Handle Assembly Providing Unlimited Roll

An example roll handle assembly includes a handle body, a roll body, a closure body, and a shuttle body. The roll body is coupled to the handle body and has a rotational degree of freedom about a roll axis relative to the handle body. The roll body is translationally constrained along the roll axis relative to the handle body. The closure body is coupled to the handle body and has one or more degrees of freedom of motion relative to the handle body. The shuttle body is coupled to the roll body and the closure body, and has a translational degree of freedom along the roll axis relative to the roll body. The shuttle body is rotationally constrained about the roll axis relative to the roll body, and has a rotational degree of freedom about the roll axis relative to the closure body.

INCORPORATION BY REFERENCE

FIELD

Described herein are handle assemblies, and apparatuses and applications using them. For example, described herein are handle assemblies with a mechanism that enables unlimited rotation (“unlimited-roll handle assemblies”) and apparatuses for minimally invasive surgical tools and remote access tools using them.

BACKGROUND

A number of remote access tools and minimally invasive surgical tools which incorporate handle assemblies with unlimited (or infinite) rotation functionality are known, for example, as described in International Patent Application Publication WO 2007/146894 A2. This application describes laparoscopy tools primarily consisting of a proximal handle, a tool frame/tool shaft, and a distal end-effector (EE). In some of these laparoscopic devices, to rotate the end-effector about the tool shaft axis (i.e., to provide a roll rotation of the end-effector), the user may have to rotate the handle about the tool shaft axis. While the handle may fit or conform in the user's hand, palm, and/or fingers in the nominal condition (i.e., prior to any roll rotation), it may no longer continue to fit/conform with the user's hand during and after the roll rotation. In fact, during such rotation, the handle may start to collide with areas of the hand that are holding the device, typically limiting the amount of roll rotation and/or requiring repositioning of the handle within the surgeon's hand to achieve maximum roll rotation at the end-effector. Thus, many of these devices may require more than one hand to operate or may require repositioning of the device during operation within a user's hand in order to continue to roll in a single direction beyond a limited amount of roll. In addition, a device that is repositioned to continue roll rotation is usually not ergonomic and more difficult to operate due to loss of access to the input joint/mechanism between the tool frame/tool shaft. Attempts have been made to address the challenge of limited rotation and reduced ergonomics by providing a rotational joint in the handle assembly between the stationary portion of the handle that is held generally by a user's hand and palm (and possibly by finger(s) and/or thumb) in the nominal condition and the roll portion (e.g. a dial, handle dial, rotation dial or the like) that is rotated with respect to the stationary portion about its center axis generally by the user's finger(s) and/or thumb; these attempts have met this challenge with only limited success, in part because rolling the device in this manner may result in winding of internal transmission members when rolling the roll portion (e.g., dial, handle dial, rotation dial or the like) relative to the stationary portion. The stationary portion of the handle is defined stationary as far as roll rotation motion is concerned. Generally, this stationary portion is “stationary” with respect to the user's palm. This stationary portion may move along with the user's hand to provide other degrees of freedom (e.g., pitch and yaw rotations in articulating laparoscopic devices).

These devices that incorporate the stationary portion and roll portion in the handle assembly may be articulating or non-articulating. In some non-articulating devices, the handle assembly and tool shaft can be rigidly connected and rotation of the entire handle assembly may drive rotation of the tool shaft and end-effector. In other non-articulating devices, the handle assembly and tool shaft can be rigidly connected and the handle may be equipped with a dial, wherein the dial is connected to the end-effector and drives the rotation of the end-effector via a roll transmission member routed through the tool shaft. Furthermore, laparoscopic devices are becoming more complex and catering to challenging laparoscopic procedures. Laparoscopic tools may now include articulating end-effectors that can be actuated by an input articulation joint between the tool shaft and the handle assembly. Articulating end-effectors enable the surgeon to alter the axis of roll rotation of the end-effector by articulating the handle assembly about an input articulation joint (also referred to as the input joint or the articulation input joint here) with respect to the tool shaft. The handle assembly in such device is not rigidly connected to the tool shaft but is instead connected via an input joint that generally allows two articulation degrees of freedom (e.g., yaw rotation and pitch rotation) and constrains, and therefore transmits, roll rotation. In some articulating devices, rotation of the end-effector may be driven by the rotation of the dial portion of the handle assembly, which further transmits roll to the end-effector via rotation of tool shaft. Here, the tool shaft is connected to the handle assembly via an input articulation joint providing yaw and pitch degrees of freedom but transmitting roll rotation from the handle assembly to the tool shaft. Similarly, the roll rotation of the tool shaft is transmitted to the end-effector via an output articulation joint. An example of such device configuration is an articulating device by Novare™ (International Patent Application Publication WO2007/146894 A2). In other articulating devices, articulation transmission and roll transmission are decoupled such that roll is directly transmitted from the rotation of the dial portion of handle assembly to the end-effector via a separate roll transmission member and not via the roll degree of constraint (DoC) with respect to the input articulation joint, tool shaft, and output articulation joint (also referred to as output joint or the articulation output joint here). This roll transmission member should be adequately stiff in torsion to transmit roll rotation. This roll transmission member may or may not be routed through the input articulation joint or the tool frame/tool shaft. An example of such device configuration is an articulation device sold by Covidien™ (U.S. Pat. No. 8,603,135).

Typically, the enhanced dexterity that these articulating tools offer comes with the tradeoff of increased resistance to roll rotation of the roll portion of the handle assembly. This resistance to roll rotation is further increased when the end-effector is articulated. This resistance may increase further when a handle input (e.g., lever within the handle assembly) is engaged, which leads to the end-effector actuation (e.g., opening and closing of a moving portion of the end-effector relative to a reference portion of the end-effector). The resistance to roll can be considerable while simultaneously performing end-effector articulation and end-effector actuation. Engagement of a handle input (e.g., handle input lever) to actuate the opening/closing of an end-effector having a jaw at the end of the tool shaft typically results in high loads generated between the stationary portion of the handle assembly held by the user and the rotatable portion of the handle assembly (e.g., dial) that interface with each other to allow rotation. The result of the high load between these independent bodies is typically an increase in frictional resistance to roll rotation which limits the surgeon's ability to use fine rotation input at the handle assembly to precisely control the end-effector roll rotation. The high jaw (open/close) actuation loads are typically transmitted from the handle input by a transmission member such as a steel cable, steel wire, a monofilament steel, a Nitinol rod, or a tungsten cable, etc. These types of transmission members function well to transfer loads from an input location to an output or remote portion of an instrument. Due to the complexity in simultaneously transmitting and providing roll, articulation, and actuation functionality to the end-effector in such devices, as well as the limitation of working within a tight volume to incorporate features to meet these functionalities, it is challenging to incorporate assemblies, mechanisms, joints, and bodies that meet the structural and interface requirements to be able to provide the aforementioned functionalities.

Described herein are apparatuses (e.g., mechanisms, devices, tools, machines, systems, etc.) including handle assemblies with an unlimited-roll mechanism which may address these problems.

SUMMARY OF THE DISCLOSURE

Described herein are apparatuses (including mechanisms, instruments, devices, tools, systems, etc.) that may include handle assemblies that provide unlimited (e.g., “infinite”) roll of a portion of the handle assembly relative to another portion of the handle assembly, and may transmit this roll to an end-effector in an advantageous manner. The unlimited-roll mechanisms described herein may be part of an apparatus that includes the handle assembly, a tool frame (which may be a tool shaft or may include a tool shaft), and an end-effector assembly. In some variations, the apparatus may include an end-effector assembly (or simply, end-effector) that can be articulated with respect to the tool frame via an end-effector articulation joint at the distal end of the device; articulation of the end-effector may be controlled by an input articulation joint (input joint) at the proximal end of the device, including between the handle assembly and the tool frame. In any of these apparatuses, the tool frame may be interfaced with a user's arm (e.g., wrist, forearm, etc.) via an arm attachment (e.g., forearm attachment), while the user's hand (palm, fingers, thumb, etc.) is interfaced with the handle assembly. The arm attachment may be connected to the tool frame by a joint (e.g., a bearing) that allows one or more degrees of freedom (e.g., pitch, yaw, roll) between the user's arm and the tool frame. In any of these apparatuses, the end-effector may have at least one moving portion (e.g., a moving jaw) that can be actuated (e.g., opened/closed) by an input control on the handle assembly that causes an output actuation of the end-effector via an end-effector jaw actuation member. In some of these apparatuses, the jaw actuation transmission member may be a tension/compression member which may be pulled by the input control in the handle assembly to cause end-effector actuation (say, jaw closure actuation). The same or a different jaw actuation transmission member, either tension/compression member may be used to cause the end-effector actuation (say, jaw opening actuation), undoing the previous actuation. This may lead to a pull (first actuation)-pull (second actuation) operation as part of end-effector actuation or a pull (first actuation)-push (second actuation) operation or a push (first actuation)-pull (second actuation) operation.

In general, the unlimited-roll handle assemblies described herein may also be referred to as unlimited rotation handle assemblies, or as unlimited rotation handle apparatuses, or as unlimited-roll handle apparatuses, or the like. In general, the stationary portion of the handle assembly may also be referred to as a handle shell, or as an ergonomic handle shell or as a handle body or as a first portion of the handle assembly or the like. In general, the rotational portion of the handle assembly may also be referred to as a rotation portion, or as a rotation dial, or as a rotating portion, or as a dial or as a second portion of the handle assembly or the like. In general, the input control in the handle assembly may also be referred to as a control, or as an input lever, or as an end-effector control, or as an input lever control or the like.

These unlimited-roll handle assemblies may allow actuation of a distal end-effector (e.g., open and close of end-effector jaws) by an input control on a first portion of the handle assembly (e.g., a handle body) using an end-effector actuation transmission member comprising a cable (steel, tungsten, etc.), steel wire, etc. or a monofilament steel or Nitinol rod, etc. to transmit actuation from the handle assembly without binding up or disruption of the end-effector actuation. This actuation may happen independently, or in parallel, or regardless of the other motions such as end-effector articulation and end-effector roll rotation.

For example, when end-effector is a jaw assembly, it may include one or two moving jaws that are movable with respect to a base end-effector portion (a first end-effector portion). These one or more moving jaws refer to the second, third, and so on end-effector portions. In some variations, one of the jaws of the jaw assembly may be part of (or rigidly attached to) the base end-effector portion. The one or more movable jaws may be moved by a jaw actuation transmission member that is connected to the shuttle portion of the handle assembly. This open/close action of the jaws in the end-effector assembly may be controlled by an end-effector control that may be a moving body (such as a lever, button, slider, etc.) in the handle assembly. Thus, disclosed herein are unlimited-roll handle assemblies that may be part of an apparatus that includes a corresponding rotation of an end-effector assembly, while being able to transmit a control input from the handle assembly to an actuation of the end-effector (e.g., open/close motion).

The apparatuses described herein may be configured for use in any application, including, but not limited to, medical devices (e.g., surgical devices including minimally invasive devices such as laparoscopes, endoscopes, etc.) and the like. For example, an articulated unlimited-roll handle assembly as described may be used as part of a remote access tool that require finesse rotation about a tool-shaft axis and manipulation or articulation of a tool shaft and/or end-effector. In general, the apparatuses described herein may be useful for a variety of purposes.

As will be described in greater detail herein, any of these apparatuses may include a handle assembly having multiple portions or bodies or components that are coupled together to provide specific rotational and/or translational degrees of freedom relative to each other to provide a reference or ground portion (also referred to herein as a palm grip, palm grip portion, handle body, handle shell, or the like) that may be held within a user's hand and to provide a rotating portion (referred to herein as a knob, dial, finger dial, rotation dial etc.) that may be operated by the fingers (including the thumb) of the same hand holding the palm grip In some variations, the handle assembly may be referred to as a handle, a handle mechanism, an unlimited-roll handle assembly, an infinite roll handle, or the like. In some variations the handle assembly includes four interconnected components (or bodies) and an end-effector control input (also sometimes referred to as closure input), such as a lever, button, dial or other control, to actuate (e.g., open/close) the end-effector. The four interconnected bodies that are part of the handle assembly may include a first handle portion (e.g., palm grip), a second handle portion (e.g., finger dial), a push rod (typically internal to the first handle portion), and a shuttle body (typically internal to the second handle portion). The push rod is typically a rigid member and may alternatively be referred to as a pull rod. The shuttle body typically connects to (or includes) a portion of an end-effector actuation transmission member, such as a transmission cable, for transmitting actuation of the end-effector control input to the end-effector. As used to describe degrees of freedom here, axis refers to a specific line in space. A body may rotate with respect to (w.r.t.) another body about a certain axis. A body may translate w.r.t. another body along a certain direction. A direction is not defined by a particular axis and is instead commonly defined by multiple parallel axes. Thus, X axis is a specific axis defined and shown in a figure, while X direction refers to the direction of this X axis. Multiple different but parallel X axes have the same X direction. Direction only has an orientation and not a location in space.

For example, a handle assembly configured as an unlimited-roll handle assembly may include a first handle portion that is an outer proximal body configured as a palm grip. Generically, this body may be referred to as handle body A (“H.Body A”), also referred to as “handle shell”. The handle assembly may also include a second handle portion configured as an outer distal body, which may be generically referred to as handle body B (“H.Body B”). These two bodies may be considered independent bodies with an established joint where additional features may exist. Within the joint between these two bodies, there may exist specific geometric features such as ribs, surfaces, edges, washers, bushings, bearings, lubricants, etc. which may function to offer some degrees of freedom while constraining others. This joint between the outer bodies may also be internally traversed by a secondary pair of bodies. These secondary bodies may have a portion of them proximal or distal to the joint between H.Body A and H.Body B. One of the secondary bodies may be generically referred to herein as handle body C (“H.Body C”) and may be, e.g., a proximal push rod having a portion of it connecting to H.Body A. The other secondary body may be generically referred to herein as handle body D (“H.Body D”) and may be, e.g., a distal shuttle having a portion of it connecting to H.Body B. Likewise, the joints between either of the inner secondary bodies with respect to each other and with respect to the outer two bodies may also comprise specific geometric features such as ribs, surfaces, edges, washers, bushings, bearings, lubricants, etc. which may function to offer some degrees of freedom while constraining others. A generic description of this four-body structure showing the degrees of constraint and degrees of freedom is illustrated inFIG. 1. A four-body unlimited-roll handle assembly such as the one shown generically inFIG. 1may be incorporated as part of an articulating laparoscopic instrument, for example. A user (such as a physician, doctor, surgeon, etc.) may hold the handle assembly and apply articulation input (causing pitch/yaw motion) through a joint distal or proximal to the handle assembly. This articulation input joint (pitch/yaw) may connect the handle assembly to the tool frame/tool shaft. This articulation input may be transmitted to an articulation output joint (pitch/yaw) at the distal end of the instrument via one or more articulation transmission members. This articulation output joint may connect the tool shaft/tool frame to the end-effector assembly. This transmission member(s) connects to the articulation input joint and an articulation output joint (proximal to the end-effector assembly). The surgeon may then rotate the end-effector about its center/roll axis (Axis2) by rotation of the second portion or dial body (H.Body B) relative to first portion of the handle assembly or proximal outer body (H.Body A) about its center axis (Axis1). While holding (grounding) the proximal outer body (H.Body A, e.g., a palm grip) in his/her palm, the user may rotate the distal outer body (e.g., H.Body B, e.g., a rotation dial) to drive rotation with a finesse twirling motion between the thumb and forefinger. A rotation joint between H.Body A (first portion) and H.Body B (second portion) presented inFIG. 1may function to reduce friction and relieve the user of strenuous resistances which can otherwise be generated when the user also chooses to activate the jaw closure, for example, by transferring translation along a first axis direction (e.g., Axis1inFIG. 2) from H.Body C to H.Body D and generating a force in the tension/compression (jaw close/open) transmission member of the handle assembly. As will be described and illustrated in greater detail below, when the user activates the end-effector input control at the handle assembly, this motion is transmitted to the translation of H.Body C along a first axis direction with respect to H.Body A via a transmission mechanism in the handle assembly. The translation of H.Body C is further transmitted to the translation of H.Body D, which is transmitted to an end-effector via an end-effector actuation transmission member. While the transmission happens, the surgeon can also infinitely rotate the rotation dial (H.Body B) on the handle assembly clockwise or counterclockwise without twisting the end-effector actuation transmission member due to keying or constrained joints between H.Body B and H.Body D.

In variations in which the handle assembly is used with an articulating joint, such as the joint between the handle assembly and the tool shaft, the articulation input joint may be a parallel kinematic (P-K) joint (e.g., per U.S. Patent Application Publication 2013/0012958 or U.S. Pat. No. 8,668,702), or a virtual center (VC) joint (e.g., per U.S. Pat. No. 5,908,436), or a parallel kinematic virtual center joint (e.g., per U.S. Pat. No. 8,668,702), or a serial kinematic (S-K) joint (e.g., per U.S. Pat. Nos. 8,465,475 or 5,713,505), or a combination of a serial kinematic and a parallel kinematic joint. The unlimited-roll handle assemblies described herein may be particularly useful with apparatuses that are articulating, e.g., having an articulation input joint between the handle assembly and the tool frame (e.g., tool shaft). Here, transmission cables (that are compliant in compression, torsion, and bending, such as a rope, braided cable, etc.) may be the effective end-effector actuation transmission member and/or end-effector articulation member. These highly compliant transmission members may be able to bend through tight bend radii and provide effective transmission. Wire that is torsionally stiff but compliant in bending may also be used for either of the two aforementioned transmissions and/or for end-effector rotation transmission. Articulation transmission members, roll transmission members, and end-effector actuation transmission members may be distinct bodies, or they may be combined into one body in a pair or triplet to perform intended transmission. The transmission members may route through different paths to link their respective joints. For example, an articulation transmission member may be routed through the body of the tool frame (e.g., tool shaft), or it may be routed externally to the body of the tool shaft.

As mentioned above, any of the apparatuses described herein may include an unlimited-roll handle assembly and an arm attachment (e.g., forearm attachment) so that a proximal end region of the apparatus may be connected to the user's arm/forearm. These apparatuses may permit improved control of the apparatus when the apparatus is rigidly coupled to the user's arm (e.g., having no degrees of freedom between the apparatus and the user's arm), but may be particularly helpful where the arm attachment permits one or more degrees of freedom between the tool frame and the user's arm, such as one or more of roll, pitch, and/or yaw degrees of freedom.

For example, described herein are apparatuses, including medical devices, comprising: an elongate tool frame having a forearm attachment portion at a proximal end, the elongate frame having a tool axis; an end-effector at a distal end of the elongate tool frame; a handle assembly that provides unlimited roll to the end-effector, wherein the handle assembly includes: a first handle portion; a second handle portion coupled to the first handle portion so that the second handle portion has one rotational degree of freedom in a first axis relative to the first handle portion but is translationally constrained relative to the first handle portion along the first axis direction; a push rod completely or partially within the first handle portion and coupled to the first handle portion so that it has one translational degree of freedom along the first axis direction relative to the first handle portion but is rotationally constrained about the first axis relative to the first handle portion; a shuttle body completely or partially within the second handle portion, wherein the shuttle body is coupled to the push rod so that it has one rotational degree of freedom about the first axis relative to the push rod but is translationally constrained along the first axis direction relative to the push rod, further wherein the shuttle body is coupled to the second handle portion so that it has one translational degree of freedom along the first axis direction relative to the second handle portion; and an end-effector control input on the first handle portion coupled to the push rod via a mechanism or other transmission system and configured to translate the push rod along the first axis direction, wherein the rotation of the second handle portion about the first axis is transmitted to the end-effector so that the end-effector rotates about its center axis in consequence of the rotation of second handle portion; and a cuff having a passage therethrough that is configured to hold a wrist or forearm of a user, wherein the cuff is configured to couple to the forearm attachment portion of the tool frame. In some instances, the shuttle body may be completely outside the second handle portion.

The forearm attachment portion and/or the cuff may be configured to permit one or more degrees of freedom between the cuff (which is typically rigidly attached to the user's arm) and the forearm attachment portion. For example, the device may include a joint between the forearm attachment portion of the tool frame and the cuff, wherein the joint is configured to provide one or more rotational degrees of freedom between the cuff and the forearm attachment portion of the tool frame. The joint may be a bearing (e.g., a machine element that constrains the relative motion to one or more desired motions such as pitch, roll, or yaw, and may reduce friction between the moving parts). For example, the device may include one or more joints between the forearm attachment portion of the tool frame and the cuff, wherein the one or more joints are configured to provide one or more of the following degrees of freedom: a roll degree of freedom with respect to the tool axis, a pitch degree of freedom between the cuff and the forearm attachment portion of the tool frame, or a yaw degree of freedom between the cuff and the forearm attachment portion of the tool frame.

In general, the cuff may include a strap and/or securement so that it may be attached securely to the user's arm (e.g., forearm), and may be removable from the forearm attachment portion of the tool frame so that it can be attached to the user's forearm, then snapped or otherwise attached to the forearm attachment portion of the tool frame.

In general, the unlimited roll between the second handle portion and the first handle portion may be transmitted to the end-effector. As mentioned, the roll between the second handle portion and the first handle portion may be transmitted by a transmission member that is separate from the tool frame and may be routed around or through the tool frame. For example, the rotation of the second handle portion may be transmitted to the end-effector through a rotation transmission extending between the second handle portion and the end-effector. Alternatively, in some variations, the tool shaft transmits the roll between the second handle portion and the first handle portion; for example, either the second handle portion or the first handle portion may be rigidly connected to the tool shaft so that roll between the second handle portion and the first handle portion is transmitted by the tool frame to the end-effector at the distal end of the apparatus. In general, because the unlimited roll between the second handle portion and the first handle portion is relative between the two, the transmission member for this roll may be connected to either the second handle portion or the first handle portion, although it is illustrated herein primarily as coupled to the second handle portion (e.g., the knob or dial at a distal region of the handle). For example, the rotation of the second handle portion (e.g., the knob or dial) may be transmitted to the end-effector because the elongate tool frame is coupled to the second handle portion so that the elongate tool frame is rotationally constrained relative to the second handle portion and the end-effector is coupled to the elongate tool frame so that the end-effector is rotationally constrained relative to the elongate tool frame.

As mentioned, any of the apparatuses described herein may include an input joint between the handle assembly and the tool frame. For example, any of these apparatuses may include an input joint wherein the input joint provides a pitch degree of freedom between the handle assembly and the tool about a pitch axis of rotation and a yaw degree of freedom between the handle assembly and the tool about a yaw axis of rotation. This input joint may be a parallel kinematic input joint or a serial kinematic input joint or a combination of parallel and serial kinematic input joint. For example, any of these devices may include an input joint between the handle assembly and the tool frame and an output joint (i.e., the articulation output joint) between the tool frame and the end-effector, wherein the input joint comprises a pitch motion path and a yaw motion path, further wherein the pitch motion path and the yaw motion path are independent and coupled in parallel (forming a parallel kinematic input joint) between the handle and the tool frame, wherein the pitch motion path captures pitch motion of the handle assembly relative to the tool frame for transmission to the output joint but does not capture yaw motion of the handle assembly relative to the tool frame for transmission to the output joint, and wherein the yaw motion path captures yaw motion of the handle assembly relative to the tool frame for transmission to the output joint but does not capture pitch motion of the handle assembly relative to the tool frame for transmission to the output joint. Alternatively, the pitch motion path and the yaw motion path may be arranged in series (as a serial kinematic input joint). However, as will be described herein, any of the devices including an input joint having more than one degree of freedom axis of rotation (e.g., pitch and yaw, pitch and roll, yaw and roll, etc.) may be configured so that the two or more axes of rotation intersect at a center of rotation (e.g., a virtual center of rotation) that is positioned behind (proximal to) the handle assembly, including at a virtual center of rotation that would be located within the user's wrist when the device is operated by the user. For example, the pitch axis of rotation and the yaw axis of rotation may intersect in a center of rotation that is proximal to the handle assembly.

