Patent Publication Number: US-11045268-B2

Title: Instrument drive unit including lead screw rails

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application a continuation of U.S. patent application Ser. No. 15/554,003, filed on Aug. 27, 2017, now U.S. Pat. No. 10,420,618, issued on Sep. 24, 2019, which is a U.S. National Stage Application filed under 35 U.S.C. § 371(a) of International Patent Application Serial No. PCT/US2016/014213, filed Jan. 21, 2016, which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/121,255, filed Feb. 26, 2015, the entire disclosure of each of which are incorporated by reference herein. 
    
    
     BACKGROUND 
     Robotic surgical systems used in minimally invasive medical procedures include a console or cart supporting a robot arm and a surgical instrument having an end effector that may include, for example, forceps, a stapler, or a grasping tool. The robot arm provides mechanical power to the surgical instrument for its operation and movement. Each robot arm may include an instrument drive unit that is operatively connected to the surgical instrument. 
     Prior to or during use of the robotic system, surgical instruments are selected and connected to the instrument drive units of each robot arm. For proper installation to be completed, certain connecting features of the surgical instrument must be matingly engaged to corresponding connecting features of the instrument drive unit. Once these features are matingly engaged, the instrument drive unit can drive the actuation of the surgical instrument. However, connection and removal of surgical instruments to instrument drive units can be difficult. 
     Accordingly, new robotic devices, systems, and methods that are reliable, precise, and that enable easy and efficient attachment and removal of surgical instruments would be desirable. 
     SUMMARY 
     The present disclosure describes robotic devices, systems, and methods that demonstrate a practical approach to meeting the performance requirements and overcoming the usability challenges associated with instrument attachment and removal. In general, the present disclosure describes robotic surgical systems that include an instrument drive unit and a surgical instrument support coupled to the instrument drive unit. The surgical instrument includes an end effector controllable to perform surgery in response to telemanipulation of actuators in the instrument drive unit. 
     In accordance with an embodiment of the present disclosure, there is provided a surgical system for selective connection to a robotic arm. The surgical system includes an instrument drive unit and a surgical instrument detachably coupled to the instrument drive unit. The instrument drive unit includes a first actuator and a first translatable member operatively coupled with the first actuator. The surgical instrument includes an adapter portion, an elongate member extending distally from the adapter portion, and an end effector mounted on a distal end of the elongate member. The adapter portion has a first rotatable member operatively associated with the first translatable member. The first rotatable member is rotatable in response to translation of the first translatable member. The end effector is operatively coupled with the first rotatable member, wherein rotation of the first rotatable member effects a first function of the end effector. 
     In an embodiment, actuation of the first actuator may cause translation of the first translatable member, which in turn, causes rotation of the first rotatable member of the adapter portion of the surgical instrument. 
     In another embodiment, the surgical instrument may further include a first cable having a first end coupled to the first rotatable member and a second end operatively associated with the end effector. In addition, the first rotatable member may include a reel portion configured to wind the first cable thereabout upon rotation of the first rotatable member. Furthermore, the first rotatable member may include a gear portion having teeth configured to mesh with teeth of the first translatable member of the instrument drive. 
     In yet another embodiment, the instrument drive unit may further include a second actuator operatively associated with the elongate member of the surgical instrument such that actuation of the second actuator causes rotation of the elongate member, which in turn, causes rotation of the end effector. In an embodiment, the second actuator may be slidably disposed such that the second actuator may be transitionable between a retracted position in which the second actuator is operatively disengage from the elongate member and an extended position in which the second actuator is operatively engaged with the elongate member. 
     In still yet another embodiment, the first and second actuators of the instrument drive unit may be controlled by telemanipulation. 
     In still yet another embodiment, the instrument drive unit may further include a third actuator and a second translatable member operatively coupled to the third actuator. In addition, the adapter portion of the surgical instrument may include a second rotatable member operatively associated with the second translatable member. The second rotatable member may be rotatable in response to actuation of the third actuator. The first and second rotatable members may be independently rotatable. 
