Highly articulated laparoscopic joint including electrical signal transmission therethrough

A robotic electromechanical surgical instrument includes a housing, an elongated shaft that extends distally from the housing, a wrist assembly supported on the elongated shaft, an end effector coupled to the wrist assembly, cables coupled to the wrist assembly, and an electrical cable coupled to the end effector. The wrist assembly includes a first joint coupled to a second joint. The first joint includes a proximal segment defining an arcuate surface and a distal segment defining an arcuate surface. The electrical cable is positioned relative to the proximal arcuate surface and the distal arcuate surface such that during articulation of the wrist assembly the electrical cable rolls off of the distal arcuate surface as the electrical cable rolls on to the proximal arcuate surface and the electrical cable rolls off of the proximal arcuate surface as the electrical cable rolls on to the distal arcuate surface.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a U.S. National Stage Application filed under 35 U.S.C. § 371(a) of International Patent Application Serial No. PCT/US2019/050272, filed Sep. 10, 2019, which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/732,108, filed Sep. 17, 2018, the entire disclosure of which is incorporated by reference herein.

International Patent Application Serial No. PCT/US2019/050272 is also a Continuation-in-Part Application of International Patent Application Serial No. PCT/US2019/012017, filed Jan. 2, 2019 (now U.S. patent application Ser. No. 16/769,938, filed under 35 U.S.C. § 371(a) on Jun. 4, 2020) which claims the benefit of and priority to U.S. Provisional Application Ser. No. 62/613,567, filed on Jan. 4, 2018, the entire content of which is incorporated herein by reference.

BACKGROUND

Robotic surgical systems have been used in minimally invasive medical procedures. Some robotic surgical systems include a console supporting a surgical robotic arm and a surgical instrument having at least one end effector (e.g., a forceps or a stapling device) mounted to the robotic arm. The robotic arm provides mechanical power to the surgical instrument for its operation and movement. Each robotic arm may include an instrument drive unit that is operatively connected to the surgical instrument. The surgical instruments may include cables that are motor driven to operate end effectors of the surgical instruments.

SUMMARY

The present disclosure relates to surgical instruments for use in surgical procedures. More specifically, the present disclosure relates to articulable robotic surgical instruments for robotic surgical systems used to conduct minimally invasive surgical procedures. The present disclosure provides for small surgical instruments for robotic surgical systems that provide increased articulation, torque transmission, and mechanical manipulation.

In accordance with an aspect of the present disclosure, a robotic electromechanical surgical instrument is provided. The surgical instrument includes a housing, an elongated shaft that extends distally from the housing, a wrist assembly supported on the elongated shaft, an end effector coupled to the wrist assembly, cables coupled to the wrist assembly, and an electrical cable coupled to the end effector.

The elongated shaft defines a longitudinal axis. The wrist assembly includes a first joint coupled to a second joint. The cables are movable to manipulate the first and second joints to enable the wrist assembly to articulate relative to the longitudinal axis. The first joint includes a proximal segment defining an arcuate surface and a distal segment defining an arcuate surface. The electrical cable is positioned relative to the proximal arcuate surface and the distal arcuate surface such that, during articulation of the wrist assembly, the electrical cable rolls off of the distal arcuate surface as the electrical cable rolls on to the proximal arcuate surface, and the electrical cable rolls off of the proximal arcuate surface as the electrical cable rolls on to the distal arcuate surface.

The proximal and distal segments of the first joint are supported for movement relative to one another to facilitate articulation of the wrist assembly relative to the longitudinal axis of the elongated shaft. A link may be coupling the proximal segment of the first joint to the distal segment of the first joint.

In certain aspects, the proximal segment of the first joint defines a proximal aperture and the distal segment of the first joint defines a distal aperture which is misaligned with the proximal aperture. The electrical cable may be disposed through the proximal aperture and the distal aperture.

In certain aspects, the electrical cable is positioned between the proximal segment and the distal segment of the first joint such that, as the distal segment articulates relative to the proximal segment, the electrical wire rolls onto the distal arcuate surface at a rate and the electrical wire rolls off of the proximal arcuate surface at the same rate.

In some aspects, the electrical cable is configured to transmit electrosurgical treatment energy to a portion of the end effector. Additionally, or alternatively, the electrical cable is configured to transmit a sensor signal from the end effector.

In some aspects, the second joint includes a proximal segment defining a proximal arcuate surface and a distal segment defining a distal arcuate surface. The electrical cable may be positioned relative to the proximal arcuate surface of the second joint and the distal arcuate surface of the second joint such that, during articulation of the wrist assembly, the electrical cable rolls off of the distal arcuate surface of the second joint as the electrical cable rolls on to the proximal arcuate surface of the second joint, and the electrical cable rolls off of the proximal arcuate surface of the second joint as the electrical cable rolls on to the distal arcuate surface of the second joint.

In certain aspects, the electromechanical surgical instrument may include a second electrical cable. The proximal segment of the first joint may define a second proximal arcuate surface, the distal segment of the first joint may define a second distal arcuate surface, and the second electrical cable is positioned such that, during articulation of the wrist assembly, the second electrical cable rolls off of the second distal arcuate surface as the electrical cable rolls on to the second proximal arcuate surface, and the second electrical cable rolls off of the second proximal arcuate surface as the second electrical cable rolls on to the second distal arcuate surface.

In certain aspects, the housing includes an electrical contact disposed thereon and the electrical cable is coupled to the electrical contact.