In any of the variations including an input joint having multiple degrees of freedom (e.g., pitch and yaw), one or more transmission members may be included to transmit the motion (e.g., pitch motion, yaw motion) to the output joint and therefore the end-effector. For example, a device may include a pitch transmission member and a yaw transmission member extending from the input joint to the output joint, wherein the pitch transmission member transmits pitch rotations and the yaw transmission member transmits yaw rotations of the input joint to corresponding rotations of the output joint.

As mentioned, any appropriate end-effector may be used. The end-effector may or may not have grasping jaws (or simply jaws) that may or may not move. For example, the end-effector may have a soft end to spread delicate tissues (e.g., dissector) or a camera or a laser pointer. Therefore, an end-effector assembly may also be referred to as an end-effector or the like. The end-effector may also have one or more moving jaws, one or more stationary jaws (stationary with respect to moving jaws), or other bodies required for end-effector actuation. In some examples, an end-effector may be configured as a jaw assembly that include jaws that open and close. The end-effector control input on the handle assembly may be actuated, e.g., by a user's finger or fingers, including the user's thumb, of the same hand holding the handle assembly. For example, any of these devices may include an end-effector assembly that is configured as a jaw assembly so that the actuation of the end-effector control input opens or closes the jaw assembly. The end-effector control input may be operated to hold the jaws open or closed (e.g., by continuing to actuate the end-effector control input). For example, when the end-effector control input is a trigger or lever on the handle assembly, holding the trigger or lever down may hold the jaws closed, whereas releasing the trigger or lever may release/open the jaws.

The end-effector may generally be configured as an assembly having multiple portions that are coupled together to allow relative motion between the parts. For example, the end-effector may include a second end-effector portion that is movably coupled to a first end-effector portion; and the apparatus (e.g., device) may further include a transmission cable connecting the shuttle body to the second end-effector portion so that actuation of the end-effector control input on the handle assembly moves the second end-effector portion relative to the first end-effector portion when the second handle portion is in any rotational position about the first axis relative to the first handle portion. As mentioned, the transmission cable may be a rope or braided material that is compliant in compression, torsion and bending.

The end-effector control input may be any appropriate control, including but not limited to a trigger, lever, or button, which is typically positioned on the first handle portion and configured for actuation by one or more of a user's fingers or thumb. This end-effector control input may be connected to the push rod (H.Body C) via an input transmission mechanism which takes input from the end-effector control input and outputs a translation of the push rod (H.Body C) along a first axis direction.

For example, a medical device having an unlimited-roll handle assembly may include: an elongate tool frame having a forearm attachment portion at a proximal end, the elongate frame having a tool axis; an end-effector at a distal end of the elongate tool frame; a handle assembly that provides unlimited roll to the end-effector, wherein the handle assembly includes: a first handle portion, a second handle portion coupled to the first handle portion so that the second handle portion has one rotational degree of freedom about a first axis relative to the first handle portion but is translationally constrained relative to the first handle portion along the first axis direction, a push rod within the first handle portion and coupled to the first handle portion so that it has one translational degree of freedom along the first axis direction relative to the first handle portion but is rotationally constrained about the first axis relative to the first handle portion, a shuttle body within the second handle portion, wherein the shuttle body is coupled to the push rod so that it has one rotational degree of freedom about the first axis relative to the push rod but is translationally constrained along the first axis direction relative to the push rod, further wherein the shuttle body is coupled to the second handle portion so that it has one translational degree of freedom along the first axis direction relative to the second handle portion but is rotationally constrained about the first axis relative to the second handle portion, wherein rotation of the second handle portion is transmitted to the end-effector so that the end-effector rotates with the second handle portion, and an end-effector control input on the first handle portion coupled to the push rod and configured to translate the push rod along the first axis direction,; and a cuff having a passage therethrough that is configured to hold a user's wrist or forearm; and a joint between the forearm attachment portion of the tool frame and the cuff, wherein the joint provides one or more of a roll degree of freedom, a pitch degree of freedom, or a yaw degree of freedom between the cuff and the forearm attachment portion of the tool frame, and wherein actuation of the end-effector control input on the handle assembly actuates the end-effector when the second handle portion is in any rotational position about the first axis relative to the first handle portion.

In general, any of these apparatuses may include an unlimited-roll handle assembly in which the shuttle body portion of the handle assembly is keyed to the knob/dial portion of the handle (e.g., second handle portion). Thus, the shuttle body may be coupled to the second handle portion so that it has one translational degree of freedom along the first axis direction relative to the second handle portion but is rotationally constrained about the first axis relative to the second handle portion. As mentioned above, the shuttle includes the structure(s) that couple(s) to the transmission member transmitting the end-effector control input (such as an end-effector actuation transmission) to the end-effector.

Also described herein are apparatuses including an unlimited-roll handle assembly in which the apparatus is configured to articulate, e.g., between the handle assembly and the tool shaft, with or without an arm attachment. For example, described herein are medical devices comprising: an end-effector at a distal end of an elongate tool frame; a handle assembly that provides unlimited roll to an end-effector, wherein the handle assembly includes: a first handle portion, a second handle portion coupled to the first handle portion so that the second handle body has one rotational degree of freedom in a first axis relative to the first handle portion but is translationally constrained relative to the first handle portion along the first axis direction, a push rod within the first handle portion and coupled to the first handle portion so that it has one translational degree of freedom along the first axis direction relative to the first handle portion but is rotationally constrained about the first axis relative to the first handle portion, a shuttle body within the second handle portion, wherein the shuttle body is coupled to the push rod so that it has one rotational degree of freedom about the first axis relative to the push rod but is translationally constrained along the first axis direction relative to the push rod, further wherein the shuttle body is coupled to the second handle portion so that it has one translational degree of freedom along the first axis direction relative to the second handle portion but is rotationally constrained about the first axis relative to the second handle portion, and an end-effector control input on the first handle portion coupled to the push rod and configured to translate the push rod along the first axis direction, wherein rotation of the second handle portion is transmitted to the end-effector so that the end-effector rotates with the second handle portion; and an input joint between the handle assembly and the tool frame configured to capture motion of the handle about a pitch axis of rotation relative to the tool frame for transmission to an output joint, and further configured to capture motion of the handle about a yaw axis of rotation relative to the tool frame for transmission to an output joint, wherein the pitch axis of rotation and the yaw axis of rotation intersect in a center of rotation; wherein the end-effector is coupled to the tool frame by the output joint. Typically, actuation of the end-effector control input on the handle assembly may actuate the end-effector when the second handle portion is in any rotational position relative to the first handle portion.

As mentioned above, the center of rotation may be posterior to the handle assembly, and may be, for example, a virtual center of rotation that would be located within a user's arm or wrist when the apparatus is held by a user. Any of these apparatuses may also include an arm (e.g., forearm) attachment. For example, any of these apparatuses may include a forearm attachment portion at a proximal end of the tool frame and a cuff having a passage therethrough that is configured to hold a wrist or forearm of a user, wherein the cuff is configured to couple to the forearm attachment portion of the tool frame. The forearm attachment may include a joint between the forearm attachment portion of the tool frame and the cuff, wherein the joint is configured to provide one or more rotational degrees of freedom between the cuff and the forearm attachment portion of the tool frame.

The input joint between the handle assembly and the tool frame/tool shaft may be referred to herein as a pitch and yaw input joint, and may comprise a pitch motion path and a yaw motion path, as described above. For example, the pitch motion path and the yaw motion path may be independent and coupled in parallel between the handle assembly and the tool frame, wherein the pitch motion path captures pitch motion of the handle assembly relative to the tool frame for transmission to the output joint but does not capture yaw motion of the handle assembly relative to the tool frame for transmission to the output joint, and wherein the yaw motion path captures yaw motion of the handle assembly relative to the tool frame for transmission to the output joint but does not capture pitch motion of the handle assembly relative to the tool frame for transmission to the output joint.

For example, a medical device may include: an end-effector at a distal end of an elongate tool frame; a handle assembly that provides unlimited roll to an end-effector, wherein the handle includes: a first handle portion, a second handle portion coupled to the first handle portion so that the second handle body has one rotational degree of freedom in a first axis relative to the first handle portion but is translationally constrained relative to the first handle portion along the first axis direction, a push rod within the first handle portion and coupled to the first handle portion so that it has one translational degree of freedom along the first axis direction relative to the first handle portion but is rotationally constrained about the first axis relative to the first handle portion, a shuttle body within the second handle portion, wherein the shuttle body is coupled to the push rod so that it has one rotational degree of freedom about the first axis relative to the push rod but is translationally constrained along the first axis direction relative to the push rod, further wherein the shuttle body is coupled to the second handle portion so that it has one translational degree of freedom along the first axis direction relative to the second handle portion but is rotationally constrained about the first axis relative to the second handle portion, and an end-effector control input on the first handle portion coupled to the push rod and configured to translate the push rod along the first axis direction, wherein rotation of the second handle portion is transmitted to the end-effector so that the end-effector rotates with the second handle portion; and an input joint between the handle and the tool frame, the input joint comprising a pitch motion path and a yaw motion path, further wherein the pitch motion path and the yaw motion path are independent and coupled in parallel between the handle assembly and the tool frame, wherein the pitch motion path captures pitch motion of the handle relative to the tool frame about a pitch axis of rotation for transmission to the output joint but does not capture yaw motion of the handle assembly relative to the tool frame for transmission to the output joint, and wherein the yaw motion path captures yaw motion of the handle assembly relative to the tool frame about a yaw axis of rotation for transmission to the output joint but does not capture pitch motion of the handle assembly relative to the tool frame for transmission to the output joint, wherein the pitch axis of rotation and the yaw axis of rotation intersect in a center of rotation that is proximal to the handle; wherein the end-effector is coupled to the tool frame by the output joint.

Any of these apparatuses may include an unlimited-roll handle assembly and an end-effector configured as a jaw assembly, either with or without an arm (e.g., forearm) attachment, and/or be configured as an articulating device (e.g., including an input joint such as a pitch and yaw input joint). For example, described herein are medical devices including: an end-effector at a distal end of an elongate tool frame; a handle assembly that provides unlimited roll to an end-effector, wherein the handle assembly includes: a first handle portion, a second handle portion coupled to the first handle portion so that the second handle body has one rotational degree of freedom in a first axis relative to the first handle portion but is translationally constrained relative to the first handle portion along the first axis direction, a push rod within the first handle portion and coupled to the first handle portion so that it has one translational degree of freedom along the first axis direction relative to the first handle portion but is rotationally constrained about the first axis relative to the first handle portion, a shuttle body within the second handle portion, wherein the shuttle body is coupled to the push rod so that it has one rotational degree of freedom about the first axis relative to the push rod but is translationally constrained along the first axis direction relative to the push rod, further wherein the shuttle body is coupled to the second handle portion so that it has one translational degree of freedom along the first axis direction relative to the second handle portion but is rotationally constrained about the first axis relative to the second handle portion, and an end-effector control input on the first handle portion coupled to the push rod and configured to translate the push rod along the first axis direction, wherein rotation of the second handle portion is transmitted to the end-effector so that the end-effector rotates with the second handle portion; wherein the end-effector includes a second end-effector portion that is movably coupled to a first end-effector portion; and a transmission cable connecting the shuttle body to the second end-effector portion so that actuation of the end-effector control input moves the second end-effector portion relative to the first end-effector portion when the second handle portion is in any rotational position with respect to the first axis relative to the first handle portion. As mentioned, the end-effector may be a jaw assembly configured so that actuation of the end-effector control input opens or closes the jaw assembly. For example, the second end-effector portion may comprise a jaw member that is pivotally hinged to the first end-effector portion. The jaw assembly may also include a third end-effector portion that is pivotally hinged to the first end-effector portion and coupled to the transmission cable. The second end-effector portion is further coupled to a third end-effector portion such that actuation of the end-effector control input on the handle moves the second and third end-effector portions relative to the first end-effector portion.

As described above, any of these apparatuses may include a forearm attachment portion at a proximal end of the tool frame and a cuff having a passage therethrough that is configured to hold a wrist or forearm of a user, wherein the cuff is configured to couple to the forearm attachment portion of the tool frame; the apparatus may also include a joint between the forearm attachment portion of the tool frame and the cuff, wherein the joint is configured to provide one or more rotational degrees of freedom between the cuff and the forearm attachment portion of the tool frame.

For example, a medical device may include: an end-effector at a distal end of an elongate tool frame; a handle assembly that provides unlimited roll to an end-effector, wherein the handle assembly includes: a first handle portion, a second handle portion coupled to the first handle portion so that the second handle body has one rotational degree of freedom in a first axis relative to the first handle portion but is translationally constrained relative to the first handle portion along the first axis direction, a push rod within the first handle portion and coupled to the first handle portion so that it has one translational degree of freedom along the first axis direction relative to the first handle portion but is rotationally constrained about the first axis relative to the first handle portion, a shuttle body within the second handle portion, wherein the shuttle body is coupled to the push rod so that it has one rotational degree of freedom about the first axis relative to the push rod but is translationally constrained along the first axis direction relative to the push rod, further wherein the shuttle body is coupled to the second handle portion so that it has one translational degree of freedom along the first axis direction relative to the second handle portion but is rotationally constrained about the first axis relative to the second handle portion, and an end-effector control input on the first handle portion coupled to the push rod and configured to translate the push rod along the first axis direction, wherein rotation of the second handle portion is transmitted to the end-effector so that the end-effector rotates with the second handle portion; wherein the end-effector comprises a jaw assembly including a first end-effector portion that is movably coupled to a second end-effector portion, wherein the second end-effector portion comprises a jaw member; and a transmission cable connecting the shuttle body to the second end-effector portion so that actuation of the end-effector control input moves the second end-effector portion relative to the first end-effector portion when the second handle portion is in any rotational position with respect to the first axis relative to the first handle portion to open or close the jaw assembly of the end-effector.

Described herein are apparatuses (e.g., mechanisms, devices, tools, machines, systems, etc.) including handle assemblies with an unlimited-roll mechanism which may incorporate certain degrees of freedoms and degrees of constraints between bodies in the handle assembly and/or in the end-effector assembly, such that there is an efficient transmission of articulation (pitch/yaw), roll, as well as end-effector actuation. These apparatuses may also incorporate certain degrees of freedoms and degrees of constraints between bodies in the handle assembly and/or in the end-effector assembly by utilizing independent transmission members. These transmission members may be end-effector articulation transmission members, end-effector roll transmission members and/or end-effector actuation transmission members. These transmission members may be independent, or two or more independent transmission members may be combined to act like a single transmission member if it helps with efficient transmission of various functionalities.

Various embodiments of handle assemblies are based on the constraint map presented in FIG. 1 of U.S. Pat. No. 9,814,451 (FIG. 24Ain this patent application). Certain of these embodiments may consist of components, namely, a handle body, a dial, a push rod and a shuttle. This constraint map represents the structural construction of the handle assemblies. The constraint map provides a genus based on which several species or embodiments can be generated. The constraint map shown inFIG. 24Ais extended inFIG. 24B. Handle assemblies mapped to the constraint map fromFIG. 24Bmay contain two additional components, namely, a closure input and a roll input. One objective of describing these additional embodiments is to present alternate forms of handle assemblies.

Various embodiments of handle assemblies based on new constraint maps are presented inFIG. 31A-B. The constraint maps are different from that of FIG. 1 of U.S. Pat. No. 9,814,451 (as well as those ofFIG. 24A-Bof this application), and includes four components/bodies namely, a handle body, a closure input, a roll input, and a shuffle. These embodiments present various joints/mechanisms present between the closure input and handle body that provide at least one degree of freedom.

Various embodiments of handle assemblies based on a constraint map are presented inFIG. 39. In addition to the constraint map ofFIG. 24A-B, the constraint map ofFIG. 39shows the presence of an articulation input joint within the handle assembly such that there exists a three degree of freedom (3 DoF) (pitch, yaw and roll) joint(s) between the handle body and articulation-roll input.

In an embodiment, a roll handle assembly may include a handle body, a roll body, a closure body, and a shuttle body. The roll body is coupled to the handle body. The roll body has a rotational degree of freedom about a roll axis relative to the handle body. The roll body is translationally constrained along the roll axis relative to the handle body. The closure body is coupled to the handle body. The closure body has one or more degrees of freedom of motion relative to the handle body. The shuttle body is coupled to the roll body and is coupled to the closure body. The shuttle body has a translational degree of freedom along the roll axis relative to the roll body. The shuttle body is rotationally constrained about the roll axis relative to the roll body. The shuttle body has a rotational degree of freedom about the roll axis relative to the closure body.

In an embodiment, a roll handle assembly may include a handle assembly, a frame, and an input joint. The handle assembly may include a handle body, a roll body, and a shuttle body. The roll body is coupled to the handle body. The roll body has a rotational degree of freedom about a roll axis relative to the handle body and is translationally constrained along the roll axis relative to the handle body. The shuttle body is coupled to the roll body and has a translational degree of freedom along the roll axis relative to the roll body. The shuttle body is rotationally constrained about the roll axis relative to the roll body. The input joint provides a pitch rotation and a yaw rotation between the handle assembly and the frame.

DETAILED DESCRIPTION

Described herein are apparatuses including an unlimited-roll handle assembly. Although the unlimited-roll handle assemblies described herein may be incorporated into any apparatus (e.g., device, tool, system, machine, etc.), described herein in particular are apparatuses including unlimited-roll handles assemblies at a proximal region of an elongate tool frame (e.g., a tool shaft or including a tool shaft) having an end-effector at the distal end of the tool frame. The apparatus may include a forearm attachment at the proximal end; the forearm attachment may allow one or more degrees of freedom between the user's forearm and the tool frame while the user's hand grips the unlimited-roll handle assembly. The apparatus may be articulating; for example, the tool frame may include an input joint between the unlimited-roll handle assembly and the tool frame that may capture movement (e.g., pitch and yaw movements) between the handle assembly and the tool frame for transmission to an output joint between the tool frame and an end-effector, so that the end-effector may be moved as the handle assembly is moved. Although any appropriate end-effector may be used, in some variations the end-effector is a jaw assembly that includes at least a pair of jaws (end-effector portions), which move to open and/or close the jaws when actuated by an end-effector control input on the handle assembly of the device.

In general, the unlimited-roll handle assemblies described herein may be configured to have four (though in some cases only three) or more parts that interact together to provide unlimited rotation of a knob or dial portion of the handle assembly about a central axis relative to a palm grip portion of the handle assembly, while still permitting the actuation of an end-effector control input to actuate the end-effector from any rotational position of the dial portion relative to the palm grip. Rotation of the knob or dial portion of the apparatus causes rotation of the end-effector, and in some cases, also causes rotation of the tool frame.

A constraint map of an unlimited-roll handle assembly or handle assembly is shown inFIG. 1, illustrating a conceptual model of the relative degrees of freedom (DoF) and degrees of constraint (DoC) between various bodies. In general, a degree of freedom (DoF) between two bodies implies that a particular relative motion in a specific direction between these two bodies is allowed. A degree of constraint (DoC) between two bodies implies that a particular motion in a specific direction between these two bodies is constrained and therefore transmitted. The handle assembly typically comprises rigid bodies that are generically referred to as: H.Body A101, H.Body B102, H.Body C103, and H.Body D104. H.Body A101may be referred to as the reference ground, in that the motion of all other bodies may be described with respect to H.Body A101. For example, H.Body A101may be a palm grip. In general, any other of these bodies may be used as the ground reference for describing the motion of the remaining bodies. At a high level, the functionality of the handle assembly is independent of which body is assumed to reference ground.

Using H.Body A101as the ground reference, H.Body C103has a single translational degree of freedom (DoF)105′ with respect to H.Body A101along a first axis direction (e.g., Axis1) and has rotational constraint (DoC)105″ with respect to H.Body A101about Axis1. This implies that relative translation along Axis1direction is allowed between H.Body C103and H.Body A101. However, relative rotation about Axis1is not allowed between the two, and therefore transmitted from one to the other and vice versa. H.Body B102has a rotational DoF106′ with respect to H.Body A101about Axis1and has translational constraint (DoC)106″ with respect to H.Body A101along Axis1direction. H.Body D104has a single translational DoF107′ with respect to H.Body B102along Axis1direction and rotational DoC constraint107″ with respect to H.Body B102about Axis1. H.Body D104has a rotational DoF108′ with respect to H.Body C103about Axis1and translational constraint (DoC)108″ with respect to H.Body C103along Axis1direction.

FIG. 2illustrates one example of an unlimited-roll handle assembly fitting the constraint map shown inFIG. 1. Even thoughFIG. 2shows H.Body A101and H.Body B102to be cylindrical in shape, the schematic diagram ofFIG. 2does not depict the actual geometric features of each bodies, and these bodies can be of any general shapes as long as they satisfy the joint conditions/constraints between the various bodies as mentioned above.

The constraint map ofFIG. 1results in the following functionality of the handle assembly: using H.Body A101as a reference (i.e., assuming it to be stationary), this mechanism allows for the independent rotation of H.Body B102with respect to H.Body A101about Axis1111. While this happens, H.Body D104rotates along with H.Body B102, also about Axis1111, and since rotation of H.Body C103is coupled to rotation of H.Body A101, H.Body C103does not rotate. At the same time, any axial translation of the non-rotating H.Body C103with respect to the stationary H.Body A101along Axis1111direction is transmitted to H.Body D104, even as H.Body B102and H.Body D104rotate about Axis1111.

The joints between the bodies within the unlimited-roll handle assembly typically comprise interfacing geometries which allow or prevent rotation with respect to one another. Also, these joints typically comprise interfacing geometries which allow or prevent translation with respect to one another. For those joints which enable rotation of one body with respect to another, this joint may comprise one or more cylindrical surfaces, and these surfaces can be enabled by a bearing, bushing, or lubricious surface treatment which minimizes frictional resistances. For translating joints, these surfaces may also comprise a linear bearing or lubricious surface treatment. As an overall mechanism, reduced frictional resistances to both translation and rotation mean that simultaneous motion of H.Body D104can occur in both rotation and translation while H.Body C103only translates and H.Body B102only rotates, all with respect to H.Body A101. Thus, another way of describing the functionality of this constraint map is that the rotation of H.Body B102and translation of H.Body C103are transmitted to H.Body D104. Considering this in reverse: H.Body D104has two DoFs with respect to H.Body A101, translation along Axis1111direction and rotation about Axis1111. Any arbitrary combination of these two motions can be separated into translation only at H.Body C103and rotation only at H.Body B102.

Any of the joints described herein may be captured for transmission to an output (e.g., output joint). The transmission may be done mechanically, electrically, or otherwise. For example, sensors may be positioned at these two bodies, e.g., a linear displacement sensor on H.Body C103and a rotary sensor on H.Body B102may give discrete/individual values for arbitrary combination of rotation and translation applied at H.Body D104. These electrical signals could then be transmitted via wired or wireless means to a mechatronic, robotic, electronic, or computer-controlled system. These sensors may use various types of encoding techniques (e.g. electrical, optical, etc.). Alternatively, instead of sensors, one could place actuators at these locations, e.g., a linear translational actuator between H.Body A101and H.Body C103and a rotary actuator between H.Body A101and H.Body B102. Any arbitrary discrete/individual motion inputs at these two bodies get added into a combined motion at H.Body D104with respect to H.Body A101.