     The surgical instrument may further include a second cable having a first end coupled to the second rotatable member and a second end operatively associated with the end effector, wherein rotation of the first and second rotatable members effects the first function of the end effector. In an embodiment, the first and second rotatable members may rotate about a common axis. 
     In another embodiment, the surgical system may further include a drape interposed between the instrument drive unit and the surgical instrument to provide a sterile barrier. 
     In yet another embodiment, the teeth of the gear portion of the first rotatable member may engage the teeth of the first translatable member of the instrument drive through a sterile barrier. 
     In accordance with another aspect of the present disclosure, there is provided a robotic surgical assembly. The robotic surgical assembly includes a robotic arm, an instrument drive unit secured to the robotic arm, and a surgical instrument detachably coupled to the instrument drive unit. The instrument drive unit includes a plurality of actuators and a plurality of translatable members operatively coupled with respective one of the plurality of actuators. The surgical instrument includes an adapter portion and an elongate member. The adapter portion has a plurality of rotatable members operatively associated with the plurality of translatable members. Each rotatable member of the plurality of rotatable members is rotatable in response to actuation of the respective one of the plurality of actuators. The elongate member extends distally from the adapter portion, wherein rotation of one of the plurality of rotatable members causes a first function of an end effector. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with a general description of the disclosure given above, and the detailed description of the embodiment(s) given below, serve to explain the principles of the disclosure, wherein: 
         FIG. 1  is a schematic illustration of a robotic surgical system in accordance with the present disclosure; 
         FIG. 2  is a perspective view of a robotic arm having a surgical assembly mounted thereon; 
         FIG. 3  is a partial, perspective view of the surgical assembly of  FIG. 2  showing an adapter portion of a surgical instrument in phantom; 
         FIG. 4  is a perspective view of the surgical assembly of  FIG. 2  showing portions of an instrument drive unit and the adapter portion of the surgical instrument in phantom; 
         FIG. 5  is a perspective view of the instrument drive unit of  FIG. 4  showing actuators and lead screws in phantom; 
         FIG. 6  is a perspective view of the surgical assembly of  FIG. 2  with the surgical instrument detached from the instrument drive unit; 
         FIG. 7  is a perspective view of a drape for use with the instrument drive unit of  FIG. 6 ; and 
         FIG. 8  is a perspective view of a body of the instrument drive unit of  FIG. 7  having a plug mounted on a rotatable adapter. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present disclosure are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term “distal” refers to that portion of a device that is farther from the user, while the term “proximal” refers to that portion of a device that is closer to the user. 
     With reference to  FIG. 1 , there is provided a robotic surgical system  1  including a plurality of robotic arms  2 ,  3 ; a control device  4 ; and an operating console  5  coupled with control device  4 . Operating console  5  includes a display device  6  and manual input devices  7 ,  8 , by means of which a person (not shown), for example a surgeon, is able to telemanipulate robotic arms  2 ,  3 . 
     Each of the plurality of robotic arms  2 ,  3  includes a plurality of members, which are connected through joints. Robotic surgical system  1  also includes a surgical assembly  100  connected to a distal end of each of robotic arms  2 ,  3 . Surgical assembly  100  includes an instrument drive unit  300  and a surgical instrument  200  detachably coupled to instrument drive unit  300 . Surgical instrument  200  includes an end effector  230 . 
     Robotic arms  2 ,  3  may be driven by electric drives (not shown) that are connected to control device  4 . Control device  4  (e.g., a computer) is set up to activate the drives, in particular by means of a computer program, in such a way that robotic arms  2 ,  3 , their surgical assemblies  100  execute a desired movement according to a movement defined by means of manual input devices  7 ,  8 . Control device  4  may also be set up in such a way that it regulates movement of robotic arms  2 ,  3  and/or of the drives. 
     With continued reference to  FIG. 1 , robotic surgical system  1  is configured for use on a patient  13  lying on a patient table  12  to be treated in a minimally invasive manner by means of end effector  230 . Robotic surgical system  1  may include more than two robotic arms  2 ,  3 . The additional robotic arms may also be connected to control device  4  and may be telemanipulatable by means of operating console  5 . One or more additional surgical assemblies  100  and/or surgical instruments  200  may also be attached to the additional robotic arm. 