According to another aspect, a wrist assembly for use with an electromechanical surgical instrument is provided. The wrist assembly includes a first joint and a second joint operably coupled to the first joint and a plurality of cables coupled to at least one of the first joint or the second joint. The plurality of cables are movable to manipulate the first and second joints to enable the wrist assembly to articulate relative to a longitudinal axis defined by the wrist assembly in an unarticulated position. The first joint includes a proximal segment defining a proximal arcuate surface and a distal segment defining a distal arcuate surface. An electrical cable is positioned relative to the proximal arcuate surface and the distal arcuate surface such that, during articulation of the wrist assembly, the electrical cable rolls off of the distal arcuate surface as the electrical cable rolls on to the proximal arcuate surface, and the electrical cable rolls off of the proximal arcuate surface as the electrical cable rolls on to the distal arcuate surface.

In certain aspects, the proximal segment of the first joint defines a proximal aperture and the distal segment of the first joint defines a distal aperture which is misaligned with the proximal aperture. The electrical cable may be disposed through the proximal aperture and the distal aperture. A link may be coupling the proximal segment of the first joint to the distal segment of the first joint.

In certain aspects, the electrical cable is positioned between the proximal segment and the distal segment of the first joint such that, as the distal segment articulates relative to the proximal segment, the electrical wire rolls onto the distal arcuate surface at a rate and the electrical wire rolls off of the proximal arcuate surface at the same rate.

In some aspects, the electrical cable is configured to transmit electrosurgical treatment energy to a portion of the end effector. Additionally, or alternatively, the electrical cable is configured to transmit a sensor signal from the end effector.

In some aspects, the second joint includes a proximal segment defining a proximal arcuate surface and a distal segment defining a distal arcuate surface. The electrical cable may be positioned relative to the proximal arcuate surface of the second joint and the distal arcuate surface of the second joint such that, during articulation of the wrist assembly, the electrical cable rolls off of the distal arcuate surface of the second joint as the electrical cable rolls on to the proximal arcuate surface of the second joint, and the electrical cable rolls off of the proximal arcuate surface of the second joint as the electrical cable rolls on to the distal arcuate surface of the second joint.

In certain aspects, the wrist assembly may include a second electrical cable. The proximal segment of the first joint may define a second proximal arcuate surface, the distal segment of the first joint may define a second distal arcuate surface, and the second electrical cable is positioned such that, during articulation of the wrist assembly, the second electrical cable rolls off of the second distal arcuate surface as the electrical cable rolls on to the second proximal arcuate surface, and the second electrical cable rolls off of the second proximal arcuate surface as the second electrical cable rolls on to the second distal arcuate surface.

Advantageously, the presently disclosed surgical instruments provide deterministic end effector position while resisting external loading (e.g., from the patient anatomy) from affecting the drive system. In addition, the presently disclosed surgical instruments include knuckle gearing (or coupling) with interlocking geometry that maintains rolling contact between gears to prevent ‘S’ condition in the joint where the end effector location would be non-deterministic.

The presently disclosed surgical instruments also provide high articulation (e.g., +/−70 degrees) in two directions while maintaining minimal bend radius. In some embodiments, additional cables can be routed to provide additional mechanical functionality at the end effector (e.g., a dedicated grasp function).

Additionally, the presently disclosed surgical instruments and wrist assemblies include structural features that facilitate passage of electrical cables therethrough with minimal resistance and minimal stress imparted on electrical cables during articulation of wrist assembly. Despite high articulation of the components of wrist assembly, the electrical cables do not translate longitudinally through any of the joints or components of the wrist assembly. This eliminates the need for tensioning or payout mechanisms that would otherwise be required to drive any cables or wires during articulation. Elimination of longitudinal translation of electrical cables also reduces the possibility of failures due to wear and abrasion of electrical cables and any components in contact with electrical cables. The electrical cables bend through only a single axis during articulation of the wrist assembly, as opposed to being bend in multiple directions, which significantly extends the lifetime of the electrical cables and even the components the electrical cables are in contact with. Additionally, the electrical cables are positioned within the wrist assembly, beneath drive cabling and shielding structures throughout the full articulation range, which reduces chances of damage to the electrical wires from incidental contact and reprocessing.

Other aspects, features, and advantages provided by some or all of the illustrative embodiments described herein will be apparent from the description, the drawings, and the claims that follow.

DETAILED DESCRIPTION

Embodiments of the present surgical instruments for robotic surgical systems are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term “distal” refers to structure that is closer to a patient, while the term “proximal” refers to structure farther from the patient.

As used herein, the term “clinician” refers to a doctor, nurse, or other care provider and may include support personnel. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

Referring initially toFIG.1, a surgical system, such as, for example, a robotic surgical system1, generally includes one or more surgical robotic arms2,3, a control device4, and an operating console5coupled with control device4. Any of the surgical robotic arms2,3may have a robotic surgical assembly100and an electromechanical surgical instrument200coupled thereto. Electromechanical surgical instrument200includes an end effector300disposed at a distal portion thereof. In some embodiments, robotic surgical assembly100may be removably attached to a slide rail40of one or more of surgical robotic arms2,3. In certain embodiments, robotic surgical assembly100may be fixedly attached to slide rail40of one or more of surgical robotic arms2,3.

Operating console5of robotic surgical system1includes a display device6, which is set up to display three-dimensional images; and manual input devices7,8, by means of which a clinician (not shown), is able to telemanipulate the robotic arms2,3of robotic surgical system1in a first operating mode, as known in principle to a person skilled in the art. Each robotic arm of robotic arms2,3may be composed of any number of members, which may be connected through any number of joints. Robotic arms2,3may be driven by electric drives (not shown) that are connected to control device4. Control device4(e.g., a computer) of robotic surgical system1is set up to activate the drives, for example, by means of a computer program, in such a way that robotic arms2,3, the attached robotic surgical assembly100, and thus electromechanical surgical instrument200(including end effector300) of robotic surgical system1execute a desired movement according to a movement defined by means of manual input devices7,8. Control device4may be set up in such a way that it regulates movement of robotic arms2,3and/or of the drives.

