Dual driving pinion crosscheck

A robotic surgical system that comprises a closure system. The closure system comprises a first pinion drivingly coupled to a first motor, a second pinion drivingly coupled to a second motor, and a closure gear selectively driven by the first pinion and the second pinion. The robotic surgical system further comprises a control circuit configured to implement a motor crosscheck operation. The control circuit is configured to receive a first parameter indicative of a first torque generated by the first motor, receive a second parameter indicative of a second torque generated by the second motor, compare the first parameter to the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicative of a status of the closure system.

BACKGROUND

The present disclosure relates to robotic surgical systems. Robotic surgical systems can include a central control unit, a surgeon's command console, and a robot having one or more robotic arms. Robotic tools can be releasably mounted to the robotic arm(s). The number and type of robotic tools can depend on the type of surgical procedure. In certain instances, robotic surgical systems can be used in connection with one or more displays and/or one or more handheld surgical instruments during a surgical procedure.

SUMMARY

In one aspect, the present disclosure provides a robotic surgical system that comprises a closure system. The closure system comprises a first pinion drivingly coupled to a first motor, a second pinion drivingly coupled to a second motor, and a closure gear selectively driven by the first pinion and the second pinion. The robotic surgical system further comprises a control circuit configured to implement a motor crosscheck operation. The control circuit is configured to receive a first parameter indicative of a first torque generated by the first motor, receive a second parameter indicative of a second torque generated by the second motor, compare the first parameter to the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicative of a status of the closure system.

In another aspect, the present disclosure provides a non-transitory computer readable medium storing computer readable instructions which, when executed, cause a machine to receive a first parameter indicative of a first torque generated by a first motor of a closure system, receive a second parameter indicative of a second torque generated by a second motor of the closure system, and implement a motor crosscheck. The first motor and the second motor are configured to concurrently drive a closure gear. The motor crosscheck comprises compare the first parameter to the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicative of a status of the closure system.

In another aspect, the present disclosure provides a robotic surgical system that comprises a closure system. The closure system comprises a first pinion drivingly coupled to a first motor, a second pinion drivingly coupled to a second motor, and a closure gear selectively driven by the first pinion and the second pinion. The closure system further comprises a processor and a memory coupled to the processor. The memory storing instructions executable by the processor to receive a first parameter indicative of a first torque from the first motor, receive a second parameter indicative of a second torque from the second motor, and receive a third parameter indicative of a first angular displacement of the first motor. The memory further stores instructions executable by the processor to receive a fourth parameter indicative of a second angular displacement of the second motor, and determine a status of the closure system based on the first parameter, the second parameter, the third parameter, and the fourth parameter. The memory further stores instructions executable by the processor to transmit a signal to a communication device indicative of the status of the closure system.

DESCRIPTION

Applicant of the present application also owns the following U.S. patent applications, filed on Dec. 30, 2020, each of which is herein incorporated by reference in its entirety:U.S. patent application Ser. No. 17,137,829 titled SURGICAL TOOL WITH TOOL-BASED TRANSLATION AND LOCK FOR THE SAME, now U.S. Patent Application Publication No. 2022/0202437;U.S. patent application Ser. No. 17,137,846 titled ROBOTIC SURGICAL TOOLS HAVING DUAL ARTICULATION DRIVES, now U.S. Patent Application Publication No. 2022/0202517; andU.S. patent application Ser. No. 17,137,852 titled TORQUE-BASED TRANSITION BETWEEN OPERATING GEARS, now U.S. Patent Application Publication No. 2022/0202514.

Applicant of the present application also owns U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, which is incorporated by reference herein in its entirety.

Applicant of the present application also owns U.S. Provisional Patent Application No. 62/611,339, titled ROBOT ASSISTED SURGICAL PLATFORM, filed Dec. 28, 2017, which is incorporated by reference herein in its entirety.

Applicant of the present application also owns the following U.S. patent applications, filed on Mar. 29, 2018, each of which is herein incorporated by reference in its entirety:U.S. patent application Ser. No. 15/940,627, titled DRIVE ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;U.S. patent application Ser. No. 15/940,676, titled AUTOMATIC TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; andU.S. patent application Ser. No. 15/940,711, titled SENSING ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS.

Before explaining various aspects of a robotic surgical platform in detail, it should be noted that the illustrative examples are not limited in application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. The illustrative examples may be implemented or incorporated in other aspects, variations, and modifications, and may be practiced or carried out in various ways. Further, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative examples for the convenience of the reader and are not for the purpose of limitation thereof. Also, it will be appreciated that one or more of the following-described aspects, expressions of aspects, and/or examples, can be combined with any one or more of the other following-described aspects, expressions of aspects, and/or examples.

Minimally-invasive surgery (MIS), such as laparoscopic surgery, typically involves techniques intended to reduce tissue damage during a surgical procedure. For example, laparoscopic procedures can involve creating a number of small incisions in the patient (e.g., in the abdomen) and introducing one or more surgical tools (e.g., end effectors and an endoscope) through the incisions into the patient. Surgical procedures may then be performed using the introduced surgical tools and with visualization aid provided by the endoscope, for example. Exemplary surgical visualization systems are further described in the following references, which are incorporated by reference herein in their respective entireties:U.S. Patent Application Publication No. 2020/0015923 A1, titled SURGICAL VISUALIZATION PLATFORM, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015904 A1, titled SURGICAL VISUALIZATION CONTROLS, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015900 A1, titled CONTROLLING AN EMITTER ASSEMBLY PULSE SEQUENCE, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015668 A1, titled SINGULAR EMR SOURCE EMITTER ASSEMBLY, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015925 A1, titled COMBINATION EMITTER AND CAMERA ASSEMBLY, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015899 A1, titled SURGICAL VISUALIZATION WITH PROXIMITY TRACKING FEATURES, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015903 A1, titled SURGICAL VISUALIZATION OF MULTIPLE TARGETS, which published on Jan. 16, 2020;U.S. Pat. No. 10,792,034, titled VISUALIZATION OF SURGICAL DEVICES, which was issued on Oct. 6, 2020;U.S. Patent Application Publication No. 2020/0015897 A1, titled OPERATIVE COMMUNICATION OF LIGHT, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015924 A1, titled ROBOTIC LIGHT PROJECTION TOOLS, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015898 A1, titled SURGICAL VISUALIZATION FEEDBACK SYSTEM, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015906 A1, titled SURGICAL VISUALIZATION AND MONITORING, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015907 A1, titled INTEGRATION OF IMAGING DATA, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015806 A1, titled ROBOTICALLY-ASSISTED SURGICAL SUTURING SYSTEMS, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015901 A1, titled SAFETY LOGIC FOR SURGICAL SUTURING SYSTEMS, which published on Jan. 16, 2020;U.S. Patent Application Publication No. 2020/0015914 A1, titled ROBOTIC SYSTEMS WITH SEPARATE PHOTOACOUSTIC RECEIVERS, which published on Jan. 16, 2020; andU.S. Patent Application Publication No. 2020/0015902 A1, titled FORCE SENSOR THROUGH STRUCTURED LIGHT DEFLECTION, which published on Jan. 16, 2020.

MIS may provide certain benefits, such as reduced patient scarring, less patient pain, shorter patient recovery periods, and/or lower medical treatment costs associated with patient recovery. Recent technological developments allow robotic systems to perform more MIS procedures. The robotic systems typically include one or more robotic arms for manipulating surgical tools based on commands from a remote operator (e.g. surgeon/clinician). A robotic arm may, for example, support at its distal end various surgical devices such as surgical end effectors, imaging devices, and cannulas for providing access to the patient's body cavity and organs.

Existing robotically-assisted surgical systems typically consist of a surgeon console and a patient-side cart with one or more interactive robotic arms controlled from the console. For example, one robotic arm can support a camera and the other robotic arm(s) can support robotic tools such as scalpels, scissors, graspers, and staplers, for example. Various exemplary robotic tools are further described herein.

A robotic surgical system disclosed herein can be a software-controlled, electro-mechanical system designed for surgeons to perform MIS procedures. The robotic surgical system can be used with an endoscope, compatible endoscopic instruments, and accessories. The system may be used by trained physicians in an operating room environment to assist in the accurate control of compatible endoscopic instruments during robotically-assisted urologic, gynecologic, gastrological, and other laparoscopic surgical procedures. The compatible endoscopic instruments and accessories for use with the surgical system are intended for endoscopic manipulation of tissue including stapling, grasping, cutting, blunt and sharp dissection, approximation, ligation, electrocautery, and suturing, for example.

An example operating room environment is shown inFIG.1. A robotic surgical system100is shown in the operating room, and the robotic surgical system100includes a user console110, a control tower130, and a surgical robot120having one or more robotic surgical arms122mounted on a surgical platform124(e.g., a table or a bed). Clinicians can mount surgical tools with end effectors to the distal ends of the robotic arms122for executing a surgical procedure. The robotic arms122are table-mounted, but in other configurations, the robotic arms can be mounted to a cart, a floor, a ceiling, a sidewall, or other suitable support surfaces. In various instances, the robotic arms can be supported by a free-standing robot having a base and/or upright column, as further described in U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019. U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019 is incorporated by reference herein in its entirety.

Generally, a user, such as a surgeon or other operator, is positioned at the user console110to remotely manipulate the robotic arms122and/or surgical instruments via teleoperation. The user console110can be located in the same operating room as the robotic system100, as shown inFIG.1. In other environments, the user console110can be located in an adjacent or nearby room, or tele-operated from a remote location in a different building, city, or country. The user console110can comprise a seat112, pedals114, one or more handheld user interface devices (UIDs)116, and a display118configured to display, for example, a view of the surgical site inside a patient. As shown in the exemplary user console110, a surgeon sitting in the seat112and viewing the open display118can manipulate the pedals114and/or handheld user interface devices116to remotely control the robotic arms122and/or surgical instruments mounted to the distal ends of the arms122. Exemplary robotic input devices are further described in the following references, which are incorporated by reference herein in their respective entireties:U.S. Patent Application Publication No. 2020/0289219 A1, titled INPUT CONTROLS FOR ROBOTIC SURGERY, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289228 A1, titled DUAL MODE CONTROLS FOR ROBOTIC SURGERY, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289216 A1, titled MOTION CAPTURE CONTROLS FOR ROBOTIC SURGERY, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289229 A1, titled ROBOTIC SURGICAL CONTROLS HAVING FEEDBACK CAPABILITIES, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289230 A1, titled ROBOTIC SURGICAL CONTROLS WITH FORCE FEEDBACK, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289217 A1, titled JAW COORDINATION OF ROBOTIC SURGICAL CONTROLS, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289220 A1, titled ROBOTIC SURGICAL SYSTEMS WITH MECHANISMS FOR SCALING SURGICAL TOOL MOTION ACCORDING TO TISSUE PROXIMITY, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289205 A1, titled ROBOTIC SURGICAL SYSTEMS WITH MECHANISMS FOR SCALING CAMERA MAGNIFICATION ACCORDING TO PROXIMITY OF SURGICAL TOOL TO TISSUE, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289221 A1, titled ROBOTIC SURGICAL SYSTEMS WITH SELECTIVELY LOCKABLE END EFFECTORS, which published on Sep. 17, 2020;U.S. Patent Application Publication No. 2020/0289222 A1, titled SELECTABLE VARIABLE RESPONSE OF SHAFT MOTION OF SURGICAL ROBOTIC SYSTEMS, which published on Sep. 17, 2020; and U.S. Patent Application Publication No. 2020/0289223 A1, titled SEGMENTED CONTROL INPUTS FOR SURGICAL ROBOTIC SYSTEMS, which published on Sep. 17, 2020.

In some variations, a user can also operate the robotic surgical system100in an “over the bed” (OTB) mode, in which the user is at the patient's side and simultaneously manipulating a robotically-driven tool/end effector attached thereto (e.g., with a handheld user interface device116held in one hand) and a manual laparoscopic tool. For example, the user's left hand may be manipulating a handheld user interface device116to control a robotic surgical component, while the user's right hand may be manipulating a manual laparoscopic tool. In these variations, the user may perform both robotic-assisted MIS and manual laparoscopic surgery on a patient.

In some aspects, the communication between the surgical robot120and the user console110can be through the control tower130, which can translate user input from the user console110to robotic control commands and transmit the control commands to the surgical robot120. The control tower130can also transmit status and feedback from the robot120back to the user console110. The connections between the surgical robot120, the user console110, and the control tower130can be via wired and/or wireless connections, and can be proprietary and/or performed using any of a variety of data communication protocols. Any wired connections can be built into the floor and/or walls and/or ceiling of the operating room. The robotic surgical system100can provide video output to one or more displays, including displays within the operating room, as well as remote displays accessible via the Internet or other networks. The video output or feed can also be encrypted to ensure privacy and all or portions of the video output can be saved to a server or electronic healthcare record system.

The robotic surgical system100can uniquely identify each tool (endoscope and/or surgical tool) as soon as it is attached to an arm122thereof, and can display the tool type and arm location on the display118at the user console110and/or a touchscreen display on the control tower130. The corresponding tool functions can be enabled and activated using the master UIDs116and foot pedals114. The patient-side assistant can attach and detach the tools, as required, throughout the procedure. A surgeon seated at the user console110can begin to perform surgery using the tools controlled by two master UIDs116and foot pedals114. The system translates the surgeon's hand, wrist, and/or finger movements through the master UIDs116into precise real-time movements of the surgical tools. Therefore, the system constantly monitors every surgical maneuver of the surgeon and can pause instrument movement if the system is unable to precisely mirror the surgeon's hand motions.

A robotic arm200is shown inFIG.2. The robotic arm200can be incorporated into the surgical robot120(FIG.1). For example, the robotic arm200can correspond to one of the robotic arms122(FIG.1) of the surgical robot120. The robotic arm200includes a tool drive220and a cannula221. A robotic surgical tool250is mounted to the tool drive220and is installed in the cannula221. The robotic arm200includes links (e.g., links201,202,203,204,205,206,207,208A,208B) and actuated joint modules (e.g., joints211,212,213,214,215,216,217) for actuating the plurality of links relative to one another. The joint modules can include various types, such as a pitch joint or a roll joint, which may substantially constrain the movement of the adjacent links around certain axes relative to others. The tool drive220is attached to the distal end of the robotic arm200and includes the sleeve or cannula221extending distally therefrom. The cannula221is configured to receive and guide the surgical tool250into the patient. The robotic tool250also includes an articulation joint or wrist256and an end effector258(FIG.2) disposed at the distal end. The joint modules211,212,213,214,215,216,217of the robotic arm200can be actuated to position and orient the tool drive220, which actuates the robotic wrist256and the end effector258for robotic surgery.

FIG.3depict the tool drive220with the surgical tool250mounted thereto andFIG.4depicts the tool drive22without a surgical tool mounted thereto. The tool drive220includes an elongated base (or “stage”)222having longitudinal tracks223and a tool carriage224, which is slidingly engaged with the longitudinal tracks223. The stage222may be configured to couple to the distal end of a robotic arm200such that articulation of the robotic arm200positions and/or orients the tool drive220in space. Additionally, the tool carriage224is configured to receive a tool base252of the robotic tool250. The robotic tool250also includes a tool shaft254extending from the tool base252and through the cannula221.

Generally, the tool carriage224provides various degrees of freedom for the robotic tool250coupled to the tool carriage224. For example, longitudinal movement of the tool carriage224along the longitudinal tracks223provides a translational degree of freedom for the surgical tool250along a tool axis. Alternative translational degrees of freedom, e.g. along an insertion axis, are further described herein.

Additionally, the tool carriage224provides a rotational degree of freedom for rotation of the surgical tool250around a tool axis, as well as various degrees of freedom for actuation or articulation of an end effector of the surgical tool (e.g., grasping or cutting). For example, the tool carriage224includes one or more motor drives (e.g., linear axis drive or rotary axis drive) whose outputs may be coupled to the input driving mechanisms of a surgical tool. A first motor drive may actuate a first degree of freedom, a second motor drive may actuate a second degree of freedom, and so on for all the additional motor drives in the tool carriage. For example, at least one motor drive may actuate rotation of the tool shaft in a first direction (e.g., clockwise) and another motor drive may actuate rotation of the tool shaft in a second direction opposite the first (e.g., counter-clockwise) in antagonistic fashion. Alternatively, at least one motor drive may actuate rotation of the tool shaft in two directions (e.g., both clockwise and counter-clockwise). Such actuation of the tool may involve, for example, a cable-driven mechanism or set of mechanisms in the tool that are coupled to the output of the motor drives in the tool carriage. Exemplary variations of the tool carriage are further described below.

The tool carriage224is configured to actuate a set of articulated movements of the robotic wrist256and the end effector258through a system of gears, shafts, cables, and/or wires that are manipulated and controlled by actuated drives. Referring toFIG.4, the tool carriage224includes six motors and six corresponding rotary drivers260,262,264,266,268, and270, which are rotary inputs to a robotic tool. The rotary drivers260,262,264,266,268, and270are arranged in two rows and extending longitudinally along the base. The rotary drivers260,262,264,266,268, and270inFIG.4are slightly staggered to reduce the overall width of the tool carriage224such that the tool carriage224is more compact. Rotary drives260,264, and268are arranged in a first row and rotary drivers262,266, and270are arranged in a second row that is slightly longitudinally offset from the first row. Tool carriages having six rotary drives are further described in U.S. Patent Application Publication No. 2020/0138534, titled ROBOTIC SURGICAL SYSTEM, which published on May 7, 2020 and U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, for example. U.S. Patent Application Publication No. 2020/0138534, titled ROBOTIC SURGICAL SYSTEM, which published on May 7, 2020 and U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, are incorporated by reference herein in their respective entireties.

In other instances, the tool carriage224may include a different configuration of actuated drives. For example, U.S. Patent Application Publication No. 2019/0201111, titled DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS, which published on Jul. 4, 2019, describes tool carriages having various drive arrangements. U.S. Pat. No. 9,072,535, titled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which issued Jul. 7, 2015, also describes tool carriages having various drive arrangements. U.S. Pat. No. 9,072,535, titled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which issued Jul. 7, 2015, and U.S. Patent Application Publication No. 2019/0201111, titled DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS, which published on Jul. 4, 2019, are incorporated by reference herein in their respective entireties. Alternative drive arrangements are further described herein.

Referring now toFIG.5, a proximal portion of a robotic tool350is shown. The robotic tool350can be similar to the robotic tool250(FIGS.2and3) in many aspects and can be adapted for use with the tool drive220(FIGS.2-4) and the surgical robot120(FIG.1), for example. The proximal portion of the robotic tool350includes a tool base352; an elongate shaft354extends distally from the base352toward an end effector. The base352includes six rotary drives360,362,364,366,368, and370that are configured to mate with six rotary motor-driven inputs on a tool carriage, such as the rotary drivers260,262,264,266,268, and270on the tool carriage224(FIG.4), for example. In various instances, each rotary drive360,362,364,366,368, and370can be associated with a degree of freedom of the robotic tool350. In other instances, one or more rotary drives can correspond to multiple degrees of freedom via a transmission. Exemplary drive arrangements for robotic tools are further described in U.S. Patent Application Publication No. 2019/0201111, titled DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS, which published on Jul. 4, 2019 and is incorporated by reference herein in its entirety.

Each rotary drive360,362,364,366,368, and370includes a rotatable disc or puck configured to align and mate with the corresponding rotary driver260,262,264,266,268, and270(FIG.4). For example, the rotary drivers260,262,264,266,268, and270and rotary drives360,362,364,366,368, and370include one or more matable surface features240(FIG.4) and340(FIG.5), respectively, configured to facilitate mating engagement between the opposing surface features240,340such that movement (i.e. rotation) of a given rotary driver260,262,264,266,268, and270correspondingly moves (i.e. rotates) the associated rotary drive360,362,364,366,368, and370.

The tool carriage224can include torque sensors and rotary encoders, which may be incorporated into the motors of some or all of the rotary drivers260,262,264,266,268, and270. The torque sensors may be configured to measure the real-time torque loading on the motors, which corresponds to the torque loading assumed by the rotary drivers260,262,264,266,268, and270and/or rotary drives360,362,364,366,368, and370in the robotic tool350coupled thereto. The rotary encoders may measure the rotational motion or output of the motors, which corresponds to the rotational motion of the rotary drivers260,262,264,266,268, and270and/or rotary drives360,362,364,366,368, and370. Monitoring torque loading and rotational motion of the motors may help determine if the surgical tool350is operating in accordance with the commands provided by the control tower130. Additionally or alternatively, torque sensors and/or rotary encoders can be operatively coupled to one or more of the rotary drives360,362,364,366,368, and370in the robotic tool350.

Referring again toFIG.5, the rotary drives360,362,364,366,368, and370in the tool base352can implement the various degrees of freedom of the robotic tool350. For example, the rotary drive360can correspond to a pitching motion of the robotic tool350, the rotary drive362can correspond to a rolling motion of the robotic tool350, the rotary drive364can correspond to a first yawing motion of the robotic tool350, the rotary drive366can correspond to a second yawing motion of the robotic tool350in an opposite direction to the first yawing motion, for example, the rotary drive368can correspond to a clamping motion (e.g. closing of the jaws) of the robotic tool350, and the rotary drive370can correspond to a firing motion (e.g. cutting and stapling of tissue) of the robotic tool350. In such instances, a single rotary drive coupled to a single rotary input in the tool carriage is configured to close the jaws.

A transmission can allow a greater amount of degrees of freedom than an arrangement in which each motor and corresponding rotary input is dedicated to a single degree of freedom. In certain instances, to achieve a higher torque state-such as when firing a firing member through thick and/or tough tissue, which requires a high torque input-more than one rotary input on the tool carriage can be drivingly coupled to a degree of freedom. Such a drive arrangement is described in U.S. Patent Application Publication No. 2019/0201111, titled DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS, which published on Jul. 4, 2019, and which is incorporated by reference herein in its entirety. In other instances, as further described herein, a single rotary drive in the base352can selectively toggle between a high-speed mode and a high-torque mode via a torque transition member.

The robotic tool350can be a stapling tool that is configured to clamp, cut, and staple tissue. Referring now toFIG.6, a surgical stapling tool450is shown. The surgical tool450is similar to the surgical tool350in many aspects and, therefore, may be used in conjunction with a robotic surgical system, such as the robotic surgical system100(FIG.1) and with the robotic arm200(FIG.2) and the tool drive220(FIGS.2and3). The surgical stapling tool450includes a tool base, or proximal housing,452which is similar in many aspects to the tool base352(FIG.5) and includes six rotary drives460,462,464,466,468, and470(FIGS.6A and6B) similar to the rotary drives360,362,364,366,368, and370(FIG.5), for example. An elongate shaft454extends distally from the tool base452. A distal end effector456is coupled to a distal end of the elongate shaft454at an articulation joint, or wrist joint,458. The distal end effector456includes a first jaw480and a second jaw482. The first jaw480and the second jaw482are configured to clamp tissue therebetween. For example, the first jaw480is a movable anvil, and the second jaw482is configured to support a fastener cartridge therein.

