Surgical tool and assembly

Surgical tools and assemblies are employed for use in minimally invasive surgical (MIS) procedures. A surgical tool assembly includes a handle assembly and a frame assembly. The handle assembly and frame assembly are designed and constructed to have an articulation input joint and a grounding joint between them. A pitch rotational degree of freedom and a yaw rotational degree of freedom are provided by way of the articulation input joint. The handle assembly is translationally constrained relative to the frame assembly by way of the grounding joint. Intermediate bodies and joints can be provided in certain surgical tool assemblies and architectures.

INTRODUCTION

This application relates generally to surgical tools that can be employed for use in minimally invasive surgical (MIS) procedures and, more particularly, to surgical tools with a handle and a frame and an input joint situated therebetween.

Surgical tools are often designed and constructed with various components to have certain kinematic architectures at the handle and frame, and to ultimately furnish certain functionalities and performances at an end effector. Particular functionality assets and drawbacks can arise among the architectures depending on how the handle and frame and components are arranged and configured with respect to one another.

SUMMARY

In an embodiment, a surgical tool assembly may include a handle assembly, a frame assembly, an articulation input joint, and an axial grounding joint. The frame assembly has a shaft. The shaft establishes an x-axis. The articulation input joint is situated between the handle assembly and the frame assembly. The articulation input joint provides a pitch rotation between the handle assembly and the frame assembly. The articulation input joint provides a yaw rotation between the handle assembly and the frame assembly. The articulation input joint establishes a first virtual center. The axial grounding joint is situated between the handle assembly and the frame assembly. The handle assembly has a translational constraint along the x-axis with respect to the frame assembly by way of the axial grounding joint. The axial grounding joint establishes a second virtual center.

In an embodiment, a pitch motion path of the articulation input joint and a yaw motion path of the articulation input joint exhibit a parallel kinematic arrangement with respect to each other.

In an embodiment, a pitch motion path of the articulation input joint and a yaw motion path of the articulation input joint exhibit a serial kinematic arrangement with respect to each other.

In an embodiment, rigid body motion transmission paths effected and furnished by way of the axial grounding joint exhibit a parallel kinematic arrangement.

In an embodiment, rigid body motion transmission paths effected and furnished by way of the axial grounding joint exhibit a serial kinematic arrangement.

In an embodiment, the handle assembly is translationally constrained along a y-axis with respect to the frame assembly by way of the axial grounding joint.

In an embodiment, the handle assembly is translationally constrained along a z-axis with respect to the frame assembly by way of the axial grounding joint.

In an embodiment, the articulation input joint and the axial grounding joint exhibit a parallel arrangement with respect to each other between the handle assembly and the frame assembly.

In an embodiment, the first virtual center of the articulation input joint and the second virtual center of the axial grounding joint exhibit a generally coincident arrangement with respect to each other.

In an embodiment, an axis of the handle assembly exhibits a generally intersecting arrangement with the first virtual center and with the second virtual center.

In an embodiment, the shaft's x-axis exhibits a generally intersecting arrangement with the first virtual center and with the second virtual center.

In an embodiment, the first virtual center of the articulation input joint resides at a location that is occupied by the handle assembly, or that is occupied by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly, or that is occupied by both the handle assembly and by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly.

In an embodiment, the second virtual center of the axial grounding joint resides at a location that is occupied by the handle assembly, or that is occupied by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly, or that is occupied by both the handle assembly and by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly.

In an embodiment, a first intermediate body is provided and a second intermediate body is provided. The first intermediate body extends from the handle assembly. The first intermediate body and the second intermediate body are connected to each other by way of a first joint. The first intermediate body has a first pitch or yaw rotational degree of freedom with respect to the second intermediate body by way of the first joint.

In an embodiment, a third intermediate body is provided. The second intermediate body and the third intermediate body are connected to each other by way of a second joint. The second intermediate body has a second pitch or yaw rotational degree of freedom with respect to the third intermediate body by way of the second joint. The first and second pitch or yaw rotational degrees of freedom are contrary with respect to each other, and opposite in nature relative to each other.

In an embodiment, the third intermediate body extends from a frame of the frame assembly.

In an embodiment, the first intermediate body is fixed to the handle assembly. The third intermediate body is fixed to the shaft.

In an embodiment, the surgical tool assembly is a handheld surgical tool assembly. The surgical tool assembly lacks a wrist grounding component that would otherwise be utilized during use of the surgical tool assembly.

In an embodiment, a surgical tool assembly may include a handle assembly, a frame assembly, one or more intermediate bodies, multiple joints, an articulation input joint, and a grounding joint. The intermediate body(ies) is coupled between the handle assembly and the frame assembly. The joints reside among the handle assembly, the frame assembly, and the intermediate body(ies). The articulation input joint is established between the handle assembly and the frame assembly by way of the intermediate body(ies) and by way of the joints. The articulation input joint provides a pitch rotational degree of freedom, or provides a yaw rotational degree of freedom, or provides both a pitch and a yaw rotational degree of freedom at one or more of the joints. The articulation input joint further provides a pitch rotational degree of freedom, or provides a yaw rotational degree of freedom, or provides both a pitch and a yaw rotational degree of freedom at one or more of another of the joints. The articulation input joint has a first virtual center. The grounding joint is established between the handle assembly and the frame assembly by way of the intermediate body(ies) and by way of the joints. The grounding joint has a second virtual center.

In an embodiment, the first virtual center of the articulation input joint and the second virtual center of the grounding joint exhibit a generally coincident arrangement with respect to each other.

In an embodiment, the handle assembly establishes a first axis. A shaft of the frame assembly establishes a second axis. The first axis generally intersects the first virtual center of the articulation input joint and generally intersects the second virtual center of the grounding joint. Likewise, the second axis generally intersects the first virtual center of the articulation input joint and generally intersects the second virtual center of the grounding joint.

In an embodiment, the handle assembly is translationally constrained along an x-axis with respect to the frame assembly by way of the grounding joint. The handle assembly is translationally constrained along a y-axis with respect to the frame assembly by way of the grounding joint. And the handle assembly is translationally constrained along a z-axis relative to the frame assembly by way of the grounding joint.

In an embodiment, the articulation input joint and the grounding joint exhibit a parallel arrangement with respect to each other between the handle assembly and the frame assembly.

In an embodiment, the joints include a first joint and a second joint. The first joint resides between the handle assembly and the intermediate body(ies). The first joint provides the pitch rotational degree of freedom or provides the yaw rotational degree of freedom. The second joint resides between the frame assembly and the intermediate body(ies). The second joint provides the other of the pitch rotational degree of freedom or the yaw rotational degree of freedom, whichever is contrary to that provided by the first joint.

In an embodiment, the intermediate body(ies) includes a first intermediate body, a second intermediate body, and a third intermediate body. The joints include a first joint and a second joint. The first intermediate body is an extension of the handle assembly. The second intermediate body is an extension of the frame assembly. The first joint resides between the first intermediate body and the third intermediate body. The second joint resides between the second intermediate body and the third intermediate body. The first joint provides the pitch rotational degree of freedom or provides the yaw rotational degree of freedom of the first intermediate body with respect to the third intermediate body. The second joint provides the other of the pitch rotational degree of freedom or the yaw rotational degree of freedom, whichever is contrary to that provided by the first joint, of the third intermediate body with respect to the second intermediate body.

In an embodiment, the first virtual center of the articulation input joint resides at a location that is occupied by the handle assembly, or that is occupied by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly, or that is occupied by both the handle assembly and by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly. In a similar manner, the second virtual center of the grounding joint resides at a location that is occupied by the handle assembly, or that is occupied by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly, or that is occupied by both the handle assembly and by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly.

In an embodiment, a surgical tool assembly may include a handle assembly, a frame assembly, a first intermediate rigid body, a second intermediate rigid body, a third intermediate rigid body, a first joint, and a second joint. The first intermediate rigid body extends from the handle assembly. The second intermediate rigid body extends from the frame assembly. The first joint resides between the first intermediate rigid body and the third intermediate rigid body. The first joint provides a pitch rotational degree of freedom, or provides a yaw rotational degree of freedom, or provides both a pitch and a yaw rotational degree of freedom of the first intermediate rigid body with respect to the third intermediate rigid body. The second joint resides between the second intermediate rigid body and the third intermediate rigid body. The second joint provides a pitch rotational degree of freedom, or provides a yaw rotational degree of freedom, or provides both a pitch and a yaw rotational degree of freedom of the third intermediate rigid body with respect to the second intermediate rigid body. A virtual center of rotation is established, at least in part, by the first joint and by the second joint. The virtual center of rotation resides at a location that is occupied by the handle assembly, or that is occupied by a user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly, or that is occupied by both the handle assembly and by the user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly.