Robotic surgical system1is configured for use on a patient “P” positioned (e.g., lying) on a surgical table “ST” to be treated in a minimally invasive manner by means of a surgical instrument, e.g., electromechanical surgical instrument200and, more specifically, end effector300of electromechanical surgical instrument200. Robotic surgical system1may include more than two robotic arms2,3, the additional robotic arms are likewise connected to control device4and telemanipulatable by means of operating console5. A surgical instrument, for example, electromechanical surgical instrument200(including end effector300thereof), may also be attached to any additional robotic arm(s).

Control device4of robotic surgical system1may control one or more motors (not shown), each motor configured to drive movement of robotic arms2,3in any number of directions. Control device4may control an instrument drive unit110including one or more motors50(or motor packs). Motors50drive various operations of end effector300of electromechanical surgical instrument200. Motors50may include a rotation motor, such as, for example, a canister motor. One or more of motors50(or a different motor, not shown) may be configured to drive a rotation of electromechanical surgical instrument200, or components thereof, relative to a longitudinal axis “L-L” thereof. The one or more motors can be configured to effect operation and/or movement of electromechanical end effector300of electromechanical surgical instrument200.

Turning now toFIG.2, electromechanical surgical instrument200of robotic surgical system1includes a housing202at a proximal end portion thereof and an elongated shaft204that extends distally from housing202. Elongated shaft204includes a wrist assembly206supported on a distal end portion of elongated shaft204that couples end effector300to elongated shaft204.

Housing202of electromechanical surgical instrument200is configured to selectively couple to instrument drive unit110of robotic surgical assembly100, for example, via side loading on a sterile interface module112of robotic surgical assembly100, to enable motors50of instrument drive unit110of robotic surgical assembly100to operate end effector300of electromechanical surgical instrument200. Housing202of electromechanical surgical instrument200supports a drive assembly203that mechanically and/or electrically cooperates with motors50of instrument drive unit110of robotic surgical assembly100.

Drive assembly203of electromechanical surgical instrument200can include any suitable electrical and/or mechanical component to effectuate driving force/movement, and which components may be similar to components of the drive assembly described in commonly owned International Application Publication No. WO2017053358, filed Sep. 21, 2016, the entire disclosure of which is incorporated by reference herein. In particular, as seen inFIGS.3and4, drive assembly203of electromechanical surgical instrument200includes a cable drive assembly203aand a firing assembly203b. The cable drive assembly203ais similar to that described in commonly owned U.S. Patent Application Publication No. 2015/0297199, filed Oct. 22, 2015 and entitled “Adapter Assembly with Gimbal for Interconnecting Electromechanical Surgical Devices and Surgical Loading Units, and Surgical Systems Thereof,” the entire disclosure of which is incorporated by reference herein.

With reference toFIGS.1and15, cable drive assembly203aof electromechanical surgical instrument200includes one or more driven members209, such as driven members209a,209b,209c,209d(FIG.15), to enable robotic surgical assembly100to transfer power and actuation forces from motors50of robotic surgical assembly100to ultimately drive movement of components of end effector300of electromechanical surgical instrument200.

As seen inFIGS.3and4, cable drive assembly203aof electromechanical surgical instrument200includes cables205, such as cables205a,205b,205c, and205d, which are coupled to a respective driven member209a,209b,209c,209d(FIG.15) of electromechanical surgical instrument200at a proximal end portion thereof. Cables205of cable drive assembly203aextend distally to distal end portions thereof, and may include ferrules205x(FIG.4) that couple to wrist assembly206of elongated shaft204at circumferentially spaced apart locations (e.g., angularly displaced) about the longitudinal axis “L-L” to enable cables205to effectuate an articulation/pitch/yaw of wrist assembly206of electromechanical surgical instrument200and end effector300of electromechanical surgical instrument200upon actuation of one or more of cables205. Cable drive assembly203acan include one or more pulleys, friction wheels, gears, couplers, rack and pinion arrangements, etc. coupled directly or indirectly to driven members209and/or cables205to facilitate driving movement imparted through driven members209and/or cables205. The cables205can be arranged such that diagonal cables (e.g. cables205d,205bor cables205a,205c; seeFIG.4) can be positioned to be driven in opposite directions in order to provide articulation in multiple axes (e.g. two). Although only four cables are shown, cable drive assembly203acan include any number of cables, for example, to provide additional functionally at the end effector300.

Turning toFIGS.5and6, wrist assembly206of elongated shaft204of electromechanical surgical instrument200includes, from proximal to distal, a first interface208coupled to a distal portion of an outer tube204aof elongated shaft204, a first joint210coupled to a distal portion of first interface208, a second joint212coupled to a distal portion of first joint210and angularly displaced therefrom (e.g., offset 90 degrees), and a second interface214coupled to a distal portion of second joint212.

With reference toFIG.7, first interface208of wrist assembly206is in the form of a tubular interface and includes a proximal housing208aand a distal housing208bthat extends distally from proximal housing208a, and a central aperture208cthat is defined therethrough to receive firing assembly203bof drive assembly203. Proximal housing208aof first interface208defines a pair of side slots208d(only one side slot208dshown with the other identically disposed on the opposite side of proximal housing208a) that receive distally extending tabs204bof outer tube204a. Proximal housing208afurther defines a plurality of cable channels208f(e.g., four) disposed at circumferentially spaced apart locations about proximal housing208a(only one cable channel208fis explicitly shown). Distal housing208bdefines a first ledge208gand a second ledge208hthat define a transverse channel208ibetween the first and second ledges208g,208h. First and second ledges208g,208hdefine cable apertures208j(e.g., two each) that align with cable channels208fto receive cables205of cable drive assembly203aof drive assembly203therethrough. First and second ledges208g,208hfurther include distal tabs208k,208L that extend distally therefrom.