     Control device  4  may control a plurality of motors (Motor  1  . . . n) with each motor configured to drive a pushing or a pulling of one or more cables such as cables  400   a - d  ( FIG. 5 ) coupled to end effector  230  of surgical instrument  200 . While cables are shown and described, it is also contemplated that cables can be replaced with rods or the like. In use, as these cables  400   a - d  are pushed and/or pulled, cables  400   a - d  effect operation and/or movement of end effector  230  of surgical instrument  200 . It is contemplated that control device  4  coordinates the activation of the various motors (Motor  1  . . . n) to coordinate a pushing or a pulling motion of one or more cables  400   a - d  in order to coordinate an operation and/or movement of one or more end effectors  230 . In embodiments, each motor can be configured to actuate a drive rod or a lever arm to effect operation and/or movement of end effectors  230  in addition to, or instead of, one or more cables  400   a - d.    
     Control device  4  can include any suitable logic control circuit adapted to perform calculations and/or operate according to a set of instructions. Control device  4  can be configured to communicate with a remote system “RS,” either via a wireless (e.g., Wi-Fi™, Bluetooth®, LTE™, etc.) and/or wired connection. Remote system “RS” can include data, instructions and/or information related to the various components, algorithms, and/or operations of robotic surgical system  1 . Remote system “RS” can include any suitable electronic service, database, platform, cloud “C” (see  FIG. 1 ), or the like. Control device  4  may include a central processing unit operably connected to memory. The memory may include transitory type memory (e.g., RAM) and/or non-transitory type memory (e.g., flash media, disk media, etc.). In some embodiments, the memory is part of, and/or operably coupled to, remote system “RS.” 
     Control device  4  can include a plurality of inputs and outputs for interfacing with the components of robotic surgical system  1 , such as through a driver circuit. Control device  4  can be configured to receive input signals and/or generate output signals to control one or more of the various components (e.g., one or more motors) of robotic surgical system  1 . The output signals can include, and/or can be based upon, algorithmic instructions which may be pre-programmed and/or input by a user. Control device  4  can be configured to accept a plurality of user inputs from a user interface (e.g., switches, buttons, touch screen, etc. of operating console  5 ) which may be coupled to remote system “RS.” 
     A database  14  can be directly and/or indirectly coupled to control device  4 . Database  14  can be configured to store pre-operative data from living being(s) and/or anatomical atlas(es). Database  14  can include memory which can be part of, and/or or operatively coupled to, remote system “RS.” Reference may be made to U.S. Patent Publication No. 2012/0116416, filed on Nov. 3, 2011, entitled “Medical Workstation,” (now U.S. Pat. No. 8,828,023), the entire content of which is incorporated herein by reference, for a detailed discussion of the construction and operation of robotic surgical system  1 . 
     Turning now to  FIGS. 2-4 , surgical assembly  100  includes instrument drive unit  300  coupled to robotic arm  2 , and a surgical instrument  200  releasably coupled to instrument drive unit  300 . Instrument drive unit  300  includes a body  312  having a first housing portion  302  and a second housing portion  304  that extends distally from first housing portion  302 . In particular, second housing portion  304  defines a cutout  319  ( FIG. 6 ) configured to receive an adapter portion  202  ( FIG. 3 ) of surgical instrument  200 . Second housing portion  304  includes lateral sides  306  ( FIG. 4 ). Each lateral side  306  defines a groove  306   a ,  306   b  ( FIG. 5 ) configured to receive a respective tab  204   a ,  204   b  ( FIG. 3 ) of adapter portion  202 . Tabs  204   a ,  204   b  may engage respective groove  306   a ,  306   b  through, e.g., snap fit or friction fit configuration, to detachably couple surgical instrument  200  to instrument drive unit  300 . In this manner, various surgical instruments may be interchangeably used with instrument drive unit  300 . Body  312  of instrument drive unit  300  includes connection surfaces  308   a ,  308   b  ( FIG. 5 ) that are configured to engage engaging surfaces  206   a ,  206   b  ( FIG. 6 ) of adapter portion  202  of surgical instrument  200 . Connection surface  308   a  ( FIG. 5 ) defines a plurality of slots  310   a - d  ( FIG. 8 ), and connection surface  308   b  defines a bore  309  ( FIG. 4 ) as will be described below. 