In other instances, the distal end effector456can include a fixed anvil and movable fastener cartridge. In still other instances, both jaws480,482can be pivotable or otherwise movable between an open configuration and a clamped configuration to clamp tissue.

In other instances, the opposing jaws480,482may form part of other types of end effectors with jaws such as, but not limited to, a tissue grasper, surgical scissors, an advanced energy vessel sealer, a clip applier, a needle driver, a babcock including a pair of opposed grasping jaws, bipolar jaws (e.g., bipolar Maryland grasper, forceps, a fenestrated20grasper, etc.) One or both of the jaws480,482may be configured to pivot to actuate the end effector456between the open and closed positions.

The articulation joint458enables the end effector456to articulate or pivot relative to the shaft454and thereby position the end effector456at desired orientations and locations relative to a surgical site. In general, the articulation joint458includes a joint configured to allow pivoting movement of the end effector456relative to the shaft454. The degrees of freedom of the wrist458can be represented by three translational variables (i.e., surge, heave, and sway), and by three rotational variables (i.e., Euler angles or roll, pitch, and yaw). The translational and rotational variables describe the position and orientation of a component of a surgical system (e.g., the end effector456) with respect to a given reference Cartesian frame. “Surge” can refer to forward and backward translational movement, “heave” can refer to translational movement up and down, and “sway” can refer to translational movement left and right. With regard to the rotational terms, “roll” can refer to tilting side to side, “pitch” can refer to tilting forward and backward, and “yaw” can refer to turning left and right.

The pivoting motion can include pitch movement about a first axis of the articulation joint458(e.g., X-axis), yaw movement about a second axis of the articulation joint458(e.g., Y-axis), and combinations thereof to allow for 360° rotational movement of the end effector456about the articulation joint458. In other applications, the pivoting motion at the articulation joint458can be limited to movement in a single plane, e.g., only pitch movement about the first axis of the articulation joint458or only yaw movement about the second axis of the articulation joint458, such that the end effector456moves only in a single plane.

The surgical tool450includes drive members that form part of an actuation system configured to facilitate articulation of the articulation joint458and actuation (operation) of the end effector456(e.g., clamping, firing, rotation, articulation, energy delivery, etc.). Some drive members may extend to the articulation joint458, and selective actuation of these drive members causes the end effector456to articulate relative to the shaft454at the articulation joint458. The end effector456is depicted in an unarticulated position inFIG.6, in which a longitudinal axis A2of the end effector456is substantially aligned with a longitudinal axis A1of the shaft454, such that the end effector456is at a substantially zero angle relative to the shaft454. In an articulated position, the longitudinal axes A1, A2would be angularly offset from each other such that the end effector456is at a non-zero angle relative to the shaft454.

Other drive members may extend to the end effector456, and selective actuation of those drive members may cause the end effector456to actuate, operate, or implement a surgical function. In the illustrated embodiment, actuating the end effector456may comprise closing and/or opening the second jaw480relative to the first jaw482(or vice versa), thereby enabling the end effector456to grasp or clamp onto tissue. In addition, once tissue is grasped or clamped between the opposing jaws480,482, actuating the end effector456may further comprise “firing” the end effector456, which may refer to causing a cutting element or knife to advance distally within a slot484defined in the second jaw482. As the cutting element moves distally, it may transect any tissue grasped between the opposing jaws480,482. Moreover, as the cutting element advances distally, a plurality of staples contained within the staple cartridge, (e.g., housed within the first jaw482) may be urged or caromed into deforming contact with corresponding anvil surfaces (e.g., staple-forming pockets), provided on the second jaw480. The deployed staples may form multiple rows of staples that seal opposing sides of tissue that may be transected with the knife or other cutting element.

In some aspects of the present disclosure, the surgical tool450may be configured to apply energy to tissue, such as radio frequency (RF) energy. In such cases, actuating the end effector456may further include applying energy to tissue grasped or clamped between two opposing jaws to cauterize or seal the captured tissue, for example.

In some aspects of the present disclosure, the surgical tool450may further include a manual closure device486accessible to a user on the exterior of the tool base or drive housing452. The manual closure device486includes a knob that a clinician may grasp and actuate. The manual closure device486may be operatively coupled to various gears and/or drive members within the drive housing452to allow a clinician to manually open and close the jaws480,482. In some cases, a clinician may be able to fully clamp and fully unclamp the jaws480,482with the manual closure device486. Manual closure devices are further described in U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, for example.

Referring toFIGS.6A and6B, the upper portion of the drive housing452is omitted from this view to expose various internal working components and parts. Several components that would otherwise be included within the drive housing452are also omitted for clarity. The rotary drives460,462,464,466,468, and470are housed in the tool base452and drivingly coupled to rotary drives on a tool drive (e.g. tool drive220). The drive arrangements inFIGS.6A and6Bare configured to transmit rotary motion from the rotary drives460,462,464,466,468, and470along the shaft454and to the articulation joint458and/or the end effector456. These drive arrangements are merely exemplary; alternative drive arrangements for conveying forces and motion from the rotary drives460,462,464,466,468, and470toward the end effector456are envisioned.

In various instances, it can be desirable to use a single rotary drive for applications requiring both high speed and high torque. For example, it can be desirable to maximize the speed output from a rotary drive in certain instances and to maximize the torque output from the rotary drive in other instances. A gear train can increase the speed of the rotary drive; however, such a gear train can correspondingly decrease the maximum torque that the rotary drive transmits via the gear train. In certain instances, a first rotary drive can be used for a high-torque degree of freedom (e.g. clamping of tissue) and a second rotary drive can be used for a high-speed degree of freedom (e.g. grasping of tissue). U.S. Patent Application Publication No. 2019/0201111, titled DRIVE ARRANGEMENTS FOR ROBOTIC-ASSISTED SURGICAL PLATFORMS, which published on Jul. 4, 2019, describes drive arrangements in which a first rotary drive corresponds to a “high force” degree of freedom and a second rotary drive corresponds to a “low force” degree of freedom. Relying upon two rotary drives makes both rotary drives unavailable for other simultaneous actuations and/or degrees of freedom. As a result, one fewer rotary drive is available for other degrees of freedom, such as for articulation of the end effector, for example.

The motors in the tool driver, which drive the rotary drives, can be limited to a maximum number of rotations per second. For example, a motor for the robotic tool can rotate with a maximum speed of four rotations per second, or 240 RPMs. Certain robotic stapling tools utilize a drive screw to close the jaws and/or fire fasteners therefrom. When using such a drive screw, eight to ten rotations of the drive screw may be required to close the jaws. In such instances, it can take two to three seconds to complete these rotations and fully close the jaws. Similarly, it can take two to three seconds to complete these rotations and fully open the jaws. Employing a gear train can increase the output speed and, thus, reduce the time required to open and close the jaws; however, such a gear train would also reduce the maximum torque output, which may be problematic for certain surgical functions, such as clamping, cutting, and/or firing of staples into thick and/or tough tissue. The foregoing maximum motor speed, estimated number of drive screw rotations, and time to open/close the jaws are exemplary. In other instances, motors having different motor speeds and/or different drive screw arrangements can be utilized.

In certain instances, a rotary drive can switch between a high-torque operating state and a high-speed operating state to selectively transmit higher speeds or higher torques. For example, higher speeds can be utilized during closing or grasping with the end effector jaws and higher torques can be utilized during clamping or firing of the end effector. A torque transition member in the proximal housing of a robotic tool can switch a rotary drive between high-speed gearing on a first side and high-torque gearing on a second side. In various instances, a threshold torque applied to the torque transition member can effect the transition. For example, upon reaching the threshold torque, a spring-activated ramped cam surface of the transition member can shift from the high-speed gearing toward the high-torque gearing to drivingly couple the rotary drive to the high-torque gearing and, thus transmit a high maximum torque to the output gear.

For example, a surgical tool for use with a robotic surgical system can be configured to receive rotary inputs from the robotic surgical system, and the surgical tool can include a distal end effector comprising jaws for clamping tissue therebetween, an intermediate shaft portion coupled to the distal end effector, and a proximal housing coupled to the intermediate shaft portion, the proximal housing comprising an arrangement of rotary drives comprising a first rotary drive. The first rotary drive can comprise an input shaft configured to receive a rotary input from the robotic surgical system, a transition nut slidably positioned on the input shaft, an output gear, a high-speed gear configured to selectively drive the output gear, a high-torque gear configured to selectively drive the output gear, and a spring arrangement configured to bias the transition nut along the input shaft from a high-speed operating state, in which the transition nut is in driving engagement with the high-speed gear, to a high-torque operating state, in which the transition nut is in driving engagement with the high-torque gear upon obtaining a threshold torque.

The foregoing arrangement utilizes a single rotary drive to achieve higher speeds during a first operating state and higher torques during a second operating state. As a result, the other rotary drives can be free for articulation or other surgical functions. The robotic tool can also achieve a quick or higher speed closure or grasping without requiring a quick-grasp mechanism in the jaws for speeding of the jaw closure, for example. Additionally, the torque transition feature can implement the transition between the high-speed operating state and the high-torque operating state upon receiving a threshold torque. Complex programming or mechanisms are not required to effect the transition, which can allow the jaws to open and close quickly to manipulate or grasp tissue while also delivering sufficient torque for clamping and/or cutting tissue, for example. Because robotic stapling tools typically require high-speeds to clamp the jaws onto tissue and high-torques to fire the staples and/or cut the tissue, the torque-transition feature in the tool base can seamlessly and automatically toggle between the operating states to meet the requisite torque and speed requirements in both instances.

Referring toFIGS.7-11, a rotary drive system500is shown. The rotary drive system500is positioned in the tool base or proximal housing of a robotic tool, such as the tool base352of the robotic tool350(FIG.5) or the tool base452of the robotic stapling tool450(FIG.6), for example. The tool base includes a frame590, which supports rotary motion of components of the rotary drive system500. In such instances, the rotary drive system500is one of the rotary drives in the tool base and is selectively coupled to one of the rotary drivers260,262,264,266,268, and270in the carriage224of the tool driver220(FIG.4). For example, the rotary drive system500can correspond to one of the rotary drives360,362,364,366,368, and370in the base352(FIG.5) and a motor in the carriage224is configured to transmit rotary motion to the rotary drive system500during use.

As further described herein, the tool base for a robotic tool can include a different number of rotary drives, for example. Moreover, the rotary drive system500can be incorporated into various proximal housings and/or tool bases for different robotic tools having one or more different surgical functions, for example.

The rotary drive system500is configured to drive an output shaft502. The output shaft502is configured to drive a rotary drive screw in certain instances. Rotation of the rotary drive screw can effect an opening and closing motion of the jaws480,482(FIG.6) to grasp and clamp tissue therebetween. Rotary drive screws are further described in U.S. Provisional Patent Application No. 63/057,430, titled SURGICAL INSTRUMENTS WITH TORSION SPINE DRIVE ARRANGEMENTS, filed Jul. 28, 2020. Rotary drive shafts are described in U.S. Patent Application Publication No. 2014/0001231, titled FIRING SYSTEM LOCKOUT ARRANGEMENTS FOR SURGICAL INSTRUMENTS, which published Jan. 2, 2014. U.S. Provisional Patent Application No. 63/057,430, titled SURGICAL INSTRUMENTS WITH TORSION SPINE DRIVE ARRANGEMENTS, filed Jul. 28, 2020 and U.S. Patent Application Publication No. 2014/0001231, titled FIRING SYSTEM LOCKOUT ARRANGEMENTS FOR SURGICAL INSTRUMENTS, published Jan. 2, 2014, are incorporated by reference herein in their respective entireties.

The rotary drive system500includes an input shaft504, which is configured to receive a rotary input from the robotic surgical system. For example, a motor in the carriage224is configured to drive rotation of the input shaft504when the robotic tool is mounted to the tool driver220(FIG.3). The rotary drive system500includes a transition nut506slidably positioned on the input shaft504. As further described herein, the transition nut506transitions the rotary drive system500between a high-speed operating state (FIG.9) and a high-torque operating state (FIG.11) based on the torque applied to the transition nut506. The rotary drive system500also includes a spring arrangement, which is configured to bias the transition nut506along the input shaft504from the high-speed operating state to the high-torque operating state. In the high-speed operating state, the transition nut506is in driving engagement with a high-speed gear train521. In the high-torque operating state, the transition nut506is in driving engagement with a high-torque gear530.

Referring primarily toFIGS.8and9, the spring arrangement includes a biasing spring528, which exerts a force on the transition nut506and pushes the transition nut506toward the high-speed gear train521. The biasing spring528is a helical compression spring housed in an internal cavity between the frame590and the transition nut506. For example, the biasing spring528is aligned longitudinally with the input axis AI. A first end of the biasing spring528abuts the second portion560of the transition nut506, and a second end of the biasing spring528abuts the frame590. The biasing spring528is positioned to bias the transition nut506toward the high-speed operating state. Alternative spring arrangements and geometries are contemplated.

In the depicted arrangement, the high-speed gear train521includes a grasping gear510. An array of beveled teeth512on the grasping gear510extend toward the transition nut506, as further described herein.

The high-speed gear train521and the high-torque gear530are configured to selectively drive an output gear501. The high-speed gear train521includes a high-speed gear520, along with additional gear(s) (e.g. gear524). The gears520and524form the gear train521, which is configured to increase the maximum output speed to the output gear501and, thus, the output shaft502. The output shaft502is aligned longitudinally with the output axis AO. In other instances, the gear train521can include a different number and/or arrangement of gears, which can similarly reduce the maximum torque and increase the maximum speed that the gear train521can transmit to the output gear501. For example, the gear train521can define a speed ratio that is greater than one and a torque ratio that is less than one. A first bevel gear532couples the gear train521and high-speed gear520thereof to the output gear501. A second bevel gear534couples the high-torque gear530to the output gear501.

The input shaft504drives rotation of the transition nut506about an input axis AI. The transition nut506transmits its rotation to the output gear501by one of the high-speed gear520or the high-torque gear530. For example, the transition nut506includes a first portion550and a second portion560flexibly or non-rigidly spaced apart from the first portion550along the input axis AI by a spring570. The spring570provides flexibility and bounce as the transition nut slides in/out of engagement with the gear teeth512, for example. The first portion550includes a first end552adjacent to the high-torque gear530. The second portion560includes a second end562adjacent to the gear train521and the grasping gear510thereof.

In the first portion550, the transition nut506includes an array of sloping teeth554around its perimeter. The sloping teeth554extend to the first end552. The sloping teeth554are helical ridges or external threads. For example, the sloping teeth554are defined by pairs of ramped or angled surfaces, which are angled relative to the axis of rotation of the transition nut506, the input axis AI. For example, each sloping tooth554includes a bottom ramp, a top ramp substantially parallel to or equidistance from the bottom ramp along its length, and a top surface between the bottom ramp and the top ramp.

The sloping teeth554engage sloping receptacles536in the high-torque gear530when the transition nut506is in the high-torque operating state. The sloping receptacles536define a complementary geometry to the sloping teeth554, such that each sloping receptacle536closely receives one of the sloping teeth554. Moreover, the complementary sloping geometry functions as a screw—the sloping teeth554being external threads and the sloping receptacles536being internal threads—such that a “screwing” rotation of the sloping teeth554into the sloping receptacles536draws the transition nut506along the input axis AI and further into engagement with the high-torque gear530. More specifically, upon engagement of the angled features554,536, the complementary geometry is configured to drive the transition nut506farther along the input shaft504and input axis AI toward the high-torque gear530such that the sloping teeth554are fully received in the sloping receptacles536and drawn into driving engagement with the high-torque gear530. Moreover, when the rotary direction of the transition nut506is reversed, the complementary sloping geometry can again function as a screw such that an “unscrewing” rotation of the sloping teeth554relative to the sloping receptacles536pulls the transition nut506along the input axis AI away from the high-torque gear530and toward the high-speed gear520.

In other instances, the high-torque gear530can include sloping teeth or external threads, and the first portion550of the transition nut506can including sloping receptacles or internal threads, for example.

The transition nut506includes an array of teeth564around the perimeter of the second portion560. The teeth564extend to the second end562. The teeth564define a substantially saw-toothed geometry and the top of each tooth564is narrower than the bottom. For example, each sloping tooth564includes a first ramped surface, a second ramped surface extending toward the first ramped surface, and a top surface between the first and second ramped surfaces. In such instances, the teeth are truncated triangular prisms, for example. Alternative teeth geometry are contemplated.

The teeth564engage corresponding teeth512in the grasping gear510when the transition nut506is in the high-speed operating state. For example, a ramped surface on each tooth512is configured to slide along a complementary ramped surface on a tooth512to move the teeth564,512between an engaged and disengaged position. The biasing spring528is configured to bias the teeth564into engagement with the teeth512. For example, in instances in which the teeth564and512are not precisely aligned when moving into engagement, the spring570can ease the transition between the different operating states. In various instances, the spring528may also ease the transition between operating states, such as when the angular direction is reversed by a motor to reverse the rotary direction of the drive screw and retract the firing member, for example, and the torque-based transition nut506disengages the high-torque gear530and moves into engagement with the high-speed gear520, for example.

The transitioning operation of the rotary drive system500is depicted inFIGS.9-11.FIG.9depicts a high-speed operating state of the rotary drive system500. Though this operating state is referred to as a high-speed operating state, the reader will appreciate that the maximum speed depends on a number of factors, such as properties of the motor, for example. The high-speed operating state, however, can be designed and optimized to output a higher maximum speed to the output gear501than the high-torque operating state. In other words, the maximum speed can be a “high-speed” relative to the maximum speed in the high-torque operating state.

FIG.11depicts a high-torque operating state of the rotary drive system500. The torque output to the output gear501during the high-torque operating state also depends on a number of factors including properties of the motor, for example. The high-torque operating state, however, can be designed and optimized to output a higher maximum torque to the output gear501than the high-speed operating state. In other words, the maximum torque can be a “high-torque” relative to the maximum torque in the high-speed operating state.

FIG.10depicts a transition between the high-speed operating state and the high-torque operating state.

Referring again toFIG.9, the spring528has biased the transition nut506into engagement with the high-speed gear train520. Specifically, the biasing spring528exerts a force upon the transition nut506along the input axis AI and in the direction of the high-speed gearing, i.e., toward the grasping gear510of the gear train521. The array of teeth564on the second portion560meshingly engage the array of teeth512on the grasping gear510.

In this arrangement, rotary motion of the input shaft504(provided by a motor in the tool driver, for example) is transmitted to the transition nut506, which rotates the grasping gear510to effect rotation of the gear train521. The gear train521is configured to increase the maximum speed such that the maximum speed delivered to the output gear501via the first bevel gear532is optimized for high-speed applications. For example, the high-speed output can be utilized for the closing of the jaws to grasp and manipulate tissue. Arrows showing exemplary rotary directions for the transition nut506, the grasping gear510, the gear train521gears, and the output gear501are included inFIG.9.

Referring now toFIG.10, when the torque applied to the transition nut506exceeds a threshold value, the torque at least partially overcomes the spring force of the spring arrangement. The array of teeth564on the second portion560of the transition nut506are configured to ride or slide along the complementary ramped surfaces of the array of teeth512on the grasping gear510as the transition nut506rotates and moves along the input axis AI toward the high-torque gearing, i.e. the high-torque gear530. Compression of the biasing spring528when the torque reaches the threshold value shifts the transition nut506out of engagement with the grasping gear510. Moreover, as the grasping gear510releases the transition nut506from meshing or driving engagement, the array of sloped teeth554on the first portion550of the transition nut506engage the sloped receptacles536in the high-torque gear530. Upon engagement, the sloped receptacles536can “grip” or “grab” the transition nut506to draw the teeth554farther into the receptacles536into the arrangement shown inFIG.11, in which the transition nut506is completely disengaged from the grasping gear510and fully engaged with the high-torque gearing.

In the high-torque operating state ofFIG.11, rotary motion of the input shaft504(provided by a motor in the tool driver, for example) is transmitted to the transition nut506, which rotates the high-torque gear530. The high-torque gear530is configured to optimize the torque delivered to the output gear501via the second bevel gear534. Specifically, the torque is optimized for high-torque applications, such as clamping of tissue by an end effector. Arrows showing exemplary rotary directions for the transition nut506, the high-torque gear530, and the output gear501are included inFIG.11.

At the end of the firing stroke, the drive arrangement is configured to reverse the firing member. For example, the drive arrangement can reverse the angular direction of the transition nut506to retract the firing member. The reversal of the transition nut506can correspond to an “unscrewing” rotation of the transition nut506, such that the transition nut506is displaced along the input axis AI away from the high-torque gear530. In such an arrangement, a return stroke of the firing member and associated reversal of the transition nut506and output gear501can automatically transition the drive arrangement to the high-speed operating state.

Owing to the geometry of the high-torque gear530and the second bevel gear534, the high-torque operating state can increase the torque supplied to the output gear501by eight times the torque of the high-speed operating state. In other instances, the torque output can be doubled, or quadrupled, for example. Variations to the number, size, and arrangement of gears between the high-torque gear530and the output gear501can further increase the torque output.

Owing to the geometry of the gear train521and the first bevel gear532, the high-speed operating state can increase the speed supplied to the output gear501by four times the speed in the high-torque operating state. In other instances, the torque output can be doubled or increased by eightfold, for example. For example, additional speed gears in the gear train521can further increase the speed output. Variations to the number, size, and arrangement of gears between the high-speed gear520and the output gear501can further increase the speed output.

In various instances, robotic tools rely on software incorporated into the operating system and the processor of the robotic surgical system to mitigate risks and avoid failures. Redundant systems and/or crosschecks may control certain robotic tools that perform high-severity tasks to mitigate the risks associated with those tasks. For example, clamping can be a high-severity task because insufficient clamping can result in an increased likelihood and/or greater incidences of staple malformation and, thus, insufficient tissue sealing, in certain instances. For example, robotic stapling tools that clamp and/or cut tissue can rely on redundant systems (e.g. mechanical and electrical lockouts) and various crosschecks to ensure the closure motions, clamping forces, and firing strokes meet predefined standards and/or thresholds. Various crosschecks may increase the costs and/or the complexity of the system, and may require additional maintenance and user-support over time. In certain instances, crosschecks for surgical tools and/or surgical functions that do not add unnecessary cost and complexity to the system may be beneficial.

