CIRCULARITY SYSTEMS AND METHODS FOR HIGH ARTICULATION SURGICAL TOOLS

A method of replacing a consumable of a surgical tool includes securing the surgical tool, which includes a drive housing, an elongate shaft, an end effector arranged at a distal end of the shaft and including opposing first and second jaws, a wrist interposing the shaft and the end effector, and a plurality of drive cables extending proximally from the end effector and through the wrist. The method further includes moving the shaft proximally away from the end effector and deeper into the drive housing, detaching the drive cables from the jaws, removing the end effector and the wrist from proximal portions of the surgical tool, replacing the consumable of the surgical tool, reconnecting the end effector and the wrist to the proximal portions of the surgical tool, reconnecting the drive cables to the jaws, and moving the elongate shaft distally toward the wrist and the end effector.

BACKGROUND

Minimally invasive surgical (MIS) instruments are often preferred over traditional open surgical devices due to reduced post-operative recovery time and minimal scarring. Laparoscopic surgery is one type of MIS procedure in which one or more small incisions are formed in the abdomen of a patient and a trocar is inserted through the incision to form a pathway that provides access to the abdominal cavity. Through the trocar, a variety of instruments and surgical tools can be introduced into the abdominal cavity. The instruments and tools introduced into the abdominal cavity via the trocar can be used to engage and/or treat tissue in a number of ways to achieve a diagnostic or therapeutic effect.

Various robotic systems have been developed to assist in MIS procedures. Robotic systems can allow for more instinctive hand movements by maintaining natural eye-hand axis. Robotic systems can also allow for more degrees of freedom in movement by including an articulable “wrist” joint that creates a more natural hand-like articulation. In such systems, an end effector positioned at the distal end of the instrument can be articulated (moved) using a cable driven motion system having one or more drive cables that extend through the wrist joint. A user (e.g., a surgeon) is able to remotely operate the end effector by grasping and manipulating in space one or more controllers that communicate with a tool driver coupled to the surgical instrument. User inputs are processed by a computer system incorporated into the robotic surgical system, and the tool driver responds by actuating the cable driven motion system. Moving the drive cables articulates the end effector to desired angular positions and configurations.

MIS instruments incorporate various high-wear components that, over time, can mechanically or physically degrade and thereby limit the useful life of the instrument. Consequently, most MIS instruments are designed to be used only for a predetermined number a procedures, following which the instrument is often discarded. As can be appreciated, this can have an adverse impact on the environment.

In an effort to maintain the value of products, while simultaneously not creating additional environmental waste, companies and manufacturers are progressively looking for ways to incorporate “circularity” into their business model. Circularity is an economic model that follows the three “Rs”: reuse, reprocess, and recycle, and aims to retain the lifespan of products through repair and maintenance, reusing, remanufacturing, or upcycling.

What is needed is a process or methodology of circularity concerning the reuse and recycling of MIS instruments, which minimizes the impact on the environment.

DETAILED DESCRIPTION

The present disclosure is related to surgical tools and, more particularly, to prolonging the lifespan of surgical tools by implementing circularity systems and methods that result in replacement of one or more consumables included in the surgical tool.

The utilization or “lifespan” of a majority of robotic (and non-robotic) surgical tools is often limited due to the life or durability of just a few components within the surgical tool, referred to herein as “consumables”. Embodiments disclosed herein describe how the design of the surgical tool can be modified to enable the consumable to be replaced rather easily, without requiring the surgical tool to be completely disassembled. Accordingly, the embodiments disclosed herein may prove advantageous in mitigating or entirely eliminating the need to scrap an entire surgical tool, but instead rehabilitate the used surgical tool by replacing one or more consumables.

FIG.1is a block diagram of an example robotic surgical system100that may incorporate some or all of the principles of the present disclosure. As illustrated, the system100can include at least one set of user input controllers102aand at least one control computer104. The control computer104may be mechanically and/or electrically coupled to a robotic manipulator and, more particularly, to one or more robotic arms106(alternately referred to as “tool drivers”). In some embodiments, the robotic manipulator may be included in or otherwise mounted to an arm cart capable of making the system portable. Each robotic arm106may include and otherwise provide a location for mounting one or more surgical instruments or tools108for performing various surgical tasks on a patient110. Operation of the robotic arms106and associated tools108may be directed by a clinician112a(e.g., a surgeon) from the user input controller102a.

In some embodiments, a second set of user input controllers102b(shown in dashed line) may be operated by a second clinician112bto direct operation of the robotic arms106and tools108via the control computer104and in conjunction with the first clinician112a. In such embodiments, for example, each clinician112a,bmay control different robotic arms106or, in some cases, complete control of the robotic arms106may be passed between the clinicians112a,bas needed. In some embodiments, additional robotic manipulators having additional robotic arms may be utilized during surgery on the patient110, and these additional robotic arms may be controlled by one or more of the user input controllers102a,b.

The control computer104and the user input controllers102a,bmay be in communication with one another via a communications link114, which may be any type of wired or wireless telecommunications means configured to carry a variety of communication signals (e.g., electrical, optical, infrared, etc.) according to any communications protocol. In some applications, for example, there is a tower with ancillary equipment and processing cores designed to drive the robotic arms106.

The user input controllers102a,bgenerally include one or more physical controllers that can be grasped by the clinicians112a,band manipulated in space while the surgeon views the procedure via a stereo display. The physical controllers generally comprise manual input devices movable in multiple degrees of freedom, and which often include an actuatable handle for actuating the surgical tool(s)108, for example, for opening and closing opposing jaws, applying an electrical potential (current) to an electrode, or the like. The control computer104can also include an optional feedback meter viewable by the clinicians112a,bvia a display to provide a visual indication of various surgical instrument metrics, such as the amount of force being applied to the surgical instrument (i.e., a cutting instrument or dynamic clamping member).

FIG.2is an isometric side view of an example surgical tool200that may incorporate some or all of the principles of the present disclosure. The surgical tool200may be the same as or similar to the surgical tool(s)108ofFIG.1and, therefore, may be used in conjunction with a robotic surgical system, such as the robotic surgical system100ofFIG.1. Accordingly, the surgical tool200may be designed to be releasably coupled to a tool driver included in the robotic surgical system100. In other embodiments, however, aspects of the surgical tool200may be adapted for use in a manual or hand-operated manner, without departing from the scope of the disclosure.

As illustrated, the surgical tool200includes an elongated shaft202, an end effector204, a wrist206(alternately referred to as a “wrist joint” or an “articulable wrist joint”) that couples the end effector204to the distal end of the shaft202, and a drive housing208coupled to the proximal end of the shaft202. In applications where the surgical tool is used in conjunction with a robotic surgical system (e.g., the robotic surgical system100ofFIG.1), the drive housing208can include coupling features that releasably couple the surgical tool200to the robotic surgical system.