First joint210of wrist assembly206includes a proximal segment210aand a distal segment210bthat are pivotally coupled together by links or caps210c,210dthat help resist axial loading (created by tensile forces from cables205) and misalignment in a transverse direction. In addition, links210c,210dhelp maintain clearance of, for instance, enmeshed gear teeth (see, e.g.,FIG.9illustrating link210dmaintaining sufficient distance or axial separation between gear teeth210jand210qso that gear teeth210jand210qdo not bind).

Proximal segment210aof first joint210includes proximal tabs210e(only one shown with an identical tab210eshown on an opposite side of proximal segment210a) that are received within transverse channel208iof first interface208. Proximal segment210adefines a transverse recess210fthat is angularly displaced from proximal tabs210e(e.g., 90 degrees) and positioned to receive distal tabs208k,208L of first interface208to prevent proximal segment210aof first joint210from rotating relative to first interface208about longitudinal axis “L-L” (FIG.2) (e.g., tongue and groove type interconnection). Proximal segment210aincludes a first coupler or gear210gand a second coupler or gear210hthat extend distally from proximal segment210on opposed sides of proximal segment210a. First and second gears210g,210hhave a plurality of spaced apart teeth210j. First and second gears210g,210hinclude pins210kthat extend laterally (e.g., perpendicularly) therefrom for engagement with links210d,210cof first joint210. Any of the presently disclosed pins may include rivets or the like. Gears210h,210gare recessed from side surfaces of proximal segment210aof first joint210to facilitate movement of links210c,210dof first joint210and distal segment210bof first joint210relative to proximal segment210a, as distal segment210barticulates relative to proximal segment210a. Proximal segment210aof first joint210further defines a central opening210mfor receiving firing assembly203bof drive assembly203therethrough, and a plurality of cable apertures210n(e.g., four) for receiving the cables205of cable drive assembly203aof drive assembly203therethrough.

Distal segment210bof first joint210includes a coupler with knuckles or gears210p(only one shown with a second identical coupler or gear210pshown on an opposite side of distal segment210b) that extend proximally from distal segment210band are positioned to enmesh or geometrically interlock (e.g., teeth210qthereof) with first and second gears210g,210hof proximal segment210aof first joint210to maintain rolling contact between respective interlocked gears (e.g.,210p,210h; seeFIGS.7,9and13) and to prevent an ‘S’ condition in the joint where the end effector location would be non-deterministic. Distal segment210bfurther includes pins or bosses210r(only one shown with a second identical pin210rshown on an opposite side of distal segment210b) that extend laterally from (e.g., perpendicularly from) gears210p. Distal segment210bfurther defines recesses210tand includes distally extending tabs210uthat are alternately interspersed and disposed at angularly displaced locations (e.g., 90 degrees apart) about a distal end portion of distal end segment210b. Distal segment210bdefines a central aperture210vfor receiving firing assembly203btherethrough and a plurality of cable apertures210w(e.g., four) for receiving cables205of cable drive assembly203atherethrough.

Each of proximal and distal segments210a,210bof first joint210include a pair of tapered surfaces210xthat provide space between the distal and proximal segments210a,210bof first joint210to enable distal segment210bto articulate relative to proximal segment210aas teeth210j,210qof proximal and distal segments210a,210benmesh with one another. Tapered surfaces210xof proximal segment210aare configured to contact tapered surfaces of distal segment210bto limit articulation (e.g., define maximum articulation in a given direction) of distal segment210brelative to proximal segment210a.

Links210c,210dof first joint210define proximal and distal pin apertures210y,210zthat receive pins210k,210rof proximal and distal segments210a,210b, respectively, to secure proximal and distal segments210a,210bof first joint210together and enable distal segment210bto articulate relative to proximal segment210a.

Second joint212of wrist assembly206is identical to first joint210of wrist assembly206but is angularly displaced (e.g., 90 degrees) relative to first joint210so that first and second joints210,212can interconnect and articulate/pivot relative to one another. In particular, second joint212includes a proximal segment212aand a distal segment212bthat are pivotally coupled together by links212c,212dsuch that proximal segment212a, distal segment212b, and links212c,212dof second joint212are identical to proximal segment210a, distal segment210b, and links210c,210dof first joint210, respectively. Proximal segment212aof second joint212is coupled to distal segment210bof first joint210such that proximal segment212aof second joint212is rotationally locked to distal segment210bof first joint210(e.g., tongue and groove type interconnection). In this manner, proximal and distal segments212a,212bof second joint212can articulate/pivot relative to one another while distal segment210bof first joint210articulates/pivots relative to proximal segment210aof first joint210.

Second interface214of wrist assembly206is in the form of a tubular interface and defines proximal and distal recesses214a,214bthat correspond to, and/or are aligned with, one another, respectively. Second interface214includes proximal and distal tabs214c,214dthat correspond to, and/or are aligned with, one another, respectively. Proximal recesses214aand proximal tabs214cof second interface214are configured to engage distally extending tabs210uand recesses210tof second joint212(e.g., tongue and groove type connection) to rotationally lock second interface214to distal segment210bof second joint212. Second interface214further defines cable slots214eat circumferentially spaced apart locations about second interface214that are positioned to receive ferrules205xand cables205therein to secure cables205to second interface214. Second interface214further defines a central aperture214fthat is configured to receive firing assembly203bof drive assembly203therethrough. Second interface214also defines alignment holes214gto facilitate alignment and securement of wrist assembly206to end effector300of electromechanical surgical instrument200.