In general, a degree of freedom (DoF) implies that a particular relative motion between two bodies in a specific direction is allowed, a degree of constraint (DoC) implies that a particular relative motion between two bodies in a specific direction is constrained and therefore transmitted. All motions inFIG. 1are defined with respect to Axis1111(not shown), which is the axis of rotation of a handle dial (corresponding to H.Body B102) with respect to a handle shell (corresponding to H.Body A101). Any motion direction not explicitly mentioned could be a DoF or DoC.

As used to describe degrees of freedom here, axis refers to a specific line in space. A body may rotate with respect to (w.r.t.) another body about a certain axis. A body may translate w.r.t. another body along a certain direction. A direction is not defined by a particular axis and is instead commonly defined by multiple parallel axes. Thus, X axis is a specific axis defined and shown in a figure, while X direction refers to the direction of this X axis. Multiple different but parallel X axes can have the same X direction. Direction only has an orientation and not a location in space.

InFIG. 1, H.Body C103is shown having a single translational DoF105′ along Axis1111(not shown) direction with respect to H.Body A101and vice versa. H.Body C103also has a rotational constraint (DoC)105″ about Axis1111with respect to H.Body A101and vice versa. This type of joint, between H.Body A101and H.Body C103, can be accomplished through a variety of embodiments. In one embodiment, the interfacing bodies have a keying feature between them which restricts relative rotation about Axis1111and simultaneously allows for relative translation along Axis1111direction.FIG. 3Aschematically describes a joint which might exist between H.Body A101and H.Body C103. Referring toFIG. 3A, an outer body with a square longitudinal slot may correspond to H.Body A101,301while the inner square key may correspond to H.Body C103,303. Considering that H.Body A101,301is fixed to the reference ground, H.Body C103,303will be allowed to translate along Axis1111,311direction while unable to rotate about Axis1111,311due to the interferences posed by the square cross-sectional joint. One might consider that this joint can also have a rectangular cross-section which can provide the same single axis (Axis1111,311) rotational constraint and single axis (Axis1111,311) translational DoF.

A functional aspect of this joint is a low friction relative sliding motion along Axis1111,311direction between H.Body A101,301and H.Body C103,303. To achieve this, the surface contact between both bodies (H.Body A101,301and H.Body C103,303) may need to be minimal so as to avoid large frictional contact between surfaces of H.Body A101,301and H.Body C103,303. Therefore, one way of achieving the same joint between H.Body A101,301and H.Body C103,303with less friction contact is to minimize the contact surface area between two bodies.FIG. 3Bshows one way to reduce the surface contact between H.Body A101,301and H.Body C103,303by interfacing the spokes of H.Body C103,303with corresponding slots in H.Body A101,301.

FIGS. 3A and 3Bshow examples of achieving the constraint and DoF between H.Body A101,301and H.Body C103,303, but they can have different geometric shapes provided that the constraints and DoFs are met. For example,FIG. 3Cshows one way this joint can be achieved by essentially providing a keying surface320via the flat end of the D-Shaft303(H.Body C103,303) that engages with a corresponding slot present in H.Body A101,301.

H.Body B102,302and H.Body D104,304have a rotational DoC107″ about Axis1111,311and a single translational DoF107′ along Axis1111,311direction. This is the same type of rotational DoC105″ and translational DoF105′ that is present between H.Body A101,301and H.Body C103,303. Therefore, each one of the ways to attain the joint between H.Body A101,301and H.Body C103,303are also applicable to the joint between H.Body B102,302and H.Body D104,304; given the constraint and DoF requirements are fulfilled.

Any of the joints between H.Body A101,301and H.Body C103,303as well as between H.Body B102,302and H.Body D104,304may include or require a low friction surface contact between the bodies. This, along with a single rotational constraint (DoC)105″,107″ about Axis1111,311and a single translational DoF105′,107′ along Axis1111,311direction, may completely define the joint between these bodies. Similarly, a single DoC, a single DoF, and functional requirements define the joint between H.Body A101,301and H.Body B102,302as well as between H.Body C103,303and H.Body D104,304. H.Body A101,301and H.Body B102,302may have a single rotational DoF106′ about Axis1111,311relative to each other and a single translational constraint (DoC)106″ along Axis1111,311direction. H.Body A101,301and H.Body B102,302may also have a functional requirement of providing low friction joint between them while they rotate relative to each other about Axis1111,311. This functional requirement comes from the fact that either of the duos, H.Body A101,301and H.Body B102,302or H.Body C103,303and H.Body D104,304, can be under compressive or tensile loading while fulfilling the rotational DoF106′,108′ about Axis1111,311and translational constraint (DoC)106″,108″ along Axis1111,311direction.

For example, if H.Body A101,301and H.Body B102,302are placed such that their surfaces normal to Axis1111,311are under compression, they need to overcome the normal forces acting on each bodies' surfaces to provide the rotational DoF106′ about Axis1111,311. Therefore, to provide the rotational DoF106′ about Axis1111,311and the translational constraint106″ along Axis1111,311direction, the surfaces of H.Body A101,301and H.Body B102,302may need to provide low friction contact such that the bodies can rotate relative to each other about Axis1111,311.FIG. 3Dshows one way of obtaining the desired rotational DoF106′ and translational constraint (DoC)106″ by providing low friction surface contact. In this example, a thrust bearing330is used to provide the rotational DoF106′ along with maintaining low friction contact between surfaces of H.Body A101,301and H.Body B102,302by holding the thrust load between the two bodies. Similarly, this functionality can be achieved in many other ways that fulfill the rotational DoF106′ and translational constraint106″ requirement. For example, either an angular contact ball bearing or a roller ball bearing, each capable of holding the required radial and thrust loads can also be used between H.Body A101,301and H.Body B102,302. Alternatively, a bushing between two bodies can be used to provide radial support as well as capacity to bear thrust load.FIG. 3Eshows one way in which the thrust load can be supported by having a thrust bearing333between H.Body A101,301and H.Body B102,302along with washers334,335on each side of the bearing333.FIG. 3Fshows another way of supporting thrust loads while providing the rotational DoF106′ about Axis1111,311by using a single washer340between H.Body A101,301and H.Body B102,302made of material with low friction coefficient like Teflon (PTFE), nylon, etc. In another alternative embodiment,FIG. 3Gshows a bushing345placed between the interfacing surfaces of H.Body A101,301and H.Body B102,302, such that it is capable of holding thrust load, thereby providing a translational constraint (DoC)106″ along Axis1111,311direction.

The same system of two bodies with an intermediate member carrying thrust load and providing a rotational DoF106′ about Axis1111,311and providing a translational constraint (DoC)106″ along Axis1111,311direction, shown inFIGS. 3D, 3E, and 3Falso works well when there is a tensile load—as opposed to compressive load—between H.Body A101,301and H.Body B102,302. An example is illustrated inFIG. 3Hwith an embodiment similar to that illustrated inFIG. 3D, wherein a thrust bearing347is located between H.Body A101,301and H.Body B102,302, facing normal to Axis1111,311. The thrust bearing347between H.Body A101,301and H.Body B102,302can be of various types, e.g., thrust needle bearing, thrust roller bearing, roller bearing, tapered roller bearing, angular contact bearing, etc., some of which are illustrated inFIGS. 3I.1through3I.4. For example,FIG. 3Hshows a thrust roller bearing347acting as joint between H.Body A101,301and H.Body B102,302. Also, H.Body C103,303and H.Body D104,304may have the same type of joint as H.Body A101,301and H.Body B102,302and comply with all the aforementioned joint types mentioned in this section.

As illustrated inFIGS. 3I.1through3I.4andFIGS. 3J and 3K, other types of bearings may be used as alternatives to, or in combination with, the above-described thrust bearings330,333,347, for example, tapered roller bearings349, radial ball bearings394, etc.

Accordingly, H.Body A101,301and H.Body B102,302can be under compressive or tensile load along Axis1111,311. Similarly, H.Body C103,303and H.Body D104,304can also be under compressive or tensile load along Axis1111,311direction. This gives two possible combinations for the whole system presented with schematic diagram inFIG. 1(to be under tensile load or compressive load). Either of the system of two bodies, H.Body A101,301and H.Body B102,302, or H.Body C103,303and H.Body D104,304can be under tensile or compressive load. As presented inFIG. 1, with H.Body A101,301serving as the reference ground, H.Body B102,302can be under tension or under compression with respect to H.Body A101,301. However, H.Body C103,303is free to move along Axis1111,311direction with respect to H.Body A101,301and has rotational constraint about Axis1111,311with respect to H.Body A101,301. H.Body C103,303can be under compression or tension with respect to H.Body D104,304, and H.Body D104,304is free to translate along Axis1111,311direction with respect to H.Body B102,302and has rotational constraint about Axis1111,311with respect to H.Body B102,302.FIG. 3Lillustrates a configuration where H.Body B102,302is under compressive load with respect to H.Body A101,301and H.Body C103,303is under tensile load with respect to H.Body D104,304. In this example, an angular contact bearing351is used between H.Body A101,301and H.Body B102,302. This accounts for a joint between H.Body A101,301and H.Body B102,302that provides the associated translational constraint (DoC)106″ and rotational DoF106′ requirements mentioned above, along with the functional requirement of providing low friction between surfaces contacting one another. Similarly, a thrust bearing330,333,347,349,394,351may be used between H.Body C103,303and H.Body D104,304. This accounts for a joint between H.Body C103,303and H.Body D104,304that provides the associated translational constraint (DoC)108″ and rotational DoF108′ requirements mentioned above, along with the functional requirement of providing low friction surface contact.

In some of these examples, even though the bodies have been illustrated as being cylindrical in shape, the constraint map (FIG. 1) doesn't imply any restriction on geometric shapes of these bodies, provided that the functionality, DoFs, and constraints are satisfied.

FIGS. 4A and 4Bshow an example of an ergonomic handle assembly400(unlimited-rotation handle assembly) that utilizes the mechanism illustrated inFIG. 3Linvolving both compressive and tensile loading conditions. This handle assembly400is an embodiment of the constraint map shown inFIG. 1. Via joint491, the rotation dial402(H.Body B102,402) is under a rotational degree of freedom (DoF)106′ about Axis1111,411and translational constraint (DoC)106″ along Axis1111,411direction with respect to Handle Shell401(H.Body A101,401). The rotation dial402transmits this rotation about Axis1111,411to H.Body D104,404, which is also referred as shuttle404. This is possible because shuttle404(H.Body D104,404) is under rotational constraint (DoC)107″ about Axis1111,411with respect to rotation dial402(H.Body B102,402) and therefore, has no relative rotation about Axis1111,411. The shuttle404(H.Body D104,404) is further interfaced with H.Body C103,403(referred as push rod or pull rod, i.e. push/pull rod403) via a joint455which allows rotational DoF108′ about Axis1111,411and translational constraint (DoC)108″ along Axis1111,411direction. The translation of shuttle404(H.Body D104,404) along Axis1111,411direction is further transmitted to the moving jaw of an end-effector via an end-effector transmission471. When the end-effector is configured as a jaw assembly, the latter may alternatively be referred to as a jaw closure transmission member471or jaw closure actuation transmission member471. In some variations, it may simply be referred to as a transmission cable (when it is a compliant cable, for example). This jaw closure actuation transmission member471can be either rigid or non-rigid body, or a combination of a rigid and non-rigid members. For example, the transmission member can be either the shaft of an apparatus (e.g., of a laparoscopic instrument) or a rod passing internally through the shaft, a cable under tension that connects to the end-effector at the distal end of the laparoscopic instrument, or a combination of a non-rigid body and a rigid body (e.g., a rod along with a cable under tension). The push/pull rod403(H.Body C103,403) and shuttle404(H.Body D104,404) are under tensile load and the rotation dial402(H.Body B102,402) is under compressive load and the latter does not translate along Axis1111,411direction with respect to handle shell401(H.Body A101,401). The push/pull rod403(H.Body C103,403) is actuated by the user by activating handle lever413, which is a mechanical extension of the push/pull rod403(H.Body C103,403) via a transmission mechanism that may comprise a linkage, cams, springs, etc.

Another variation of an ergonomic handle assembly400shown inFIGS. 4A and 4Bcan be constructed via a flexure-based design, also known as a compliant mechanism, that realizes the constraint map ofFIG. 1by employing compliant or flexure joints between the bodies H.Body A101, H.Body B102, H.Body C103, and H.Body D104to achieve the necessary constraints.

An apparatus incorporating the unlimited-roll handle assemblies illustrated inFIGS. 4A and 4Bis shown inFIGS. 5, 7, and 8as part of a medical device (specifically a laparoscopic device). These embodiments depict apparatuses in the beta configuration (defined later). More particularly,FIGS. 5, 7, and8show a laparoscopic surgical instrument having an end-effector configured as a jaw assembly; wherein inFIG. 5the jaws are open, inFIG. 7the jaws are shown closed, and inFIG. 8. the jaws are closed on a needle-like object and the end-effector assembly is articulated.

Referring toFIGS. 5 through 8, the exemplary apparatus500in beta configuration (defined later) includes a tool frame525, the latter of which includes a tool shaft526and a forearm attachment portion527at the proximal end528of the tool frame525.FIG. 6shows an example of a wrist cuff605—having a passage therethrough—that is configured to hold a wrist607or forearm608of a user and may be coupled to the forearm attachment portion520,527. For example, in some embodiments, the wrist cuff605is operatively coupled to the forearm attachment portion520,527of the tool frame525via a bearing therebetween that allows the wrist cuff605to slide or roll so that there is a roll rotational degree of freedom between the tool frame525and the wrist cuff605about a tool axis515(Axis3515). A proximal unlimited-roll handle assembly400—for example, as shown inFIGS. 4A and 4B—may be connected to the tool frame525by an input joint529, the latter of which may be configured to capture motion between the tool frame525and the unlimited-roll handle assembly400, as shown inFIGS. 5, 7 and 8. In this example, the input joint529includes a pair of transmission strips533,534that are connected between the unlimited-roll handle assembly400and the forearm attachment portion527by corresponding associated hinged joints530, and that may be connected in parallel to respective pivoting joints (not shown) in order to provide for separately receiving pitch and yaw rotations of the unlimited-roll handle assembly400relative to the tool frame525. An output joint583(shown as an end-effector articulation output joint) between an end-effector565and the tool shaft526receives transmission input (pitch and yaw motion) from the input joint529to articulate the end-effector565.

In this example, the unlimited-roll handle assembly400includes an ergonomic palm grip portion101,501(handle shell501) that connects to the rotation dial102,502, which enclose an internal push rod and shuttle (not visible), wherein these four elements are constrained per the constraint map shown inFIG. 1. The unlimited-roll handle assembly400also includes an end-effector control input such as a handle lever549and an associated closure actuation549′ (seeFIG. 5). This control input (i.e., handle lever549) is as a mechanical extension (e.g., via a mechanism) of the internal push rod. In alternate configurations, the handle lever549is coupled to the push rod via a transmission mechanism that may comprise a linkage, cams, springs, etc. A transmission cable566connects to the shuttle and acts as a jaw closure actuation transmission member471extending from the shuttle and through the tool shaft526to the end-effector565. This transmission cable566may be enclosed by a protective and/or supporting sheath or cover or conduit for some or entire portion of its length. The end-effector565itself is a jaw assembly including a first end-effector portion569(ground), in this example, including a fixed jaw569to which a pivoting second end-effector portion (moving jaw568) is attached. The transmission cable566may couple to the moving jaw568at the end-effector closure output577.

InFIG. 5, when the user's forearm608is mounted to the proximal end528of the tool frame525and the palm grip portion101,501is held in the user's hand609so that the user can rotate the rotation dial102,502between the thumb and fingers, rotation of the dial portion102,502of the unlimited-roll handle assembly400rotates the entire tool frame525, and therefore the end-effector565that is attached to the distal end578of the tool frame525via an end-effector output articulating joint583. Thus, the handle shell101,501may rotate about a first axis111,511referred to as handle articulated roll axis511(Axis1), so as to cause the tool shaft526to rotate about a third axis515referred to as the tool shaft roll axis515(Axis3), which in turn causes the end-effector565to roll about a second axis513, referred to as an end-effector articulated roll axis513(Axis2).

The rotation dial102,502(H.Body B) as shown inFIG. 5is rotated about Axis1111,511. The rotation of H.Body B102,502leads to a rotation of the tool frame525via the transmission strips533,534(as they constrain rotation DoF between H.Body B102,502and tool frame525), which in turn causes a rotation of the tool shaft526(about Axis3515) operatively coupled to the tool frame525, and a rotation of the end-effector565(about Axis2513) operatively coupled to the tool shaft526. When the handle shell101,501is articulated using the input articulation joint529, the end-effector565articulates via the end-effector output articulation joint583, wherein the end-effector articulated roll axis513(Axis2) is distinct from the tool shaft roll axis515(Axis3).

The above description is also relevant when describing apparatuses that either do not attach to the forearm608or that attach to the forearm608via a roll joint, so that rotation of the dial portion102,502of the unlimited-roll handle assembly400leads to roll rotation of a forearm attachment apparatus600about the wrist607via the transmission strips533,534(as they constrain the roll rotation), leading to a rotation of tool frame525, the tool shaft526, and eventually the end-effector565.FIG. 6illustrates an example of an embodiment of a forearm attachment apparatus600comprising a 3-axis gimbal assembly including a wrist cuff605that securely attaches to the user's wrist607/forearm608, leaving the user's hand609free to move (e.g., to grasp the handle shell101,501and manipulate the rotation dial102,502and actuate the end-effector control input549). In this embodiment, the forearm attachment apparatus600allows pitch, yaw, and roll degrees of freedom; the wrist cuff605pivotally attaches to a deviation ring514with a first pair of pins610that provide for rotation about flexion/extension axis of rotation516. The deviation ring514is in turn pivotally attached to a sled518with a second pair of pins611that provide for rotation about a deviation axis of rotation521, wherein the sled518is configured to roll within a raised inner track519of an outer guide ring520about a corresponding roll axis of rotation531. Accordingly, the forearm attachment apparatus600provides for pitch, yaw, and roll degrees of freedom between the wrist cuff605and the tool frame525when coupled to the tool frame525of the apparatus500. For example, in one set of embodiments, the outer guide ring maybe formed as part of the forearm attachment portion527of the apparatus500, or it may be attached thereto. The wrist cuff605may be releasably coupled into the deviation ring514via a snap-fit coupling540or some other type of coupling.

FIG. 8shows another view of the beta configuration (defined later) laparoscopic instrument ofFIGS. 5-7with the end-effector565in an articulated position and holding a needle that may be used to suture tissues. The end-effector fixed jaw569(ground) and the end-effector moving jaw568can be rotated about the end-effector articulated roll axis513(Axis2) such that the tool shaft526/tool frame525rotates about the tool shaft roll axis515(Axis3) while the handle assembly is rotated about the handle articulated roll axis511(Axis1); all while simultaneously holding the needle securely by forcing the end-effector moving jaw568towards the end-effector fixed jaw (ground)569via a jaw closure actuation transmission member471connected to H.Body D104,404within the unlimited-roll handle assembly400. The apparatus500shown inFIGS. 5-8may fit a constraint map such as the one shown inFIG. 20A.

Another variation of an apparatus incorporating the unlimited-roll handle assemblies illustrated inFIGS. 4A and 4Bthat conform to the constraint map illustrated inFIG. 1is shown inFIG. 9.FIG. 9illustrates a tool apparatus in the alpha configuration. In this example, the rotation of a rotation dial102,902(H.Body B) about Axis1111,911leads to rotation of an associated end-effector assembly965(shown here as a jaw assembly including a moving jaw968and a fixed jaw969) about Axis2913. Here, the tool frame925including the tool shaft926does not rotate about their associated axis (Axis3915) thereof when the rotation dial (H.Body B) rotates with respect to the handle shell (H.Body A) about Axis1. The tool frame925may still be connected to a wrist cuff605mounted on a user's forearm608via a forearm attachment apparatus600that may provide for a pitch and/or yaw rotational DoF, as described hereinabove. The end-effector assembly965has a rotational DoF with respect to the distal end927of the associated end-effector articulation output joint928about Axis2913(similar to that between H.Body A101,901and H.Body B102,902about Axis1111,911) and an end-effector rotation transmission member950connects H.Body B102,902directly to the end-effector assembly965via the torsionally stiff end-effector rotation transmission member950. This may also be the jaw closure actuation transmission member471or may house and therefore route, a flexible jaw closure actuation transmission member471, for example, a hollow flexible shaft (end-effector rotation transmission member950) that is torsionally stiff that can transmit rotation from one end to another, housing a cable that is flexible in bending (jaw closure actuation transmission member471) there within.

Another example of an apparatus1000incorporating the above-described unlimited-roll handle assembly400ofFIGS. 4A and 4Bis shown inFIG. 10. This apparatus1000is configured as a straight stick device with a non-articulating end-effector1065. Other straight stick apparatuses—for example, as described in U.S. Pat. Nos. 4,712,545, 5,626,608, and 5,735,874—may benefit from incorporation of the unlimited-roll handle apparatuses, for example, the unlimited-roll handle assembly400illustrated inFIGS. 4A and 4B.FIG. 10shows an example of a surgical instrument comprising an unlimited-roll handle assembly400(including a palm grip portion101,1001and a dial portion102,1002), a tool shaft1026, and the non-articulating end-effector1065configured as a jaw assembly, wherein, for example, there is a rotation joint1067between the moving jaw1068and fixed jaw1069of the non-articulating end-effector1065. The non-articulating end-effector1065connects to the rotation dial102,1002(H.Body D) via a jaw closure actuation transmission member (not visible inFIG. 10). This apparatus1000provides the functionality of closing and opening the non-articulating end-effector1065by moving the moving jaw1068relative to the fixed jaw1069. The apparatus1000may also provide the rotation of the non-articulating end-effector1065about the handle axis1011(Axis1111), wherein the shaft axis1015(Axis3) remains parallel to the handle axis1011(Axis1111) under rotation of the H.Body B102,1002, tool shaft1026, and the non-articulating end-effector1065attached hereto.

Referring toFIG. 11, in accordance with another set of embodiments that incorporate the unlimited-roll handle assembly400illustrated inFIGS. 4A and 4B, articulation at the input joint529is captured via either a serial kinematic input articulation joint or a parallel kinematic input articulation joint. For example,FIG. 11shows an articulating laparoscopic device1100. Such devices include a handle shell101,1101, handle lever1153, handle dial102,1102, shuttle104,1104, pull/push rod103,1103, jaw closure actuation transmission member1139, tool shaft1126and an articulating end-effector1165. Similar to the above-described non-articulating laparoscopic device1000, the articulating laparoscopic device1100also incorporates an end-effector rotation joint1067(open/close functionality) operative between a moving jaw1168and a fixed jaw1169, and in addition to this open/close end-effector rotation joint1067, also contains an output articulation joint1143for end-effector articulation and a corresponding associated input articulation joint1142. The input articulation joint1142may be implemented as either a serial kinematic (S-K) input joint or parallel kinematic (P-K) input joint. Some articulating instruments that consist of serial kinematic (S-K) input joint (such as the one shown inFIG. 11) can be found, for example, in U.S. Pat. Nos. 8,465,475; 5,713,505, 5,908,436, U.S. application Ser. No. 11/787,607 and U.S. Pat. No. 8,029,531. Examples of articulating instruments incorporating a parallel kinematic (P-K) input joint may be found, for example, in U.S. patent application publication No. 2013/0012958. In such devices, although the end-effector may be a jaw assembly and may be shown in an open jaw condition, an associated articulating instrument can also perform rotation with the end-effector rotation joint in a closed jaw condition or with the output articulation joint in an articulated condition.