In an embodiment, an articulation input joint is established between the handle assembly and the frame assembly by way of the first intermediate rigid body, the second intermediate rigid body, and the third intermediate rigid body, and by way of the first joint and the second joint. The articulation input joint has the virtual center of rotation. A grounding joint is established between the handle assembly and the frame assembly by way of one or more of the first intermediate rigid body, the second intermediate body, and/or the third intermediate body. The grounding joint has a second virtual center. The virtual center of rotation of the articulation input joint and the second virtual center of the grounding joint exhibit a generally coincident arrangement with respect to each other.

In an embodiment, the second virtual center of the grounding joint resides at the location that is occupied by the handle assembly, or that is occupied by the user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly, or that is occupied by both the handle assembly and by the user's hand when the user is manipulating the handle assembly during use of the surgical tool assembly.

In an embodiment, the handle assembly establishes a first axis. A shaft of the frame assembly establishes a second axis. The first axis generally intersects the virtual center of rotation of the articulation input joint and generally intersects the second virtual center of the grounding joint. The second axis generally intersects the virtual center of rotation of the articulation input joint and generally intersects the second virtual center of the grounding joint.

In an embodiment, the handle assembly is translationally constrained along an x-axis with respect to the frame assembly by way of the grounding joint. The handle assembly is translationally constrained along a y-axis with respect to the frame assembly by way of the grounding joint. And the handle assembly is translationally constrained along a z-axis relative to the frame assembly by way of the grounding joint.

In an embodiment, the articulation input joint and the grounding joint exhibit a parallel arrangement with respect to each other between the handle assembly and the frame assembly.

In an embodiment, an articulation input joint is established between the handle assembly and the frame assembly by way of the first intermediate rigid body, the second intermediate rigid body, and the third intermediate rigid body, and by way of the first joint and the second joint. A pitch motion path of the articulation input joint and a yaw motion path of the articulation input joint exhibit a serial kinematic arrangement with respect to each other. A grounding joint is established between the handle assembly and the frame assembly by way of one or more of the first intermediate rigid body, the second intermediate body, and/or the third intermediate body. Rigid body motion transmission paths effected and furnished by way of the grounding joint exhibit a serial kinematic arrangement.

Various embodiments of a surgical tool assembly may include one or more or any technically-feasible combinations of any of the recitations and subject matter set forth in paragraphs of this summary section.

DETAILED DESCRIPTION

Multiple embodiments of surgical tools and assemblies are depicted in the figures and detailed in this description. Definitions of certain terms are presented prior to particular figure references in this description:

1.1 Body—Body is a discrete continuous component that can be used as structural components to form an assembly or sub-assembly. The displacement/motion state of a body can be completely defined with respect to a reference ground by six degrees of freedom (DoF). A body can be part of an assembly, where the assembly may include multiple bodies that are inter-connected by joints. Generally, a body may be rigid (i.e., with no compliance) or may be compliant. One or more discrete bodies may be connected together via a rigid joint. These bodies together are still termed as a body as there are no single or multi degree of freedom joints between these bodies. In certain scenarios, this body may be produced out of a single/monolithic structure and therefore, be only a single body. In certain scenarios, a body may be compliant (i.e., not rigid) but still discrete and continuous. In any case, the body may be monolithic or assembled using rigid joints. The body may be of homogenous material composition or heterogenous material composition.

1.2 Mechanism/Joint/Connector—In general, there may be a certain equivalence between the terms “mechanism” and “joint.” A “joint” may be alternatively referred to as a “connector” or a “constraint.” All of these can be viewed as allowing certain motion(s) along certain degree(s) of freedom between two bodies and constraining the remaining motions. A mechanism generally comprises multiple joints and bodies. Typically, a joint may be of simpler construction, while a mechanism may be more complex as it can comprise multiple joints. A joint refers to a mechanical connection that allows motions as opposed to a fixed joint (e.g., welded, bolted, screwed, or glued jointly). In the latter case, fixed joint, two bodies are fused with each other and are considered one and the same in the kinematic sense (because there is no relative motion allowed or there are no relative degrees of freedom between the two). The term “fixed joint” may be used herein to refer to this kind of joint between two bodies. When reference to the term “joint” is made, it means a connection that allows at least some motions or degrees of freedom, e.g., a pin joint, a pivot joint, a universal joint, a ball and socket joint, etc.

1.3 Degree of Freedom (DoF)—As noted, a joint or mechanism allow certain motions between two bodies and constrains the remaining motions. “Degrees of freedom” is a technical term to capture or convey these “motions.” In total, there are six independent motions and therefore degrees of freedom possible between two rigid bodies when there is no joint between them: three translations and three rotations. A joint will allow anywhere between zero and six DoFs between the two bodies. For the case when the joint allows zero DoFs, this effectively becomes a “fixed joint,” as described above, where the two bodies are rigidly fused or connected to each other. In this case, from a kinematic sense, the two bodies are one and the same. For the case when the joint allows six DoFs, this effectively means that the joint does not constrain any motions between the two bodies. In other words, the motions of the two bodies is entirely independent of each other. A joint for the purpose this application may allow one, or two, or three, or four, or five DoF between two rigid bodies. If it allows one DoF, then the remaining five possible motions are constrained by the joint. If it allows two DoF, then the remaining four possible motions are constrained by the joint, and so on.

1.4 Degree of Constraint (DoC)—“Degree of constraint” refers to directions along which relative motion is constrained between two bodies. Since relative motion is constrained, these are directions along which motion and loads (i.e., forces or moments) can be transmitted from one body to the other body. Since the joint does not allow relative motion between the two bodies in the DoC direction, if one body moves in the DoC direction, it drives along with it the other body along that direction. In other words, motions are transmitted from one rigid body to another in the DoC directions. Consequently, loads are also transmitted from one rigid body to another in the DoC directions, which are sometimes also referred to as the load bearing directions or simply bearing directions. The term “retention” may also be used in the context of a DoC direction. For example, one body may be constrained or equivalently retained with respect to a second body along a certain DoC. This means that relative motion is not allowed between the two bodies in the DoC direction, or equivalently the direction of constraint, or equivalently the direction of retention. Retention of all six DoFs means the same thing as having six DoCs between two bodies.

1.5 Local Ground—In the context of an assembly of bodies connected by joints (e.g., a multi-body system, a mechanism), one or more bodies may be referred to as the “reference” or “ground” or “local ground.” The body referred to as the local ground is not necessarily an absolute ground (i.e., attached or bolted to the actual ground). Rather, the body that is selected as a local ground simply serves as a mechanical reference with respect to which the motions of all other bodies are described or investigated.

1.6 Axis and Direction—Axis refers to a specific line in space. A body may rotate with respect to (w.r.t.) another body about a certain axis. Alternatively, a body may translate w.r.t. another body in a certain direction. A direction is not defined by a particular axis and is instead commonly defined by multiple parallel axes. Thus, x-axis is a specific axis defined in space, while X direction refers to the direction of the x-axis or any other axis that is parallel to the x-axis. Multiple different but parallel axes can have the same X direction. Direction only has an orientation and not a location in space. In at least some embodiments, and with particular reference toFIG.1, a coordinate system is presented with the x-axis coinciding with an axis of a tool shaft (introduced below) of the surgical tool, the y-axis oriented relative thereto, and the z-axis coming out of the paper.

1.7 Serial Kinematic Joint/Mechanism—The term “kinematics” may refer to the geometric study and description of motion of bodies relative to other bodies. A serial kinematic joint, or serial kinematic mechanism, consists of bodies connected via a serial chain of connectors, joints, or mechanisms. If one traces or scribbles a line from one body to another in a serial kinematic joint/mechanism, there exists only one mechanical path (or line) of motion transmission. In a somewhat simplistic example of a serial kinematic joint/mechanism, a first body and a second body are connected to each other via four connectors and three intermediate bodies. The first body and second body may be considered rigid, and the intermediate bodies may be considered rigid for practical purposes. The connectors may be simple or complex joints that may allow certain motions while constrain other motions. The connectors and intermediate bodies may span in what is effectively a single line and mechanical path between the first and second bodies.

