Motor interface for parallel drive shafts within an independently rotating member

Mechanisms, assemblies, systems, tools, and methods incorporating the use of an offset drive shaft within an independently rotating member are provided. An example mechanism includes a base and a main shaft mounted to rotate relative to the base, a first drive shaft mounted inside the main shaft, and a first drive feature engaged with the first drive shaft. The main shaft includes a proximal end, a distal end, and a main shaft rotational axis defined therebetween. The first drive shaft is offset from the main shaft rotational axis. A first drive feature rotational axis is defined for the first drive feature and is fixed relative to the base as the main shaft rotates. The first drive feature rotates the first drive shaft.

BACKGROUND

Minimally invasive surgical techniques are aimed at reducing the amount of extraneous tissue that is damaged during diagnostic or surgical procedures, thereby reducing patient recovery time, discomfort, and deleterious side effects. As a consequence, the average length of a hospital stay for standard surgery may be shortened significantly using minimally invasive surgical techniques. Also, patient recovery times, patient discomfort, surgical side effects, and time away from work may also be reduced with minimally invasive surgery.

A common form of minimally invasive surgery is endoscopy, and a common form of endoscopy is laparoscopy, which is minimally invasive inspection and surgery inside the abdominal cavity. In standard laparoscopic surgery, a patient's abdomen is insufflated with gas, and cannula sleeves are passed through small (approximately one-half inch or less) incisions to provide entry ports for laparoscopic instruments.

Laparoscopic surgical instruments generally include an endoscope (e.g., laparoscope) for viewing the surgical field and tools for working at the surgical site. The working tools are typically similar to those used in conventional (open) surgery, except that the working end or end effector of each tool is separated from its handle by an extension tube (also known as, e.g., an instrument shaft or a main shaft). The end effector can include, for example, a clamp, grasper, scissor, stapler, cautery tool, linear cutter, or needle holder.

To perform surgical procedures, the surgeon passes working tools through cannula sleeves to an internal surgical site and manipulates them from outside the abdomen. The surgeon views the procedure from a monitor that displays an image of the surgical site taken from the endoscope. Similar endoscopic techniques are employed in, for example, arthroscopy, retroperitoneoscopy, pelviscopy, nephroscopy, cystoscopy, cisternoscopy, sinoscopy, hysteroscopy, urethroscopy, and the like.

Minimally invasive telesurgical robotic systems are being developed to increase a surgeon's dexterity when working on an internal surgical site, as well as to allow a surgeon to operate on a patient from a remote location (outside the sterile field). In a telesurgery system, the surgeon is often provided with an image of the surgical site at a control console. While viewing a three dimensional image of the surgical site on a suitable viewer or display, the surgeon performs the surgical procedures on the patient by manipulating master input or control devices of the control console. Each of the master input devices controls the motion of a servo-mechanically actuated/articulated surgical instrument. During the surgical procedure, the telesurgical system can provide mechanical actuation and control of a variety of surgical instruments or tools having end effectors that perform various functions for the surgeon, for example, holding or driving a needle, grasping a blood vessel, dissecting tissue, or the like, in response to manipulation of the master input devices.

Manipulation and control of these end effectors is a particularly beneficial aspect of robotic surgical systems. For this reason, it is desirable to provide surgical tools that include mechanisms that provide three degrees of rotational movement of an end effector to mimic the natural action of a surgeon's wrist. Such mechanisms should be appropriately sized for use in a minimally invasive procedure and relatively simple in design to reduce possible points of failure. In addition, such mechanisms should provide an adequate range of motion to allow the end effector to be manipulated in a wide variety of positions.

Non robotic linear clamping, cutting and stapling devices have been employed in many different surgical procedures. For example, such a device can be used to resect a cancerous or anomalous tissue from a gastro-intestinal tract. Unfortunately, many known surgical devices, including known linear clamping, cutting and stapling devices, often have opposing jaws that may be difficult to maneuver within a patient. For known devices having opposing jaws that are maneuverable within a patient, such devices may not generate sufficient clamping force for some surgical applications (e.g., tissue clamping, tissue stapling, tissue cutting, etc.), which may reduce the effectiveness of the surgical device.

Thus, there is believed to be a need for an improvement in the maneuverability of surgical end effectors, particularly with regard to minimally invasive surgery. In addition, there is believed to be a need for surgical end effectors with high actuation force, for example, high clamping force.

BRIEF SUMMARY

Mechanisms, assemblies, systems, tools, and methods are provided, many of which incorporate the use of an offset drive shaft within an independently rotating member. Such mechanisms, assemblies, systems, tools, and methods may be particularly beneficial for use in surgery, for example, in minimally invasive surgery, in minimally invasive robotic surgery, as well as other types of surgery. The combination of an offset drive shaft mounted for rotation within an independently rotatable instrument shaft allows significant actuation power to be transferred to an end effector while leaving a central region of the instrument shaft available for routing of other components, for example, control cables, control wires, catheters, or other such components. Drive shaft actuation can be used to articulate and/or orient an end effector, for example, so as to provide a relatively high desired clamping force, such as for cutting or stapling, optionally with a limited response rate. Cable actuation may be used for relatively lower force articulation and/or orientation of the end effector when a higher response rate is desired, such as when telesurgically grasping and manipulating tissues. Exemplary hybrid cable/shaft actuated systems may selectably actuate a single grasping/treatment jaw joint using either a high force shaft drive or a high response cable drive. While the various embodiments disclosed herein are primarily described with regard to surgical applications, related mechanisms, assemblies, systems, tools, and methods may find use in a wide variety of applications, both inside and outside a human body, as well as in non-surgical applications.

