the cables. A reduction or loss of integrity in one cable of a cable pair can result in the release of energy stored in the other cable of the cable pair. This release of energy can result in a non-commanded movement of a portion of the end effector. Such a non-commanded movement of the end effector, or a portion thereof, is not desirable during an MIS procedure.

[0007] In some known systems, the integrity' of the cables is ascertained based on monitored current draw, electrical potential, rotational position, speed, or other similar parameters of the drive assemblies. In such systems, a system controller can monitor the parameters of the drive assembly to identify parameters that are indicative of a loss of integrity of one of the cables. Upon recognition of the loss of integrity7, the system controller must then determine an appropriate corrective response and generate a command signal to the drive assemblies. Known systems have demonstrated an inability to implement the corrective response quickly enough to preclude a non-commanded movement of the end effector.

[0008] Thus, a need exists for improved medical devices, including systems that mitigate or eliminate a non-commanded movement of the end effector corresponding to a reduction or loss of integrity in one cable of a cable pair.Summary

[0009] This summary introduces certain aspects of the embodiments described herein to provide a basic understanding. This summary is not an extensive overview of the inventive subject matter, and it is not intended to identify key or critical elements or to delineate the scope of the inventive subject matter.

[0010] In some embodiments, the present disclosure is directed to a surgical system. The surgical system includes a first drive assembly, a second drive assembly, a medical instrument, and a controller. The medical instrument includes a first tension member, a second tension member, and a sensor unit. The first tension member is operably coupled between the firstAttorney Docket No. P06879-WOdrive assembly and an end effector. The second tension member is operably coupled between the second drive assembly and the end effector. The sensor unit is operably coupled to the first tension member and configured to produce an output associated with an operating state of the first tension member. The operating state is at least one of an intact state or an at least partially broken state of the first tension member. The controller is operably coupled to the first drive assembly, the second drive assembly and the sensor unit. The controller is configured to perform a set of operations. The set of operations includes causing a tensile load to be applied to the first tension member and the second tension member via the first drive assembly and the second drive assembly on a condition that the first tension member is in the intact state. The set of operations also includes detecting, based on the output of the sensor unit, a transition of the first tension member from the intact state towards the at least partially broken state. Further, the set of operations includes affecting an operation of the second drive assembly to mitigate a non-commanded movement of the end effector in response to the detecting.

[0011] In some embodiments, affecting the operation of the second drive assembly includes reversing a rotational direction of the second drive assembly to increase a length of the second tension member between the second drive assembly and the end effector.

[0012] In some embodiments, affecting the operation of the second drive assembly includes reversing a rotational direction of the second drive assembly to reduce a tensile load transmitted to the end effector via the second tension member.

[0013] In some embodiments, affecting the operation of the second drive assembly includes altering a rotational speed of the second drive assembly in accordance with a damping transition to reduce a tensile load transmitted to the end effector via the second tension member.

[0014] In some embodiments, affecting the operation of the second drive assembly includes halting a rotation of the second drive assembly.

[0015] In some embodiments, the sensor unit includes a switch having a first switch state and a second switch state. The switch is in the first switch state on the condition that the first tension member is in the intact state. The switch transitions to the second switch state in response to the transition of the first tension member towards the at least partially broken state. The output of the sensor unit corresponds to the transition of the switch to the second switch state.Attorney Docket No. P06879-WO

[0016] In some embodiments, the sensor unit includes an actuating key and a switch. The actuating key is positioned between the first tension member and the switch. The actuating key is positioned at a compressed position in response to a tensile load applied to the first tension member on the condition that the first tension member is in the intact state. The switch is maintained in a first switch state by the actuating key at the compressed position. The actuating key is positioned at an uncompressed position and the switch is transitioned to a second switch state in response to the transition of the first tension member to the at least partially broken state. The output of the sensor unit corresponds to the transition of the switch to the second switch state.

[0017] In some embodiments, the actuating key includes a contact surface shaped to receive a force from the first tension member. On a condition that the actuating key is at the compressed position, the contact surface is aligned with a guide structure that defines a guide path of the of the first tension member. On a condition that the actuating key is at the uncompressed position, the contact surface is proud of the guide structure and is at least partially within the guide path of the first tension member.

[0018] In some embodiments, the second switch state is a default switch state for the switch.

[0019] In some embodiments, the first tension member is a first cable of a cable pair and the second tension member is a second cable of the cable pair, and the medical instrument includes a proximal mechanical structure. The sensor unit includes an elongated body positioned within the proximal mechanical structure between the first cable and the second cable. The elongated body is at a first position on the condition that the first cable is in the intact state. On a condition that the first cable is transitioned to the at least partially broken state, the elongated body is configured to move to a second position in response to a tensile load within the second cable. The output of the sensor unit with the elongated body at the second position is indicative of the transition of the first cable to the at least partially broken state.

[0020] In some embodiments, the elongated body extends between a first guide portion and a second guide portion. The first guide portion is positioned to engage the first cable and the second guide portion is positioned to engage the second cable. The elongated body is movable relative to a fixed portion of the sensor unit to transition the sensor unit between a first switchAttorney Docket No. P06879-WOstate and a second switch state. A movement of the elongated body from the first position to the second position is prevented by a tension in each cable of the cable pair on a condition that each cable of the cable pair is in the intact state.

[0021] In some embodiments, the sensor unit includes a deformable member coupled to the first tension member. The deformable member includes a first electrical contact and a second electrical contact that is movable relative to the first electrical contact. On the condition that the first tension member is in the intact state, the sensor unit is in a first switch state in which the second electrical contact is separated from the first electrical contact. On the condition that the first tension member transitions to the at least partially broken state, the sensor unit is in a second switch state in which the second electrical contact is electrically coupled to the first electrical contact. The output of the sensor unit corresponds to the transition of the sensor unit to the second switch state.

[0022] In some embodiments, the first electrical contact is a first conductive insert coupled to a first lead line. The second electrical contact is a second conductive insert coupled to a second lead line. The transition to the second switch state closes an electrical circuit.

[0023] In some embodiments, the sensor unit includes an insulated conductive element of the first tension member. The insulated conductive element extends between the first drive assembly and the end effector. The set of operations includes delivering a continuity signal to the insulated conductive element. The detection of the transition of the first tension member to the at least partially broken state based on the output of the sensor unit includes detecting a disruption of the continuity signal.

[0024] In some embodiments, the present disclosure is directed to a medical instrument that includes a proximal mechanical structure, a tension member, and a sensor unit. The proximal mechanical structure includes a capstan and defines a shaft opening at a coupling with an instrument shaft. The tension member is operably coupled between an end effector and the capstan. The tension member extends in a first direction betw een the capstan and the shaft opening and in a second direction between the shaft opening and the end effector. The first direction and the second direction form a non-zero angle. The sensor unit is positioned between the capstan and the shaft opening. The sensor unit has a first switch state on a condition that the tension member is in an intact state and a second switch state on a condition that the tension member is in an at least partially broken state.Attorney Docket No. P06879-WO

[0025] In some embodiments, the sensor unit includes an actuating key and a switch. The actuating key is positioned between the tension member and the switch. The actuating key is positioned at a compressed position in response to a tensile load applied to the tension member on the condition that the tension member is in the intact state. The switch is maintained in the first switch state by the actuating key at the compressed position. The actuating key is positioned at an uncompressed position and the switch is transitioned to the second switch state on the condition that the tension member is in the at least partially broken state.

[0026] In some embodiments, the proximal mechanical structure includes a guide structure positioned between the shaft opening and the capstan. The guide structure defines a guide path into the shaft opening. The tension member is configured to transition within the guide path between the first direction and the second direction. The actuating key includes a contact surface shaped to receive a force from the tension member. On a condition that the actuating key is at the compressed position, the contact surface is aligned with the guide structure. On a condition that the actuating key is at the uncompressed position, the contact surface is proud of the guide structure and is at least partially within the guide path.

[0027] In some embodiments, the switch is a momentary switch. The second switch state is a default switch state for the momentary switch.

[0028] In some embodiments, the capstan is one capstan of a set of capstans, the tension member is one tension member of a set of tension members operably coupled to the end effector, the actuating key is one actuating key of a set of actuating keys, and the switch is one switch of a set of switches. Each actuating key of the set of actuating keys is positioned to engage a different tension member of the set of tension members such that each actuating key is positioned at the compressed position in response to a tensile load applied to the corresponding tension member on the condition that the corresponding tension member is in the intact state. Each switch of the set of momentary switches is maintained in the first switch state by the corresponding actuating key at the compressed position.

[0029] In some embodiments, the first switch state is an open switch state. The second switch state is a closed switch state that completes a circuit. The completion of the circuit is indicative of the tension member being in the at least partially broken state

[0030] In some embodiments, the first switch state is a closed switch state that completes a circuit. The second switch state is an open switch state that interrupts the circuit. TheAttorney Docket No. P06879-WOinterruption of the circuit is indicative of the tension member being in the at least partially broken state

[0031] In some embodiments, the present disclosure is directed to a medical instrument that includes a proximal mechanical structure, a cable pair, and a sensor unit. The proximal mechanical structure includes a first capstan and second capstan. The proximal mechanical structure defines a shaft opening into an instrument shaft. A first cable of the cable pair is operably coupled between a tool member and the first capstan. A second cable of the cable pair is operably coupled between the tool member and the second capstan. The cable pair is configured to transfer a mechanical input from the first capstan and the second capstan to the tool member. The sensor unit is positioned within the proximal mechanical structure between the first and second capstans and the shaft opening, and also between the first cable and the second cable. The sensor unit has a first switch state on a condition that the first cable is in an intact state and a second switch state on a condition that the first cable is in an at least partially broken state. The sensor unit includes a body that is movable from a first position to a second position in response to a tensile load within the second cable on the condition that the first cable is in the at least partially broken state.

[0032] In some embodiments, the body extends between a first guide portion and a second guide portion. The first guide portion is positioned to engage the first cable and the second guide portion is positioned to engage the second cable on a condition that the first cable and the second cable are in an intact state. The body is movable relative to a fixed portion of the sensor unit to transition the sensor unit between the first switch state and the second switch state. A movement of the body from the first position to the second position is prevented by a tension in each cable of the cable pair on a condition that each cable of the cable pair is in the intact state.

[0033] In some embodiments, the body is slidable laterally along a first axis from the first position to the second position. The first axis is orthogonal to a second axis. The second axis bisects the shaft opening. The body is centered on the second axis when the body is at the first position.

[0034] In some embodiments, the first guide portion is positioned to displace a portion of the first cable away from the second axis on a condition that the second cable is in an intactAttorney Docket No. P06879-WOstate. The second guide portion is positioned to displace a portion of the second cable away from the second axis on the condition that the first cable is in the intact state.

[0035] In some embodiments, the body defines a guide channel configured to receive a guide mechanism of the proximal mechanical structure. An interaction of the guide mechanism and the guide channel maintain the body at a single position along the second axis and guide a movement along the first axis from the first position to the second position.

[0036] In some embodiments, the body moves laterally along the first axis from the first position to the second position on the condition that the first cable is transitioned to the at least partially broken state. The lateral movement is toward the first cable.

[0037] In some embodiments, the first position of the body defines an operational cable path for the cable pair. The second position of the body defines a tension-release cable path for the second cable on the condition that the first cable is transitioned to the at least partially broken state. The operational cable path has a length that is greater than the tension-release cable path.

[0038] In some embodiments, the first switch state is an open switch state. The second switch state is a closed switch state that completes a circuit. The completion of the circuit is indicative of the first cable being in the at least partially broken state.

[0039] In some embodiments, the first switch state is a closed switch state that completes a circuit. The second switch state is an open switch state that interrupts the circuit. The interruption of the circuit is indicative of the first cable being in the at least partially broken state.

[0040] In some embodiments, the present disclosure is directed to a medical instrument that includes a proximal mechanical structure, a tension member, and a sensor unit. The tension member is operably coupled between an end effector and the proximal mechanical structure. The sensor unit is coupled to the tension member. The sensor unit has a first switch state on a condition that the tension member is in an intact state and a second switch state on a condition that the tension member is in an at least partially broken state.

[0041] In some embodiments, the sensor unit includes a deformable member coupled to the tension member. The deformable member includes a first electrical contact and a secondAttorney Docket No. P06879-WOelectrical contact that is movable relative to the first electrical contact. On the condition that the tension member is in the intact state, the sensor unit is in a first switch state in which the second electrical contact is separated from the first electrical contact. On the condition that the tension member transitions to the at least partially broken state, the sensor unit is in a second switch state in which the second electrical contact is electrically coupled to the first electrical contact. The output of the sensor unit corresponds to the transition of the sensor unit to the second switch state.

[0042] In some embodiments, the first electrical contact is a first conductive insert coupled to a first lead line. The second electrical contact is a second conductive insert coupled to a second lead line. The transition to the second switch state closes an electrical circuit.

[0043] In some embodiments, the second switch state is a default switch state for the sensor unit. A tensile load within the tension member exerts a torque on the deformable member to move the second electrical contact relative to the first electrical contact and maintain the sensor unit in the first switch state on the condition that the tension member is in the intact state.

[0044] In some embodiments, the present disclosure is directed to a medical instrument that includes a proximal mechanical structure and an instrument shaft coupled to the proximal mechanical stmcture. The medical instrument also includes an end effector coupled to the instrument shaft. The end effector includes a tool member. The medical instrument further includes a cable pair positioned partially along the instrument shaft and operably coupled between the proximal mechanical structure and the tool member. The cable pair includes a first cable and a second cable. The cable pair is configured to transfer a mechanical input from the proximal mechanical stmcture to the tool member. Additionally, the medical instrument includes a tension-release member coupled to the instrument shaft. The tension-release member has a first position that defines an operational cable path for the cable pair and a second position that defines a tension-release cable path for the second cable of the cable pair on a condition that a first cable of the cable pair is in at least a partially broken state. The operational cable path has a length that is greater than the tension-release cable path.

[0045] In some embodiments, the present disclosure is directed to a medical instrument that includes a proximal mechanical structure. The proximal mechanical structure includes a first capstan, a second capstan, and a tension-release member. The proximal mechanical structure defines a shaft opening into an instrument shaft. The tension-release member isAttorney Docket No. P06879-WOpositioned between the first and second capstans and the shaft opening. The medical instrument also includes a first cable of a cable pair operably coupled between a tool member and the first capstan. The medical instrument includes a second cable of the cable pair operably coupled between the tool member and the second capstan. The cable pair is configured to transfer a mechanical input from the first capstan and the second capstan to the tool member. The tension-release member has a first position that defines an operational cable path for the cable pair. The tension-release member has a second position that defines a tension-release cable path for the second cable of the cable pair on a condition that the first cable of the cable pair is in at least a partially broken state. The operational cable path has a length that is greater than the tension-release cable path.

[0046] In some embodiments, the tension-release member includes an elongated body extending between a first guide portion and a second guide portion. The first guide portion is positioned to engage the first cable to displace a portion of the first cable away from the second axis on a condition that the second cable is in an intact state. The second guide portion is positioned to engage the second cable to displace a portion of the second cable away from the second axis on a condition that the first cable is in an intact state. The elongated body defines a guide channel configured to receive a guide mechanism of the proximal mechanical structure. An interaction of the guide mechanism and the guide channel maintains the tension-release member at a single position along the second axis and guide a movement along the first axis from the first position to the second position.

[0047] In some embodiments, the present disclosure is directed to a medical instrument that includes a proximal mechanical structure and an instrument shaft coupled to the proximal mechanical structure. The medical instrument also includes an end effector coupled to the instrument shaft. The end effector includes a tool member. Additionally, the medical instrument includes a cable extending between the proximal mechanical structure and the tool member. The cable has a first cable portion, a second cable portion, and a third cable portion between the first cable portion and the second cable portion. The first cable portion and the second cable portion each are coupled to the proximal mechanical structure. The third cable portion is engaged with a coupling portion of the tool member to produce a friction coupling of the cable to the tool member. The friction coupling is configured to limit movement of the third cable portion relative to the tool member on a condition that the cable is in an intact stateAttorney Docket No. P06879-WOand to allow the cable to decouple from the tool member on a condition that the second cable portion is transitioned to a parted state.

[0048] Other medical devices, related components, medical device systems, and / or methods according to embodiments will be or become apparent to one with skill in the art upon review of the following drawings and detailed description. It is intended that all such additional medical devices, related components, medical device systems, and / or methods included within this description be within the scope of this disclosure.Brief Description of the Drawings

[0049] FIG. 1 is a plan view of a minimally invasive teleoperated medical system according to an embodiment being used to perform a medical procedure such as surgery.