FIGS. 12 and 13illustrate other unlimited-roll handle assembly variations that follow the constraint map illustrated inFIG. 1. These handle assembly variations may be used with any of the other apparatus components described herein (including with other device architectures and/or constraint maps). For example, inFIG. 12, the rotation dial102,1202is proximal to the palm grip/handle shell portion101,1201. The apparatus may include a shaft1226and an end-effector1265and may include the same axes as described above (first Axis111,1211, second Axis1213, and third Axis1215). As indicated in the constraint map ofFIG. 1, joint characteristics (DoFs and DoCs) between H.Body A101,1201and H.Body C103(Handle Lever1203is a mechanical extension of H.Body C103) are the same as the ones between H.Body B102,1202and H.Body D104(not shown inFIG. 12). Also, joint characteristics (DoFs and DoCs) between H.Body A101,1201and H.Body B102,1202are the same as the ones between H.Body C103and H.Body D. Any of the four bodies can be referred as ground reference. InFIG. 12, when mapped to the constraint map ofFIG. 1, H.Body B102,1202is located away from to the tool shaft1226and towards the proximal end of the hand609. H.Body A101,1201is located towards the proximal end of the tool shaft1226. H.Body B102,1202is rotated w.r.t. H.Body A101,1201about axis11211,111. Here, H.Body C103rotates with respect to H.Body D104. Another way of explaining this embodiment (shown inFIG. 12) is that the handle assembly's rotation dial is now placed at the proximal end of the handle assembly.

Any of the apparatuses described herein may include a rotation lock/ratcheting mechanism, as illustrated inFIG. 13. The handle assembly shown here follows the constraint map ofFIG. 1and consists of a joint1317between H.Body A101,1301and H.Body B102,1302that provides a rotational DoF about Axis1111. This rotation can be made more tactile by the application of a ratcheting feature1319between H.Body A101,1301and H.Body B102,1302. Ratcheting between H.Body A101,1301and H.Body B102,1302can provide a sense of discrete rotation steps while rotating about Axis1.FIG. 13illustrates a ratchet mechanism1319along with a thrust bearing1317(that provides rotational DoF106′ and translational DoC106″) located between the palm grip/handle shell101,1301and the rotation dial102,1302. The shuttle104,1304and push rod103,1303otherwise operate per the constraint diagram ofFIG. 1and handle assembly400ofFIG. 4.

The unlimited-roll handle assemblies described herein may also be used with an apparatus configured to provide a pecking motion at the end-effector. For example, referring toFIG. 14, other embodiments of an unlimited-roll handle assembly400ofFIG. 4(fitting the constraint map ofFIG. 1) may provide for the opening and closing of an end-effector jaw triggered directly by radially pressing the rotation dial102,1402(H.Body B). For example, the embodiment illustrated inFIG. 14comprises a handle shell101,1401(H.Body A), held in a hand609of the user, and may include a rotation dial102,1402(H.Body B) that can rotate relative to handle shell101,1401(H.Body A) about Axis1111,1411. The rotation dial104,1404(H.Body B), when radially pressed, pushes a shuttle104,1404(H.Body D) along Axis1111,1411direction in accordance with the translational DoF of the shuttle104,1404(H.Body D) with respect to the rotation dial104,1404(H.Body B) along Axis1111,1411. This closes a combined shaft and end-effector1432that may be rigidly connected to the rotation dial102,1402(H.Body B), as shown inFIG. 14. The flexible nature of the body representing combined shaft and end-effector1432directs the movement of shuttle104,1404(H.Body D)—as a sleeve1404′—over the combined shaft and end-effector1432. This sleeve1404′/shuttle104,1404(H.Body D), controls the opening and closing of the associated end-effector1432′, the latter of which acts as a double action jaw that can have various applications in open surgery, for example, in eye surgery, or in minimal invasive surgery. The push/pull rod (H.Body C, which can't be seen inFIG. 14) may be keyed to the interior of the handle shell101,1401(H.Body A) and attached via a spring, so that after the push/pull rod (H.Body C) is moved relative to handle shell101,1401(H.Body A), it retracts back to its original position with the help of the spring. Accordingly, this provides for the motion of the push/pull rod (H.Body C) and shuttle104,1404(H.Body D) along Axis1111,1411direction when the shuttle104,1404(H.Body D) is pushed along Axis1direction by radially pressing the rotation dial104,1404(H.Body B), and provides for retracting both the shuttle104,1404(H.Body D) and the push/pull rod (H.Body C) to their original position thereafter. Accordingly, for this embodiment, the combined end-effector1432can be rotated about Axis1(111,1411), and the associated end-effector1432′ can be used to grab or clamp external bodies by pecking the shuttle104,1404(H.Body D), which closes of the end-effector1432′, and can then be used to release the external body by releasing the shuttle104,1404(H.Body D), which opens the end-effector1432′.

Referring toFIG. 15, in accordance with another embodiment, an apparatus1500utilizing a pull-pull configuration for jaw closure transmission incorporates an unlimited-roll handle assembly400such as was shown inFIG. 4A, including a shuttle104,404(H.Body D) keyed to H.Body B102,402. An associated jaw closure (open/close) actuation transmission member1530is first pulled to close an end-effector moving jaw1567with respect to a corresponding end-effector fixed jaw1568, and is then subsequently released to open the end-effector moving jaw1567with respect to the end-effector fixed jaw1568. The jaw closure (open/close) actuation transmission member1530is attached to H.Body D104,404where H.Body D can translate with respect to H.Body B102,402as a result of the translational DoF107′ along Axis1111,411direction, but has a translational constraint (DoC)108″ with respect to H.Body C103,403. Once H.Body D104,404moves along Axis1111,411direction to pull the jaw closure (open/close) actuation transmission member1530to close the jaws1567,1568(i.e., bringing the end-effector moving jaw1567and end-effector fixed jaw1568together), a second jaw closure (open/close) actuation transmission member1532is pulled to open the end-effector moving jaw1567. To open the jaws1567,1568the second jaw closure actuation transmission member1532may be pulled. In one embodiment, the second jaw closure actuation transmission member1532can be pulled using a pull spring1513, grounded at a reference frame called “Spring Reference Ground1512”. Depending on how the roll transmission member is routed throughout the whole assembly, “Spring Reference Ground1512” can occur at different locations in the assembly, as follows: (1) If roll transmission is by means of an input articulating joint529, a tool frame/tool shaft1526, and an output articulating joint583, then the “spring reference ground1512” can occur at the H.Body B102,402, or the tool frame/tool shaft1526, or the end-effector fixed jaw1568; (2) If roll transmission is by means of an independent roll transmission member routed across the input articulating joint529, through tool frame/tool shaft1526, and through the output articulating joint583(given an extra roll DoF between output joint distal end and end-effector base), then the “spring reference ground1512” can occur at H.Body B102,402or at the end-effector fixed jaw1568.

In some variations, the unlimited-roll handle assembly is generally configured to include a forearm attachment apparatus600. The unlimited-roll handle apparatus1600may provide the ability for simultaneously transmitting roll and closure action to H.Body D104with respect to H.Body A101. Such a variation that includes a forearm attachment apparatus600that provides for addition degrees of freedom (DoFs) was described above inFIGS. 5-8, and another example is shown inFIG. 16.FIG. 16illustrates a tool apparatus embodiment in the alpha configuration (defined later). In this example, a (one) joint—referred to as a forearm attachment apparatus1611—exists between a wrist attachment/wrist cuff1609and a tool frame1625. The forearm attachment apparatus1611(similar to600shown inFIG. 6) may be used to couple the wrist attachment/wrist cuff1609to the tool frame1625, allowing either zero, or one, or more degrees of freedom between the user's forearm and the unlimited-roll handle apparatus1600, depending upon the nature of the forearm attachment apparatus1611. The forearm attachment apparatus600may be used with either articulating devices or non-articulating devices. For example, one embodiment can include a roll DoF by providing a roll rotation joint1611′ between the wrist attachment/wrist cuff1609and the tool frame1625. This joint may use a “sled518”—for example, as illustrated inFIG. 6—which can provide for a roll rotational DoF about the roll axis111,531or the arm axis612. Another embodiment can provide for a pitch DoF by providing a rotation joint to allow rotation about the flexion/extension axis of rotation516. Another embodiment can provide for a yaw DoF by providing a rotation joint to allow rotation about the deviation axis of rotation521. Another embodiment can provide for both pitch and yaw DoF by providing one or more rotation joints that allow rotation about the flexion/extension axis of rotation516and rotation about the deviation axis of rotation521, respectively, for example, by incorporating an intermediate body referred to as a deviation ring514, for example, as illustrated inFIG. 6. Another embodiment can provide for roll (about the arm axis612), pitch (about the flexion/extension axis of rotation516), and yaw (about the deviation axis of rotation521) degrees of freedom (DoFs). Also as shown inFIG. 16, a joint exists between the tool frame1625and the tool shaft1626, called a shaft-frame joint1685, which may have a zero DoF joint (i.e., a rigid connection between the tool shaft1626and the tool frame1625), which, for the embodiments disclosed herein, is the default configuration. The device1600illustrated inFIG. 16includes a handle palm grip101,1601(H.Body A), a rotation dial102,1602(H.Body B), an end-effector input1612(e.g. a handle lever549), a shaft-frame joint1685, an end-effector1668at a distal end1627of the tool shaft1626, for which are defined an associated handle axis111(Axis1), an associated tool shaft axis1615(Axis3) and an associated end-effector axis1613(Axis2).

Some variations of a non-articulating instrument1600that is forearm mounted and that incorporates the unlimited-roll handle assembly400ofFIGS. 4A and 4Bmay include a separate tool frame1625and a separate tool shaft1626. In one such configuration, the tool frame1625and wrist attachment/wrist cuff1609may be rigidly attached (i.e., 0 DoF). In this case, if the tool shaft1626is rigidly connected to the rotation dial102,1602(H.Body B), then the device1600may be configured so that there is at least one roll rotation DoF between the tool shaft1626and the tool frame1625. Furthermore, a shaft-frame joint1685can have a roll DoF, a pitch DoF, and/or a yaw DoF.

Any of the apparatuses incorporating an unlimited-roll handle assembly described herein may also include a virtual center (VC)1721associated with an input articulation joint, for example, as shown inFIG. 17. This device1700can have either a serial or parallel kinematic input joint, with the associated joint axes intersecting at the virtual center (VC)1721. This device1700is similar to that shown inFIGS. 5,7, and 8, but explicitly shows the virtual center (VC)1721. The device1700also includes an end-effector assembly1765that is also configured as a jaw assembly.

Example: Medical Device

FIGS. 18A-18Dillustrate one example of a medical device1800configured as a laparoscopic apparatus including an unlimited-roll handle assembly400(similar to that illustrated inFIGS. 4A and 4B), an elongate tool frame525, a forearm attachment apparatus600(similar to that illustrated inFIG. 6) having multiple degrees of freedom between the user's arm and the tool frame525, an end-effector assembly1765configured as a jaw assembly, and an input joint1801that captures pitch and yaw rotation of the unlimited-roll handle assembly400for transmission to an output joint583, e.g. an end-effector output articulating joint583′, so that the end-effector assembly1765may articulate in the same direction as does the unlimited-roll handle assembly400, for example, as illustrated inFIGS. 19A-19C. A schematic constraint diagram for the medical device1800shown inFIGS. 18A-18Dis shown inFIG. 20A, corresponding to beta configuration (defined later). An alternative constraint diagram for a medical device1800as described herein is shown inFIG. 20B, which corresponds to alpha configuration (defined later).

Referring again toFIGS. 18A-18D, the overall medical device1800comprises a pulley block1805, a tool frame525including a tool shaft526(the tool shaft526may be considered a portion of the tool frame525), all rigidly inter-connected to one another. The pulley block1805serves as the outer ring1805of a forearm attachment joint1807that interfaces with the distal forearm608′ of a user via a wrist cuff1803, as described above.

In this example, the wrist cuff1803and the outer ring1805are all part of the forearm attachment joint1807(corresponding to the forearm attachment apparatus600ofFIG. 6). The forearm attachment joint1807comprises the outer ring1805, a sled518, a deviation ring514, and the wrist cuff1803(all connected in series), as illustrated inFIG. 6and described hereinabove, and provide three rotational degrees of freedom (DoFs) between the wrist cuff1803and the outer ring1805, i.e., roll, pitch, and yaw. Roll is the rotation direction about the axis of the outer ring1805, which is the same as the axis of the tool shaft526. Pitch and yaw are orthogonal rotations about the pitch axis1833and yaw axis1831, respectively, as illustrated inFIG. 18C. These axes can assume any orientation and one of these orientations may align with the transmission pulley axes. In this particular orientation, the pitch axis of rotation (1833) aligns with the rotation axis of transmission pulley1813.1and the yaw axis of rotation aligns with the rotation axis of transmission pulley1813.2. These axes, namely transmission pulley rotation axis1833.2and transmission pulley rotation axis1831.2, are shown inFIG. 18C. When the medical device1800is mounted on the forearm608(i.e., the wrist cuff1803is attached to the forearm608/wrist607of a user), the forearm attachment joint1807provides the above three rotational degrees of freedom between the tool frame525and user's/surgeon's forearm608.

The tool frame525extends from the outer ring1805/pulley block1805and is shaped around the unlimited-roll handle assembly400to accommodate a user's hand609(over its entire range of articulation) while supporting the unlimited-roll handle assembly400. The tool frame525rigidly connects to the tool shaft526, which further extends in a distal direction (i.e., away from the forearm attachment joint1807and the user). A two-DoF articulating joint (also referred to as the output joint583/end-effector articulating joint583′) is located at the end (also referred to as the output of the medical device1800) of the tool shaft526. These two degrees of freedom are pitch rotation and yaw rotation, which are controlled/actuated by articulating the input joint1801(discussed below) between the unlimited-roll handle assembly400and the pulley block1805. Additionally, the end-effector assembly1765is equipped with a pair of jaws1756that can be opened and closed in response to a handle lever549of the unlimited-roll handle assembly400.

The input joint1801is located between the unlimited-roll handle assembly400and the pulley block1805at the proximal end528of the medical device1800and provides for two rotational degrees of freedom (DoF) (pitch rotation and yaw rotation) therebetween. The input joint1801is a parallel kinematic mechanism comprising two flexure transmission strips533,534and two transmission pulleys1813.1,1813.2(a pitch pulley1813.1and a yaw pulley1813.2, shown inFIG. 18C). The axes of the pulleys1813.1,1813.2, when extrapolated, intersect at a virtual center (VC)1821in space. For this reason, the parallel kinematic input joint1801′ of the medical device1800is also referred to as a Virtual Center mechanism1801′ or a Virtual Center input joint1801′. When the medical device1800is mounted on a user's forearm608via the forearm attachment joint1807and the user's hand609holds the handle shell101,501of the unlimited-roll handle assembly400, the overall geometry of the medical device1800is such that the virtual center (VC)1821produced by the parallel kinematic input joint1801′ approximately coincides with the center of rotation the user's wrist joint607. This ensures a natural, comfortable, unrestricted articulation of the surgeon's wrist607while using the medical device1800.

Given the above configuration of the medical device1800, the yaw and pitch rotations of the user's wrist607with respect to his/her forearm608are translated to the corresponding rotations of the unlimited-roll handle assembly400with respect to the pulley block1805/tool frame525. The parallel kinematic design of the virtual center mechanism1801′ is such that the two rotation components (pitch and yaw) of the handle shell101,501with respect to the pulley block1805are mechanically separated/filtered into a pitch-only rotation at the pitch pulley1813.1and a yaw-only rotation at the yaw pulley1813.2. The pitch pulley1813.1and yaw pulley1813.2are respectively pivoted (and mounted) with respect to the pulley block1805about the corresponding associated pitch rotation axis1833and yaw rotation axis1831, respectively. The pitch and yaw rotations of the unlimited-roll handle assembly400(and therefore, of the surgeon's wrist607) thus captured at the pitch1813.1and yaw1813.2transmission pulleys are then transmitted as corresponding rotations of the end-effector articulating joint583via cables that originate at the transmission pulleys1813.1,1813.2and run through the pulley block1805, tool frame525, and tool shaft526all the way to the end-effector assembly1765. These cables may or may not be continuous.

In addition to the yaw and pitch rotational degrees of freedom (DoFs) provided by the input joint1801, the input joint also provides/allows for an axial translational degree of freedom along the roll axis111,1835, which provides/allows for a range of user hand609sizes to be accommodated by the medical device1800, and ensures free and unrestricted hand609/wrist607articulation.

Furthermore, the flexure transmission strips533,534are stiff in twisting about the roll axis111,1835, which ensures that the input joint1801constrains (and therefore transmits) roll rotation from the distal end of the unlimited-roll handle assembly400(i.e., the dial) via the flexure transmission strips533,534to the pulley block1805. Note that pulley block1805serves as the outer ring1805of the forearm attachment joint1807, which provides a well-defined low-resistance rotation about roll axis111,1835with respect to the wrist cuff1803shown inFIG. 18C. This implies that when the user holds the handle shell101,501in his/her palm, he/she can articulate the handle shell101,501in any desired yaw and pitch directions, resulting in corresponding articulation of the end-effector assembly1765. Then he/she can twirl the dial portion102,502of the unlimited-roll handle assembly400—i.e. the rotation dial102,502—with his/her thumb and fingers (typically index finger) while keeping the articulation of the unlimited-roll handle assembly400fixed. The twirling of the rotation dial102,502(i.e., roll rotation) is transmitted to the pulley block1805/outer ring1805via the parallel kinematic input joint1801′ (i.e. via the flexure transmission strips533,534of the Virtual Center mechanism1801′). The pulley block1805then rotates about the roll axis111,1835with respect to the wrist cuff1803, which is attached to the forearm608of the user. As a result, the entire tool frame525rotates about the roll axis111,1835with respect to the forearm608of the user. Since the tool shaft526is rigidly connected to the tool frame525, the tool shaft526also rotates about the roll axis111,1835. The roll rotation of the tool shaft526is transmitted to the end-effector assembly1765as well via the output joint583(i.e. via the end-effector articulating joint583′). Because the articulation of the end-effector assembly1765(at the output joint583) is controlled by the corresponding articulation of the unlimited-roll handle assembly400(about the input joint1801), if the latter is held fixed, the former is also held fixed, while roll rotation is transmitted all the way from the twirling motion of the surgeon's fingers to the end-effector assembly1765. This particular mode of operating the medical device1800is referred to as articulated roll.

In addition to producing end-effector roll via twirling of the surgeon's thumb and fingers (resulting in rotation of the rotation dial102,502with respect to the handle shell101,501), another way to produce this roll is when the surgeon rotates (about the roll axis111,1835) the entire unlimited-roll handle assembly400by pronating and supinating his/her hand609and forearm608. This roll motion is also transmitted to the tool frame525via the flexure transmissions strips533,534of the Virtual Center mechanism1801′ and the pulley block1805, and subsequently transmitted to the end-effector assembly1765via the tool shaft526. However, the amount of roll motion achieved in this manner is limited by the range of pronation/supination allowed by the user's (i.e. surgeon's) hand609/forearm608.

On the other hand, by having two distinct components in the unlimited-roll handle assembly400—the handle shell101,501and the rotation dial102,502—this limitation is overcome. The handle shell101,501, which remains fixed in the user's hand609, is indeed limited in its roll angle by the pronation/supination limit of the user's hand609/forearm608. However, the user can—via his/her fingers—endlessly, or infinitely, roll-rotate the rotation dial102,502with respect to the handle shell101,501. This infinite-roll rotation is then transmitted to the end-effector assembly1765, as described above. This infinite-roll capability provides significant and unique functionality to the surgeon in complex surgical procedures, such as when sewing, knot-tying, etc.

As noted already, the unlimited-roll handle assembly400comprises a rotation dial102,502and a handle shell101,501, which are connected by a rotation joint therebetween which has a single rotational DoF about the roll axis111,1835. Additionally, the unlimited-roll handle assembly400also houses an end-effector actuation mechanism that is actuated by the handle lever549, wherein as the handle lever549is depressed (by the user's fingers, typically middle, ring, and pinky fingers) with respect to the handle shell101,501, the end-effector actuation mechanism translates this action into a pulling action of a transmission cable566of an end-effector transmission471. This pulling action is transmitted through the rotating interface/joint between the handle shell101,501and the rotation dial102,502to the end-effector assembly1765via the transmission cable566within a flexible conduit between the rotation dial102,502and tool frame525, then through the tool shaft526, and finally to the end-effector jaws1756of the end-effector assembly1765via the end-effector articulating joint583. A jaw closure mechanism in the end-effector assembly1765closes the end-effector jaws1756responsive to the pulling action of the transmission cable566, as would be needed to operate shears, graspers, a needle-holder, etc.

The virtual center (VC)1721provided by the input joint1801coincides with the center of rotation of the wrist joint607of the user operating the medical device1800. Furthermore, the three rotational axes of the corresponding three rotational degrees of freedoms (yaw axis1831, pitch axis1833, and roll axis1835) provided by the forearm attachment joint1807may all intersect at one point, referred to as the center of rotation of the forearm attachment joint1807. This center of rotation of the forearm attachment joint1807may coincide with the center of rotation of the input joint1801(i.e. the virtual center (VC) of rotation1721of the unlimited-roll handle assembly400with respect to the pulley block1805).

Accordingly, the center of rotation of the forearm attachment joint1807may also coincide with the center of rotation of the user's wrist joint607when the medical device1800is mounted on a user's forearm608.

In particular, when the user's wrist607in not articulated (i.e., is in a nominal position) the forearm axis should coincide with the axis of the outer ring1805, which should coincide with the axis of the tool shaft526, which should coincide with the axis of the end-effector assembly1765. This is when the unlimited-roll handle assembly400is not articulated with respect to the pulley block1805(i.e., is nominal) and therefore the end-effector assembly1765is not articulated with respect to the tool shaft526.

To facilitate the ease of performing an infinity roll of the medical device1800, the overall weight of the medical device1800may be distributed such that its center of gravity lies close to the roll axis111,1835of the medical device1800, which ensures that as the user rolls the medical device1800(as described above), he/she is not working with or against gravity. With the weight of the medical device1800supported at the user's forearm608and a trocar on the patient's body, locating the center of gravity of the medical device1800on the roll axis111,1835makes driving the roll rotation relatively effortless because gravity no longer has an effect on the roll rotation.

In addition to all the functionality mentioned above, the overall design and construction of the medical device1800also helps filter out hand tremors and prevent them from reaching the end-effector assembly1765. In the medical device1800, the handle assembly400—and therefore surgeon's hand609—are isolated from the pulley block1805/tool frame525/tool shaft526by means of the flexure transmission strips533,534, which because of their material and/or construction, prevent any hand tremors from reaching the tool shaft526and end-effector assembly1765. The tool frame525is mounted on the forearm608via the forearm attachment joint1807. Therefore, the tool shaft526, which is connected to the tool frame525, is controlled by the forearm608of the surgeon. Not only does this help drive power motions (translating the tip of the shaft in three directions), but the forearm608has many fewer tremors compared to the hand609, so the shaft will experience fewer tremors as well.