Certain robotic tools utilize multiple motors for certain surgical functions. For example, a robotic stapling tool can utilize dual motors for advancing a closure member, performing the closure stroke, and/or clamping tissue. A crosscheck that relies on a dual-motor closure system to create crosscheck algorithms can mitigate risks and avoid failures related to high-severity clamping errors, for example.

For example, a robotic surgical system can include a closure system including a first pinion drivingly coupled to a first motor, a second pinion drivingly coupled to a second motor, and a closure gear selectively driven by the first pinion and the second pinion. The robotic surgical system can further include a control circuit configured to implement a motor crosscheck operation in which the control circuit is configured to receive a first parameter indicative of a first torque generated by the first motor, receive a second parameter indicative of a second torque generated by the second motor, compare the first parameter to the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicative of a status of the closure system.

In various instances, the control circuit of such a robotic surgical system can also be configured to determine when the closure system has achieved a steady state in the motor crosscheck operation, and to compare the first parameter to the second parameter after the closure system has achieved the steady state.

The motor crosscheck operation can proceed after a homing operation and/or after a clamping event.

Such a robotic surgical system may mitigate certain risks and avoid failures related to high-severity clamping errors. Moreover, such crosschecks can improve the operation of the surgical tool without necessitating redundant motor controls and/or requiring dedicated safety processing units, for example.

FIG.12shows an example drive arrangement800. The drive arrangement800is used to clamp the jaws of an end effector, such as the jaws480and482of the end effector456(FIG.6), for example. In other instances, a robotic surgical system can utilize the drive arrangement for additional and alternative surgical functions, such as firing fasteners into tissue and/or severing tissue, for example. The drive arrangement800includes a first pinion802and a second pinion804. A motor and corresponding rotary drive are configured to drive the pinions802,804. For example, each of the driving pinions802and804can be driven by one of the motors and one of the corresponding rotary drivers260,262,264,266,268, and270in the tool driver220(FIG.4) in certain aspect of the present disclosure.

The pinions802and804drive the closure gear806, which effects the closure motion of the end effector. The torques on the pinions802and804and, in certain instances, the torque applied to the closure gear806can be monitored and compared during a crosscheck procedure to determine if the drive arrangement800is operating properly or is in a fault state, for example. The robotic surgical system can implement the crosscheck procedure at various times during the lifecycle and/or usage cycles of the robotic tool. For example, each time the robotic tool is mounted to the tool drive on the robotic arm, one or more crosscheck procedures can be implemented. Additionally or alternatively, in certain instances, the robotic surgical system can implement a crosscheck at the completion of a homing operating and/or each closure event (e.g. closure stroke). For example, when a robotic tool is mounted to a tool driver, the robotic system can undergo a homing operation, in which positions of the various components are determined and recorded to ascertain various limits of the system. Homing operations are further described in U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, for example. In certain instances, a clinician can selectively implement a crosscheck and/or override a suggested crosscheck operation.

In one example, to conduct a crosscheck procedure for the robotic tool, the first driving pinion802is rotated in a first direction indicated by the arrow808(clockwise in the view inFIG.12) and the second driving pinion804is rotated in a second direction indicated by the arrow810(counter-clockwise in the view ofFIG.12). The first direction is opposite the second direction. Owing to the arrangement of the driving pinions802and804relative to the closure gear806, when the driving pinions802,804rotate in opposite or opposing directions, the closure gear806may rock, sway, or otherwise move within the backlash defined by the gear teeth. For example, the closure gear806may rattle when touched owing to the backlash permitted by the gear teeth.

A graphical representation820of torque and angular displacement over time for the drive arrangement800is shown inFIG.13. From time t0to t1, the closure gear806can shift or rattle within the backlash defined by the gear teeth. When the driving pinions802,804run out of backlash, they import torque on each other at time t1and continue to exert counter-exerted torques upon each other through a dynamic region822during which the absolute torque values fluctuate/vacillate. After the dynamic region822, the drive arrangement800enters a steady-state region824at time t2during which the torques measured by the driving pinions802,804may substantially level out and define fewer fluctuations over time. One or more metrics can be utilized to determine and/or compute when the driving pinions802and804achieve steady-state status and enter the steady-state region.

The torque for each driving pinion802and804can be monitored during the crosscheck procedure. For example, a control circuit can monitor and compare the torques throughout the steady-state region824. If the magnitudes of the opposing torques are close to each other—i.e. within some predefined threshold value—the control circuit can conclude that the torque values can be trusted. However, if the magnitudes of the opposing torques are not significantly close to each other—i.e. outside a predefined threshold difference—the robotic surgical system can enter an error or fault state. For example, the robotic surgical system can determine the robotic tool is in a fault state. The robotic surgical system can alert the user to the error/fault state and/or can implement one or more lockouts (absolute and/or discretionary) upon entering the error/fault state. In certain instances, the error/fault state may require a recalibration and/or re-inspection of the robotic tool.

A control circuit828for a dual driving pinion arrangement, such as the drive arrangement800(FIG.12), for example, is shown inFIG.14. The control circuit828includes a processor840in signal communication with a memory842and with a communication device844. A first drive system850and a second drive system852are in signal communication with the processor840. The first drive system850includes a motor854, an input drive856coupled to the motor854, a torque sensor830, and a rotary encoder/position sensor834. The input drive856can correspond to the first pinion gear802(FIG.12) in the drive arrangement800, for example. The second drive system852includes a motor858, an input drive860coupled to the motor858, a torque sensor832, and a rotary encoder/position sensor836. The input drive860can correspond to the second pinion gear804(FIG.12) in the drive arrangement800, for example. In such instances, the torque sensors830and832determine the torque on the first driving pinion802and the second driving pinion804, respectively. Moreover, the position sensors834and836determine the angular position of the first driving pinion802and the second driving pinion804, respectively.

The control circuit828also includes an output drive862, a torque sensor864and a rotary encoder/position sensor866therefor. The output drive862can correspond to the closure gear806(FIG.12) in the drive arrangement800, for example. In such instances, the torque sensor864determines the output torque applied to the closure gear806, and the position sensor866determines the angular position of the closure gear806.

During the crosscheck procedure, the torque sensors830,832and the position sensors834,836are configured to transmit signals to the processor840indicative of the torque and angular position of the input drives856,860. The torque sensor864and the position sensor866can also be in signal communication with the processor840and configured to transmit signals thereto indicative of the torque and the angular position of the output drive862. The torques detected by the torque sensors830,832, and864and transmitted to the processor840are monitored over time and can be recorded in the memory842.

In various instances, the processor840is configured to determine when the dual driving pinion system has achieved steady-state and, in the steady-state operating state, to compare the input torques detected by torque sensors832and834. If the comparison between the absolute torques determined by the torque sensors832and834exceeds a threshold value, the control circuit828is configured to enter a fault state. Operations for the fault state are stored in the memory842and implemented by the processor840and include, for example, providing an output signal to the clinician or to another surgical system with a communication device844and/or implementing one or more lockouts to protect the integrity of the robotic tool and safety of the patient.

Another crosscheck operation for a robotic tool is shown inFIGS.15-17. In various instances, the crosscheck operation ofFIGS.15-17can be employed with the drive arrangement800and the control circuit828. To conduct this crosscheck operation, the first driving pinion802is rotated in a first direction indicated by the arrow908(counterclockwise in the view inFIG.15) and the second driving pinion804is also rotated in the first direction indicated by the arrow910(counterclockwise in the view ofFIG.15). Owing to the arrangement of the driving pinions802and804relative to the closure gear806, the rotation of the driving pinions802,804in the first direction is also configured to rotate the closure gear806in the first direction (counterclockwise in the view ofFIG.15) as well, as indicated by the arrow912, for example. In such instances, the driving pinions802and804work together to rotate the closure gear until the closure gear completes the full closure stroke. The full closure stroke is typically completed when clamping tissue or during a “homing” operation, for example.

Referring primarily now toFIG.16, the torque on the driving pinions802and804is then relieved upon reaching a bottomed-out state. Thereafter, one driving pinion can be configured to hold its position during a crosscheck operation, while the other pinion drives against it through the output gear806. For example, the first pinion gear802can seek to rotate in a second direction indicated by the arrow908′ (clockwise in the view ofFIG.16), which is opposite to the first direction of the arrow908inFIG.15, while the second pinion gear804resists rotation. In such instances, the first pinion gear802moves through the backlash region defined between the meshed gear teeth and, then, the pinion gears802and804have opposing torques, which can be monitored and compared during the crosscheck operation.

A graphical representation920of torque and angular displacement over time for the drive arrangement800and the crosscheck sequence depicted inFIGS.15and16is shown inFIG.17. At time t1, the closure stroke is initiated during which the driving pinions802and804cooperatively drive the closure gear806through the closure region926. In the closure region926, the torque and the angular displacement of the pinions802,804and the closure gear806increases. At time t2, the closure stroke is completed and the torque on the closure gear806is relieved.

The driving torques are relieved and at time t2the first pinion802reverses direction (FIG.16) and then moves through the backlash defined by the meshing gear teeth during the region928. For the crosscheck operation, a dynamic region922is followed by a steady-state region924, similar to the dynamic region822and the steady-state region824(FIG.13), respectively, for example. In the crosscheck operation ofFIG.17, the torque on the first pinion gear802continues to a non-zero absolute torque. As the first pinion gear802generates a non-zero absolute torque, the second pinion804generates an opposing torque at time t3, which marks the beginning of the dynamic region922. In the dynamic region922, the absolute torque values of the first pinion802and the second pinion804, which are in opposing directions, increase. Upon reaching the steady-state region924at time t4, the absolute torques on the driving pinions802and804maintain substantially constant values opposing each other. At time t5, the steady-state region924ends and the crosscheck procedure has been completed.

The opposing torques for each driving pinion802and804can be monitored during the crosscheck procedure ofFIGS.15-17. For example, the torques can be monitored and compared during the steady-state region924. If the magnitudes of the opposing torques are close to each other—i.e., within some predefined threshold value—the control circuit can conclude that the torque values can be trusted. However, if the magnitudes of the opposing torques are not significantly close to each other, the robotic surgical system can enter an error or fault state. For example, the robotic surgical system can determine the robotic tool is in a fault state. The robotic surgical system can alert the user to the error/fault state and/or can implement one or more lockouts (absolute and/or discretionary). In certain instances, the fault state may require a recalibration and/or re-inspection of the robotic tool.

Additionally or alternatively, the crosscheck procedure can monitor the angular travel of the pinion gears802,804from the end of the closure stroke at time t2to the beginning of the steady-state region924at time t4. The angular travel is the difference between the first plateau indicating angular displacement for the first driving pinion802and the second plateau indicating angular displacement for the first driving pinion802. In other words, the first driving pinion802rotates from a first position at the end of the closure stroke926to a second position at the beginning of the steady-state region924, and the difference in angular position can be compared to the stored backlash value. The backlash value can be measured during manufacturing and stored in the memory of the robotic tool and/or robotic surgical system, for example. If the angular travel of the first driving pinion802does not match the stored backlash value, within some threshold, the processor can signal an error or fault state. Conversely, if the angular travel is sufficiently close to the stored backlash value, the processor can transmit a signal indicating the robotic tool has passed the check.

In various instances, the foregoing sequence can be repeated with the second pinion gear804switching rotary direction while the first pinion gear802seeks to maintain a constant angular position. The opposing torque values and the angular travel of the second driving pinion804during the “homing” operating can be monitored and compared, as further described herein with respect to the first driving pinion802, for example.

Another crosscheck operation for a surgical tool is shown inFIGS.18-20. In various instances, the crosscheck operation ofFIGS.18-20can be employed with the drive arrangement800and the control circuit828. InFIG.20, a stiffness of one of the driving pinions802,804can be compared to a stored stiffness value to determine if the driving pinion802,804passes the crosscheck. A stiffness1006plotted in a graphical representation inFIG.20reflects the angular position and torque measurements inFIGS.18and19, respectively.

More specifically, the angular position of the driving pinions802,804and the closure gear806(FIG.15) over time is shown in the graphical representation1000inFIG.18. The torque on the driving pinions802,804over time is shown in the graphical representation1002inFIG.19. Initially, as described herein with respect toFIG.15, the driving pinions802and804work together to collectively rotate the closure gear806until the closure gear completes the full closure stroke at time t1. Thereafter, the closure gear806can be bottomed-out such that further rotation of the closure gear806is prevented after time t1. To conduct the crosscheck operation, one of the driving pinions802,804can apply further torque to the bottomed-out closure gear806while the other driving pinion floats or hovers within the backlash regions of the gear teeth. In the example ofFIGS.18and19, the first pinion gear802continues to apply torque to the closure gear806at time t2, while the second pinion gear804is allowed to move or shift through the backlash.

In such an arrangement, the closure gear806cannot rotate any further; however, the stiffness1006(FIG.20) of the first driving pinion802in applying torque to the closure gear806can be calculated based on the torque and position measurements after time t2, when the first driving pinion802continues to apply torque to the closure gear806. A plot of the stiffness1006relative to a two-dimensional stiffness threshold1008in the graphical representation1004conveys the comparison conducted in the crosscheck operation. For example, if the stiffness1006falls outside the stiffness threshold1008, the system can indicate an error or fault state.

In various instances, the stiffness threshold1008can be defined by a slope of the stiffness for torque over angular displacement plus and minus a value corresponding to a threshold amount, percentage, and/or standard deviation, for example.

In various instances, the foregoing sequence can be repeated with the second pinion gear804continuing to apply torque to the closure gear806while the first pinion gear802freewheels. The stiffness of the second pinion gear804can be compared to a threshold stiffness to determine an error or fault state of the second pinion gear804.

In various instances, one or more of the various crosscheck procedures can be implemented after a homing operation and/or clamping event for a dual motor closure system. The crosscheck procedures can check the integrity of the system and motors thereof without requiring redundant motor controllers or dedicated safety processing units, for example. In such instances, the dual motor closure system can be crosschecked without adding additional cost and/or complexity. The reader will further appreciate that such a crosscheck procedure can be performed with respect to other dual motors systems for a robotic surgical tool in certain instances.

In certain instances, a robotic surgical tool having an articulation joint may define an articulation range of motion with hard stops or mechanical limits at the ends of the articulation range of motion. For example, an interference at the mechanical limit can prevent further motion beyond the mechanical limit and outside the articulation range of motion. Upon reaching the end of the articulation range of motion, the articulation joint can bump into the mechanical limit. Driving articulation of the robotic surgical tool against the mechanical limit(s) at the end of the articulation range of motion may damage the robotic surgical tool and/or the articulation system thereof over time in certain instances. Damage to the robotic surgical tool can be a function of the impact force, velocity and/or torque of the rotary drive inputs, for example.

In certain instances, to avoid bumping the mechanical limit, a control circuit can control the articulation system such that the articulation joint is limited to move within a narrower range of motion than the full articulation range of motion. For example, the mechanical limits of the articulation range of motion can be stored in the memory and/or obtained during a homing operation. The articulation system may effectively reduce the operating range of the articulation joint to less than the full articulation range of motion to maintain a safety zone or range of motion away from the mechanical limit(s). The safety zone can be configured to account for measurement error in the articulation joint during the homing operation and/or variations to the joint over time, for example. A safety zone reduces the available range of motion of the articulation joint and, thus, may unduly limit the articulation range of motion of the robotic surgical tool in certain instances.

Alternatively, it can be advantageous in certain instances to maximize the articulation range of motion and move the articulation joint within the full articulation range of motion and up to the mechanical limits while minimizing damage to the robotic surgical tool or articulation mechanism thereof. Such an articulation drive mechanism can be sufficiently robust to drive the articulation joint through its full range of motion up to the mechanical limit(s). For example, the articulation drive system may be configured to detect regions in the articulation range where the device is close to the mechanical limit and regions that are farther from the mechanical limit. Additionally, the articulation drive mechanism may operate the articulation joint differently in the regions closer to the mechanical limit to avoid damaging the articulation mechanism while still functioning fully and efficiently. For example, when the articulation joint angle is in a range of motion farther from the mechanical limit, the articulation joint may operate at a full speed and/or torque. When the articulation joint angle is in a range of motion closer to the mechanical limit, the articulation joint may operate at a limited speed and/or a limited torque. The limited speed and/or torque can allow the articulation joint to approach the mechanical limit and bump the limit softly or gently to avoid damaging the articulation mechanism. Stated differently, the articulation joint can softly bump the mechanical limit of the articulation joint and, thus, minimize wear and/or damage to the drive mechanism and/or to the articulation joint from the contact, for example.

In one aspect the present disclosure, a control circuit for use with a robotic surgical system can be configured to receive a parameter indicative of a rotary position of an articulation motor that is configured to drive an articulation joint of a robotic surgical tool. The articulation motor can be configured to move through a first range of positions and a second range of positions. The first range of positions and the second range of positions can be non-overlapping ranges. The control circuit can also be configured to implement a first operating state, and implement a second operating state when the parameter corresponds to a transition of the articulation motor from the first range of positions to the second range of positions. The second operating state can be different than the first operating state. The control circuit can be further configured to re-implement the first operating state when the parameter corresponds to a return of the articulation motor from the second range of positions into the first range of positions by a threshold anti-dither angle.

In certain instances, the foregoing articulation drive mechanism can provided a greater range of motion than articulation systems in which the articulation motion is confined to outside the safety zones defined in regions adjacent to the mechanical limits. Such an articulation drive mechanism can reduce incidences of crashing into the mechanical limit at significant speeds and/or torques, which avoids producing high impact loads that may damage the articulation system and/or robotic surgical tool, for example.

Referring toFIG.21, a robotic surgical tool3100is shown. The robotic surgical tool3100can be controlled by the control circuit3020(FIG.22) and can be used in conjunction with a robotic surgical system, such as the robotic surgical system100(FIG.1) and with the robotic arm200(FIG.2) and the tool drive220(FIGS.2and3). The robotic surgical tool3100includes a tool base, or proximal housing,3102that is similar in many aspects to the tool base352(FIG.5) and includes six rotary drives3160,3162,3164,3166,3168, and3170similar to the rotary drives360,362,364,366,368, and370of tool base352(FIG.5), for example. As with the rotary drives of the tool base352, the rotary drives of the tool base3102are configured to mate with six motor-driven rotary inputs or drivers on a tool carriage, such as the rotary drivers260,262,264,266,268, and270on the tool carriage224(FIG.4), for example. In various instances, each rotary drive3160,3162,3164,3166,3168, and3170can be associated with a degree of freedom of the robotic surgical tool3100.

A control circuit, for example the control circuit3020(FIG.22), may be in communication with one or more torque sensors and/or one or more rotary encoders, such as torque sensors3030,3032and position sensors3034,3036. The torque sensor(s) and/or rotary encoder(s) can be monitoring devices, which are configured to monitor operational parameters of the robotic surgical tool3100. The torque sensors, for instance, may be configured to monitor torque, and the rotary encoders may be configured to monitor motion (rotational or linear). The torque sensors and the rotary encoders can be incorporated into the motors of some or all of the drivers260,262,264,266,268, and270(FIG.5). Additionally or alternatively, the torque sensors and/or the rotary encoders can be operatively coupled to one or more of the rotary input drives3160,3162,3164,3166,3168, and3170on the tool base3102. The torque sensors may be configured to measure the real-time torque loading on the motors, which corresponds to the torque loading by the drivers260,262,264,266,268, and270, and/or the drive inputs3160,3162,3164,3166,3168, and3170, in various instances. The rotary encoders may measure the rotational motion or output of the motors, which corresponds to the rotational motion of the drivers260,262,264,266,268, and270and/or the drive inputs3160,3162,3164,3166,3168, and3170. Monitoring torque loading and rotational motion of the motors may help determine if the robotic surgical tool3100is operating in accordance with the commands provided by the control circuit.

Referring toFIG.22, a control circuit3020for controlling two motors that drive an articulation joint, such as the drivers264and266(FIG.5), for example, is shown inFIG.22. The control circuit3020includes a processor3040in signal communication with a memory3042and with a communication device3044. A first drive system3050and a second drive system3052are in signal communication with the processor3040. The first drive system3050includes a motor3054, an input drive3056coupled to the motor3054, a torque sensor3030, and a rotary encoder/position sensor3034. The input drive3056can correspond to the drive input3164and the motor3054can correspond to the driver264, for example. In other aspects of the present disclosure, different drivers and drive inputs can correspond to the motor3054and input drive3056.

The second drive system3052includes a motor3058, an input drive3060coupled to the motor3058, a torque sensor3032, and a rotary encoder/position sensor3036. The input drive3060can correspond to the drive input3166and the motor3058can correspond to the driver266, for example. In other aspects, different drivers and drive inputs can correspond to the motor3058and input drive3060. In such instances, the torque sensors3030and3032determine the torque on the motor3054and the motor3058, respectively. The torque sensors3030and3032can determine the torque on the drivers264and266, for example. Moreover, the position sensors3034and3036determine the angular position of the motor3054and the motor3058, respectively. The position sensors3034and3036can determine the angular position on the drivers264and266, for example.

The control circuit3020also includes an output drive3062, a torque sensor3064, and a rotary encoder/position sensor3066. The output drive3062can correspond to an articulation joint3108(FIG.21), for example. In such instances, the torque sensor3064determines the output torque applied to the articulation joint3108, and the position sensor3066determines the angular position of the articulation joint3108.

Referring primarily toFIG.21, an elongate shaft3104extends distally from the tool base3102; the elongate shaft3104includes a proximal end3110a distal end3112. A distal end effector3106is coupled to the distal end3112of the elongate shaft3104at an articulation joint, or wrist joint,3108. The articulation joint3108is similar to the articulation joint458(FIG.6) in certain aspects of the present disclosure.

The articulation joint3108enables the end effector3106to articulate or pivot relative to the shaft3104and thereby position the end effector3106at desired orientations and locations relative to a surgical site. For example, rotation of the rotary drive3164and the rotary drive3166may cause the articulation joint3108to rotate. Specifically, rotation of the rotary drive3164in a direction3122and of the rotary drive3166in a direction3124may cause the articulation joint3108to rotate in a direction3120. In other aspects of the present disclosure, different rotational directions and/or rotary drives can effect articulation of the articulation joint3108.

Referring toFIG.23, a soft bump articulation control process3000for a robotic surgical tool is shown. The soft bump articulation control process3000is configured to control the articulation motors coupled to the rotary drivers that drive the articulation system in the robotic surgical tool. For example, the soft bump articulation control process3000is configured to control the articulation of the articulation joint3108of the robotic surgical tool3100in various instances. The soft bump articulation control process3000is configured to allow the articulation mechanism to move through the full articulation range of motion. The full articulation range of motion reaches the mechanical joint limits with a soft bump at the mechanical joint limit, which is when the mechanical limit of the joint is reached. In such instances, the joint can slowly and softly hit the mechanical limit without damaging the robotic surgical tool3100. This soft bump articulation control process3000allows the articulation joint3108to be driven to any location in its full articulation range of motion.