[0050] FIG. 2 is a perspective view of a user control console of the minimally invasive teleoperated surgery system shown in FIG. 1.

[0051] FIG. 3 is a perspective view of an optional auxiliary unit of the minimally invasive teleoperated surgery system shown in FIG. 1.

[0052] FIG. 4 is a front view of a manipulator unit, including a plurality of instruments, of the minimally invasive teleoperated surgery system shown in FIG. 1.

[0053] FIG. 5 is an illustration of a portion of the teleoperated system of FIG. 1, illustrating an instrument carriage of the manipulator unit, according to an embodiment.

[0054] FIG. 6 is a perspective view of a portion of a medical instrument of the minimally invasive teleoperated surgery system shown in FIG. 1.

[0055] FIG. 7 is a top perspective view of a portion of a proximal mechanical structure of the medical instrument of FIG. 6.

[0056] FIG. 8A is a schematic illustration of a surgical system with a sensor unit in a first switch state according to an embodiment.

[0057] FIG. 8B is a schematic illustration of a surgical system with the sensor unit in a second switch state according to an embodiment.Attorney Docket No. P06879-WO

[0058] FIG. 9 is a flow chart of a set of operations for control of a surgical system according to an embodiment.

[0059] FIG. 10 is a perspective view of a guide structure and sensor unit of a medical instrument according to an embodiment.

[0060] FIG. 11 is a close-up perspective view of the guide structure and sensor unit of FIG.10.

[0061] FIG. 12 is a perspective view of the sensor unit of FIG. 10 in a second switch state.

[0062] FIG. 13 is a perspective view of the sensor unit of FIG. 10 with a switch being in a first switch state.

[0063] FIGS. 14A and 14B are a schematic illustration of a sensor unit in a first position and in a second position respectively according to an embodiment.

[0064] FIG. 15 is a side view of the sensor unit of FIG. 14A.

[0065] FIG. 16 is a perspective view of a sensor unit according to an embodiment.

[0066] FIG. 17A is a cross-sectional view of the sensor unit of FIG. 16 in a first switch state.

[0067] FIG. 17B is a cross-sectional view of the sensor unit of FIG. 16 in a second switch state.

[0068] FIG. 18 is a schematic illustration of a controller for use with a minimally invasive teleoperated surgery system according to an embodiment.

[0069] FIG. 19A is a schematic illustration of a medical instrument with a tension-release member in a first position that defines an operational cable path according to an embodiment.

[0070] FIG. 19B is a schematic illustration of a medical instrument with a tension-release member in a second position that defines a tension-release cable path according to an embodiment.

[0071] FIG. 20 is a transparent top view of a tension-release member according to an embodiment.Attorney Docket No. P06879-WO

[0072] FIG. 21A is a transparent view of a portion of the instrument shaft of FIG. 6 having the tension-release member of FIG. 20 in a first position according to an embodiment.

[0073] FIG. 21 B is a transparent view of a portion of the instrument shaft of FIG. 6 having the tension-release member of FIG. 20 in a second position according to an embodiment

[0074] FIGS. 22 A and 22B are cross-sectional views of the portion of the instrument shaft of FIGS. 21 A and 21 B respectively taken at x-x of FIG. 6.

[0075] FIGS. 23A and 23B are schematic illustrations of a tension-release member in a first position and in a second position respectively according to an embodiment.

[0076] FIG. 24 is a schematic illustration of a tool member according to an embodiment.Detailed Description

[0077] The embodiments described herein can advantageously be used in a wide variety' of grasping, cutting, and manipulating operations associated with minimally invasive surgery. In some embodiments, an end effector of the medical device can move with reference to the main body of the instrument in three mechanical DOFs, e.g., pitch, yaw, and roll (shaft roll). There may also be one or more mechanical DOFs in the end effector itself, e.g., two jaws, each rotating with reference to a clevis (2 DOFs) and a distal clevis that rotates with reference to a proximal clevis (one DOF).

[0078] The medical devices of the present application enable motion in three degrees of freedom (e g., about a pitch axis, a yaw axis, and a grip axis) using multiple cables. In some embodiments, four cables are used, thereby reducing the total number of cables required, reducing the space required within the shaft and wrist, reducing overall cost, and enables further miniaturization of the wrist and shaft assemblies to promote MIS procedures. In some embodiments, six cables are used. It is appreciated that the various embodiments provided herein are adaptable to other systems with more or fewer cables based on the disclosure provided herein.

[0079] Generally, the present disclosure is directed to systems and methods for mitigating a non-commanded movement of a surgical instrument. In particular, the systems and methods described herein facilitate the rapid detection of a loss of integrity (e.g., a reduction or loss of tension such as may be encountered in the event of a cable break) in a cable or in one cable ofAttorney Docket No. P06879-WOa pair of cables without monitoring a parameter (e.g., current draw, rotational position, speed, or other similar parameter) of a drive assembly. Upon the detection of the loss of integrity, the systems and methods facilitate the rapid reduction in tension affecting the end effector of the medical instrument, thereby mitigating or preventing a non-commanded movement of the surgical instrument that would otherwise occur.

[0080] In some embodiments, the detection of the loss of integrity of the tension member can be achieved via a sensor unit that is operably coupled to a system controller. The rapid detection can be facilitated by the use of a sensor unit that has a binary' output. In other words, the sensor unit can output to the controller merely an indication as to whether or not the tension member is compromised (e.g.. parted) or not. Said another way, the sensor unit can output to the controller an indication of one of two possible states of the tension member; and intact state or an at least partially broken state. The binary' nature of the output of the sensor unit facilitates a more rapid detection and response to a loss of integrity' of the tension member than would otherwise be possible via the monitoring of drive assembly parameters.

[0081] In some embodiments described herein, the sensor unit can also automatically reduce the tension affecting the medical instrument. In such embodiments, the sensor unit can have a first position that defines an operational cable path for a cable pair of the medical instrument. The operational cable path can, for example, correspond to a design (or nominal) cable path for each cable of the cable pair on a condition that both cables of the cable pair are in an intact state. The sensor unit can be movable from the first position to a second position in response to a transition of the first cable of the cable pair to at least a partially broken state (e.g.. in response to a cable break). The second position can define a tension-release cable path for the second cable of the cable pair on a condition that the first cable of the cable pair is in at least a partially broken state. The tension-release cable path can have a length that is shorter than the length of the operational cable path. The transition to the shorter-1 ength tension-release cable path reduces the magnitude of the tension exerted on a portion of the end effector by the intact, second cable. The reduction in the magnitude of the tension mitigates or eliminates a non-commanded movement of the end effector, or a portion thereof, that would otherwise be driven by the tension in the intact cable. It should be appreciated that the immediate reduction in tension resulting from the movement of the tension-release member can be followed by a controller-implemented action to further mitigate or preclude the non-commanded movement of the end effector, or a portion thereof.Attorney Docket No. P06879-WO

[0082] In addition to the systems and methods described herein that facilitate the rapid detection, via the controller, of a loss of integrity in a cable or in one cable of a pair of cables, the present disclosure is also directed to the systems that can include mechanical structures and configurations that automatically reduce a tension affecting the end effector of the medical instrument in response to a reduction or loss of tension (e.g., a cable break) in a cable or in one cable of a pair of cables. The reduction in tension is achieved as an immediate mechanical response that does not involve a controller nor a control input for the initial response.

[0083] In some embodiments described herein, the reduction in tension can be achieved via a tension-release member. The tension-release member can have a first position that defines an operational cable path for a cable pair of the medical instrument. The operational cable path can, for example, correspond to a design (or nominal) cable path for each cable of the cable pair on a condition that both cables of the cable pair are in an intact state. The tension-release member can be movable from the first position to a second position in response to a transition of the first cable of the cable pair to at least a partially broken state (e.g., in response to a cable break). The second position can define a tension-release cable path for the second cable of the cable pair on a condition that the first cable of the cable pair is in at least a partially broken state. The tension-release cable path can have a length that is shorter than the length of the operational cable path. The transition to the shorter-length tension-release cable path reduces the magnitude of the tension exerted on a portion of the end effector by the intact, second cable. The reduction in the magnitude of the tension mitigates or eliminates a non-commanded movement of the end effector, or a portion thereof, that would otherw ise be driven by the tension in the intact cable. It should be appreciated that the immediate reduction in tension resulting from the movement of the tension-release member can be followed by a controller-implemented action to further mitigate or preclude the non-commanded movement of the end effector, or a portion thereof.

[0084] In some embodiments as described herein, the reduction in tension can be achieved via a cable-to-jaw coupling arrangement. For example, a unitary cable can be engaged with a coupling portion of the tool member (e.g., a jaw) of the end effector to produce a friction coupling of the cable to the tool member. The friction coupling can be configured to limit movement of the cable relative to the tool member on a condition that the cables in intact state but allow the cable to decouple from the tool member on the condition that a portion of the cable transitions to a parted state. Said another way. the unitary cable can be wrapped aroundAttorney Docket No. P06879-WOat least one pin of the tool member to transfer a load from the proximal mechanical structure of the medical instrument to the tool member. The cable can be held coupled to the tool member via the capstan effect rather than a crimp or other similar mechanical cable-to-jaw coupling. Accordingly, in the event of the cable break, the unbroken side of the cable pulls free due to the absence of the counter tension required to keep the w raps in place.

[0085] As used herein, the term “about” when used in connection with a referenced numeric indication means the referenced numeric indication plus or minus up to 10 percent of that referenced numeric indication. For example, the language “about 50” covers the range of 45 to 55. Similarly, the language “about 5” covers the range of 4.5 to 5.5.

[0086] As used in this specification and the appended claims, the w ord “distal” refers to direction towards a work site, and the word “proximal” refers to a direction away from the work site. Thus, for example, the end of a medical device that is closest to the target tissue would be the distal end of the medical device, and the end opposite the distal end (i.e., the end manipulated by the user or coupled to the actuation shaft) w ould be the proximal end of the medical device.

[0087] Further, specific words chosen to describe one or more embodiments and optional elements or features are not intended to limit the invention. For example, spatially relative terms — such as “beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, and the like — may be used to describe the relationship of one element or feature to another element or feature as illustrated in the figures. These spatially relative terms are intended to encompass different positions (i.e., translational placements) and orientations (i.e., rotational placements) of a device in use or operation in addition to the position and orientation shown in the figures. For example, if a device in the figures is turned over, elements described as "below" or “beneath” other elements or features would then be “above” or “over” the other elements or features. Thus, the term “below” can encompass both positions and orientations of above and below. A device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Likewise, descriptions of movement along (translation) and around (rotation) various axes include various spatial positions and orientations. The combination of a body’s position and orientation define the body’s pose.Attorney Docket No. P06879-WO

[0088] Similarly, geometric terms, such as “parallel’', “perpendicular’, “round”, or “square”, are not intended to require absolute mathematical precision, unless the context indicates otherwise. Instead, such geometric terms allow for variations due to manufacturing or equivalent functions. For example, if an element is described as “round” or “generally round,” a component that is not precisely circular (e.g., one that is slightly oblong or is a many-sided polygon) is still encompassed by this description.

[0089] In addition, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context indicates otherwise. The terms “comprises”, “includes”, “has”, and the like specify the presence of stated features, steps, operations, elements, components, etc. but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, or groups.

[0090] As used in this specification and the appended claims, the word “member” refers to a constituent portion of a larger structure or mechanism. A “member” can refer to an individual contiguous structure or multiple connected structures such as a mechanism.

[0091] Unless indicated otherwise, the terms apparatus, medical device, medical instrument, and variants thereof, can be interchangeably used.

[0092] Inventive aspects are described with reference to a teleoperated surgical system. An example architecture of such a teleoperated surgical system is the da Vinci® surgical system commercialized by Intuitive Surgical, Inc.. Sunnyvale, California. Knowledgeable persons will understand, however, that inventive aspects disclosed herein may be embodied and implemented in various ways, including computer-assisted, non-computer-assisted, and hybrid combinations of manual and computer- assisted embodiments and implementations. Implementations are merely presented as examples, and they are not to be considered as limiting the scope of the inventive aspects disclosed herein. As applicable, inventive aspects may be embodied and implemented in both relatively smaller, hand-held, hand-operated devices and relatively larger systems that have additional mechanical support.

[0093] FIG. 1 is a plan view illustration of a teleoperated surgical system 1000 that operates with at least partial computer assistance (a “telesurgical system”). Both telesurgical system 1000 and its components are considered medical devices. Telesurgical system 1000 is a Minimally Invasive Robotic Surgical (MIRS) system used for performing a minimally invasive diagnostic or surgical procedure on a Patient P who is lying on an Operating table 1010. TheAttorney Docket No. P06879-WOsystem can have any number of components, such as a user control unit 1100 for use by a surgeon or other skilled clinician S during the procedure. The MIRS system 1000 can further include a manipulator unit 1200 (popularly referred to as a surgical robot), an optional auxiliary equipment unit 1150, and a controller 1800. The manipulator unit 1200 can include an arm assembly 1300 and a surgical instrument tool assembly removably coupled to the arm assembly. The manipulator unit 1200 can manipulate at least one removably coupled instrument 1400 through a minimally invasive incision in the body or natural orifice of the patient P while the surgeon S views the surgical site and controls movement of the instrument 1400 through control unit 1100. An image of the surgical site is obtained by an endoscope (not shown), such as a stereoscopic endoscope, which can be manipulated by the manipulator unit 1200 to orient the endoscope. The auxiliary equipment unit 1150 can be used to process the images of the surgical site for subsequent display to the Surgeon S through the user control unit 1100. The number of instruments 1400 used at one time will generally depend on the diagnostic or surgical procedure and the space constraints within the operating room, among other factors. If it is necessary to change one or more of the instruments 1400 being used during a procedure, an assistant removes the instrument 1400 from the manipulator unit 1200 and replaces it with another instrument 1400 from a tray 1020 in the operating room. Although shown as being used with the instruments 1400, any of the instruments described herein can be used with the MIRS 1000.

[0094] FIG. 2 is a perspective view of the control unit 1100. The user control unit 1100 includes a left eye display 1112 and a right eye display 1114 for presenting the surgeon S with a coordinated stereoscopic view of the surgical site that enables depth perception. The user control unit 1100 further includes one or more input control devices 1116, which in turn cause the manipulator unit 1200 (shown in FIG. 1) to manipulate one or more tools. The input control devices 1116 provide at least the same degrees of freedom as instruments 1400 with which they are associated to provide the surgeon S with telepresence, or the perception that the input control devices 1116 are integral with (or are directly connected to) the instruments 1400. In this manner, the user control unit 1100 provides the surgeon S with a strong sense of directly controlling the instruments 1400. To this end, position, force, strain, or tactile feedback sensors (not shown) or any combination of such sensations, from the instruments 1400 back to the surgeon's hand or hands through the one or more input control devices 1116.Attorney Docket No. P06879-WO

[0095] The user control unit 1100 is shown in FIG. 1 as being in the same room as the patient so that the surgeon S can directly monitor the procedure, be physically present if necessary, and speak to an assistant directly rather than over the telephone or other communication medium. In other embodiments, however, the user control unit 1100 and the surgeon S can be in a different room, a completely different building, or other location remote from the patient, allowing for remote surgical procedures.

[0096] FIG. 3 is a perspective view of the auxiliary equipment unit 1150. The auxiliary equipment unit 1150 can be coupled with the endoscope (not shown) and can include one or more controllers with processors to process captured images for subsequent display, such as via the user control unit 1100. or on another suitable display located locally (e.g., on the unit 1150 itself as shown, on a wall-mounted display) and / or remotely. For example, where a stereoscopic endoscope is used, the auxiliary equipment unit 1150 can process the captured images to present the surgeon S with coordinated stereo images of the surgical site via the left eye display 1112 and the right eye display 1114. Such coordination can include alignment between the opposing images and can include adjusting the stereo working distance of the stereoscopic endoscope. As another example, image processing can include the use of previously determined camera calibration parameters to compensate for imaging errors of the image capture device, such as optical aberrations.