The terms “proximal” and “distal” are defined herein relative to a robotic surgical system having an interface configured to mechanically and electrically couple the surgical tool200(e.g., the housing208) to a robotic manipulator. The term “proximal” refers to the position of an element closer to the robotic manipulator and the term “distal” refers to the position of an element closer to the end effector204and thus further away from the robotic manipulator. Alternatively, in manual or hand-operated applications, the terms “proximal” and “distal” are defined herein relative to a user, such as a surgeon or clinician. The term “proximal” refers to the position of an element closer to the user and the term “distal” refers to the position of an element closer to the end effector204and thus further away from the user. Moreover, the use of directional terms such as above, below, upper, lower, upward, downward, left, right, and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward or upper direction being toward the top of the corresponding figure and the downward or lower direction being toward the bottom of the corresponding figure.

During use of the surgical tool200, the end effector204is configured to move (pivot) relative to the shaft202at the wrist206to position the end effector204at desired orientations and locations relative to a surgical site. To accomplish this, the housing208includes (contains) various drive inputs and mechanisms (e.g., gears, actuators, etc.) designed to control operation of various features associated with the end effector204(e.g., clamping, firing, cutting, rotation, articulation, etc.). In at least some embodiments, the shaft202, and hence the end effector204coupled thereto, is configured to rotate about a longitudinal axis A1of the shaft202. In such embodiments, at least one of the drive inputs included in the housing208is configured to control rotational movement of the shaft202about the longitudinal axis A1.

The shaft202is an elongate member extending distally from the housing208and has at least one lumen extending therethrough along its axial length. In some embodiments, the shaft202may be fixed to the housing208, but could alternatively be rotatably mounted to the housing208to allow the shaft202to rotate about the longitudinal axis A1. In yet other embodiments, the shaft202may be releasably coupled to the housing208, which may allow a single housing208to be adaptable to various shafts having different end effectors.

The end effector204can exhibit a variety of sizes, shapes, and configurations. In the illustrated embodiment, the end effector204comprises a needle driver that includes opposing first (upper) and second (lower) jaws210,212configured to move (articulate) between open and closed positions. As will be appreciated, however, the opposing jaws210,212may alternatively form part of other types of end effectors such as, but not limited to, a surgical scissors, a clip applier, a tissue grasper, a vessel sealer, a combination tissue grasper and vessel sealer, a babcock including a pair of opposed grasping jaws, bipolar jaws (e.g., bipolar Maryland grasper, forceps, a fenestrated grasper, etc.), etc. One or both of the jaws210,212may be configured to pivot to articulate the end effector204between the open and closed positions.

FIG.3illustrates the potential degrees of freedom in which the wrist206may be able to articulate (pivot) and thereby move the end effector204. The wrist206can have any of a variety of configurations. In general, the wrist206comprises a joint configured to allow pivoting movement of the end effector204relative to the shaft202. The degrees of freedom of the wrist206are represented by three translational variables (i.e., surge, heave, and sway), and by three rotational variables (i.e., Euler angles or roll, pitch, and yaw). The translational and rotational variables describe the position and orientation of the end effector204with respect to a given reference Cartesian frame. As depicted inFIG.3, “surge” refers to forward and backward translational movement, “heave” refers to translational movement up and down, and “sway” refers to translational movement left and right. With regard to the rotational terms, “roll” refers to tilting side to side, “pitch” refers to tilting forward and backward, and “yaw” refers to turning left and right.

The pivoting motion can include pitch movement about a first axis of the wrist206(e.g., X-axis), yaw movement about a second axis of the wrist206(e.g., Y-axis), and combinations thereof to allow for 360° rotational movement of the end effector204about the wrist206. In other applications, the pivoting motion can be limited to movement in a single plane, e.g., only pitch movement about the first axis of the wrist206or only yaw movement about the second axis of the wrist206, such that the end effector204moves only in a single plane.

Referring again toFIG.2, the surgical tool200may also include a plurality of drive cables (obscured inFIG.2) that form part of a cable driven motion system configured to facilitate actuation and articulation of the end effector204relative to the shaft202. Moving (actuating) one or more of the drive cables moves the end effector204between an unarticulated position and an articulated position. The end effector204is depicted inFIG.2in the unarticulated position where a longitudinal axis A2of the end effector204is substantially aligned with the longitudinal axis A1of the shaft202, such that the end effector204is at a substantially zero angle relative to the shaft202. Due to factors such as manufacturing tolerance and precision of measurement devices, the end effector204may not be at a precise zero angle relative to the shaft202in the unarticulated position, but nevertheless be considered “substantially aligned” thereto. In the articulated position, the longitudinal axes A1, A2would be angularly offset from each other such that the end effector204is at a non-zero angle relative to the shaft202.

Similar to most surgical tools, the surgical tool200includes various high-wear components referred to herein as “consumables” that, over time, can mechanically or physically degrade and thereby limit the useful life of the surgical tool200. Consequently, the surgical tool200may be designed to be used for only a predetermined number of procedures. Once the predetermined number of procedures is reached, the operator (e.g., a nurse, a doctor, etc.) may be unable to continue using the surgical tool200. In such cases, the surgical tool200would conventionally be discarded, which can have an adverse impact on the environment.

According to embodiments of the present disclosure, instead of discarding the surgical tool200, the surgical tool200may be subject to circularity processing or a circular economy model or approach designed to reprocess and recycle the surgical tool200for further use. In circularity processing, the surgical tool200is decommissioned upon reaching the predetermined number of procedures, and then subsequently sent to a service center where trained technicians clean and mount the surgical tool200to a disassembly fixture. While mounted to the disassembly fixture, various portions of the surgical tool200may be disassembled to access and remove one or more consumables forming part of the surgical tool200. The removed consumables can then be cleaned and refurbished or replaced with new consumables. The surgical tool200may then be reassembled, cleaned, tested, delivered to a distribution center, and subsequently sent to an end user (e.g., a hospital, a surgeon, an operator, etc.) for further use.

FIG.4is an isometric side view of an example surgical tool circularity processing system400, according to one or more embodiments. As illustrated, the surgical tool circularity processing system400includes a disassembly fixture402configured to receive and mount the surgical tool200. The disassembly fixture402may be provided at a service center that employs technicians trained to clean, disassemble, and refurbish the surgical tool200, as described herein.

As illustrated, the disassembly fixture402provides an elongate base404having a first or “distal” end406aand a second or “proximal” end406bopposite the distal end406a. In some embodiments, as illustrated, the base404may exhibit a generally rectangular shape, but could alternatively exhibit other shapes without departing from the scope of the disclosure.

A drive housing mount408may be provided at the proximal end406band configured to receive and seat the drive housing208, which may include a bottom portion410amateable with a top portion410b. In the illustrated embodiment, the drive housing208is shown received within the drive housing mount408such that the bottom portion410afaces upwards and is otherwise exposed. In such embodiments, some or all of the bottom portion410amay be removed by the technician to access various internal components of the drive housing208, as described in more detail below. In other embodiments, or in addition thereto, a robotic manipulator (not shown) may be attached to the bottom portion410ato manipulate and operate one or more drive inputs412rotatably mounted to the bottom of the drive housing208. In other embodiments, however, the drive housing208may be received within the drive housing mount408with the top portion410bfacing upwards, without departing from the scope of the disclosure.

