Surgical Instrument Drive Unit with Compact Multi-Motor Gear Layout
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Solution Overview
Problem
Surgical robotic systems lack a handle assembly to actuate the functions of end effectors, requiring an instrument drive unit to interface with each surgical instrument, which is typically coupled to the robotic arm via a slide, limiting flexibility and efficiency.
Innovation Solution
An instrument drive unit with a carriage, electric motors, drive shafts, and gears is introduced, allowing for a compact design that enables bottom-loading of surgical instruments and independent actuation of functions through vertically stacked and offset gears, reducing the overall height and improving usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an instrument drive unit is introduced to interface with each surgical instrument, then the system can actuate functions of end effectors, but the device complexity increases
Solution Approach 1:
The instrument drive unit is segmented into multiple independent electric motors (first electric motor, second electric motor, third electric motor) that can independently actuate different functions of the surgical instrument. This segmentation allows for modular control where each motor handles a specific function, simplifying the control architecture while maintaining operational capability.
Solution Approach 2:
The instrument drive unit is designed as a universal interface that can actuate multiple functions of the surgical instrument through a single integrated unit. The multiple electric motors within the drive unit can collectively perform various operations (e.g., firing, articulation, grasping) that would otherwise require separate mechanisms, reducing overall system complexity.
2Length of moving object
If the instrument drive unit uses traditional coupling via slide, then the axial position can be adjusted, but the system footprint increases
Solution Approach 1:
The instrument drive unit utilizes vertical stacking of electric motors and drive shafts in the vertical dimension rather than extending horizontally along the axial dimension. This dimensional reorganization allows the drive unit to maintain axial position adjustability through the slide mechanism while minimizing the horizontal footprint of the stationary components.
Solution Approach 2:
The drive shafts are rotationally supported within the carriage in a nested arrangement, with multiple drive shafts and their corresponding electric motors compactly organized within the confined space of the instrument drive unit. This nesting allows multiple functional components to occupy minimal space while maintaining full operational capability.
3Adaptability or versatility
If multiple drive shafts are rotationally supported in the carriage, then independent actuation is enabled, but the height of the drive unit increases
Solution Approach 1:
The drive shafts and electric motors are arranged in the horizontal plane rather than being stacked vertically. This dimensional change allows multiple drive shafts to be rotationally supported within the carriage without increasing the vertical height of the drive unit, while still enabling independent actuation of each surgical instrument function.
4Area of stationary object
If vertically stacked electric motors are used, then the horizontal footprint is reduced, but the vertical height increases
Solution Approach 1:
The electric motors are arranged horizontally within the carriage rather than being stacked vertically. This dimensional reorganization reduces the vertical height of the drive unit while maintaining compact horizontal dimensions, effectively trading vertical space for horizontal space optimization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The instrument drive unit enhances the usability and safety of surgical robotic systems by enabling efficient actuation of surgical instruments, reducing the system's footprint, and simplifying emergency instrument removal.
Implementation Method 1
a plurality of electric motors disposed about the plurality of drive shafts... Each rotor is configured to rotate a corresponding drive gear in response to an activation of a respective electric motor
Implementation Method 2
a plurality of drive gears. Each drive gear is fixed to a corresponding drive shaft and is configured for interfacing with a corresponding driven member... Each rotor is configured to rotate a corresponding drive gear
Data Source
Figure 1
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AI summary
An instrument drive unit for use in a robotic surgical system includes a carriage configured to be coupled to a robotic arm, a plurality of drive shafts rotationally supported in the carriage, a plurality of electric motors disposed about the plurality of drive shafts, and a plurality of drive gears. Each electric motor includes a stator and a rotor disposed within the stator. Each drive gear is fixed to a corresponding drive shaft and is configured for interfacing with a corresponding driven member of the electromechanical surgical instrument. Each rotor is configured to rotate a corresponding drive gear in response to an activation of a respective electric motor to actuate a function of the electromechanical surgical instrument.