1.8 Parallel Kinematic Joint/Mechanism—In a somewhat simplistic example of a parallel kinematic mechanism, the first body is connected to the second body via multiple independent chains and lines of intermediate bodies. Each such chain represents a mechanical path of motion transmission. If one traces possible lines from the first body to the second body, there is more than one mechanical path, which makes this a parallel design. The connection paths are not parallel in a geometric sense (e.g., two straight lines being parallel such as the opposing sides of a rectangle), but parallel in the kinematic sense, which implies multiple (more than one), independent, non-overlapping chains or paths between the first body and second body. The connectors here are simple or complex joints that may allow certain motions and constrain other motions. For convenience, the term joint and connector may be used interchangeably.

1.9 Virtual Center of Rotation—When provided in an embodiment, a virtual center of rotation, (also referred to as “virtual center”), refers to a center of rotation where two or more axis of rotation coincide or intersect. For example, two axes of rotation can intersect. An axis of rotation of a first rotational direction, such as a pitch axis, and an axis of rotation of a second rotational direction, such as a yaw axis, intersect at a virtual center of rotation. The virtual center may be located in a vacant space devoid of any other components of a parallel kinematic mechanism, for example.

1.10 User Interface—When provided in an embodiment, a user interface refers to the input interface that a user interacts with to provide input to a machine or instrument or mechanism with the objective of producing some change or outcome in the machine or instrument or mechanism. User interface is often an ergonomic feature on a body, which is part of an instrument, that is triggered or actuated by the user, e.g., a knob on a car dashboard can be rotated by a user to increase/decrease speakers' sound volume. Here, the knob and, specifically, the knurled outer circumference (feature) of the knob is the user interface.

1.11 Transmission Member—When provided in an embodiment, a transmission member is a rigid or compliant body that transmits motions from one body to another body. A transmission member may be a compliant wire, cable, cable assembly, flexible shaft, etc.

1.12 Handle Body—When provided in an embodiment, a handle body refers to a body in the handle assembly which is considered as a local ground while describing the handle assembly and associated mechanisms. When provided, the handle body is held by the user while other bodies within handle assembly may be put in motion with respect to the handle body via the user interface.

1.13 Handle Assembly—When provided in an embodiment, a handle Assembly is a term used for an assembly that, in some embodiments, at least consists of the handle body and user interface.

1.14 Tool Frame—When provided in an embodiment, the tool frame refers to a structural body that may be part of a tool apparatus or surgical tool. In certain tool apparatuses, it may be connected to handle assembly and/or an elongated tool shaft. Terms namely “tool frame” and “frame” may be used interchangeably throughout the document.

1.15 Tool Shaft—When provided in an embodiment, a tool shaft is generally a rigid extension of the frame, at its proximal end, which is a slender and elongated member, commonly a cylinder, that houses the end-effector assembly at its distal end. The tool shaft may simply be referred to as the shaft. The axis of the tool shaft may be referred to as axis3or Tool Shaft Roll Axis or Tool Shaft Axis throughout the description.

1.16 End-Effector Assembly—When provided in an embodiment, the end-effector (EE) assembly may be referred to as the EE assembly. In some embodiments, the EE assembly may exist at the distal end of the tool shaft. An EE assembly may contain one or more jaws (or EE jaws). There can be two types of EE assembly. The first type of EE assembly consists of two EE jaws, namely a moving jaw and a fixed jaw. There may also exist an EE frame that acts a local reference ground for the moving jaw and any other moving body within the EE assembly. In such an assembly, the moving jaw moves relative to the EE frame by rotating about a pivot pin. This motion of the moving jaw with respect to the EE frame is termed as jaw closure motion. The fixed jaw may also be coupled to EE Frame such that it is a rigid extension of the EE Frame. The EE frame may be further coupled to the shaft via an output articulation joint.

When an instrument incorporates an output articulation joint, the EE frame rotates about an Axis2while the tool shaft rotates about Axis3. When there is no input at the articulation input joint, Axis2and Axis3are oriented parallel to the X-axis. In cases where there is an input at the articulation input joint, Axis2will be deviate from a parallel orientation to the x-axis by rotating varying amounts about the y-axis and z-axis. The EE assembly rotation about the y-axis may also be referred to as EE yaw, whereas rotation about the z-axis may be referred to as EE pitch.

1.17 Roll Transmission Member—When provided in an embodiment, this transmission member helps transmit rotation of rotation input or dial w.r.t. the handle body to produce EE roll motion.

1.18 Articulation Transmission Member—When provided in an embodiment, the articulation transmission member is a transmission member, or connector, that transmits articulation (pitch and yaw motion) from an articulation input joint to an articulation output joint.

1.19 Jaw Closure Transmission Assembly—When provided in an embodiment, a jaw closure transmission assembly refers to bodies, joints, mechanisms and/or jaw closure transmission member(s) that exist between the handle assembly and the EE assembly and facilitate jaw closure motion. In an example, the body within the handle assembly that produces output motion (e.g., a shuttle) is coupled to the proximal body that is part of the jaw closure transmission assembly. Similarly, the moving jaw within the EE assembly is coupled to the distal most body that is part of the jaw closure transmission assembly. Terms “jaw closure transmission assembly” and “jaw actuation transmission assembly” may be used interchangeably throughout the description.

1.20 EE Roll Transmission Assembly—When provided in an embodiment, the EE roll transmission assembly refers to bodies, joints, mechanisms and/or roll transmission member(s) that may exist between the handle assembly and the EE assembly and facilitate EE roll motion. In an example, body within the handle assembly that produces output motion (e.g., the shuttle) is coupled to the proximal body that is part of the roll transmission assembly. Similarly, components within the EE assembly (e.g., an EE frame) is coupled to the distal most body that is part of the roll transmission assembly.

2. Surgical Tool and Assembly, Functional Attributes, and User Experience

In general, a surgical tool10can be employed for use in minimally invasive surgical (MIS) procedures, and can be a handheld instrument. The surgical tool10may also be referred to as a tool apparatus; or, in the case of it being handheld, may be referred to as a handheld tool apparatus. The surgical tool10may have various designs, constructions, and components in different embodiments, which may be dictated in part or more on the intended application and ultimate use of the surgical tool10.FIG.1presents a schematic representation of an embodiment of the surgical tool10. The figure is intended to provide an introduction of some of the more primary components of the surgical tool10, per an embodiment, as well as an overall arrangement of those components relative to one another (FIG.17also provides a depiction of many of the components). In this embodiment, the surgical tool10has a handle assembly12, a frame assembly14, and an end-effector (EE) assembly16. The handle assembly12, according to this embodiment, includes a handle body18, a closure input20, and a dial22. The handle assembly12establishes a handle axis24(also referred to as Axis1in this description) that is arranged longitudinally and centrally therethrough, per this embodiment. The frame assembly14, according to this embodiment, includes a frame26and a tool shaft, or just shaft28. The shaft28establishes a shaft axis or x-axis30(also referred to as Axis3in this description). An articulation input joint (AIJ)32is situated between the handle assembly12and the frame assembly14. A roll actuation joint34and a closure actuation joint36extend from the handle assembly12. An output articulation joint38is situated between the shaft26and the EE assembly16. Lastly, the EE assembly16, according to this embodiment, includes an EE base40, an EE frame42, a moving jaw44, and a fixed jaw46. The EE assembly16establishes an EE axis48(also referred to as Axis2in this description) that is arranged longitudinally therethrough, per this embodiment. Various surgical tool assemblies can include one or more of these components, or a combination of the components.

The tool apparatus, or surgical tool10, hence includes the handle assembly12, the frame assembly14, and the EE assembly16that are related via a plurality of joints and connectors. Collectively, the collection of bodies, joints, and connectors facilitate the translation of useful user input motions at the handle assembly12into useful motions of the EE Assembly16distally located with respect thereto. Intermediate to the handle assembly12and EE assembly16is located the frame assembly14. The system facilitates the transmission of seven distinct motions from the handle assembly12to the EE assembly16via the frame assembly14(i.e., three translations, three rotations, and jaw open-close). Due to the independence of different motion transfer paths, the system is configured such that it provides a degree of device usability that is higher than past MIS devices. In at least some embodiments, the surgical tool10lacks electrical components among the handle assembly12, frame assembly14, and EE assembly16, and can hence be considered a purely mechanical device and assembly.

The system is comprised of the three assemblies: the handle assembly12which receives the user inputs, the frame assembly14which includes the rigidly connected shaft28, and the EE assembly16. Between each assembly are a plurality of joints and intermediate bodies configured to receive and map motions between the bodies. The joints and intermediate bodies may simply be referred to collectively as a connection. One focus of this application relates to the configuration of connections that reside between the handle assembly12and the frame assembly14and their collective impact on EE assembly motions.

