Surgical Instrument Adapter Backlash Control

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Surgical instruments with robotically controlled systems face issues of backlash, leading to unpredictable motion during instrument installation, which can affect the precision and reliability of minimally invasive medical procedures.

Innovation Solution

A surgical system with a low backlash mechanical interface that includes a drive output assembly with a cylindrical drive output disk, alignment elements, and preload springs to ensure precise alignment and secure engagement of surgical instruments, minimizing backlash and ensuring controlled torque transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical interface is used to couple drive output to surgical instrument, then torque transmission is achieved, but backlash causes unpredictable motion and reduces precision

Engineering Contradiction:
Improveprecision of torque transmissionVSAvoidbacklash control
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The drive dogs are pre-loaded against the drive dog receptacles through spring mechanisms before operation begins. This preliminary application of force eliminates backlash by ensuring continuous contact between mating surfaces, preventing any play or looseness that would cause unpredictable motion during torque transmission.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system changes the force parameter by applying a constant preload force through springs to the mechanical interface. This parameter change transforms the mechanical coupling from a loose fit with backlash to a tightly engaged connection where the drive dogs are continuously pressed against the receptacles, eliminating play and ensuring precise motion control.

Inventive Principle:
Principle #35Parameter changes

2Measurement precision

If alignment elements are added to ensure precise engagement, then positioning accuracy improves, but device complexity increases

Engineering Contradiction:
Improvealignment accuracyVSAvoidnumber of interface components
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The alignment elements utilize asymmetric geometric features such as tapered surfaces and specifically shaped drive dogs that naturally guide the instrument into correct alignment during insertion. The asymmetric geometry provides self-aligning characteristics that achieve precise positioning without requiring additional active alignment mechanisms or complex control systems.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The mechanical interface features self-aligning properties where the drive dogs and receptacles automatically position themselves correctly through their geometric design. The tapered surfaces and shaped features cause the components to naturally settle into the correct orientation during assembly, eliminating the need for external alignment devices or complex positioning mechanisms.

Inventive Principle:
Principle #25Self-service

Data Source

PatentUS10993773B2Instrument sterile adapter drive features
Publication Date: 2021.05.04 INTUITIVE SURGICAL OPERATIONS INC
  • US10993773B2 patent drawing
  • US10993773B2 patent drawing
  • US10993773B2 patent drawing

AI summary

A surgical system (200) includes a surgical instrument (260) that is sensitive to backlash that would adversely affect the transmission of controlled torque and position to the surgical instrument. The surgical instrument (260) is coupled to motors in a surgical instrument manipulator assembly (240) via a mechanical interface. The combination of the mechanical interface and surgical instrument manipulator assembly (240) have low backlash, e.g., less than 0.7 degrees. The backlash is controlled in the surgical instrument manipulator assembly (240). From the drive output disk (545) in the surgical instrument manipulator assembly to the driven disk (964) of the surgical instrument, the mechanical interface has zero backlash for torque levels used in surgical procedures.