With reference toFIGS.7-14, firing assembly203bof drive assembly203of electromechanical surgical instrument200, which is in the form of a multi-stage universal joint assembly, includes a drive shaft220, a ball shaft222that extends distally from drive shaft220, a first bearing224supported on ball shaft222to rotatably support ball shaft222, a first ball housing226coupled to a distal portion of ball shaft222, a first dual ball shaft228coupled to first ball housing226and supporting a second bearing230that rotatably supports first dual ball shaft228, a second ball housing232coupled to a distal portion of first dual ball shaft228, a second dual ball shaft234coupled to a distal portion of second ball housing232and supporting a third bearing236that rotatably supports second dual ball shaft234, and a drive coupler238supported on a distal portion of second dual ball shaft234.

Drive shaft220of firing assembly203bof drive assembly203has a proximal end portion coupled to a driven member211(FIG.15) of drive assembly203that operably couples to one or more of motors50of robotic surgical assembly100(seeFIGS.1and15) to enable drive shaft220to rotate about longitudinal axis “L-L,” as indicated by arrows “A” (FIG.7). Drive shaft220extends to a keyed distal portion220aconfigured to be received by a proximal portion of ball shaft222. Keyed distal portion220ais shown with a rectangular configuration, but may have any suitable non-circular configuration such as a triangle, square, star, etc. Keyed distal portion220adefines a pin hole220cconfigured to receive a pin220dtherein.

Ball shaft222of firing assembly203bhas proximal portion222adefining a keyed bore222b(FIG.10) that is configured to receive keyed distal portion220aof drive shaft220therein to enable ball shaft222to rotate with drive shaft220. Keyed bore222bcan have any suitable non-circular configuration and may be configured to complement keyed distal portion220aof drive shaft220to facilitate a rotatably locked connection between ball shaft222and drive shaft220such that ball shaft222and drive shaft220rotate together. Ball shaft222further defines a pin hole222cthat receives pin220dtherein to rotatably couple drive shaft220to ball shaft222(seeFIGS.7and11). Ball shaft222defines an annular clip channel222ein an outer surface thereof. Annular clip channel222eis configured to receive a clip222f(e.g., an E-clip) to obstruct axial movement of first bearing224to enable first bearing224of firing assembly203bto be maintained axially fixed on a bearing surface222gof ball shaft222. Ball shaft222further includes a ball member222hsupported on a distal end portion of ball shaft222. Ball member222hof ball shaft222defines a transverse opening222itherethrough configured to receive a ball pin222jdefining a pin hole222ktherein. Ball member222hfurther defines an elongated slot222mthat is configured to align with pin hole222kof ball pin222j.

First ball housing226of firing assembly203bof drive assembly203has a proximal shell226adefining a proximal bore226btherein that rotatably receives ball member222hof ball shaft222therein. Proximal shell226afurther defines a pin passage226cthat receives a pin226dtherethrough. Pin226dis receivable within elongated slot222mof ball member222hof ball shaft222while received through proximal shell226aof first ball housing226to rotatably couple ball member222hof ball shaft222to proximal shell226aof first ball housing226(seeFIGS.7and8) to define a universal joint and to enable pin226dto move through elongated slot222mof ball member222has first ball housing226articulates/pivots about ball member222h(see, for example, articulation/pivoting indicated by arrows “D” inFIG.16).

First ball housing226of firing assembly203balso includes a distal shell226iconfigured to couple to first dual ball shaft228. Distal shell226idefines a distal bore226jand a pin passage226ktherethrough that receives a pin226mtherein to rotatably/articulatably couple first dual ball shaft228to distal shell226i(e.g., to define another universal joint).

First dual ball shaft228of firing assembly203bincludes a proximal ball member228athat extends proximally from a bearing support surface228b, and a distal ball member228cthat extends distally from bearing support surface228bthat rotatably supports second bearing230. Proximal and distal ball members228a,228cdefine transverse openings228d,228etherethrough, respectively, and elongated slots228n,228ptherethrough, respectively. Transverse openings228d,228eof proximal and distal ball members228a,228care configured to receive ball pins228j,228ktherein, respectively. Each ball pin228j,228kdefines a pin hole228mtherein. Pin hole228mof ball pin228kand elongated slot228nof ball member228aare configured to receive pin226mof first ball housing226to rotatably/articulatably couple first dual ball shaft228to distal shell226iof first ball housing226(e.g., to define universal joints).

Second ball housing232of firing assembly203bof drive assembly203is identical to first ball housing226of firing assembly203band includes a proximal shell232a, a distal shell232bthat extends distally from proximal shell232a, and pins232c,232dthat are received within proximal and distal shells232a,232b, respectively. Pins232c,232dof second ball housing232rotatably couple second ball housing232to ball members228c,234aof first dual ball shaft228and second dual ball shaft234, respectively, (e.g., to define universal joints) similar to the rotatable/articulatable coupling described above with respect to first ball housing226and ball members222h,228aof ball shaft222and first dual ball shaft228, respectively.

Second dual ball shaft234of firing assembly203bof drive assembly203is similar to first dual ball shaft228of firing assembly203band includes a proximal ball member234athat extends proximally from a bearing support surface234bthat supports third bearing236, and a distal ball member234cthat extends distally from bearing support surface234b. Bearing support surface234bfurther defines an annular clip channel234dthat is configured to receive a clip234e(e.g., an E-clip) to obstruct axial movement of third bearing236and axially support third bearing236on bearing support surface234bof second dual ball shaft234. Second dual ball shaft234further includes ball pins234f,234g. Proximal ball member234aof second dual ball shaft234is rotatably coupled to distal shell232bof second ball housing232(e.g., a universal joint) and distal ball member234cof second dual ball shaft234rotatably supports drive coupler238thereon.