[0097] FIG. 4 shows a front perspective view of the manipulator unit 1200. The manipulator unit 1200 includes the components (e.g., arms, linkages, motors, sensors, and the like) to provide for the manipulation of the instruments 1400 and an imaging device (not shown), such as a stereoscopic endoscope, used for the capture of images of the site of the procedure. Specifically, the instruments 1400 and the imaging device can be manipulated by teleoperated mechanisms having one or more mechanical joints. Moreover, the instruments 1400 and the imaging device are positioned and manipulated through incisions or natural orifices in the patient P in a manner such that a center of motion remote from the manipulator and typically located at a position along the instrument shaft is maintained at the incision or orifice by either kinematic mechanical or software constraints. In this manner, the incision size can be minimized.

[0098] FIG. 5 is a perspective view of a portion of an arm assembly 1300 and an instrument carriage 1330 to which an instrument 1400 can be removably coupled. The instrument carriage 1330 includes teleoperated actuators (e.g., motors 1340 with coupled drive discs 1320) toAttorney Docket No. P06879-WOprovide controller motions to the instrument 1400, which translates into a variety of movements of a tool or tools at a distal end portion 1402 (FIG. 6) of the instrument 1400. The arm assembly 1300 includes a connecting portion 1324 in which the instrument carriage 1330 can be coupled. The instrument carriage 1330 may be translatable relative to the arm assembly 1300, for example, along an insertion axis extending between a proximal end and a distal end of the arm assembly 1300 for insertion and removal of the instrument into a patient. The translation of the instrument carriage 1330 can develop a corresponding linear motion of the instrument 1400. In addition, the arm assembly 1300 can provide for additional degrees of freedom to orient and position the instrument carriage 1330 and instrument 1400 at a desired location. When an instrument 1400 is coupled to the instrument carnage 1330, input provided by a surgeon S to the user control unit 1100 (a “master” command) is translated into a corresponding action by the instrument 1400 (a ’slave” response) via drive discs 1320 of the instrument carriage 1330 that are operatively coupled instrument discs (FIG. 6) on the instrument 1400.

[0099] The instrument camage 1330 includes a carriage interface that includes drive discs 1320 that are configured to be operatively coupled with instrument discs 1702 (see FIG. 6) at a drive member interface. In embodiments utilizing a sterile adapter or other similar structure, the drive discs 1320 may be matingly coupled to couplers of the instrument sterile adapter. The instrument carriage 1330 also includes an indentation or cutout region 1310 in which the instrument shaft (shaft) 1410 (FIG. 6) of the instrument 1400 can extend when the instrument 1400 is supported by the manipulator unit 1200. In some embodiments, the drive discs 1320 of the carriage 1330 may be directly coupled to inputs of the instrument discs 1702 of the instrument 1400 without an intermediary' sterile adapter.

[0100] In some embodiments, the system 1000 can include at least one drive assembly (e.g., a first drive assembly 1050 and a second drive assembly 1060) configured to control a position of tension members of the instrument 1400. The drive assembly can, in some embodiments, include the teleoperated actuator (e.g., a motor 1340 with coupled drive disc 1320) of the arm assembly 1300, which produces and transmits torque in response to a controller command, as well as corresponding rotational drive components of the instrument 1400, which receive the torque from the motor and apply a tension to a tension member 1420 (FIG. 7). The corresponding rotational drive components can, for example, include an instrument disc 1702 and a capstan 1710 (FIG. 7), about which a tension member 1420 can be wound or otherwise coupled. In some embodiments, the drive assembly can be containedAttorney Docket No. P06879-WOentirely within the instrument 1400 such that the motor is also positioned within the proximal mechanical structure 1700 (FIG. 6) with the corresponding rotational drive components.

[0101] FIG. 6 is a perspective view of a portion of the instrument 1400 according to an embodiment. In some embodiments, the instrument 1400 or any of the components therein are optionally parts of a surgical system that performs surgical procedures, and which can include a manipulator unit, a series of kinematic linkages, a set of cannulas, or the like. The instrument 1400 (and any of the instruments described herein) can be used in any suitable surgical system, such as the MIRS system 1000 shown and described above. As shown in FIG. 6, the instrument 1400 includes a proximal mechanical structure 1700 (depicted with an outer cover removed), an instrument shaft 1410, a distal end portion 1402, and a set of cables (not depicted in FIG.6). The cables function as tension members that couple the proximal mechanical structure 1700 to the distal end portion 1402. In some embodiments, the distal end portion 1402 of the instrument 1400 can include a wrist assembly 1500 coupled to the instrument shaft 1410. In some embodiments, the distal wrist assembly can support an end effector 1460. The instrument 1400 is configured such that movement of one or more of the cables produces movement of the end effector 1460 (e.g., pitch, yaw, or grip) and / or the wrist assembly 1500 about axes of an instrument coordinate system. The instrument coordinate system can include a longitudinal axis ALO defined by the instrument shaft and at least one lateral axis ALA extending orthogonally to the longitudinal axis ALO.

[0102] In some embodiments, the instrument shaft 1410 can be any suitable elongated shaft that is coupled to the wrist assembly 1500 and to the proximal mechanical structure 1700. Specifically, the instrument shaft 1410 includes a proximal end 1411 that is coupled to the proximal mechanical structure 1700, and a distal end portion 1412 that is coupled to the wrist assembly 1500 (e.g., a proximal link of the wrist assembly 1500). The instrument shaft 1410 defines a passageway or series of passageways through which the cables and other components can be routed from the proximal mechanical structure 1700 to the wrist assembly 1500.

[0103] In some embodiments, the instrument shaft 1410 can be formed, at least in part with, for example, an electrically conductive material such as stainless steel. In such embodiments, the shaft may include any of an inner insulative cover or an outer insulative cover. Thus, the instrument shaft 1410 can be a shaft assembly that includes multiple different components. For example, the instrument shaft 1410 can include (or be coupled to) a spacer that provides the desired fluid seals, electrical isolation features, and any other desired components for couplingAttorney Docket No. P06879-WOthe wrist assembly 1500 to the instrument shaft 1410. Similarly stated, although the wrist assembly 1500 (and other wrist assemblies or links described herein) are described as being coupled to the instrument shaft 1410, it is understood that any of the wrist assemblies or links described herein can be coupled to the shaft via any suitable intermediate structure, such as a spacer and a cable guide, or the like.

[0104] In some embodiments, the end effector 1460 can include at least one tool member 1462 having a contact portion configured to engage or manipulate a target tissue during a surgical procedure. For example, in some embodiments, the contact portion can include an engagement surface that functions as a gripper, cutter, tissue manipulator, or the like. In other embodiments, the contact portion can be an energized tool member that is used for cauterization or electrosurgical procedures. The end effector 1460 may be operatively coupled to the proximal mechanical structure 1700 such that the tool member 1462 rotates relative to instrument shaft 1410. In this manner, the contact portion of the tool member 1462 can be actuated to engage or manipulate a target tissue during a surgical procedure. The tool member 1462 (or any of the tool members described herein) can be any suitable medical tool member. Moreover, although only one tool member 1462 is identified, as shown, the instrument 1400 can include two tool members that cooperatively perform gripping or shearing functions. In other embodiments, an end effector can include more than two tool members.

[0105] The proximal mechanical structure 1700 is configured to be removably coupled to the arm assembly 1300 manipulator unit 1200 (FIG. 4). The manipulator unit 1200 includes teleoperated actuators (e g., motors 1340 with coupled drive discs 1320) to provide controller motions to the instrument 1400, which translates into a variety of movements of a tool or tools at the distal end portion 1402 of the instrument 1400. Wlien an instrument 1400 is coupled to the arm assembly 1300, input provided by a surgeon S to the user control unit 1100 (a “master” command) is translated into a corresponding action by the instrument 1400 (a “slave” response) via drive discs of the arm assembly 1300 that are operatively coupled instrument discs 1702 on the instrument 1400.

[0106] In some embodiments, the proximal mechanical structure 1700 is operably coupled to the wrist assembly 1500 and / or the end effector 1460 via at least one tension member. The tension member can, for example, be a cable or other similar structure configured to transmit a tensile load. As depicted in FIG. 7, in some embodiments, the instrument 1400 includes at least a first cable 1420 and a second cable 1430. In some embodiments, the first cable 1420Attorney Docket No. P06879-WOand the second cable 1430 can be arranged as a cable pair. In some embodiments, the first cable 1420 in the second cable 1430 can be portions of a single, continuous cable. However, in some embodiments, the first cable 1420 in the second cable 1430 can be two separate cables arranged as the cable pair to work in conjunction with one another to achieve a singular effect.

[0107] The instrument 1400 is configured such that movement of the first cable 1420 in response to a torque input from a first drive assembly 1050 and second cable 1430 in response to a torque input from a second drive assembly 1060 produces rotation of the end effector 1460 about a first axis of rotation (which functions as the yaw axis; the term yaw is arbitrary ) of the wrist assembly about a second axis of rotation (which functions as the pitch axis; the term pilch is arbitrary), a cutting rotation of the tool members of the end effector 1460 about the first axis of rotation, or any combination of these movements. Additional examples and disclosures of the actuation of the end effector with relevant axes, e.g., first axis and second axis, are further disclosed in U. S. application no. 18 / 683,651 entitled “Surgical Instrument Cable Control and Routing Structures" filed on February 14. 2024, which is incorporated herein by reference in its entirety.

[0108] As depicted in FIG. 7, in some embodiments, the first cable 1420 can include a proximal portion 1421 and a distal portion (not shown). The proximal portion 1421 of the first cable 1420 can be coupled to a first capstan 1710. In some embodiments, the second cable 1430 can include a proximal portion 1431, and a distal portion (not shown). The proximal portion 1431 of the second cable 1430 can be coupled to a second capstan 1720. The distal portions of the first cable 1420 and the second cable 1430 can be coupled to a portion of the wrist assembly 1500 or the end effector 1460 (e.g., the tool member 1462). Thus, movement of the first capstan 1710 and the second capstan 1720 can move the proximal end portions of the first cable 1420 and the second cable 1430 to move the portion of the wrist assembly 1500 or the end effector 1460.

[0109] The end effector 1460 can be operatively coupled to the proximal mechanical structure 1700 such that the tool member(s) 1462 rotates about the first axis of rotation. For example, a drive pulley (not shown) of the tool member 1462 can coupled to the distal end of the first cable 1420 and the second cable 1430 such that a tension force exerted by the cable pair produces a rotation torque about the first axis. In this manner, the tool member 1462 can be actuated to engage or manipulate a target tissue during a surgical procedure.Attorney Docket No. P06879-WO

[0110] In some embodiments, the proximal mechanical structure 1700, can include at least one chassis 1762, at least one capstan (e.g., the first capstan 1710, the second capstan 1720. the third capstan 1730, the fourth capstan 1740), and a guide structure 1780. The at least one capstan is coupled to the tension members (e.g., the first cable 1420, the second cable 1430) to move the tension members relative to (e.g., across) the guide structure 1780 in response to a motor input.

[0111] As shown in FIG. 7, the guide structure 1780, which is also referred to as a “waterfall” structure, can include an upper portion 1783 and a lower portion 1784. The lower portion 1784 is mounted to a component within the proximal mechanical structure 1700. such as the chassis 1762. The upper portion 1783 includes multiple guide grooves 1785 on a top guide surface 1786. The guide grooves 1785 extend along the top guide surface 1786 to at least one opening defined in the top surface 1786. As shown in FIG. 7, the cable pair is routed along the top surface 1786 within the guide grooves 1785 and through the openings to be routed to the passageway defined by the instrument shaft 1410. Said another way, the guide structure 1780 is formed to direct the cables from the proximal mechanical structure 1700 and into or along the instrument shaft 1410. Accordingly, the guide structure 1780 causes a change in the direction of the cables between the portions that are within the proximal mechanical structure and the portions that are within / along the instrument shaft 1410.

[0112] In some embodiments, the capstan(s) can include an upper portion, a lower portion, and a spool therebetween. The upper portion can function as an anchor portion to secure an associated tension member to the capstan. In some embodiments, the upper portion can include a specific configuration to allow for a cable to be coupled to the capstan without the use of external mechanisms (e g., crimp joints, adhesive, knots) to maintain the coupling of the cable to the capstan. Such configuration can include, for example, grooves and recesses within which the cable can be wrapped, as shown and described in U. S. application no. 18 / 683,651 entitled “Surgical Instrument Cable Control and Routing Structures” filed on February 14, 2024, which is incorporated herein by reference in its entirety. In other embodiments, however, the upper portion can include recesses or channels that receive a crimp or know to secure the cable therein. The spool can include a cable wrap surface (which functions as a drive surface) and a side wall. The tension member can be coupled to the corresponding capstan such that a proximal end portion of the tension member wraps about the cable wrap surface.Attorney Docket No. P06879-WO

[0113] In some embodiments, a housing cover, which is not depicted in FIGS. 6 and 7, encloses the proximal mechanical structure 1700, including the chassis 1762. The chassis 1762 provides structural support for mounting and aligning components in the proximal mechanical structure 1700. For example, the chassis 1762 defines a shaft opening 1712 that is communicatively coupled to the passageway defined by the instrument shaft 1410. In some embodiments, the chassis 1762 includes one or more bearing surfaces or defines one or more openings configured to rotatably support the capstans (e.g., the first capstan 1710 and the second capstan 1720).

[0114] In addition to providing mounting support for the internal components of the proximal mechanical structure 1700. the chassis 1762 can include external features (e.g., recesses, clips, etc.) that interface with a docking port of a drive device (not shown). The drive device can be, for example, a handheld system or a computer-assisted teleoperated system that can receive and manipulate the medical instrument 1400 to perform various surgical operations. The drive device can include one or more motors to drive capstans of the proximal mechanical structure 1700. In other embodiments, the drive device can be an assembly that can receive and manipulate the instrument 1400 to perform various operations.

[0115] Although the proximal mechanical structure 1700 is shown as including at least one capstan (e.g., the first capstan 1710, the second capstan 1720, the third capstan 1730, the fourth capstan 1740), in other embodiments, a mechanical structure can include one or more linear actuators that produce translation (linear motion) of a portion of the cables. Such proximal mechanical structures can include, for example, a gimbal, a lever, or any other suitable mechanism to directly pull (or release) an end portion of any of the cables. For example, in some embodiments, the proximal mechanical structure 1700 can include any of the proximal mechanical structures or components described in U. S. Patent Application Pub. No. US 2015 / 0047454 A1 (filed Aug. 15, 2014), entitled “Lever Actuated Gimbal Plate,” or U. S. Patent No. US 6,817,974 B2 (filed Jun. 28, 2001), entitled “Surgical Tool Having Positively Positionable Tendon- Actuated Multi-Disc Wrist Joint,” each of which is incorporated herein by reference in its entirety.

[0116] FIGS. 8A and 8B are schematic illustrations of a system 2000 according to an embodiment. The system 2000 can, for example, include any of the features and / or elements described herein with reference to any other surgical system, such as system 1000 described above. As depicted, the system 2000 can include a first drive assembly 2050, a second driveAttorney Docket No. P06879-WOassembly 2060, and an instrument 2400. The instrument 2400 can include a first tension member 2420, a second tension member 2430, and a sensor unit 2600. The first tension member 2420 can be operably coupled between the first drive assembly 2050 and an end effector 2460. Likewise, the second tension member 2430 can be operably coupled between the second drive assembly 2060 and the end effector 2460. Accordingly, the first tension member 2420 and the second tension member 2430 are positioned to transfer a torque, in the form of tension within the respective tension member, from the drive assemblies to the end effector 2460. In some embodiments, the first tension member 2420 and the second tension member 2430 are arranged as a first cable and a second cable of a cable pair configured to transfer a mechanical input (e.g., a tensile load) from the first drive assembly 2050 and / or the second drive assembly 2060 a portion of the end effector 2460. In some embodiments, a tensile load is simultaneously applied to each cable and a difference in the magnitude of the applied tensile loads between the cables causes a movement of the portion of the end effector 2460.

[0117] As depicted, the sensor unit 2600 is operably coupled to the tension members of the instrument 2400. The sensor unit 2600 is configured to produce an output that is associated with an operating state of the tension member(s). For example, the sensor unit 2600 can be operably coupled to the first tension member 2420 and configured to produce an output associated with the operating state of the first tension member 2420. The operating state of the tension member(s) can be either an intact state Si, as depicted in FIG. 8A, or an at least partially broken state Sp. In FIG. 8B, the first tension member 2420 is depicted as being parted (e.g., broken or separated) and, therefore, in the at least partially broken state Sp. The at least partially broken state Sp can correspond to a loss of integrity of the first tension member 2420 that precludes the transmission of a desired tensile magnitude within the first tension member 2420 to the end effector 2460.