As illustrated, the drive housing mount408may include a plurality of structural elements extending from or otherwise forming part of the body404and designed to receive and seat the drive housing208. More particularly, the drive housing mount408may include a cradle or “yoke”414, a rear support416, and one or more side supports418(two visible) provided at various locations between the yoke414and the rear support416. The yoke414may be configured to support the distal end of the drive housing208, and the rear support416may be configured to support the proximal end of the drive housing208. The side supports418may be configured to support the lateral sides of the drive housing208.

In some embodiments, the drive housing mount408may further include a clamp420operable to secure the drive housing208to the base404when properly received within the drive housing mount408. In some embodiments, as illustrated, the clamp420may be mounted to the rear support416, but could alternatively be mounted other portions of the drive housing mount408or the base404, without departing from the scope of the disclosure.

A vise, referred to herein as an “end effector mount”422, may be provided and otherwise defined at or near the distal end406aof the base404and configured to receive and seat the distal end of the surgical tool200. More specifically, and as shown in the enlarged, inset graphic, the end effector mount422may include a bracket or stand424and a securing clasp or mechanism426may be pivotably attached to the stand424. The securing mechanism426may include a pivot joint428, a securing bar430extending from the pivot joint428, and a mechanical fastener432arranged at the end of the securing bar430opposite the pivot joint428. As mounted to the pivot joint428, the securing bar430may be vertically offset a short distance from the stand424, such that a gap434is provided between the securing bar430and the top of the stand424. The gap434may be large enough to receive the distal end of the surgical tool200when the securing mechanism426is secured to the stand424.

To secure the distal end of the surgical tool200to the disassembly fixture402and, more particularly, to the end effector mount422, the distal end of the surgical tool200is first placed atop the stand424such that the shaft202or portions of the wrist206engage the top of the stand424. In some embodiments, as illustrated, the top of the stand424may define and otherwise provide an arcuate groove436sized to receive and seat the distal end of the surgical tool200; e.g., the wrist206and/or the end effector204. The securing bar430may then be pivoted about the pivot joint428until the mechanical fastener432is able to locate and mate with a corresponding securing receptor433(e.g., a threaded aperture). Operating or otherwise securing the mechanical fastener432to the securing receptor433may place a load on the distal end of the surgical tool200, which helps prevent the surgical tool200from moving up or down, or translating axially. In the illustrated embodiment, the mechanical fastener432comprises a thumbscrew, but could alternatively comprise other types of mechanical fasteners or fastening means suitable for securing the securing bar430to the stand424and thereby helping to secure the surgical tool200to the disassembly fixture402.

Those skilled in the art will readily appreciate that the end effector mount422including the securing mechanism426is merely one example embodiment consistent with the principles of the present disclosure. Indeed, other means and configurations of the end effector mount422and/or the securing mechanism426are possible and contemplated herein, without departing from the scope of the disclosure.

FIGS.5A and5Bare enlarged isometric views of the distal end of the surgical tool200mounted to the end effector mount422, according to one or more embodiments. Once the distal end of the surgical tool200is properly mounted to the end effector mount422, as shown inFIG.5A, the shaft202may be moved and otherwise translated proximally relative to and away from the end effector204(not visible), as indicated by the arrow B inFIG.5B.

In some embodiments, to move the shaft202in the proximal direction B, a distal end502of the shaft202may need to be released from a proximal clevis sleeve504operatively coupled to or forming part of the wrist206(mostly occluded). The proximal clevis sleeve504, alternately referred to as a “shaft adapter,” may be a generally cylindrical and hollow structure sized to receive and secure the distal end502of the shaft202within its interior. The distal end502of the shaft202may be releasably coupled to the proximal clevis sleeve504and releasable from the proximal clevis sleeve504by applying opposing, radially-inward directed loads (e.g., pinching) against the proximal clevis sleeve504, as shown by the arrows C inFIG.5A. Applying the opposing radial loads C causes the proximal clevis sleeve504to elastically deform, which releases the distal end502from the proximal clevis sleeve504and allows the shaft202to move proximally B and away from the proximal clevis sleeve504.

FIG.5Cis an enlarged, isometric view of the proximal clevis sleeve504and the distal end502of the shaft202, according to one or more embodiments. The proximal clevis sleeve504is shown inFIG.5Cin phantom (dashed lines) to enable viewing of an example releasable connection506operable to releasably connect the distal end502of the shaft202to the proximal clevis sleeve504. In some embodiments, as illustrated, the releasable connection506may include one or more dimples or “projections”508provided on the inner radial surface of the proximal clevis sleeve504and configured to be received within a corresponding one or more grooves510defined on the outer radial surface of the shaft202at or near the distal end502.

While the projections508are shown provided on the inner radial surface of the proximal clevis sleeve504and the grooves510are shown on the outer radial surface of the shaft202, it will be appreciated that the location of the projections508and the grooves510may be switched, without departing from the scope of the disclosure. Moreover, whileFIG.5Cdepicts a single projection508received within a corresponding single groove510, the releasable connection506may include additional projections508and corresponding grooves510at other angular locations. In at least one embodiment, for example, a second projection508and corresponding second groove510may be provided on the angular opposite side of the proximal clevis sleeve504(180° offset).

Referring now toFIGS.5D and5E, with continued reference toFIG.5C, illustrated are isometric and end views, respectively, of the proximal clevis sleeve504, according to one or more embodiments. As illustrated, the proximal clevis sleeve504may include two projections508arranged on angular opposite sides of the inner radial surface of the proximal clevis sleeve504. The projections508protrude radially inward to be able to be received within corresponding grooves510provided on the shaft202. In some embodiments, as illustrated, the projections508may provide rounded and otherwise curved outer surfaces, which may be advantageous in allowing the projections508to be more easily received within and dislodged from the grooves510as the axial position of the shaft202is manipulated.

In some embodiments, the proximal clevis sleeve504may be made of an elastic or semi-rigid material, such as a plastic or a metal, which may be able to flex upon assuming the opposing radial loads C, as described above. As illustrated, the opposing radial loads C may be applied to the proximal clevis sleeve504at a location perpendicular to the angular position of the projections508(90° offset) and otherwise in a plane perpendicular to a plan passing through the projections508. Upon assuming the opposing radial loads C, the proximal clevis sleeve504may flex radially outward at the location of the projections508and transition into a generally oval shape. As will be appreciated, this allows the projections508to radially separate and dislodge from the corresponding grooves510, thereby allowing the shaft202to be removed from the interior of the proximal clevis sleeve504.