The connections between the handle and frame assemblies12,14that are used for positioning and orientation of the shaft28and EE assembly16may constitute and make-up the articulation input joint32and may constitute and make-up a grounding joint50(sometimes referred to as an axial grounding joint (AGJ)50). A purpose of the AIJ32is to translate two rotational degrees of freedom of the handle assembly12(pitch and yaw) to the EE Assembly16. Additionally, the AIJ32may passively translate the third rotational degree of freedom, roll about the x-axis, from the handle assembly12to the EE assembly16as well. Further, it may be referenced that the roll motions are translated via the roll actuation joint34. Although the roll actuation joint34may be independent in some device architectures, the roll motions may be generally translated and integral to the AIJ32. In an embodiment, the pair of intermediate bodies that facilitate the transfer of motions and that are located between the frame assembly14and handle assembly12may be flex strips52. Each flex strip52is connected to the handle and frame assemblies12,14via a hinge joint. The flex strips52may be a flexible body, or mechanism, which provides one DoF between the oppositely spaced hinge joints.

A purpose of the AGJ50is to translate three translational rigid body DoFs (motions in x-axis, y-axis, and z-axis directions) from the handle assembly12to the EE assembly16via the frame assembly14and translate one rotational DoF (roll). In other words, the AGJ50constrains three rigid body DoFs (motions in x-axis, y-axis, and z-axis directions) between the handle assembly12and the frame assembly14with respect to each other, and constrains one rotational DoF (roll) between the handle assembly12and the frame assembly14with respect to each other. But the AGJ50does not constrain the pitch rotational DoF between the handle assembly12and the frame assembly14with respect to each other, and does not constrain the yaw rotational DoF between the handle assembly12and the frame assembly14with respect to each other.

Enhanced usability of the surgical tool10, as compared to past MIS instruments and according to at least one embodiment, is facilitated by parallel configuration of the AIJ32and the AGJ50.FIG.4is a schematic diagram demonstrating the parallel configuration of the AIJ32and the AGJ50. The AIJ32can be structured as a parallel-kinematic (PK) mechanism in certain embodiments whereby the pitch and yaw motions are independently mapped from the handle assembly12through the frame assembly14to the EE assembly16. The PK configuration that facilitates mapping of handle assembly12motions to the EE assembly16, via the frame assembly14, are described in U.S. Pat. No. 8,668,702 which is hereby incorporated herein by reference. The AGJ50can be an additional parallel control path, per an embodiment, from the handle assembly12to the frame assembly14. The connection allows for mapping of rigid body motions from the handle assembly12to be translated directly to the frame assembly14and, in-turn, to the EE assembly16. The parallel nature of the AIJ32and AGJ50means that articulation input motions at the AIJ32may be mapped to the end effector assembly16independent of rigid body translational motions through the AGJ50.

To frame usability benefits, it may be assumed that the use case for the surgical tool10involves, at a minimum, a user (typically a surgeon) and a trocar (i.e., device that allows insertion of an instrument into a patient's body during a surgical operation; an access portal for the instrument; a grounded device providing two rigid body translational DoC to the instrument shaft; restricts tool shaft motion in y-direction and z-direction). The user grasps the handle body18while positioning the surgical tool10such that the shaft28of the frame assembly14extends through the trocar. The trocar provides an effective single point, simple support for the shaft28to constrain the motions. When viewing the location of the trocar simple support as local ground, the trocar does not provide any rotational constraint in any of the three rotational DoF for the shaft28(rotation about y-axis, rotation about z-axis, and roll about the shaft x-axis). The trocar also does not constrain translation motion along the shaft28; thus, allowing sliding motion in x-direction. The limitations of motion for the surgical tool10may be dictated only by the inherent geometrical constraints of the system.

When grasping the handle assembly12, the user controls the position and orientation of the EE assembly16through input motions of the handle assembly12. When a user grasps the handle assembly12and provides a yaw motion input, a proportional yaw motion output of the EE assembly16will be produced. Likewise, pitch motion input at the handle assembly12translates to a pitch motion at the EE assembly16. The yaw motion input and the pitch motion input are via the AIJ32, per at least some embodiments. When the user moves the handle assembly12in the X-direction (parallel to the X-axis), the EE assembly16moves accordingly along the shaft axis30through the trocar and as if it were rigidly connected to the handle assembly12. For handle assembly12motions in the direction of the positive Z-direction (+Z) or positive Y-direction (+Y), the EE assembly16translates inversely, and proportional, due to the DoC of the trocar pivot. In other words, handle assembly12motion in a direction parallel with the +Y will result in proportional motion of the EE assembly16in a negative Y-direction (−Y); this holds true for handle assembly12motions in the Z-direction. This may be referred to as the fulcrum effect. These movements in the X-, Y-, and Z-directions are via the AGJ50, per at least some embodiments. The resultant input control system provided to the user allows the user to precisely and predictably control the position and orientation of the shaft28.

As stated, each of the independent input motions at the handle assembly12described may be orchestrated without impact to other unintended motions of the EE assembly16relative to the shaft28local ground. The orientation of the EE assembly16is controlled through pitch and yaw input motions at the handle assembly12(change in rotational orientation of Axis1). When the pitch and yaw orientation of the EE assembly16change, Axis2shifts and is no longer parallel with Axis3. Yaw input motion at the handle assembly12will produce proportional yaw output motion of the EE assembly16. The EE assembly16motion occurs without effect to shaft28position or orientation relative to the trocar nor does it impact the pitch orientation of the EE assembly16. Likewise, pitch input at the handle assembly12will only produce EE assembly16pitch motion. The independence of each relationship allows for a user to precisely and predictably control the orientation of the EE assembly16relative to the shaft28.

According to at least some embodiments, and with general reference now toFIGS.9-16, the construction of the AIJ32includes the handle assembly12and the frame assembly14joined by a pair of intermediate bodies54: a first intermediate body56and a second intermediate body58. The intermediate bodies54take different forms in different embodiments, and may be in the form of flexible connector members or the flex strips52. The intermediate bodies54are orthogonally oriented relative to one another and mounted directly to the handle assembly12via first pin joints60. The intermediate bodies54are joined to the frame assembly14via second pin joints62. The second pin joints62are not rigidly attached to the frame26, and rather are mounted to a first pulley64and a second pulley66that are allowed one rotational DoF. The first and second pulleys64,66are oriented such that their axes of rotation are orthogonally positioned to each other and lie in the Y-Z plane (plane oriented perpendicular to the X-axis). The intersection of a corresponding first pulley axis68and a second pulley axis70may be referred to as a virtual center72of the AIJ32(VC-AIJ), or a first virtual center72. The resultant AIJ configuration allows for pitch and yaw motions of the handle assembly12to directly, and via the intermediate bodies54or flex strips52, result in equivalent rotational motions of the first and second pulleys64,66pivoting on the frame assembly14. The pulley motions may, in-turn, be connected to cable systems and produce work that is used to control the position of the EE assembly16or any other type of controllable mechanism. Additionally, the AIJ32provides the roll DoC between the handle assembly12and frame assembly14, thus allowing roll input motions at the handle assembly12to translate to equivalent roll output motions at the shaft28and EE assembly16. The collective impact of the AIJ components is that the AIJ32provides pitch and yaw DoC between the handle assembly12and first and second pulleys64,66and roll DoC between the handle assembly12and frame assembly14. The AIJ32does not create X-direction, Y-direction, or Z-direction DoC between the handle assembly12and adjacent bodies. Further, a pitch axis74and a yaw axis76are established via the pitch and yaw motions effected by the AIJ32. And, at least in this embodiment, a third intermediate body78in the form of a rotation or deviation ring is provided. The AIJ32may be established, per an embodiment, by the collection of the first intermediate body56, the second intermediate body58, the first pulley64, the second pulley66, the first pulley axis68, and the second pulley axis70.