Thus the flexure transmission strips533,534may help separate out the yaw and pitch rotation components of the rotation of the handle shell101,501(and handle assembly400) with respect to the pulley block1805(equivalently, the yaw and pitch rotations of the hand609with respect to the forearm608), and separately transmit these components of rotation to the corresponding pitch1813.1and yaw1813.2transmission pulleys, the latter of which are mounted on the pulley block1805. The flexure transmission strips533,534also help transmit the roll rotation from the unlimited-roll handle assembly400to the pulley block1805, tool frame525, tool shaft526, all the way to the end-effector assembly1765, and also help filter out or block hand tremors from reaching the pulley block1805, and therefore from reaching the tool frame525, and therefore from reaching the tool shaft526, and finally, therefore, from reaching the end-effector assembly1765.

The use of an unlimited-roll handle assembly400enables surgeons to have better control of the surgical instrument during surgery as a result of being able to transfer natural, ergonomic, and intuitive motion from the surgeon's hand609/wrist607/forearm608to the end-effector assembly1765. The Virtual Center mechanism1801′ (i.e. the input joint) allows the pitch and yaw rotations of the surgeon's wrist607to be mapped and transferred intuitively and fluidly to corresponding rotations of the end-effector articulation joint583. Without the benefit of the unlimited-roll handle assembly400to perform a roll of the end-effector assembly1765, the surgeon would otherwise be limited to pronation and supination of his/her forearm608, which is inherently biomechanically limited in its range of roll rotation.

However, with the addition of the unlimited-roll handle assembly400, the surgical instruments described herein can intuitively and ergonomically provide for the end-effector assembly1765to directly inherit or receive the yaw, pitch, and roll of the input of the medical device1800. In addition to roll resulting from pronation and supination of the surgeon's forearm608/wrist607, roll is also achieved with the rolling of the rotation dial102,502by the surgeon's thumb/fingers. Roll produced from both these sources is transferred or transmitted to the end-effector assembly1765. When the surgeon articulates his wrist607, i.e. his hand609is in an articulated position with respect to his/her forearm608, the handle shell101,501held by the surgeon's hand is in an articulated position with respect to the tool frame (such articulation provided by the input articulation joint). Articulation of this input joint results in articulation of the output joint. This implies that the axis of the end-effector assembly1765(i.e. Axis2) is no longer aligned with the axis of the tool shaft526(i.e. Axis3). In such an articulated configuration of the end-effector assembly1765(e.g. shown inFIG. 18B), the surgeon is able to ergonomically perform an articulated roll by maintain his wrist607in a fixed articulated orientation, and rolling the rotation dial102,502with his/her thumb/fingers by an unlimited amount. This enables an articulated roll in any and every orientation of the wrist607. The roll of the end-effector assembly1765is no longer limited by the surgeon's biomechanical limitation in pronation and supination of his forearm608/wrist607. By controlling the roll of the instrument's end-effector assembly1765from the rotation dial102,502by his thumb/fingers, the surgeon is able to perform an infinite amount of roll while still being able to use the actuate the handle lever549of the end-effector actuation mechanism to control the open/close actuation of the end-effector assembly1765in any articulated orientation of his wrist607.

Furthermore, the unlimited-roll handle assemblies described herein enable simultaneous and predictable control of all the minimal access tool's advanced features with an ergonomic interface. This handle features power motions, finesse motions, and intuitive control of articulation. These three actions are individually aligned to optimal regions of the user's hand609. Power motions such as gripping the handle body and lever to close the end-effector jaw assembly are provided by the palm and fingers (particularly the middle finger, ring finger and litter finger). Finesse motions such as rotating the rotation dial102,502are provided by the thumb and index finger (although middle finger can also contribute to this action). The separation of power and finesse actions to these regions of the hand609minimizes user fatigue. This also reduces the cognitive load for the user, reducing their mental fatigue. Similar to using a computer joystick, articulation is controlled by directing the handle assembly held in the user hand609to the desired angle by articulating the user wrist607.

Yet further, the unlimited-roll handle assemblies described herein enable the simultaneous actions of open/close, roll rotation, and articulation (or any combination). Like one's own hand609, motions are fluid and natural. Performing a “running stitch” by rotating the rotation dial102,502in continuous direction without unwinding, unlocking, or other intermediate steps is a novelty compared with other suturing instruments. This is made possible by weight balancing the instrument about the tool shaft axis (e.g., Axis3) and simplifying the mechanics of instrument rotation as described herein. When the rotation dial102,502on the unlimited-roll handle assembly400is rotated, the entire instrument rotates or orbits in the same direction around the user's wrist607. During this process, the frame also rotates but the virtual center associated with the input joint remains located at the center of the user's wrist607. Consequently, performance is consistent and predictable, even during complex moves like an articulated roll rotation.

As perceived by the user, the unlimited-roll handle assembly apparatuses described herein enable a finesse roll of the associated unlimited-roll handle assembly while engaging the end-effector closure mechanism and end-effector articulation. Initially, the unlimited-roll handle assembly as previously described comprises optimized bearings between the various bodies within the mechanism. It is by way of the bearings between various bodies of the handle assembly that the surgeon notices minimal or very little difference in the resistance to rotate when the jaw closure lever is engaged or disengaged. Infinite rotation of the unlimited-roll handle assembly is enabled by a swivel joint and several keying features within the handle assembly which prevent the jaw closure cable from twisting upon itself during rotation.

During use, these unlimited-roll handle-based assemblies may allow the surgeon to perform an articulation of the end-effector assembly1765of the overall medical device1800by articulating their own wrist607while comfortably holding the handle shell101,501and handle lever549. Articulation of the unlimited-roll handle assembly leverages the distal end of the rotation dial102,502, to drive (i.e. rotate) the flexure transmission strips533,534along with their associated transmission pulleys1813.1,1813.2, whose axes are centered at the surgeon's wrist607in accordance with what is also referred to as the Virtual Center mechanism1801′. Rotation of the two transmission pulleys1813.1,1813.2drives associated articulation cables within the frame to provide for controlling the corresponding articulation of the end-effector assembly1765, about the end-effector output articulation joint583′. Once an articulated position is established, the surgeon may choose to close the jaw by actuating the handle lever549on the handle assembly400. The process of suturing with a needle requires that the surgeon roll-rotate the end-effector assembly1765about its articulated axis, thereby driving the needle about its curvature axis through various tissue planes. These unlimited-roll handle-based assemblies may (in conjunction with the other features described herein) provide the surgeon with easy access to the rotation dial102,502that provides for rotating both the associated flexure transmission strips533,534and the associated transmission pulleys1813.1,1813.2about the surgeon's wrist607, as enabled by an associated three-axis wrist gimbal (i.e., the forearm attachment joint1807). The three-axis wrist gimbal constrains and centers the medical device1800about the surgeon's wrist607so that rotation of the rotation dial102,502and Virtual Center mechanism1801′ drives a predictable concentric rotation of the pulley block1805, tool frame525, tool shaft526, and end-effector assembly1765about the surgeon's wrist607.

These devices provide for finesse rotation control with relatively low resistances to rotation both within the unlimited-roll handle assembly (addressed via bearings) and at the wrist gimbal (addressed via minimized contact surfaces and low friction plastic materials), with overall balance of the device (addressed by establishing a center of gravity on the axis of rotation and redistribution of weight throughout the device), and with the use of flexure transmission strips533,534which offer little compliance in torsion/twisting about roll axis111,1835.

Furthermore, basic definitions are now provided for certain terms as used herein.

Mechanism and joint—There is a certain equivalence between the terms “mechanism” and “joint.” A “joint” may also be alternatively referred to as a “connector” or a “constraint.” All of these can be viewed as allowing certain motion(s) along a certain degree(s) of freedom (DoF) between two bodies and constraining the remaining motions. A mechanism generally comprises multiple joints and rigid bodies. Typically, a joint is of simpler construction, while a mechanism is more complex as it can comprise multiple joints. But what is simple and what is complex depends on the context. A mechanism under consideration may appear simple or small in the context of a much bigger mechanism or machine, in which case the particular mechanism under consideration may be called a joint. Thus, what was viewed as a mechanism may also be viewed as a joint. Also note that “joint” here refers to a mechanical connection that allows motions as opposed to a fixed joint (such as welded, bolted, screwed, or glued jointly). In the latter case, the two bodies are fused with each other and are considered one and the same in the kinematic sense (because there is no relative motion allowed or there are no degree of freedoms). The term “fixed joint” is used herein to refer to this kind of joint between two bodies. When reference to the term “joint” is made, it means a connection that allows certain motions, e.g., pin joint, a pivot joint, a universal joint, a ball, and socket joint, etc. Thus, the joint that we are referring to here interfaces one body with another in a kinematic sense.

Axis and direction—Axis refers to a specific line in space. A body may rotate with respect to (w.r.t.) another body about a certain axis. Alternatively, a body may translate w.r.t. another body in a certain direction. A direction is not defined by a particular axis and is instead commonly defined by multiple parallel axes. Thus, X-axis is a specific axis defined and shown in a figure, while X direction refers to the direction of this X-axis. Multiple different but parallel X axes can have the same X direction. Direction only has an orientation and not a location in space. In this sense “axis” is more precision, “direction” is more general. If one specifies an axis, the direction is defined because axis has a direction. If one specifies a direction, there need not be any axis defined. Here, axis1and direction1are defined further which are used to define motion and constraints of the described system.

Degree of freedom (DoF)—As noted already, a joint or mechanism allows certain motions between two bodies and constrains the rest. “Degrees of freedom” is a technical term to capture or convey these “motions.” In all, there are six independent degrees of freedom possible between two rigid bodies when there is no joint between them: three translations and three rotations. A joint will allow anywhere between 0 and 6 DoF between the two bodies. For the case when the joint allows 0 DoF, this effectively becomes a “fixed joint,” described above, where the two bodies are rigidly fused or connected to each other. From a kinematic sense, the two bodies are one and the same. For the case when the joint allows 6 DoF, this effectively means that there is no joint, or that the joint really does not constrain any motions between the two bodies such as when two bodies are connected via a spring or members that are compliant in all directions. Any practical joint allows 1, or 2, or 3, or 4, or 5 DoF between two rigid bodies. If it allows one DoF, then the remaining 5 possible motions are constrained by the joint. If it allows 2 DoF, then the remaining 4 possible motions are constrained by the joint and so on.

Degree of constraint (DoC)—Degree of constraint refers to directions along which relative motion is constrained between two bodies. Since relative motion is constrained, these are directions along which motion that can be transmitted from one body to the other body. Since the joint does not allow relative motion between the two bodies in the DoC direction, if one body moves in the DoC direction, it drives along with it the other rigid body as well along that direction. In other words, load (e.g., force or torque) and motion are transmitted from one rigid body to another in the DoC directions.

Local ground—In the context of an assembly of bodies (or a multi-body system, or a mechanism) including multiple bodies and joints, one or more bodies may be referred to as the “reference” or “ground” or “local ground” or “reference ground.” The body referred to as the local ground is not necessarily an absolute ground (i.e., attached or bolted to the actual ground). Rather, the body that is selected as a local ground simply serves as a mechanical reference with respect to which the motions of all other bodies is described or studied. Also, selecting a body in an assembly/multi-body system/mechanism as the local ground doesn't limit the functionality of the assembly/multi-body system/mechanism. E.g., in case of the handle assemblies described here, the Handle Body may be chosen as the local ground and motion of other bodies may be defined with respect to the Handle Body (i.e., assuming the Handle Body is kept stationary). However, this does not mean that the handle assembly is only functional when the Handle Body is held stationary. Rather, at a high level, the functionality of the handle assembly is independent of which body is assumed to local ground.

Body—Body is a discrete component that is part of an assembly, possibly inter-connected by joints or mechanism. This discrete component is rigid and thereby, facilitates rigid body motion transmission. This means that there is no loss in transmission when force travels through the body along DoC. In certain scenarios, a body may be compliant (not rigid). In such cases, exception to the baseline definition will be specifically mentioned herein. In certain scenarios, the term body maybe used for an assembly of bodies. Specific features of the body that are relevant to the discussion will be specified while describing a body. Also, body is used as a common term describing a discrete component that is part of an assembly or a mechanism. As described further, structural components that are used to form an assembly or sub-assembly are terms as “bodies.” The term “body” and “component” may be interchangeably used throughout the description and hold the same meaning.

Transmission member—A transmission member is a rigid/compliant body that transmits motions from one body to another body. A transmission member maybe a compliant wire/cable/cable assembly, flexible shaft, etc.

User interface—A user interface acts as an input interface that user interacts with to produce certain output at the other end of a machine or instrument or mechanism. User interface is generally an ergonomic feature on a body, which is part of an instrument, that is triggered by the user. E.g., a knob on a car dashboard can be rotated by a user to increase/decrease speakers' volume. In this example, the knob and specifically, knurled outer circumference (feature) of the knob is the user interface.

Handle assembly terminologies—Components named in U.S. Pat. No. 9,814,451B2 (FIG. 1in the application) are given alternate equivalent names in this application for clarity purposes. “H.Body A” is referred to as “Handle Body,” “H.Body B” is referred to as “Dial,” “H.Body C” is referred to as “Push Rod” and “H.Body D” is referred to as “Shuttle.”

Axis1—Axis1refers to the axis about which Dial rotates w.r.t. the Handle Body. This axis is also defined as the axis about which the Push Rod has a rotational DoF w.r.t. the Shuttle.

Direction1—This is the direction along which the Shuttle translates w.r.t. the Dial. This is also the direction along which the Push Rod translates w.r.t. the Handle Body.

Handle body—Handle Body refers to a body in the handle assembly which is considered as a local ground while describing the handle assembly and associated mechanisms. The Handle Body is held by the user while other bodies within handle assembly are put in motion with respect to (w.r.t.) the Handle Body. Handle Body described herein may also be referred to as “palm grip”, “palm grip portion”, or “handle shell.”

Closure body—Closure Body refers to a body in the handle assembly which has at least 1 degree of freedom motion w.r.t. the Handle Body and in certain embodiments can be rotationally constrained (DoC) w.r.t. the Handle Body about axis1. Closure Body may also interface with another body called Closure Input. Once the Closure Input is actuated w.r.t. the Handle Body, it may lead to translation of the Closure Body w.r.t. the Handle Body along direction1. The Closure Body, when it has a translation degree of freedom relative to the Handle Body along axis1, is termed a Push Rod. Push Rod is also described in U.S. Pat. No. 9,814,451B2.

Shuttle—Shuttle refers to a body in the handle assembly which rotates w.r.t. the Push Rod about axis1and translates w.r.t. the Dial along direction1. The Shuttle is also rotationally constrained w.r.t. the Dial about axis1.

Roll body—Roll Body refers to a body in the handle assembly which has rotational DoF w.r.t. the Handle Body. Roll Body, in certain handle assembly embodiments, can be a visible (an external component accessible by the user) component of the handle assembly. Apart from the function and structure of Dial that is described in U.S. Pat. No. 9,814,451B2, Roll Body may also interface with another body called Roll Input. Once the Roll Input is rotated w.r.t. the Handle Body about its roll axis, it may lead to rotation of the Roll Body w.r.t. the Handle Body about axis1. The terms “dial” or “knob” are used interchangeably for the term Roll Body.

Tool frame—Tool frame refers to a structural body that is part of a tool apparatus. In certain tool apparatuses, it may be connected to a handle assembly and/or an elongated tool shaft. The terms “tool frame” and “frame” may be used interchangeably throughout the document.

EE (end-effector) assembly—With general reference toFIGS. 21A and 21B, EE assembly2010or end-effector assembly or jaw assembly exists at the distal end of the elongated tool shaft2011. An EE assembly may contain one or more jaws (or EE jaws). There are two types of EE assembly2010. The first type of EE assembly2010consists of two EE jaws, namely “Moving Jaw”2012and “Fixed Jaw”2014. There also exists “EE Frame”2016that acts as a local reference ground for Moving Jaw2012and any other moving body within the EE assembly2010. In this assembly, Moving Jaw2012moves relative to EE Frame2016by rotating about a pivot pin2018shown inFIG. 21A. This motion of Moving Jaw2012w.r.t. EE Frame2016is termed as “jaw closure motion.” Jaw closure motion and “jaw open/close motion” maybe used interchangeably throughout the description. InFIG. 21A, Fixed Jaw2014is also coupled to EE Frame2016such that it is a rigid extension of the EE Frame2016. While describing this EE assembly2010that is shown inFIG. 21A, Fixed Jaw2014is treated as a local reference like EE Frame2016. This is because Fixed Jaw2014is a rigid extension of EE Frame2016in this EE assembly2010. In other EE assemblies, Fixed Jaw2014may have one or more DoF joint w.r.t. the EE Frame2016. The EE Frame2016is further coupled to the tool shaft2011via an output articulation joint2020in case the EE assembly2010is part of a tool apparatus that provides articulation function.

“EE roll motion” is the second output motion at the EE assembly2010. EE roll motion can refer to two separate rotations of EE assembly2010about different axes. Rotation about axis2refers to rotation of EE assembly2010about EE assembly's roll axis. Rotation about axis3refers to rotation of EE assembly2010about the tool shaft2011roll axis. In the case of the EE assembly2010shown inFIG. 21A, upon rotation of the overall tool apparatus including handle assembly2022and tool shaft2011about axis3, EE assembly2010also rotates about axis3. Whereas, roll motion that is generated by rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of tool shaft2011about axis3and rotation of EE assembly2010about axis2. This is further described while presenting various tool apparatus configurations in the description.

The second type of EE assembly2010consists of two EE jaws, namely “Moving Jaw”2012and “Fixed Jaw”2014. The assembly also contains EE Frame2016. In this assembly, Moving Jaw2012moves relative to EE Frame2016by rotating about a pivot pin2018shown inFIG. 21B. Fixed jaw2014is also coupled to EE Frame2016such that it is a rigid extension of the EE Frame2016. While describing this EE assembly2010that is shown inFIG. 21B, Fixed Jaw2014is treated as a local reference like EE Frame2016. This is because Fixed Jaw2014is a rigid extension of EE Frame2016in this EE assembly2010. The assembly also consists of a body/component proximal to the EE assembly called “EE base”2028. The EE base2028has a 1 DoF rotation joint to the EE Frame2016. This rotation joint provides a roll DoF about axis2. This joint can be formed by a thrust bearing, roll bearing, plain bearing, etc.FIG. 21Bshows a thrust bearing2030between EE Frame2016and EE base2028. EE base2028is coupled to tool shaft2011via an articulation output joint2020. In the case of the second type of EE assembly2010, rotation of Fixed Jaw2014/EE Frame2016w.r.t. EE base2028does not lead to rotation of output articulation joint2020and thereby, does not lead to rotation of tool shaft2011about axis3. Whereas in first type of EE assembly2010, rotation of Fixed Jaw2014/EE Frame2016involves rotation of the output articulation joint2020. In the first type of EE assembly2010, the output articulation joint2020provides a roll rotation DoC between Fixed Jaw2014/EE Frame2016and tool shaft2011axis2in order to transmit roll motion.

In case of EE assembly2010shown inFIG. 21B, upon rotation of the overall tool apparatus including handle assembly2022and tool shaft2011about axis3, EE assembly2010also rotates about axis3. Whereas, roll motion that is generated by rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of EE Frame2016/Fixed Jaw2014and Moving Jaw2012about axis2. It does not lead to rotation of tool shaft2011about axis3. This corresponds to an alpha configuration, which is further described while presenting various tool apparatus configurations in the description.

Also, the entire EE assembly2010may rotate about its roll axis termed as “EE roll axis” or “axis2” w.r.t. to the EE base2028. EE assembly2010may be interchangeably referred to as “jaw assembly” or “end-effector assembly” in this document.

Roll input—“Roll Input” or “Rotation input” refers to the body that is part of the handle assembly2022which is rotated or activated to produce rotation of the EE assembly2010about axis2(EE roll axis). Here, both handle assembly2022and EE assembly2010are part of a tool apparatus where handle assembly2022is proximal to the user and EE assembly2010is distal to the user. Roll Input, in its simplest form, is the Dial2024which is part of the handle assembly2022. Roll Input, in another scenario, may be an assembly that may consist of an external Roll Input body which is visible or externally accessible by the user. In this scenario, Roll Input acts as a user interface. This assembly may also consist of the Dial2024which mates with the Shuttle such that the Shuttle has a rotational DoC w.r.t. Dial2024about axis1and translational DoF w.r.t. Dial2024along direction1. The Dial2024also has rotational DoF w.r.t. Handle Body2026about axis1. In the case Roll Input is an assembly, rotation of external Roll Input may be transmitted to Dial2024via roll transmission mechanism. This mechanism may include mechanical transmission components including but not limited to linkages, pulley, compliant mechanisms/members, cable, threaded screw, pneumatic and/or gears. This mechanism may be an electromechanical transmission mechanism that may include sensors (rotation/position/force), actuators (rotary motors, linear motors, solenoids), and/or transducers.

Closure input—This refers to the body that is part of the handle assembly2022which is triggered or activated to cause actuation of member(s) of the EE assembly2010. Closure Input, in its simplest form, is the Push Rod which is part of the handle assembly2022. This is the first scenario where Closure Input is the Push Rod itself. Closure Input, in a second scenario, may be an assembly which includes an external Closure Input which is visible or externally accessible by a user. In this scenario, Closure Input acts as a user interface. This assembly may also consist the Push Rod which mates with the Shuttle such that Shuttle has a rotation DoF w.r.t. Push Rod about axis1and a translational DoC w.r.t. Push Rod along direction1. Therefore, translation of Push Rod leads to translation of Shuttle. In the case Closure Input is an assembly, 1 DoF motion of external Closure Input w.r.t. Handle Body2026is transmitted to Push Rod via a closure transmission mechanism. This mechanism may be a mechanical transmission mechanism which may use linkages, pulley, compliant mechanisms/members, cable, threaded screw, pneumatic and/or gears. This mechanism may be an electromechanical transmission mechanism that may include sensors (rotation/position/force), actuators (rotary motors, linear motors, solenoids) and/or transducers. This second scenario is shown via various embodiments that follow the constraint map shown inFIG. 31B.

In a third scenario, Closure Input may just be an external Closure Input component. In this scenario, Closure Input has at least 1 DoF w.r.t. Handle Body2026and interfaces with Shuttle such that Shuttle has a translational DoF w.r.t. Dial along direction1and a rotational DoC w.r.t. Dial about axis1. Motion of external Closure Input may be transmitted to Shuttle via a closure mechanism. This mechanism may be a mechanical transmission mechanism which may use linkages, pulley, compliant mechanisms/members, cable, threaded screw, pneumatic and/or gears. This mechanism may be an electromechanical transmission mechanism that may include sensors (rotation/position/force), actuators (rotary motors, linear motors, solenoids) and/or transducers. This third scenario is shown via various embodiments that follow the constraint map shown inFIG. 31.

Jaw closure transmission member (TM)—This transmission member/body helps transmit translation of Shuttle w.r.t. Dial2024along direction1to the jaw closure motion within the EE assembly2010. The transmission member can be a mechanical component, e.g., a solid wire (sometimes also called piano wire) or a flexible braided cable. This member may be torsionally stiff along its centroidal axis. E.g., a Nitinol wire which is stiff against a torsional load but flexible against bending load. Whereas a braided steel cable made with individual steel filaments, which is flexible in bending, not torsionally stiff and may wound on itself upon rotation about its centroidal axis. “Jaw closure transmission member” and “Jaw closure actuation transmission member” may be used interchangeably herein.

Roll Transmission Member (TM)—This transmission member helps transmit rotation of rotation input or Dial2024w.r.t. Handle Body2026to produce EE roll motion.