In a first aspect, a mechanism including an offset drive shaft mounted within a rotating main shaft is provided. The mechanism includes a base, a main shaft mounted to rotate relative to the base, a first drive shaft mounted inside the main shaft, and a first drive feature engaged with the first drive shaft. The main shaft includes a proximal end, a distal end, and a main shaft rotational axis defined therebetween. The first drive shaft is offset from the main shaft rotational axis. A first drive feature rotational axis is defined for the first drive feature and is fixed relative to the base as the main shaft rotates. The first drive feature rotates the first drive shaft.

Various approaches may used to rotate the first drive shaft via the first drive feature. For example, the main shaft rotational axis and the first drive feature rotational axis can be coincident. Engagement between the first drive feature and the first drive shaft can permit an axial movement of the first drive shaft relative to the base. The first drive feature can be engaged with the first drive shaft through an opening in the main shaft. The first drive shaft can include a second drive feature that protrudes through the main shaft opening and engages the first drive feature. The second drive feature can include external gear teeth. The first drive feature can include an internal ring gear.

In many embodiments, the mechanism includes a third drive feature for rotating the main shaft. For example, a third drive feature having a third drive feature rotational axis can engage the main shaft. The third drive feature rotational axis can be fixed relative to the base as the third drive feature rotates the main shaft.

In many embodiments, a second drive shaft is mounted inside the main shaft and offset from the main shaft rotational axis. A fourth drive feature having a fourth drive feature rotational axis can be engaged with the second drive shaft. A fourth drive feature rotational axis can be fixed relative to the base as the main shaft rotates. The fourth drive feature can rotate the second drive shaft. The fourth drive feature can be engaged with the second drive shaft through an opening in the main shaft.

In many embodiments, the support of the first drive shaft is integrated into the main shaft. For example, the main shaft can include a recess configured to interface with a bearing supporting the first drive shaft, and the mechanism can further include the bearing supporting the first drive shaft. The mechanism can further include a retaining ring to retain the bearing supporting the first drive shaft.

In many embodiments, an end effector is coupled with the distal end of the main shaft. The end effector can be coupled with the first drive shaft and/or with the second drive shaft. The end effector can be rotated by a rotation of the main shaft. A rotation of the first drive shaft and/or of the second drive shaft can actuate the end effector.

In many embodiments, the mechanism further comprises a control cable drive feature and a control cable engaged with the control cable drive feature. The control cable can be routed within the main shaft between the main shaft proximal and distal ends. The mechanism can further comprise an end effector coupled with the control cable. A motion of the control cable can actuate the end effector.

In another aspect, a robotic assembly including an offset drive shaft mounted within a rotating main shaft is provided. The robotic assembly includes a base; a main shaft mounted to rotate relative to the base; a drive shaft mounted inside the main shaft; an actuation assembly coupled with the main shaft and the drive shaft; and an end effector coupled with the main shaft. The main shaft includes a proximal end, a distal end, and a main shaft rotational axis defined therebetween. The drive shaft is offset from the main shaft rotational axis. The actuation assembly is operable to independently rotate the main shaft relative to the base, and rotate the drive shaft relative to the main shaft. The end effector includes a shaft driven mechanism coupled with the drive shaft.

In many embodiments, the robotic assembly further comprises a second drive shaft mounted inside the main shaft and offset from the main shaft rotational axis. The actuation assembly can be further operable to independently rotate the second drive shaft relative to the main shaft. The end effector can further comprise a second shaft driven actuation mechanism operatively coupled with the second drive shaft.

In many embodiments, the robotic assembly further comprises a control cable coupled with the end effector. The control cable can be routed within the main shaft between the main shaft proximal and distal ends. A motion of the control cable can actuate the end effector.

In another aspect, a robotic system including an offset drive shaft mounted within a rotating main shaft is provided. The robotic system includes a base; a main shaft mounted to rotate relative to the base; a first drive shaft mounted inside the main shaft; a second drive shaft mounted inside the main shaft; an actuation assembly coupled with the main shaft, the first drive shaft, and the second drive shaft; a controller; and an end effector coupled with the main shaft so that the end effector is rotated by a rotation of the main shaft. The main shaft includes a proximal end, a distal end, and a main shaft rotational axis defined therebetween. The first drive shaft and the second drive shaft are offset from the main shaft rotational axis. The controller includes an input and an output. The input is coupled with an input device to receive at least one input signal from the input device. The output is coupled with the actuation assembly to output at least one control signal to the actuation assembly. The controller includes a processor and a tangible medium containing instructions that when executed cause the processor to generate the at least one control signal in response to the at least one input signal so that the input device can be used by a user to independently rotate the main shaft relative to the base, rotate the first drive shaft relative to the main shaft, and rotate the second drive shaft relative to the main shaft. The end effector includes a first shaft driven mechanism coupled with the first drive shaft and a second shaft driven actuation mechanism coupled with the second drive shaft.

In many embodiments, the actuation assembly comprises additional components. For example, the actuation assembly can include a first motor coupled with the first drive shaft and the controller. The actuation assembly can include a second motor coupled with the second drive shaft and the controller. The actuation assembly can include a main shaft motor coupled with the main shaft and the controller. The actuation assembly can include a first encoder coupled with the first motor and the controller. The first encoder can output a first motor position signal to the controller in response to a position of the first motor. The actuation assembly can include a second encoder coupled with the second motor and the controller. The second encoder can output a second motor position signal to the controller in response to a position of the second motor. The actuation assembly can include a main shaft encoder coupled with the main shaft motor and the controller. The main shaft encoder can output a main shaft position signal to the controller in response to a position of the main shaft motor.