Prior to starting a teleoperation with a surgical robot and the robotic surgical tool3100, the robotic surgical tool3100can be attached to the surgical robot and a homing operation for the robotic surgical tool can be performed. For example, when the robotic surgical tool is mounted to the tool driver, the robotic system can undergo a homing operation, in which positions of the various components are determined and recorded to ascertain various limits of the surgical system. For example, a start location of the rotary inputs attached to the rotary drivers of the robotic surgical tool may be determined by the homing process. The mechanical limits of a joint in a robotic surgical tool, such as the articulation joint3108, for example, may also be determined during the homing process.

In other instances, a robotic surgical system may not perform a homing process and the mechanical limits and/or current joint locations may be stored in a memory and recalled from the memory upon attachment of the robotic surgical tool to the surgical robot.

If a mechanical limit is reached at a high speed and/or torque, the high impact load may damage the robotic surgical tool or its articulation drive system. A reduction in the range of articulation motion for the tool may be around 1%, 2%, 5%, 10%, or higher to ensure that measurement error of the joint's location does not result in contacting the mechanical limit of the joint at a high speed and/or torque.

FIG.23describes the soft bump articulation control process3000for two motors that drive an articulation joint and do not have a reduction from the maximum operating range. In certain instances, the soft bump articulation control process3000can be adapted to have only one motor and, in other instances, more than two motors driving an articulation motion.

Referring still toFIG.23, at a step3002in the soft bump articulation control process3000, the teleoperation begins and the control circuit3020starts a normal articulation control mode3006(or first operating state). During the normal articulation control mode3006, the motors that control the articulation joint, such as the motors driving the rotary drivers264,266(FIG.4) which are mated to the rotary drives3164,3166, for example, are operated under normal or standard speeds and torques. Additionally, under the normal articulation control mode3006, the motors that drive the articulation joint are driven at the desired input inverse kinematics and operated under normal speeds and torques. The two input motor angles can be monitored. Stated differently, parameters indicative of a rotary position of each articulation motors can be monitored during the first operating state. Additionally, a parameter indicative of the position of the articulation joint can be monitored during the first operating state.

If either motor angle exceeds a threshold rotation angle, then the control circuit3020transitions from the normal articulation control mode3006to an upper articulation bump control mode3004(or second operating state) or a lower articulation bump control mode3008(or third operating state), as further described herein. Stated differently, the control circuit3020operates the articulation motors in a first operating state, e.g. normal articulation control mode3006, in a range of positions and transitions to a second operating state, e.g. the upper articulation bump control mode3004or the lower articulation bump control mode3008, in a different range of positions.

The control circuit3020transitions from the normal articulation control mode3006to the upper articulation bump control mode3004following a path3010when the angle of a first articulation motor exceeds an upper articulation bump threshold angle. Stated differently, the control circuit3020operates a first articulation motor and a second articulation motor in a first operating state, e.g. normal articulation control mode3006, when the rotary position of the first articulation motor is in a first range of positions. The control circuit3020operates the first and the second articulation motors in a second operating state, e.g. upper articulation bump control mode3004, when the rotary position of the first articulation motor is in a second range of positions. In certain instances, the first range of positions and the second range of positions are non-overlapping. In certain instances, the first range of positions and the second range of positions are contiguous. The control circuit3020transitions the first and second articulation motors from the first operating state to the second operating state when the rotary position of the first articulation motor moves from the first range of positions to the second range of positions. In certain instances, the first and second articulation motors could be the motors driving the rotary drives3164and3166or vice versa.

In certain instances, an upper articulation bump threshold angle may be a motor rotation angle that corresponds to 1%, 2%, 5%, 10%, or any articulation angle within 15% of the upper mechanical limit of the articulation joint. Additionally, or alternatively, the upper articulation bump threshold could be any motor rotation angle that ensures that the upper mechanical limit is not reached in the normal articulation control mode3006.

During the upper articulation bump control mode3004, the two input motor angles and the articulation joint angle can be monitored. Stated differently, parameters indicative of the positions of the input motors and articulation joint can be monitored during the second operating state. If the articulation joint angle is increasing in the upper articulation bump control mode3004(i.e. moving toward the mechanical upper limit), then the articulation motors can be driven at the desired inverse kinematics and operated under limited speeds and/or limited torques. The motor torques and/or motor speeds can be limited to less than the standard torque and/or speed permitted during the normal articulation control mode3006, which can allow the articulation joint3108to reach its mechanical upper limit without causing a high impact load on the articulation system or robotic surgical tool3100. Stated differently, when the first articulation motor and the second articulation motors are in the second operating state and the rotary position of the first articulation motor is moving away from the first range of positions, then the maximum allowable speed and maximum allowable torque for the first and second articulation motors are lower than in first operating state.

In various instances, if the articulation joint angle is decreasing in the upper articulation bump control mode3004(i.e. moving away from the mechanical upper limit), then the two articulation motors are driven at the desired inverse kinematics and may be operated under normal speeds and torques. Stated differently, when the first and second articulation motors are in the second operating state and the rotary position of the first articulation motor is moving toward the first range of positions, then the maximum allowable speed and maximum allowable torque for the first and second articulation motors may be the same as in the first operating state, for example. Once the first articulation motor angle decreases past the upper articulation bump threshold angle and an additional anti-dither angle, the control circuit3020transitions from the upper articulation bump control mode3004back to the normal articulation control mode3006following a path3012. Stated differently, the control circuit3020re-implements the first operating state from the second operating state for the first and second articulation motors when the rotary position of the first articulation motor returns to the first range of positions from the second range of positions by a threshold anti-dither angle. The additional anti-dither angle is a small angle that allows for a smooth transition between the upper articulation bump control mode3004and the normal articulation control mode3006. In certain instances, the anti-dither angle is an angle that is less than ten degrees and may be one or two degrees, for example. In certain instances, the anti-dither angle is zero.

The control circuit3020transitions from the normal articulation control mode3006to the lower articulation bump control mode3008following a path3014when the angle of the second articulation motor exceeds a lower articulation bump threshold angle. Stated differently, the control circuit3020operates the first and second articulation motors in a first operating state, e.g. normal articulation control mode3006, when the rotary position of the second articulation motor is in a third range of positions. The control circuit3020operates the first and second articulation motors in a third operating state, e.g. lower articulation bump control mode3008, when the rotary position of the second articulation motor is in a fourth range of positions. In certain instances, the third range of positions and the fourth range of positions are non-overlapping. In certain instances, the third range of positions and the fourth range of positions are contiguous. The control circuit3020transitions the first and second articulation motors from the first operating state to the third operating state when the rotary position of the second articulation motor moves from the third range of positions to the fourth range of positions. In certain instances, the first and second articulation motors could be the motors driving the rotary drives3164and3166or vice versa.

In certain instances, the lower articulation bump threshold angle may be a motor rotation angle that corresponds to 1%, 2%, 5%, 10%, or any articulation angle within 15% of the lower mechanical limit of the articulation joint. Additionally, or alternatively, the lower articulation bump threshold could be any motor rotation angle that ensures that the lower mechanical limit in the normal articulation operating mode3006.

During the lower articulation bump control mode3008, the two input motor angles and articulation joint angle can be monitored. Stated differently, parameters indicative of the positions of the input motors and the articulation joint can be monitored during the third operating state. If the articulation joint angle is decreasing in the lower articulation bump control mode3008(i.e. moving toward the mechanical lower limit), then the articulation motors are driven at the desired inverse kinematics and operated under limited speeds and/or limited torques. The articulation input motor torques and speeds are limited to allow the articulation joint to reach the mechanical lower limit of the articulation joint without causing high impact loads. Stated differently, when the first and second articulation motors are in the third operating state and the rotary position of the second articulation motor is moving away from the third range of positions, then the maximum allowable speed and maximum allowable torque for the first and second articulation motors are lower than in first operating state.

In various instances, if the articulation joint angle is increasing in the lower articulation bump control mode3008(i.e. moving away from the mechanical lower limit), then the two articulation motors are driven at the desired inverse kinematics and operated under normal speeds and torques. Stated differently, when the first and second articulation motors are in the third operating state and the rotary position of the second articulation motor is moving toward the third range of positions, then the maximum allowable speed and maximum allowable torque for the first and second articulation motors may be the same as in the first operating state, for example. Once the second articulation motor angle increases past the lower articulation bump threshold angle and an additional anti-dither angle, the control circuit3020transitions from lower articulation bump control mode3008back to normal articulation control mode3006following path3016. Stated differently, the control circuit3020re-implements the first operating state from the third operating state for the first and second articulation motors when the rotary position of the second articulation motor returns to the third range of positions from the fourth range of positions by a threshold anti-dither angle.

The additional anti-dither angle is a small angle that allows for a smooth transition between the lower articulation bump control mode3008and the normal articulation control mode3006. In certain instances, the anti-dither angle is an angle that is less than ten degrees and may be one or two degrees, for example. In certain instances, the anti-dither angle can be zero.

The control circuit3020can be implemented as a non-transitory computer readable medium storing computer readable instructions. Accordingly, the non-transitory computer-readable medium includes any type of tangible machine-readable medium suitable for storing or transmitting electronic instructions or information in a form readable by a machine (e.g., a computer), which can implement the transitions between operating states and/or modes3004,3006, and/or3008.

In various instances, the soft bump articulation control process3000can be used to control other joints on a robotic surgical tool in which the joint is configured to bumps a mechanical joint limit during its range of motion.

Referring now toFIG.24, a portion of a robotic surgical tool3200is shown. The robotic surgical tool3200is similar in many aspects to the robotic surgical tool3100. The robotic surgical tool3200includes a tool base, or proximal housing,3202, which is similar in many aspects to the tool base3102and includes six rotary drives3260,3262,3264,3266,3268, and3270. Certain portions of the proximal housing3202are removed from the robotic surgical tool3200inFIG.24to expose an interior portion of the proximal housing3202including the six rotary drives3260,3262,3264,3266,3268, and3270and components of the articulation system housed therein.

An elongate shaft3204extends distally from the tool base3202; the elongate shaft3204includes a proximal end3210and a distal end3212. A distal end effector3206is coupled to the distal end3212of the elongate shaft3204at an articulation joint, or wrist joint,3208. The articulation joint3208is similar to the articulation joint3108in many aspects of the present disclosure. The articulation joint3208enables the end effector3206to articulate or pivot relative to the elongate shaft3204and thereby position the end effector3206at desired orientations and locations relative to a surgical site.

Referring still toFIG.24, the rotary drive3264drives a first drive rack3240. Rotational movement of the rotary drive3264corresponds to linear movement of the first drive rack3240in either a direction3222or a direction3232depending on the rotational direction of the rotary drive3264. The first drive rack3240includes a first fork3242matable with a first articulation yoke3244. More specifically, the first fork3242is configured to be received within an annular slot3246defined in the first articulation yoke3244. Engagement between the first fork3242and the annular slot3246allows the first drive rack3240to drive the first articulation yoke3244linearly along an internal shaft3280in either the direction3222or the direction3232. The internal shaft3280extends from within the tool base3202at a location3218through the elongated shaft3204to the articulation joint3208.

The first articulation yoke3244is coupled to a first articulation band3248, which extends distally to the articulation joint3208. As illustrated, the first articulation band3248is arranged within a corresponding slot defined in the internal shaft3280, such that the internal shaft3280guides the first articulation band3248as it extends distally to the articulation joint3208. Axial movement of the first articulation yoke3244along a longitudinal axis parallel to the internal shaft3280correspondingly moves the first articulation band3248, which corresponds to articulation of the articulation joint3208. In certain instances, movement of the first articulation yoke3244in the direction3232may cause the articulation joint3208to articulate and move the end effector3206in a direction3230, for example. In certain instances, movement of the first articulation yoke3244in the direction3222may cause the articulation joint3208to articulate and move the end effector3206in a direction3220, for example.

Referring still toFIG.24, the rotary drive3266drives a second drive rack3250. Rotational movement of the rotary drive3266corresponds to linear movement of the second drive rack3250in either a direction3224or a direction3234depending on the rotational direction of the rotary drive3266. The second drive rack3250includes a second fork3252matable with a second articulation yoke3254. More specifically, the second fork3252is configured to be received within an annular slot3256defined in the second articulation yoke3254. Moreover, engagement between the second fork3252and the annular slot3246allows the second drive rack3250to drive the second articulation yoke3254linearly along the internal shaft3280in either the direction3224or the direction3234.

The second articulation yoke3254may be coupled to a second articulation band3258, which extends distally to the articulation joint3208. As illustrated, the second articulation band3258is arranged within a corresponding slot defined in the internal shaft3280, such that the internal shaft3280guides the second articulation band3258as it extends distally to the articulation joint3208. Axial movement of the second articulation yoke3254along a longitudinal axis parallel to the internal shaft3280correspondingly moves the second articulation band3258, which causes the articulation joint3208to articulate. In certain instances, movement of the second articulation yoke3254in the direction3234may cause the articulation joint3208to articulate and move the end effector3206in the direction3230, for example. In certain instances, movement of the second articulation yoke3254in the direction3224may cause the articulation joint3208to articulate and move the end effector3206in the direction3220, for example.

Axial movement of the first and second articulation yokes3244,3254can cooperatively actuate the first and second articulation bands3248,3258and, thereby, articulate the end effector3206as further described herein. Movement of the first articulation yoke3244in the direction3232and movement of the second articulation yoke3254in the direction3234corresponds to articulation of the end effector3206in the direction3230. Said another way, movement of the first articulation yoke3244and the second articulation yoke3254away from each other corresponds to articulation of the end effector3206in the direction3230. Additionally, movement of the first articulation yoke3244in the direction3222and movement of the second articulation yoke3254in the direction3224corresponds to articulation of the end effector3206in the direction3220. Stated differently, movement of the first articulation yoke3244and the second articulation yoke3254toward each other corresponds to articulation of the end effector3206in the direction3220. In at least one aspect of the present disclosure, the first and second articulation yokes3244,3254protagonistically operate such that one of the articulation yokes3244,3254pulls one of the articulation bands3248,3258proximally while the other articulation yokes3244,3254pushes the other articulation band3248,3258distally.

In other aspects, the first and second articulation yokes3244,3254may be operated independently without the other being operated (affected). In certain instances, the first and second articulation yokes3244,3254may operate antagonistically where one reduces the force effect of another. In an antagonistic operation, one of the articulation yokes3244,3254pulls (or pushes) the articulation bands3248,3258associated therewith proximally (or distally) with a first force while the other one of the articulation yokes3244,3254pulls (or pushes) the articulation bands3248,3258associated therewith proximally (or distally) with a second force. When the first force is larger than the second force, the first force can overcome the second force, as well as the internal losses of the device (i.e., friction) and loads imparted on the end effector3206via the external environment, such that that the articulation yoke3244,3254providing the first force moves proximally (or distally) while the articulation yoke3244,3254providing the second force moves distally (or proximally).

Still referring primarily toFIG.24, the internal shaft3280extends distally within the elongated shaft3204and is connected to the articulation joint3208. The articulation bands3248,3258extend distally towards the articulation joint3208within corresponding slots defined within the internal shaft3280. The corresponding slots may be provided on opposite sides of the internal shaft3280, or may be defined elsewhere about the internal shaft3280in other instances.

FIG.25is a cross-sectional view of the proximal housing3202taken across the plane indicated inFIG.24. The articulation bands3248,3258sit inside slots on either side of the internal shaft3280. The internal shaft3280extends through the second articulation yoke3254. The second articulation band3258attaches to the second articulation yoke3254. The first articulation band3248extends along the slot in the internal shaft3280and through the second articulation yoke3254. The second drive rack3250attaches to the second articulation yoke3254at the second fork3252.

In various instances, the sliding of the articulation yokes3244,3254along the internal shaft3280can generate friction and corresponding internal losses. To effect the articulation motion, the articulation yokes3244,3254must overcome the frictional losses and move along the internal shaft3280. Articulation systems including articulation yokes configured to slide along an internal support chassis, like those shown inFIGS.24and25are further described in U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, which is incorporated by reference herein in its entirety.

Internal moving parts that translate along each other to articulate an end effector generate friction. For example, the articulation yokes3244,3254that move along the internal shaft3280of the robotic surgical tool3200shown inFIG.24generate friction during an articulation motion. In certain instances, the articulation of the end effector can cause significant frictional forces between the internal translating parts during normal loading conditions. Such frictional forces require the drive mechanism to supply more input torque to overcome the friction. In various instances, the high friction can cause a brake-like effect, which requires additional input torque for various subsystems that interact with the translating parts in order to overcome the friction. In various instances, it can be advantages to reduce the friction on the moving parts of a robotic surgical tool during an articulation motion.

An articulation drive system that mechanically reduces the friction between certain translating parts may be advantageous in certain instances. Such an articulation drive system can be sufficiently robust to articulate the end effector without requiring additional torque input due to frictional losses along the translating surfaces. For example, the incorporation of rolling elements (e.g. roto-linear ball bearings) between certain translating parts can reduce the frictional forces and losses therebetween.

In one aspect the present disclosure, a robotic surgical tool can comprise a housing, an end effector, and an elongate shaft extending distally from the housing to the end effector. The robotic surgical tool can further comprise an articulation joint configured to articulate the end effector relative to the elongate shaft during an articulation motion, an internal shaft extending distally from the housing through the elongate shaft, and an articulation drive system. The articulation drive system can comprise an articulation yoke coupled to the internal shaft, an articulation band coupled to the articulation yoke and extending distally along the internal shaft to the articulation joint, and rolling elements intermediate the internal shaft and the articulation yoke. The articulation yoke can be configured to roll along the rolling elements during the articulation motion.

In certain instances, the foregoing arrangement can reduce frictional losses between certain translating parts of the articulation drive system. Moreover, the reduced friction can improve load handling and requires less input torque. There may also be less induced friction on adjacent subsystems in certain instances.

Referring toFIGS.26and27, portions of a robotic surgical tool3300are shown. The robotic surgical tool3300is similar in many aspects to the robotic surgical tool3200. For example, the robotic surgical tool3300includes an internal shaft3380, an articulation joint3308, a surgical end effector3306, and an articulation system including articulation yokes3344,3354. The articulation yokes3344,3354are similar in many aspects to the articulation yokes3244,3254(FIG.24). Unlike the robotic surgical tool3200, the robotic surgical tool3300also includes rolling element pads3382around the internal shaft3380between the articulation yokes3344,3354and the internal shaft3380. The rolling element pads3382include roto-linear elements (e.g. balls within a continuous looped track), which can reduce the friction caused from movement of the articulation yokes3344,3354along the internal shaft3380.

The internal shaft3380extends distally and is coupled to an articulation joint, or wrist joint,3308at the distal end of the internal shaft3380. In various instances, a tool shaft can surround the internal shaft3380and also surround the components of the articulation system extending between the proximal housing to the end effector3306. The internal shaft3380can be a chassis or support for the tool shaft and other components extending between the proximal housing and the end effector. For example, the internal shaft3380can support a firing member.

The articulation joint3308is similar in many aspects to the articulation joint3208. The articulation joint3308enables the end effector3306to articulate or pivot relative to the internal shaft3380and thereby position the end effector3306at desired orientations and locations relative to a surgical site.

Referring still toFIGS.26and27, a first drive rack3340attaches to the first articulation yoke3344with a first fork3242matable to the first articulation yoke3344. More specifically, the first fork3342is configured to be received within an annular slot3346defined in the first articulation yoke3344. Moreover, engagement between the first fork3342and the annular slot3346allows the first drive rack3340to drive the first articulation yoke3344linearly along the internal shaft3380in a direction3322or a direction3332. Movement of the first articulation yoke3344in the direction3322or the direction3332along the internal shaft3380corresponds to articulation of the end effector3306in the direction3320or the direction3330. The articulation yoke stop3374prevents the first articulation yoke3344from moving too far proximally, i.e. too far in the direction3332, on the internal shaft3380.

A second drive rack3350attaches to the second articulation yoke3354with a second fork3352matable to the second articulation yoke3354. More specifically, the second fork3352is configured to be received within an annular slot3356defined in the second articulation yoke3354. Moreover, engagement between the second fork3352and the annular slot3356allows the second drive rack3350to drive the second articulation yoke3354linearly along the internal shaft3380in a direction3324or a direction3334. Movement of the second articulation yoke3354in the direction3324or the direction3334along the internal shaft3380corresponds to articulation of the end effector3306in the direction3320or the direction3330.

Accordingly, axial movement of the first and second articulation yokes3344,3354, cooperatively actuate the first and second articulation bands3348,3358and, thereby, articulate the end effector3306, as further described herein. Movement of the first articulation yoke3344in the direction3332and movement of the second articulation yoke3354in the direction3334corresponds to articulation of the end effector3306in the direction3330. Said another way, movement of the first articulation yoke3344and the second articulation yoke3354away from each other corresponds to articulation of the end effector3306in the direction3330. Additionally, movement of the first articulation yoke3244in the direction3222and movement of the second articulation yoke3254in the direction3224corresponds to articulation of the end effector3206in the direction3220. Said another way, movement of the first articulation yoke3244and the second articulation yoke3254toward each other corresponds to articulation of the end effector3206in the direction3220.

The articulation yokes3344,3354are configured to slide along multiple rolling element pads3382that are set into the internal shaft3380. In certain instances, the rolling element pads3382may be press-fit into recesses or cavities in the internal shaft3380. In various instances, there may be two, four, or eight rolling element pads3382set around the circumference of the internal shaft3380. The internal shaft3380includes four rolling element pads3382around the circumference thereof. The reader will appreciate that there may be other suitable numbers of rolling element pads3382around the circumference of the internal shaft3380, and the rolling element pads3382can be positioned to cover the region along which the articulation yokes3344,3354move along the internal shaft3380.

Referring now toFIG.28, an exploded view of a rolling element pad3382is shown. Each rolling element pad3382includes a rolling element retainer3384, rolling elements, or balls,3386, and a rolling element base3390. The rolling elements3386in each rolling element pad3382are divided into two sets of rolling elements3386that sit in separate and independent continuous loop tracks3392. The continuous loop tracks3392are defined between the rolling element retainer3384and the rolling element base3390. The rolling elements3386can roll around their continuous loop track3392, which allows the rolling elements3386to move and roll as the articulation yokes3344,3354move relative to the internal shaft3380. In such instances, the rolling element pads3382comprise roto-linear bearings for the articulation yokes3344,3354. The slits or windows3388in the rolling element retainer3384allow the rolling elements3386to interact with objects outside of the rolling element retainer3384, such as the articulation yokes3344,3354, for example. The rolling elements3386stick out past the slits3388so that the articulation yokes3344,3354are supported by and sit on the rolling elements3386and do not slide directly on the rolling element retainer3384.