FIGS.6A and6Bare enlarged isometric views of the drive housing208. More specifically,FIGS.6A-6Bdepict progressive steps to free the proximal end of the shaft202, thereby allowing the shaft202to move in the proximal direction B and deeper into the interior of the drive housing208. As illustrated, the shaft202extends through an aperture602defined in the drive housing208and extends into the interior of the drive housing208. The proximal end of the shaft202may be secured within the interior the drive housing208such that the shaft202is prevented from translating axially in either direction (distally or proximally). In order to shift the shaft202in the proximal direction B, as discussed above with reference toFIG.5B, the proximal end of the shaft202must first be freed from engagement with the drive housing208

In some embodiments, an access panel or “carriage cover”604may be provided on the bottom portion410aof the drive housing208. In at least one embodiment, as illustrated, the carriage cover604may be mechanically fastened to the bottom portion410using one or more mechanical fasteners606(one shown). Once the carriage cover604is removed, a technician can access the interior the drive housing208and, specifically, the portion of the shaft202that needs to be disengaged to allow the shaft202to move in the proximal direction B.

Referring toFIG.6B, one or more retention clips608(one shown) may be mounted within the interior of the drive housing208and configured to secure the shaft202at a distal position. Removing the carriage cover604may allow a technician to access the retention clip608. Once the retention clip608is removed, the shaft202may be able to move in the proximal direction B. In the illustrated embodiment, the retention clip608comprises a type of C-clip or U-clip capable of extending partially around another object, such as the shaft202or a structure adjacent the shaft202and able to interact with the shaft202, such as a shaft collar. When the shaft202is in its distal-most position, as shown inFIGS.2,4, and5A, the retention clip608may be arranged to abut or engage a portion of the shaft202, thereby preventing the shaft202from moving in the proximal direction B.

To be able to move the shaft202proximally B, as described in the process outlined inFIGS.5A and5Babove, the retention clip608must either be removed or flexed out of engagement with the proximal end of the shaft202. In embodiments, where the retention clip608comprises a C-clip, a U-clip or the like, the retention clip608may be manually removed by a technician and otherwise flexed out of engagement with the shaft202. Those skilled in the art, however, will readily recognize that the retention clip608may comprise other types of mechanical components or devices capable of securing the shaft202in its distal-most position, without departing from the scope of the disclosure.

FIG.6Cis an enlarged bottom view of the drive housing208, according to one or more additional embodiments. InFIG.6C, the carriage cover604is shown in phantom (dashed lines), thereby exposing a retention clip610arranged within the interior of the drive housing208. The retention clip610may be similar in some respects to the retention clip608ofFIG.6B. For example, similar to the retention clip608, the retention clip610may comprise a C-clip, a U-clip, or the like. Moreover, the retention clip610may be configured to extend at least partially about the outer circumference of the shaft202and thereby secure the shaft202at a distal position. Furthermore, removing the retention clip610from engagement with the shaft202may allow the shaft202to move in the proximal direction B. Unlike the retention clip608, however, the retention clip610may not need to be removed entirely from the interior of the drive housing208. Rather, the retention clip610need only be slightly opened and flexed out of engagement with the shaft202by a technician, which enables the shaft202to be moved proximally B and further into the interior of the drive housing208.

FIGS.7A and7Bare enlarged views of the distal end of the surgical tool200, according to one or more embodiments. More specifically,FIGS.7A-7Bare enlarged views of the end effector204and the wrist206and include corresponding upper and lower images, where the upper image is a side view of the end effector204and the wrist206, and the lower image is rotated 90° to provide a top view of the same. Moreover, the upper image includes the end effector mount422, and the securing mechanism426is shown clamped down against a portion of the wrist206, which interposes the end effector204and the proximal clevis sleeve504. InFIGS.7A-7B, the shaft202has been removed from the proximal clevis sleeve504, as generally described above with reference toFIGS.5A-5B, and the end effector204is shown in the unarticulated position where the jaws210,212are closed.

FIGS.7A-7Balso show progressive manipulation of the end effector204relative to the wrist206, in accordance with the disassembly procedures described herein. More particularly,FIG.7Ashows the end effector204in a first or “assembled” state, where the end effector204is operationally mounted to the wrist206, andFIG.7Bshows the end effector204moved distally to a second or “extended” state.

Referring first toFIG.7A, the wrist206operatively couples the end effector204to the shaft202, and in the illustrated embodiment, to the proximal clevis sleeve504, which couples to the shaft202as generally described above. To accomplish this, the wrist206includes a distal clevis702aand a proximal clevis702b. The end effector204(i.e., the jaws210,212) is rotatably mounted to the distal clevis702aat a first axle704a(lower image), the distal clevis702ais rotatably mounted to the proximal clevis702bat a second axle704b(upper image), and the proximal clevis702bis coupled to the proximal clevis sleeve504(upper image). In the illustrated depiction, the securing mechanism426is clamped down against the proximal clevis702bto secure the wrist206and the end effector204to the end effector mount422. In other embodiments, however, the securing mechanism426may be clamped down against other portions of the wrist206, without departing from the scope of the disclosure.

The wrist206provides a first pivot axis P1that extends through the first axle704aand a second pivot axis P2that extends through the second axle704b. The first pivot axis P1is substantially perpendicular (orthogonal) to the longitudinal axis A2of the end effector204, and the second pivot axis P2is substantially perpendicular (orthogonal) to both the longitudinal axis A2and the first pivot axis P1. Movement about the first pivot axis P1provides “yaw” articulation of the end effector204, and movement about the second pivot axis P2provides “pitch” articulation of the end effector204. In the illustrated embodiment, the jaws210,212are mounted at the first pivot axis P1, thereby allowing the jaws210,212to pivot relative to each other to open and close the end effector204or alternatively pivot in tandem to articulate the orientation of the end effector204.

As best seen in the lower image ofFIG.7A, a plurality of drive cables, shown as drive cables706a,706b,706c, and706d, extend proximally from the end effector204and extend through the wrist206. The drive cables706a-dmay form part of the cable driven motion system housed within the drive housing208(FIG.2), and may comprise cables, bands, lines, cords, wires, woven wires, ropes, strings, twisted strings, elongate members, belts, shafts, flexible shafts, drive rods, or any combination thereof. The drive cables706a-dcan be made from a variety of materials including, but not limited to, a metal (e.g., tungsten, stainless steel, nitinol, etc.), a polymer (e.g., ultra-high molecular weight polyethylene), a synthetic fiber (e.g., KEVLAR®, VECTRAN®, etc.), an elastomer, or any combination thereof. While four drive cables706a-dare depicted inFIG.6B, more or less than four may be employed, without departing from the scope of the disclosure.

The drive cables706a-dextend from the end effector204toward the drive housing208(FIGS.2and4) where they are operatively coupled to various actuation mechanisms or devices that facilitate longitudinal movement (translation) of the drive cables706a-d. Selective actuation of the drive cables706a-dat the drive housing208applies tension (i.e., pull force) to the given drive cable706a-din the proximal direction, which urges the given drive cable706a-dto translate longitudinally. More specifically, selective actuation causes a corresponding drive cable706a-dto translate longitudinally and thereby cause pivoting movement of the end effector204. One or more drive cables706a-d, for example, may translate longitudinally to cause the end effector204to articulate (e.g., both of the jaws210,212angled in a same direction), to cause the end effector204to open (e.g., one or both of the jaws210,212move away from the other), or to cause the end effector204to close (e.g., one or both of the jaws210,212move toward the other).