Drive coupler238of firing assembly203bdefines a proximal bore238a(FIG.8) that rotatably receives distal ball member234cof second dual ball shaft234, and a distal bore238bthat is configured to couple to end effector300of electromechanical surgical instrument200. Although distal bore238bof drive coupler238is shown including a non-circular configuration, such as a D-shaped configuration, distal bore238bcan have any non-circular configuration (e.g., triangular, rectangular, pentagonal, etc.) to facilitate a rotatably locked connection between firing assembly203band end effector300so that end effector300, or components thereof, can rotate with firing assembly203bof drive assembly203. Drive coupler238further defines a pin hole238cthat receives a pin238dto rotatably couple drive coupler238to distal ball member234cof second dual ball shaft234.

With reference toFIG.3, end effector300of electromechanical surgical instrument200includes a mounting portion302on a proximal end portion thereof, and a first jaw member304(e.g., an anvil) and a second jaw member306(e.g., a cartridge assembly) that are coupled to mounting portion302. First and second jaw members304,306are positioned for pivotal movement between open (FIG.3) and closed (not shown) positions. First and second jaw members304,306support a drive assembly308that is configured to fire a fastener cartridge310supported in second jaw member306.

As seen inFIG.4, mounting portion302of end effector300includes mounting tabs302aand defines mounting recesses302bthat engage respective distal recesses214band distal tabs214dof second interface214of wrist assembly206. Mounting portion302further includes alignment pins302that are received within alignment holes214gof second interface214of wrist assembly206. Mounting portion302further defines a central opening302dthat is configured to receive drive coupler238of firing assembly203bto couple drive coupler238to drive assembly308of end effector300.

With reference toFIG.10, drive assembly308of end effector300includes a driven coupler308athat is received in distal bore238bof drive coupler238of firing assembly203bof drive assembly203. Driven coupler308aof drive assembly308includes a non-circular configuration (e.g., D-shape) that is keyed to distal bore238bof drive coupler238of firing assembly203bso that driven coupler308aand drive coupler238are rotatably locked with respect to one another such that driven coupler308aand drive coupler238rotate together as drive coupler238rotates. Driven coupler308ais pinned to a lead screw308bthat supports a drive beam308csuch that rotation of driven coupler308acauses lead screw308bto rotate and axially advance drive beam308calong lead screw308b. For a more detailed description of components of example end effectors similar to end effector300, reference can be made to U.S. Patent Application Publication Nos. 2016/0242779 and 2015/0297199, the entire disclosures of each of which are incorporated by reference herein.

In use, with electromechanical surgical instrument200coupled to robotic surgical assembly100as seen inFIG.1, one or more motors50of instrument drive unit110can be actuated to rotate one or more of driven members209of electrosurgical instrument200to push and/or pull one or more cables205of cable drive assembly203aof drive assembly203of electromechanical surgical instrument200. As cables205of cable drive assembly203aaxially translate, as indicated by arrows “B” (FIG.9), one or both of first and second joints210,212of wrist assembly206rotate and/or articulate with one or more of first ball housing226, first dual ball shaft228, second ball housing232, and/or second dual ball shaft234of firing assembly203bof drive assembly203, relative to longitudinal axis “L-L,” as indicated by arrows “C” and “D” (seeFIGS.12-16). Each of first and second joints210,212can be configured to articulate through an articulation angle of up to 70 degrees such that first joint210can be articulated through an articulation angle “α” up to 70 degrees while second joint212is articulated through an articulation angle “Θ” up to 70 degrees, as seen inFIG.16. As can be appreciated, one or more components of firing assembly203b(e.g., first ball housing226, first dual ball shaft228, second ball housing232, and/or second dual ball shaft234, etc.) pivot, rotate, and/or articulate as first and second joint210,212pivot, rotate, and/or articulate.

While first and/or second joints210,212of wrist assembly206are disposed in an articulated (FIGS.12-16) or an unarticulated position (FIG.2), firing assembly203bcan be rotated about longitudinal axis “L-L,” as indicated by arrows “A,” (seeFIGS.2and7) in response to rotation of driven member211(FIG.15) by one or more of motors50of instrument drive unit110(FIG.1). Rotation of firing assembly203bof drive assembly203causes drive coupler238of firing assembly203bto rotate lead screw308bof end effector300about its axis, e.g., axis “Z-Z,” as indicated by arrows “F” (FIG.10). Rotation of lead screw308bof end effector300causes drive beam308cof end effector300to advance distally along lead screw308b, as indicated by arrow “G,” so that first and second jaw members304,306of end effector300move from the open or unapproximated position (FIG.3) thereof to the closed or approximated position (not shown) thereof. As drive beam308cof end effector300continues to advance distally along first and second jaw members304,306, drive beam308cfires fastener cartridge310(FIG.3) to fasten and/or sever tissue captured between first and second jaw members304,306similar to that described in U.S. Patent Application Publication No. 2015/0297199 referenced above.

Turning now toFIGS.17,18,19A-19C, and20A-20C, an alternative embodiment of an electromechanical surgical instrument is shown and described as electromechanical surgical instrument2000. Electromechanical surgical instrument2000is similar to electromechanical surgical instrument200, described above, includes all of the same features and components as electromechanical surgical instrument200, and is usable with (and interfaces with) surgical system1(FIG.1) in the same manner as electromechanical surgical instrument200. However, electromechanical surgical instrument2000additionally includes electrical cables1000,2000, and wrist assembly2600and housing2020for supporting electrical cables1000,2000. Accordingly, for brevity, only the basic components of electromechanical surgical instrument2000, and the differences between electromechanical surgical instrument2000and electromechanical surgical instrument200, will be described.