Referring primarily toFIG.28, the rolling elements3386of each rolling element pad3382are held in the continuous loop track3392(FIG.28) by the rolling element retainer3384. The articulation yokes3344,3354(FIGS.26and27) slide on the rolling elements3386during the linear movement of the articulation yokes3344,3354along the internal shaft3380. The articulation yokes3344,3354do not slide directly on the rolling element retainer3384, but slide on the rolling elements3386that radially protrude beyond the retainer3384. The rolling elements3386roll along the continuous loop track3392during the movement of the articulation yokes3344,3354.

InFIG.28, there are two continuous loop tracks3392per rolling element pad3382and each articulation yoke3344,3354sits on rolling elements3386of a different continuous loop track3392. In such instances, the rolling elements3386associated with each articulation yoke3344,3354(FIGS.26and27) can travel in the same direction as the corresponding articulation yoke3344,3354. As described herein, the articulation yokes3344,3354can move axially relative to each other (toward each other/together and away from each other/apart) and, thus, the rolling elements3386in the continuous loop tracks3392of the same rolling element pad3382can simultaneously or concurrently roll in different directions.

The rolling of the rolling elements3386is configured to reduce the friction caused by the movement of the articulation yokes3344,3354. Such a reduction in friction can allow for better handling of the articulation joint3308and require less input torque to articulate the end effector3306relative to the elongate shaft of the robotic surgical tool3300. Moreover, there can be less induced friction on adjacent subsystems, such as the closure and shaft rolling subsystems of the robotic surgical tool, for example.

In various instances, it may be difficult for a clinician to visualize the orientation of a robotic surgical tool during a surgical procedure. For example, it may be difficult to visualize the orientation of the tool with respect to a constrained anatomy in which only an end effector, or portion thereof, is visible in the camera view.

In certain instances, an augmented rendering of the robotic surgical tool can be shown to the user to demonstrate the tool's orientation. The augmented rendering may show joints of the robotic surgical tool that are out of view/off camera. It is desirable to convey such information to the clinician without being overly distracting to the clinician. For example, the orientation may be depicted on the display at a transitional state between completion of a homing operation and the beginning of the teleoperation. The augmented rending of the robotic surgical tool can then be minimized or otherwise moved to a remote and/or unobtrusive location on the display screen so as to not distract the clinician.

In certain instances, an end effector overlay feature for a surgical imaging system can inform the clinician of the function and orientation of the robotic surgical tool without distracting the clinician from the surgical operation. The position of the robotic surgical tool in relation to the camera is already calculated by the robotic surgical system for tool mapping purposes in various instances.

Surgical camera views of a robotic surgical tool3530during a surgical procedure are shown in a series of views inFIGS.30A-D, in which the orientation of the robotic surgical tool3530is conveyed to a clinician in the camera view3500with an end effector overlay feature. In various instances, such a feature can take advantage of the state between completion of the homing operation and the beginning of teleoperation of the robotic surgical tool3530to overlay, demonstrate, and minimize the augmented rendering of the distal end effector for the clinician's benefit and convenience.

In various instances, the control system, such as the control tower130(FIG.1) for example, can complete a homing operation and then wait for a clinician to manually extend the robotic surgical tool3530into the surgical field. The control system can track the orientation and position of the robotic surgical tool3530relative to the camera and monitor the camera view3500. The control system can wait for a minimum amount of the end effector of the robotic surgical tool3530to appear within view, as shown inFIG.30A, in various instances. The control system can then overlay an augmented rendering3520of the end effector on top of the actual end effector image on the display screen. Though the augmented rendering3520may be over the end effector on the display screen, the augmented rendering can be transparent and/or a skeleton/phantom depiction such that the end effector can also be seen by the clinician.

FIG.29is a flowchart3400showing the process of displaying the augmented rendering3520on the camera view3500. In step3410, the camera view has the abstract augmentation3510of the surgical tool3530in an unobtrusive location of the camera view3500and the surgical tool3530is not yet in the camera view3500. At step3420, the surgical tool3530enters the camera view3500. Step3430commences when enough of the surgical tool enters the camera view3500. At step3430, an augmented rendering3520is overlaid on the camera view3500. Next, at step3440, the surgical tool3530joint orientations are shown to the clinician. At step3450, the augmented rendering3520is removed by panning and scaling the augmented rendering3520toward the abstract augmentation3510. At step3460, the augmented rendering3430has reached the abstract augmentation3510and disappeared from the primary and/or central portion of the display screen.

The augmented rendering3520is a conical schematic reflecting the conical orientation of the jaws of the robotic surgical tool3530. In other instances, the augmented rendering can be a different three-dimensional shape, such as a sphere or a prism. The shape of the augmented rendering3520can correspond to a general shape of the robotic surgical tool3530in various instances. The reader will appreciate that alternative robotic surgical tools, e.g. electrosurgery devices, scalpels, clip appliers, clamps, and/or ultrasonic tools, can employ the end effector overlay feature described herein.

In various instances, the augmented rendering3520can show the surgical tool3530joint orientations (Step3440ofFIG.29). In one example the joint orientations are shown by leaving the augmented rendering3520over the surgical tool3530for a period of time. Once the period of time has expired, the augmented rendering3520can be reduced in scale and moved off the actual robotic surgical tool3530to a less clinically-obtrusive location. For example, the augmented rendering3520can be moved to a side bar or a corner of the camera view3500. When the robotic surgical tool3530moves during teleoperation, the augmented rendering3520can then moves accordingly, which can aid in visualization of the robotic surgical tool.

The augmented rendering3520can show the orientation and functionality of the robotic surgical tool3530by rotating the joints of the robotic surgical tool3530on the augmented rendering3520. For example, the augmented rendering3520includes marks3522,3524at the distal end thereof. The marks3522,3524can be configured to rotate about the longitudinal axis, i.e. a roll axis, to shown the roll functionality of the robotic surgical tool3530. In certain instances, the marks3522,3524can be conveyed to a clinician as a variation in the line type of the augmented rendering3520, as shown inFIG.30A, and/or as a different color, for example. The marks3522,3524can also be implemented by other signals, which allow the function (e.g. rotation about the longitudinal axis) to be conveyed to the clinician in a simplified and easy-to-identify manner. The marks3522,3524can also be conveyed with a break in the line depicting the augmented rendering3520.

An abstract augmentation3510of the robotic surgical tool3530is shown in an unobtrusive location of the camera view3500. InFIGS.30A-D, the unobtrusive location is the top left corner of the camera view3500. Alternative locations are also possible, such as on a side bar or at any of the corners of the camera view3500, for example. The abstract augmentation3510shows a rendering of the robotic surgical tool3530that shows the orientation of the entire robotic surgical tool3530including joints that are not in the camera view3500. These orientations may be challenging for a clinician to appreciate in a typical view, in which most of the elongated shaft of the robotic surgical tool3530are not shown in the camera view. For example, the articulation joint place markers3512and roll place markers3514are shown in the abstract augmentation3510ofFIGS.30A-30D. The rendering on the abstract augmentation3510can move as the robotic surgical tool3530moves, which provides the clinician with feedback and information about the overall orientation of the joints of the robotic surgical tool3530.

FIGS.30A-30Dshow four stages of animation of the augmented rendering3520going from full overlay inFIG.30Ato the abstract augmentation3510inFIG.30D.FIG.30Ashows the augmented rendering3520in a fully overlaid state.FIGS.30B and30Care transitional frames of the augmented rendering3520panning and scaling toward the abstract augmentation3510.FIG.30Dshows a post-overlay scene with just the abstract augmentation3510in the top-left corner. The transition between the full overlay stage (FIG.30A) and pure abstract augmentation3510stage (FIG.30D) can be smooth in implementation. The augmented rendering3520pans and scales to become part of the abstract augmentation3510.

In various instances, the rotation about a longitudinal axis is shown by roll place markers3514and the rotation about the articulation joint is shown by articulation place markers3512, for example. The roll place markers3514and/or the articulation place markers3512can include marks, which can correspond to the marks on the augmented rendering3520. For example, the marks can include the same signal and/or color to convey the correspondence to the clinician.

The augmented rendering3520can be configured to show the orientation of the surgical tool3530(Step3440ofFIG.29) by remaining on the robotic surgical tool3530for a period of time. Once the period of time is over, the augmented rendering3520can move off the robotic surgical tool3530to the abstract augmentation3510, in certain aspects of the present disclosure. For example, the augmented rendering3520can pan and scale to the abstract augmentation3510located in the unobtrusive location.

In certain instances, the augmented rendering3520can show the orientation of the surgical tool3530(Step3440ofFIG.29) by remaining overlaid on the robotic surgical tool3530until the robotic surgical tool3530enters a teleoperation mode and a minimum amount of roll and/or articulation is implemented. In such instances, the augmented rendering3520moves with the robotic surgical tool3530, which allows the clinician to observe the motion of the augmented rendering3520. Once a minimum amount of travel or movement has been observed, the augmented rendering3520can pan and scale to the abstract augmentation3510located in the unobtrusive location.

In still other instances, the augmented rendering3520can be configured to show the orientation of the surgical tool3530(Step3440ofFIG.29) by having the augmented rendering3520automatically oscillate the joints of the robotic surgical tool3530. This process could be used to catch the clinician's attention. For example, the roll joint and/or the articulation joints can initially be slightly oscillated to alert the clinician to their locations. After such an oscillation, the augmented rendering3520can return to matching the orientation of the robotic surgical tool, and then pan and scale to the abstract augmentation3510located in the unobtrusive location.

It is noted that there could be other methods to perform step3440ofFIG.29with the augmented rendering3520and abstract augmentation3510. Any method that uses the augmented rendering3520and abstract augmentation3510to show the surgical tool3530joint orientations could be used.

A robotic surgical system2100is shown inFIG.31. Various aspects of the robotic surgical system2100are further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, for example. U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, is incorporated by reference herein in its entirety.

The robotic surgical system2100includes a base2101coupled to one or more robotic arms, e.g., the robotic arms2102inFIG.31. The base2101is communicatively coupled to a command console or user console, which is further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, for example. In various instances, the command console for the robotic surgical system2100is similar in many aspects to the user console110(FIG.1). The base2101can be positioned such that the robotic arm2102has access to perform a surgical procedure on a patient, while a user, such as a clinician or surgeon, for example, can control the robotic surgical system2100from the comfort of the command console. In some instances, the base2101can be coupled to a surgical operating table or a bed for supporting the patient. In other instances, the robotic arms can be supported by a free-standing robot having a base and/or column, for example, as further described in U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, for example.

In some instances, the base2101may include subsystems such as control electronics, pneumatics, power sources, optical sources, and the like. The robotic arm2102includes multiple arm segments2110coupled at joints2111, which provides multiple degrees of freedom, e.g., seven degrees of freedom corresponding to seven arm segments, for the robotic arm2102. The base2101may contain a source of power2112, pneumatic pressure2113, and control and sensor electronics2114—including components such as a central processing unit, data bus, control circuitry, and memory—and related actuators such as motors to move the robotic arm2102. The electronics2114in the base2101may also process and transmit control signals communicated from the command console. The base2101also includes wheels2115to transport the robotic surgical system100.

In some aspects of the present disclosure, the robotic arm2102includes set up joints that use a combination of brakes and counter-balances to maintain a position of the robotic arm2102. The counter-balances may include gas springs or coil springs. The brakes, which are fail-safe brakes in certain instances, may include mechanical and/or electrical components. Further, the robotic arms2102can be gravity-assisted passive support type robotic arms.

Each robotic arm2102may be coupled to a tool driver2117, which is also referred to herein as an instrument device manipulator (IDM), using a changer interface2116. The tool driver2117can serve as a tool holder. In some instances, the tool driver2117can be removable, such that the tool driver2117can be replaced with a different type of tool driver. For example, the tool drivers220(FIG.2-4) for the robotic surgical system100(FIG.1) can be interchangeable with the tool driver2117(FIG.31) in certain instances. For example, a first type of tool driver that manipulates an endoscope can be replaced with a second type of tool driver that manipulates a laparoscope. The changer interface2116includes connectors to transfer pneumatic pressure, electrical power, electrical signals, and optical signals from the robotic arm2102to the tool driver2117. The changer interface2116can be a set screw or base plate connector. The tool driver2117manipulates surgical tools, such as the surgical tool2118, for example, using techniques including direct drive, harmonic drive, geared drives, belts and pulleys, magnetic drives, and the like. The changer interface2116is interchangeable based on the type of tool driver2117and can be customized for a certain type of surgical procedure. The robotic arm2102can include joint level torque sensing and a wrist at a distal end, in various instances.

The surgical tool2118can be a laparoscopic, endoscopic and/or endoluminal tool, for example, that is capable of performing a procedure on a patient at a surgical site. In some aspects of the present disclosure, the surgical tool2118includes a laparoscopic tool, which can be inserted into an incision of a patient. The laparoscopic tool can comprise a rigid, semi-rigid, or flexible shaft. When designed for laparoscopy, the distal end of the shaft can be connected to an end effector that may comprise, for example, a wrist, a grasper, a scissors, a stapler, or other surgical device. Exemplary end effectors for cutting and fastening tissue are further described herein.

In certain aspects of the present disclosure, the surgical tool2118comprises an endoscopic surgical tool that is inserted into the anatomy of a patient to capture images of the anatomy (e.g., body tissue). The endoscopic tool, or endoscope, can include a tubular and flexible shaft. The endoscope includes one or more imaging devices (e.g., cameras or sensors) that capture images at the surgical site. The imaging devices may include one or more optical components such as an optical fiber, fiber array, or lens. The optical components move along with the tip of the surgical tool2118such that movement of the tip of the surgical tool2118results in changes to the images captured by the imaging devices. Exemplary imaging devices and visualization systems are further described herein.

In other instances, the surgical tool2118comprises an endoluminal tool, which can be inserted through a natural orifice of a patient, such as a bronchoscope or urethroscope. The endoluminal tool can also include a tubular and flexible shaft. When designed for endoluminal surgery, the distal end of the shaft can be connected to an end effector that may comprise, for example, a wrist, a grasper, scissors, or other surgical device.

The robotic arms2102of the robotic surgical system2100can manipulate the surgical tool2118using elongate movement members. The elongate movement members may include pull-wires, also referred to as pull or push wires, cables, fibers, or flexible shafts. For example, the robotic arms2102are configured to actuate multiple pull-wires coupled to the instrument2118to deflect, articulate, and/or rotate the tip of the surgical tool2118. The pull-wires may include both metallic and non-metallic materials such as stainless steel, Kevlar, tungsten, carbon fiber, and the like. In some aspects of the present disclosure, the surgical tool2118may exhibit nonlinear behavior in response to forces applied by the elongate movement members. The nonlinear behavior may be based on stiffness and compressibility of the tool2118, as well as variability in slack or stiffness between different elongate movement members.

Referring still toFIG.31, the robotic surgical system2100also includes a controller2120, which can be a computer processor, for example. The controller2120includes a calibration module2125, image registration module2130, and a calibration store2135. The calibration module2125can characterize the nonlinear behavior of the tool using a model with piecewise linear responses along with parameters such as slopes, hysteresis, and dead zone values. The robotic surgical system2100can more accurately control the surgical tool2118by determining accurate values of the parameters. In some instances, some or all functionality of the controller2120is performed outside the robotic surgical system2100. For example, certain functionalities can be performed on another computer system or server communicatively coupled to the robotic surgical system2100.

Another surgical robot2200is shown inFIG.32. Various aspects of the surgical robot2200are further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, for example.

The surgical robot2200can be incorporated into the robotic surgical system2100ofFIG.31in certain aspects of the present disclosure. The surgical robot2200includes one or more robotic arms2202each having a tool driver2217and a surgical tool2218attached thereto. InFIG.32, the robotic arms2202are attached to adjustable rails2250coupled to a patient platform2260in the form of a bed. In the surgical robot2200, three robotic arms2202are attached to the adjustable rail2250on a first side of the patient platform2260, while two robotic arms2202are attached to the adjustable rail2250on a second side of the patient platform2260, thereby providing a system with bilateral arms. The surgical robot2200can also include a controller like the controller2120(FIG.31), for example, and can be communicatively coupled to a command console, such that a surgeon's inputs at the command console can be implemented by the surgical robot2200via the controller.

FIG.33illustrates a perspective view of a tool driver2300, which is also referred to herein as an IDM. Various aspects of the tool driver2300are further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, for example.

The tool driver2300can be used with the robotic surgical system2100and with the surgical robot2200, for example. The tool driver2300is configured to attach a surgical tool to a robotic arm in a manner that allows the surgical tool to be continuously rotated, or “rolled”, about a longitudinal axis of the surgical tool. The tool driver2300includes a base2302and a surgical tool holder assembly2304coupled to the base2302. The surgical tool holder assembly2304service as tool holder for holding a surgical tool, such as the surgical tool2118(FIG.31) or the surgical tool2218(FIG.32).

The surgical tool holder assembly2304further includes an outer housing2306, a surgical tool holder2308, an attachment interface2310, a passage2312, and a plurality of torque couplers2314that have splines2318. The passage2312comprises a through-bore that extends from one face of the tool driver2300to an opposing face of the tool driver2300along the axis2316. The tool driver2300can be used with a variety of surgical tools, which may include a handle, or housing, and an elongated body, or shaft, and which may be for a laparoscope, an endoscope, or other types of surgical tools. An exemplary surgical tool2400is shown inFIG.34, for example.

The base2302removably or fixedly mounts the tool driver2300to a robotic surgical arm of a robotic surgical system. InFIG.33, the base2302is fixedly attached to the outer housing2306of the surgical tool holder assembly2304. In alternative instances, the base2302is structured to include a platform, which is adapted to rotatably receive the surgical tool holder2308on the face opposite from the attachment interface2310. The platform may include a passage aligned with the passage2312to receive the elongated body of the surgical tool and, in some instances, an additional elongated body of a second surgical tool mounted coaxially with the first surgical tool. One or more motors can be housed in the base2302. For example, the surgical tool holder2308can include multiple motors, which are configured to drive, i.e. rotate torque drivers2314with a torque and rotary velocity, which can be controlled by the controller, for example.

The surgical tool holder assembly2304is configured to secure a surgical tool to the tool driver2300and rotate the surgical tool relative to the base2302. Mechanical and electrical connections are provided from the surgical arm to the base2302and then to the surgical tool holder assembly2304to rotate the surgical tool holder2308relative to the outer housing2306and to manipulate and/or deliver power and/or signals from the surgical arm to the surgical tool holder2308and ultimately to the surgical tool. Signals may include signals for pneumatic pressure, electrical power, electrical signals, and/or optical signals.

The attachment interface2310is a face of the surgical tool holder2308that attaches to the surgical tool. The attachment interface2310includes a first portion of an attachment mechanism that reciprocally mates with a second portion of the attachment mechanism located on the surgical tool. The attachment interface2310is further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, for example.

Various tools can attach to the tool driver2300, including tools used for laparoscopic, endoscopic and endoluminal surgery. Tools can include tool-based insertion architectures that reduce the reliance on robotic arms for insertion. In other words, insertion of a surgical tool (e.g., towards a surgical site) can be facilitated by the design and architecture of the surgical tool. For example, in some instances, wherein a tool comprises an elongated shaft and a handle, the architecture of the tool enables the elongated shaft to translate longitudinally relative to the handle along an axis of insertion. Various advantages of tool-based insertion architectures are further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, which is incorporated by reference herein its entirety.

A surgical tool2400having a tool-based insertion architecture is shown inFIG.34. Various aspects of the surgical tool2400are further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, for example.

The surgical tool2400enables a translation of the surgical tool2400(e.g., translation of its shaft2402and end effector2412relative to a tool driver and/or distal end of the robotic arm) along an insertion axis. In such instances, the surgical tool2400can be moved along the insertion axis without reliance—or with less reliance—on movement of a robotic arm. The surgical tool2400includes an elongated shaft2402, an end effector2412connected to the shaft2402, and a handle2420, which may also be referred to as an instrument housing or base, coupled to the shaft2402. The elongated shaft2402comprises a tubular member having a proximal portion2404and a distal portion2406. The elongated shaft2402includes one or more channels or grooves along its outer surface. The grooves are configured to receive one or more wires or cables2430therethrough. The cables2430run along an outer surface of the elongated shaft2402. In other aspects of the present disclosure, certain cables2430can run through the shaft2402and may not be exposed. Manipulation of the cables2430(e.g., via the tool driver2300) results in actuation of the end effector2412, for example.

The end effector2412comprises laparoscopic, endoscopic, or endoluminal components, for example, and can be designed to provide an effect to a surgical site. For example, the end effector2412can comprise a wrist, grasper, tines, forceps, scissors, clamp, knife, and/or fasteners. Exemplary surgical end effectors are further described herein. The cables2430that extend along the grooves on the outer surface of the shaft2402can actuate the end effector2412. The cables2430extend from a proximal portion2404of the shaft2402, through the handle2420, and toward a distal portion2406of the shaft2402, where they actuate the end effector2412.

The instrument handle2420includes an attachment interface2422having one or more mechanical inputs2424, e.g., receptacles, pulleys or spools, that are designed to be reciprocally mated with one or more torque couplers2314(FIG.33) on the attachment interface2310of the tool driver2300. The attachment interface2422is capable of attaching to the tool driver2300via a front-mount, back-mount and/or top mount. When physically connected, latched, and/or coupled together, the mated mechanical inputs2424of the instrument handle2420may share axes of rotation with the torque couplers2314of the tool driver2300, thereby allowing the transfer of torque from the motors in the tool driver2300to the instrument handle2420. In some instances, the torque couplers2314may comprise splines that are designed to mate with receptacles on the mechanical inputs. Cables2430that actuate the end effector2412engage the receptacles, pulleys, or spools of the handle2420, such that the transfer of torque from the tool driver2300to the instrument handle2420results in actuation of the end effector2412.

The surgical tool2400can include a first actuation mechanism2450(FIG.35) that controls actuation of the end effector2412. The tool2400can also include a second actuation mechanism that enables the shaft2402to translate relative to the handle2420along an axis of insertion A. In various instances, the first actuation mechanism2450can be decoupled from the second actuation mechanism, such that actuation of the end effector2412is not affected by the translation of the shaft2402, and vice versa.