According to at least some embodiments, and still with general reference toFIGS.9-16, the AGJ50is constituted by a gimbal structure that provides for a flexibly grounded attachment of the handle assembly12to the frame assembly14. The structure is constructed in a manner so that it does not impede the handle assembly12motions needed for AIJ32inputs, while providing the grounding constraints between the bodies. In other words, the AGJ50is configured in such a manner that it provides grounded attachments between the handle assembly12and the frame assembly14to provide direct positional control of a proximal point on the frame assembly14located at the center of the gimbal. The AGJ50, per at least some embodiments, provides X-direction, Y-direction, and Z-direction DoCs. The movement of the frame26(X-direction, Y-direction, Z-direction) via the handle assembly12at the center of the gimbal is accomplished independent of any pitch or yaw motions influence of the handle assembly12. The AGJ50may be established, per an embodiment, by the collection of the pitch axis74, the yaw axis76, and the third intermediate body78.

The handle assembly12is connected to the third intermediate body78, or the deviation ring, that contains two sets of pin joints orthogonally oriented around its circumference: a third set of pin joints80and a fourth set of pin joints82. The third set of pin joints80is a pitch DoF joint, while the fourth set of pin joints82is a yaw DoF joint. The pitch DoF joint80is connected to the handle assembly12or to unitary extension arms84of the handle assembly12, while the yaw DoF joint82is connected to the frame assembly14. The extension arms84can themselves be rigid bodies. In at least some embodiments, the extensions arms84can be a constituent part of the handle assembly12or can constitute intermediate bodies of the surgical tool10. The architecture of the handle assembly12, when connected to the deviation ring pitch DoF joint80, positions the handle axis24, at the center of the deviation ring78. The deviation ring yaw DoF joint82at the frame assembly14may be split into an additional intermediate member and two joints that allow for a roll DoF (a bearing or rotationally sliding member); however, this is not necessary for function.

The center point defined by the deviation ring78is at an intersection of the two axes created by the pitch DoF joint80and the yaw DoF joint82—namely, at the intersection of the pitch axis74and the yaw axis76. The center of rotation may also be referred to as a virtual center86of the AGJ50(VC-AGJ), or a second virtual center86. The VC-AGJ86is located at a point that also intersects the shaft axis30. In other embodiments the VC-AGJ86may be located at point that does not intersect the shaft axis30. It is helpful to view the VC-AGJ86as the point whereby the user controls the position of the proximal end of the frame26. It is from that point that the user may raise or lower the surgical tool10(Y-direction motion), move the surgical tool10from side-to-side (Z-direction motion), and drive or retract the surgical tool10from the trocar along the shaft axis30(X-direction motion).

According to at least some embodiments, device usability is influenced by the relative locations of the VC-AIJ72, VC-AGJ86, the handle axis24(Axis1), and the shaft axis30(Axis3). Furthermore, usability is influenced by the positioning of the user interfaces that control the influential points. The handheld architecture, per at least some embodiments, incorporates co-location and intersection of these elements. The VC-AIJ72and VC-AGJ86can exhibit a generally coincident arrangement relative to each other according to at least some embodiments. In this sense, the VC-AIJ72and VC-AGJ86may simply be referred to as the virtual center. Stated another way, the VC-AIJ72and the VC-AGJ86may reside at the same and single virtual center. Further, the handle axis24and the shaft axis30can exhibit a generally intersecting arrangement with the VC-AIJ72and with the VC-AGJ86, per at least some embodiments. That is, the handle axis24can intersect the VC-AIJ72and can intersect the VC-AGJ86, and the shaft axis30can likewise intersect the VC-AIJ72and can intersect the VC-AGJ86. As used herein, the phrases “generally coincident” and “generally intersect,” and their grammatical variations, are intended to account for certain engineering and manufacturing tolerances and slight imprecisions that may arise—and without deviation from the intended functionality and outcome—such that mathematical precision is not implied and, in some instances, is not possible.

Per at least some embodiments, the handle assembly12is the control point to effect articulation of the EE assembly16via the AIJ32, the roll position of the frame assembly14and the EE assembly16via the AIJ32, and the position of the EE assembly16via the virtual center (i.e., VC-AIJ72and VC-AGJ86) and the AGJ50. In other words, all useful motions of the EE assembly16can be controlled through a single user interface element, or touch point—namely the handle assembly12. When a user grips the handle assembly12, the user gains control of all useful motions of the surgical tool10within the palm of the user's hand. This differs from certain past MIS instruments in which a grounding component is effected at a user's wrist via a wrist grounding component that is received over the user's wrist; the surgical tool10lacks such a wrist grounding component according to the embodiments of the figures.

Furthermore, it may not only be that the user can control all useful EE motions through position and orientation of the handle assembly12, but device usability may be influenced by relative position of the handle assembly12along the handle axis24relative to the virtual center (i.e., VC-AIJ72and VC-AGJ86). With reference toFIG.14, at least per this embodiment, the handle assembly12may be delineated as having three regions: a proximal region88, a distal region90, and a central region92. The proximal region88is where the user's palm resides and grips. It is at this location of the handle assembly12that the surgical tool10is principally supported. The distal region90is where the user's fingers reside and is where fine motions inputs are received. The central region92is the zone between the proximal and distal regions88,90of the handle assembly12and may simply be the plane which bisects the handle assembly12. The handle assembly12may be embodied as basic as a single rigid cylindrical member with mounts to the AIJ32and AGJ50members, or in a form that is ergonomically designed for a hand of a user (e.g., optimized for right-hand grip, left-hand grip, small hand, large hand, or non-handed and universal). A handle to provide the desired degree of usability for the surgical tool10, it is within the central region92of the handle assembly12that the virtual center (i.e., VC-AIJ72and VC-AGJ86) may be located, per at least some embodiments.

In at least some embodiments, the handle assembly12does not necessarily need to be embodied as illustrated in the figures and including two sub-assemblies, namely the handle body18and dial22. The handle assembly12may simply be a single body without discrete distinctions between its regions. In such an embodiment, the surgical tool10would not facilitate roll functionality within the device. The user, however, may provide a roll input by pronation or supination of their hand, and by extension of their wrist and forearm. Their pronation or supination input motions will result in roll about the shaft axis30.

The handle assembly12may be configured that the proximal and distal regions88,90are two separate bodies which incorporate a relative roll DoF therebetween. With this configuration, and the bodies maintain a consistent handle axis24while providing roll DoF between the two bodies. The distal body in the handle assembly12may be called the dial22. The dial22is intended to be controlled by a user that grips the dial22and rotationally positions it relative to the proximal handle body18. When a device is configured with a handle assembly12containing the dial22, the components within the device that are impacted by roll are depicted inFIG.2. Namely, the AIJ32, closure actuation joint36, frame assembly14, frame26, shaft28, output articulation joint38, and EE assembly16would all rotate with the dial22upon roll functionality, according to at least some embodiments.

With the virtual center (i.e., VC-AIJ72and VC-AGJ86) located in the central region92of the handle assembly12, the proximal and distal regions88,90of the handle assembly12may consequently inherit unique characteristics per at least some embodiments. For example, when the handle assembly12rotates about the pitch axis74, a portion of the handle assembly12moves in a positive +Z-direction and the opposite portion of the handle assembly12moves inversely in a negative −Z-direction. Similarly, when the handle assembly12rotates about the yaw axis76, a portion of the handle assembly12moves in a positive +Y-direction and the opposite portion of the handle assembly12moves in a −Y direction. When there is a pitch input to the handle assembly12, yaw input to the handle assembly12, or any combination thereof, there is no impact to the location of the virtual center and, in turn, no impact to the position or orientation of the frame assembly14relative to the trocar. Conversely, with rigid body motions of the handle assembly12in X-, Y-, and Z-directions the motions directly impact frame position at the virtual center. Due to the parallel kinematic structures, the rigid body motion inputs to the handle assembly12have no impact to the pitch and yaw orientation of the handle assembly12nor the EE assembly16. When the EE assembly16is not articulated, it can be seen that the EE axis48is co-linear with the shaft axis30and handle axis24.

Moreover, in at least some embodiments, the VC-AIJ72resides at a location that is occupied by the handle assembly12, such as at a location occupied by the handle body18or at a location occupied by the dial22. The VC-AIJ72can further reside at a location that is occupied by a user's hand94(FIG.13) when the user is grasping the handle assembly12in order to manipulate the handle assembly12—this location could be at the handle body18, at the dial22, or at a distance set back and rearward of the handle body18generally along the handle axis24. This location could also be within the confines established in part by a user's palm when the user is grasping the handle assembly12in order to manipulate it. In a similar way, the VC-AGJ86can reside at a location that is occupied by the handle assembly12, such as at a location occupied by the handle body18or at a location occupied by the dial22. The VC-AGJ86can further reside at a location that is occupied by the user's hand94when the user is grasping the handle assembly12in order to manipulate the handle assembly12—this location could be at the handle body18, at the dial22, or at a distance set back and rearward of the handle body18generally along the handle axis24. This location could also be within the confines established in part by a user's palm when the user is grasping the handle assembly12in order to manipulate it.