     With reference now to  FIGS. 4 and 5 , instrument drive unit  300  supports a plurality of actuators or motors  314   a - e  and a plurality of lead screws  316   a - d  ( FIG. 5 ) operatively coupled with respective motors  314   a - d . Specifically, motor  314   e  is slidably disposed in first housing portion  302  and is coupled to a rotatable adapter  315  configured to operatively engage elongate member  210  of surgical instrument  200 . 
     Connection surface  308   b  of first housing portion  302  of instrument drive unit  300  defines bore  309  ( FIG. 4 ) configured to receive rotatable adapter  315  therethrough. First housing portion  302  further defines a slot  317  ( FIG. 5 ) configured to slidably receive a lever  311 . Lever  311  is configured to slide motor  314   e  along a longitudinal axis “X-X” ( FIG. 4 ) between an extended position ( FIG. 5 ) in which rotatable adapter  315  ( FIG. 5 ) extends through bore  309  of connection surface  308   b  and a retracted position ( FIG. 4 ) in which rotatable adapter  315  ( FIG. 5 ) is disposed proximal of bore  309 . Lever  311  may be placed in the retracted position ( FIG. 4 ) to facilitate, e.g., attachment and detachment, of surgical instrument  200  to and from instrument drive unit  300 . 
     With continued reference to  FIG. 5 , motors  314   a - d  are coupled with respective lead screws  316   a - d . Each lead screw  316   a - d  is threadably associated with a non-rotatable support member or nut  318  (only one shown in  FIG. 5 ). Each support member  318  is slidably received through respective slot  310   a - d  ( FIG. 8 ) defined in connection surface  308   a  of second housing portion  304 . Each support member  318  is coupled with a respective rack member  320   a - d  having teeth. Under such a configuration, actuation of respective motor  314   a - d  causes concomitant rotation of respective lead screw  316   a - d . Rotation of respective lead screw  316   a - d  causes translation of respective support member  318  within respective slot  310   a - d , which in turn, imparts translation to respective rack member  320   a - d . Independent actuation of motors  314   a - d  enables independent translation of rack members  320   a - d.    
     With reference now to  FIGS. 5 and 6 , surgical instrument  200  includes adapter portion  202 , elongate member  210  extending from adapter portion  202 , and end effector  230  ( FIG. 2 ) at a distal end of elongate member  210 . Adapter portion  202  includes engaging surfaces  206   a ,  206   b  ( FIG. 6 ) configured to engage and/or oppose connection surfaces  308   a ,  308   b  ( FIG. 5 ) of instrument drive unit  300 , respectively. Adapter portion  202  supports a plurality of gears  216   a - d  ( FIG. 6 ) on, e.g., a common axis “Y-Y” ( FIG. 4 ), for independent rotation thereof. In particular, each gear  216   a - d  has a reel portion  217   a - d  ( FIG. 4 ). Each reel portion  217   a - d  of gear  216   a - d  is coupled to a respective cable  400   a - d  ( FIG. 5 ). Engaging surface  206   b  ( FIG. 6 ) of adapter portion  202  defines a plurality of apertures  209   a - d  ( FIG. 4 ). At least a portion of each gear  216   a - d  extends through respective aperture  209   a - d , such that each gear  216   a - d  engages respective rack member  320   a - d . In this manner, translation of rack member  320   a - d  causes rotation of respective gear  216   a - d  of adapter portion  202 . 