In various instances, an actuation mechanism can include one or more pulleys mounted on a rotary axis to change relative cable length and, in other instances, mounting a pulley on a lever, gear or track-based system to adjust its location. Additionally or alternatively, ball spline rotary shafts that travel down a length of a tool can also be used to transmit forces in a mechanically-remote way. Various actuation mechanisms are further described in U.S. Pat. No. 10,470,830, titled SYSTEM AND METHODS FOR INSTRUMENT BASED INSERTION ARCHITECTURES, issued Nov. 12, 2019, for example.

Referring toFIG.35, the first actuation mechanism2450can provide N+1 wrist motion, wherein N is the number of degrees of freedom provided by N+1 cables. The first actuation mechanism2450for actuating the end effector2412comprises at least one cable segment2430that extends through at least one set of pulleys. In the actuation mechanism ofFIG.35, a first cable, or first cable segment, extends through pulley members2450a,2450b,2450c, while a second cable, or second cable segment, extends through pulley members2450d,2450e,2450f. The cables2430are grounded at or near the proximal end2404(FIG.34) of the shaft2402, then extends through the set of pulleys2450a,2450b,2450c,2450d,2450e,2450flocated within the housing2420, before terminating at or near the end effector2412. Cable total path length is kept constant by grounding each cable2430at or near the proximal end2404of the shaft2402, and relative length changes are made by moving one or more pulleys (e.g., pulley members2450band2450e) relative to each other as indicated by the arrows inFIG.35, thereby enabling actuation of the end effector2412. In some instances, the pulleys can be moved via linear or rotary motion of corresponding mechanical inputs2424. The first actuation mechanism2450can permit free movement of the instrument shaft2402relative to the actuation pulleys2450a,2450b,2450c,2450d,2450e,2450fthereby allowing an additional cable to be included to permit insertion and retraction of the instrument shaft1202at the same time as end effector1212actuation.

Robotic surgical tools having tool-based insertion architecture, such as the surgical tool2400shown inFIG.34, for example, may be subjected to high loads during certain surgical actuations or surgical functions. For example, a surgical tool that is used to clamp, cut, staple and/or fasten tissue may be subjected to high clamping and firing loads when clamping certain types of tissue and/or when firing fasteners. In certain instances, the clamping and firing loads on a surgical tool can exceed 300 lbf, for example. The tool-based insertion architecture in the housing of such a surgical tool should be configured to withstand such loads. In certain instances, a lead screw may be used to translate the tool housing along the elongate shaft, which may withstand the high clamping and firing loads. However, a lead screw arrangement may be bulky and/or costly in certain instances.

Alternatively, a translation mechanism that is lightweight, nimble, and/or less expensive than a lead screw may be advantageous in certain instances. Such a translation mechanism can be sufficiently robust to withstand significant forces during use, such as the high forces transmitted during clamping and/or firing, for example. For example, a pulley and cable arrangement can be used in combination with one or more pivoting locks, which are configured to resist the high clamping and/or firing forces.

In one aspect of the present disclosure, a surgical tool can include a surgical end effector comprising opposing jaws, an elongate shaft extending distally to the surgical end effector, and a housing defining a passage therethrough, wherein the elongate shaft extends through the passage. The surgical tool can also include an actuation mechanism configured to selectively move the housing along the elongate shaft relative to the surgical end effector, wherein the actuation mechanism comprises a pulley, a cable engaged with the pulley and a lock arrangement configured to releasably lock the housing relative to the elongate shaft. The lock arrangement can include a washer positioned around the elongate shaft, wherein the cable is engaged with the washer, and wherein the washer is configured to pivot relative to the elongate shaft between a locked orientation and an unlocked orientation. Moreover, an actuation of the pulley can apply a tension to the cable to pivot the washer to the unlocked orientation.

In various instances, such a lock arrangement can also include a second washer positioned around the elongate shaft, wherein an opposite end of the cable is engaged with the second washer, and wherein the second washer is configured to pivot relative to the elongate shaft between a locked orientation and an unlocked orientation.

In certain instances, the foregoing arrangement can securely ground translation of the surgical tool housing along the elongate shaft of the surgical tool without requiring a high mechanical advantage linear motion, such as the linear motion achieved with a lead screw, for example. Moreover, the actuation mechanism for effecting the tool-based translation can be nimble and lightweight, for example.

Referring now toFIG.36, a surgical tool2500is shown. The surgical tool2500includes a housing2520, which is also referred to herein as a handle or tool base, an elongate shaft2530slidably positioned through a portion of the housing2520, and a distal end effector2512. The housing2520can be similar to the housing2420(FIG.34) in many aspects. For example, the housing2520can include an attachment interface having one or more mechanical inputs, such as receptacles, pulleys, and/or spools, that are designed to reciprocally mate with one or more torque couplers2314(FIG.33) on the attachment interface2310of the tool driver2300and to receive actuation motion(s) from a robotic system. One or more actuation mechanisms, such as the actuation mechanism2550, for example, can be positioned in the housing2520and configured to effect one or more surgical actuations, such as articulation, clamping, and/or firing of the end effector2512.

Translation of the end effector2512can be achieved with the actuation mechanism2570, which includes a pulley arrangement2572and a lock arrangement2584. The pulley arrangement2572includes a pulley wheel2574, a capstan2576, and a cable2578extending from a first end2580to a second end2582. The cable2578terminates at the first end2580and at the second end2582. The first end2580and the second end2582are mounted to features in the housing2520, which are further described herein. The cable2578inFIG.36is not a continuous loop. Rather, the cable2578comprises a piece of cable with ends2580,2582that are configured to move relative to each other in certain instances to change the length of the cable loop. An actuation of the pulley arrangement2572is configured to apply tension to the cable2578to exert a pulling force on the housing2520along the length of the elongate shaft2530. For example, rotation of the capstan2576, applies tension to the cable2578. When the actuation mechanism2570is unlocked, as further described herein, the pulling force on the cable2578is configured to pull the housing2520along the length of the elongate shaft2530, such that the end effector2512is displaced along the longitudinal axis A of the surgical tool2500.

The elongate shaft2530is grounded at its proximal end2532to a component2502of the surgical robot, such as a distal end of a robotic arm, which is similar in many aspects to the robotic arm2102(FIG.31) and the robotic arm2202(FIG.32), for example. Similarly, the distal end2534of the elongate shaft2530is grounded to a distal portion of the surgical tool2500. More specifically, the distal end2534is fixed to a bracket2514mounted to the end effector2512. The housing2520is configured to move along the elongate shaft2530between the component2502and the bracket2514.

The actuation mechanism2570also includes the lock arrangement2584in combination with the pulley arrangement2572. The lock arrangement2584is depicted schematically inFIG.36. The lock arrangement2584is configured to releasably lock the housing2520to the elongate shaft2530such that forces applied to the elongate shaft2530during certain surgical actuations and/or functions (e g clamping and/or firing) do not effect longitudinal displacement of the housing2520relative to the elongate shaft2530and do not move the end effector2512along the insertion axis A.

Generally, the end effector2512would not be advanced or retracted along the insertion axis, or longitudinal axis of the elongate shaft2530, during a clamping and/or firing actuation. More specifically, while tissue is being clamped, cut, and/or stapled, for example, the longitudinal position of the end effector2512is often fixed, which may avoid damaging and/or traumatizing the tissue in certain instances. To this end, the lock arrangement2584can be configured to lock the longitudinal position of the housing2520on the elongate shaft2530during a clamping and/or firing actuation. When in the locked configuration, any forces transmitted between the housing2520and the shaft2530can be resisted by the lock arrangement2584in order to hold the end effector2512stationary relative to the tissue being clamped, transected, and/or stapled, for example.

Referring now toFIG.37, a surgical tool2600is shown. Portions of the surgical tool2600are removed fromFIG.37for clarity. For example, portions of a housing2620are removed fromFIG.37. The surgical tool2600can be similar in many aspects to the surgical tool2500. For example, the surgical tool2600includes a housing2620, which is also referred to herein as a handle or tool base, an elongate shaft2630slidably positioned through the housing2620, and a distal end effector2612. The housing2620can be similar to the housing2420(FIG.34) in many aspects. For example, the housing2620can include an attachment interface having one or more mechanical inputs, such as receptacles, pulleys, and/or spools, that are designed to reciprocally mate with one or more torque couplers2314(FIG.33) on the attachment interface2310of the tool driver2300, which are configured to receive actuation motion from the robotic system. One or more actuation mechanisms in the housing2620can be configured to effect one or more surgical actuations, such as articulation, clamping, and/or firing of the end effector2612, for example. The housing2620can be built around the elongate shaft2630, for example.

The elongate shaft2630extends from the surgical robot to the end effector2612. For example, a proximal end2632of the elongate shaft2630is mounted to a robotic arm2602of a robotic surgical system, and a distal end2634of the elongate shaft2630is mounted to a distal flange2614of the end effector2612. The housing2620is slidably positioned around the elongate shaft2630between the proximal end2632and the distal end2634.

The surgical tool2600includes an actuation mechanism2670including a pulley arrangement2672and a lock arrangement2684. The pulley arrangement2672is similar in many aspects to the pulley arrangement2572(FIG.36) and includes a pulley2674mounted to the robotic arm2602, a capstan2676mounted to the flange2614, and a cable2678engaged with the pulley2674and the capstan2676and extending therebetween. The cable2678is mounted to the housing2620via the lock arrangement2684. Moreover, the pulley arrangement2672and, more specifically, the cable2678thereof, is configured to move the lock arrangement2684between the unlocked configuration and the locked configuration.

The lock arrangement2684is configured to releasably lock the housing2620relative to the elongate shaft2630. The lock arrangement2684includes a first lock2686and a second lock2688. The locks2686,2688are washer-shaped and have a central bore or through-hole, which is configured to receive the elongate shaft2630therethrough. In other words, the first lock2686and the second lock2688are positioned around the elongate shaft2630within the housing2620. A first end2636of the cable2678is engaged with the first lock2686and a second end2638of the cable2678is engaged with the second lock2688. The locks2686,2688are configured to pivot relative to the elongate shaft2630as they move between a locked orientation and an unlocked orientation. More specifically, an actuation of the pulley arrangement2672, e.g. rotation of the capstan2767, is configured to apply a tension to the cable2678to pull the ends2636,2638and pivot the locks2686,2688to the unlocked configuration.

In the locked configuration, the first lock2686and the second lock2688are oriented at an oblique angle relative to a longitudinal axis defined by the elongate shaft2630. More specifically, an axis extending through the central bore in each lock2686,2688is obliquely-oriented relative to the longitudinal axis of the elongate shaft2630. In the unlocked configuration, the first lock2686and the second lock2688are configured to pivot toward a parallel orientation, in which the locks2686,2688are parallel, or nearly parallel with each other. As the locks2686,2688pivot toward the unlocked configuration, the axes extending through the central bore in each lock2686,2688are configured to move into axial alignment with the longitudinal axis of the elongate shaft2630. The first lock2686and the second lock2688can be referred to as screen door locks or, collectively, as opposing screen door locks, in certain instances.

The lock arrangement2684includes a spring2690positioned between the first lock2686and the second lock2688. The spring2690biases a portion of the first lock2686away from a portion of the second lock2688, such that the locks2686,2688pivot into an angled orientation relative to the elongate shaft2630. In various instances, the tension applied by the actuation of the pulley arrangement2672is configured to overcome the biasing force of the spring2690to move the first lock2686and the second lock2688from their locked configurations to their unlocked configurations and, thus, to unlock the actuation mechanism2670and the lock arrangement2684thereof. In such an arrangement, the tension in the cable2678first overcomes the lock arrangement2684and then pulls on the elongate shaft2630to achieve a displacement along the insertion axis A.

Referring still toFIG.37, the housing2620includes a body portion2622having an internal cavity2626, which receives at least a portion of the locks2686,2688and a portion of the elongate shaft2630. The body portion2622includes an internal wall2624that defines a portion of the internal cavity. The actuation of the pulley arrangement2672is configured to push a portion of the first lock2686against the internal wall2624to draw or pull the housing2620along the elongate shaft2630. In various instances, when the tension in the cable2678is relieved, the spring2690is configured to return the locks2686,2688to their locked configurations, in which clamping and firing loads directed to the elongate shaft2630are resisted by the lock arrangement2684.

In various instances, the lock arrangement2684can be incorporated into the surgical tool2500(FIG.36). For example, the lock arrangement2584(FIG.36) can include the lock arrangement2684or components thereof.

Referring now to a flow chart inFIG.38, a transection operation2800is depicted. Various surgical tools comprising end effectors for transecting tissue are described herein and these various surgical tools and/or robotic surgical systems therefor can utilize the transection operation2800to cut tissue and/or fire fasteners. The reader will understand that various control circuits can be utilized to implement the transection operation2800, including a control circuit, controller, computer processor located in the controller2120(FIG.31) and/or in the control tower130(FIG.1), for example.

An example control circuit2728for implementing the transection operation2800(FIG.38) is shown inFIG.39, for example. The control circuit2728includes a processor2740in signal communication with a memory2742, a communication device2744, a drive system2752, and inputs2780,2782. The processor2740includes a clock, or timer,2741, which is configured to time various stages or sub-stages in the transection operation2800(FIG.38), as further described herein.

The memory2742stores program instructions, which are configured to implement various surgical operations, including a clamping operation2840and the transection operation2800(FIG.38) or various stages thereof. The memory2742also stores various threshold parameters related to transitioning between the stages in the transection operation2800, such as bailout threshold parameters, for example. Additional parameters stored in the memory2742are further described herein.

The communication device2744is configured to convey information from the processor2740to external devices, such as a graphical user interface (GUI)2790, for example. Various outputs to the GUI2790are further described herein.

The drive system2752includes a motor2758, an input drive2760coupled to the motor2758, a torque sensor2732, a rotary encoder/position sensor2736, and a velocity sensor2738. The drive system2752corresponds to a rotary drive in a tool holder or tool drive, as further described herein. The drive system2752is configured to provide rotary input to the surgical tool to effect a surgical function. More specifically, the drive system2752corresponds to a firing drive system, which is configured to effect a firing motion of the surgical tool. In various instances, the input drive2760can correspond to one of the torque couplers2314inFIG.33. For example, output from the motor2758can be transferred to a torque coupler2314and, ultimately, to a surgical tool to effect the surgical function. More specifically, one of the torque couplers2314is configured to transfer output motions from the firing motor2758to the surgical tool to effect a firing stroke. The torque sensor2732can detect the torque from the firing motor2758and/or input drive2760coupled thereto, for example, the position sensor2736can detect the rotary position of the input drive2760, for example, and the velocity sensor2738can detect the rotary velocity of the input drive2760, for example.

The control circuit2728also includes inputs2780,2782, which are configured to convey signals to the processor2740indicative of inputs from the surgeon and/or clinician positioned at the command console. In various instances, the input2780can correspond to the active/inactive status of a transection input, such as a transection pedal at the command console, for example, and the input2782can correspond to the active/inactive status of a clamping input, such as a clamping pedal at the command console, for example.

Referring again toFIG.38, the transection operation2800includes bailout detection, graphical user interface (GUI) prompts and/or alerts, stall detection, and various safety faults, as further described herein. The transection operation2800can utilize velocity, torque, and/or position sensors to transition between states and progress through the transition operation2800. Various sensors in the robot and/or surgical tool can be configured to detect the velocity, torque, and/or position of the input components (e.g. input actuators and/or pedals), rotary drive members (e.g. motors and/or rotary drives in the tool drive and/or the tool base), and of output components (e.g. the firing member and/or cutting edge).

In various instances, the transection operation2800may follow a clamping step or clamping operation2840. During a normal, uninterrupted transection, the transection operation2800can proceed from the clamping operation2840, to an Outset State2802, to a Pre-Lockout Region State2804, to a Lockout Region State2808, to a Transection State2816, to a Transection-Completed State2818, to a Retraction State2830, and finally to a Transection-Ended state2834. However, the control circuit is configured to monitor various parameters during the transection operation2800and certain parameters at certain stages may trigger a variation from the normal, uninterrupted transection operation2800. For example, torque and/or velocity of the firing member can cause the operation2800to detour from the above-summarized flow between the Outset State2802and the Transection-Ended state2834. Additional states in the operation2800can include a Pre-Lockout Pause State2806, a Lockout Pause State2810, a Lockout-Detected State2812, a Lockout-Damaged State2814, a Transection-Canceled State2820, a Transection Pause State2822, a Damaged State2824, a Transection-Stalled State2826, a Stall Limit State2828, a Retraction-Stalled State2832, a Bailout-Attempt State2836, and/or a Non-Recoverable State2838, for example.

In various instances, the transection operation2800relates to a clinician's activation of the transection input (e.g. a pedal) to transection or cut the tissue clamped between the end effector jaws. Cutting the tissue generally relies on extending a knife or cutting edge distally through clamped tissue. In various aspects of the present disclosure, the transection of tissue is accompanied with nearly simultaneous stapling of tissue. For example, the cutting edge can sever tissue directly following the stapling of the tissue.

In various instances, when a surgical tool is mounted to a robotic arm, the surgical robot can initially implement a homing operation, in which the angular position of the torque couplers and/or rotary inputs are measured and recorded in the memory of the control circuit (e.g. memory2742) at the various limits or “bumps” in the range of motion of the surgical tool. Homing operations are further described herein and in U.S. patent application Ser. No. 16/553,725, titled ARTICULATING INCLUDING ANTAGONISTIC CONTROLS FOR ARTICULATION AND CALIBRATION, filed Aug. 28, 2019, for example.

After homing and clamping, the transection operation2800can commence with entry into the Outset State2802. Upon entering the Outset State2802, the control circuit (e.g. the control circuit2728) can check Condition A, which corresponds to the disablement value (DV) of future firings by the surgical system and/or surgical tool. Condition A is satisfied when the DV stored in the memory (e.g. the memory2742) is false/negative, which indicates that future firings of the surgical system and/or surgical tool have not been disabled. If Condition A is satisfied, the transection operation2800proceeds from the Outset State2802to the Pre-Lockout Region State2804. Alternatively, if the DV is true/positive such that Condition A is not satisfied, future firings have been disabled and the operation2800does not proceed from the Outset State2802. In various instances, if the DV is true/positive, the control circuit can convey the disablement state to a user via the GUI (e.g. the GUI2790), for example. In various instances, the GUI may be updated throughout the operation2800. For example, a firing member and/or cutting edge extension function can send updated signals to the GUI throughout the operation2800regarding the position and/or status of the cutting edge (e.g. before a lockout region, in the lockout region, in a transection region, at a terminal transection position, and so on).

Upon entry to the Pre-Lockout Region State2804, a firing motor angle (FMA) from a position sensor (e.g. the position sensor2736), a firing motor velocity (FMV) from a velocity sensor (e.g. the velocity sensor2738), and a firing motor torque (FMT) from a torque sensor (e.g. the torque sensor2732) are set or targeted by the control circuit (e.g. the control circuit2728). The target FMA corresponds to a terminal transection angle (TTA) at which the firing member has reached a terminal or distal-most position within the end effector. The target FMV corresponds to a pre-lockout region velocity stored in the memory (e.g. the memory2742). The motor associated with the firing actuation (e.g. the firing motor2758) is configured to deliver the target FMT. In the Pre-Lockout Region State2804, the target FMT corresponds to a pre-lockout region operating torque stored in the memory (e.g. the memory2742). In the Pre-Lockout Region State2804, if the FMA from the position sensor (e.g. the position sensor2736) exceeds a threshold non-opening angle associated with a firing member position that prevents unclamping or opening of the jaws, then a non-opening code (NOC) is set to positive/true. The threshold non-opening angle can be recorded during the homing operation, for example, and stored in the memory (e.g. the memory2742). The NOC corresponds to an inability to open the jaws. In various instances, the NOC can remain positive/true until the operation2800proceeds to the Transection-Ended State2834.

In the Pre-Lockout Region State2804, the control circuit (e.g. the control circuit2728) can check for Conditions B and C. Condition B corresponds to the FMA from the position sensor (e.g. the position sensor2736) being equal to or greater than a minimum cartridge lockout angle, which is stored in the memory (e.g. memory2742). In such instances, the FMA can indicate that the firing member has been extended into the lockout region. If Condition B is satisfied during the Pre-Lockout Region State2804, then the operation2800proceeds to the Lockout Region State2808, which is further described herein.

Condition C corresponds to the inactive status of a transection pedal (e.g. the input2780). If Condition C is satisfied during the Pre-Lockout Region State2804, i.e. the transection pedal becomes inactive, then the operation2800proceeds to a Pre-Lockout Pause State2806, which is further described herein.

During the normal, uninterrupted transection, the firing member can be advanced from the pre-lockout region into the lockout region (e.g. satisfying Condition B) without incidence. As a result, the operation2800proceeds to Lockout Region State2808during which the firing member can traverse the cartridge lockout, for example. The lockout region can correspond to the region in the staple cartridge in which an empty, spent, and/or missing cartridge lockout is positioned. In various instances, the cartridge lockout comprises a mechanical feature in a proximal portion of the end effector and/or cartridge which prevents the cutting edge on the firing member from being advanced distally into tissue when the cartridge (or absence thereof) would not adequately fasten the to-be-transected tissue.

Upon entry to the Lockout Region State2808, the FMA, FMV, and FMT are set or targeted by the control circuit (e.g. the control circuit2728). The target FMA can again correspond to the terminal transection angle (TTA). The target FMV corresponds to a lockout region velocity stored in the memory (e.g. memory2742), which may be different from the pre-lockout region velocity. Moreover, the target FMT corresponds to a lockout region operating torque also stored in the memory (e.g. memory2742). In the Lockout Region State2808, if the FMA from a position sensor (e.g. the position sensor2736) exceeds the threshold non-opening angle associated with a position that prevents unclamping or opening of the jaws, then the NOC (associated with an inability to open the jaws) is set to positive/true.

In the Lockout Region State2808, the control circuit (e.g. the control circuit2728) can check for Conditions G, H, I, and J. Condition G corresponds to the FMA from the position sensor (e.g. the position sensor2736) being equal to or greater than a maximum cartridge lockout angle, which can be determined during a homing operation, for example, and stored in the memory (e.g. memory2742). In such instances, the firing motor angle can indicate that the firing member has been extended past the lockout region. If Condition G is satisfied during the Lockout Region State2808, then the operation2800proceeds to the Transection State2816, which is further described herein.

Condition H corresponds to (A) the FMT from the torque sensor (e.g. the torque sensor2732) being equal to or greater than the lockout region operating torque and (B) the FMV from a velocity sensor (e.g. the velocity sensor2738) being equal to or less than the lockout region velocity for a period of time exceeding a lockout threshold time stored in the memory (e.g. memory2742). For example, a high torque from the motor and applied to the firing member may result in minimal or no displacement of the firing member when the lockout is obstructing the firing path in order to prevent transection of unstapled tissue, for example. Condition H indicates that a cartridge lockout has occurred. If Condition H is satisfied during the Lockout Region State2808, then the operation2800proceeds to the Lockout-Detected State2812, which is further described herein.

Condition I corresponds to the FMT from the torque sensor (e.g. the torque sensor2732) being equal to or greater than a damaged-lockout threshold torque, which is stored in the memory (e.g. the memory2742) and can indicate that the cartridge lockout has been damaged. In various instances, the damaged-lockout threshold torque can be greater than the lockout region operating torque. If Condition I is satisfied during the Lockout Region State2808, then the operation2800proceeds to the Lockout-Damaged State2814.

Condition J corresponds to the inactive status of the transection pedal (e.g. the input2780). If Condition J is satisfied during the Lockout Region State2808, i.e. the transection pedal becomes inactive, then the transection operation2800proceeds to the Lockout Pause State2810, which is further described herein.

During the normal, uninterrupted transection, the firing member can be advanced from the lockout region into a transection region (satisfying condition G) without incidence. As a result, the operation2800proceeds to the Transection State2816. Upon entry to the Transection State2816, a transection count stored in the memory of the control circuit (e.g. the memory2742of the control circuit2728) is incremented up by one. Moreover, the FMA, FMV, and FMT for the Transection State2816are set or targeted. The target FMA can again correspond to the terminal transection angle (TTA) and the target FMV can correspond to a transection region velocity stored in the memory (e.g. the memory2742). In various instances, the transection region velocity can be different than the pre-lockout region velocity and/or the lockout region velocity. The target FMT corresponds to a transection operating torque stored in the memory (e.g. the memory2742).

In the Transection State2816, the control circuit (e.g. the control circuit2728) can check for Conditions N, O, P, Q and R. Condition N corresponds to the inactive status of the transection pedal (e.g. the input2780). If Condition N is satisfied during the Transection State2816, i.e. the transection pedal becomes inactive, then the operation2800proceeds to a Transection Pause State2822, which is further described herein.

Condition O corresponds to the FMT from the torque sensor (e.g. the torque sensor2732) being equal to or greater than a maximum transection torque, which is stored in the memory (e.g. the memory2742) and indicates that the firing member (e.g. knife/cutting edge) has been subjected to high torques during the Transection State2816and may be damaged. If Condition O is satisfied during the Transection State2816, the operation2800proceeds to the Damaged State2824, which is further described herein.

Condition P corresponds to both (A) the FMT from the torque sensor (e.g. the torque sensor2732) being equal to or greater than the transection operating torque and (B) the FMV from a velocity sensor (e.g. the velocity sensor2738) being equal to or below a stall threshold velocity with both (A) and (B) being true for a time period exceeding a stall threshold time (STT) stored in the memory (e.g. the memory2742). Condition P can indicate that the firing member, or knife, has stalled during the Transection State2816. Condition Q corresponds to the number of firing member stalls being equal to or less than a maximum number of firing member stalls, which is stored in the memory (e.g. the memory2742). If Conditions P and Q are satisfied, the operation2800proceeds to the Transection-Stalled State2826, which is further described herein. If Condition P is satisfied, but Condition Q is not satisfied, the operation2800proceeds to a Stall Limit State2828, which is further described herein and indicates that the surgical device has exceeded the stall limit.

Condition R corresponds to the FMA from the position sensor (e.g. the position sensor2736) achieving the terminal transection angle (TTA), which indicates the firing member has traveled to the end of the transection or cutline, for example. If Condition R is satisfied, the operation2800proceeds to the Transection-Completed State2818.

During the normal, uninterrupted transection, the firing member can be advanced to the end of the transection region (satisfying condition R) without incidence. As a result, the operation2800proceeds to the Transection-Completed State2818. Upon entry to the Transection-Completed State2818, the control circuit (e.g. the control circuit2728) is configured to issue GUI feedback to the GUI (e.g. the GUI2790) indicating the transection or firing stroke is complete, thus, ready to transition to the Retraction State2830.

During the normal, uninterrupted transection, the firing member proceeds from the Transection-Completed State2818to the Retraction State2830without incidence. Upon entry to the Retraction State2830, a FMA, FMV, FMT are set or targeted by the control circuit (e.g. the control circuit2728). The target FMA can correspond to an after-homing firing angle, which is stored in the memory (e.g. the memory2742), and the target FMV can correspond to a retraction velocity, which is also stored in the memory (e.g. the memory2742). The target FMT can correspond to a retraction operating torque stored in the memory (e.g. the memory2742). In the retraction state2830, the control circuit (e.g. the control circuit2728) can check for Conditions Y and Z.

Condition Y corresponds to both (A) the FMT from the torque sensor (e.g. the torque sensor2732) being equal to or greater than the retraction operating torque and (B) the FMV from a velocity sensor (e.g. the velocity sensor2738) being equal to or less than the retraction velocity with both (A) and (B) being true for a time period equal to or greater than the stall threshold time (STT) stored in the memory (e.g. the memory2742). Condition Y indicates that the firing member has stalled during retraction. If Condition Y is satisfied during the retraction state2830, the operation2800proceeds to the Retraction-Stalled State2832.

Condition Z corresponds to the FMA from the position sensor (e.g. the position sensor2736) achieving the after-homing firing angle. Condition Z can indicate that the firing member has returned to its after-homing, pre-firing-stroke angle. If Condition Z is satisfied during the Retraction State2830, the operation2800proceeds to the Transection-Ended State2834.

Upon entry to the Transection-Ended State2834, the NOC (associated with the inability to open the jaws) stored in the memory (e.g. the memory2742) is set to negative/false, which indicates that the firing member has been sufficiently retracted to permit opening or unclamping of the jaws. The operation2800then proceeds to the Clamping Operation2840.

In various instances, the operation2800can detour from the Pre-Lockout Region State2804to the Pre-Lockout Pause State2806. From the Pre-Lockout Pause State2806, the operation2800may return to the Pre-Lockout Pause State2806, or may proceed to the Transection-Cancelled State2020, or the Bailout Attempt State2036. Upon entry to the Pre-Lockout Pause State2806, the control circuit (e.g. the control circuit2728) is configured to store the FMA from the position sensor (e.g. the position sensor2736), which corresponds to the pre-lockout pause angle. The control circuit is configured to target the pre-lockout pause angle during the Pre-Lockout Pause State2806. For example, the pre-lockout pause angle can be held or maintained during the Pre-Lockout Pause State2806.

In the Pre-Lockout Pause State2806, the control circuit (e.g. the control circuit2728) can check for Conditions D, E, and F. Condition D corresponds to the active status of the transection pedal (e.g. the input2780). If Condition D is satisfied during the Pre-Lockout Pause State2806, i.e. the transection pedal becomes active, then the operation2800returns to the Pre-Lockout Region State2804, which is further described herein.

Condition E corresponds to the active status of the clamping pedal (e.g. the input2782). If Condition E is satisfied during the Pre-Lockout Pause State2806, i.e. the clamping pedal becomes active, then the operation2800proceeds to the Transection-Canceled State2820, which is further described herein.

Condition F corresponds to both (A) the FMT from a torque sensor (e.g. the torque sensor2732) being equal to or greater than a bailout detection torque and (B) the FMV from a velocity sensor (e.g. the velocity sensor2738) being equal to or less than a bailout detection velocity with both (A) and (B) being true for a time period equal to or greater than a bailout detection time stored in the memory (e.g. the memory2742). Condition F can indicate a surgeon or clinician is attempting and/or effecting a bailout step while the firing member moves through the pre-lockout region. For example, during a surgical procedure, the surgeon or clinician can manually manipulate the firing member via a bailout lever or actuator on the housing of the surgical tool, which may involve decoupling the firing member from the firing motor and retracting the firing member manually, for example. If Condition F is satisfied during the Pre-Lockout Pause State2806, then the transection operation2800proceeds to the Bailout-Attempt State2836, which is further described herein.

In various instances, the operation2800can detour from the Lockout Region State2808to the Lockout Pause State2810. From the Lockout Pause State2810, the operation2800may return to the Lockout Region State2808, or may proceed to the Transection-Canceled State2020or the Bailout Attempt State2036. Upon entry to the Lockout Pause State2810, the control circuit (e.g. the control circuit2728) is configured to store the FMA, which corresponds to the lockout pause angle. The control circuit is configured to target the lockout pause angle during the Lockout Pause State2810. For example, the FMA can be held or maintained during the Lockout Pause State2810.

In the Lockout Pause State2810, the control circuit (e.g. the control circuit2728) can check for Conditions K, L, and M. Condition K corresponds to the active status of the transection pedal (e.g. the input2780). If Condition K is satisfied during the Lockout Pause State2810, i.e. the transection pedal becomes active, then the operation2800returns to the Lockout Region State2808, which is further described herein.

Condition L corresponds to the active status of the clamping pedal (e.g. the input2782). If Condition L is satisfied during the Lockout Pause State2810, i.e. the clamping pedal becomes active, then the operation2800proceeds to the Transection-Canceled State2820, which is further described herein.

Condition M corresponds to both (A) the FMT from the torque sensor (e.g. the torque sensor2732) being equal to or greater than the bailout detection torque and (B) the FMV from a velocity sensor (e.g. the velocity sensor2738) being equal to or less than the bailout detection velocity with both (A) and (B) being true for a time period equal to or greater than the bailout detection time. The bailout detection torque, bailout detection velocity, and bailout detection time are the same threshold values in the Pre-Lockout Pause State2806. For example, Condition M can be the same as Condition F. In other instances, different bailout threshold values can apply during the Pre-Lockout Pause State2806and the Lockout Pause State2810. Condition M can indicate a surgeon or clinician is attempting and/or effecting a bailout step while the firing member moves through the lockout region. For example, during a surgical procedure, the surgeon or clinician can manually manipulate the firing member, which may involve decoupling the firing member from the firing motor and retracting the firing member manually, for example. If Condition M is satisfied during the Lockout Pause State2810, then the transection operation2800proceeds to the Bailout-Attempt State2836, which is further described herein.

In various instances, the operation2800can detour from the Lockout Region State2808to the Lockout-Detected State2812and, then, to the Retraction State2830. Upon entry to the Lockout-Detected State2812, the control circuit (e.g. the control circuit2728) is configured to convey determination of the lockout and the locked-out state to a clinician via the GUI (e.g. the GUI2790), for example. For example, the control circuit can issue an error message informing the clinician that a cartridge is missing and/or that the installed cartridge is empty/spent. From the Lockout-Detected State2812, the operation2800can proceed to the Retraction State2830, which is further described herein.

In various instances, the operation2800can detour from the Lockout Region State2808to the Lockout-Damaged State2814and, then, to the Retraction State2830. Upon entry to the Lockout-Damaged State2814, the control circuit (e.g. the control circuit2728) is configured to convey a message to the clinician indicating that damage has been detected and the surgical tool is likely damaged or otherwise inoperable. For example, the control circuit can issue an error message via the GUI (e.g. the GUI2790). Moreover, the control circuit can update the DV to true/positive, which indicates that future firings of the surgical system and/or surgical tool have been disabled. As further described herein, when the DV is true/positive, Condition A is not satisfied and a subsequent operation2800would not proceed from the Outset State2802. From the Lockout-Damaged State2814, the operation2800can proceed to the Retraction State2830, with is further described herein.

In various instances, the operation2800can detour from various states to the Transection-Canceled State2820and, then, to the Retraction State2830. For example, the transection operation2800can be canceled and, thus, detour to the Transection-Canceled State2820directly from the Pre-Lockout Pause State2806(Condition E), the Lockout Pause State2810(Condition L), the Transection Pause State2822(Condition T), or the Transection-Stalled State2826(Condition V). For example, actuation of the clamping operation (e.g. activation of the clamping pedal or other input) can cancel the operation2800and the operation can proceed directly to the Transection-Canceled State2820. Upon entry to the Transection-Canceled State2820, the control circuit (e.g. the control circuit2728) is configured to convey a message to the clinician indicating that the transection operation2800has been canceled. For example, the control circuit can issue an error message via the GUI (e.g. the GUI2790). From the Transection-Canceled State2820, the operation2800can proceed to the Retraction State2830, with is further described herein.

In various instances, the operation2800can detour from the Transection State2816to the Transection Pause State2822. For example, deactivation of the clamping pedal or other input during the Transection State2816can pause the transection operation2800. Upon entry to the Transection Pause State2822, the control circuit (e.g. the control circuit2728) is configured to store the FMA, which corresponds to the transection pause angle. The control circuit is configured to target the transection pause angle during the Transection Pause State2822. For example, the transection pause angle can be held or maintained during the Transection Pause State2822.

In the Transection Pause State2822, the control circuit (e.g. the control circuit2728) can check for Conditions S, T, and U. Condition S corresponds to the active status of the transection pedal (e.g. the input2780). If Condition S is satisfied during the Transection Pause State2822, i.e. the transection pedal becomes active, then the operation2800returns to the Transection State2816, which is further described herein.

Condition T corresponds to the active status of the clamping pedal (e.g. the input2782). If Condition T is satisfied during the Transection Pause State2822, i.e. the clamping pedal becomes active, then the operation2800proceeds to the Transection-Canceled State2820, which is further described herein.

Condition U corresponds to both (A) the FMT from the torque sensor (e.g. the torque sensor2732) being equal to or greater than the bailout detection torque and (B) the FMV from a velocity sensor (e.g. the velocity sensor2738) being equal to or less than the bailout detection velocity with both (A) and (B) being true for a time period equal to or greater than the bailout detection time. The bailout detection torque, bailout detection velocity, and bailout detection time are the same threshold values in the Pre-Lockout Pause State2806and Lockout Pause State2810. In other instances, different bailout threshold values can apply during the Pre-Lockout Pause State2806, the Lockout Pause State2810, and/or the Transection Pause State2822. For example, Condition U can be the same as Condition F and/or Condition M. In other instances, different bailout threshold values can apply during the Transection Pause State2822. Condition U can indicate a surgeon or clinician is attempting and/or effecting a bailout step during a tissue transection step. For example, during a surgical procedure, the surgeon or clinician can manually manipulate the firing member, which may involve decoupling the firing member from the firing motor and retracting the firing member manually, for example. If Condition U is satisfied during the Transection Pause State2822, then the transection operation2800proceeds to the Bailout-Attempt State2836, which is further described herein.

In various instances, the operation2800can detour from the Transection State2816to the Damaged State2824and, then, to the Retraction State2830. Detection of a high torque on the firing motor and/or firing member during the Transection State (e.g. Condition O), which is associated with damage to the surgical device, can trigger the detour to the Damaged State2824. Upon entry to the Damaged State2824, the control circuit (e.g. the control circuit2728) is configured to convey a message to the clinician indicating that damage has been suspected and the surgical tool is likely damaged or otherwise inoperable. For example, the control circuit can issue an error message via the GUI (e.g. the GUI2790). Moreover, the control circuit can update the DV stored in the memory (e.g. the memory2742) to true/positive, which indicates that future firings of the surgical system and/or surgical tool have been disabled. As further described herein, when the DV is true/positive, Condition A is not satisfied and a subsequent operation2800would not proceed from the Outset State2802. From the Damaged State2824, the operation2800can proceed to the Retraction State2830, which is further described herein.

In various instances, the operation2800can detour from the Transection State2816to the Transection-Stalled State2826. For example, if certain monitored parameters (e.g. FMV and FMT) indicate that the firing member has stalled during the Transection State and the total number of firing member stalls is less than a maximum threshold, the operation2800can enter the Transection-Stalled State2826.

Upon entry to the Transection-Stalled State2826, a transection-stall count stored in the memory of the control circuit (e.g. the memory2742of the control circuit2728) is incremented up by one. As further described herein, the transection-stall count is compared to a threshold maximum number of firing member stalls stored in the memory for Condition Q in the Transection State2816. Moreover, the control circuit is configured to convey or communicate the stall and, in certain instances, the transection-stall count, to the clinician. For example, the control circuit can issue GUI feedback via the GUI (e.g. the GUI2790) indicating the operation2800has stalled and, thus, entered the Transection-Stalled State2826.

Upon entry to the Transection-Stalled State2826, the control circuit (e.g. the control circuit2728) is also configured to store the FMA from the position sensor (e.g. the position sensor2736), which corresponds to the stall angle, and set a timer and/or set a time parameter of an internal clock (e.g. the clock2741) to the current time, i.e. the time the Transection-Stalled State2826was initiated. Moreover, the FMA, Alf V and FMT are set or targeted by the control circuit. The target FMA angle can correspond to a back-off angle, and the target FMV can again correspond to the transection region velocity, which is the same target FMV as during the Transection State2816, in various instances. The target FMT corresponds to the transection operating torque, which is the same target FMT as during the Transection State2816, in various instances.

In the Transection-Stalled State2826, the control circuit (e.g. the control circuit2728) can check for Conditions V, W, and X. Condition V corresponds to the active status of the clamp pedal (e.g. the input2782). If Condition V is satisfied during the Transection-Stalled State2826, i.e. the clamp pedal becomes active, then the operation2800proceeds to the Transection-Canceled State2820, which is further described herein.

Condition W corresponds to both (A) the current time minus the recorded time parameter being equal to or greater than a transection back-off time and (B) the transection pedal status (e.g. status of the input2780) changing from inactive to active. Condition W corresponds to the duration of the stall being less than a threshold time period stored in the memory (e.g. the memory2742) and the transection pedal returning to an active status. In such instances, Condition W is satisfied, and the operation returns to the Transection State2816.

Condition X corresponds to both (A) the FMT from the torque sensor (e.g. the torque sensor2732) begin equal to or greater than the bailout detection torque and (B) the FMV from a velocity sensor (e.g. the velocity sensor2738) being equal to or less than the bailout detection velocity with both (A) and (B) being true for a time period equal to or greater than the bailout detection time. The bailout detection torque, bailout detection velocity, and bailout detection time are the same threshold values in the Pre-Lockout Pause State2806, Lockout Pause State2810, Transection Pause State2822, and/or the Transection-Stalled State2826. For example, Condition X can be the same as Condition F, Condition M, and/or Condition U. In other instances, different bailout threshold values can apply during the Transection-Stalled State2826.

Condition X can indicate a surgeon or clinician is attempting and/or effecting a bailout step while the firing member moves through the lockout region. For example, during a surgical procedure, the surgeon or clinician can manually manipulate the firing member, which may involve decoupling the firing member from the firing motor and retracting the firing member manually, for example. If Condition X is satisfied during the Transection Stalled State2826, then the transection operation2800proceeds to the Bailout-Attempt State2836, which is further described herein.

In various instances, the operation2800can detour from the Transection State2816to the Stall Limit State2828and then to the Transection-Canceled State2820. For example, the operation2800can proceed to the Stall Limit State2828if the various parameters for entering the Transection-Stalled State2826are satisfied; however, the surgical tool has exceeded the threshold maximum number of firing member stalls. In other words, the surgical tool has already stalled more times than is reasonable and/or expected. Upon entry to the Stall Limit State2828, the control circuit (e.g. the control circuit2728) is configured to convey the determination regarding the stall limit to a clinician via the GUI (e.g. the GUI2790), for example. In various instances, the control circuit can issue an error message to the GUI informing the clinician that the stall limit has been reached and/or the Stall Limit State2828has commenced. From the Stall Limit State2828, the operation2800can proceed to the Retraction State2830, which is further described herein.

In various instances, the operation can detour from the Retraction State2830to the Retraction-Stalled State2832. For example, the firing member may become stuck or otherwise inoperable by the motor (e.g. the firing motor2758) during the Retraction State2830. Upon entry to the Retraction-Stalled State2832, the control circuit (e.g. the control circuit2728) can issue a message and/or convey the state of the surgical tool to a clinician or user. For example, the control circuit can convey signals to the GUI (e.g. the GUI2790), which indicate one or more troubleshooting steps for the clinician. The troubleshooting steps can be configured to remedy a mechanically bound-up surgical tool and/or firing system thereof. The control circuit can also update the DV stored in the memory (e.g. the memory2742) to true/positive, which indicates that future firings of the surgical system and/or surgical tool have been disabled. As further described herein, when the DV is true/positive, Condition A is not satisfied and a subsequent operation2800would not proceed from the Outset State2802. From the Retraction-Stalled State2832, the operation2800can proceed to the Non-Recoverable State2838, with is further described herein.

In various instances, the operation2800can enter the Bailout-Attempt State2836from the Pre-Lockout Pause State2806, the Lockout Pause State2810, the Transection Pause State2822, and/or the Transection-Stalled State2826. The Bailout-Attempt State2836can corresponds to a higher FMT from the torque sensor (e.g. the torque sensor2732) and lower FMV from a velocity sensor (e.g. the velocity sensor2738) than during typical advancement and retraction of the firing member, as further described herein. Upon entry to the Bailout-Attempt State2836, the control circuit (e.g. the control circuit2728) provides feedback to the clinician regarding how to bailout the surgical device. For example, the control circuit can issue signals to the GUI (e.g. the GUI2790) indicative of instructions (verbal and/or visual) regarding how to manually extract the surgical device (e g manually retract the firing member such that the jaws can release any tissue clamped therebetween). From the Bailout-Attempt State2836, the operation can proceed to the Non-Recoverable State2838.

The operation2800can enter the Non-Recoverable State2838from the Bailout-Attempt State2836and/or the Retraction-Stalled State2832, for example. The surgical device can be non-recoverable upon entering the Non-Recoverable State2838. In various instances, the control circuit (e.g. the control circuit2728) can provide signals to the GUI (e.g. the GUI2790) regarding the non-recoverable condition of the surgical tool. In such instances, a new clamping operation2840and/or a new transection operation2800can be prevented. The surgical tool can be retired and/or returned to the manufacturer for inspection and/or repair, in certain instances.

EXAMPLES

Various aspects of the subject matter described herein are set out in the following numbered examples.

Example 1—A surgical tool configured to receive rotary inputs from a robotic surgical system. The surgical tool comprises a distal end effector comprising jaws for clamping tissue therebetween, an intermediate shaft portion coupled to the distal end effector, and a proximal housing coupled to the intermediate shaft portion. The proximal housing comprises an arrangement of rotary drives comprising a first rotary drive. The first rotary drive comprises an input shaft configured to receive a rotary input from the robotic surgical system, a transition nut slidably positioned on the input shaft, and an output gear. The first rotary drive further comprises a high-speed gear configured to selectively drive the output gear, a high-torque gear configured to selectively drive the output gear, and a spring arrangement configured to bias the transition nut along the input shaft from a high-speed operating state, in which the transition nut is in driving engagement with the high-speed gear, to a high-torque operating state, in which the transition nut is in driving engagement with the high-torque gear upon obtaining a threshold torque.