As described in detail below, wrist assembly2600includes structural features that facilitate passage of electrical cables1000,2000therethrough with minimal resistance and minimal stress imparted on electrical cables1000,2000during articulation of wrist assembly2600. Despite high articulation of the components of wrist assembly2600, electrical cables1000,2000do not translate longitudinally through any of joints2100,2120. This eliminates the need for tensioning or payout mechanisms that would otherwise be required to drive any cables or wires during articulation. Elimination of longitudinal translation of electrical cables1000,2000also reduces the possibility of failures due to wear and abrasion of electrical cables1000,2000and any components in contact with electrical cables1000,2000. Additionally, electrical cables1000,2000bend through only a single axis during articulation of the wrist assembly2600, as opposed to being bent in multiple directions, which significantly extends the lifetime of the electrical cables1000,2000and even the components the electrical cables1000,2000are in contact with. Additionally, the electrical cables1000,2000are positioned within the wrist assembly2600, beneath drive cabling and shielding structures throughout the full articulation range, which reduces chances of damage to the electrical cables1000,2000from incidental contact and reprocessing.

Electromechanical surgical instrument2000of robotic surgical system1(FIG.1) includes a housing2020at a proximal end portion thereof and an elongated shaft2040that extends distally from housing2020. A wrist assembly2600is supported on a distal end portion of elongated shaft2040that couples end effector300to elongated shaft2040.

Housing2020of electromechanical surgical instrument2000is configured to selectively couple to instrument drive unit110of robotic surgical assembly100(FIG.1), for example, via side loading on a sterile interface module112of robotic surgical assembly100, to enable motors50of instrument drive unit110of robotic surgical assembly100to operate end effector300of electromechanical surgical instrument2000. Housing2020of electromechanical surgical instrument2000supports a drive assembly2030(including cable drive assembly2030aand firing assembly2030b) that mechanically and/or electrically cooperates with motors50of instrument drive unit110of robotic surgical assembly100. Additionally, housing2020includes a first electrical contact2091on a proximal portion thereof which interfaces with a corresponding electrical contact (not shown) of instrument drive unit110to create an electrical connection between electrical cable1000and the other components of robotic surgical system1(e.g., an electrosurgical generator, controller, sensor, etc.). Housing2020similarly includes a second electrical contact2092on a proximal portion thereof which interfaces with a corresponding electrical contact (not shown) of instrument drive unit110to create an electrical connection between electrical cable2000and the other components of robotic surgical system1(e.g., an electrosurgical generator, controller, sensor, etc.). It is contemplated that electromechanical surgical instrument2000may additionally include a printed circuit board (not shown) to which electrical cable1000and/or electrical cable2000are coupled.

Electrical cables1000,2000may be utilized to create an electrical connection between any portion of electromechanical surgical instrument2000(e.g., end effector300) and any component(s) of robotic surgical system1(e.g., robotic arms2,3, control device4, and/or operating console5). In one aspect, at least one of electrical cables1000,2000is used to transmit electrosurgical treatment energy from an electrosurgical generator “G” (seeFIG.1) to a portion of end effector300, such as an energy delivery portion or device (not shown) coupled to end effector300. Additionally, one or both of electrical cables1000,2000may be utilized to transmit sensor signals between end effector300(or sensors coupled thereto) and any other component(s) of robotic surgical system1.

Wrist assembly2600is supported on elongated shaft2040and includes a first joint2100coupled to a second joint2120. First joint2100includes a proximal segment2100adefining a proximal arcuate surface2104aand a distal segment2100bdefining a distal arcuate surface2104bon each side thereof. Proximal segment2100ais coupled to distal segment2100bvia a pair of links2110a,2110b. Similarly, second joint2120includes a proximal segment2120adefining a proximal arcuate surface2124aand a distal segment2120bdefining a distal arcuate surface2124bon each side thereof. Proximal segment2120ais coupled to distal segment2120bvia a pair of links2112a,2112b.

As described above with respect to wrist assembly260, an end effector300is coupled to wrist assembly2600and a plurality of cables are coupled to the wrist assembly2600to manipulate first joint2100and second joint2120to enable wrist assembly2600to articulate relative to the longitudinal axis “L” (FIG.2) defined by elongated shaft2040.

Electrical cables1000,2000pass through first joint2100and second joint2200of wrist assembly2600, and the distal portion of each of electrical cables1000,2000couple to end effector300. In particular, proximal segment2100aof first joint2100defines a proximal aperture2102aand distal segment2100bof first joint2100defines a distal aperture2102b, which is misaligned with the proximal aperture2102a. Similarly, proximal segment2120aof second joint2120defines a proximal aperture2122aand distal segment2120bof second joint2120defines a distal aperture2122b, which is misaligned with the proximal aperture2122a. Electrical cable1000passes through proximal aperture2102adefined by the proximal segment2100aof first joint2100, distal aperture2102bdefined by distal segment2100bof first joint2100, proximal aperture2122adefined by proximal segment2120aof second joint2120, and distal aperture2122bdefined by distal segment2120bof second joint2120. Similarly, electrical cable2000passes through respective apertures defined on the other side of first joint2100and second joint2120, respectively.

With respect to first joint2100, and with particular reference toFIGS.19A-19C, proximal arcuate surface2104a, proximal aperture2102a, distal arcuate surface2104b, and distal aperture2102bare positioned and dimensioned such that, during articulation of wrist assembly2600, electrical cable1000rolls off of distal arcuate surface2104bwhen electrical cable1000rolls on to proximal arcuate surface2104a, and electrical cable1000rolls off of proximal arcuate surface2104awhen electrical cable1000rolls on to distal arcuate surface2104b. With this configuration, it is possible to position electrical cable1000between proximal segment2100aand distal segment2100bsuch that, as distal segment2100barticulates relative to proximal segment2100a, electrical wire1000rolls onto distal arcuate surface2104bat the same rate that it is rolled off of proximal arcuate surface2104a. Thus, during articulation, stress imparted on one portion of electrical cable1000within the first joint2100is always accompanied by counteracting relief of stress on another portion of electrical cable1000within the first joint2100.