Moving the drive cables706a-dcan be accomplished in a variety of ways, such as by triggering an associated actuator or mechanism operatively coupled to or housed within the drive housing208(FIGS.2and4). Moving a given drive cable706a-dconstitutes applying tension (i.e., pull force) to the given drive cable706a-din a proximal direction, which causes the given drive cable706a-dto translate and thereby cause the end effector204to move (articulate) relative to the shaft602.

As best seen in the lower image ofFIG.7A, the wrist206includes a first set of pulleys710aand a second plurality of pulleys710b, each configured to interact with and redirect the drive cables706a-dfor engagement with the end effector204. The first set of pulleys710ais mounted to the proximal clevis702bat the second axle704band the second set of pulleys710bis also mounted to the proximal clevis702bbut at a third axle704clocated proximal to the second axle704b. The first and second sets of pulleys710a,bcooperatively redirect the drive cables706a-dthrough an “S” shaped pathway before the drive cables706a-dare operatively coupled to the end effector204.

In at least one embodiment, a pair of drive cables706a-dis operatively coupled to each jaw210,212and configured to “antagonistically” operate the corresponding jaw210,212. In the illustrated embodiment, for example, the first and second drive cables706a,bmay be coupled at the first jaw210, and the third and fourth drive cables706c,dmay be coupled at the second jaw212. Actuation of the first drive cable706aacts on and pivots the first jaw210about the first pivot axis P1toward the open position. In contrast, actuation of the second drive cable706balso acts on and pivots the first jaw210about the first pivot axis P1in the opposite direction and toward the closed position. Similarly, actuation of the third drive cable706cacts and pivots the second jaw212about the first pivot axis P1toward the open position, while actuation of the fourth drive cable706dalso acts on but pivots the second jaw212about the first pivot axis P1in the opposite direction and toward the closed position.

Accordingly, the drive cables706a-dmay be characterized or otherwise referred to as “antagonistic” cables that cooperatively (yet antagonistically) operate to cause relative or tandem movement of the first and second jaws210,212. When the first drive cable706ais actuated (moved), the second drive cable706bnaturally follows as coupled to the first drive cable706a, and vice versa. Similarly, when the third drive cable706cis actuated, the fourth drive cable706dnaturally follows as coupled to the third drive cable706c, and vice versa.

Moreover, coordinated actuation of the drive cables706a-dmay also articulate the end effector204about the second pivot axis P2. Consequently, the end effector204can articulate with multiple degrees of freedom, e.g., a degree of freedom by articulating about the first pivot axis P1and another degree of freedom by articulating about the second pivot axis P2. The wrist206in this embodiment is pivotable about the second pivot axis P2in a single plane, e.g., in one of pitch and yaw, and the end effector204is pivotable about the first pivot axis P1in a single, different plane, e.g., the other of pitch and yaw.

As best seen in the lower image ofFIG.7A, the proximal clevis702bprovides opposing first and second arms712laterally offset from each other and extending distally toward the end effector204. A gap (space) is formed between the arms712to receive the first and second sets of pulleys710a,band also to provide space to potentially accommodate the other elements of the end effector204that pass through the wrist206and extend to the end effector204. As best seen in the upper image ofFIG.7A, in some embodiments, each arm712may provide and otherwise define an open-ended slot714(only one visible inFIG.7A) open in the distal direction. Each open-ended slot714may comprise a portion of the proximal clevis702bwhere the material of the proximal clevis702bdoes not encircle (circumscribe) the second pivot axis P2(e.g., the “pitch” axis).

Each open-ended slot714may be configured to receive and seat a corresponding retaining cap or “end cap”716secured to the opposing ends of the second axle704b. In some embodiments, the end caps716may form an integral part of the second axle704b. In other embodiments, however, the end caps716may each comprise separate component parts configured to be operatively coupled to the opposing ends of the second axle704band configured to help secure the first set of pulleys710ato the proximal clevis702b.

Referring now to bothFIGS.7A-7B, since each slot714is open-ended in the distal direction, the end effector204may be pulled in the distal direction during disassembly, as shown by the arrow C, thereby transitioning the end effector204from the assembled state, as shown inFIG.7A, to the extended state, shown inFIG.7B. The slot714defined in the arms712provides and otherwise defines a first aperture718a(FIG.7B) and a second aperture718b(FIG.7A), where the first aperture718ais located proximal to the second aperture718bbut contiguous therewith via a smaller portion (reduced section) of the slot714. As illustrated, each arm712may also provide and otherwise define a slit720that is contiguous with the slot714, but extends longitudinally away from the slot714in the proximal direction. The slit720introduces a point of weakness to each arm712, thereby allowing opposing portions of each arm712to flex as the second axle704bmoves between the first aperture718aand the second aperture718b, and otherwise as the end effector204moves from the assembled state to the extended state.

FIG.7Adepicts the end effector204in the assembled state, where the second axle704bis received within the first aperture718a, andFIG.7Bdepicts the end effector204in the extended state, where the second axle704bis moved distally D and received within the second aperture718b. A technician can move the end effector204to the extended state by manually moving the end effector204in the distal direction D. As the end effector204moves distally D, the second axle704bmoves (transitions) from the first aperture718ato the second aperture718b, and the first set of pulleys710acorrespondingly move distally away from the second set of pulleys710b, which remain mounted to the proximal clevis702bat the third axle704c. Moving the second axle704bfrom the first aperture718ato the second aperture718bcorrespondingly moves the first pulley set710adistally, which enables the drive cables706a-dto be both unthreaded and re-threaded through the pulley sets710aand710bwith both the distal and proximal crimps on the drive cables706a-d. This may prove advantageous in eliminating the need for a regional service center to have to do any crimping (i.e., the drive cables will arrive at the regional service center without any needs for crimping).

To enable the end effector204to be pulled distally, the surgical tool200(FIG.2) may provide or otherwise incorporate slack into the design at the drive housing208(FIGS.2and4). In such embodiments, for example, the drive cables706a-dmay each be configured to payout slack as the end effector204is pulled distally in the direction D. In at least one embodiment, this can be accomplished for the drive cables706a-dby rotating the input capstans to unspool or payout cable through various spooling capstan mechanisms.

FIG.7Cis an enlarged side view of another example of the end effector204and the wrist206, according to one or more additional embodiments. As illustrated, the arm712of the proximal clevis702bincludes an alternative embodiment of the open-ended slot714that opens in the distal direction. Similar to the embodiment of the open-ended slot714provided inFIGS.7A-7B, the slit720is contiguous with the open-ended slot714and extends proximally therefrom to allow opposing portions of the arm712to flex radially outward as the second axle704bmoves from the assembled state to the extended state.

In the illustrated embodiment, the open-ended slot714includes the first aperture718a(shown in dashed lines), but omits the second aperture718b(FIG.7A). Instead, as the second axle704bescapes the first aperture718a, the second axle704B may enter a substantially planar or straight section722of the open-ended slot714. This allows the distal clevis702aand the jaws210,212to be moved even more distally to make it easier to replace the drive cables706a-d. In addition, this also enables easy replacement of the distal clevis702aand the jaws210,212if they were damaged or worn.