Example 2—The surgical tool of Example 1, wherein the transition nut comprises a perimeter, a first end, and an array of sloping teeth around the perimeter extending to the first end.

Example 3—The surgical tool of Example 2, wherein the high-torque gear comprises an array of complementary sloping receptacles configured to receive the array of sloping teeth when the transition nut is in the high-torque operating state.

Example 4—The surgical tool of Examples 1, 2, or 3, wherein the transition nut further comprises a second end, and a first array of teeth around the perimeter extending to the second end.

Example 5—The surgical tool of Example 4, further comprising a grasping gear drivingly engaged with the high-speed gear, wherein the grasping gear comprises a second array of teeth configured to receive the first array of teeth when the transition nut is in the high-speed operating state.

Example 6—The surgical tool of Example 5, wherein the spring arrangement comprises a first spring configured to bias the first array of teeth toward the second array of teeth.

Example 7—The surgical tool of Examples 1, 2, 3, 4, 5, or 6, wherein the spring arrangement further comprises a second spring configured to bias the first end of the transition nut away from the second end of the transition nut.

Example 8—The surgical tool of Examples 1, 2, 3, 4, 5, 6, or 7, further comprising an output shaft drivingly coupled to the output gear, wherein the output shaft is configured to drive a rotary drive screw to effect a closure of the jaws.

Example 9—The surgical tool of Examples 1, 2, 3, 4, 5, 6, 7, or 8, wherein the first rotary drive further comprises a gear train comprising the high-speed gear, and wherein the gear train comprises a speed ratio greater than one.

Example 10—A surgical tool for a robotic surgical system. The surgical tool comprises a distal end effector comprising jaws for clamping tissue therebetween, an intermediate shaft portion coupled to the distal end effector, and a proximal housing coupled to the intermediate shaft portion. The proximal housing comprises an input shaft configured to receive a rotary input from the robotic surgical system, a transition nut slidably positioned on the input shaft, and an output gear. The proximal housing further comprises a first rotary drive configured to selectively drive the output gear, a second rotary drive configured to selectively drive the output gear, and a spring arrangement configured to bias the transition nut along the input shaft to couple the input shaft with either the first rotary drive or the second rotary drive based on a threshold torque applied to the transition nut.

Example 11—The surgical tool of Example 10, wherein the transition nut rotates with the input shaft.

Example 12—The surgical tool of Examples 10 or 11, wherein the spring arrangement comprises a first spring configured to bias the transition nut out of engagement with the second rotary drive and into engagement with the first rotary drive when the threshold torque is exceeded.

Example 13—The surgical tool of Examples 10, 11, or 12, wherein the transition nut comprises a perimeter, a first end, and an array of sloping teeth around the perimeter extending to the first end. The transition nut further comprises a second end, a first array of teeth around the perimeter extending to the second end, and a second spring configured to bias the first end away from the second end.

Example 14—The surgical tool of Example 13, wherein the first rotary drive comprises a high-torque gear comprising complementary sloping receptacles configured to receive the array of sloping teeth when the input shaft is engaged with the first rotary drive, and wherein the surgical tool is in a high-torque operating state when the first rotary drive is engaged with the input shaft.

Example 15—The surgical tool of Examples 13 or 14, wherein the second rotary drive comprises a high-speed gear and a grasping gear drivingly engaged with the high-speed gear, wherein the grasping gear comprises a second array of teeth configured to receive the first array of teeth when the input shaft is engaged with the second rotary drive, and wherein the surgical tool is in a high-speed operating state when the second rotary drive is engaged with the input shaft.

Example 16—The surgical tool of Examples 10, 11, 12, 13, 14, or 15, wherein the second rotary drive further comprises a gear train comprising the high-speed gear, and wherein the gear train comprises a speed ratio greater than one.

Example 17—The surgical tool of Examples 10, 11, 12, 13, 14, 15, or 16, further comprising an output shaft drivingly coupled to the output gear, wherein the output shaft is configured to drive a rotary drive screw to effect a closure of the jaws.

Example 18—A rotary drive system for rotating a drive screw in a robotic surgical tool. The rotary drive system comprises an input shaft configured to receive a rotary input from a robotic surgical system, a transition nut slidably positioned on the input shaft, and an output gear drivingly coupled to an output shaft. The rotary drive system further comprises a first rotary drive configured to selectively drive the output gear, a second rotary drive configured to selectively drive the output gear, and a spring arrangement configured to bias the transition nut along the input shaft into engagement with either the first rotary drive or the second rotary drive based on a threshold torque applied to the transition nut.

Example 19—The rotary drive system of Example 18, wherein the first rotary drive comprises a high-torque gear that comprises complementary sloping receptacles configured to receive an array of sloping teeth on the transition nut when the input shaft is engaged with the first rotary drive.

Example 20—The rotary drive system of Examples 18 or 19, wherein the second rotary drive comprises a high-speed gear and a grasping gear drivingly engaged with the high-speed gear, wherein the grasping gear comprises an array of teeth configured to engage the transition nut when the input shaft is engaged with the second rotary drive.

Example 21—A robotic surgical system that comprises a closure system. The closure system comprises a first pinion drivingly coupled to a first motor, a second pinion drivingly coupled to a second motor, and a closure gear selectively driven by the first pinion and the second pinion. The robotic surgical system further comprises a control circuit configured to implement a motor crosscheck operation. The control circuit is configured to receive a first parameter indicative of a first torque generated by the first motor, receive a second parameter indicative of a second torque generated by the second motor, compare the first parameter to the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicative of a status of the closure system.

Example 22—The robotic surgical system of Example 21, wherein the control circuit is further configured to determine when the closure system has achieved a steady state in the motor crosscheck operation, and compare the first parameter to the second parameter after the closure system has achieved the steady state.

Example 23—The robotic surgical system of Examples 21 or 22, wherein the first pinion and the second pinion simultaneously drive the closure gear to effect a closure stroke.

Example 24—The robotic surgical system of Examples 21, 22, or 23, wherein the status transmitted by the control circuit corresponds to a fault state when the comparison of the first parameter to the second parameter exceeds a threshold value.

Example 25—The robotic surgical system of Example 24, wherein the robotic surgical system is configured to implement a lockout when the status corresponds to the fault state.

Example 26—The robotic surgical system of Examples 21, 22, 23, 24, or 25, wherein, to implement the motor crosscheck operation, the first motor is configured to drive the closure gear in a first direction, and wherein the second motor is configured to drive the closure gear in a second direction opposite to the first direction.

Example 27—The robotic surgical system of Examples 21, 22, 23, 24, 25, or 26, wherein the first motor is configured to transfer torque to the second pinion.

Example 28—The robotic surgical system of Examples 21, 22, 23, 24, 25, 26, or 27, wherein the second motor is configured to transfer torque to the first pinion.

Example 29—The robotic surgical system of Examples 21, 22, 23, 24, 25, 26, 27, or 28, wherein the second pinion is configured to move through a backlash region prior to the closure system achieving a steady state.

Example 30—The robotic surgical system of Example 29, wherein the control circuit is further configured to record a duration of the backlash region and obtain the duration to a stored value.

Example 31—A non-transitory computer readable medium storing computer readable instructions which, when executed, cause a machine to receive a first parameter indicative of a first torque generated by a first motor of a closure system, receive a second parameter indicative of a second torque generated by a second motor of the closure system, and implement a motor crosscheck. The first motor and the second motor are configured to concurrently drive a closure gear. The motor crosscheck comprises compare the first parameter to the second parameter, and transmit a signal to a communication device, wherein the signal is based on the comparison and indicative of a status of the closure system.

Example 32—The non-transitory computer readable medium storing computer readable instructions of Example 31, which, when executed, further cause the machine to determine when the closure system has achieved a steady state, and compare the first parameter to the second parameter after the closure system has achieved the steady state.

Example 33—The non-transitory computer readable medium storing computer readable instructions of Examples 31 or 32, which, when executed, further cause the machine to enter a fault state when the comparison of the first parameter to the second parameter exceeds a threshold value.

Example 34—The non-transitory computer readable medium storing computer readable instructions of Example 33, which, when executed, further cause the machine to implement a lockout state when the status corresponds to the fault state.

Example 35—A robotic surgical system that comprises a closure system. The closure system comprises a first pinion drivingly coupled to a first motor, a second pinion drivingly coupled to a second motor, and a closure gear selectively driven by the first pinion and the second pinion. The closure system further comprises a processor and a memory coupled to the processor. The memory storing instructions executable by the processor to receive a first parameter indicative of a first torque from the first motor, receive a second parameter indicative of a second torque from the second motor, and receive a third parameter indicative of a first angular displacement of the first motor. The memory further stores instructions executable by the processor to receive a fourth parameter indicative of a second angular displacement of the second motor, and determine a status of the closure system based on the first parameter, the second parameter, the third parameter, and the fourth parameter. The memory further stores instructions executable by the processor to transmit a signal to a communication device indicative of the status of the closure system.

Example 36—The robotic surgical system of Example 35, wherein the memory further stores instructions executable by the processor to implement a motor crosscheck in which the first pinion and the second pinion are rotated in opposite directions.

Example 37—The robotic surgical system of Example 35, wherein the memory further stores instructions executable by the processor to implement a motor crosscheck in which the first pinion is driven by the first motor and the second pinion is not driven by the second motor.

Example 38—The robotic surgical system of Examples 35, 36 or 37, wherein the memory further stores instructions executable by the processor to measure a backlash angle during the motor crosscheck, and compare the backlash angle to a backlash value stored in the memory.

Example 39—The robotic surgical system of Examples 35, 36, 37, or 38, wherein the memory further stores instructions executable by the processor to implement a motor crosscheck in which a stiffness of the first pinion is computed from the first torque and the first angular displacement, and the stiffness is compared to a threshold.

Example 40—The robotic surgical system of Examples 35, 36, 37, 38, or 39, wherein the memory stores instructions executable by the processor to implement a motor crosscheck after at least one of a homing operation or clamping event by the closure system.

Example 41—A control circuit for use with a robotic surgical system. The control circuit is configured to receive a parameter indicative of a rotary position of an articulation motor. The articulation motor is configured to drive an articulation joint of a robotic surgical tool, wherein the articulation motor is configured to move through a first range of positions and a second range of positions. The first range of positions and the second range of positions are non-overlapping. The control circuit is further configured to implement a first operating state, and implement a second operating state when the parameter corresponds to a transition of the articulation motor from the first range of positions to the second range of positions. The second operating state is different than the first operating state. The control circuit is further configured to re-implement the first operating state when the parameter corresponds to a return of the articulation motor from the second range of positions into the first range of positions by a threshold anti-dither angle.

Example 42—The control circuit of Example 41, wherein the first range of positions and the second range of positions are contiguous.

Example 43—The control circuit of Examples 41 or 42, wherein the second range of positions comprises an upper mechanical limit of the articulation joint.

Example 44—The control circuit of Examples 41, 42, or 43, wherein a maximum allowable speed of the articulation motor is less in the second operating state than in the first operating state when the parameter is moving away from the first range of positions.

Example 45—The control circuit of Examples 41, 42, 43, or 44, wherein a maximum allowable torque of the articulation motor is less in the second operating state than in the first operating state when the parameter is moving away from the first range of positions.

Example 46—The control circuit of Examples 41, 42, or 43, wherein a maximum allowable speed and a maximum allowable torque of the articulation motor is less in the second operating state than in the first operating state when the parameter is moving away from the first range of positions.

Example 48—The control circuit of Example 47, wherein the control circuit is further configured to implement a third operating state when the second parameter corresponds to a transition of the second articulation motor from the third range of positions to the fourth range of positions, wherein the third operating state is different than the first operating state. The control circuit is further configured to re-implement the first operating state when the second parameter corresponds to a return of the second articulation motor from the fourth range of positions into the third range of positions by a threshold anti-dither angle.

Example 49—The control circuit of Examples 47 or 48, wherein the fourth range of positions comprises a lower mechanical limit of the articulation joint.

Example 50—A non-transitory computer readable medium storing computer readable instructions which, when executed, cause a machine to receive a first parameter indicative of a rotary position of a first articulation motor, receive a second parameter indicative of a rotary position of a second articulation motor, and implement a first operating state. The non-transitory computer readable medium storing computer readable instructions which, when executed, further cause a machine to transition from the first operating state to a second operating state when the first parameter corresponds to a transition of the first articulation motor from a first range of positions to an upper range of positions, wherein the second operating state is different than the first operating state. The non-transitory computer readable medium storing computer readable instructions which, when executed, further cause a machine to return to the first operating state from the second operating state when the first parameter corresponds to a return of the first articulation motor from the upper range of positions into the first range of positions by a first anti-dither angle. The non-transitory computer readable medium storing computer readable instructions which, when executed, further cause a machine to implement a third operating state when the second parameter corresponds to a transition of the second articulation motor from a second range of positions to a lower range of positions, wherein the third operating state is different than the first operating state. The non-transitory computer readable medium storing computer readable instructions which, when executed, further cause a machine to return to the first operating state from the third operating state when the second parameter corresponds to a return of the second articulation motor from the lower range of positions into the second range of positions by a second anti-dither angle.

Example 51—A robotic surgical tool that comprises a housing, an end effector, and an elongate shaft extending distally from the housing to the end effector. The robotic surgical tool further comprises an articulation joint configured to articulate the end effector relative to the elongate shaft during an articulation motion, an internal shaft extending distally from the housing through the elongate shaft, and an articulation drive system. The articulation drive system comprises an articulation yoke coupled to the internal shaft, an articulation band coupled to the articulation yoke and extending distally along the internal shaft to the articulation joint, and rolling elements intermediate the internal shaft and the articulation yoke, wherein the articulation yoke is configured to roll along the rolling elements during the articulation motion.

Example 52—The robotic surgical tool of Example 51, wherein the rolling elements are positioned around the circumference of the internal shaft.

Example 53—The robotic surgical tool of Examples 51 or 52, further comprises a rolling element pad. The rolling element pad comprises a base secured to the internal shaft, a retainer secured to the base, wherein the base and the retainer form a continuous loop track therebetween. The rolling element pad further comprises the rolling elements, wherein the rolling elements comprise spheres positioned in the continuous loop track.

Example 54—The robotic surgical tool of Example 53, wherein the retainer comprises a window, and

wherein a set of the rolling elements protrude through the window and contact the articulation yoke.

Example 55—The robotic surgical tool of Examples 53 or 54, wherein the rolling element pad is press-fit into a recess in the internal shaft.

Example 56—The robotic surgical tool of Examples 53, 54, or 55, wherein the continuous loop track comprises a first continuous loop track, and wherein the base and the retainer form a second continuous loop track configured to receive a plurality of the rolling elements therein.

Example 57—The robotic surgical tool of Example 56, wherein the articulation yoke comprises a first articulation yoke configured to slidably engage the rolling elements positioned in the first continuous loop track during the articulation motion, wherein the articulation drive system further comprises a second articulation yoke coupled to the internal shaft at a location distal to the first articulation yoke, and wherein the second articulation yoke is configured to slidably engage the rolling elements positioned in the second continuous loop track during the articulation motion.

Example 58—The robotic surgical tool of Example 57, wherein the articulation band comprises a first articulation band attached to the first articulation yoke and extending along the internal shaft to the articulation joint, and wherein the articulation drive system further comprises a second articulation band attached to the second articulation yoke and extending along the internal shaft to the articulation joint.

Example 59—The robotic surgical tool of Examples 57 or 58, wherein the articulation drive system is configured to move the first articulation yoke and second articulation yoke relative to each other and along the internal shaft to effect the articulation motion.

Example 60—A surgical tool that comprises a surgical end effector comprising opposing jaws, an elongate shaft extending distally to the surgical end effector, and a housing defining a passage therethrough, wherein the elongate shaft extends through the passage. The surgical tool further comprises an actuation mechanism configured to selectively move the housing along the elongate shaft relative to the surgical end effector. The actuation mechanism comprises a pulley, a cable engaged with the pulley, and a lock arrangement configured to releasably lock the housing relative to the elongate shaft. The lock arrangement comprises a washer positioned around the elongate shaft. The cable is engaged with the washer. An actuation of the pulley is configured to apply a tension to the cable to pivot the washer relative to the elongate shaft from a locked orientation to an unlocked orientation.

Example 61—The surgical tool of Example 60, wherein the washer comprises a first washer, wherein the lock arrangement further comprises a second washer positioned around the elongate shaft, wherein the cable is engaged with the second washer, and wherein the second washer is configured to pivot relative to the elongate shaft between a locked orientation and an unlocked orientation.

Example 62—The surgical tool of Example 61, wherein, in their locked orientations, the first washer and the second washer are obliquely-oriented relative to a longitudinal axis of the elongate shaft, and wherein the first washer and the second washer are configured to pivot toward a parallel orientation when they move to their unlocked orientations.

Example 63—The surgical tool of Examples 61 or 62, wherein the lock arrangement further comprises a spring between the first washer and the second washer, and wherein the spring biases a portion of the first washer away from a portion of the second washer.

Example 64—The surgical tool of Example 63, wherein the tension applied by the actuation of the pulley is configured to overcome a biasing force of the spring to move the first washer and the second washer from their locked orientations to their unlocked orientations.

Example 65—The surgical tool of Examples 61, 62, 63, or 64, wherein the tension in the cable applied by the actuation of the pulley is configured to pivot the first washer and second washer to the unlocked orientation and then pull on the elongate shaft to move the housing along the elongate shaft.

Example 66—The surgical tool of Examples 60, 61, 62, 63, 64, or 65, wherein the housing comprises a body comprising an internal wall, wherein the internal wall defines a portion of an internal cavity in the body, and wherein the washer extends at least partially into the internal cavity.

Example 67—The surgical tool of Example 68, wherein the actuation of the pulley is configured to push the washer against the internal wall to draw the housing along the elongate shaft.

Example 68—The surgical tool of Examples 60, 61, 62, 63, 64, 65, 66, or 67, wherein the surgical end effector further comprises a firing member configured to cut tissue positioned between the opposing jaws.

Example 69—The surgical tool of Examples 60, 61, 62, 63, 64, 65, 66, 67, or 68, wherein the surgical end effector further comprises a staple cartridge comprising staples.

Example 70—A surgical tool that comprises a surgical end effector, an elongate shaft extending distally to the surgical end effector, and a housing defining a passage therethrough, wherein the elongate shaft extends through the passage. The surgical tool further comprises an actuation mechanism configured to selectively move the housing along the elongate shaft relative to the surgical end effector. The actuation mechanism comprises a pulley, a capstan, and a cable engaged with the pulley and the capstan. The actuation mechanism further comprises a lock arrangement configured to releasably lock the housing relative to the elongate shaft. The lock arrangement comprising a first washer positioned around the elongate shaft. A first end of the cable is engaged with the first washer. The first washer is configured to pivot relative to the elongate shaft between a locked orientation and an unlocked orientation. The lock arrangement further comprising a second washer positioned around the elongate shaft. A second end of the cable is engaged with the second washer. The second washer is configured to pivot relative to the elongate shaft between a locked orientation and an unlocked orientation. The lock arrangement further comprising a spring between the first washer and the second washer, wherein the spring is configured to bias a portion of the first washer away from a portion of the second washer to pivot the first washer and second washer into the locked orientations. A rotation of the capstan is configured to apply a tension to the cable to pivot the first washer and second washer to their unlocked orientations.

Example 71—The surgical tool of Example 70, wherein, in the locked orientations, the first washer and the second washer are obliquely-oriented relative to a longitudinal axis of the elongate shaft, and wherein the first washer and the second washer are configured to pivot toward parallel from their locked orientations to their unlocked orientations.

Example 72—The surgical tool of Examples 70 or 71, wherein the tension applied by the rotation of the capstan is configured to overcome the biasing force of the spring to move the first washer and the second washer from their locked orientations to their unlocked orientations.

Example 73—The surgical tool of Examples 70, 71, or 72, wherein the housing comprises a body comprising an internal wall, wherein the internal wall defines a portion of an internal cavity in the body, and wherein the first washer extends at least partially into the internal cavity.

Example 74—The surgical tool of Example 73, wherein the rotation of the capstan is configured to push the first washer against the internal wall to draw the housing along the elongate shaft.

Example 75—The surgical tool of Examples 70, 71, 72, 73, or 74, wherein the tension in the cable applied by the rotation of the capstan is configured to pivot the first washer and second washer to their unlocked orientations and pull the housing along the elongate shaft.

Example 76—A surgical tool that comprises an elongate shaft, and a housing defining a passage therethrough, wherein the elongate shaft extends through the passage. The surgical tool further comprises an actuation mechanism configured to selectively move the housing along the elongate shaft. The actuation mechanism comprises a pulley arrangement, and a lock arrangement configured to releasably lock the housing relative to the elongate shaft. The lock arrangement comprises a lock positioned around the elongate shaft. An actuation of the pulley arrangement is configured to move the lock from a locked orientation to an unlocked orientation.

Example 77—The surgical tool of Example 76, wherein the lock is configured to pivot from the locked orientation to the unlocked orientation.

Example 78—The surgical tool of Examples 76 or 77, wherein, in the locked orientation, the lock is obliquely-oriented relative to a longitudinal axis of the elongate shaft.

Example 79—The surgical tool of Examples 76, 77, or 78, wherein the lock arrangement further comprises a spring configured to bias the lock toward the locked orientation.

A network may include a packet switched network. The communication devices may be capable of communicating with each other using a selected packet switched network communications protocol. One example communications protocol may include an Ethernet communications protocol which may be capable permitting communication using a Transmission Control Protocol/Internet Protocol (TCP/IP). The Ethernet protocol may comply or be compatible with the Ethernet standard published by the Institute of Electrical and Electronics Engineers (IEEE) titled “IEEE 802.3 Standard”, published in December, 2008 and/or later versions of this standard. Alternatively or additionally, the communication devices may be capable of communicating with each other using an X.25 communications protocol. The X.25 communications protocol may comply or be compatible with a standard promulgated by the International Telecommunication Union-Telecommunication Standardization Sector (ITU-T). Alternatively or additionally, the communication devices may be capable of communicating with each other using a frame relay communications protocol. The frame relay communications protocol may comply or be compatible with a standard promulgated by Consultative Committee for International Telegraph and Telephone (CCITT) and/or the American National Standards Institute (ANSI). Alternatively or additionally, the transceivers may be capable of communicating with each other using an Asynchronous Transfer Mode (ATM) communications protocol. The ATM communications protocol may comply or be compatible with an ATM standard published by the ATM Forum titled “ATM-MPLS Network Interworking 2.0” published August 2001, and/or later versions of this standard. Of course, different and/or after-developed connection-oriented network communication protocols are equally contemplated herein.