[0118] In some embodiments, the system 2000 includes a controller 2800. The controller 2800 can include any of the features or elements described herein with reference to controller 1800 (FIG. 18). As depicted, the controller 2800 can be operably (e.g., communicatively) coupled to a combination of the first drive assembly 2050, the second drive assembly 2060, and the sensor unit 2600. The controller 2800 can be configured to perform any of a set of operations 80, such as depicted in FIG. 9. The set of operations can facilitate the rapid detection of a transition of the first tension member 1420 to the at least partially broken state Sp, as depicted in FIG. 8B, and the implementation of a mitigating response to reduce or preclude aAttorney Docket No. P06879-WOnon-commanded movement of the end effector 2460 in response to a tensile load remaining in the intact, second tension member 1430.

[0119] As depicted in FIG. 9 at 81, in some embodiments, the set of operations 80 includes causing a tensile load to be applied to the first tension member 2420 via the first drive assembly 2050 and to the second tension member 2430 via the second drive assembly 2060 on a condition that the first tension member 2420 is in the intact state Si, as depicted in FIG. 8A. For example, the controller 2800 can cause a rotation of the motors of the first and second drive assemblies 2050, 2060 to apply a torque to each of the first tension member 2420 and the second tension member 2430 on a condition that each tension member of the pair of tension members is in an intact state Si. The torque applied by the rotation of the motors is manifested as a tensile load within each of the first tension member 2420 and the second tension member 2430. The magnitude of the applied tensile load can, in some embodiments, be different in each tension member of the pair of tension members to cause a rotation of the end effector 2460.

[0120] As depicted at 82, in some embodiments, the set of operations 80 includes detecting, based on the output of the sensor unit 2600, a transition of the first tension member 1420 from an intact state Si, as depicted in FIG. 8A, towards an at least partially broken state Sp (e.g., a parted sate), as depicted in FIG. 8B. The output of the sensor unit 2600 can be a binary output corresponding to either the presence or absence of a signal between the sensor unit 2600 and the controller 2800. Said another way, the sensor unit 2600 can output only one of two indications for each tension member. The first indication corresponds to the tension member being in an intact state Si, while the second indication corresponds to the transition of the tension member toward the at least partially broken state Sp. For example, in some embodiments, the output of the sensor unit 2600 can correspond to the interruption of a continuity signal, wherein the presence of the continuity signal corresponds to the first tension member 2420 being in the intact state Si and the interruption of the signal corresponds to the transition of the first tension member 1420 toward the at least partially broken state Sp. By way of additional illustration, in some embodiments, the output of the sensor unit 2600 can correspond to the delivery of the signal, such as in response to the closing of the circuit. In such an embodiment, the absence of a signal being received from the sensor unit 2600 by the controller 2800 is indicative of the first tension member 2420 being in the intact state Si, while the receipt of a signal from the sensor unit 2600 is indicative of the transition of the first tension member 2420 toward the at least partially broken state Sp. The use of the binary output toAttorney Docket No. P06879-WOindicate the state of the monitored tension member facilitates the rapid detection of the loss of integrity of the tension member and. by extension, the rapid implementation of mitigation measures to limit or preclude the undesirable, non-commanded movement of the end effector 2460.

[0121] Referring to FIGS. 8A and 8B, the sensor unit 2600 can, for example, include a switch 2640. The switch 2640 can have a first switch state SSi and a second switch state SS2. The switch 2640 can be in the first switch state SSi on a condition that the first tension member 2420 is in the intact state Si. The switch 2640 can be configured to then transition to the second switch state SS2 in response to the transition of the first tension member 2640 towards the at least partially broken state Sp. Accordingly, in some embodiments, the output of the sensor unit 2600 can correspond to the transition of the switch 2640 to the second switch state SS2. In some embodiments, the transition of the switch 2640 to the second switch state SS2 can correspond to the opening of a circuit. However, in some embodiments, the transition of the switch 2640 to the second switch state SS2 can correspond to the closing of a circuit.

[0122] In some embodiments, the sensor unit 2600 can include a conductive element (e.g., an insulated conductive element) of the first tension member 1420. The conductive element can, for example, extend between the first drive assembly 2050 and the end effector 2460. As depicted at 83 and FIG. 9, the set of operations 80 can, in some embodiments, optionally include delivering a continuity signal to the conductive element. The controller 2800 can, therefore, be configured to receive the continuity signal on a condition that the first tension member 1420 is in the intact state Si. Accordingly, the detection of the transition of the first tension member 1420 to the at least partially broken state Sp can include, at 84, detecting a disruption of the continuity signal. The disruption of the continuity signal being, therefore, indicative of the transition of the first tension member 1420 to the at least partially broken state SP.

[0123] As depicted at 85 in FIG. 9, in some embodiments, the set of operations 80 includes affecting an operation of the second drive assembly 2060 to mitigate a non-commanded movement of the end effector 2460 in response to the detection of the transition of the first tension member 2420 from the intact state Si towards the at least partially broken state SP. In some embodiments, affecting the operation of the second drive assembly 2060 can include halting a rotation of the second drive assembly 2060 as an initial response to the transition of the first tension member 2420 to the at least partially broken state Sp.Attorney Docket No. P06879-WO

[0124] In some embodiments, to affect the operation of the second drive assembly 2060, the controller 2800 reverses a rotational direction of the second drive assembly 2060. Reversing the rotational direction of the second drive assembly 2060 can, for example, reduce a tensile load transmitted to the end effector 2460 via the second tension member 2430. In some embodiments, reversing the rotational direction of the second drive assembly 2060 can increase a length of the intact, second tension member 2430 between the second drive assembly 2060 and the end effector 2460. Reversing the rotational direction of the second drive assembly 2060 can, therefore, establish slack along the second tension member 2430. The presence of slack along the second tension member 2430 reduces or eliminates the tensile load within the second tension member 2430. The reduction or elimination of the tensile load accordingly minimizes or precludes delivery of the tensile load to the end effector 2460. Therefore, an undesirable, non-commanded movement of the end effector 2460 that would have otherwise occurred in response to the tensile load in second tension member 2430 (e.g., one cable of a cable pair) in the absence of a tensile load in the first tension member 2420 (e.g., due to the transition to the at least partially broken state Sp) is minimized or precluded.

[0125] In some embodiments, to affect the operation of the second drive assembly 2060, the controller 2800 the rotational speed of the second drive assembly 2060 is altered in accordance with a damping transition while the rotational direction remains unchanged. The damping transition is an instruction implemented by the controller 2800 to dissipate the stored energy over a longer period of time than would be experienced if the rotational direction was reversed as described above. Said another way, the damping transition precludes a rapid release of energy as might be encountered in an undamped system. The dissipation of the stored energy accordingly minimizes or precludes delivery of the tensile load to the end effector 2460. Therefore, an undesirable, non-commanded movement of the end effector 2460 that would have otherwise occurred in response to the tensile load in second tension member 2430 (e.g., one cable of a cable pair) in the absence of a tensile load in the first tension member 2420 (e.g., due to the transition to the at least partially broken state Sp) is minimized or precluded.

[0126] FIGS. 10-13 depict a sensor unit 3600 according to an embodiment. The sensor unit 3600 can, for example, be used with any instrument described herein, such as instrument 1400 or instrument 2400, having at least one cable configured to transfer a mechanical input from a proximal mechanical structure (e.g., proximal mechanical structure 1700) to a portion of an end effector (e.g., the tool member 1462). The cable(s) can, as described above, beAttorney Docket No. P06879-WOarranged as a first cable 1420 of a cable pair that includes a second cable 1430. For the purposes of illustration, unless stated otherwise, the sensor unit 3600 is described below with reference to the instrument 1400, the first tension member 1420, and the first capstan 1710.

[0127] FIG. 10 is a perspective view of the guide structure 1780 and the sensor unit 3600 co-located therewith according to an embodiment. Similarly, FIG. 11 is a close-up view of a portion of the guide structure 1780 and the sensor unit 3600 depicted in FIG. 10. As depicted in FIG. 7, the guide structure 1780 can be positioned between the shaft opening 1712 defined by the proximal mechanical structure 1700 (e.g., defined at least in part by the chassis 1762) and the drive components (e.g., the first capstan 1710 and the second capstan 1720 as depicted in FIG. 7) of the proximal mechanical structure 1700. The guide structure 1780 (which is also referred to as a “waterfall” due to the directional change imparted on the tension members by the guide structure 1780) includes the upper portion 1783 that defines at least one guide groove 1785. The guide groove 1785 extends along the top guide surface 1786 radially outward from the shaft opening 1712. The guide structure 1780 can, for example, define a distinct, separate guide path Gp into the shaft opening 1712 for each tension member (e.g., the first tension member 1420 and the second tension member 1430) of the instrument 1400.

[0128] In some embodiments, the first tension member 1420 is configured to transition within the guide path Gp between the first direction as indicated by arrow D1 and the second direction as indicated by arrow D2. Accordingly, the first tension member 1420 extends generally in the first direction D1 between the first capstan 1710 and the shaft opening 1712 and in the second direction D2 between the shaft opening 1712 and the end effector 1460 (FIG.6). Said another way, the first tension member 1420 can extend generally in the first direction D1 between the first capstan 1710 and the shaft opening 1712 and is redirected by the guide structure 1780 to extend in the second direction D2 between the shaft opening 1712 and the end effector 1460. It should be appreciated that the first direction DI and the second direction D2 form a non-zero angle. For example, in some embodiments, the first direction DI and the second direction D2 form an angle in a range of 70 degrees to 120 degrees (e.g., substantially 90 degrees).

[0129] In some embodiments, the sensor unit 3600 is co-located with the guide structure 1780. Said another way, in some embodiments, the sensor unit 3600 is integrated with or incorporated into the guide structure 1780. Accordingly, at least a portion of the sensor unit 3600 is positioned between the drive components and the shaft opening 1712. For example,Attorney Docket No. P06879-WOthe sensor unit 3600 can be positioned between the first capstan 1710 and the shaft opening 1712. In such an embodiment the sensor unit 3600 can have a first switch state SSi on a condition that the first tension member 1420 is in an intact state and a second switch state SS2 on a condition that the first tension member 1420 is transitioned toward at least partially broken state. In other words, the sensor unit 3600 can transition from the first switch state SSi to the second switch state SS2 in response to a reduction in the integrity of the first tension member 1420 resulting in an undesirable (e.g. un-commanded or unintended) decrease in tension within the first tension member 1420.

[0130] In some embodiments, the first switch state SSi is an open switch state, while the second switch state SS2 is a closed switch state that completes a circuit. In such embodiments, the completion of the circuit is indicative of the transition of the first tension member 1420 towards the at least partially broken state. In some embodiments however, the first switch state SSi is a closed switch state that completes a circuit, while the second switch state SS2 is an open switch state that interrupts the circuit. The interruption of the circuit is indicative of the transition of the first tension member 1420 towards the at least partially broken state. For example, in the first switch state SSi, the sensor unit 3600 can deliver a continuity signal to the controller 1800 that is indicative of the first tension member 1420 being in the intact state. The disruption of the continuity signal corresponding to the transition of the sensor unit 4600 to the second switch state SS2 is, therefore, indicative of the transition of the first tension member 1420 towards the at least partially broken state.

[0131] Referring to FIGS. 10-13, in some embodiments, the sensor unit 3600 includes an actuating key 3642 and a switch 3640. The switch 3640 is configured to move from the first switch state SSi (depicted in FIG. 13) to the second switch state SS2 (depicted in FIG. 12) with the transition of the first tension member 1420 to the at least partially broken state. The switch 3640 can, for example, be a momentary switch with the second switch state SS2 being the default switch state for the momentary’ switch. Said another way, as a momentary switch, the switch 3640 can be biased toward the second switch state SS2. Accordingly, in the absence of a force maintaining the switch 3640 in the first switch state SSi, the switch 3640 defaults to the second switch state SS2, which is indicative of the transition of the first tension member 1420 to the at least partially broken state.

[0132] As depicted in FIG. 13, the actuating key 3642 is positioned between the first tension member 1420 and the switch 3640. The actuating key 3642 is positioned at aAttorney Docket No. P06879-WOcompressed position Pc, as depicted in FIG. 13, in response to a tensile load applied to the first tension member 1420 on a condition that the first tension member 1420 is in the intact state. The switch 3640 is maintained in the first switch state SSi by the actuating key 3642 at the compressed position Pc. Said another way, on a condition that the first tension member 1420 is under tension, a force exerted on the actuating key 3642 by the first tension member 1420 maintains the actuating key 3642 at the compressed position Pc and. therefore, the switch 3640 in the first switch state SSi. As depicted in FIGS 10-12, the actuating key 3642 is positioned at an uncompressed position Pu on the condition that the first tension member 1420 transitions toward the at least partially broken state. As depicted in FIG. 12, the transition of the actuating key 3642 to the uncompressed position Pu results in the transition of the switch 3640 to the second switch state SS2.

[0133] In some embodiments, the actuating key 3642 includes a contact surface 3643. The contact surface 3643 is shaped to receive a force from the first tension member 1420. The contact surface 3643 can, for example, be shaped to minimize a friction between the actuating key 3642 and the first tension member 1420 on a condition that the first tension member 1420 is in contact with and exerting a force on the actuating key 3642. On a condition that the actuating key 3642 is at the compressed position Pc, the contact surface 3643 is aligned with the guide structure 1780. For example, in the compressed position Pc. the contact surface 3643 can be substantially aligned with the guide grooves 1785. Said another way, in some embodiments, the contact surface 3643 can be substantially flush with aline extending radially outward from the shaft opening 1712 along the vertex of the guide groove 1785. In some embodiments, the contact surface 3643 can have a radius of curvature that coincides with the radius of curvature of the guide groove 1785. Accordingly, in the compressed position, the radius of curvature of contact surface 3643 can be axially aligned with the radius of curvature of the guide grooves 1785.

[0134] As depicted in FIGS. 10 and 11, on a condition that the actuating key 3642 is at the uncompressed position Pu, the contact surface 3643 is proud of the guide structure 1780. For example, on the condition that the actuating key 3642 is at the uncompressed position Pu, a portion of the actuating key 3642 including the contact surface 3643 extends radially inward from a concave surface of the guide groove 1785 toward a longitudinal axis of the guide groove 1785. Accordingly, the actuating key 3642 being at the uncompressed position Pu corresponds to positioning the contact surface 3643 and a portion of the actuating key 3642 at least partiallyAttorney Docket No. P06879-WOwithin the guide path Gp defined by the guide groove 1785. Said another way, at the uncompressed position Pu, a portion of the actuating key 3642 including the contact surface 3643 is positioned within partially obstructs the guide path Gp. The portion of the actuating key 3642 is moved from the guide path with the movement to the compressed position Pc in response to the force applied to the contact surface 3643 by the first tension member 1420 in the intact state under a tensile load. Said yet another way, the absence of the first tension member 1420 within the guide path Gp permits the positioning of the portion of the actuating key 3642 including the contact surface 3643 within the guide path Gp, while the positioning of the first tension member 1420 within the guide path Gp precludes the positioning of the portion of the actuating key 3642 in the guide path Gp.

[0135] As depicted in FIG. 7, in some embodiments, the proximal mechanical structure 1700 can include a set of capstans and a set of tension members operably coupled to the end effector 1460 (FIG. 6). Accordingly, as depicted in FIGS. 10-13, the sensor unit 3600 can include a set of pairings of actuating keys and corresponding switches. Each actuating key is positioned to engage a different tension member of the instrument 1400 such that each actuating key is positioned at the compressed position Pc in response to a tensile load applied to the corresponding tension member on a condition that the corresponding tension member is in the intact state. Each switch of the set of pairings is maintained in the first switch position SSi by the corresponding actuating key at the compressed position Pc. In some embodiments for example, the instrument 1400 can include four tension members. Accordingly, the sensor unit 3600 can include four pairings of the actuating keys and the switches. With the four pairings, the sensor unit 3600 can, therefore, indicate to the controller 1800 a transition of anyone of the four tension members to the at least partially parted state. Said another way, with the four pairings, the sensor unit 3600 can indicate the occurrence of a cable break in anyone of the tension members of the instrument 1400, thereby, facilitating the implementation of a mitigating action to minimize or preclude an un-commanded movement of the end effector 1460.