FIG.8is an enlarged view of the end effector204moved to the extended state, according to one or more embodiments. As illustrated, each drive cable706a-dterminates at the end effector204. More specifically, as mentioned above, the first and second drive cables706a,bmay terminate at the first jaw210, and the third and fourth drive cables706c,dmay terminate at the second jaw212. Moreover, each drive cable706a-dmay include a first or “distal” crimp802secured to its distal end, and each distal crimp802may be configured to be received within a corresponding counterbore804defined in a corresponding one of the first and second jaws210,212. More particularly, the first jaw210may provide and otherwise defined two counterbores804configured to receive the distal crimps802secured to the distal ends of the first and second drive cables706a,b, and the second jaw212may provide and otherwise define an additional two counterbores804configured to receive the distal crimps802secured to the distal ends of the third and fourth drive cables706c,d.

Each jaw210,212may further provide and otherwise define a common aperture806that is contiguous with the counterbores804defined in the corresponding jaw210,212. The diameter of the common aperture806is larger than the diameter of each distal crimp802, and thereby provides a means to assemble the distal crimps802to the corresponding counterbores804, but also provides a means to remove the distal crimps802from the counterbores804during disassembly.

More specifically, to receive a distal crimp802within a corresponding counterbore804, the distal crimp802may first be inserted through or otherwise received within the common aperture806, following which the corresponding drive cable706a-dmay be threaded into the counterbore804. Once the drive cable706a-dis threaded into the counterbore804, the drive cable706a-dmay be retracted to seat the corresponding distal crimp802within the associated counterbore804. Disassembly or removal of the distal crimp802from the counterbore804may be accomplished by reversing the foregoing process. Once each of the distal crimps802are successfully removed from the corresponding counterbores804, the end effector204may be separated from portions of the wrist206by manually pulling in the distal direction D. The common aperture806may prove advantageous in allow the drive cables706adto be replaced at a service center with the distal crimps802and proximal crimps (as discussed below) on both ends of the drive cables706a-d. This eliminates the need for crimping at the service center.

FIGS.9A and9Bare isometric views of the distal end of the surgical tool200showing additional progressive steps of disassembly, according to embodiments of the present disclosure. More particularly,9A-9B show progressive disassembly of the end effector204and the wrist206from proximal portions of the surgical200.

InFIG.9A, the drive cables706a-dare coupled to the end effector204, as generally described above, where the distal crimps802(FIG.8) are received within the corresponding counterbores804(FIG.8) of each jaw210,212. As illustrated, the drive cables extend through the wrist, which includes a distal seal assembly902arranged at least partially within the proximal clevis sleeve504(shown in dashed lines). The distal seal assembly902may comprise a generally cylindrical structure sized to be received within the interior of the proximal clevis sleeve504and defining a plurality of apertures that extend axially therethrough to accommodate the drive cables706a-das they extend to the end effector204. In example operation, the distal seal assembly902may be configured to allow pressure to be maintained with the abdomen of the patient (i.e., provides a gas seal) to create abdominal space to perform a procedure laparoscopically. The distal seal assembly902also minimizes the amount of patient fluid and tissue entering the shaft202(FIG.2), which makes it easier to clean the device for the subsequent patient.

InFIG.9B, the distal crimps802are shown detached from the corresponding jaws210,212, in the disassembly process generally described with reference toFIG.8above. After detaching the distal crimps802from the corresponding jaws210,212, the distal crimps802may be fished through the first and second sets of pulleys710a,brotatably mounted to the proximal clevis702b. The distal end of the surgical tool200may then be removed from proximal portions of the surgical tool200. More specifically, the end effector204and the wrist206may be manually moved in the distal direction D, which may allow the distal seal assembly902to exit the proximal clevis sleeve504, thereby effectively detaching the end effector204and the wrist206from proximal portions of the surgical tool200.

At this point, if desired, the entire end effector204and the wrist206, including all of the “consumables” or high-wear components pertaining to such components, may be replaced. In such embodiments, a new or refurbished end effector and/or wrist may be provided, and the foregoing steps of disassembly and detachment up to this point may be reversed to reattach the component parts to the remaining (proximal) portions of the surgical tool200(FIG.2).

Alternatively, if it is desired to replace individual “consumables” pertaining to the end effector204or the wrist206, the end effector204may undergo further disassembly. Example consumables of the end effector204that may be replaced by further disassembling the end effector204include, but are not limited to, the jaws210,212(one or both), and example consumables of the wrist206that may be replaced include, but are not limited to the first and second sets of pulleys710a,b, the proximal clevis702B, the proximal clevis sleeve504, or any combination thereof.

FIGS.10A and10Bdepict additional steps of disassembly, according to one or more additional embodiments of the present disclosure. More specifically,FIGS.10A-10Bdepict one embodiment of the drive cable706a-dwhere a proximal end of each drive cable706a-dmay include a second or “proximal” crimp1002secured thereto. In such embodiments, each proximal crimp1002may be configured to be received within a hypotube1006or an intermediate socket component that attaches to hypotube1006that extends into the shaft202. Each hypotube1006may be coupled to a corresponding proximal extension of the drive cables706a-dthat extend to the drive housing208(FIGS.2and4). In such embodiments, the drive cables706a-dmay be referred to and otherwise characterized as “distal cables”, and the proximal extensions secured to each hypotube1006and extend to the drive housing208may be referred to as “proximal cables”.

As illustrated, each hypotube1006includes a cable socket1004, which provides a crimp opening1008that exhibits a diameter larger than the diameter of the proximal crimp1002. Accordingly, the drive cables706a-d(e.g., the “distal cables”) may be secured to a corresponding hypotube1006by aligning the corresponding proximal crimp1002with the crimp opening1008, receiving the proximal crimp1002within the cable socket1004, and then pulling distally on the drive cable706a-dto receive and seat the proximal crimp1002within the cable pocket1004. Disassembly or removal of the proximal crimp1002from the cable socket1004may be accomplished by reversing the foregoing process.

FIG.11is an isometric view of the drive cables706a-d(e.g., the “distal cables”) and the distal seal assembly902, according to one or more embodiments. Once each of the distal crimps802are successfully detached (disassembled) from the jaws210,212, as generally described above with reference toFIGS.9A-9B, and the proximal crimps1002are successfully removed from the corresponding cable sockets1004, as generally described above with reference toFIGS.10A-10B, the drive cables706a-dand the distal seal assembly902may be replaced and/or refurbished. In such embodiments, the drive cables706a-dand the distal seal assembly902may be characterized as “consumables”.

The foregoing steps of disassembly and detachment of the surgical tool200(FIG.2) up to this point may then be reversed to place the surgical tool200back into service. In particular, in a process that reverses the process outlined inFIGS.10A-10Babove, the proximal crimps1002of each drive cable706a-dmay be aligned with the crimp opening1008of a corresponding hypotube1006, inserted into the cable socket1004, and then the drive cables706a-dmay be pulled distally to receive and seat the proximal crimps1002within the corresponding cable pockets1004.