Electrical cable2000is similarly arranged with similar arcuate surfaces present on the other side of proximal segment2100aand distal segment2100bof first joint2100. In particular, the proximal segment2100aof first joint2100defines a second proximal arcuate surface2104aa(FIG.18) on the other side thereof, and distal segment2100bof first joint2100defines a second distal arcuate surface2104bbon the other side thereof. Second electrical cable2000is positioned such that, during articulation of wrist assembly2600, second electrical cable2000rolls off of second distal arcuate surface2104bbas electrical cable2000rolls on to second proximal arcuate surface2104aa, and second electrical cable2000rolls off of second proximal arcuate surface2104aaas second electrical cable2000rolls on to second distal arcuate surface2104bb.

With respect to second joint2120, and with particular reference toFIGS.20A-20C, proximal arcuate surface2124a, proximal aperture2122a, distal arcuate surface2124b, and distal aperture2122bare positioned and dimensioned such that, during articulation of wrist assembly2600, electrical cable1000rolls off of distal arcuate surface2124bwhen electrical cable1000rolls on to proximal arcuate surface2124a, and electrical cable1000rolls off of proximal arcuate surface2124awhen electrical cable1000rolls on to distal arcuate surface2124b. With this configuration, it is possible to position electrical cable1000between proximal segment2120aand distal segment2120bsuch that as distal segment2120barticulates relative to proximal segment2120a, electrical wire1000rolls onto distal arcuate surface2124bat the same rate that it is rolled off of proximal arcuate surface2124a. Thus, during articulation, stress imparted on one portion of electrical cable1000is always accompanied by counteracting relief of stress on another portion of electrical cable1000.

Electrical cable2000is similarly arranged with similar arcuate surfaces present on the other side of proximal segment2120aand distal segment2120bof second joint2120. In particular, proximal segment2120aof second joint2120defines a second proximal arcuate surface2124aa(FIG.18) on the other side thereof, and distal segment2120bof second joint2120defines a second distal arcuate surface2124bbon the other side thereof. Second electrical cable2000is positioned such that during articulation of wrist assembly2600second electrical cable2000rolls off of second distal arcuate surface2124bb, as electrical cable2000rolls on to second proximal arcuate surface2124aaand second electrical cable2000rolls off of second proximal arcuate surface2124aaas second electrical cable2000rolls on to second distal arcuate surface2124bb.

FIG.19Aillustrates first joint2100of wrist assembly2600in an unarticulated position. In this position, electrical wire1000is in contact with both arcuate surface2104aof proximal segment2100aand arcuate surface2104bof distal segment2100b. When first joint2100is transitioned from an unarticulated position (FIG.19A) to one fully articulated position (FIG.19B), electrical cable1000contacts a larger area of arcuate surface2014aand is no longer in contact with arcuate surface2104b. Likewise, when first joint2100is transitioned from an unarticulated position (FIG.19A) to another fully articulated position (FIG.19C), electrical cable1000is no longer in contact with arcuate surface2104aand contacts a larger area of arcuate surface2104b. As first joint2100transitions between the unarticulated position and the multiple articulated positions, electrical cable1000bends through only one axis, as opposed to bending in multiple directions, which extends its lifetime. Although not shown, electrical cable2000similarly interacts with arcuate surfaces on the other side of first joint2100as first joint2100transitions between the unarticulated position and the multiple articulated positions.

FIG.20Aillustrates second joint2120of wrist assembly2600in an unarticulated position. In this position, electrical wire1000is in contact with both arcuate surface2124aof proximal segment2120aand arcuate surface2124bof distal segment2120b. When second joint2120is transitioned from an unarticulated position (FIG.20A) to one fully articulated position (FIG.20B), electrical cable1000contacts a larger area of arcuate surface2024aand is no longer in contact with arcuate surface2124b. Likewise, when second joint2120is transitioned from an unarticulated position (FIG.20A) to another fully articulated position (FIG.20C), electrical cable1000is no longer in contact with arcuate surface2124aand contacts a larger area of arcuate surface2124b. As second joint2120transitions between the unarticulated position and the multiple articulated positions, electrical cable1000bends through only one axis, as opposed to bending in multiple directions, which extends its lifetime. Although not shown, electrical cable2000similarly interacts with arcuate surfaces on the other side of second joint2120as the second joint2120transitions between the unarticulated position and the multiple articulated positions.

Although electromechanical surgical instrument200,2000is described herein in connection with robotic surgical system1, the presently disclosed electromechanical surgical instruments200,2000can be provided in the form of a hand held electromechanical instrument, which may be manually driven and/or powered. For instance, U.S. Patent Application Publication No. 2015/0297199, referenced above, describes one example of a powered hand held electromechanical instrument, one or more of the components of which (e.g., the surgical device or handle thereof) can be utilized in connection with the presently disclosed surgical instrument200,2000.

Persons skilled in the art will understand that the structures and methods specifically described herein and shown in the accompanying figures are non-limiting exemplary embodiments, and that the description, disclosure, and figures should be construed merely as exemplary of particular embodiments. It is to be understood, therefore, that the present disclosure is not limited to the precise embodiments described, and that various other changes and modifications may be effected by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, the elements and features shown or described in connection with certain embodiments may be combined with the elements and features of certain other embodiments without departing from the scope of the present disclosure, and that such modifications and variations are also included within the scope of the present disclosure. Accordingly, the subject matter of the present disclosure is not limited by what has been particularly shown and described.