Articulation Transmission Member—This transmission members that help transmit articulation (pitch and yaw motion) from the articulation input joint, which may exist between handle assembly2022and tool shaft2011, to the articulation output joint2020(present between tool shaft2011and EE assembly2010). Typically, these articulation transmission members may comprise cables, crimps, pulleys, etc.

Jaw closure transmission assembly—Jaw Closure Transmission Assembly refers to bodies, joints, mechanisms, and/or jaw closure transmission member(s) that exist between the handle assembly2022and EE assembly2010and facilitate Jaw Closure Motion. Specifically, the body within the handle assembly2022that produces output motion (e.g., Shuttle) is coupled to the proximal body that is part of jaw closure transmission assembly. Similarly, the moving jaw within the EE assembly2010is coupled to the distal most body that is part of the jaw closure transmission assembly. Terms “jaw closure transmission assembly” and “jaw actuation transmission assembly” may be used interchangeably throughout the description.

EE roll transmission assembly—EE Roll Transmission Assembly refers to bodies, joints, mechanisms and/or roll transmission member(s) that exist between the handle assembly2022and EE assembly2010and facilitate EE Roll Motion.

Articulation transmission assembly—Articulation Transmission Assembly refers to bodies, joints, mechanisms and/or articulation transmission member(s) that help transmit input motion (pitch and yaw rotation motion) generated by the user via input articulation joint to the output articulation joint2020. Specifically, the body that couples with the body within the tool apparatus that receives input from the user is the proximal body of the articulation transmission assembly. Similarly, the body that couples with either the EE Frame2016or EE Base2028depending on the type of EE assembly2010under consideration is the distal-most body within the articulation transmission assembly.

Tool Apparatus, its Functions and its Configurations (FIGS. 22A and 22B)

Handle assembly2022described herein may be part of a tool apparatus which can include the handle assembly2022, a tool frame2032, the elongated tool shaft2011, which is a rigid extension of the tool frame2032, and the EE assembly2010located at the distal end of the tool shaft2011. The tool apparatus may provide various functions which correspond to following output motions: i) jaw closure motion at the EE assembly2010; ii) articulation motion (pitch and yaw rotation) of the EE assembly2010; iii) rigid body motion of the tool shaft2011and EE assembly2010; and iv) articulated roll motion of the EE assembly2010(or portion thereof).

This apparatus can have different configurations. Two configurations that are used herein to describe the tool apparatus functions are shown inFIGS. 22A-B. In both these configurations, handle assembly2022consists of at least a closure input2048, handle body2026, and dial2024. There exists a closure actuation transmission interface2036between dial2024and frame2032. This closure actuation transmission interface2036comprises a jaw closure transmission member2038and a jaw closure transmission member conduit2039(e.g. flexible sheath or conduit, also shown inFIG. 23) between the dial and the frame that guides the jaw closure transmission member2038. The jaw closure transmission member conduit2039may be coupled to (e.g. rigidly connected to or seated against) the Frame2032on it distal end and coupled to (e.g. rigidly connected to or seated against) the Handle Body2026on its proximal end. Alternatively, on its proximal end, the jaw closure transmission member conduit2039may be coupled to the Dial2024via an interface that seats the conduit's proximal end against Dial2024axially but allows relative roll rotation between the two. The jaw closure transmission member2038facilitates the transmission of the relative motion of the Closure Input2048w.r.t. the Handle Body2026to the EE assembly2010. This relative motion leads to motion of the Moving Jaw2012w.r.t. the Fixed Jaw2014about a pivot pin2018(with an Axis4) to produce jaw closure motion. In certain tool apparatus configurations, translation motion of jaw closure transmission member2038at the distal end of tool apparatus requires to be converted to rotation of the Moving Jaw2012w.r.t. the Fixed Jaw2014about Axis4. Therefore, there may exist bodies, e.g., rack-pinion transmission assembly, pulleys, gears, linkage, cams, pins, etc. to convert the translation motion of jaw closure transmission member2038to rotation motion of the Moving Jaw2012w.r.t. the Fixed Jaw2014.

Articulation function of the tool apparatus is a function in which pitch and yaw rotations (i.e. output motions) are produced at the EE assembly2010at distal end of the tool apparatus. These output motions are generated by pitch and yaw rotation input motion of the handle assembly2022. There exists a 2-DoF output articulation joint2020that exists between the shaft2011(also referred as the tool shaft) and EE assembly2010. There also exists a 2-DoF input articulation joint2040that exists between the handle assembly2022and frame2032. Articulation motion of the handle assembly2022w.r.t. frame2032is transmitted to the articulation motion of the EE assembly2010w.r.t. tool shaft2011via various intermediate joints, mechanisms and/or transmission members (i.e. articulation transmission members). There may exist two different configurations for the tool apparatus that are shown inFIGS. 22A-B.

FIG. 22Ashows a tool apparatus configuration and embodiment where the input articulation joint2040exists between handle body2026and frame2032. Also, the EE assembly2010is similar to the one shown inFIG. 21B. EE assembly2010, in this case, consists of bodies namely, EE base2028, Moving Jaw2012, and Fixed Jaw2014. InFIGS. 21A-Band22A-B, the Fixed Jaw2014is shown as a rigid extension of EE Frame2016. In other instances, the Fixed Jaw204can be separate body coupled to EE Frame2016. There exists the output articulation joint2020between the proximal portion of the EE assembly2010(which in this embodiment is the EE base2028) and the distal end of the shaft2011. The need for EE base2028and a 1-DoF roll rotation joint between EE base2028and EE frame2016is discussed while describing EE roll motion in the following paragraphs. This configuration is termed as “alpha configuration.” Also depicted in the embodiment shown inFIG. 22Aare two transmission interfaces—roll transmission interface2037and closure actuation transmission interface2036. Associated with these two transmission interfaces are two respective transmission members, namely a roll transmission member2042and the jaw closure transmission member2038. Although illustrated as two separate transmission interfaces and therefore two separate transmission members, in some scenarios, a single transmission interface and a single associated transmission member may be used. In such scenarios, the single transmission member has adequate axial and torsional stiffness can be used to transmit both roll rotation as well as jaw closure actuation from the handle assembly to the end-effector assembly.

FIG. 22Bshows an alternate tool apparatus configuration and embodiment where the input articulation joint2040exists between the dial2024and the frame2032. Also, the EE assembly2010is similar to the one shown inFIG. 21A. In this configuration, the EE assembly2010consists of bodies namely, Moving Jaw2012and Fixed Jaw2014. Once again, the Fixed Jaw2014shown here is a rigid extension of the EE frame2016but in other instances these two may be separate bodies that are coupled to each other. There exists an output articulation joint2020between the proximal portion of the EE assembly2010and the distal portion of shaft2011. In this embodiment, the proximal portion of the EE assembly2010is the EE Frame2016. This configuration is termed as “beta configuration.”

Each of the 2-DoF input and output articulation joint(s),2040and2020respectively, can be either a parallel kinematic input joint or a serial kinematic input joint. Examples of tool apparatus with parallel kinematic input joint is shown in U.S. Pat. No. 8,668,702, U.S. patent application publication No. 2013/0012958 and U.S. Pat. No. 10,405,936. Examples of tool apparatus with serial kinematic input joints are U.S. Pat. Nos. 5,908,436; 6,994,716; and U.S. application Ser. No. 11/787,607. The center of rotation of the input articulation joint2040can lie proximal or distal to the handle assembly2022. Here the “distal” represents the direction where the end-effector assembly lies w.r.t. the tool shaft/tool frame, and “proximal” represents the direction where the handle assembly lies w.r.t. the tool shaft/tool frame.

In both configurations and embodiments shown, motion of the frame2032w.r.t. an external reference ground such as a patient's bed or body is transmitted to the tool shaft2011and the EE assembly2010. Therefore, shaft2011has 3 translation DoFs (along X, Y, and Z axis direction) and 3 rotation DoFs (pitch, yaw, and roll rotation) w.r.t. the reference ground. The interface between the instrument shaft2011and the patient's body (e.g. via a trocar or cannula) eliminates some of these 6 DoFs. When the EE assembly2010is not articulated, roll rotation of the EE assembly2010and tool shaft2011takes place about axis3. In this scenario, axis1, axis2, and axis3are all colinear. In another scenario where EE assembly2010is articulated, roll rotation of EE assembly2010takes place about axis2while the roll rotation of the shaft2011takes place about axis3, and the roll rotation of dial2024takes place about axis1. In this articulated condition or scenario of the tool apparatus, axis1, axis2and axis3are no longer collinear. This roll rotation function of the end-effector when it is articulated is referred to as “articulated roll.”

In both tool apparatus configurations shown inFIGS. 22A and 22B, the legend on the bottom right of the figure indicates that any body or component that is shown with a “cross-hatch pattern fill” rotates in roll a respective axis (Axis1, Axis2, or Axis3) in response to roll rotation of the dial2024whereas any body or component that is show without a “cross-hatch pattern fill” does not rotate with the dial2024. In the case of the alpha configuration, roll rotation of handle body2026about axis1w.r.t. an external reference ground leads to rigid body roll motion of the frame2032and tool shaft2011about axis3, and EE assembly2010about axis2. In this configuration, the input articulation joint2040as well as the output articulation joint2020, both transmit roll. In other words, roll rotation is a Degree of Constraint (DoC) for both these joints. Separately, roll rotation of dial2024w.r.t. handle body2026about axis1leads to rotation of only the EE frame2016(and its extension Fixed Jaw2014) w.r.t. EE Base2028about axis2, while the rest of the frame2032and shaft2011do not roll w.r.t. the handle body2026. This rotation of EE Frame2016(and therefore Fixed Jaw2014) w.r.t. EE Base2028is possible because there exists a 1 roll DoF joint between the EE frame2016and the EE Base2028that provides roll motion of the EE Frame2016(along with the rest of the proximal portion of EE assembly2010) about axis2. This rotation of dial2024leading to rotation of EE Frame2016is transmitted via a roll transmission interface2037, comprising a roll transmission member2042. When the EE assembly2010is not articulated, axis2is collinear with axis3. When the handle body2026is articulated w.r.t. the frame2032, and as a result EE assembly2010is articulated w.r.t. the shaft20111, and therefore axis2is no longer collinear with axis3. In this articulated condition, when the dial2024is rotated w.r.t. handle body2026about axis1, this leads to the rotation of EE Frame2016w.r.t. EE Base2028about axis2, which is no longer collinear with axis3. This motion is called “articulated roll”.

Thus, in the case of the alpha configuration, there are two roll transmission assemblies. To produce rotation of frame2032, tool shaft2011, and EE Base2028, the whole handle assembly2022(including the handle body2026) is rotated about axis1w.r.t. an external reference ground. This roll rotation is transmitted via input articulation joint2040to rigid bodies (namely frame2032and tool shaft2011), and further via output articulation joint2020all the way to the EE Base2028. Input articulation joint2040and output articulation joint2020provide a DoC in roll rotation direction in order to transmit roll motion to the EE assembly2010. All these input and output articulation joints, and tool frame and shaft rigid bodies are part of first roll transmission assembly. Here, EE assembly2010whether articulated w.r.t. the tool shaft2011or not, rotates about the tool shaft roll axis or axis3and not about its own roll axis (axis2).

In the alpha configuration, to produce relative roll motion of EE Frame2016w.r.t. EE Base2028about axis2, dial2024can be rotated w.r.t. handle body2026about axis1. This is accomplished via the second roll transmission assembly, which consists of a proximal body (e.g. shown inFIG. 25C) that couples with dial2024(or roll body), which is part of the handle assembly2022. This proximal body is either integral to or coupled to the proximal end of the roll transmission member2042, which may be guided through a roll transmission member conduit2035that is part of the roll transmission interface2037(seeFIG. 22A). When a roll transmission member conduit is employed, the roll transmission member conduit2035may be coupled to the Frame2032on it distal end and coupled to the Handle Body2026on its proximal end. Alternatively, on its proximal end, the roll closure transmission member conduit2035may be coupled to the Dial2024via an interface that allows relative roll rotation between the two. In some instances, a roll transmission member conduit may not be employed at all. The roll transmission member2042may further pass through a portion of the tool frame2032, the tool shaft2011, through the output articulation joint2020, and through the EE Base2028. The distal portion of this roll transmission member2042terminates at and is coupled to the EE Frame2016. When the dial2024is rotated w.r.t. handle body26about axis1(in any articulated orientation of the handle assembly2022w.r.t. frame2032), this roll rotation of dial is transmitted via the second roll transmission assembly to the end-effector assembly2010such that the EE frame EE Frame2016rotates w.r.t. EE Base2028about axis2. Thus, there are two distinct roll transmission assemblies in the alpha configuration. There can be a version of the alpha configuration where there is only one roll transmission assembly e.g. the second roll transmission assembly. In this version of alpha configuration, either the input articulation joint2040does not provide a DoC about the roll rotation, or the output articulation joint2020does not provide a DoC about the roll rotation, or neither provide a DoC about the roll rotation. As a result, transmission of roll rotation is no longer possible via the first roll transmission assembly, and only functional roll transmission assembly is the second roll transmission assembly described above.

In the case of the beta configuration (FIG. 22B), rotation of dial2024w.r.t. handle body2026about axis1leads to rigid body roll rotation of the entire frame2032, tool shaft2011, and EE frame2016. The EE frame2016always rotates about axis2. When the EE assembly2010is not articulated w.r.t. shaft2011, the axis2is collinear with axis3. When the EE assembly2010is in an articulated position, axis2is at an articulation angle w.r.t. axis3. This roll rotation is transmitted from the Dial2024via input articulation joint2040, rigid bodies (namely frame2032and tool shaft2011), and output articulation joint2020. In the case, the input articulation joint2040and output articulation joint2020each provide a DoC in the roll rotation direction in order to transmit roll motion from the Dial2024to the EE frame2016. When the handle assembly2022is articulated w.r.t. the frame2032and thereby EE assembly2010is articulated w.r.t. the shaft2011, roll rotation of the dial2024w.r.t. handle body2026about axis1leads to roll rotation of the EE frame2016about axis2. Roll rotation of the EE frame2016causes roll rotation of the whole EE assembly2010(which includes Moving Jaw2012and Fixed Jaw2014) about axis2. In this articulated configuration, axis2and axis3are no longer collinear.

In the beta configuration, EE roll motion is transmitted via a single roll transmission assembly consisting of roll motion transmission via rigid body roll rotation of the frame and shaft, and via input and output articulation joints. Whereas, in alpha configuration, EE roll motion transmission can take place via two roll transmission assemblies, as described above.

FIG. 23shows an embodiment of a tool apparatus which includes a parallel kinematic input articulation joint that has a center of rotation (Virtual Center) proximal to the handle assembly2022. This tool apparatus embodiment is based on the beta configuration that has been discussed above. There exists the handle assembly2022within this tool apparatus along with frame2032, tool shaft2011and EE assembly2010. The handle assembly2022that is part of this tool apparatus is discussed in detail in sections below.

Handle Constraint Maps A and B

FIG. 24Arepresents a constraint map termed as “constraint map A” that is used to describe the relationship between various bodies that constitute the handle assembly2022. The handle assembly2022may consist of four bodies namely, Handle Body2026, Dial2024, Push Rod2044, and Shuttle2046. In the embodiments of handle assembly that map to the constraint map shown inFIG. 24A, Handle Body2026can be considered as the local ground.

Closure Body (i.e., Push Rod)2044has a 1-DoF translational joint w.r.t. Handle Body2026along direction1. Push Rod2044also has a rotational DoC w.r.t. Handle Body2026about axis1. In other words, the Push Rod2044is rotationally constrained (e.g., keyed) w.r.t. Handle Body2026and if Handle Body2026is rotated about axis1, it rotates the Push Rod2044along with itself. The Roll Body (i.e. Dial)2024has a 1 DoF rotational joint w.r.t. Handle Body2026. Dial2024rotates about axis1relative to Handle Body2026. Dial2024also has 1 translational DoC w.r.t. Handle Body2026along direction1. Therefore, translation of Handle Body2026along direction1leads to translation of the Dial2024as well. The Shuttle2046has a 1 DoF rotational joint w.r.t. Push Rod2044, i.e., Shuttle2046can rotate about axis1w.r.t. Push Rod2044. The Shuttle2046also has a translational DoC w.r.t. Push Rod2044along direction1. Therefore, along direction1, translation of the Push Rod2044is transmitted to Shuttle2046. The Shuttle2046has a 1 DoF translational joint w.r.t. Dial2024along direction1. The Shuttle2046also has a 1 rotational DoC w.r.t. Dial2024about axis1. Therefore, rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1due to the presence of rotational DoC between Shuttle2046and Dial2024.

As seen in FIG.24B, which shows “constraint map B”, handle assembly2022may also comprise additional bodies, such as Closure Input2048and Roll Input2050. Closure Input2048may be coupled to the Push Rod2044via a direct structural connection or via a Closure Input Mechanism that transmits the input motion of the Closure Input2048w.r.t. the Handle Body2026to the translation along direction1of Push Rod2044w.r.t. Handle Body2026. In the former scenario, where the Closure Input2048has a direct structural connection to Push Rod2044, the Push Rod2044itself serves as the Closure Input2048. Here the Closure Input2048is integral to or an extension of the Push Rod2044. However, in other scenarios, the Closure Input2048may be coupled to the Push Rod2044via a Closure Input Mechanism (which is shown via various embodiments in the next section). Actuation of the Closure Input2048may be done manually by the user, or by using an electro-mechanical actuator, or pneumatic actuator, or hydraulic actuator, or another actuator. Additional mechanical transmission components (such as gears, pulleys, levers, tension cables, etc.) may be used between the actuator and the Closure Input2048. Such mechanical transmission components may also be included in the Closure Input Mechanism.

Roll Input2050may be coupled to the Dial2024via a direct structural connection or via a Roll Input Mechanism that transmits the input motion of the Roll Input2050w.r.t. the Handle Body2026to the rotation about axis1of Dial2024w.r.t. Handle Body2026. In the former limiting case, where the Roll Input2050has a direct structural connection to the Dial2024, the Dial2024itself serves as the Roll Input2050. Roll Input2050is integral to or an extension of the Dial2024. However, in a more general case, the Roll Input2050is coupled to the Dial2024via a Roll Input Mechanism (which shall be described in detail later). Actuation of the Roll Input2050may be done by the user manually, or by using electro-mechanical actuator, or pneumatic actuator, or hydraulic actuator, or another actuator. Mechanical transmission components and systems (namely, gears, pulleys, levers, tension cables, etc.) may be used between such actuator and the Roll Input2050, and/or within the Roll Input Mechanism.

Input received at Closure Input2048leads to translation of Shuttle2046along direction1w.r.t. Handle Body2026. Input received at Roll Input2050leads to rotation of Shuttle2046about axis1w.r.t. Handle Body2026. These inputs can simultaneously be received by the handle system shown inFIG. 24A-Bin order to produce a combined or simultaneous translation and rotation of Shuttle2046.

Tool Apparatus Configuration Maps

When the handle assembly ofFIG. 24Bis employed in a tool apparatus, inputs received at the Closure Input2048and Roll Input2050lead to jaw closure motion and EE roll motion, respectively, at the EE assembly2010. Based on the input provided by the user to the handle assembly2022at Closure Input2048, the output motion of the handle assembly2022is a translation of Shuttle2046along direction1w.r.t. Dial2024as well as w.r.t. Handle Body2026. Based on input provided by the user to the handle assembly2022at the Roll Input2050, the output motion of the handle assembly2022is a rotation of Shuttle2046about axis1w.r.t. Handle Body2026. Therefore, the handle assembly2022is such that two separate and independent inputs lead to a combined translation and rotation output motion at a single body, namely, the Shuttle2046. The main benefit of providing independent inputs to the handle assembly2022is the ability to independently optimize bodies, joints, mechanisms, and transmission members that are part of roll transmission assembly and jaw closure transmission assembly.

Tool apparatus in beta configuration shown inFIG. 23includes handle assembly2022that follows the constraint map shown inFIG. 24B, the elongated tool shaft2011which is distal to the handle assembly2022, and the EE assembly2010that exists at the distal end of the tool shaft2011. Translation of Shuttle2046(e.g. shown as Shuttle104,404inFIGS. 4A and 4B) w.r.t. Dial2024(e.g. shown as Rotation Dial102,402inFIGS. 4A and 4B) along direction1leads to open/close actuation of Moving Jaw2012w.r.t. Fixed Jaw2014(e.g. shown inFIG. 21A). As part of jaw closure transmission assembly, there exists the jaw closure transmission member2038(routed via jaw closure transmission member conduit2039) that transmits translation of shuttle2046to produce jaw closure motion at the End-Effector Assembly2010. This jaw closure transmission member2038has to have adequate stiffness along direction1at the location where it couples with the Shuttle, and more generally along its entire length in order to capture and transmit translation of the shuttle2046. This jaw closure transmission member2038may be a flexible (bendable) solid wire (e.g., piano wire, Nitinol wire) which may or may not be torsionally stiff when rotated about its centroidal axis; it may be a solid rod that may not be flexible in bending and/or torsion; it may be a braided cable assembly, which is flexible in bending and/or torsional, or it may be a member with a combination of these attributes. All these transmission members offer relatively high axial stiffness along their respective lengths.

Also, rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. In this case (similar to the beta configuration ofFIG. 22B), roll transmission assembly consists of rigid bodies (frame2032, tool shaft2011), and input and output articulation joint2040,2020.

In this case, jaw closure and roll transmission assemblies are independent and thus can be independently analyzed, designed, and optimized. E.g., bodies, joints, and mechanisms that belong to the jaw closure transmission assembly can be independently optimized for mechanical advantage, forces, materials used, efficiency, etc. without an impacting roll rotation transmission. Similarly, bodies, joints, and mechanisms that belong to the roll transmission assembly can be independently optimized to transmit roll efficiently without impacting the jaw closure transmission.

As part of the handle assemblies that map to constraint maps A and B, the Shuttle2046is pulled by the Push Rod (or Closure Body)2044towards the proximal end of the handle assembly2022(also shown as400inFIGS. 4A and 4B). The Closure Input2048may be a a rigid extension of the Push Rod2044, in which case the Closure Input2048may translate w.r.t. Handle Body2026along direction1. In other instances, the Closure Input2048may be coupled to the Push Rod2044via a Closure Input Mechanism. In these instances, motion of the Closure Input2048w.r.t. the Handle Body2026may lead to translation of the Push Rod2044w.r.t. Handle Body2026along direction1. This leads to actuation of the Moving Jaw2012w.r.t. Fixed Jaw2014in EE assembly2010.

In case of some tool apparatuses, actuating the Moving Jaw2012w.r.t. the Fixed Jaw2014may require a high amount of force due to the requirement of high clamping loads between the two jaws or due to high losses and/or resistance between bodies within the jaw closure transmission assembly. This means that the Push Rod2044needs to pull the Shuttle2046with a high force along direction1. Rotating Shuttle2046w.r.t. Push Rod2044simultaneously while the interface between the Push Rod2044and the Shuttle2046is under high load (due to various reasons mentioned above) may turn out to be hard to perform and inefficient due to high resistance if there is no well-defined and intentional load bearing interface between the Shuttle2046and Push Rod2044.