[0136] FIGS. 14A and 14B are a schematic illustration and FIG. 15 is a side view of a sensor unit 4600 according to an embodiment. The sensor unit 4600 can, for example, be used with any instrument described herein, such as instrument 1400, having a cable pair configured to transfer a mechanical input from a proximal mechanical structure (e.g., proximal mechanical structure 1700) to a portion of an end effector (e.g., the tool member 1462). Such a cable pairAttorney Docket No. P06879-WOcan, as described above, include a first cable 1420 and a second cable 1430. For the purposes of illustration, the sensor unit 4600 is described below with reference to the instrument 1400 and, in particular, to the proximal mechanical structure 1700.

[0137] As depicted, in some embodiments, the sensor unit 4600 is positioned between the first and second capstans 1710. and the shaft opening 1712. In some embodiments, being positioned between the capstans and the shaft opening 1712 refers to the physical positioning of the sensor unit 4600. In some embodiments, being positioned between the capstans and the shaft opening 1712 refers to the operable positioning of the sensor unit 4600. The sensor unit 4600 can, in some embodiments, be further positioned between the first cable 1420 and the second cable 1430 of a cable pair operably coupled between a tool member (e.g.. tool member 1462) and a corresponding first capstan 1710 and second capstan 1720.

[0138] In some embodiments, the sensor unit 4600 has a first switch state SSi on a condition that the first cable 1420 is in an intact state Si as depicted in FIG. 14A. The sensor unit 4600 also has a second switch state SS2 on a condition that the first cable 1420 is in at least a partially broken state Sp (e.g., a parted state) as depicted in FIG. 14B. Accordingly, the sensor unit 4600 can, in some embodiments, include a body 4630. In some embodiments, the body 4630 can extend between a first guide portion 4632 and a second guide portion 4634. The first guide portion 4632 is positioned to engage the first cable 1420 of the cable pair and the second guide portion 4634 is positioned to engage the second cable 1430 of the cable pair. The body 4630 is movable from a first position Pi, as depicted in FIG. 14A, to a second position P2, as depicted in FIG. 14B, in response to a tensile load within the second cable 1430 on a transition of the first cable 1420 toward the at least partially broken state Sp. Said another way. the body 4630 is movable toward the second position P2 in response to a force exerted on the second guide portion 4634 by the second cable 1430 on the transition of the first cable 1420 toward the at least partially broken state Sp.

[0139] In some embodiments, the first guide portion 4632 and the second guide portion 4634 are each a fixed guide surface. Accordingly, the first guide portion 4632 and the second guide portion 4634 can be shaped to reduce a friction between elongated body 4630 and the cable pair. In some embodiments, the first guide portion 4632 and the second guide portion 4634 are formed from a low friction material. In some embodiments, the first guide portion 4632 and the second guide portion 4634 include a low friction coating. In some embodiments,Attorney Docket No. P06879-WOthe first guide portion 4632 and the second guide portion 4634 include a rotatable element. The rotatable element can, for example, be a pulley, a roller, or a captive ball.

[0140] As depicted in FIG. 15, in some embodiments, the body 4630 is movable relative to a fixed portion 4636 of the sensor unit 4600. The movement of the body 4630 relative to the fixed portion 4636 of the sensor unit 4600 can transition the sensor unit 4600 between the first switch state SSi and the second switch state SS2. In some embodiments, the fixed portion 4636 can be a switch that is mechanically actuated, electromechanically actuated, magnetically actuated or other similar switch architecture that is actuated by the movement of the body 4630 relative to the fixed portion 4636. In some embodiments, the first switch state SSi is an open switch state, and the second switch state SS2 is a closed switch state that completes a circuit. The completion of the circuit is indicative of the transition of the first cable 1420 toward the at least partially broken state Sp. However, in some embodiments, the first switch state SSi is a closed switch state that completes a circuit, and the second switch state is an open switch state that interrupts the circuit. The interruption of the circuit is indicative of the transition of the first cable 1420 toward the at least partially broken state Sp.

[0141] In some embodiments, the sensor unit 4600 is slidable laterally along a first axis Ai from the first position Pi to the second position P2. As depicted, the first axis Ai is orthogonal to a second axis A2. The second axis A2 bisects the shaft opening 1712. The sensor unit 4600 is, in some embodiments, centered on the second axis A2 when at the first position Pi. The movement of the sensor unit 4600 along the first axis Ai (e.g., a lateral movement) from the first position Pi to the second position P2 is in response to a transition of the first cable 1420 of the cable pair toward the at least partially broken (e.g., parted) state. The movement is. therefore, away from the second cable 1430 toward the first cable 1420 or a region of the proximal mechanical structure 1700 previously occupied by the first cable 1420. As depicted in FIG. 14B, the movement of the sensor unit 4600 can, for example, be in the direction indicated by arrow D3.

[0142] In some embodiments, the sensor unit 4600 is maintained in the first position Pi by the tension in each of the first cable 1420 and the second cable 1430 of the cable pair in an intact state exerting a lateral force on the sensor unit 4600. The lateral force exerted by the first cable 1420 is exerted, at least partially, toward the second axis A2. Similarly, the lateral force exerted by the second cable 1430 is exerted, at least partially, toward the second axis A2 in a direction that is opposite the force exerted by the first cable 1420. Said another way, aAttorney Docket No. P06879-WOlateral movement (e.g., a movement parallel to the first axis Ai) of the sensor unit 4600 from the first position Pi to the second position P2 is limited by a tension in each cable 1420, 1430 of the cable pair on a condition that each cable 1420, 1430 of the cable pair is in an intact state (e.g., retains a design structural integrity).

[0143] As depicted in FIG. 14B, the sensor unit 4600 moves parallel to the first axis Ai within the proximal mechanical structure 1700 from the first position Pi to the second position P2 in response to the transition of the first cable 1420 of the cable pair to the at least partially broken (e.g., parted) state Sp. In other words, the loss of tension in one or the cables of the cable pair results in the force exerted on the sensor unit 4600 by the intact cable, which has a tensile load, causing the sensor unit 4600 to move toward the second position P2 (e.g., away from the intact second cable 1430), as such a movement is no longer resisted by tension in the now compromised (e.g., parted) cable.

[0144] In some embodiments, the elongated body 4630 defines a guide channel 4631. The guide channel 4631 is configured to receive a guide mechanism 1701 of the proximal mechanical structure 1700. The guide mechanism 1701 can, for example, be shaped to allow a lateral movement of the sensor unit 4600 in response to a parting of the first cable 1420 while precluding a rotation of the sensor unit 4600 relative to the second axis A2. For example, the guide mechanism 1701 can have a noncircular shape and instead, have a shape that is oval, rectilinear, or a combination thereof. In some embodiments, the guide mechanism 1701 can remain at a fixed position relative to the first axis Ai and can include a friction reducing element, such as a bearing or a bushing, positioned to contact the guide channel 4631. An interaction of the guide mechanism 1701 and the guide channel 4631 maintains the sensor unit 4600 at a single position along the second axis A2 and guides a movement of the sensor unit 4600 along the first axis Ai from the first position Pi to the second position P2 in response to a transition of the first cable 1420 to at least a partially broken state.

[0145] As depicted in FIG. 14A, in some embodiments, the first position Pi of the sensor unit 4600 defines at least a portion of the operational cable path OCP for the cable pair. The operational cable path OCP can, for example, correspond to a design (or nominal) cable path for each cable of the cable pair on a condition that both cables of the cable pair are in an intact state. The sensor unit 4600 is movable from the first position Pi to a second position P2 (as depicted in FIG. 14B) that defines a tension-release cable path TCP for the second cable 1430 of the cable pair on a condition that the first cable 1420 is in at least a partially broken stateAttorney Docket No. P06879-WO(e.g., parted). The length of the operational cable path OCP is greater than the length of the tension-release cable path TCP. Therefore, transition of the second cable 1430 (i.e., the intact cable) from the operational cable path OCP to the tension-release cable path TCP reduces or eliminates a tensile load within the second cable 1430, thereby, precluding or mitigating an un-commanded movement of at least a portion of the end effector that would have otherwise been the result of receiving a tensile load from only a single, intact cable upon the transition of the other cable of the cable pair to at least a partially broken state.

[0146] FIGS. 14A and 14B depict the movement of the second cable 1430 from the operational cable path OCP (depicted in FIG. 14A) to the tension-release cable path TCP (depicted in FIG. 14B) corresponding to the movement of the sensor unit 4600 from the first position Pi to the second position P2. In response to the movement of the sensor unit 4600, a portion of the second cable 1430 moves from a deflected path to a straight-line path. In FIG.14B, the second cable 1430 is in the tension-release cable path TCP and the delivery of a tensile load is eliminated or mitigated by the resultant slack in the second cable 1430 resulting from the shorter length of the tension-release cable path TCP.

[0147] In some embodiments, the engagement of the first cable 1420 by the first guide portion 4632 displaces a portion of the first cable 1420 away from the second axis A2 and away from the second cable 1430 on a condition that the sensor unit 4600 is in the first position Pi. Said another way, on a condition that the second cable 1430 is in an intact state, the first guide portion 4632 is positioned to displace a portion of the first cable 1420 from a straight-line path to establish the operational cable path OCP at a length that is greater than the tension-release cable path TCP. Likewise, the second guide portion 4634 is positioned to engage the second cable 1430 of the cable pair. On a condition that the sensor unit 4600 is in the first position Pi, the engagement of the second cable 1430 by the second guide portion 4634 displaces a portion of the second cable 1430 away from the second axis A2 and away from the first cable 1420. Said another way, on a condition that the first cable 1420 is in an intact state, the second guide portion 4634 is positioned to displace a portion of the second cable 1430 from a straight-line path to establish the operational cable path OCP at a length that is greater than the tension-release cable path TCP. Said yet another way, the elongated body extending between the first guide portion 4632 and the second guide portion 4634 spreads the first cable 1420 and the second cable 1430 away from one another and the corresponding straight-line path each would take in the absence of the sensor unit 4600. In some embodiments, in the second positionAttorney Docket No. P06879-WOP2, the first guide portion 4632 has an absence of contact w ith the first cable 1420 due to the first cable 1420 being in a parted state.

[0148] FIGS. 16, 17A, and 17B depict a sensor unit 5600 according to an embodiment. The sensor unit 5600 can, for example, be used with any instrument described herein, such as instrument 1400 or instrument 2400, having at least one cable configured to transfer a mechanical input from a proximal mechanical structure (e.g., proximal mechanical structure 1700) to a portion of an end effector (e.g., the tool member 1462). The cable(s) can, as described above, be arranged as a first cable 1420 of a cable pair that includes a second cable 1430. For the purposes of illustration, unless stated otherwise, the sensor unit 5600 is described below with reference to the instrument 1400 and the first tension member 1420.

[0149] In some embodiments, at least a portion of the sensor unit 5600 is coupled directly to the tension member 1420. The sensor unit 5600 has a first switch state SSi, as depicted in FIG. 17 A, on a condition that the tension member 1420 is in an intact state. The sensor unit 5600 also has a second switch state SS2, as depicted in FIGS. 16 and 17B, on a condition that the tension member 1420 is in at least a partially broken state.

[0150] In some embodiments, the sensor unit 5600 includes a deformable member 5650. For example, FIG. 16 is a perspective view of the deformable member 5650. FIG. 17A is a cross-sectional view of the deformable member 5650 of FIG. 16 in the first switch state SSI based on the tension member 1420 being in the intact state. FIG. 17B is a cross-sectional view of the deformable member 5650 of FIG. 16 in the second switch state SS2 in the absence of the tension member 1420, such as may result from the parting of the tension member 1420.

[0151] The deformable member 5650 can, for example include a first electrical contact 5651. The deformable member 5650 can also include a second electrical contact 5652. The second electrical contact 5652 is movable relative to the first electrical contact 5651. In the first switch state SSi, as depicted in FIG. 17A, the second electrical contact 5652 is separated from the first electrical contact 5651. For example, the second electrical contact 5652 can be coupled to an elastically deformable portion of the deformable member 5650 that is displaced relative to the remaining portions of the deformable member 5650 by the presence of the tension member 1420 in the intact state, thereby, physically separating the second electrical contact 5652 from the first electrical contact 5651. On a condition that the tension member 1420 transitions to the at least partially broken state, the sensor unit 5600 moves from the firstAttorney Docket No. P06879-WOswitch state SSi to the second switch state SS2 in which the second electrical contact 5652 is electrically coupled to the first electrical contact 5651, thereby, completing a circuit. Accordingly, the output of the sensor unit 5600 corresponds to the closed circuit resulting from the transition of the sensor unit 5600 to the second switch state SS2.

[0152] As depicted in FIG. 16, in some embodiments, the first electrical contact 5651 is a first conductive insert that is coupled to a first lead line 5653. Similarly, the second electrical contact 5652 can be a second conductive insert that is coupled to a second lead line 5654. The first electrical contact 5651 and the second electrical contact 5652 can, therefore, received by (e.g., inserted into) the deformable member 5650 formed from a nonconductive, elastically deformable material, such as a polymer. In some embodiments, the first electrical contact 5651 can be a first conductive region of the deformable member 5650, while the second electrical contact 5652 can be a second conductive region of the deformable number 5650. Each of the first conductive region and a second conductive region can be coupled to a nonconductive portion of the deformable member 5650.

[0153] In some embodiments, the second switch state SS2 is the default switch state for the sensor unit 5600. Accordingly, absent the effects of the tension member 1420, the first electrical contact 5651 and the second electrical contact 5652 are electrically coupled to one another. Said another way, a tensile load within the tension member 1420 exerts a torque on the deformable member 5650 to move the second electrical contact 5652 relative to the first electrical contact 5651. The torque exerted on the deformable member by the tension member 1420 under the tensile load maintains the sensor unit 5650 in the first switch state on the condition that the tension member 1420 is in the intact state. In the absence of the tension member 1420, such as may be encountered in the event of a cable break, the sensor unit 5600 defaults to the second switch state SS2, which is indicative of the cable break.

[0154] As shown particularly in FIG. 18, a schematic diagram of one embodiment of suitable components that may be included within the controller 1800 is illustrated. In some embodiments, the controller 1800 is positioned within a component of the surgical system 1000, such as the user control unit 1100 and / or the optional auxiliary equipment unit 1150. However, the controller 1800 may also include distributed computing systems wherein at least one aspect of the controller 1800 is at a location which differs from the remaining components of the surgical system 1000 for example, at least a portion of the controller 1800 may be an online controller.Attorney Docket No. P06879-WO

[0155] As depicted, the controller 1800 includes one or more processor(s) 1802 and associated memory device(s) 1804 configured to perform a variety of computer implemented functions (e.g., performing the methods, steps, calculations and the like and storing relevant data as disclosed herein). Additionally, in some embodiments, the controller 1800 includes a communication module 1806 to facilitate communications between the controller 1800 and the various components of the surgical system 1000.

[0156] As used herein, the term “processor” refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. Additionally, the memory device(s) 1804 may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable nonvolatile medium (e.g., a flash memory), a floppy disc, a compact disc read only memory (CD ROM), a magneto optical disc (MOD), a digital versatile disc (DVD) and / or other suitable memory elements. Such memory device(s) 1804 may generally be configured to store suitable computer readable instructions that, when implemented by the processor(s) 1802, configure the controller 1800 to perform various functions.

[0157] The communication module 1806 may include a control input module 1808 configured to receive control inputs from the operator / surgeon S, such as via the input device 1116 of the user control unit 1100. The communication module 1806 may also include a sensor interface 1810 (e.g., one or more analog to digital converters) to permit signals transmitted from one or more sensors (e.g.. sensor units 2600, 3600, 4600. and / or 5600 as described herein) to be converted into signals that can be understood and processed by the processors 1802. The sensors may be communicatively coupled to the communication module 1806 using any suitable means. For example, the sensors may be coupled to the communication module 1806 via a wired connection and / or via a wireless connection, such as by using any suitable wireless communications protocol known in the art. Additionally, in some embodiments, the communication module 1806 includes a device control module 1814 configured to modify an operating state of the instrument 1400 (and / or any of the instruments described herein.

[0158] FIGS. 19A and 19B are schematic illustrations of an instrument 6400 according to an embodiment. The instrument 6400 can, for example, include any of the features and / or elements described herein with reference to any other instrument, such as instrument 1400Attorney Docket No. P06879-WOdescribed above. As depicted, the instrument 6400 can include a proximal mechanical structure 6700 that includes at least one tool-drive member (e.g., capstan) 6710. The instrument 6400 can also include an end effector 6460 that includes a tool member 6462. The end effector 6460 and / or the tool member 6462 is operably coupled to the proximal mechanical structure 6700 via a cable pair (not shown). The cable pair can, for example, include a first cable and a second cable that are configured to transfer a mechanical input (e.g., a tensile load) from the proximal mechanical structure to a portion of the end effector 6460, such as the tool member 6462. In some embodiments, a tensile load is simultaneously applied to each cable and a difference in the magnitude of the applied tensile loads between the cables causes a movement of the portion of the end effector 6460.