     Each cable  400   a - d  has a first end that is coupled to respective reel portion  217   a - d  ( FIG. 4 ) of respective gear  216   a - d  and a second end that is coupled to end effector  230  at a distal end of elongate member  210 . Each cable  400   a - d  may be coupled to end effector  230  such that actuation of each cable  400   a - d  or combination thereof performs a function of end effector  230 . Longitudinal translation of one or more of cables  400   a - d  imparts movement (e.g., rotation, pivoting, articulation, longitudinal/lateral translation, etc.) on end effector  230 , or portions thereof. For instance, U.S. patent application Ser. No. 14/257,063, filed Apr. 21, 2014 (now U.S. Patent Publication No. 2015/0297199 (now U.S. Pat. No. 10,080,552)), and entitled “Adapter Assembly with Gimbal for Interconnecting Electromechanical Surgical devices and Surgical Loading Units, and Surgical Systems Thereof,” the entire contents of which are hereby incorporated by reference, describes surgical stapling devices with end effectors that support distally advanceable sleds operatively coupled to a rotatable lead screw to fire surgical staples. Elongate member  210  is dimensioned to receive each of the plurality of cables  400   a - d  and to enable each of the plurality of cables  400  to linearly translate therethrough. 
     With reference now to  FIGS. 7 and 8 , instrument drive unit  300  may be provided with a protective barrier or drape  500 . For instance, U.S. Pat. No. 7,886,743 entitled “Sterile Drape Interface for Robotic Surgical Instrument” describes a sterile drape covering at least a portion of the robotic surgical manipulator. Instrument drive unit  300  may be covered with drape  500  prior to mounting surgical instrument  200  thereon. Drape  500  may be formed of, e.g., a flexible material. Drape  500  may include a rotation collar  510  formed of, e.g., a rigid polymer. Rotation collar  510  may be welded onto drape  500 . Rotation collar  510  is configured to receive rotatable adapter  315  coupled with motor  314   e . Drape  500  may further include a reinforced support  550  formed of, e.g., a rigid polymer sheet, to provide a reinforced surface on which rack members  320   a - d  translate. Rotatable adapter  315  may be provided with a sterile barrier plug  330  to provide a sterile barrier between the interchangeable rotating parts. 
     In operation, surgical instrument  200  is detachably mounted on instrument drive unit  300  supported on robotic arm  2 ,  3 , while lever  311  of instrument drive unit  300  is in the retracted state. Gears  216   a - d  of adapter portion  202  engage respective rack members  320   a - d . At this time, lever  311  of instrument drive unit  300  may be transitioned to the extended state such that rotatable adapter  315  coupled with motor  314   e  operatively engages elongate member  210  of surgical instrument  200 . 
     With surgical instrument  200  operatively coupled to instrument drive unit  300 , one or more of the plurality of motors  314   a - d  are activated to rotate one or more of lead screws  316   a - d . Rotation of lead screw  316   a - d  of instrument drive unit  300  causes translation of respective rack member  320   a - d , which in turn, causes rotation of respective gear  216   a - d  of surgical instrument  200 . Rotation of respective gear  216   a - d  translates respective cable  400   a - d . Longitudinal translation of cables  400   a - d , or combination thereof, imparts movement (e.g., rotation, pivoting, articulation, longitudinal/lateral translation, etc.) on end effector  230 , or portions thereof. In addition, actuation of motor  314   e  causes rotation of rotatable adapter  315  (about longitudinal axis “X-X”) which is operatively coupled with elongate member  210  of surgical instrument  200 . In this manner, actuation of motor  314   e  causes rotation of elongate member  210  of surgical instrument  200 . 
     Persons skilled in the art will understand that the structures and methods specifically described herein and shown in the accompanying figures are non-limiting exemplary embodiments, and that the description, disclosure, and figures should be construed merely as exemplary of particular embodiments. It is to be understood, therefore, that the present disclosure is not limited to the precise embodiments described, and that various other changes and modifications may be effected by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, the elements and features shown or described in connection with certain embodiments may be combined with the elements and features of certain other embodiments without departing from the scope of the present disclosure, and that such modifications and variations are also included within the scope of the present disclosure. Accordingly, the subject matter of the present disclosure is not limited by what has been particularly shown and described.