In case of a handle assembly2022that follows the constraint map shown inFIGS. 24A-B, there exists a well-defined bearing interface between Shuttle2046and Push Rod2044that lets the two bodies have a relative rotation in the presence of the high axial load. This well-defined load bearing interface may consist of a thrust bearing, a roller bearing, or a lubricious plain bearing (e.g.FIGS. 3D,3E,3F) that helps mitigate the impact of high axial load on the rotation of the Shuttle2046with respect to the Push Rod2044, and eventually on the roll rotation of the EE assembly2010when the Moving Jaw2012is actuated w.r.t. the Fixed Jaw2014. Therefore, the presence of a well-defined bearing interface within the handle assembly2022that makes roll transmission efficient without impacting jaw closure transmission is a functional need of an efficient instrument/apparatus.

FIG. 25Ashows a tool apparatus configuration map (i.e. schematic drawing) that incorporates the handle assembly2022based on constraint map B ofFIG. 24B. This tool apparatus configuration map correlates to the beta configuration of tool apparatus presented inFIG. 22B. In this configuration, there exist two independent transmission assemblies, namely jaw closure transmission assembly and roll transmission assembly. Actuation of Closure Input2048relative to Handle Body2026leads to translation of Closure Body or Push Rod2044along direction1. Since the Shuttle2046has a translation DoC w.r.t. Push Rod2044along direction1, translation of the Push Rod w.r.t. the Handle Body leads to translation of Shuttle2046w.r.t. the Handle along direct1. The legend on the bottom right ofFIGS. 25A-Cindicate the following: A single-line represents a joint or mechanism that offers at least 1 DoF (e.g. input articulation joint, output articulation joint, etc.) between bodies, components, or sub-assemblies; a double-line represents a transmission member (e.g. cables) that transmits a motion from one body/component/sub-assembly to another; a triple-line represents an interface that may be either a rigid/direct coupling between two bodies/components/sub-assemblies or a joint/mechanism that offers at least 1 DoF between two bodies/components/sub-assemblies; and a dashed single-line represents a sub-assembly.

Referring toFIG. 25A, Proximal Body, which is part of the jaw closure transmission assembly, is coupled to and therefore translates along with Shuttle2046, and thereby transmits motion to jaw closure transmission member2038which is attached or coupled to the Proximal Body. At the distal end, jaw closure transmission member2038. On its distal end, the jaw closure transmission member is coupled to Distal Body, which in turn is coupled to the Moving Jaw2012in the end-effector assembly2010, either directly or via a mechanism that converts the translation of the Distal Body into rotation of the Moving Jaw2012w.r.t. EE Frame2016(and Fixed Jaw2014) about pivot axis4to produce jaw closure motion. The Proximal Body, jaw closure transmission member(s), and various intermediate bodies (e.g. Intermediate Body1and Intermediate Body2) are all part of the Jaw Closure Transmission Assembly. The Proximal Body may be coupled to the Shuttle either via a rigid/direct coupling or via a joint/mechanism, as represented by a triple-line. Similarly, the Distal Body may be coupled to the Moving Jaw either via a direct/rigid coupling or via joint/mechanism.FIG. 25Ashows “Intermediate Body1” and “Intermediate Body2” and a joint/mechanism between them to depict the diverse types of components that can exist within the jaw closure transmission assembly. There may exist more than two Intermediate Bodies, joints/mechanisms, and transmission members within a transmission assembly.

In a tool apparatus that maps to the configuration map shown inFIG. 25A, EE roll motion is produced by rotation of Roll Input2050relative to Handle Body2026. This configuration map correlates to the beta configuration of tool apparatus presented inFIG. 22B. Transmission of EE roll motion from the handle assembly2022to the EE assembly2010for this beta configuration is described above. . At the input end, the Shuttle2046has a roll DoC about axis1w.r.t. the Dial2024. Therefore, as the user rotates the Dial2024, the Shuttle2046also rotates. There also exists a roll DoF between the Push Rod2044and Shuttle2046about axis1such that Shuttle2046can rotate relatively freely without being impacted by jaw closure transmission that also originates within the handle assembly2022(at Closure Input2048). The presence of Shuttle2046, a discrete body within handle assembly2022, maintains the independence between jaw closure transmission assembly and roll transmission assembly.

In the prior art, there exist tool apparatuses that follow another tool apparatus configuration map shown inFIG. 25Bwhich lacks Shuttle2046within the handle assembly2022. This configuration map does not incorporate a handle assembly based on the constraint maps ofFIG. 24A or 24B. With the exception of the shuttle, all the other bodies and associate joints within the handle assembly2022shown inFIG. 25Bcorrespond to the handle assembly constraint map shown inFIG. 24B. Jaw closure motion is transmitted from the proximal end of tool apparatus to the EE assembly2010by actuation of Closure Input2048leading to translation of Push Rod2044w.r.t. Handle Body2026along direction1. Closure Body or Push Rod2044is further connected to the jaw closure transmission member2038with Proximal Body. This Proximal Body or proximal end of transmission member has a translation DoC w.r.t. Push Rod2044along direction1. Therefore, the translation of the Push Rod2044is transmitted to the Proximal Body and/or the proximal end of the transmission member, both of which exist within the jaw closure transmission assembly. Proximal Body is rigidly connected or coupled to the proximal end of the jaw closure transmission member2038. Alternatively, Proximal Body may simply be the a relatively rigid end proximal end of the jaw closure transmission member2038. Within the jaw closure transmission assembly, there may either be a Distal Body rigidly coupled to the distal end of the jaw closure transmission member2038, or a Distal body that itself is the distal end of the jaw closure transmission member2038. Further, as in the case of FIG.25A, this Distal Body may be coupled to the Moving Jaw2012of the EE assembly2010either directly or via a mechanism that converts the translation of jaw closure transmission member2038(and therefore the Distal Body) to the rotation of Moving Jaw2012relative to EE Frame/Fixed Jaw. This mechanism may contain linkages, rack and pinion assembly, pulleys, cams, pins, etc.

In certain scenarios ofFIG. 25B, the Distal Body or the distal end of the jaw closure transmission member2038may have a roll DoC (e.g. via a keying feature or a pin) w.r.t. the Moving Jaw2012about axis2such that rotation of Moving Jaw2012about axis2leads to rotation of the Distal Body or the distal end of the jaw closure transmission member2038. EE roll motion is produced by rotation of Roll Input2050(or directly of the Dial2024) relative to Handle Body2026. This configuration map (FIG. 25B) also aligns with the beta configuration of tool apparatus presented inFIG. 22B. Transmission of EE roll rotation of the Roll Input2050(Dial2024) relative to Handle Body2016(all part of the handle assembly2022) to tool frame2032and shaft2011via the input articulation joint2040and further to the EE assembly2010via the output articulation join2020, for this beta configuration is described above. Eventually, the roll rotation of the EE assembly2010causes the EE Frame2016, Fixed Jaw2014, and Moving Jaw2012to also roll rotate about axis2.

As noted above, rotation of Moving Jaw2012about axis2may also lead to rotation of the Distal Body or the distal end of the jaw closure transmission member2038due to presence of a roll DoC about axis2. Though jaw closure transmission member2038does not transmit roll rotation in this configuration, it rotates nevertheless due to the EE roll motion about its centroidal axis. Rotation of jaw closure transmission member2038initiated at the distal end of the instrument should ideally have a corresponding, matching rotation at the proximal end where it interfaces with the Proximal Body. In case rotation of the distal end does not have a matching rotation on the proximal end, it may lead to unnecessary storage and wastage of energy as well as other functionality issues such as jamming due to twisting of the jaw closure transmission member2038and, as a result can impact EE roll motion and jaw closure motion. This highlights the importance of a distinct Shuttle component present in the configuration map ofFIG. 25Abut absent inFIG. 25B.

For the tool apparatus configuration map ofFIG. 25B, the jaw closure transmission member2038(and more generally the jaw closure transmission assembly) has to have certain design characteristics. Even though it does not transmit roll rotation, it has to be torsionally stiff about its centroidal axis along with being axially stiff. It also has to have low friction or frictionless interface throughout its length along the shaft before it interfaces with the Closure Body or Push Rod2044. It also has to have a roll DoF at its proximal end w.r.t. Push Rod2044about axis1. This roll DoF joint helps allow the same rotation of Proximal Body (or proximal end of the jaw closure transmission member2038) as that of the Distal body (or distal end of the jaw closure transmission member2038).

Thus, the lack of Shuttle2046(as in case of Prior Art) is acceptable only when there is an efficient roll DoF joint between the Proximal Body (or proximal end of the jaw closure transmission member2038) w.r.t. Push Rod2044and that the jaw closure transmission member2038(as well as the jaw closure transmission assembly) is adequately stiffness in torsion (i.e. about its centroidal axis or the roll rotation axis). This is necessary ensure that the jaw closure transmission member can rotate freely without twisting about its centroidal axis and without impacting the EE roll motion or the jaw actuation. Presence of Shuttle2046and a roll DoC between Shuttle2046and Dial2024about axis1provides an efficient solution and relieves the need for the above design characteristics namely high torsional stiffness and axial stiffness for jaw closure transmission member2038. This means that a cable that is axially stiff but is not stiff in torsion can be used as a jaw closure transmission member in tool apparatus of the beta configuration. The advantage of using such a jaw closure transmission member is that it also flexible in bending, which allows for a tight bend radius and large range of articulation at the output articulation joint2020.

In contrast to the tool apparatus configuration map shown inFIG. 25A, there exists tool apparatuses that are based on another configuration map (FIG. 25C) where the handle assembly2022does not include Shuttle2046. InFIG. 25C, with the exception of the shuttle, all other bodies and associated joints within the handle assembly2022are mapped to the constraint map shown inFIG. 24B. This tool apparatus configuration ofFIG. 25Caligns with the alpha configuration of tool apparatus shown inFIG. 22A. As noted in the description of the alpha configuration, there can be two transmission interfaces and associated transmission assemblies and transmission members—one for jaw closure transmission and one for roll rotation transmission. These two transmission interfaces and associated transmission members can either be distinct or combined. In other words, the same transmission member can serve as the jaw closure transmission member as well as the roll rotation transmission member. This latter case is illustrated in the tool apparatus configuration map ofFIG. 25C. Here, Proximal Body, which is part of the “combined roll rotation and jaw closure transmission assembly” is either rigidly connected/coupled to the distal end of the to the “combined roll rotation and jaw closure transmission” member. Roll rotation of the Roll Input2050is transmitted to Dial2024via a Roll Input Mechanism (described later). Roll Rotation is transmitted from Dial2024to the roll to the Proximal Body (or proximal end of the combined roll rotation and jaw closure transmission member) via a joint that provides roll DoC w.r.t. Dial2024about axis1and translation DoF along direction1. Furthermore, this Proximal Body (or proximal end of the combined roll rotation and jaw closure transmission member) is connected to the Closure Body or Push Rod2044via joint that provides translational DoC along axis1and rotational DoF about axis1. The Distal Body (or distal end of the combined roll rotation and jaw closure transmission member), which is part of the combined roll rotation and jaw closure transmission assembly, couples to the EE assembly2010(specifically the EE frame2016and Moving Jaw2012) via a joint/mechanism. This mechanism allows relative translation of the Distal Body w.r.t. EE frame2016(i.e. DoF along axis2) but constrains and therefore transmits roll between the two (i.e. DoC about axis2e.g. via a keying feature). This mechanism also couples the Distal Body (or distal end of the combined roll rotation and jaw closure transmission member) to the Moving Jaw2012so as to convert the translation of the former to rotation of the latter (i.e. Moving Jaw2012) relative to EE Frame/Fixed Jaw about pivot axis4to produce jaw closure motion. This mechanism may contain linkages, rack and pinion assembly, pulleys, cams, pins, gears, cable, etc.

This functionality may call for the combined roll and jaw closure transmission member to have certain design characteristics. This Proximal Body or the proximal end of this transmission member should have a joint with at least 1 DoF (roll rotation) w.r.t. closure body or Push Rod2044. This joint may be achieved via a bearing interface between the Proximal Body (or the proximal end of transmission member) and Push Rod2044using thrust bearing, lubricious plain bearing, etc. This transmission member also has to be torsionally stiff about its centroidal axis as well as axially stiff (both under tension and compression) to transmit both roll rotation and jaw closure actuation, respectively. The torsional stiffness has to be high not only to transmit roll but also so that any friction at the joint between Push Rod/Closure Body2024and the Proximal Body (or the proximal end of the transmission member), which is supposed to provide rotational DoF about axis1and translational DoC along axis1, does not cause the transmission member to get twisted (i.e. torsionally wound up) especially when jaw closure actuation force is applied via the transmission member. These design characteristics of large axial and torsional stiffness also impact the transmission member's ability to bend, which limits the tool apparatus' ability to provide large range of articulation and tight bend radius at the output articulation joint2020. For example, a braided cable with small diameter (while ideal in terms of bendability) is not ideal for this transmission member since such cables are neither torsionally stiff about their centroidal axis nor axially stiff when under compression. A stiffer transmission member (e.g. a solid wire, monofilament, or a thick braided cable with large diameter) provides the desirable high axial stiffness (in tension and compression) and torsional stiffness, it ends being too stiff in bending as well, thereby making large articulation and tight bend radius at the output articulation joint difficult to achieve. This shows the limitations of the prior art tool apparatuses that are based on the tool apparatus configuration map ofFIG. 25Cthat lacks a distinct Shuttle body/component. In the absence of a Shuttle and its associated well defined and properly designed respective joints w.r.t. to the Roll Body and Closure Body, the combined jaw closure transmission member has to meet the above requirements of high axial and torsional stiffness. These requirements adversely impacts the bendability of this transmission member, thereby limiting range of articulation and tight bend radius of the output articulation joint.

In this configuration (FIG.25C), there is not a well-defined bearing interface that provides the roll DoF about axis1between Push Rod/Closure Body2044and Proximal Body (or proximal end of the transmission member). Such a well-defined and properly designed bearing interface isolates the impact of high jaw closure transmission load (e.g. axial tension or force) on the transmission member. However, due to the lack of Shuttle body within handle assembly2022in this configuration, the combined roll and jaw closure transmission member needs the aforementioned design characteristics (e.g. adequately high torsional stiffness), which limits articulation performance.

Handle Assembly Embodiments—Mapping to Constraint Maps A and B

FIG. 26represents an embodiment of a handle assembly2022including Handle Body2026, Closure Input2048, Push Rod2044, Dial2024and Shuttle2046. This handle assembly2022is an embodiment that follows the constraint map shown inFIG. 24A-B. Roll Input2050is represented in its simplest form as Dial2024itself. Here, rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. There exists a plain bearing2052made from lubricious material (e.g., Delrin, Teflon, PEEK, PTFE coated aluminum) between the Dial2024and Handle Body2026. There exists a thrust bearing2054between Shuttle2046and Push Rod2044. There exists a roll DoC joint between Dial2024and Shuttle2046about direction1. There exists a Closure Input Mechanism2056between Closure Input2048and Push Rod2044such that actuation of the Closure Input2048leads to translation of Push Rod2044along direction1, while the Push Rod2044has a roll DoC joint w.r.t. Handle Body2026about direction1. Therefore, there exists a prismatic joint2058between the Push Rod2044and Handle Body2026. If this roll DoC joint did not exist, the roll friction between the Push Rod2044and Shuttle2046will cause the Push Rod2044to transmit the frictional roll torque to the Closure Input2048. This may lead to high force requirement to actuate the Closure Input2048due to introduction of reaction loads at the pivot joint between Closure Input2048and Handle Body2026. In case of low roll friction between Push Rod2044and Shuttle2046, this roll DoC may not be needed.

In the embodiment shown inFIG. 26, Closure Input mechanism2056is represented by a rack and pinion gearset2060transmission assembly. Here, Closure Input2048is a handle lever with an integrated pinion gear while Push Rod2044has a rack gear integrated into it. Upon rotation of Closure Input2048about its pivot axis w.r.t. Handle Body2026, the rack can move back and forth along direction1. Further, presence of a prismatic joint2062provides translation DoF w.r.t. Handle Body2026along direction1.

FIG. 27represents another embodiment of a handle assembly2022that includes Handle Body2026, Dial2024, Push Rod2044, Closure Input2048, and Shuttle2046. This handle assembly2022is an embodiment that follows the constraint map shown inFIGS. 24A-B. Roll Input2050is represented in its simplest form as Dial2024itself. Here, rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. There exists a plain bearing2064made from lubricious material (e.g., Delrin, Teflon, PEEK, PTFE coated aluminum) between the Dial2024and Handle Body2026. There exists a thrust bearing2066between Shuttle2046and Push Rod2044. There exists a roll DoC joint about axis1between Dial2024and Shuttle2046as Dial2024acts as Roll Input2050. There exists a Closure Input mechanism2056between Closure Input2048and Push Rod2044such that it leads to translation of Push Rod2044along direction1while the Push Rod2044has a roll DoC joint w.r.t. Handle Body2026about axis1. Therefore, there exists a prismatic joint2068between the Push Rod2044and Handle Body2026. The Closure Input Mechanism2056consists of a screw mechanism2070that exists between Closure Input2048and Push Rod2044.

In the embodiment shown inFIG. 27, Closure Input2048acts as a screw whereas Push Rod2044acts as a nut as part of this screw mechanism2070. Closure Input2048has a translational DoC joint w.r.t. Handle Body2026along direction1and a rotational DoF w.r.t. Handle Body2026about axis1. Threads of the screw (here, Closure Input2048), are mated with the nut (Push Rod2044). Push Rod2044has a translational DoF w.r.t. Handle Body2026along direction1and a rotational DoC w.r.t. Handle Body2026about axis1. Therefore, the rotation of screw leads to translation of the Push Rod2044. This Closure Input2048(screw), may be operated by the user by turning the proximal end of the screw or via actuator (e.g., a stepper or servo motor). Also, the screw shown here may be a lead screw or a ball screw, depending on the other requirements of the application where this handle assembly2022is incorporated. ThoughFIG. 27shows a bearing between Closure Input2048and Handle Body2026on the distal side, there may exist applications where a bearing interface between Closure Input2048and Handle Body2026may be required on the proximal side. Similarly, although a bearing between Shuttle2046and Push Rod2044is shown on the proximal side, there may exist applications where a bearing interface between Closure Input2048and Handle Body2026may be required on the distal side.

FIG. 28Arepresents a handle assembly2022including Handle Body2026, Push Rod2044, Closure Input2048, Dial2024, and Shuttle2046. This handle assembly2022is an embodiment that follows the constraint map shown inFIGS. 24A-B. Roll Input2050is represented in its simplest form as Dial2024itself. Here, rotation of Dial2024w.r.t. Handle Body2026about axis1′ leads to rotation of Shuttle2046about axis1′. There exists a plain bearing (e.g. bushing) made from lubricious material (e.g. Delrin, Teflon, PEEK, PTFE coated aluminum) or a ball bearing between the Dial2024and Handle Body2026. There exists a thrust bearing2072between Shuttle2046and Push Rod2044. The Shuttle2046also translates w.r.t. Dial2024along direction1′ and thus, has a prismatic joint2074w.r.t. Dial2024. There exists a roll DoC joint between Dial2024and Shuttle2046as Dial2024acts as Roll Input2050. There exists a Closure Input Mechanism2056between Closure Input2048and Push Rod2044such that it leads to translation of Push Rod2044along a path which is not the same as direction1. Also, the Push Rod2044has a roll DoC joint w.r.t. Handle Body2026about axis1.

In the embodiment shown inFIG. 28A, this Closure Input Mechanism2056comprises a flexible member2076(e.g., flexible wire) which is able to bend along a certain angle θ (here 90 degrees) and translate along its centroidal axis direction. This axis is defined as axis1′. This flexible wire, therefore, has a translational DoF w.r.t. Handle Body2026along axis1′ direction and is confined to move along this axis direction by guiding features of Handle Body2026present all around the wire. The flexibility of the wire provides the ability to bend but the wire needs to be stiff along its centroidal axis such that it transmits motion from Closure Input2048to the Push Rod2044. This wire may be a Nitinol wire, a polymer composite which includes stiff member like spring steel and elastomeric resins, etc.

This Closure Input Mechanism2056may comprise a flexible wire which is flexible to bend but stiff along its centroidal axis or, as shown inFIG. 28B, may be a serial chain of single DoF pivot joints about axis1″, where axis1″ is perpendicular to both axis1and axis1′. An embodiment showing a pivot chain2078with such pivot joints is shown inFIG. 28B.FIG. 28Cshows the use of the pivot chain2078where Closure Input Mechanism2056consists of a serial chain2078of pivot joints that are guided by slot features present within the Handle Body2026. At their two ends, the flexible wire or serial chain of joints may be rigidly connected to Closure Input2048and Push Rod2044respectively.

FIGS. 29A-Brepresents a handle assembly2022including Handle Body2026, Push Rod2044, Dial2024, Roll Input2050, and Shuttle2046. The handle assembly2022is an embodiment that follows the constraint map shown inFIGS. 24A-B. There exists a ball bearing2080between Dial2024and Handle Body2026. There exists a thrust bearing2082between Shuttle2046and Push Rod2044. There exists a Roll Input2050which is a distinct component that interfaces with Dial2024via a Roll Input transmission. Rotation of Roll Input2050about axis1′, which perpendicular to axis1w.r.t. Handle Body2026, is transmitted to Dial2024via a bevel gear assembly2084. Roll Input2050and Dial2024act as a bevel gearset such that rotation of Roll Input2050about axis1′ is transmitted to the rotation of Dial2024w.r.t. Handle Body2026about axis1. Here, these gears transmit rotation of Roll Input2050to Dial2024with the angle by90° between the respective axis of Roll Input2050and Dial2024(axis1). These gears may be designed to interface at other angles between axis1and axis1′. This rotation of Dial2024leads to rotation of Shuttle2046about axis1. The Shuttle2046also translates w.r.t. Dial2024along direction1. Closure Input2048exists in form of the Push Rod2044in its simplest form. There exists a translation DoF between Push Rod2044and Handle Body2026along direction1. AlthoughFIG. 29shows a bearing between Push Rod2044and Handle Body2026on the distal side, there may exist applications where a bearing interface between Closure Input2048and Handle Body2026may be called for on the distal side.

FIGS. 30A-B(front view and isometric view, respectively) represent a handle assembly2022including Handle Body2026, Push Rod2044, Dial2024, and Shuttle2046. This handle assembly2022is an embodiment that follows the constraint map shown inFIG. 24A. Here, rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. Roll Input2050is represented in its simplest form as Dial2024itself. There exists a roll DoC joint between Dial2024and Shuttle2046as Dial2024acts as Roll Input2050. The figure does not show the Closure Input2048and Closure Input Mechanism2056. This embodiment represents a Dial-Shuttle interface to be a compliant mechanism2086that allows translation of Shuttle2046along direction1. Also, Handle Body-Push Rod interface consists of a compliant mechanism2088that allows translation of Push Rod2044along direction1while the Push Rod2044has a roll DoC joint w.r.t. Handle Body2026about axis1. This compliant mechanism (2086,2088) may consist of 2 parallel beams that connect radially between Handle Body2026and Push Rod2044; as well as radially between Dial-Shuttle. Also, there exists a roll DoF about axis1and translation DoC along direction1between Push Rod2044and Shuttle2046.

FIG. 30C,FIG. 30DandFIG. 30Eshow embodiments of flexure or compliant bearings that provide 1 DoF translation along direction1. Such flexure bearing may be used as the interface between Dial2024and Shuttle2046, and/or Handle Body2026and Push Rod2044.FIG. 30Cshows a linear 1-DoF linear flexure bearing2090.FIG. 30Dshows an ortho-planar spring2092. When the inner ring is pushed along axis1, ortho-planar spring2092helps a linear motion for the inner ring relative to the outer ring. Here, the outer ring can be integrated with the Dial2024whereas the inner ring can be connected to the Shuttle2046. Similarly, the outer ring can be integral to the Handle Body2026whereas inner ring can be structurally connected to the Push Rod2044.

Handle Assembly Constraint Map C

FIG. 31Apresents a constraint map showing a four-body system which includes Closure Body2044, Handle Body2026, Roll Input2050, and Shuttle2046. There exists at least 1-DoF joint or mechanism between Closure Body2044and Handle Body2026. There exists a 1-DoF rotational joint providing rotation about axis1and 1 translational DoC along direction1between the Roll Input2050and Handle Body2026. There also exists a 1-DoF translational joint along direction1and 1 rotational DoC joint constraining rotation about axis1between Shuttle2046and Roll Input2050. Therefore, the output of the 1-DoF joint/mechanism that exists between Closure Body2044and Handle Body2026is transmitted to 1 DoF translation of Shuttle2046w.r.t. Roll Input2050. This transmission may occur via a transmission member or by a one or more DoF joint that may exist between Shuttle2046and Closure Body2044. This handle assembly2022may be a part of an apparatus/instrument that consists of an elongated tool shaft2011that has an EE assembly2010at its distal end (as shown inFIG. 23). The elongated tool shaft2011may lie distal to the handle assembly2022. The EE assembly2010, as described earlier, may consist of a Moving Jaw2012and a Fixed Jaw2014. Translation of Shuttle2046w.r.t. Roll Input2050along direction1may lead to the relative motion of Moving Jaw2012w.r.t. Fixed Jaw2014. Also, rotation of Roll Input2050may lead to rotation of EE assembly2010about its roll axis.

FIG. 31Bpresents an extended constraint map showing a six-body system which includes Closure Body2044, Handle Body2026, Roll Body2024, Shuttle2046, Closure Input2048, and Roll Input2050. There exists at least a 1-DoF joint or mechanism between Closure Body2044and Handle Body2026. This constraint map C′ is an extension of constraint map C shown inFIG. 31A. There exists a Closure Input Mechanism2056between Closure Input2048and Closure Body2044such that translation input can be transmitted via Closure Input2048. There also exists a Roll Input Mechanism2094between Roll Input2050and Roll Body2024such that rotation input can be transmitted via Roll Input2050. Each of these two mechanisms help transmit motion by providing a DoC between Closure Input2048and Closure Body2044, and between Roll Input2050and Roll Body2024. Embodiments shown in the following sections map to constraint map C. As constraint map B is an extension of constraint map A, similarly constraint map C′ is an extension of constraint map C.

Handle Assembly Embodiments—Mapping to Constraint Map C

FIGS. 32A-Brepresents a handle assembly2022including Handle Body2026, Closure Body2044, Roll Input2050, and Shuttle2046. This embodiment maps to the constraint map shown inFIG. 31. Here, Roll Input2050can be termed as Roll Input2050as it is present in its simplest form. Rotation of Roll Input2050w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. Also, the Shuttle2046can translate w.r.t. Roll Input2050along direction1. Therefore, the Shuttle2046has a prismatic joint2096w.r.t. Roll Input2050. The Shuttle2046is an elongated member which extends towards the proximal end such that it has a ball/oval end which interfaces with the Closure Body2044. Closure Body2044is shown as a level that has a 1-DoF rotation joint w.r.t. Handle Body2026. The user triggers this input on one end of the pivot which leads to rotation of its other end about the pivot axis. This other end interfaces with the Shuttle2046. Therefore, the ball end of the Shuttle2046interfaces with the Closure Body2044. Closure Body2044has two prongs or a wishbone-like or a slot feature which can pull the Shuttle2046by pulling the ball end of the Shuttle2046. This feature on Closure Body2044may have features to pull the Shuttle's proximal end and/or push the proximal end of the Shuttle2046.

As the Closure Body2044rotates about the pivot, its two-prong end rotates about the pivot joint axis. This end produces a translation of Shuttle's proximal end along direction1. Translation of proximal end of Shuttle2046leads to translation of the distal end of the Shuttle2046which interfaces with the Roll Input2050. Therefore, the interface between Shuttle2046and Closure Body2044is such that the proximal end of Shuttle2046translates w.r.t. Closure Body2044as the Closure Body2044(lever) rotates about its pivot axis in order to produce a translation w.r.t. Roll Input2050along direction1.FIG. 32AandFIG. 32Brepresents a ball/oval end of the Shuttle2046. This end may be conical or anchor-like or any other feature which can interface with Closure Body2044in order to produce a translation of Shuttle2046along direction1. Also, this translation can be towards the proximal end and/or towards the distal end.

FIG. 33represents a handle assembly2022that includes Handle Body2026, Roll Input2050, Closure Body2044, and Shuttle2046. This embodiment maps to the constraint map shown inFIG. 31. Here, Roll Input2050can be termed as Roll Input2050as it is present in its simplest form. Rotation of Roll Input2050w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. Also, the Shuttle2046can translate w.r.t. Roll Input2050along direction1. Therefore, the Shuttle2046has a prismatic joint2098w.r.t. Roll Input2050. There exists a screw mechanism3010between Closure Body2044and Handle Body2026. Closure Body2044acts as a screw and Handle Body2026acts like a nut. Handle Body2026is held stationary by the user while the Closure Body2044(screw) is actuated by the user. Therefore, Closure Body2044moves w.r.t. Handle Body2026by rotating about axis1and translating along direction1. Here, Handle Body2026acts as a local ground. At the distal end of the Closure Body2044, there exists a ball joint between Closure Body2044and Shuttle2046such that Shuttle2046can rotate relative to Closure Body2044about axis1. Also, due to the presence of this ball joint, rotation of the distal end of Closure Body2044(screw) w.r.t. Handle Body2026does not lead to transmission of rotation to the Shuttle2046. Translation of distal end of Closure Body2044leads to the transmission of translation to Shuttle2046. Therefore, the Shuttle2046translates along direction1w.r.t. Roll Input2050. Here, the actuation of the screw may take place by rotation of the proximal end of Closure Body2044by the user manually or using a mechanical actuator or via an electromechanical actuator (e.g., linear motor).

FIG. 34Arepresents a diaphragm spring3012which is commonly used in automotive applications as part of the clutch assembly. Diaphragm spring3012is pre-bent and is biased towards one direction. When the spring3012is deflected in the opposite direction, it tends to get back to its pre-bent configuration.

FIG. 34BandFIG. 34C(different views of the same assembly) represents a handle assembly2022including Handle Body2026, Closure Body2044, Roll Body2024, and Shuttle2046. This embodiment maps to the constraint map shown inFIG. 31. Here, Roll Body2024can be termed as Roll Input2050as it is present in its simplest form. Rotation of Roll Input2050w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. Also, the Shuttle2046can translate w.r.t. Roll Input2050along direction1. Therefore, the Shuttle2046has a prismatic joint3014w.r.t. Roll Input3050. There exists a Closure Body2044that interfaces with a diaphragm spring3012. This spring3012, as shown inFIG. 34Ais meant to interface with Shuttle2046such that it produces the translation of Shuttle2046w.r.t. Roll Input2050along direction1. Therefore, the Closure Body2044produces 1 DoF w.r.t. Handle Body2026(as mentioned in the constraint map C shown inFIG. 31). The spring3012consists of an outer ring which is constrained w.r.t. Handle Body2026and has an inner orifice. Between the outer ring and inner orifice, lies compliant radial beams which can deflect in order to produce a displacement of the inner orifice. The Closure Body2044may have an elongated member (Closure Input2048, shown inFIGS. 34B-C) which the user can actuate and deflect the radial beams mentioned above.

The Shuttle2046is an elongated member that elongates proximal to the feature that mates with Roll Input2050via the prismatic joint3014. The proximal end of the Shuttle2046may be a ball end or an oval end or similar feature that can be constrained to the inner orifice of the diaphragm spring3012. Once the Shuttle2046is mated to this orifice, deflection of diaphragm spring3012w.r.t. Handle Body2026leads to translation of Shuttle2046via pulling of the proximal end of the Shuttle2046. This deflection of the spring3012may take place via cables that pull around the inner orifice or via an elongated rigid member as shown inFIGS. 34A-Bthat extends external to the handle assembly2022.

As mentioned, deflection of the spring3012can be carried out via pulling of cables, or a rigid extension of the diaphragm spring3012. In the case where cables are used, the cables may be constrained along the direction1w.r.t. handle assembly2022. The cable(s) mentioned here constitute the Closure Input Mechanism2056. This Closure Input Mechanism2056may also consist of braided cable(s) or nitinol wire(s) or linkage mechanism or other similar means of transmission. Upon rotation of the Roll Input2050, the ball end of the Shuttle2046will rotate relative to the diaphragm spring3012about axis1. This sliding of the ball may require the presence of a thrust bearing or ball bearing interface w.r.t. the Closure Body2044. Or the ball may be made out a lubricious material (e.g., POM/Acetal, PEEK, PTFE, etc.) in order to prevent impact on roll due to friction at this interface with Closure Body2044.

Handle Assembly Embodiments—Discrete Dial Rotation (Rotation Resistance Force Members)

FIGS. 35A-Crepresent a configuration of Roll Input2050and Shuttle2046which can be part of a handle assembly2022that maps to any one of the constraint maps shown inFIG. 24A,FIG. 24BorFIG. 31. Here, Roll Input2050can be termed as Dial2024as it is present in its simplest form. Rotation of Dial2024w.r.t. Handle Body2026about axis1leads to rotation of Shuttle2046about axis1. Also, the Shuttle2046can translate w.r.t. Dial2024along direction1. Therefore, the Shuttle2046has a prismatic joint w.r.t. Dial2024.

In this embodiment, the Dial2024and Shuttle2046interface forms two one-way ratchets. One benefit of the existence of a ratchet is to provide discrete motion feedback while the Dial2024is rotated either clockwise (CW) or counterclockwise (CCW) about axis1.FIG. 35Ashows a configuration in which CCW rotation of Dial2024about axis1produces relative motion between Dial2024and Shuttle2046. There exists a compliant clutch mechanism between Dial2024and Shuttle2046such that when the Dial2024is rotated CCW, the compliant portion of the Dial2024which serves as a pawl deflects and skips over the angled teeth profile present on the Shuttle2046. Whereas, when the Dial2024is rotated CW, it leads to rotation of Shuttle2046along with its own rotation about axis1. This embodiment is shown inFIG. 35Ais termed as a counterclockwise ratchet.

FIG. 35Bshows a configuration in which CW rotation of Dial2024about axis1produces relative motion between Dial2024and Shuttle2046. There exists a compliant clutch mechanism between Dial2024and Shuttle2046such that when the Dial2024is rotated CW, the compliant portion of the Dial2024which serves as a pawl deflects and skips over the angled teeth profile present on the Shuttle2046. Whereas when the Dial2024is rotated CCW, it leads to rotation of Shuttle2046along with its own rotation about axis1. This embodiment is shown inFIG. 35Bis termed as a clockwise ratchet.

FIG. 35Cshows an embodiment showing the clutch mechanism shown inFIG. 35AandFIG. 35Bas part of a single assembly where the Shuttle2046fromFIG. 35Ais coupled to Shuttle2046fromFIG. 35Busing a common shaft and common axis (axis1). Also, Dial2024fromFIG. 35Ais coupled to Dial2024fromFIG. 35Bwhich are merged while being spaced axially along axis1.FIG. 35Cshows a configuration of the Dial-Shuttle interface in which CCW rotation of Dial2024about axis1will produce relative motion between Dial2024and Shuttle2046at section1and CW rotation of Dial2024about axis1will produce relative motion between Dial2024and Shuttle2046at section2. Therefore, during CCW rotation of Dial2024about axis1, discrete rotation feedback will be achieved via ratchet system present in section1, and during CW rotation of Dial2024about axis1, discrete rotation feedback will be achieved via ratchet system present in section2. This way, a user may receive haptic, and/or audio, and/or visual feedback while rotating the Dial2024. Also, when Dial2024is rotated with a high revolution per minute (rpm), it will come to halt relatively quickly when compared to a Dial-Shuttle configuration that lacks ratcheting.

FIGS. 36A-Cshows Handle Body2026and Dial2024which may be part of a handle assembly2022that may map to the constraint map shown inFIGS. 24A-BorFIG. 31. Here, Roll Input2050can be termed as Dial2024as it is present in its simplest form. Rotation of Dial2024w.r.t. Handle Body2026can be controlled such that angular orientation of Dial2024can be locked w.r.t. Handle Body2026via locking levers3016.

In this embodiment, position locking levers3016are class I levers that are pivoted on the Dial2024. These lever(s)3016may be singular or multiple (e.g., three locking levers located at an offset of one-hundred-and-twenty degrees (120°) that may be operated by the index finger, middle finger and/or thumb of the user). These levers3016may also be spring-loaded (e.g., via a torsion spring at the rotation pivot for each locking lever) such that it is always biased towards locking state. Each lever3016may have a peg that sits into one of many slots present on Handle Body2026.

FIG. 36Dshows an isolated cross-section of a locking lever3016and Handle Body2026feature that interfaces with locking lever(s). Once pressed, these levers raise above the Handle Body2026such that locking lever(s) can rotate as Dial2024rotates about axis1. When the user releases these levers, the levers sit in a respective slot on the Handle Body2026and lock the rotation of Dial2024w.r.t. Handle Body2026about axis1. This mechanism provides a discrete rotation of Dial2024w.r.t. Handle Body2026about axis1with pitch being dependent on the pitch of slots on Handle Body2026which interface with locking lever(s).

FIG. 37Arepresents a bistable rotation mechanism embodiment (that may be part of a handle assembly) showing the interface between Handle Body2026and Dial2024such that the rotation of Dial2024w.r.t. Handle Body2026about axis1is binary in nature. These bodies may be part of a handle assembly2202that may map to the constraint map shown inFIGS. 24A-BorFIG. 31. The Dial2024can be rotated CW by one discrete angle and Dial2024can be rotated CCW by one discrete angle. This is possible due to the presence of a bi-stable compliant mechanism3018shown in isolation inFIG. 37Bthat exists between the Dial2024and Handle Body2026. The bi-stable compliant mechanism3018comprises multiple instances of parallel beams connected on one end to the Handle Body and on the other end to the Dial, followed by additional multiple instances of parallel beams attached to Dial on one end and to the Handle Body on the other end. This forms multiple instances of opposing sets of parallel beams between the Handle Body and Dial.

InFIG. 37A, CCW rotation of the Dial2024from the given configuration (stable state1shown inFIG. 37Bfor the bi-stable compliant mechanism3018) will lead to rotation of Dial2024by a certain degree. Once the bi-stable compliant mechanism3018finds its other unique stable state, it will halt the rotation of the Dial2024. This brings each of the bi-stable compliant mechanism3018to stable state2, also shown inFIG. 37B. Similarly, rotation of Dial2024CW from the new configuration will bring the bi-stable compliant mechanism3018back to its original stable configuration, i.e., stable state1. There may exist one or more such bi-stable compliant mechanisms3018between the Dial2024and Handle Body2026. Also, the amount of rotation of Dial2024w.r.t. Handle Body2026about axis1on either side may depend on the length of parallel beams that are part of the bi-stable compliant mechanism3018.

FIG. 38Ashows an embodiment which consists of a Handle Body2026and Dial2024. This embodiment may be incorporated in a handle assembly2202that maps to constraint map shown inFIGS. 24A-BorFIG. 31. In this embodiment, there exists a detent spring3020which is housed in a frame3022. This detent spring3020sits into detent features onto the Dial2024which are located around the circumference of the Dial2024at a certain pitch. The frame3022for detent spring3020may be placed on a rail such that it can translate w.r.t. the Handle Body2026along direction1. The frame3022may be moved w.r.t. Handle Body2026by the user to switch the rotation of Dial2024w.r.t. Handle Body2026between discrete or continuous states.

In a discrete state, the Dial2024can rotate w.r.t. Handle Body2026such that it rotates discretely based on the pitch of detent features on the Dial2024. In a continuous state, the Dial2024may rotate freely w.r.t. Handle Body2026. The frame3022may also be locked w.r.t. handle assembly2022in the discrete or continuous state using a push-push button3024. The push-push button3024calls for motion of frame3022towards the Handle Body2026along direction1to push the button to lock the frame3022in a continuous Dial2024rotate state. In order to reset it back to discrete rotation state, it may need another push towards the Handle Body2026along direction1. Instead of a push-push button3024, there may be other mechanisms such as bi-stable springs to create two states, or rotation push-push button mechanism which is used in many ball-point pens, etc.

FIG. 38Bshows an example of an embodiment similar to one shown inFIG. 38A. Here components of a computer mouse can be considered as Handle Body2026, Dial2024and the switch that helps toggle between discrete and continuous Dial2024rotation states. Pressing the button interfaces a pawl or gear to the outer surface of Dial2024. The outer surface of Dial2024has slots or serrations or gear tooth features. This way, rotation of Dial2024w.r.t. Handle Body2026about axis1provides haptic feedback on each specific angle rotation (dependent on the pitch of serrations/slots on the Dial2024).

Handle Assembly Constraint Map D

FIG. 39shows a constraint map which represents DoFs and DoCs between Handle Body2026and “3DOF joint.” This “Art-roll Input” may replace Roll Input2050and/or Dial2024in constraint maps shown inFIGS. 24A-BorFIG. 31to produce a handle assembly2022that includes an articulation input joint along with existing functions, i.e., rotation of Roll Input2050leading to rotation of the end-effector and actuation of Closure Input2048leading to the closing of Moving Jaw2012w.r.t. Fixed Jaw2014. Here, “Art-roll Input” can be described as an assembly that includes two components, namely “Roll Input” (described above) and “Articulation Dial.” Articulation Dial has a 2-DoF joint w.r.t. either Roll Input2050or Handle Body2026that produces pitch and yaw motion by rotation about pitch and yaw axes respectively. This 2-DoF joint/mechanism is termed as an articulation input mechanism.

This handle assembly2022may be part of an apparatus which includes an elongated tool shaft2011and EE assembly2010at the distal end of the tool shaft2011. There may also exist an articulation output joint2020between tool shaft2011and EE assembly2010. Articulation input mechanism maybe a serial or parallel kinematic mechanism which takes pitch and yaw rotation as inputs and may transmit to output articulation joint2020present between tool shaft2011and EE assembly2010producing pitch and yaw motion output motion of end-effector respectively.

Handle Assembly Embodiments—Mapping to Constraint Map D

FIG. 40throughFIG. 42show a handle assembly2022, particularly only components namely Handle Body2026and Art-roll Input. Some of these figures may also contain a roll transmission member3026which transmit roll motion between the Roll Input2050and the EE assembly2010to produce rotation. Some of these figures may also contain an articulation transmission member which transmits articulation motion (pitch and yaw motion) from articulation input mechanism to articulation output mechanism. Also, “Roll Input” is present in its simplest form as Dial2024in these embodiments. Terms, namely, “Roll Input”, “Dial”, and “roll Dial” may be used interchangeably in the description.

InFIG. 40, there exists a 2-DoF pitch and yaw rotational joint between Articulation Dial3028and Handle Body2026. Also, there exists a 1-DoF rotational joint3030between Roll Dial2024and Articulation Dial3028. There exist pitch and yaw motion transmission members which are rigidly mounted to Articulation Dial3028such that they capture pitch and yaw motion respectively. These members are referred to inFIG. 40as cables. These cables may be flexible wires made from nitinol, Kevlar, braided stainless steel/tungsten assembly, or flexible polymers, or a combination of these materials. Each cable or a pair of cables may transmit pitch motion (or yaw motion) due to respective pitch motion (or yaw motion) of Articulation Dial3028w.r.t. Handle Body2026. Moving Articulation Dial3028to produce pitch motion produces a pull force on a pitch cable. Similarly, moving Articulation Dial3028to produce yaw motion produces a pull force on a yaw cable. Combining these motions to produce a compound motion consisting of pitch and yaw motion of Articulation Dial3028produces pull on both pitch and yaw cables.

There may exist an apparatus consisting of a tool frame, an elongated tool shaft rigidly attached to tool frame and an EE assembly at the distal end of the tool shaft. There may exist a 2-DoF output articulation joint between the tool shaft and EE assembly. The 2-DoF articulation output joint is connected to a 2-DoF articulation input joint via pitch and yaw transmission members. In this arrangement, pitch and yaw cables connect to the output articulation joint and may be routed through the tool frame and/or tool shaft. Also, EE assembly may rotate w.r.t. reference ground or tool shaft. In this arrangement, the roll Dial is rigidly attached to the roll transmission member such that rotation of roll Dial may lead to rotation of EE assembly about tool axis via roll transmission member. The 2-DoF spring joint may be constructed using helical spring, flexible coil spring, or flexible polymer assembly. It may be formed by a combination of these materials.

FIG. 41represents a handle assembly2022consisting of Handle Body2026, Roll Dial2024, and Articulation Dial3028. Here, Handle Body2026serves as the reference ground and Roll Dial2024has 1 rotational DoF w.r.t. Handle Body2026about axis1. There exists a 2 DoF articulation joint between Articulation Dial3028and Roll Dial2024such that the pitch and yaw motion of Articulation Dial3028w.r.t. Roll Dial2024is encoded by pitch and yaw encoders3032,3034respectively. Pitch and yaw encoders3032,3034rotate about pitch and yaw axes respectively. Articulation Dial3028is represented as a spherical ball that eventually rotates two rollers, namely pitch and yaw rollers. These rollers are here described as “encoders.” The pitch and yaw rotation data encoded by the respective encoders3032,3034may be transmitted to 2-DoF output articulation joint between tool shaft2011and end-effector. Further, the rotation of Roll Dial2024w.r.t. Handle Body2026about axis1may either be encoded or transmitted mechanically leading to rotation of the end-effector. Mechanical transmission of rotation of Roll Dial2024may occur via roll transmission member that is rigidly mounted to the Roll Dial2024.

FIG. 42represents a handle assembly2022consisting of Handle Body2026, roll Dial2024, and articulation Dial3028. Here, Handle Body2026serves as the reference ground and roll Dial2024has 1 rotational DoF w.r.t. Handle Body2026about axis1. There exists a 2-DoF articulation joint between articulation Dial3028and roll Dial2024such that the pitch and yaw motions of articulation Dial3028w.r.t. the roll Dial2024are captured by capturing strain produced in pitch and yaw transducers3036,3038respectively. These transducers3036,3038may be piezoelectric strips/plates or smart memory alloys or other strain transducers. This strain captured by the transducers3036,3038is converted into electric signals which may be transmitted to 2-DoF output articulation joint between tool shaft2011and EE assembly2010. Further, the rotation of roll Dial2024w.r.t. Handle Body2026about axis1may either be encoded or transmitted mechanically leading to rotation of end-effector. Mechanical transmission of rotation of roll Dial2024may occur via roll transmission member that is rigidly mounted to the roll Dial2024.

When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features, and/or other elements that may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that when a feature or element is referred to as being “connected”, “attached”, or “coupled” to another feature or element, it can be directly connected, attached, or coupled to the other feature or element or intervening features or other elements that may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached”, or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. It is understood that the features of various implementing embodiments may be combined to form further embodiments of the invention. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

The examples and illustrations included herein show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. These embodiments consist of bodies that have various types of joints and/or mechanisms namely, prismatic, revolute, cylindrical, etc. between them. These joints and/or mechanisms may consist of discrete elements/bodies/component or these joint/mechanisms may be created by compliant extensions of other bodies and/or assemblies.