Additionally, in at least some embodiments, the configuration of the surgical tool10allows for a functional performance characteristic called an articulated roll. The articulated roll takes place when the handle assembly12is first rotated to position that may be any combination of pitch/yaw angle and the handle assembly12is maintained in that orientation relative to the trocar relative ground. Then, the user provides a roll input to the distal region90of the handle assembly12(e.g., the dial22). The result is that the orientation of the handle assembly12may remain stationary while the frame26rolls, or spins along the shaft axis30. Combining the articulated roll input with functionality provided by a connected AIJ32, the user may replicate the articulated roll at the EE assembly16.

The location of the virtual center (i.e., VC-AIJ72and VC-AGJ86) may also have an interesting impact on user experience during articulation motions. When the user provides a positive pitch input to the handle assembly12, the distal region90of the handle assembly12moves in a positive +Y-direction. This correlates directly with the desired effect to the EE assembly16distally mounted to the frame26and shaft28subassembly when connected via pulleys and cables. In other words, the fine motor movement of the user's thumb and forefinger while gripping the distal region90of the handle assembly12are intuitively mapped to end-effector assembly motion. This occurs even despite the negative Y displacement of the proximal region88of the handle assembly12where a great proportion of the user input forces are located. The intuitive relationship exists for handle assembly12yaw motions as well.

In a parallel-kinematic (PK) mechanism, for pitch inputs, the handle assembly12rotates about the virtual center (i.e., VC-AIJ72and VC-AGJ86). For clockwise pitch inputs (relative to orientation ofFIG.1) at the handle assembly12, the distal region90of the handle assembly12shifts in the negative −Y-direction while the proximal region88of the handle assembly12shifts in the positive +Y-direction. The resultant motion of the EE assembly16is to articulate in a similar clockwise direction (south, or +Z axis rotation). This contrasts with the handle assembly12motion in a serial-kinematic (SK) mechanism with a distally located virtual center whereby the entire handle assembly12shifts in a positive +Y-direction while rotating clockwise. For a user to point the EE assembly16into the south direction of a device using a SK joint, the user raises the handle assembly12while rotating it about a distally-located virtual center.

3. Surgical Tool and Assembly Architectures I-V

According to at least some embodiments, the surgical tool10may be an assembly of various sub-assemblies, namely, the handle assembly12, the frame26, the shaft28, and the EE assembly16. There may also exist various joints/mechanisms and transmission assemblies within and/or between the sub-assemblies to facilitate certain functionality of the surgical tool10. The surgical tool10may provide various functions which correspond to following output motions: i) articulation motion (i.e., pitch and yaw rotation) of the EE assembly16; ii) rigid body motion of the shaft28and the EE assembly16; iii) articulated roll motion of the EE assembly16(or portion thereof); and iv) jaw closure motion at the EE assembly16.

Although the surgical tool10may be configured with the jaw closure motion function (iv), the function is facilitated via a series of interconnected transmission members mounted between the bodies mentioned above. This embodiment (FIG.1) would have the handle assembly12, frame assembly14, and EE assembly16(or similarly manipulated assembly).

Of the four functions identified, the two primary functions per certain embodiments are articulation motion of the EE assembly16and rigid body motion of the shaft28and of the EE assembly16. The articulation function and rigid body motion, and particularly the rigid body motion along the shaft axis30, are described by way of surgical tool constraint maps.FIGS.9-16show embodiments of the interfaces between the handle assembly12and the frame assembly14that are established via joints/mechanisms. This function pertaining to rigid body motion of handle assembly12, frame26, and the overall surgical tool10along the shaft axis30is also referred to as axial grounding. One interface relates to the articulation function which is facilitated by a 2 DoF pitch and yaw motion articulation input joint/mechanism. This joint is the AIJ32. Another interface is related to the axial grounding function which is facilitated by a 1 DoC joint/mechanism along shaft axis30. This joint is the AGJ50. These respective joints may be same or separate joints/mechanisms, according to different embodiments. Various constraint maps that are discussed below go through different types of such joints.

FIG.3is a chart that presents multiple surgical tool architectures and various joints that can effect the functionality at the interfaces set forth above, per at least some embodiments of the surgical tool10.

Surgical tool architecture I refers to an apparatus which utilizes a parallel-kinematic (PK) joint as the AIJ32. The PK AIJ32provides independent pitch and yaw motion paths to transmit motion from the handle assembly12to the EE assembly16. The PK AIJ32is also a virtual center (VC1) joint, meaning it establishes the VC-AIJ72. The AGJ50for architecture I is a serial-kinematic (SK), virtual center (VC2) joint. The VC-AGJ86is established in this architecture. The VC-AIJ72and VC-AGJ86generally intersect and coincide, as previously described, to form a common virtual center of rotation. In case the VC-AIJ72and VC-AGJ86do not intersect and coincide, the kinematics may get compromised and this may lead to binding/freezing of motion due to a lack of a single virtual center of rotation. Architecture I is shown in the schematic diagram ofFIG.5. InFIG.5, the PK AIJ32is demonstrated via the intermediate body1, intermediate body2, pitch DoF pin joint1, flexible connector/joint1allowing pitch motion transmission, yaw DoF pin joint2, and flexible connector/joint2allowing yaw motion transmission. The SK AGJ50is demonstrated via the intermediate body3, pitch DoF joint, and yaw DoF joint.

Surgical tool architecture II utilizes an AIJ32that is a serial-kinematic (SK), non-virtual center (VC) joint. In a non-VC joint, the pitch axis of rotation74and the yaw axis of rotation76do not intersect with each other. The AGJ50in the case of architecture II is a SK, VC joint. The VC-AGJ86is established in this architecture. Architecture II is shown in the schematic diagram ofFIG.6. InFIG.6, the SK AIJ32is demonstrated via the intermediate body1, pitch DoF joint1, and yaw DoF joint1. The SK AGJ50is demonstrated via the intermediate body2, pitch DoF joint2, and yaw DoF joint2.

Surgical tool architecture III utilizes an AIJ32that is a parallel-kinematic (PK), virtual center (VC1) joint. The VC-AIJ72is established in this architecture. The AGJ50in the case of architecture III is a parallel-kinematic (PK), virtual center (VC2) joint which also provides translation DoC along shaft axis30apart from allowing pitch and yaw DoF motions. The VC-AGJ86is established in this architecture. The VC-AIJ72and VC-AGJ86generally intersect and coincide, as previously described, to form a common virtual center of rotation. In case the VC-AIJ72and VC-AGJ86do not intersect and coincide, the kinematics may get compromised and this may lead to binding/freezing of motion due to a lack of a single virtual center of rotation. Architecture III is shown in the schematic diagram ofFIG.7. InFIG.7, the PK AIJ32is demonstrated via the intermediate body1, intermediate body2, pin joint1, flexible connector/joint1, pin joint2, and flexible connector/joint2. The PK AGJ50is demonstrated by the intermediate body3, intermediate body4, pin joint3, flexible connector/joint3, pin joint4, and joint providing translation DoC along the shaft axis30.

Surgical tool architecture IV utilizes an AIJ32that is a serial-kinematic (SK), non-virtual (VC) joint. In a non-VC joint, the pitch axis of rotation74and the yaw axis of rotation76do not intersect with each other. The AGJ50in the case of architecture IV is a parallel-kinematic (PK), VC joint which also provides translation DoC along shaft axis30apart from allowing pitch and yaw DoF motions. The VC-AGJ86is established in this architecture. Architecture IV is shown in the schematic diagram ofFIG.8. InFIG.8, the SK AIJ32is demonstrated via the intermediate body3, pitch DoF joint, and yaw DoF joint. The PK AGJ50is demonstrated by the intermediate body1, intermediate body2, pitch DoF pin joint1, joint providing translation DoC along the shaft axis30, yaw DoF pin joint2, and flexible connector/joint2allowing yaw motion transmission.

