Robotic Surgical Tool Connector for Replaceable Energy Applicators

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Solution Overview

Problem

Existing surgical robotic manipulators require improvements in their end effectors to enhance functionality and efficiency during surgical procedures.

Innovation Solution

A surgical tool system that includes an energy applicator with a shaft, a support structure, a connector assembly for locking the energy applicator, and a protective sheath that is releasably coupled to the tool assembly, allowing for concentric arrangement around the shaft and facilitating easy replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the energy applicator is permanently fixed to the support structure, then the structural integrity and stability are improved, but the adaptability and ease of replacement are worsened

Engineering Contradiction:

Improvestructural integrityVSAvoidease of replacement

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The connector assembly is divided into separate components: a connector body fixed to the support structure, and a connector member attached to the energy applicator. These segments can be independently replaced while maintaining structural integrity during use. The segmentation allows the energy applicator to be detached and replaced without compromising the overall system stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector assembly transitions from a static permanent fixation to a dynamic releasable connection. The resilient member enables the connector to move between locked and unlocked states, providing both structural stability during operation and ease of replacement when needed. This dynamic capability resolves the contradiction between fixed integrity and replaceability.

Inventive Principle:

Principle #15Dynamics

2Reliability

If the protective sheath is permanently attached to the tool assembly, then the protection and stability are improved, but the ease of repair and replacement are worsened

Engineering Contradiction:

Improveprotection stabilityVSAvoidease of sheath replacement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The protective sheath is segmented from the tool assembly through the releasable connector assembly. This allows the sheath to remain attached and provide protection during surgical procedures, while enabling quick removal and replacement if damage or wear occurs. The connector assembly acts as a separable interface that maintains protection during use but facilitates easy repair.

Inventive Principle:

Principle #1Segmentation

3Reliability

If the connector assembly uses complex locking mechanisms, then the reliability of attachment is improved, but the device complexity and ease of operation are worsened

Engineering Contradiction:

Improveattachment reliabilityVSAvoidconnector complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The resilient member automatically engages with the connector body to lock the energy applicator in place without requiring additional locking actions. The self-service mechanism provides reliable attachment through elastic retention, eliminating the need for complex multi-step locking procedures while maintaining secure connection during use.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The complex mechanical locking system is replaced with a simpler elastic retention mechanism. The resilient member uses elastic deformation and recovery to provide secure attachment, substituting intricate mechanical interlocks with a more straightforward elastic engagement that is both reliable and easier to operate.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Object-affected harmful factors

If the protective sheath completely encloses the shaft, then the protection is improved, but the heat dissipation and access are worsened

Engineering Contradiction:

Improveprotection from damageVSAvoidheat dissipation

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The protective sheath provides localized protection where needed while leaving portions of the shaft exposed. The sheath covers the shaft along its length but may have openings, windows, or reduced coverage areas that allow heat dissipation and access to specific regions. This local quality approach balances protection with thermal management and surgical access requirements.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12295593B2Systems and tools for use with surgical robotic manipulators

Publication Date: 2025.05.13 MAKO SURGICAL CORP

AI summary

A tool for use with a surgical robotic manipulator that comprises an energy applicator, a tool assembly, and a protective sheath. The energy applicator including a shaft extending along an axis between a proximal end and a distal end. The tool assembly comprises a support structure to support the energy applicator, a connector assembly arranged to engage and releasably lock the energy applicator to the support structure in a locked state, and a drive system coupled to the support structure to rotatably drive the shaft of the energy applicator about the axis. The protective sheath releasably couples to the tool assembly, such that the protective sheath is arranged concentrically about the shaft of the energy applicator between the distal end of the shaft and the connector assembly. The connector assembly has a connector member to facilitate releasable coupling of the protective sheath to the tool assembly.