[0159] As depicted, the instrument 6400 can include a tension-release member 6600. The tension-release member 6600 can, for example, be positioned operably between the tool-drive member 6710 and the tool member 6462. The tension-release member 6600 has a first position Pi, as depicted in FIG. 19A. In the first position Pi, the tension-release member 6600 defines at least a portion of an operational cable path OCP for the cable pair. The tension-release member 6600 is maintained in the first position Pi by a tensile load in both the first cable and the second cable of the cable pair. The operational cable path OCP corresponds to a design (e.g., nominal or intended) cable path for the cable pair during an operation in which both the first cable and the second cable are in an intact state. The operational cable path OCP can include any (or all) of a portion defined by tension-release member 6600, a portion defined by the shaft of the instrument 6400, and a portion within the proximal mechanical structure 6700. As depicted in FIG. 19B, the tension-release member 6600 is movable from the first position Pi to a second position P2 on a condition that one cable of the cable pair is in at least a partially broken state (e.g., is broken, parted, or has otherwise lost structural integrity resulting in a substantial degradation in tensile strength). Said another way, the tension-release member 6600 is maintained in the first position by the tensile load in each cable of the cable pair. Accordingly, the loss of tension corresponding to the transition of one cable to the at least partially broken state results in the movement of the tension-release member 6600 to the second position P2 in response to the tension remaining in the intact cable. The tension-release member 6600 in the second position P2 defines a tension-release cable path TCP for the intact cable of the cable pair. The length Li of the operational cable path is greater than the length L2 of the tension-release cable path TCP.Attorney Docket No. P06879-WO

[0160] The shorter length L2 of the tension-release cable path TCP results in the substantially instantaneous reduction or elimination of the tensile load applied to the end effector 6460 by the intact cable. Said another way, the movement of the tension-release member 6600 from the first position Pi to the second position P2 produces slack in the intact cable for a given rotational position of the tool-drive member 6710. The production of slack in the intact cable results in a substantially instantaneous reduction of the tension within the cable without requiring an unwinding (e.g., unspooling) of the tool-drive member 6710. Said yet another way, upon the transition of the intact cable from the operational cable path OCP to the tension-release cable path TCP, the length of the cable remains the same as it was in the operational cable path OCP though the tension-release cable path TCP is shorter than the operational cable path OCP. Accordingly, the intact cable in the tension-release cable path TCP is slack and the tensile load that was being applied by the tool-drive member 6710 to the intact cable at the moment the structural integrity of the other cable of the cable pair is lost is reduced or not transmitted to the end effector 6460 by the remaining intact cable of the cable pair. The reduction or elimination of the tensile load resulting from the shorter length L2 of the tension-release cable path TCP precludes or mitigates an un-commanded movement of at least a portion of the end effector 6460 upon a transition of one of the cables of the cable pair to the at least partially broken state. The preclusion or mitigation of an un-commanded movement of a portion of the end effector 6460 desirably limits any resultant interactions of the end effector 6460 with the surgical site.

[0161] FIG. 20 is a transparent top view7of a tension-release member 7600 according to an embodiment. The tension-release member 7600 can, for example, be used with any instrument described herein, such as instrument 1400 or instrument 6400, having a cable pair configured to transfer a mechanical input from a proximal mechanical structure (e.g., proximal mechanical structure 1700) to a portion of an end effector (e.g., the tool member 1462). Such a cable pair can, as described above, include a first cable 1420 and a second cable 1430. For the purposes of illustration, the tension-release member 7600 is described below with reference to the instrument 1400.

[0162] As depicted in FIGS. 21A, 21B, 22A, and 22B, in some embodiments, the tension-release member 7600 is coupled to an instrument shaft (e.g., instrument shaft 1410). The tension-release member 7600 has a first position Pi (as depicted in FIGS. 21A and 22A) that defines the operational cable path OCP for the cable pair. The tension-release memberAttorney Docket No. P06879-WO7600 is movable from the first position Pi to a second position P2 (as depicted in FIGS. 21B and 22B) that defines the tension-release cable path TCP for the second cable 1430 of the cable pair on a condition that the first cable 1420 is in at least a partially broken state (e.g., parted). The length of the operational cable path OCP is greater than the length of the tension-release cable path TCP. Therefore, transition of the second cable 1430 (i.e., the intact cable) from the operational cable path OCP to the tension-release cable path TCP reduces or eliminates a tensile load within the second cable 1430, thereby, precluding or mitigating an un-commanded movement of at least a portion of the end effector that would have otherwise been the result of receiving a tensile load from only a single, intact cable upon the transition of the other cable of the cable pair to at least a partially parted state.

[0163] In some embodiments, the instrument shaft 1410 defines a longitudinal centerline CLi. The longitudinal centerline CLi can, for example, extend along the longitudinal axis ALOI defined by the instrument shaft 1410. As depicted in FIG. 21A, the tension-release member 7600 is aligned with the longitudinal centerline CLi when the tension-release member 7600 is in the first position Pi. Said another way, a longitudinal centerline CL2 of the tension-release member 7600 can be coaxial with the longitudinal centerline CLi of the instrument shaft 1410 on the condition that the tension-release member 7600 is in the first position Pi. The tension-release member 7600 is maintained in the first position Pi by the tension in each of the first cable 1420 and the second cable 1430 of the cable pair in an intact state exerting a lateral force on a restriction portion 7624 of the tension-release member 7600. The lateral force exerted by the first cable 1420 is exerted away from the longitudinal centerline CLi in a first direction that is opposite of the lateral force exerted by the second cable 1430. Said another way, a lateral movement (e.g., a movement parallel to the lateral axis ALA (FIG. 6)) of the tension-release member 7600 from the first position Pi to the second position P2 is limited by a tension in each cable 1420, 1430 of the cable pair on a condition that each cable 1420, 1430 of the cable pair is in an intact state (e.g., retains a design structural integrity).

[0164] As depicted in FIGS. 21B and 22B, the tension-release member 7600 moves laterally within the instrument shaft 1410 from the first position Pi to the second position P2 in response to the transition of the first cable 1420 of the cable pair to the at least partially broken (e.g., parted) state. In other words, the loss of tension in one or the cables of the cable pair results in the force exerted on the tension-release member 7600 by the intact cable, which has a tensile load, causing the tension-release member 7600 to move toward the second positionAttorney Docket No. P06879-WOP2, as such a movement is no longer resisted by tension in the now compromised (e.g., parted) cable. In the second position P2, a longitudinal axis ALO2 (e.g., the longitudinal centerline CL2) of the tension-release member 7600 is displaced laterally relative to the longitudinal centerline CLi of the instrument shaft 1410. In some embodiments, the lateral movement from the first position Pi to the second position P2 is in the direction of the second cable, such as depicted in FIGS. 21B and 22B.

[0165] FIG. 22B depicts the movement of the second cable 1430 from the operational cable path OCP to the tension-release cable path TCP corresponding to the movement of the tension-release member 7600 from the first position Pi (FIG. 22A) to the second position P2. In response to the movement of the tension-release member 7600, the second cable 1430 moves from lateral position A, which corresponds to the second cable 1430 being the operational cable path OCP as depicted in FIG. 22A, in the direction of the arrow Di to lateral position B. At lateral position B, the second cable 1430 is in the tension-release cable path TCP and the delivery of a tensile load is eliminated or mitigated by the resultant slack (or reduction in tension) in the second cable 1430 resulting from the shorter length of the tension-release cable path TCP.

[0166] As depicted in FIGS. 21A and 21B, in some embodiments, the tension-release member 7600 is at a constant longitudinal position LP relative to the instrument shaft 1410 at both the first position Pi and the second position P2. To maintain the longitudinal position LP, in some embodiments, the tension-release member 7600 can be flexibly coupled to an inner surface 1414 of the instrument shaft 1410. For example, an elastomeric member (not shown) can be positioned between the outer surface 7610 of the tension-release member 7600 and the inner surface 1414 of the instrument shaft 1410 to maintain the tension-release member 7600 at the longitudinal position.

[0167] As depicted in FIGS 20-22B, in some embodiments, the tension-release member 7600 has a cylindrical body 7602. The cylindrical body 7602 extends between a first end portion 7604 and a second end portion 7606. The cylindrical body 7602 can include an outer surface 7610 and an inner surface 7620. The inner surface 7620 is in contact with each of the first cable 1420 and the second cable 1430 on a condition that the tension-release member 7600 is in the first position Pi (FIGS. 21 A and 22A). Accordingly, the inner surface 7620 is shaped to guide the cable pair and define a cable path through the cylindrical body 7602. The cable path through the cylindrical body 7602 is a portion of (or forms a part of) the operational cableAttorney Docket No. P06879-WOpath OCP and / or the tension-release cable path TCP. For example, in some embodiments, the inner surface 7620 of the cylindrical body 7602 has a concave shape. The concave shape can extend between the first end portion 7604 and the second end portion 7606 and surround the longitudinal centerline CL2 of the cylindrical body 7602.

[0168] In some embodiments, to establish the operational cable path OCP at a length that is greater than the tension-release cable path TCP, the inner surface 7620 can include the restriction portion 7624. The restriction portion 7624 can be positioned between the first end portion 7604 and the second end portion 7606. Accordingly, each of the first end portion 7604 and the second end portion 7606 can have an inner diameter IDE (FIG. 20) that is greater than an inner diameter IDM of the restriction portion 7624. The inner diameter IDM can be the inner diameter of the tension-release member 7600, which can be in a range of 60 percent to 90 percent of the outer diameter OD of the tension-release member 7600. The inner diameter IDM can, therefore, establish a point of minimal separation between each cable of the cable pair and the longitudinal centerline CL2 of the tension-release member 7600 on a condition that the tension-release member 7600 is at the first position Pi. The point of minimal separation between each cable of the cable pair and longitudinal centerline CL2 corresponds to a point of maximal deflection of each cable from a straight-line path, the return to which results in the slack in the intact cable. Accordingly, in some embodiments, it is desirable to maximize the magnitude of the deflection from the straight-line path by minimizing the inner diameter IDM such that sufficient slack is produced to prevent the transmission of the tensile load.

[0169] The inner diameter IDM can correspond to a point of minimal clearance within the cylindrical body 7602. Said another way, the restriction portion 7624 can correspond to constricting region that causes each cable of the cable pair to deviate from a straight-line path (e.g. between consecutive support points) on a condition that the tension-release member 7600 is at the first position Pi. The straight-line path can, for example, correspond to the tension-release cable path TCP.

[0170] In some embodiments, the inner surface 7620 defines a bore 7622 through which the cable pair is routed on a condition that the tension-release member 7600 is in the first position Pi. Correspondingly, in response to the transition of the first cable 1420 to a parted state, in some embodiments only the second cable 1430 can be routed through the bore 7622 with the tension-release member 7600 in the second position P2. In some embodiments, the inner surface 7620 can define a circular hyperboloid.Attorney Docket No. P06879-WO

[0171] In some embodiments, both the inner surface 7620 and the outer surface 7610 of the tension-release member 7600 can have a concave shape. For example, in some embodiments, the tension-release member 7600 can have a toroidal shape. A central opening defined by the toroidal shape can be sized to receive the cable pair and deviate both the first cable 1420 and the second cable 1430 from a straight-line path on the condition that the tension-release member 7600 is in the first position Pi.

[0172] To facilitate movement from the first position Pi toward the second position P2, the tension-release member 7600 can be surrounded by a separation from the inner surface 1414 of the instrument shaft 1410. Said another way, the tension-release member 7600 can be spaced apart from the inner surface 1414 of the shaft 1410. For example, in some embodiments, the outer diameter OD (FIG. 20) of the tension-release member 7600 is in a range of 60 percent to 80 percent of an inner diameter IDs of the instrument shaft 1410.

[0173] Although the tension-release member 7600 is shown as being coupled to and within the shaft 1410, in other embodiments a tension-release member can be in any suitable location within an instrument. FIGS. 23 A and 23B are a schematic illustration of a tension-release member 8600 according to an embodiment. The tension-release member 8600 can, for example, be used with any instrument described herein, such as instrument 1400 or instrument 6400, having a cable pair configured to transfer a mechanical input from a proximal mechanical structure (e.g., proximal mechanical structure 1700) to a portion of an end effector (e.g., the tool member 1462). Such a cable pair can, as described above, include a first cable 1420 and a second cable 1430. For the purposes of illustration, the tension-release member 8600 is described below with reference to the instrument 1400 and in particular to the proximal mechanical structure 1700.

[0174] As depicted, in some embodiments, the tension-release member 8600 is positioned between a tool-drive member (e.g., the first capstan 1710 and the second capstan 1720) of the proximal mechanical structure 1700 and the shaft opening 1712. In some embodiments, being positioned between the tool-drive member and the shaft opening 1712 refers to the physical positioning of the tension-release member 8600. In some embodiments, being positioned between the tool-drive member and the shaft opening 1712 refers to the operable positioning of the tension-release member 8600. The tension-release member 8600 can, in some embodiments, be further positioned between the first cable 1420 and the second cable 1430 ofAttorney Docket No. P06879-WOa cable pair operably coupled between a tool member (e.g., tool member 1462) and a corresponding tool-drive member (e.g., the first capstan 1710 and the second capstan 1720).

[0175] The tension-release member 8600 has a first position Pi (as depicted in FIG. 23A) that defines a portion of the operational cable path OCP for the cable pair. The tension-release member 8600 is movable from the first position Pi to a second position P2 (as depicted in FIG.23B) that defines the tension-release cable path TCP for the second cable 1430 of the cable pair on a condition that the first cable 1420 is in at least a partially broken state (e.g., parted). The length of the operational cable path OCP is greater than the length of the tension-release cable path TCP. Therefore, transition of the second cable 1430 (i.e., the intact cable) from the operational cable path OCP to the tension-release cable path TCP reduces or eliminates a tensile load within the second cable 1430, thereby, precluding or mitigating an un-commanded movement of at least a portion of the end effector that would have otherwise been the result of receiving a tensile load from only a single, intact cable upon the transition of the other cable of the cable pair to at least a partially broken state.

[0176] In some embodiments, the tension-release member 8600 is slidable laterally along a first axis Ai from the first position Pi to the second position P2. As depicted, the first axis Ai is orthogonal to a second axis A2. The second axis A2 bisects the shaft opening 1712. The tension-release member 8600 is, in some embodiments, centered on the second axis A2 when at the first position Pi. The movement of the tension-release member 8600 along the first axis Ai (e.g., a lateral movement) from the first position Pi to the second position P2 is in response to a transition of the first cable 1420 of the cable pair to an at least partially broken (e.g., parted) state. The movement is, therefore, away from the second cable 1430 toward the first cable 1420 or a region of the proximal mechanical structure 1700 previously occupied by the first cable 1420. As depicted in FIG. 23B, the movement of the tension-release member 8600 can, for example, be in the direction indicated by arrow D4.

[0177] In some embodiments, the tension-release member 8600 is maintained in the first position Pi by the tension in each of the first cable 1420 and the second cable 1430 of the cable pair in an intact state exerting a lateral force on the tension-release member 8600. The lateral force exerted by the first cable 1420 is exerted, at least partially, toward the second axis A2. Similarly, the lateral force exerted by the second cable 1430 is exerted, at least partially, toward the second axis A2 in a direction that is opposite the force exerted by the first cable 1420. Said another way, a lateral movement (e g., a movement parallel to the first axis Ai) of theAttorney Docket No. P06879-WOtension-release member 8600 from the first position Pi to the second position P2 is limited by a tension in each cable 1420, 1430 of the cable pair on a condition that each cable 1420, 1430 of the cable pair is in an intact state (e.g., retains a design structural integrity).

[0178] As depicted in FIG. 23B, the tension-release member 8600 moves parallel to the first axis Ai within the proximal mechanical structure 1700 from the first position Pi to the second position P2 in response to the transition of the first cable 1420 of the cable pair to the at least partially broken (e.g., parted) state. In other words, the loss (or reduction) of tension in one or the cables of the cable pair results in the force exerted on the tension-release member 8600 by the intact cable, which has a tensile load, causing the tension-release member 8600 to move toward the second position P2 (e.g.. away from the intact second cable 1430), as such a movement is no longer resisted by tension in the now compromised (e g., parted) cable.