Surgical tool architecture V utilizes an AIJ32that is a serial-kinematic (SK), virtual center (VC1) joint. The VC-AIJ72is established in this architecture. The AGJ50in the case of architecture V is a serial-kinematic (SK), virtual center (VC2) joint which also provides translation DoC along the shaft axis30apart from allowing pitch and yaw DoF motions. The VC-AGJ86is established in this architecture. The VC-AIJ72and VC-AGJ86generally intersect and coincide, as previously described, to form a common virtual center of rotation. Architecture V is shown in the schematic diagram ofFIG.33. InFIG.33, the SK AIJ32is demonstrated via the intermediate body1, intermediate body2, intermediate body3, rotational DoF joint1, and rotational DoF joint2. The SK AGJ50is demonstrated via the intermediate body1, intermediate body2, intermediate body3, rotational DoF joint1, and rotational DoF joint2.

3.1 Architecture I

The embodiments ofFIGS.9-23,28, and32all present the surgical tool10and an assembly thereof consisting of the handle assembly12and frame assembly14that exhibit the first architecture I. In architecture I, as set forth above, the PK AIJ32is provided, and the VC-AIJ72and VC-AGJ86are established. These embodiments map to the schematic diagram ofFIG.5. With general reference toFIGS.9-23,28, and31, the first pulley axis68and the second pulley axis70represent the two axes of rotation which are orthogonal with respect to each other. About the first and second pulley axes68,70, the two degrees of freedom are captured to produce articulation at the EE assembly16. The first and second pulley axes68,70, in certain scenario, may generally intersect and generally coincide with the pitch axis74and the yaw axis76, respectively. The first and second pulley axes68,70also meet via intersection at the VC-AIJ72.

The handle assembly12, specifically the dial22in this embodiment, is connected to the frame26via the first pulley64which is considered an intermediate body54in at least some embodiments, and is connected to the frame26via the second pulley66which is also considered an intermediate body54in at least some embodiments. Rotation of the first pulley64about the first pulley axis68captures one motion, whereas rotation of the second pulley66about the second pulley axis70captures another motion. Given the orthogonality between the first and second pulley axes68,70, these two motions are mutually exclusive and therefore, account for two DoF motions of the EE assembly16. The first intermediate body56, or first connector, that links the dial22to the first pulley64transmits handle assembly12motion when it rotates about the first pulley axis68, and conversely does not transmit handle assembly12motion when it rotates solely about the second pulley axis70. The same holds true for the second intermediate body58, or second connector, that links the dial22to the second pulley66. In the embodiments ofFIGS.9-14, the first and second intermediate bodies56,58are shown as a series of planar linkages with pivots that facilitate rotation of the handle assembly12relative to the frame26about the pitch and yaw axes74,76. In the embodiments ofFIGS.15-23and28, the first and second intermediate bodies56,58are shown as the flex strips52with pivots that facilitate rotation of the handle assembly12relative to the frame26about the pitch and yaw axes74,76. These intermediate bodies56,58may also be flexible living hinges composed of a material such as polypropylene.

As set forth above, in architecture I, the SK AGJ50is provided and the VC-AGJ86is established. InFIGS.9-16, the pitch and yaw DoF motions of the handle assembly12, specifically the dial22, are captured by the pitch DoF joint80between the dial22and the third intermediate body78or deviation ring, and is captured by the yaw DoF joint82between the frame assembly14and the third intermediate body78or deviation ring. In addition, as described, the AGJ50provides the translation degree of constraint along the shaft axis30between the handle assembly12and the frame assembly14, among the other translation degrees of constraint provided by the AGJ50between the handle assembly12and the frame assembly14(i.e., y-axis and z-axis). The VC-AIJ72and VC-AGJ86generally coincide to provide a unified surgical tool and assembly consisting of two different types of joints that facilitate articulation and axial grounding functions. Here too, the handle axis24intersects the VC-AIJ72and intersects the VC-AGJ86, and the shaft axis30likewise intersects the VC-AIJ72and intersects the VC-AGJ86.

In architecture I, and as previously described, the VC-AIJ72resides at a location that is occupied by the handle assembly12, can reside at a location that is occupied by a user's hand94when the user is grasping the handle assembly12in order to manipulate the handle assembly12, or can reside at both locations when those locations are one and the same. In a similar way, the VC-AGJ86resides at a location that is occupied by the handle assembly12, can reside at a location that is occupied by a user's hand94when the user is grasping the handle assembly12in order to manipulate the handle assembly12, or can reside at both locations when those locations are one and the same.

Furthermore, the embodiments ofFIGS.17-23andFIG.28differs in some regards with the embodiments ofFIGS.9-16. For instance, the frame26inFIGS.17-23and28has unitary extension arms96. The extension arms96are rigid bodies, and can constitute intermediate bodies of the surgical tool10or can be constituent parts of the frame assembly14. Also, the pin joints that furnish the pitch DoF joint80are a connection between the frame26and its extension arms96and the third intermediate body78or deviation ring; and the pin joints that furnish the yaw DoF joint82are a connection between the handle assembly12and its extension arms84and the third intermediate body78or deviation ring. The embodiment ofFIG.32is similar in many regards to that ofFIGS.17-23and28. The frame26and extension arms96inFIG.32present a fuller ring-like shape than the same components inFIGS.17-23and28.

3.2 Architecture II

The embodiment ofFIG.24presents the surgical tool10and assembly thereof consisting of the handle assembly12and frame assembly14that exhibit the second architecture II. In architecture II, as set forth above, the SK AIJ32is provided and is a non-VC joint, and the SK AGJ50is provided and the VC-AGJ86is established. This embodiment maps to the schematic diagram ofFIG.6. With reference toFIG.24, the AGJ50of architecture II can be similar to the AGJ50presented inFIGS.15and16. InFIG.24, and as before, the AGJ50provides the translation degree of constraint along the shaft axis30between the handle assembly12and the frame assembly14, among the other translation degrees of constraint provided by the AGJ50between the handle assembly12and the frame assembly14(i.e., y-axis and z-axis). Unlike other embodiments, the second pulley axis70of the AIJ32is established between the handle assembly12and the first intermediate body56. The second pulley axis70is along the first pin joint60thereat, and the first and second pulley axes68,70do not intersect (hence, non-VC AIJ joint). Here, the first intermediate body56is a compliant member which allows for rotation of the handle assembly12about the VC-AGJ86. And unlike other embodiments, a rotary encoder98is situated at the first pin joint60between the handle assembly12and the first intermediate body56. The rotary encoder98serves to capture rotation about the second pulley axis70. As in previous embodiments, the first intermediate body56rotates with respect to the frame assembly12and frame26via the first pulley64and about the first pulley axis68. Rotation of handle assembly12and thereby the first intermediate body56about the first pulley axis68may connect to a mechanism transmission assembly that terminates at the EE assembly16.

3.3 Architecture III

The embodiment ofFIG.25presents the surgical tool10and assembly thereof consisting of the handle assembly12and frame assembly14that exhibit the third architecture III. In architecture III, as set forth above, the PK AIJ32is provided and the VC-AIJ72is established, and the PK AGJ50is provided and the VC-AGJ86is established. This embodiment maps to the schematic diagram ofFIG.7. With reference toFIG.25, the PK AIJ32of architecture III can be similar to the AIJ32of architecture I and presented inFIGS.9-23,28, and32. Unlike previous embodiments, the PK AGJ50includes a constraint peg100which facilitates the translation degree of constraint along the shaft axis30between the handle assembly12and the frame assembly14provided by the AGJ50. The constraint peg100can be a rigid body extension of the handle assembly12and of the dial22. As before, the AGJ50also provides translation degrees of constraint in the y-axis and z-axis between the handle assembly12and the frame assembly14. Further, a fourth intermediate body102and a fifth intermediate body104are provided in the third architecture III as part of the AGJ50. The fourth and fifth intermediate bodies102,104are able to rotate about the pitch and yaw axes74,76, respectively, and with respect to the frame26and its extension arms96in order to furnish two DoF motion of the handle assembly12. The extension arms96inFIG.25present a full ring shape, as indicated by reference numeral106.

3.4 Architecture IV

The embodiment ofFIGS.26and27present the surgical tool10and assembly thereof consisting of the handle assembly12and frame assembly14that exhibit the fourth architecture IV. Combining the components and assemblies of the AIJ32ofFIG.26(as described with reference toFIG.24and architecture II) with the AGJ50ofFIG.27(as described with reference toFIG.25and architecture III) provides the fourth architecture IV. In architecture IV, as set forth above, the SK AIJ32is provided and is a non-VC joint, and the PK AGJ50is provided and the VC-AGJ86is established. This embodiment maps to the schematic diagram ofFIG.8. The constraint peg100facilitates the translation degree of constraint along the shaft axis30between the handle assembly12and the frame assembly14provided by the AGJ50. The AGJ50also provides translation degrees of constraint in the y-axis and z-axis between the handle assembly12and the frame assembly14. The fourth intermediate body102and the fifth intermediate body104are provided in the fourth architecture IV as part of the AGJ50.