In many embodiments, the robotic system further comprises a control cable coupled with the end effector. The control cable can be routed within the main shaft between the main shaft proximal and distal ends. A motion of the control cable can actuate the end effector.

In another aspect, a robotic tool including an offset drive shaft mounted within a rotating main shaft is provided. The robotic tool is configured for mounting on a manipulator having a tool interface with first, second, and third drive features. The robotic tool includes a proximal tool chassis releasably mountable to the tool interface; a distal end effector having a distal degree of freedom and a shaft driven actuation mechanism; a main shaft having a proximal end adjacent the chassis, a distal end adjacent the end effector, a bore extending therebetween, and a lateral opening distally of the proximal end; and a hybrid cable/shaft drive system operatively coupling the drive features of the tool interface to the end effector when the chassis is mounted to the tool interface. Actuation of the first drive feature rotates the main shaft and the end effector relative to the chassis about a main shaft rotational axis. Cables extending from the chassis distally within the bore of the main shaft couple the distal degree of freedom of the end effector to the second drive feature. The first drive shaft couples the shaft driven actuation mechanism of the end effector to the third drive feature through the lateral opening in the main shaft. The first drive shaft is offset from the main shaft rotational axis.

In another aspect, a method for transmitting torque through an offset drive shaft routed within a rotatable main shaft is provided. The method includes supporting a main shaft to rotate relative to a base so that the main shaft rotates about a main shaft rotational axis, supporting a drive shaft to rotate relative to the main shaft so that the drive shaft rotates about a drive shaft rotational axis that is offset from the main shaft rotational axis, engaging the drive shaft with a drive feature having a drive feature rotational axis that is fixed relative to the base as the main shaft rotates, rotating the main shaft relative to the base, and rotating the drive feature relative to the main shaft so as to rotate the drive shaft relative to the main shaft. In many embodiments, the main shaft rotates relative to the base and the drive shaft rotates relative to the main shaft simultaneously.

In another aspect, a minimally invasive surgical method is provided. The method includes introducing an end effector to an internal surgical site within a patient through a minimally invasive aperture or natural orifice by manipulating a base, rotating the end effector relative to the base, and performing a surgical task with the end effector by rotating a first drive shaft relative to the instrument shaft so that the first drive shaft actuates the end effector. In the method, the end effector is supported relative to the base by an elongated instrument shaft, the end effector is rotated relative to the base by rotating the instrument shaft relative to the base about an instrument shaft rotational axis, and the first drive shaft rotates relative to the instrument shaft about a first drive shaft rotational axis that is offset from the instrument shaft rotational axis. In many embodiments, the method further comprises actuating the end effector by rotating a second drive shaft relative to the instrument shaft, the second drive shaft rotating about a second drive shaft rotational axis that is offset from the instrument shaft rotational axis.

For a fuller understanding of the nature and advantages of the present invention, reference should be made to the ensuing detailed description and accompanying drawings. Other aspects, objects and advantages of the invention will be apparent from the drawings and detailed description that follows.

DETAILED DESCRIPTION

Mechanisms, assemblies, systems, tools, and methods incorporating the use of an offset drive shaft within an independently rotating member are provided. Such mechanisms, assemblies, systems, tools, and methods may be particularly beneficial for use in surgery, for example, in minimally invasive surgery, minimally invasive robotic surgery, as well as other types of surgery. While the various embodiments disclosed herein are primarily described with regard to surgical applications, related mechanisms, assemblies, systems, tools, and methods can be used in a wide variety of applications, both inside and outside a human body, as well as in non-surgical applications.

Minimally Invasive Robotic Surgery

Referring now to the drawings, in which like reference numerals represent like parts throughout the several views,FIG. 1is a plan view illustration of a Minimally Invasive Robotic Surgical (MIRS) system10, typically used for performing a minimally invasive diagnostic or surgical procedure on a Patient12who is lying down on an Operating table14. The system can include a Surgeon's Console16for use by a Surgeon18during the procedure. One or more Assistants20may also participate in the procedure. The MIRS system10can further include a Patient Side Cart22(surgical robot), and an Electronics Cart24. The Patient Side Cart22can manipulate at least one removably coupled tool assembly26(hereinafter simply referred to as a “tool”) through a minimally invasive incision in the body of the Patient12while the Surgeon18views the surgical site through the Console16. An image of the surgical site can be obtained by an endoscope28, such as a stereoscopic endoscope, which can be manipulated by the Patient Side Cart22so as to orient the endoscope28. The Electronics Cart24can be used to process the images of the surgical site for subsequent display to the Surgeon18through the Surgeon's Console16. The number of surgical tools26used at one time will generally depend on the diagnostic or surgical procedure and the space constraints within the operating room among other factors. If it is necessary to change one or more of the tools26being used during a procedure, an Assistant20may remove the tool26from the Patient Side Cart22, and replace it with another tool26from a tray30in the operating room.

FIG. 2is a perspective view of the Surgeon's Console16. The Surgeon's Console16includes a left eye display32and a right eye display34for presenting the Surgeon18with a coordinated stereo view of the surgical site that enables depth perception. The Console16further includes one or more input control devices36, which in turn cause the Patient Side Cart22(shown inFIG. 1) to manipulate one or more tools. The input control devices36will provide the same degrees of freedom as their associated tools26(shown inFIG. 1) so as to provide the Surgeon with telepresence, or the perception that the input control devices36are integral with the tools26so that the Surgeon has a strong sense of directly controlling the tools26. To this end, position, force, and tactile feedback sensors (not shown) may be employed to transmit position, force, and tactile sensations from the tools26back to the Surgeon's hands through the input control devices36.

The Surgeon's Console16is usually located in the same room as the patient so that the Surgeon may directly monitor the procedure, be physically present if necessary, and speak to an Assistant directly rather than over the telephone or other communication medium. However, the Surgeon can be located in a different room, a completely different building, or other remote location from the Patient allowing for remote surgical procedures (i.e., operating from outside the sterile field).

FIG. 3is a perspective view of the Electronics Cart24. The Electronics Cart24can be coupled with the endoscope28and can include a processor to process captured images for subsequent display, such as to a Surgeon on the Surgeon's Console, or on another suitable display located locally and/or remotely. For example, where a stereoscopic endoscope is used, the Electronics Cart24can process the captured images so as to present the Surgeon with coordinated stereo images of the surgical site. Such coordination can include alignment between the opposing images and can include adjusting the stereo working distance of the stereoscopic endoscope. As another example, image processing can include the use of previously determined camera calibration parameters so as to compensate for imaging errors of the image capture device, such as optical aberrations.

FIG. 4diagrammatically illustrates a robotic surgery system50(such as MIRS system10ofFIG. 1). As discussed above, a Surgeon's Console52(such as Surgeon's Console16inFIG. 1) can be used by a Surgeon to control a Patient Side Cart (Surgical Robot)54(such as Patent Side Cart22inFIG. 1) during a minimally invasive procedure. The Patient Side Cart54can use an imaging device, such as a stereoscopic endoscope, to capture images of the procedure site and output the captured images to an Electronics Cart56(such as the Electronics Cart24inFIG. 1). As discussed above, the Electronics Cart56can process the captured images in a variety of ways prior to any subsequent display. For example, the Electronics Cart56can overlay the captured images with a virtual control interface prior to displaying the combined images to the Surgeon via the Surgeon's Console52. The Patient Side Cart54can output the captured images for processing outside the Electronics Cart56. For example, the Patient Side Cart54can output the captured images to a processor58, which can be used to process the captured images. The images can also be processed by a combination the Electronics Cart56and the processor58, which can be coupled together so as to process the captured images jointly, sequentially, and/or combinations thereof. One or more separate displays60can also be coupled with the processor58and/or the Electronics Cart56for local and/or remote display of images, such as images of the procedure site, or other related images.

FIGS. 5A and 5Bshow a Patient Side Cart22and a surgical tool62, respectively. The surgical tool62is an example of the surgical tools26. The Patient Side Cart22shown provides for the manipulation of three surgical tools26and an imaging device28, such as a stereoscopic endoscope used for the capture of images of the site of the procedure. Manipulation is provided by robotic mechanisms having a number of robotic joints. The imaging device28and the surgical tools26can be positioned and manipulated through incisions in the patient so that a kinematic remote center is maintained at the incision so as to minimize the size of the incision. Images of the surgical site can include images of the distal ends of the surgical tools26when they are positioned within the field-of-view of the imaging device28.

Offset Drive Shaft(s) within a Rotatable Shaft

FIG. 6diagrammatically illustrates a robotic assembly70having two offset drive shafts within a rotatable main shaft, in accordance with many embodiments. The robotic assembly70includes an end effector72that is coupled with the distal end of a rotatable main shaft74, and an actuation assembly76coupled with both the main shaft74and the end effector72.

The end effector72includes an end effector base, a first actuation mechanism78, a second actuation mechanism80, and a control cable mechanism(s)82. The end effector base is pivotally coupled to the rotatable main shaft74. The first actuation mechanism78and the second actuation mechanism80are shaft driven and can be used to actuate and/or articulate a variety of end effector features and/or devices, for example, a clamping feature, a movable cutting feature, a cutting and stapling device, or another suitable end effector feature and/or device that can be actuated and/or articulated with a shaft driven mechanism. The control cable mechanism(s)82can also be used to actuate and/or articulate a variety of end effector features and/or devices, particularly those where a fast response is desired, for example, a grasping feature, a main shaft to end effector base wrist that is used to articulate the end effector base relative to the main shaft, or another suitable feature and/or device that can be actuated and/or articulated via one or more control cables.

The end effector base is coupled with the rotatable main shaft74so that a rotation of the main shaft74about a main shaft rotation axis produces a corresponding rotation of the end effector base. As discussed above, the ability to independently rotate the main shaft74provides increased end effector maneuverability relative to a non rotating main shaft, which may be beneficial during certain surgical procedures, for example, during certain minimally invasive surgical procedures. The end effector base can also be coupled with the rotatable main shaft74with a suitable wrist mechanism84that provides additional end effector maneuverability.

Two drive shafts are used to drive the end effector shaft driven actuation mechanisms. A first drive shaft86is mounted for rotation about a first drive shaft rotational axis that is offset from the main shaft rotation axis. The first drive shaft86is operatively coupled with the first actuation mechanism78. Likewise, a second drive shaft88is mounted for rotation about a second drive shaft rotational axis that is offset from the main shaft rotation axis. The second drive shaft88is operatively coupled with the second actuation mechanism80.

The actuation assembly76is coupled with the rotatable main shaft74, the first drive shaft86, the second drive shaft88, and the control cable mechanism(s)82. The rotatable main shaft74is mounted for rotation relative to a base of the actuation assembly76. The actuation assembly76is operable to produce rotation of the rotatable main shaft74relative to the base. The actuation assembly76is also operable to generate any combination of rotation of the rotatable main shaft74relative to the base, rotation of the first drive shaft86relative to the rotatable main shaft74, and rotation of the second drive shaft88relative to the rotatable main shaft74. As such, the first actuation mechanism78and/or the second actuation mechanism80can be actuated independently and/or simultaneously with rotation of the rotatable main shaft74.

The actuation assembly76is configured to provide the above described functionality in which the first drive shaft86and the second drive shaft88can be independently rotated relative to the rotatable main shaft74, even during rotation of the rotatable main shaft74relative to the base. The actuation assembly76includes a main shaft motor90coupled with a main shaft encoder92and a main shaft interface94, a first motor96coupled with a first encoder98and a first interface100, a second motor102coupled with a second encoder104and a second interface106, and a control cable motor(s)108coupled with a control cable encoder(s)110and a control cable interface(s)112. The main shaft interface94is coupled with the rotatable main shaft74so as to transfer rotational motion from the main shaft motor90to the rotatable main shaft74. The main shaft motor90can be fixedly coupled with the base so that the transferred rotational motion results in rotation of the rotatable main shaft74relative to the base. The main shaft encoder92measures the orientation of the main shaft motor90, the main shaft interface94, and/or the rotatable main shaft74and can be coupled with a controller (not shown inFIG. 6) so as to provide the controller with the measured orientation. The first interface100is coupled with the first drive shaft86so as to be operable to transfer rotational motion from the first motor96to the first drive shaft86during any orientation and/or rotational motion of the rotatable main shaft74. The first encoder98measures the orientation of the first motor96, the first interface100, and/or the first drive shaft86and can be coupled with the controller so as to provide the controller with the measured orientation. The second interface106is coupled with the second drive shaft88so as to be operable to transfer rotational motion from the second motor102to the second drive shaft88during any orientation and/or rotational motion of the rotatable main shaft74. The second encoder104measures the orientation of the second motor102, the second interface106, and/or the second drive shaft88and can be coupled with the controller so as to provide the controller with the measured orientation. The control cable interface(s)112is coupled with control cable(s)114that are operatively coupled with the control cable mechanism(s)82. The control cable(s)114can be routed so as to tolerate a range of rotational orientations of the rotatable main shaft74, for example, by being routed in the vicinity of the main shaft rotational axis to minimize changes in control cable length due to rotation of the rotatable main shaft74, and by being configured to tolerate any twisting of control cable(s) and/or twisting between control cables that may result for some rotational orientations of the main shaft74(e.g., by having a construction that tolerates cable-to-cable rubbing). The control cable encoder(s)110measures the orientation of the control cable motor(s)108and/or the control cable interface(s)112and can be coupled with the controller so as to provide the controller with the measured orientation(s).

FIG. 7is a simplified block diagram illustrating the integration of components of the robotic assembly70with a controller116, in accordance with many embodiments. The controller116includes at least one processor118, which communicates with a number of peripheral devices via a bus subsystem120. These peripheral devices typically include a storage subsystem122.

The storage subsystem122maintains the basic programming and data constructs that provide the functionality of the controller116. Software modules for implementing the robotic assembly functionality discussed above are typically stored in the storage subsystem122. The storage subsystem122typically includes a memory subsystem124and a file storage subsystem126.

The memory subsystem124typically includes a number of memories including a main random access memory (RAM)128for storage of instructions and data during program execution and a read only memory (ROM)130, in which fixed instructions are stored.

The file storage subsystem126provides persistent (non-volatile) storage for program and data files, and can include a hard drive, a disk drive, or other non-volatile memory such as a flash memory. An input device, for example a disk drive, can be used to input the software modules discussed above. Alternatively, other known structures may alternatively be used to input the software modules, for example, a USB port.

In this context, the term “bus subsystem” is used generically so as to include any mechanism for letting the various components and subsystems communicate with each other as intended. The bus subsystem120is shown schematically as a single bus, but a typical system has a number of buses such as a local bus and one or more expansion buses (e.g., ADB, SCSI, ISA, EISA, MCA, NuBus, or PCI), as well as serial and parallel ports.

The controller116controls components of the robotic assembly70in response to assorted received signals, including signals from the input control device(s)36(shown inFIG. 2), as well as from the main shaft encoder92, the first encoder98, the second encoder104, and the control cable encoder(s)110. The components controlled include the main shaft motor90, the first motor96, the second motor102, and the control cable motor(s)108. Additional components (not shown), such as digital/analog converters can be used to interface components with the controller116.

FIG. 8is a simplified block diagram illustrating the integration of a robotic surgery tool132within a robotic surgery system, in accordance with many embodiments. The tool132includes a proximal tool chassis134configured to be releasably mountable on a manipulator136having a tool interface configured to interface with the proximal tool chassis134. The tool132further includes an elongate main shaft74that is mounted to rotate relative to the proximal tool chassis134when rotated by a main shaft motor, as discussed above. An end effector140is coupled with a distal end of the main shaft74so as to rotate along with the main shaft. A main control system142is operatively coupled with the manipulator136. An auxiliary control system144can also be operatively coupled with the manipulator136. The combination of the main control system142and the auxiliary control system144can be used to control all possible articulations of the tool132via the manipulator136. For example, the auxiliary control system144can control the drive motors for first drive shaft rotation and second drive shaft rotation. The main control system142can control a drive motor for main shaft rotation and one or more control cable drive motors. Such an auxiliary controller can be used to supplement existing robotic surgery system configurations so as to allow the use of the presently disclosed robotic tools having one or more offset drive shafts routed within an independently rotating main shaft.

FIG. 9is a perspective view of a robotic surgery tool132, in accordance with many embodiments. As discussed above, the tool132includes a proximal tool chassis134configured to be releasably mountable on a tool manipulator136. The rotatable main shaft74couples the end effector140with the proximal tool chassis134.

FIG. 10is a perspective view of the proximal tool chassis134ofFIG. 9(without the cover), showing an actuation assembly142, in accordance with many embodiments. The actuation assembly142includes a first motor96for actuating a first offset drive shaft and a second motor102for actuating a second offset drive shaft. The various encoders discussed above (e.g., the main shaft encoder92, the first encoder98, the second encoder104, and the control cable encoder(s)110) can be integrated within the actuation assembly142. The first motor96is coupled with a set of electrical connection pins144configured to couple with a mating electrical connector that is coupled with a controller for selectively driving the first motor96. Likewise, the second motor102is coupled with a set of electrical connection pins146configured to couple with a mating electrical connector that is coupled with the controller for selectively driving the second motor102.

FIG. 11is a perspective view of a cross section of the actuation assembly142ofFIG. 10, illustrating components used to actuate a first offset internal drive shaft, in accordance with many embodiments. The first motor96is rotationally coupled with a first motor gear148. The first motor gear148engages and drives a first coupling shaft proximal gear150, which drives a first coupling shaft152. The coupling shaft152in turn rotates a first coupling shaft distal gear154. The first coupling shaft distal gear154engages a first annular gear156, which includes both external gear teeth158that engage the first coupling shaft distal gear154and internal ring gear teeth160. The first annular gear156is mounted to rotate about the centerline of the rotatable main shaft74via a first annular gear bearing162. The first drive shaft86is mounted to rotate about a first drive shaft rotation axis that is offset from the rotatable main shaft rotation axis. The first drive shaft86is mounted to the main shaft via two first drive shaft support bearings164. The first drive shaft86is coupled with a first drive shaft gear166, which includes external gear teeth that protrude from an opening in a main shaft coupling fitting168so as to engage the internal gear teeth160of the first annular gear156. In operation, rotation of the first motor96rotates the first motor gear148, which rotates the first coupling shaft proximal gear150, which rotates the coupling shaft152, which rotates the first coupling shaft distal gear154, which rotates the first annular gear156, which rotates the first drive shaft gear166, which rotates the first drive shaft86relative to the main shaft74.

In many embodiments, the actuation assembly142is designed to accommodate a range of axial motion of the first drive shaft86, for example, by designing the first annular gear156and the opening in the main shaft coupling fitting168for a range of axial motion of the first drive shaft86(e.g., by increasing the dimension of the opening and the annular gear156in the direction of the axial motion of the first drive shaft86over a size sufficient to accommodate the protruding gear teeth of the first drive shaft gear166thereby allowing the first drive shaft gear166to slide axially relative to the internal ring gear teeth of the first annular gear156). Such axial motion of the first drive shaft86may occur during articulation of an end effector base relative to the main shaft where the end effector base rotates about a wrist axis that is offset from the centerline of the first drive shaft86.

FIG. 11also illustrates actuation components used to actuate the second offset internal drive shaft88, in accordance with many embodiments. The second drive shaft88is mounted to rotate about a second drive shaft rotation axis that is offset from the rotatable main shaft rotation axis. The second drive shaft88is mounted to the main shaft via second drive shaft support bearings170. The second drive shaft88is coupled with a second drive shaft gear172, which includes external gear teeth that protrude from an opening in a main shaft coupling fitting168so as to engage internal ring gear teeth of a second annular gear174. The second annular gear174is mounted to rotate about the centerline of the rotatable main shaft74via a second annular gear bearing175. As discussed above with regard to the first drive shaft, the actuation assembly142can also be designed to accommodate a range of axial motion of the second drive shaft88, for example, by designing the second annular gear174and the opening in the main shaft coupling fitting168for a range of axial motion of the second drive shaft88.

FIG. 12is a perspective view illustrating components of the actuation assembly142ofFIG. 10that are used to actuate a second offset internal drive shaft, in accordance with many embodiments. The second motor102is rotationally coupled with a second motor gear176. The second motor gear176engages and drives a second coupling shaft proximal gear178, which drives a second coupling shaft180. The second coupling shaft180in turn rotates a second coupling shaft distal gear182. The second coupling shaft distal gear182engages the second annular gear174, which includes both external gear teeth that engage the second coupling shaft distal gear182and internal ring gear teeth. The second annular gear174is mounted to rotate about the centerline of the rotatable main shaft via a second annular gear bearing. In operation, rotation of the second motor102rotates the second motor gear176, which rotates the second coupling shaft proximal gear178, which rotates the second coupling shaft180, which rotates the second coupling shaft distal gear182, which rotates the second annular gear174, which rotates the second drive shaft gear172, which rotates the second drive shaft88relative to the rotatable main shaft74.

In many embodiments, the main shaft coupling fitting168includes external gear teeth184engaged with a main shaft interface94(not shown) that is driven by the main shaft motor90(not shown.) The main shaft interface94and the main shaft motor90can be located on a tool manipulator136(shown inFIG. 8) so as to be coupled with the main shaft coupling fitting168when the proximal tool chassis134is mounted on a tool manipulator136.

FIG. 13is a perspective view of a cross section of components of the actuation assembly ofFIG. 10, illustrating various components and the routing of end effector control cables, in accordance with many embodiments. The proximal tool chassis134includes a base186that provides a mounting base for various components. The main shaft coupling fitting168is mounted to rotate relative to the base186via two bearings188. The main shaft coupling fitting168supports the rotatable main shaft74. The main shaft74has an axial bore through which the first drive shaft86, the second drive shaft88, and two pairs of control cables114are routed. The first drive shaft86and the second drive shaft88are offset from the centerline of the main shaft coupling fitting168and the rotatable main shaft74, which allows the control cables114to be routed along the centerline of the main shaft. In many embodiments, rotation of the main shaft relative to the base produces twisting of control cables114due to the corresponding rotation of the end effector base relative to the proximal chassis base186. Routing the control cables114along the centerline of the main shaft may help to reduce detrimental impacts to the operation of the control cables that may occur in connection with such twisting, for example, by reducing cable to cable frictional forces and/or by reducing associated control cable stretching.

In many embodiments, a pair of control cables is actuated by a common actuation mechanism, for example, by a capstan around which the pair of control cables is wrapped. Such a common actuation mechanism can be used to retract one control cable of a pair of control cables while the other control cable of the pair is let out by a corresponding amount.FIG. 13illustrates a first capstan190for actuating a first control cable pair and a second capstan192for actuating a second control cable pair.

In many embodiments, the first drive shaft86is rotationally coupled with a first drive shaft extension200via a first splined coupling194that couples a distal end of the first drive shaft86with a proximal end of the first drive shaft extension200. The first splined coupling194can be used to enable the use of a conveniently sized first drive shaft86, for example, so that the first drive shaft86can be produced without undue expense, and so as to be more easily assembled into the overall assembly. The first splined coupling194can also provide for the accommodation of a range of axial motion of the first drive shaft extension200, which, as discussed above, may result during the articulation of the end effector base relative to the main shaft due to the first drive shaft extension200being offset from the main shaft centerline. Likewise, a second splined coupling196can be used in connection with the second offset drive shaft88, and may provide similar benefits.

FIG. 14is a cross-sectional view of components of the actuation assembly ofFIG. 10, further illustrating various components and the routing of end effector control cables, in accordance with many embodiments. The internal ring gear teeth of the first annular gear156interact with the first drive shaft gear166so that rotation of the first annular gear156relative to the main shaft coupling fitting produces a corresponding rotation of the first drive shaft86relative to the main shaft coupling fitting. The internal ring gear teeth of the second annular gear174interact with the second drive shaft gear172so that rotation of the second annular gear174relative to the main shaft coupling fitting produces a corresponding rotation of the second drive shaft88relative to the main shaft coupling fitting.

FIG. 15Ais a perspective view of the main shaft coupling fitting168, in accordance with many embodiments. The main shaft coupling fitting168includes a number of openings, slots, fastener holes, as well as external gear teeth. A first opening206accommodates the protruding gear teeth of the first drive shaft gear166. A second opening208accommodates the protruding gear teeth of the second drive shaft gear172. A third opening210accommodates a protruding feature of a drive shaft bearing support fitting used to support the proximal end of the second drive shaft. A number of fastener holes212are provided that accommodate drive shaft support bearing mounting fasteners. In many embodiments, the main shaft coupling fitting168includes symmetrical features so as to allow for a reversible installation of the first and second drive shafts. The external gear teeth184are used to rotate the main shaft coupling fitting168relative to the base of the proximal tool chassis. Two slots214accommodate the first splined coupling194and the second splined coupling196.

FIG. 15Bis a perspective view of an internal subassembly that includes the two internal offset drive shafts and associated support bearing mounting components, in accordance with many embodiments. The first drive shaft proximal portion198and the second drive shaft proximal portion202are received within bearings that are supported by four internal support fittings216. The four internal support fittings216are held in position within the main shaft coupling fitting168via a corresponding four external support fittings218, which are coupled with the internal support fittings216via two fasteners220per fitting pair.

FIGS. 15C and 15Dare views showing the combination of the components ofFIGS. 15A and 15B, in accordance with many embodiments.FIG. 15Cis a perspective view of the combination andFIG. 15Dshows an end view, which shows the fasteners220, the external gear teeth184, an external support fitting218, the first drive shaft gear166, the second drive shaft gear172, two internal support fittings216, and a retainer ring222used to secure the second drive shaft proximal end relative to an internal support fitting216. A central space224located between adjacent internal support fittings216accommodates the routing of the control cables (not shown).

Alternative approaches can be used to support an offset internal drive shaft. For example,FIG. 16is a perspective view of an actuation assembly230having a reduced part count configuration. The actuation assembly230provides for the independent actuation of the above described two offset drive shaft86,88, but eliminates some of the above described components used to support the two offset drive shafts86,88. The actuation assembly230does include some of the above describe components, for example, the first drive shaft86(hidden from view), the second drive shaft88, the first annular gear156, and the second annular gear174. The actuation assembly230includes a main shaft coupling fitting168A that is configured with integrated support for the drive shaft support bearings. Similar to the above described main shaft coupling fitting168, the main shaft coupling fitting168A includes external gear teeth184for engagement with the above described main shaft interface94(not shown).

FIG. 17is a perspective cross-sectional view of the actuation assembly230, illustrating details of the integration of the support for the drive shaft bearings into the main shaft coupling fitting168A. The main shaft coupling fitting168A is configured with externally accessible recesses232,234,236that interface with first drive shaft support bearings164A,164B and second drive shaft support bearings170A,170B. Retainer rings244,246are used to retain the support bearings164A,164B within the recess234. Retainer rings240,242are used to retain the support bearings170A,170B within the recess236. The distally disposed recess232is shaped to accommodate the distal end of the first drive shaft86. The proximally disposed recess234is shaped to support the proximally disposed support bearings164A,164B and to accommodate the proximal end of the first drive shaft86. The main shaft coupling fitting168A includes a bore238configured to slidingly receive and accommodate the first drive shaft86. The distally disposed recess236is shaped to support the support bearings170A,170B and to accommodate the second drive shaft88.

The first drive shaft86can be assembled into the actuation assembly230using the following assembly sequence. First, the support bearing164A is placed in its installed position. The retainer ring244is then moved from the proximal end of the main shaft coupling fitting168A into its installed position. A subassembly comprising the first annular gear156and the first annular gear bearing162is then moved from the proximal end of the main shaft coupling fitting168A into its installed position. The first drive shaft86is then installed by threading the distal end of the first drive shaft86through the support bearing164A, and through the bore238. The support bearing164B is then slid along the recess234into its installed position. Finally, the retainer ring246is then moved from the proximal end of the main shaft coupling fitting168A into its installed position. A similar sequence can be used for the installation of the second drive shaft88into the actuation assembly230.

FIGS. 18A and 18Bare proximal and distal end views, respectively, of the actuation assembly230.FIG. 18Ashows the proximally located support bearing164B relative to the proximal recess234and the first drive shaft86. The retainer rings240,242,244,246are locally shaped to accommodate the support bearings170A,170B,164A,164B, respectively.FIG. 18Bshows the distal ends of the first drive shaft86and the second drive shaft88, the associated recesses234,236in the main shaft coupling fitting168A, as well as the support bearing170A disposed in the recess236.

FIG. 19is a plan view illustration of the integration of the actuation assembly230within a proximal tool chassis250, in accordance with many embodiments. In addition to supporting and actuating the actuation assembly230, the proximal tool chassis250further includes actuation and routing components for three pairs of control cables that are routed within the rotatable main shaft.

FIG. 20is a simplified perspective view diagrammatic illustration of a surgical assembly260, in accordance with many embodiments. The surgical assembly260includes a proximal actuation mechanism262, a rotatable main shaft264, an end effector266, and a wrist mechanism268. The end effector266can include one or more shaft driven mechanisms (e.g., a clamping mechanism, a linear cutting mechanism, a stapling mechanism). The surgical assembly260can also include one or more cable actuated mechanisms, for example, a cable actuation mechanism that articulates a base of the end effector relative to the main shaft via the wrist mechanism268, and/or a cable actuation mechanism that articulates a portion of the end effector relative to the end effector base. The proximal actuation mechanism262can include the above discussed actuation mechanism for the mounting and actuation of one or more offset drive shafts routed within the rotatable main shaft264. The proximal actuation mechanism262can be configured for use in a variety of applications, for example, as a hand held device with manual and/or automated actuation for the rotation of the main shaft264and/or the one or more internal drive shafts. As such, the surgical assembly260can have applications beyond minimally invasive robotic surgery, for example, non-robotic minimally invasive surgery, non-minimally invasive robotic surgery, non-robotic non-minimally invasive surgery, as well as other applications where the use of one or more offset drive shafts within a rotatable outer shaft would be beneficial.

FIG. 21is a simplified flow diagram of a method270for transmitting torque through an offset drive shaft routed within a rotatable main shaft, in accordance with many embodiments. In step272, a main shaft is supported to rotate relative to a base. In step274, a drive shaft is supported to rotate relative to the main shaft about a drive shaft rotational axis that is offset from the main shaft rotational axis. In step276, the offset drive shaft is engaged with a drive feature having a rotational axis that is fixed relative to the base. In step278, the main shaft is rotated relative to the base. In step280, the drive shaft is rotated relative to the main shaft by rotating the drive feature relative to the main shaft. The steps of method270can be accomplished, for example, using the embodiments discussed above with respect toFIG. 6throughFIG. 19.

FIG. 22is a simplified flow diagram of a minimally invasive surgical method290, in accordance with many embodiments. In step292, an end effector of a surgical tool is introduced to a surgical site, for example, an internal surgical site via a minimally invasive aperture or natural body orifice. The end effector is mounted to a distal end of an elongated instrument shaft mounted to rotate relative to a base so that the end effector can be rotated with the instrument shaft relative to the base. The end effector is operatively coupled with a first drive shaft so that rotating the first drive shaft relative to the instrument shaft actuates an end effector first mechanism, the first drive shaft being mounted to rotate relative to the instrument shaft about a first drive shaft rotational axis that is offset from the instrument shaft rotational axis. In step294, the end effector is rotated by rotating the instrument shaft. In step296, a surgical task is performed with the end effector by actuating the end effector first mechanism.

In many embodiments, the method290involves the use of an end effector that is actuated by two drive shafts. A wide range of end effector mechanisms can be drive shaft actuated. For example, the end effector can include a clamping feature actuated by the first drive shaft. The end effector can include a movable cutting feature actuated by the second drive shaft. The surgical task can include clamping tissue with the clamping feature and cutting tissue with the movable cutting feature. The second drive shaft can be mounted to rotate relative to the instrument shaft about a second drive shaft rotational axis that is offset from the instrument shaft rotational axis. The end effector can include a cutting and stapling device actuated by the second drive shaft. The surgical task can include clamping tissue with the clamping feature, stapling tissue with the cutting and stapling device, and cutting tissue with the cutting and stapling device.

It is understood that the examples and embodiments described herein are for illustrative purposes and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims. Numerous different combinations are possible, and such combinations are considered to be part of the present invention.