[0179] FIGS. 23A and 23B depict the movement of the second cable 1430 from the operational cable path OCP (depicted in FIG. 23A) to the tension-release cable path TCP (depicted in FIG. 23B) corresponding to the movement of the tension-release member 8600 from the first position Pi to the second position P2. In response to the movement of the tension-release member 8600, a portion of the second cable 1430 moves from a deflected path to a straight-line path. In FIG. 23B, the second cable 1430 is in the tension-release cable path TCP and the delivery of a tensile load is eliminated or mitigated by the resultant slack in the second cable 1430 resulting from the shorter length of the tension-release cable path TCP.

[0180] In some embodiments, the tension-release member 8600 includes an elongated body 8630. The elongated body 8630 can extend between a first guide portion 8632 and a second guide portion 8634. The first guide portion 8632 is positioned to engage the first cable 1420 of the cable pair. On a condition that the tension-release member 8600 is in the first position Pi, the engagement of the first cable 1420 by the first guide portion 8632 displaces a portion of the first cable 1420 away from the second axis A2 and away from the second cable 1430. Said another way, on a condition that the second cable 1430 is in an intact state, the first guide portion 8632 is positioned to displace a portion of the first cable 1420 from a straight-line path to establish the operational cable path OCP at a length that is greater than the tension-release cable path TCP. Likewise, the second guide portion 8634 is positioned to engage the second cable 1430 of the cable pair. On a condition that the tension-release member 8600 is in the first position Pi, the engagement of the second cable 1430 by the second guide portion 8634 displaces a portion of the second cable 1430 away from the second axis A2 and away from theAttorney Docket No. P06879-WOfirst cable 1420. Said another way, on a condition that the first cable 1420 is in an intact state, the second guide portion 8634 is positioned to displace a portion of the second cable 1430 from a straight-line path to establish the operational cable path OCP at a length that is greater than the tension-release cable path TCP. Said yet another way, the elongated body extending between the first guide portion 8632 and the second guide portion 8634 spreads the first cable 1420 and the second cable 1430 away from one another and the corresponding straight-line path each would take in the absence of the tension-release member 8600. In some embodiments, in the second position P2, the first guide portion 8632 has an absence of contact with the first cable 1420 due to the first cable 1420 being in a parted state.

[0181] In some embodiments, the first guide portion 8632 and the second guide portion 8634 are each a fixed guide surface. Accordingly, the first guide portion 8632 and the second guide portion 8634 can be shaped to reduce a friction between elongated body 8630 and the cable pair. In some embodiments, the first guide portion 8632 and the second guide portion 8634 are formed from a low friction material. In some embodiments, the first guide portion 8632 and the second guide portion 8634 include a low friction coating. In some embodiments, the first guide portion 8632 and the second guide portion 8634 include a rotatable element. The rotatable element can, for example, be a pulley, a roller, or a captive ball.

[0182] In some embodiments, the elongated body 8630 defines a guide channel 8631. The guide channel 8631 is configured to receive a guide mechanism 1701 of the proximal mechanical structure 1700. The guide mechanism 1701 can, for example be shaped to allow a lateral movement of the tension-release member 8600 in response to a parting of the first cable 1420 while precluding a rotation of the tension-release member 8600 relative to the second axis A2. For example, the guide mechanism 1701 can have a noncircular shape and instead, have a shape that is oval, rectilinear, or a combination thereof. In some embodiments, the guide mechanism 1701 can remain at a fixed position relative to the first axis Ai and can include a friction reducing element, such as a bearing or a bushing, positioned to contact the guide channel 8631. An interaction of the guide mechanism 1701 and the guide channel 8631 maintains the tension-release member 8600 at a single position along the second axis A2 and guides a movement of the tension-release member 8600 along the first axis Ai from the first position Pi to the second position P2 in response to a transition of the first cable 1420 to at least a partially broken state.Attorney Docket No. P06879-WO

[0183] FIG. 24 is a schematic illustration of a tool member 9462 according to an embodiment. The tool member 9462, for example, be used with any instrument described herein, such as instrument 1400 or instrument 6400, having at least one tension member configured to transfer a mechanical input from a proximal mechanical structure (e.g., proximal mechanical structure 1700) to the tool member 1462. For the purposes of illustration, the tool member 9462 is described below with reference to the instrument 1400.

[0184] In some embodiments, the instrument 1400 includes a unitary cable 9420. The cable 9420 is routed from the proximal mechanical structure 1700 to the tool member 9462 and then back to mechanical structure 1700. In such an embodiment, the cable 9420 can include a first cable portion 9421 and a second cable portion 9423 that are each coupled to either a single capstan, or a corresponding pair of capstans operating in conjunction with one another. The cable 9420 can extend from the capstan(s), along the instrument shaft (e.g., within the passageway defined by the instrument shaft 1410), to the tool member 9462, which is operably coupled to a third cable portion 9422 (e.g., a distal portion of the cable 9420) that is between the first cable portion 9421 and the second cable portion 9423. In such an embodiment, the first cable portion 9421 and the second cable portion 9423 can be associated with opposing directions of a single degree of freedom. This arrangement, which is generally referred to as an antagonist drive system, allows for independent control of the movement of (e.g., pulling in or paying out) each of the ends of the cable 9420. The proximal mechanical structure 1700 produces movement of the cable 9420, which operates to produce the desired articulation movements (pitch, yaw, or grip) at the tool member 9462. In this manner, the proximal mechanical structure 1700 can maintain the desired tension within the first cable portion 9421 and the second cable portion 9423 to produce the desired movements at the tool member 9462.

[0185] As depicted in FIG. 24, the third cable portion 9422 is engaged with a coupling portion 9463 of the tool member 9462. The engagement betw een the third cable portion 9422 and the coupling portion 9463 produces a friction coupling of the cable 9420 to the tool member 9462. Said another way, the third cable portion 9422 can use the capstan effect to engage the coupling portion 9463 rather than a crimp or other similar mechanical cable-to jaw coupling. Accordingly, the friction coupling is configured to limit movement of the third cable portion 9422 relative to the tool member 9462 on a condition that the cable 9420 is in an intact state. However, the friction coupling is also configured to allow the cable 9420 (i.e., the third cable portion 9422) to decouple from the tool member 9462 on a condition that the first cable portionAttorney Docket No. P06879-WO9421 is transitioned to a parted state. The parted state of the first cable portion 9421 precludes transmission of the tension within the first cable portion 9421 to the tool member 9462. Accordingly, the loss of counter tension, which is required to maintain the friction coupling via the capstan effect, stemming from the parting of the first cable portion 9421 results in intact second cable portion 9423 pulling free from the tool member 9462 due to tension within the second cable portion 9423 at the moment the first cable portion 9421 transitions to the parted state.

[0186] By operably decoupling the intact second cable portion 9423 from the tool member 9462 in response to the parting of the first cable portion 9421, the tension in the second cable portion 9423 is precluded from transmission to the tool member 9462. This operable decoupling of the intact cable portion prevents or mitigates the non-commanded movement of the tool member 9462 that would otherwise result from the tension in the intact second cable portion 9423 being unopposed due to the parting of the first cable portion 9421.

[0187] In some embodiments, to establish the friction coupling, the third cable portion 9422 is wrapped at least partially around the coupling portion 9463 of the tool member 9462. For example, in some embodiments, the third cable portion 9422 can be wrapped at least 2 revolutions about the coupling portion 9463. The third cable portion 9422 is maintained in the wrapped state by opposing tensions in each of the first cable portion 9421 and the second cable portion 9423 on a condition that the cable 9420 is in an intact state. However, on a transition of the first cable portion 9421 to a parted state, the loss of the corresponding tension provided by the first cable portion 9421 results in the unwrapping of the third cable portion 9422 in response to the tension in the second cable portion 9423.

[0188] In some embodiments, the coupling portion 9463 is shaped such that a resultant friction force between the third cable portion 9422 and the tool member 9462 is at a magnitude which precludes the movement of the third cable portion 9422 relative to the coupling portion 9463 on a condition that the cable 9420 is in the intact state. However, on a condition that the first cable portion 9421 is transitioned to a parted state, the friction force between the third cable portion 9422 and the coupling portion 9463 is reduced to a magnitude that allows the movement of the third cable portion 9422 relative to the coupling portion 9463. Accordingly, the reduction in the friction force permits the automatic operable decoupling of the second cable portion 9423 from the tool member 9462 in response to tension within the second cable portion 9423.Attorney Docket No. P06879-WO

[0189] As depicted, in some embodiments the tool member 9462 is pivotable about a pivot axis Ap. Additionally, the tool member 9462 includes a gripping portion 9464. The gripping portion 9464 defines a longitudinal axis ALOT of the tool member 9462. In some embodiments, the longitudinal axis ALOT of the tool member 9462 intersects the pivot axis Ap. As depicted, in some embodiments, the coupling portion 9463 is divided by the longitudinal axis ALOT of the tool member 9462. In such embodiments, the first cable portion 9421 contacts the coupling portion 9463 on a first side of the longitudinal axis ALOT, while the second cable portion 9423 contacts the coupling portion 9463 on a second side of the longitudinal axis ALOT opposite the first side.

[0190] In some embodiments, the coupling portion 9463 includes an elliptic cylinder. The elliptic cylinder can have a length that intersects the longitudinal axis ALOT of the tool member 9462 such that the longitudinal axis ALOT divides the elliptic cylinder. The first cable portion 9421 can contact a first end of the elliptic cylinder on a first side of the longitudinal axis ALOT while the second cable portion 9423 contacts a second end of the elliptic cylinder on a second side of the longitudinal axis ALOT. The third cable portion 9422 between the first cable portion 9421 and the second cable portion 9423 can be wrapped about the elliptic cylinder on the condition that the cable 9420 is in the intact state. The third cable portion 9422 can be configured to unwind from the elliptic cylinder on the condition that the first cable portion 9421 is transitioned to the parted state and, therefore, precluded from applying a necessary counter tension to maintain the wraps of the third cable portion 9422 about the elliptic cylinder.

[0191] As depicted in FIG. 24, in some embodiments, the coupling portion 9463 includes a first pin 9465. The first pin 9465 can be positioned on the first side of the longitudinal axis ALOT of the tool member 9462. The coupling portion 9463 can also include a second pin 9466 positioned on the second side of the longitudinal axis ALOT opposite the first pin 9465. In such an embodiment, the third cable portion 9422 is wrapped about the first pin 9465 and the second pin 9466 on the condition that the cable 9420 is in the intact state. The third cable portion 9422 is configured to unwind from the first pin 9465 and the second pin 9466 on the condition that the first cable portion 9421 is transitioned to the parted state.

[0192] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Where methods and / or schematics described above indicate certain events and / or flow patterns occurring in certain order, the ordering of certain events and / or operations may be modified. While theAttorney Docket No. P06879-WOembodiments have been particularly shown and described, it will be understood that various changes in form and details may be made.

[0193] For example, any of the instruments described herein (and the components therein) are optionally parts of a surgical assembly that performs minimally invasive surgical procedures, and which can include a manipulator unit, a series of kinematic linkages, a series of cannulas, or the like. Thus, any of the instruments described herein can be used in any suitable surgical system, such as the MIRS system 1000 shown and described above. Moreover, any of the instruments shown and described herein can be used to manipulate target tissue during a surgical procedure. Such target tissue can be cancer cells, tumor cells, lesions, vascular occlusions, thrombosis, calculi, uterine fibroids, bone metastases, adenomyosis, or any other bodily tissue. The presented examples of target tissue are not an exhaustive list. Moreover, a target structure can also include an artificial substance (or non-tissue) within or associated with a body, such as for example, a stent, a portion of an artificial tube, a fastener within the body or the like.

[0194] For example, any of the tool members can be constructed from any material, such as medical grade stainless steel, nickel alloys, titanium alloys or the like. Further, any of the links, tool members, tension members, or components described herein can be constructed from multiple pieces that are later joined together. For example, in some embodiments, a link can be constructed by joining together separately constructed components. In other embodiments however, any of the links, tool members, tension members, or components described herein can be monolithically constructed.

[0195] Although the instruments are generally shown as having an axis of rotation of the tool members that is normal to an axis of rotation of the wrist member, in other embodiments any of the instruments described herein can include a tool member axis of rotation that is offset from the axis of rotation of the wrist assembly by any suitable angle.

[0196] Although various embodiments have been described as having particular features and / or combinations of components, other embodiments are possible having a combination of any features and / or components from any of embodiments as discussed above. Aspects have been described in the general context of medical devices, and more specifically surgical instruments, but inventive aspects are not necessarily limited to use in medical devices.

Claims

Attorney Docket No. P06879-WOWhat is claimed is:

1. A surgical system, comprising:a first drive assembly;a second drive assembly;a medical instrument including a first tension member, a second tension member, and a sensor unit, the first tension member being operably coupled between the first drive assembly and an end effector, the second tension member being operably coupled between the second drive assembly and the end effector, the sensor unit being operably coupled to the first tension member and configured to produce an output associated with an operating state of the first tension member, the operating state being at least one of an intact state or an at least partially broken state of the first tension member; anda controller operably coupled to the first drive assembly, the second drive assembly and the sensor unit, the controller being configured to perform a plurality of operations comprising:causing a tensile load to be applied to the first tension member and the second tension member via the first drive assembly and the second drive assembly on a condition that the first tension member is in the intact state,detecting, based on the output of the sensor unit, a transition of the first tension member from the intact state towards the at least partially broken state, and affecting an operation of the second drive assembly to mitigate a non-commanded movement of the end effector in response to the detecting.

2. The surgical system of claim 1, wherein:affecting the operation of the second drive assembly includes reversing a rotational direction of the second drive assembly to increase a length of the second tension member between the second drive assembly and the end effector.

3. The surgical system of claim 1, wherein:affecting the operation of the second drive assembly includes reversing a rotational direction of the second drive assembly to reduce a tensile load transmitted to the end effector via the second tension member.Attorney Docket No. P06879-WO4. The surgical system of claim 1, wherein:affecting the operation of the second drive assembly includes halting a rotation of the second drive assembly.

5. The surgical system of claim 1, wherein:affecting the operation of the second drive assembly includes altering a rotational speed of the second drive assembly in accordance with a damping transition to reduce a tensile load transmitted to the end effector via the second tension member.

6. The surgical system of claim 1, wherein:the sensor unit includes a switch having a first switch state and a second switch state: the switch is in the first switch state on the condition that the first tension member is in the intact state;the switch transitions to the second switch state in response to the transition of the first tension member towards the at least partially broken state; andthe output of the sensor unit corresponds to the transition of the switch to the second switch state.

7. The surgical system of claim 1, wherein:the sensor unit includes an actuating key and a switch;the actuating key is positioned between the first tension member and the switch; the actuating key is positioned at a compressed position in response to a tensile load applied to the first tension member on the condition that the first tension member is in the intact state;the switch is maintained in a first switch state by the actuating key at the compressed position;the actuating key is positioned at an uncompressed position and the switch is transitioned to a second switch state in response to the transition of the first tension member to the at least partially broken state; andthe output of the sensor unit corresponds to the transition of the switch to the second switch state.

8. The surgical system of claim 7, wherein:Attorney Docket No. P06879-WOthe actuating key includes a contact surface shaped to receive a force from the first tension member;on a condition that the actuating key is at the compressed position, the contact surface is aligned with a guide structure that defines a guide path of the of the first tension member; andon a condition that the actuating key is at the uncompressed position, the contact surface is proud of the guide structure and is at least partially within the guide path of the first tension member.

9. The surgical system of claim 7, wherein:the second switch state is a default switch state for the switch.

10. The surgical system of claim 1, wherein:the first tension member is a first cable of a cable pair and the second tension member is a second cable of the cable pair;the medical instrument includes a proximal mechanical structure;the sensor unit includes an elongated body positioned within the proximal mechanical structure between the first cable and the second cable;the elongated body is at a first position on the condition that the first cable is in the intact state;on a condition that the first cable is transitioned to the at least partially broken state, the elongated body is configured to move to a second position in response to a tensile load within the second cable; andthe output of the sensor unit with the elongated body at the second position is indicative of the transition of the first cable to the at least partially broken state.