Other Types of Transmission Members

Furthermore, for embodiments of the surgical tool10that employ the flex strips52as an intermediate body—for example, the embodiments of architecture I—the flex strips52could take a different form and could be replaced by other types of transmission members. When employed in embodiments of the first architecture I, an additional rotational DoF may be furnished between the flex strips52(and transmission members) and the handle assembly12about the handle axis24in order to preclude an unwanted binding condition that might otherwise arise. InFIG.28, a joint107provides the rotational DoF between the flex strips52and an end of the handle assembly12(e.g., dial22) about the handle axis24. The joint107can be a pin joint, for instance. One example of a type of transmission member is presented inFIG.29. A telescoping transmission member108can be connected between the handle and frame assemblies12,14via hinged joints. One of the hinged joints is at the handle assembly12, and can be at the dial22; the other of the hinged joints is at the first or second pulleys64,66. The hinged joint at the dial22is, in this embodiment, via a tab109(FIGS.30,31). The tab109furnishes the additional rotational DoF between the telescoping transmission member108(as well as the transmission members set forth in this paragraph) and the handle assembly12about the handle axis24in order to preclude the unwanted binding condition. A slot111accommodates the additional rotational DoF. Individual bodies110, four in total here, can expand and contract relative to one another in order to lengthen and shorten the overall extent of the telescoping transmission member108.FIG.30presents another example. An extendable transmission member112can similarly be connected between the handle and frame assemblies12,14via hinged joints. A first body114is hinged to the handle assembly12. A slidable body116is hinged to the first body114via a hinged joint118. The slidable body116slides and moves fore and aft relative to a second body120, thereby lengthening and shortening the overall extent of the extendable transmission member112. The second body120is hinged to the first and/or second pulley64,66.FIG.31presents yet another example. A curved transmission member122can similarly be connected between the handle and frame assemblies12,14via hinged joints. A first curved body124is hinged to the handle assembly12, and a second curved body126is hinged to the first and/or second pulley64,66. A hinged joint128connects the first and second curved bodies124,126together. The transmission members108,112, and122have been found to resolve the unwanted binding condition that may arise in some circumstances amid use of the surgical tool10. Moreover, the transmission members108,112, and122could replace the first and second intermediate bodies54,56in the embodiments ofFIGS.9-23,28, and32.

3.5 Architecture V

The embodiments ofFIGS.34-40present the surgical tool10and an assembly thereof consisting of the handle assembly12and frame assembly14that exhibit the fifth architecture V. In architecture V, as set forth above, the SK AIJ32is provided, the SK AGJ50is provided, and the VC-AIJ72and VC-AGJ86are established. These embodiments map to the schematic diagram ofFIG.33. As before, the VC-AIJ72and VC-AGJ86exhibit a generally coincident arrangement relative to each other, and the handle axis24and the shaft axis30exhibit a generally intersecting arrangement with the VC-AIJ72and with the VC-AGJ86. In architecture V, the VC-AIJ72resides at a location that is occupied by the handle assembly12, can reside at a location that is occupied by the user's hand94when the user is grasping the handle assembly12in order to manipulate the handle assembly12, or can reside at both locations when those locations are one and the same. In a similar way, the VC-AGJ86resides at a location that is occupied by the handle assembly12, can reside at a location that is occupied by the user's hand94when the user is grasping the handle assembly12in order to manipulate the handle assembly12, or can reside at both locations when those locations are one and the same. The AGJ50provides the translation degree of constraint along the shaft axis30between the handle assembly12and the frame assembly14, or along the x-axis, and provides the translation degrees of constraint between the handle assembly12and the frame assembly14in the y-axis and the z-axis. Unlike previous embodiments, in architecture V and in the embodiments ofFIGS.34-40, the first pulley axis68coincides and corresponds with the pitch axis74, and the second pulley axis70similarly coincides and corresponds with the yaw axis76. In other words, the first pulley axis68and pitch axis74constitute one and the same axis, and the second pulley axis70and yaw axis76constitute one and the same axis.

A first intermediate body130extends from the handle assembly12, and particularly from the dial22. The first intermediate body130is a rigid body. End-to-end over its full extent, the first intermediate body130has an arcuate profile and a half-ring shape. The first intermediate body130is rigidly fixed to the handle assembly12, and can be a unitary extension thereof and a unitary extension of the dial22. Indeed, the first intermediate body130can be a constituent part of the handle assembly12, and hence could be considered a part of the handle assembly12. In this embodiment, there is no relative movement between the first intermediate body130and the dial22amid use of the surgical tool10. A second intermediate body132extends from the frame assembly14, and particularly from the shaft28or from a shaft mount134. The second intermediate body132is a rigid body. End-to-end over its full extent, the second intermediate body132has an arcuate profile and a half-ring shape. The second intermediate body132is rigidly fixed to the frame assembly14, and can be a unitary extension thereof and a unitary extension of the shaft28or shaft mount134. Indeed, the second intermediate body132can be a constituent part of the frame assembly14, and hence could be considered a part of the frame assembly14. In this embodiment, there is no relative movement between the second intermediate body132and the shaft28amid use of the surgical tool10.

The third intermediate body78, or deviation ring, is joined to the first intermediate body130via a first joint or the fourth set of pin joints82, and is joined to the second intermediate body132via a second joint or the third set of pin joints80. Over its full extent, the third intermediate body78has a full-ring shape. The third intermediate body78is a rigid body. The fourth set of pin joints82provides a yaw DoF joint between the first intermediate body130and the third intermediate body78. The third set of pin joints80provides a pitch DoF joint between the second intermediate body132and the third intermediate body78. The fourth set of pin joints82constitutes the sole connection and joint between the first intermediate body130and the third intermediate body78, and, likewise, the third set of pin joints80constitutes the sole connection and joint between the second intermediate body132and the third intermediate body78. The fourth set of pin joints82includes a pair of individual pin joints82distanced one-hundred-and-eighty degrees (180°) apart from each other over the circumference of the third intermediate body78. Similarly, the third set of pin joints80includes a pair of individual pin joints80distanced one-hundred-and-eighty degrees (180°) apart from each other over the circumference of the third intermediate body78. Relative to one another, individual pin joints80,82are orthogonally arranged, and distanced ninety degrees (90°) apart over the circumference of the third intermediate body78.

At one of the pair of individual pin joints82, the second pulley66is situated and captures yaw rotation of the first intermediate body130with respect to the third intermediate body78about the second pulley axis70and about the yaw axis76. As previously described, the captured yaw rotation is transmitted to the EE assembly16via the articulation transmission member which may be in the form of a wire or cable of the second pulley66that is routed to the EE assembly16. At one of the pair of individual pin joints80, the first pulley64is situated and captures pitch rotation of the second intermediate body132with respect to the third intermediate body78about the first pulley axis68and about the pitch axis74. As previously described, the captured pitch rotation is transmitted to the EE assembly16via the articulation transmission member which may be in the form of a wire or cable of the first pulley64that is routed to the EE assembly16.

In yet another embodiment of the fifth architecture V similar to the embodiment presented particularly byFIGS.34-39, the third intermediate body78can be set back farther rearward relative to the handle assembly12than shown. The handle assembly12would remain in its location illustrated. This possibility is represented inFIG.38by the arrowed line136. The first and second intermediate bodies130,132would in turn have greater rearward extents to make their respective connections to the third intermediate body78and hence serve to position the third intermediate body78. The effect of this embodiment would be to locate the VC-AIJ72and the VC-AGJ86farther rearward of the handle assembly12, and even distanced beyond the handle assembly12. The VC-AIJ72and VC-AGJ86could then be located closer to a user's palm, for instance.

With particular reference now toFIG.40, in this embodiment of architecture V, a swash plate138is furnished adjacent the shaft28. The articulation transmission members in the form of wires or cables140, for example, of the first and second pulleys64,66are routed through the swash plate138in order to provide a means to modify a transmission ratio between handle rotation and EE assembly16articulation depending on the desired force or motion of handle input and EE output. Different ratios, per this embodiment, can be effected by radially changing the termination or grounding points of input wires140(from the frame26) and output wires140(to the EE assembly16). Further, the swash plate138would effect a smoother transition of forces and cable pulls when the handle assembly12is articulated in different directions since the cables are connected to the same plate.

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

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