Moreover, in a process that reverses the process outlined inFIGS.9A-9Babove, after the drive cables706a-dare threaded through the second plurality of pulleys710band the distal seal assembly902located in the shaft adapter504, the end effector204and the wrist206may be moved in the proximal direction B. The distal crimps802may then be fished through and otherwise threaded back through the first set of pulleys710,bto be received at the corresponding jaws210,212.

In a process that reverses the process outlined inFIG.8above, the distal crimps802of each drive cable706a-dmay be mounted to the jaws210,212of the end effector204. More specifically, the distal crimps802may be inserted through or otherwise received within the corresponding common aperture806, following which the corresponding drive cable706a-dmay be threaded into the counterbore804. Once the drive cable706a-dis threaded into the counterbore804, the drive cable706a-dmay be retracted to seat the corresponding distal crimp802within the associated counterbore804.

In a process that reverses the process outlined inFIGS.7A-7B, the end effector204may be moved in the proximal direction B to correspondingly move the second axle704bin the same direction within the open-ended slot714until returning to the assembled state. Moving the second axle704bin the proximal direction B within open-ended slot714may cause the opposing portions of each arm712to flex radially outward. Moreover, moving the end effector204proximally B to the assembled state also moves the first set of pulleys710aback toward the second set of pulleys710brotatably mounted to the proximal clevis702bat the third axle704c.

In a process that reverses the process outlined inFIGS.5A-5Babove, the shaft202may then be manually moved distally D and otherwise back toward the end effector204. In such embodiments, the distal end of the shaft202may be received within the proximal clevis sleeve504. In at least one embodiment, the shaft202is moved distally D until it bottoms out within the proximal clevis sleeve504. In some embodiments, it may be necessary to apply the opposing radial loads C to the proximal clevis sleeve504to cause the proximal clevis sleeve504to flex radially outward at the location of the projections508and thereby assume a generally oval shape. This may help the projections508be received within the corresponding grooves510defined on the outer radial surface of the shaft202.

Moreover, in a process that reverses the process outlined inFIGS.6A-6B, once the shaft202reaches its distal position, the retention clip608(or the retention clip610ofFIG.6C) may be reinstalled within the interior of the drive housing208to secure the shaft202at the distal position. The carriage cover604may then be reinstalled and secured in place with the mechanical fastener606.

Finally, in a process that reverses the process outlined inFIG.4above, the surgical tool200may be detached and removed from the disassembly fixture402. The surgical tool200may then be cleaned and tested, then delivered to a distribution center and subsequently sent to an end user (e.g., a hospital, a surgeon, an operator, etc.) for further use.

A. A method of replacing a consumable of a surgical tool includes securing the surgical tool, the surgical tool including a drive housing, an elongate shaft extending distally from the drive housing, an end effector arranged at a distal end of the shaft and including opposing first and second jaws, a wrist interposing the distal end of the shaft and the end effector, and a plurality of drive cables extending proximally from the end effector and through the wrist. The method further including moving the shaft proximally away from the end effector and deeper into the drive housing, detaching the plurality of drive cables from the first and second jaws, displacing the end effector and the wrist distally from proximal portions of the surgical tool, replacing the consumable of the surgical tool, reconnecting the end effector and the wrist to the proximal portions of the surgical tool, reconnecting the plurality of drive cables to the first and second jaws, and moving the elongate shaft distally toward the wrist and the end effector.

B. A surgical tool configured for a circularity processing system includes a drive housing, an elongate shaft extending distally from the drive housing, an end effector arranged at a distal end of the shaft and including opposing first and second jaws, the first jaw defining a first counterbore and a first common aperture contiguous with the first counterbore, and the second jaw defining a second counterbore and a second common aperture contiguous with the second counterbore, a wrist interposing the distal end of the shaft and the end effector, and a plurality of drive cables extending proximally from the end effector and through the wrist, the plurality of drive cables including a first drive cable having a first distal crimp receivable within the first counterbore, and a second drive cable having a second distal crimp receivable within the second counterbore, wherein a diameter of the first common aperture is larger than a diameter of the first distal crimp, and wherein a diameter of the second common aperture is larger than a diameter of the second distal crimp.

C. A surgical tool configured for a circularity processing system includes a drive housing, an elongate shaft extending distally from the drive housing and having one or more grooves defined on an outer radial surface at or near a distal end of the shaft, an end effector arranged at the distal end of the shaft and including opposing first and second jaws, a wrist interposing the distal end of the shaft and the end effector, a proximal clevis sleeve operatively coupled to the wrist and operable to receive the distal end of the shaft, one or more projections being defined on an inner radial surface of the proximal clevis sleeve and receivable within the one or more grooves when the distal end of the shaft is received within the proximal clevis sleeve, wherein applying opposing radial loads on the proximal clevis sleeve dislodges the one or more projections from the one or more grooves and allows the shaft to move proximally away from the proximal clevis sleeve.

D. A surgical tool configured for a circularity processing system includes a drive housing, an elongate shaft extending distally from the drive housing, an end effector arranged at a distal end of the shaft and including opposing first and second jaws, a wrist interposing the shaft and the end effector and including a proximal clevis having opposing first and second arms laterally offset from each other and extending distally, each arm defining an open-ended slot that opens distally, and a set of pulleys rotatably mounted to the proximal clevis at an axle receivable within the open-ended slot of each arm, the set of pulleys being rotatable about a pivot axis extending through the axle, wherein material of the proximal clevis fails to encircle the pivot axis.