11. The surgical system of claim 10, wherein:the elongated body extends between a first guide portion and a second guide portion; the first guide portion is positioned to engage the first cable and the second guide portion is positioned to engage the second cable;the elongated body is movable relative to a fixed portion of the sensor unit to transition the sensor unit between a first switch state and a second switch state; andAttorney Docket No. P06879-WOa movement of the elongated body from the first position to the second position is prevented by a tension in each cable of the cable pair on a condition that each cable of the cable pair is in the intact state.

12. The surgical system of claim 1, wherein:the sensor unit includes a deformable member coupled to the first tension member; the deformable member includes a first electrical contact and a second electrical contact that is movable relative to the first electrical contact;on the condition that the first tension member is in the intact state, the sensor unit is in a first switch state in which the second electrical contact is separated from the first electrical contact;on the condition that the first tension member transitions to the at least partially broken state, the sensor unit is in a second switch state in which the second electrical contact is electrically coupled to the first electrical contact; andthe output of the sensor unit corresponds to the transition of the sensor unit to the second switch state.

13. The surgical system of claim 12, wherein:the first electrical contact is a first conductive insert coupled to a first lead line;the second electrical contact is a second conductive insert coupled to a second lead line;andthe transition to the second switch state closes an electrical circuit.

14. The surgical system of claim 1, wherein:the sensor unit includes an insulated conductive element of the first tension member; the insulated conductive element extends between the first drive assembly and the end effector;the plurality of operations includes delivering a continuity signal to the insulated conductive element; andthe detection of the transition of the first tension member to the at least partially broken state based on the output of the sensor unit includes detecting a disruption of the continuity signal.

15. A medical instrument, comprising:Attorney Docket No. P06879-WOa proximal mechanical structure including a capstan and defining a shaft opening at a coupling with an instrument shaft;a tension member operably coupled between an end effector and the capstan, the tension member extending in a first direction between the capstan and the shaft opening and in a second direction between the shaft opening and the end effector, the first direction and the second direction forming a non-zero angle; anda sensor unit positioned between the capstan and the shaft opening, the sensor unit having a first switch state on a condition that the tension member is in an intact state and a second switch state on a condition that the tension member is in an at least partially broken state.

16. The medical instrument of claim 15, wherein:the sensor unit includes an actuating key and a switch;the actuating key is positioned between the tension member and the switch;the actuating key is positioned at a compressed position in response to a tensile load applied to the tension member on the condition that the tension member is in the intact state;the switch is maintained in the first switch state by the actuating key at the compressed position; andthe actuating key is positioned at an uncompressed position and the switch is transitioned to the second switch state on the condition that the tension member is in the at least partially broken state.

17. The medical instrument of claim 16, wherein:the proximal mechanical structure includes a guide structure positioned between the shaft opening and the capstan;the guide structure defines a guide path into the shaft opening, the tension member configured to transition within the guide path between the first direction and the second direction;the actuating key includes a contact surface shaped to receive a force from the tension member;on a condition that the actuating key is at the compressed position, the contact surface is aligned with the guide structure; andAttorney Docket No. P06879-WOon a condition that the actuating key is at the uncompressed position, the contact surface is proud of the guide structure and is at least partially within the guide path.

18. The medical instrument of claim 16, wherein:the switch is a momentary switch; andthe second switch state is a default switch state for the momentary switch.

19. The medical instrument of claim 16, wherein:the capstan is one capstan of a plurality of capstans;tension member is one tension member of a plurality of tension members operably coupled to the end effector;the actuating key is one actuating key of a plurality of actuating keys;the switch is one switch of a plurality of switches;each actuating key of the plurality of actuating keys is positioned to engage a different tension member of the plurality of tension members such that each actuating key is positioned at the compressed position in response to a tensile load applied to the corresponding tension member on the condition that the corresponding tension member is in the intact state; andeach switch of the plurality of switches is maintained in the first switch state by the corresponding actuating key at the compressed position.

20. The medical instrument of claim 15, wherein:the first switch state is an open switch state;the second switch state is a closed switch state that completes a circuit; andthe completion of the circuit is indicative of the tension member being in the at least partially broken state.

21. The medical instrument of claim 15, wherein:the first switch state is a closed switch state that completes a circuit;the second switch state is an open switch state that interrupts the circuit; andthe interruption of the circuit is indicative of the tension member being in the at least partially broken state.

22. A medical instrument, comprising:Attorney Docket No. P06879-WOa proximal mechanical structure, the proximal mechanical structure including a first capstan and second capstan, the proximal mechanical structure defining a shaft opening into an instrument shaft;a first cable of a cable pair operably coupled between a tool member and the first capstan; a second cable of the cable pair operably coupled between the tool member and the second capstan, the cable pair being configured to transfer a mechanical input from the first capstan and the second capstan to the tool member; anda sensor unit positioned within the proximal mechanical structure between the first and second capstans and the shaft opening and between the first cable and the second cable, the sensor unit having a first switch state on a condition that the first cable is in an intact state and a second switch state on a condition that the first cable is in an at least partially broken state, the sensor unit including a body that is movable from a first position to a second position in response to a tensile load within the second cable on the condition that the first cable is in the at least partially broken state.

23. The medical instrument of claim 22, wherein:the body extends between a first guide portion and a second guide portion;the first guide portion is positioned to engage the first cable and the second guide portion is positioned to engage the second cable on a condition that the first cable and the second cable are in an intact state;the body is movable relative to a fixed portion of the sensor unit to transition the sensor unit between the first switch state and the second switch state; anda movement of the body from the first position to the second position is prevented by a tension in each cable of the cable pair on a condition that each cable of the cable pair is in the intact state.

24. The medical instrument of claim 23, wherein:the body is slidable laterally along a first axis from the first position to the second position;the first axis is orthogonal to a second axis;the second axis bisects the shaft opening; andthe body is centered on the second axis when the body is at the first position.

25. The medical instrument of claim 24, w herein:Attorney Docket No. P06879-WOthe first guide portion is positioned to displace a portion of the first cable away from the second axis on a condition that the second cable is in an intact state; andthe second guide portion is positioned to displace a portion of the second cable away from the second axis on the condition that the first cable is in the intact state.

26. The medical instrument of claim 24, wherein:the body defines a guide channel configured to receive a guide mechanism of the proximal mechanical structure; andan interaction of the guide mechanism and the guide channel maintain the body at a single position along the second axis and guide a movement along the first axis from the first position to the second position.

27. The medical instrument of claim 24, wherein:the body moves laterally along the first axis from the first position to the second position on the condition that the first cable is transitioned to the at least partially broken state; andthe lateral movement is toward the first cable.

28. The medical instrument of claim 22, wherein:the first position of the body defines an operational cable path for the cable pair;the second position of the body defines a tension-release cable path for the second cable on the condition that the first cable is transitioned to the at least partially broken state; andthe operational cable path has a length that is greater than the tension-release cable path.

29. The medical instrument of claim 22, wherein:the first switch state is an open switch state;the second switch state is a closed switch state that completes a circuit; andthe completion of the circuit is indicative of the first cable being in the at least partially broken state.

30. The medical instrument of claim 22, wherein:the first switch state is a closed switch state that completes a circuit;the second switch state is an open switch state that interrupts the circuit; andAttorney Docket No. P06879-WOthe interruption of the circuit is indicative of the first cable being in the at least partially broken state.

31. A medical instrument, comprising:a proximal mechanical structure;a tension member operably coupled between an end effector and the proximal mechanical structure; anda sensor unit coupled to the tension member, the sensor unit having a first switch state on a condition that the tension member is in an intact state and a second switch state on a condition that the tension member is in an at least partially broken state.

32. The medical instrument of claim 31, wherein:the sensor unit includes a deformable member coupled to the tension member;the deformable member includes a first electrical contact and a second electrical contact that is movable relative to the first electrical contact;on the condition that the tension member is in the intact state, the sensor unit is in a first switch state in which the second electrical contact is separated from the first electrical contact;on the condition that the tension member transitions to the at least partially broken state, the sensor unit is in a second switch state in which the second electrical contact is electrically coupled to the first electrical contact; andan output of the sensor unit corresponds to the transition of the sensor unit to the second switch state.

33. The medical instrument of claim 32, wherein:the first electrical contact is a first conductive insert coupled to a first lead line;the second electrical contact is a second conductive insert coupled to a second lead line;andthe transition to the second switch state closes an electrical circuit.

34. The medical instrument of claim 32, wherein:the second switch state is a default switch state for the sensor unit; anda tensile load within the tension member exerts a torque on the deformable member to move the second electrical contact relative to the first electrical contact and maintainAttorney Docket No. P06879-WOthe sensor unit in the first switch state on the condition that the tension member is in the intact state.

35. A medical instrument, comprising:a proximal mechanical structure;an instrument shaft coupled to the proximal mechanical structure;an end effector coupled to the instrument shaft, the end effector including a tool member; a cable pair positioned partially along the instrument shaft and operably coupled between the proximal mechanical structure and the tool member, the cable pair including a first cable and a second cable, the cable pair being configured to transfer a mechanical input from the proximal mechanical structure to the tool member; anda tension-release member coupled to the instrument shaft, the tension-release member having a first position that defines an operational cable path for the cable pair, the tension-release member having a second position that defines a tension-release cable path for the second cable of the cable pair on a condition that a first cable of the cable pair is in at least a partially broken state, the operational cable path having a length that is greater than a length of the tension-release cable path.

36. The medical instrument of claim 35, wherein:the instrument shaft defines a longitudinal centerline;the tension-release member is aligned with the longitudinal centerline when the tension-release member is in the first position; anda lateral movement of tension-release member from the first position to the second position is limited by a tension in each cable of the cable pair on a condition that each cable of the cable pair is in an intact state.

37. The medical instrument of claim 35, wherein:the instrument shaft defines a longitudinal centerline;the tension-release member moves laterally within the instrument shaft from the first position to the second position in response to the transition of the first cable of the cable pair to the at least partially broken state; anda longitudinal axis of the tension-release member is laterally displaced from the longitudinal centerline on a condition that the tension-release member is at the second position.Attorney Docket No. P06879-WO38. The medical instrument of claim 37. wherein:the lateral movement is toward the second cable.

39. The medical instrument of claim 35, wherein:the tension-release member is at a constant longitudinal position relative to the instrument shaft at both the first position and the second position.

40. The medical instrument of claim 39, wherein:the tension-release member is flexibly coupled to an inner surface of the instrument shaft at the constant longitudinal position.

41. The medical instrument of claim 35, wherein:the instrument shaft defines a longitudinal centerline;an outer diameter of the tension-release member is in a range of 60 percent to 80 percent of an inner diameter of the instrument shaft;an inner diameter of the tension-release member is in a range of 60 percent to 90 percent of the outer diameter of the tension-release member; andthe inner diameter of the tension-release member establishes a point of minimal separation between each cable of the cable pair and the longitudinal centerline on a condition that the tension-release member is at the first position.

42. The medical instrument of claim 35, wherein:the tension-release member has an outer surface and an inner surface;the inner surface defines a bore through which the cable pair is routed; andthe inner surface defines a circular hyperboloid.

43. The medical instrument of claim 35, wherein:the tension-release member has a toroidal shape.

44. The medical instrument of claim 35, wherein:the tension-release member has a cylindrical body extending between a first end portion and a second end portion, the cylindrical body including an outer surface and an inner surface, the inner surface defining a cable path through the cylindrical body;Attorney Docket No. P06879-WOthe inner surface includes a restriction portion positioned between the first end portion and the second end portion; andthe first end portion and the second end portion each have an inner diameter that is greater than an inner diameter of the restriction portion.

45. The medical instrument of claim 44, wherein:the cylindrical body defines a longitudinal centerline; andthe inner surface of the cylindrical body has a concave shape extending between the first end portion and the second end portion and surrounding the longitudinal centerline of the cylindrical body.

46. A medical instrument, comprising:a proximal mechanical structure, the proximal mechanical structure including a first capstan, a second capstan, and a tension-release member, the proximal mechanical structure defining a shaft opening into an instrument shaft, the tension-release member being positioned between the first and second capstans and the shaft opening; a first cable of a cable pair operably coupled between a tool member and the first capstan;anda second cable of the cable pair operably coupled between the tool member and the second capstan, the cable pair being configured to transfer a mechanical input from the first capstan and the second capstan to the tool member, wherein:the tension-release member has a first position that defines an operational cable path for the cable pair.the tension-release member has a second position that defines a tension-release cable path for the second cable of the cable pair on a condition that the first cable of the cable pair is in at least a partially broken state, andthe operational cable path has a length that is greater than the tension-release cable path.

47. The medical instrument of claim 46, wherein:a movement of tension-release member from the first position to the second position is limited by a tension in each cable of the cable pair on a condition that each cable of the cable pair is in an intact state.Attorney Docket No. P06879-WO48. The medical instrument of claim 46, wherein:the tension-release member is slidable laterally along a first axis from the first position to the second position;the first axis is orthogonal to a second axis;the second axis bisects the shaft opening; andthe tension-release member is centered on the second axis when the tension-release member is at the first position.

49. The medical instrument of claim 48, wherein:the tension-release member includes an elongated body extending between a first guide portion and a second guide portion;the first guide portion is positioned to engage the first cable to displace a portion of the first cable away from the second axis on a condition that the second cable is in an intact state;the second guide portion is positioned to engage the second cable to displace a portion of the second cable away from the second axis on a condition that the first cable is in an intact state;the elongated body defines a guide channel configured to receive a guide mechanism of the proximal mechanical structure; andan interaction of the guide mechanism and the guide channel maintains thetension-release member at a single position along the second axis and guides a movement along the first axis from the first position to the second position.

50. The medical instrument of claim 49. wherein:each of the first guide portion and the second guide portion are a fixed guide surface.

51. The medical instrument of claim 49, wherein:each of the first guide portion and the second guide portion include a rotatable element.

52. The medical instrument of claim 48, wherein:the tension-release member moves laterally along the first axis from the first position to the second position in response to the transition of the first cable of the cable pair to the at least partially broken state; andthe lateral movement is away from the second cable.Attorney Docket No. P06879-WO53. A medical instrument, comprising:a proximal mechanical structure;an instrument shaft coupled to the proximal mechanical structure;an end effector coupled to the instrument shaft, the end effector including a tool member;anda cable extending between the proximal mechanical structure and the tool member, the cable having a first cable portion, a second cable portion, and a third cable portion between the first cable portion and the second cable portion, the first cable portion and the second cable portion each being coupled to the proximal mechanical structure, the third cable portion being engaged with a coupling portion of the tool member to produce a friction coupling of the cable to the tool member, the friction coupling being configured to limit movement of the third cable portion relative to the tool member on a condition that the cable is in an intact state and to allow the cable to decouple from the tool member on a condition that the first cable portion is transitioned to a parted state.

54. The medical instrument of claim 53, wherein:the third cable portion is wrapped at least partially around the coupling portion of the tool member.

55. The medical instrument of claim 54, wherein:the third cable portion is wrapped at least two revolutions about the coupling portion.

56. The medical instrument of claim 53, wherein:the coupling portion is shaped to establish a friction force between the third cable portion and the tool member at a magnitude that precludes a movement of the third cable portion relative to the coupling portion on a condition that the cable is in the intact state; andon the condition that the first cable portion is transitioned to a parted state, the friction force between the third cable portion and the coupling portion is reduced to a magnitude that allows the movement of the third cable portion relative to the coupling portion such that the second cable portion in the intact state is decoupled from the tool member.Attorney Docket No. P06879-WO57. The medical instrument of claim 56. wherein:the tool member is pivotable about a pivot axis;the tool member includes a gripping portion that defines a longitudinal axis of the tool member;the longitudinal axis intersects the pivot axis;the coupling portion is divided by the longitudinal axis;the first cable portion contacts the coupling portion on a first side of the longitudinal axis;andthe second cable portion contacts the coupling portion on a second side of the longitudinal axis opposite the first side.

58. The medical instrument of claim 57, wherein:the coupling portion includes an elliptic cylinder;the third cable portion is wrapped about the elliptic cylinder on the condition that the cable is in the intact state; andthe third cable portion being configured to unwind from the elliptic cylinder on the condition that the first cable portion is transitioned to the parted state.

59. The medical instrument of claim 57. wherein:the coupling portion includes a first pin positioned on the first side of the longitudinal axis and a second pin positioned on the second side of the longitudinal axis;the third cable portion is wrapped about the first pin and the third cable portion is wrapped about the second pin on the condition that the cable is in the intact state; and the third cable portion is configured to unwind from the first pin and the second pin on the condition that the first cable portion is transitioned to the parted state.

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