Each of embodiments A, B, C, and D may have one or more of the following additional elements in any combination: Element 1: wherein the surgical tool further includes a proximal clevis sleeve operatively coupled to the wrist and the distal end of the shaft is received within the proximal clevis sleeve, and wherein moving the elongate shaft proximally comprises applying opposing radial loads on opposite sides of the proximal clevis sleeve and thereby elastically deforming the proximal clevis sleeve, dislodging one or more projections defined on an inner radial surface of the proximal clevis sleeve from one or more corresponding grooves defined on an outer radial surface of the shaft when the proximal clevis sleeve elastically deforms, and moving the shaft proximally once the one or more projections are dislodged from the one or more corresponding grooves. Element 2: wherein the surgical tool further includes one or more retention clips provided within an interior of the drive housing and engageable with the shaft within the drive housing, and wherein moving the shaft proximally comprises accessing an interior of the drive housing, moving the one or more retention clips out of engagement with the shaft, and moving the shaft proximally and further into the interior of the drive housing. Element 3: wherein the wrist includes a proximal clevis having opposing first and second arms laterally offset from each other and extending distally, each arm defining an open-ended slot that opens distally, and the surgical tool further includes first and second sets of pulleys rotatably mounted to the proximal clevis at first and second axles, respectively, and wherein detaching the plurality of drive cables from the first and second jaws is preceded by moving the end effector distally relative to the wrist and thereby moving the first axle distally within the open-ended slots, and separating the first set of pulleys from the second set of pulleys as the first axle moves distally within the open-ended slots. Element 4: wherein each open-ended slot defines a first aperture and a second aperture contiguous with and located distal to the first aperture, and wherein moving the first axle distally within the open-ended slots comprises flexing opposing portions of each arm radially outward as the first axle moves distally within the open-ended slots and transitions from the first aperture to the second aperture. Element 5: wherein a distal crimp is secured to a distal end of each drive cable, and wherein detaching the plurality of drive cables from the first and second jaws comprises dislodging the distal crimp from a counterbore defined in a corresponding one of the first and second jaws, aligning the distal crimp with a common aperture contiguous with the counterbore, a diameter of the common aperture being larger than a diameter of the distal crimp, and advancing the distal crimp through the common aperture. Element 6: wherein the plurality of drive cables comprises first and second drive cables operatively coupled to the first jaw, and third and fourth drive cables operatively coupled to the second jaw, and wherein detaching the plurality of drive cables from the first and second jaws comprises dislodging distal crimps attached to distal ends of the first and second drive cables from first and second counterbores, respectively, defined in the first jaw, dislodging distal crimps attached to distal ends of the third and fourth drive cables from third and fourth counterbores, respectively, defined in the second jaw, aligning the distal crimps of the first and second drive cables with a first common aperture defined in the first jaw and contiguous with the first and second counterbores, a diameter of the first common aperture being larger than a diameter of the distal crimps of the first and second drive cables, aligning the distal crimps of the third and fourth drive cables with a second common aperture defined in the second jaw and contiguous with the third and fourth counterbores, a diameter of the second common aperture being larger than a diameter of the distal crimps of the third and fourth cables, advancing the distal crimps of the first and second drive cables thorough the first common aperture, and advancing the distal crimps of the third and fourth drive cables thorough the second common aperture. Element 7: wherein the surgical tool further includes a proximal clevis sleeve operatively coupled to the wrist and the distal end of the shaft is receivable within the proximal clevis sleeve, and a distal seal assembly arranged within the proximal clevis sleeve and through which the plurality of drive cables extend, and wherein removing the end effector and the wrist from proximal portions of the surgical tool comprises detaching the plurality of drive cables from the first and second jaws, pulling the plurality of drive cables through and out of engagement with the wrist, and moving the end effector and the wrist distally away from the proximal portions of the surgical tool and thereby removing the distal seal assembly from the proximal clevis sleeve. Element 8: wherein a proximal crimp is secured to a proximal end of each drive cable and the surgical tool further includes a plurality of hypotubes arranged within the shaft, each hypotube being configured to receive the proximal crimp of a corresponding one of the drive cables, the method further comprising detaching each proximal crimp from the plurality of hypotubes, and replacing at least one of the plurality of drive cables and the distal seal assembly, wherein the consumable comprises the at least one of the plurality of drive cables and the distal seal assembly. Element 9: wherein securing the surgical tool comprises mounting the surgical tool to a disassembly fixture, which includes the steps of mounting the drive housing to a drive housing mount of the disassembly fixture, and securing the end effector to an end effector mount of the disassembly fixture. Element 10: wherein the plurality of drive cables comprises first and second drive cables operatively coupled to the first jaw, and third and fourth drive cables operatively coupled to the second jaw, each drive cable having a distal crimp secured to a distal end and a proximal crimp secured to a proximal end, and wherein replacing the consumable of the surgical tool comprises replacing one or more of the plurality of drive cables.

Element 11: wherein the first jaw further defines a third counterbore continuous with the first common aperture and the second jaw further defines a fourth counterbore contiguous with the second common aperture, the plurality of drive cables further including a third drive cable having a third distal crimp receivable within the third counterbore, and a fourth drive cable having a fourth distal crimp receivable within the fourth counterbore, wherein the diameter of the first common aperture is larger than a diameter of the third distal crimp, and wherein the diameter of the second common aperture is larger than a diameter of the fourth distal crimp. Element 12: further comprising a proximal clevis sleeve operatively coupled to the wrist and operable to receive the distal end of the shaft, one or more grooves defined on an outer radial surface of the shaft, and one or more projections defined on an inner radial surface of the proximal clevis sleeve and receivable within the one or more grooves when the distal end of the shaft is received within the proximal clevis sleeve, wherein applying opposing radial loads on the proximal clevis sleeve dislodges the one or more projections from the one or more grooves. Element 13: further comprising one or more retention clips provided within an interior of the drive housing and engageable with the shaft within the drive housing, wherein disengaging the one or more retention clips from the shaft allows the shaft to move proximally and further into the interior of the drive housing. Element 14: wherein the wrist includes a proximal clevis having opposing first and second arms laterally offset from each other and extending distally, each arm defining an open-ended slot that opens distally, a first set of pulleys rotatably mounted to the proximal clevis at a first axle, a second set of pulleys rotatably mounted to the proximal clevis at a second axle located proximal to the first axle. Element 15: further comprising a proximal clevis sleeve operatively coupled to the wrist and operable to receive the distal end of the shaft, a distal seal assembly arranged within the proximal clevis sleeve and through which the plurality of drive cables extend, a proximal crimp secured to a proximal end of each drive cable, and a plurality of hypotubes arranged within the shaft and configured to receive the proximal crimp of a corresponding one of the drive cables, wherein the plurality of drive cables and the distal seal assembly are removable from the proximal clevis sleeve and the wrist.

Element 16: further comprising one or more retention clips provided within an interior of the drive housing and engageable with the shaft within the drive housing, wherein disengaging the one or more retention clips from the shaft allows the shaft to move proximally and further into the interior of the drive housing. Element 17: wherein the wrist includes a proximal clevis having opposing first and second arms laterally offset from each other and extending distally, each arm defining an open-ended slot that opens distally, a first set of pulleys rotatably mounted to the proximal clevis at a first axle, a second set of pulleys rotatably mounted to the proximal clevis at a second axle located proximal to the first axle. Element 18: wherein each open-ended slot defines a first aperture and a second aperture contiguous with and located distal to the first aperture, and wherein moving the first axle distally within the open-ended slots causes opposing portions of each arm to flex as the first axle moves from the first aperture to the second aperture.

Element 19: wherein each open-ended slot defines a first aperture and a second aperture contiguous with and located distal to the first aperture, and wherein moving the axle distally within the open-ended slots causes opposing portions of each arm to flex as the axle moves from the first aperture to the second aperture. Element 20: wherein the set of pulleys comprises a first set of pulleys and the axle comprises a first axle, the surgical tool further comprises a second set of pulleys rotatably mounted to the proximal clevis at a second axle located proximal to the first axle, and wherein moving the first axle distally within the open-ended slots from the first aperture to the second aperture transitions the end effector from an assembled state to an extended state where the first axle is moved distally from the second axle.

By way of non-limiting example, exemplary combinations applicable to A, B, C, and D include: Element 3 with Element 4; Element 7 with Element 8; Element 17 with Element 18; and Element 20 with Element 21.

The use of directional terms such as above, below, upper, lower, upward, downward, left, right, uphole, downhole and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure.