Patent Description:
Manually-operated surgical instruments often included a handle assembly for actuating the functions of the surgical instrument. However, when using a robotic surgical system, no handle assembly was typically present to actuate the functions of the end effector. Accordingly, to use each unique surgical instrument with a robotic surgical system, an instrument drive unit was used to interface with the selected surgical instrument to drive operations of the surgical instrument.

The instrument drive unit was typically coupled to the robotic arm via a slide. The slide allowed the instrument drive unit and the attached surgical instrument to move along an axis of the slide, providing a means for adjusting the axial position of the end effector of the surgical instrument relative to a patient. An example of prior art drive unit is disclosed in <CIT> (Intuitive Surgical Operations).

In accordance with the present invention, a surgical robotic system is provided as defined in claim <NUM> and includes an elongated slide defining a longitudinal axis, a carriage for supporting an instrument drive unit, a drive motor, and a motor release mechanism. The carriage is coupled to the slide and movable relative thereto along the longitudinal axis. The drive motor is operably coupled to the carriage and configured to drive the movement of the carriage relative to the slide. The motor release mechanism is configured to selectively disengage the drive motor from the carriage to permit a manual movement of the carriage along the slide.

The system includes a pulley that operably couples the drive motor and the carriage. An activation of the motor release mechanism disengages the pulley from the drive motor.

The system further includes a motor output member rotatable by the drive motor. An activation of the motor release mechanism slides the pulley relative to the motor output member from a first position to a second position. In the first position, the pulley and the motor output member are rotatable with one another, and in the second position the pulley is independently rotatable relative to the motor output member.

The system may further include a torque transfer pin non-rotatably coupling the pulley with the motor output member. The pulley may be configured to slide between the first and second positions along the torque transfer pin.

In aspects, the system may further include a one way bearing disposed between the pulley and the motor output member. The one way bearing may be configured to allow rotation of the pulley relative to the motor output member in a first direction, and resist rotation of the pulley relative to the motor output member in a second direction.

The one way bearing may be disposed within the pulley, and the motor output member may extend through the one way bearing and the pulley.

In certain aspects, the one way bearing may be non-rotationally fixed to the motor output member.

In aspects, the motor release mechanism may include a hub axially retained with the pulley and threadedly coupled to the motor output member. A rotation of the hub may move the pulley relative to the motor output member between the first and second positions.

The motor release mechanism may further include a knob configured to slide into and out of non-rotatable engagement with the hub.

The system further includes a belt operably coupled to the pulley and fixed to the carriage, such that movement of the belt drives a movement of the carriage along the side.

The system may further include a robotic arm having the slide coupled thereto.

Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:.

Embodiments of the presently disclosed surgical robotic system and methods of use thereof 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 "proximal" refers to that portion of the surgical robotic system or component thereof that is closest to the clinician, while the term "distal" refers to that portion of the surgical robotic system or component thereof further from the clinician.

As will be described in detail below, provided is a surgical robotic system including a robotic arm, an elongated slide or rail coupled to the robotic arm, a belt and pulley system for driving movement of an instrument drive unit along the slide, and a motor release mechanism for selectively disengaging the belt and pulley system from a drive motor. During an emergency (e.g., a power outage), the motor release mechanism may be activated to allow for manual movement of the instrument drive unit along the slide. The motor release mechanism includes a one way bearing that allows for manual movement of the instrument drive unit in the direction away from a patient and resists manual movement of the instrument drive unit in a direction toward the patient.

Referring initially to <FIG>, a surgical system, such as, for example, a surgical robotic system <NUM>, generally includes a plurality of surgical robotic arms <NUM>, <NUM> having an instrument drive unit <NUM> and an electromechanical instrument <NUM> removably attached thereto; a control device <NUM>; and an operating console <NUM> coupled with control device <NUM>. Operating console <NUM> includes a display device <NUM>, which is set up in particular to display three-dimensional images; and manual input devices <NUM>, <NUM>, by means of which a person (not shown), for example a surgeon, is able to telemanipulate robotic arms <NUM>, <NUM> in a first operating mode, as known in principle to a person skilled in the art.

Each of the robotic arms <NUM>, <NUM> may be composed of a plurality of members, which are connected through joints. Robotic arms <NUM>, <NUM> may be driven by electric drives (not shown) that are connected to control device <NUM>. Control device <NUM> (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 <NUM>, <NUM>, the attached instrument drive units <NUM>, and thus electromechanical instrument <NUM> execute a desired movement according to a movement defined by means of manual input devices <NUM>, <NUM>. Control device <NUM> may also be set up in such a way that it regulates the movement of robotic arms <NUM>, <NUM> and/or of the drives.

Surgical robotic system <NUM> is configured for use on a patient "P" lying on a surgical table "ST" to be treated in a minimally invasive manner by means of a surgical instrument, e.g., electromechanical instrument <NUM>. Surgical robotic system <NUM> may also include more than two robotic arms <NUM>, <NUM>, the additional robotic arms likewise being connected to control device <NUM> and being telemanipulatable by means of operating console <NUM>. A surgical instrument, for example, an electromechanical surgical instrument <NUM> (including an electromechanical end effector (not shown)), may also be attached to the additional robotic arm.

Control device <NUM> may control a plurality of motors, e.g., motors (Motor <NUM>. n), with each motor configured to drive movement of robotic arms <NUM>, <NUM> in a plurality of directions. Further, control device <NUM> may control a plurality of motors (not explicitly shown) of instrument drive unit <NUM> to drive various operations of surgical instrument <NUM>. The instrument drive unit <NUM> transfers power and actuation forces from its motors to driven members (not shown) of the electromechanical instrument <NUM> to ultimately drive movement of components of the end effector (not shown) of the electromechanical instrument <NUM>, for example, a movement of a knife blade (not shown) and/or a closing and opening of jaw members (not shown) of the end effector.

For a more detailed description of the construction and operation of components of an exemplary robotic surgical system, reference may be made to U. Publication No. <CIT> (<CIT>), entitled "Medical Workstation," (hereinafter, "the '<NUM> Patent"), and International Patent Publication <CIT>, (hereinafter, "the '<NUM> Publication").

With reference to <FIG>, the surgical robotic system <NUM> includes a carriage <NUM> on which the instrument drive unit <NUM> is supported or carried, and the slide <NUM>, which supports the carriage <NUM>. The carriage <NUM> is configured to fix the instrument drive unit <NUM> thereto, such that movement of the carriage <NUM> along and relative to the slide <NUM> causes the instrument drive unit <NUM> to move therewith. The carriage <NUM> is slidably coupled to a linear track <NUM> defined longitudinally along an outer sleeve <NUM> of the slide <NUM>, as will be described below.

The slide <NUM> may have a generally rectangular shape and is constructed from an inner shaft <NUM> and an outer sleeve or sheath <NUM> disposed around the inner shaft <NUM>. In embodiments, the slide <NUM> may assume any suitable shape, such as, for example, tubular or cylindrical. The inner shaft <NUM> is coupled to an end of the robotic arm <NUM> (<FIG>) either in a fixed or rotatable manner. The inner shaft <NUM> has a bottom end portion 140a and a top end portion 104b and defines a longitudinal axis "X" therebetween. The inner shaft <NUM> may have an overall length approximately equal to half the length of a conventional slide.

The outer sleeve <NUM> of the slide <NUM> is disposed about the inner shaft <NUM> and is telescopically coupled thereto. As such, the outer sleeve <NUM> is slidable along and relative to the longitudinal axis "X" of the inner shaft <NUM> between a retracted position, as shown in <FIG>, and an extended position, as shown in <FIG>. When the outer sleeve <NUM> is in the retracted position, the slide has a first length "L1" (<FIG>), substantially equal to approximately half the length of a conventional slide (e.g., as shown and described in the '<NUM> Patent, and the '<NUM> Publication), and when the outer sleeve is in the extended position, the slide <NUM> has a second length "L2" (<FIG>), substantially equal to approximately the full length of a conventional slide.

The outer sleeve <NUM> of the slide <NUM> defines a longitudinally-extending track <NUM>. The track <NUM> of the outer sleeve <NUM> may be a single rail or a pair of parallel rails. As mentioned above, the carriage <NUM> is slidably coupled to the track <NUM> of the outer sleeve <NUM>. More specifically, the carriage <NUM> has a coupling member or flange <NUM> extending from a back side thereof and through an elongated slot <NUM> of the outer sleeve <NUM>. The coupling member <NUM> of the carriage <NUM> is received in an interior chamber <NUM> (<FIG>) of the outer sleeve <NUM> and is fixed to a belt or cable <NUM> of a belt and pulley system <NUM> of the slide <NUM> for driving the movement of the carriage <NUM> between the ascended and descended positions, as will be described in detail.

The elongated slot <NUM> is defined along the length of the outer sleeve <NUM> and runs parallel with the track <NUM> between a bottom end portion 106a of the outer sleeve <NUM> and a top end portion 106b of the outer sleeve <NUM>. The elongated slot <NUM> of the outer sleeve <NUM> has an upper limit defining a surface feature <NUM> that prevents the carriage <NUM> from ascending beyond the upper limit. In embodiments, the surface feature <NUM> may be a projection extending outwardly from the top end portion 106b of the outer sleeve <NUM>. Upon the coupling member <NUM> of the carriage <NUM> contacting the surface feature <NUM>, a threshold force exerted on the carriage <NUM> in an upward direction causes the outer sleeve <NUM> to rise relative to the inner shaft <NUM>.

The top end portion 106b may further include a locking feature <NUM>, such as, for example, a roller catch, a magnetic latch, or the like. The locking feature <NUM> is configured to selectively lock the carriage <NUM> to the top end portion 106b of the outer sleeve <NUM> when the carriage <NUM> enters the ascended position. As such, with the outer sleeve <NUM> in the extended position relative to the inner shaft <NUM>, as shown in <FIG>, a downward force exerted on the carriage <NUM> via the belt <NUM> causes the outer sleeve <NUM> to move downwardly with the carriage <NUM> due to the locking feature <NUM> locking the outer sleeve <NUM> and the carriage <NUM> to one another. Upon the bottom end portion 106a of the outer sleeve <NUM> bottoming out on the bottom end portion 104a of the inner shaft <NUM>, the locking feature <NUM> releases the carriage <NUM> to allow the carriage <NUM> to descend along the track <NUM> of the outer sleeve <NUM>.

With reference to <FIG>, the belt and pulley system <NUM> or drivetrain of the slide <NUM> is illustrated. The drivetrain <NUM> is operably coupled to a drive motor <NUM> disposed in the bottom end portion 104a of the inner shaft <NUM>. The drivetrain <NUM> includes a pair of first and second pulleys 114a, 114b coupled to the outer shaft <NUM>, and a third pulley 114c coupled to the inner shaft <NUM>. The first pulley 114a is axially fixed and rotatably coupled to the top end portion 106b of the outer sleeve <NUM> of the slide <NUM>, and the second pulley 114b is axially fixed and rotatably coupled to the bottom end portion 10ba of the outer sleeve <NUM>. As such, as the outer sleeve <NUM> moves relative to the inner shaft <NUM> toward the extended position, the first and second pulleys 114a, 114b move therewith. The third pulley 114c is axially fixed and rotatably coupled to the top end portion 104b of the inner shaft <NUM>.

The second pulley 114b is disposed between the first and third pulleys 114a, 114c and is longitudinally spaced from the first pulley 114a along the length of the outer sleeve <NUM>. As shown in <FIG>, when the outer sleeve <NUM> is in the retracted position, the first and third pulleys 114a, 114c are disposed adjacent one another, with the second pulley 114b longitudinally spaced from the third pulley 114c. As shown in <FIG>, when the outer sleeve <NUM> is in the extended position, the first and third pulleys 114a, 114c are longitudinally spaced from one another, with the second and third pulleys 114b, 114c proximate to one another.

With specific reference to <FIG>, the second pulley 114b is positioned relative to the first and third pulleys 114a, 114c so that a net downward force, in the direction indicated by arrow "A" in <FIG>, is exerted on the outer sleeve <NUM>. In particular, the second pulley 114b has a vertical axis "Y" extending through a center point thereof and parallel with the longitudinal axis "X" (<FIG>) of the inner shaft <NUM>. The first pulley 114a is disposed a first distance "d1" from the vertical axis "Y" in a transverse direction, and the third pulley 114c is disposed a second distance "d2" from the vertical axis "Y" in the transverse direction, less than the first distance "d1. " Accordingly, a first portion "P1" of the belt <NUM> extends from the second pulley 114b to the first pulley 114a at an angle greater than an angle at which a second portion "P2" of the belt <NUM> extends from the second pulley 114b to the third pulley 114c. Due to the difference in these angles, the downward force exerted by the first pulley 114a on the outer sleeve <NUM> is greater than the upward force exerted by the third pulley 114c on the outer sleeve <NUM>, whereby the outer sleeve <NUM> has a constant net downward force imparted thereon. Stated differently, a sum of all of the Y-components of force acting on first portion "P1" of belt <NUM>, and second portion "P2" of belt <NUM>, due to the angles of inclination of first portion "P1" and second portion "P2" of belt <NUM>, is such that there is constant net downward force imparted on outer sleeve <NUM>.

The belt <NUM> is operably coupled to the drive motor <NUM>, via a main pulley <NUM> (<FIG>), and each of the first, second, and third pulleys 114a-c. The belt <NUM> is wrapped over the first pulley 114a, under the second pulley 114b, and over the third pulley 114c. The belt <NUM> is driven by the motor <NUM> and is fixed to the coupling member <NUM> of the carriage <NUM>, such that an activation of the motor <NUM> causes the belt <NUM> to move around the pulleys 114a-c and move the attached carriage <NUM> along the outer sleeve <NUM> either toward the ascended position or the descended position.

In operation, prior to performing a surgical procedure, the instrument dive unit <NUM> may be attached to the carriage <NUM>, and the electromechanical instrument <NUM> may be attached to the instrument drive unit <NUM>. With the instrument drive unit <NUM> and the associated electromechanical instrument <NUM> attached to the carriage <NUM>, a longitudinal position (e.g., height) of the carriage <NUM> along the longitudinal axis "X" may be adjusted. For example, to raise the carriage <NUM>, the motor <NUM> of the slide <NUM> is activated to move the belt <NUM> upwardly relative to the outer sleeve <NUM> of the slide <NUM>. The carriage <NUM> is raised to the ascended position and contacts the locking feature <NUM> and/or the surface feature <NUM> of the top end portion 106b of the outer sleeve <NUM>. With the carriage <NUM> fixed to the top end portion 106b of the outer sleeve <NUM>, an activation of the motor <NUM> causes the carriage <NUM> to exert an upward force on the outer sleeve <NUM> to move the outer sleeve <NUM> upwardly relative to the inner shaft <NUM>. As the outer sleeve <NUM> moves, the first and second pulleys 114a, 114b move therewith and relative to the third pulley 114c. In the fully extended position, as shown in <FIG>, the slide <NUM> assumes a length substantially equal to the length of a conventional slide.

To lower the carriage <NUM> from the extended position, the motor <NUM> is activated to drive the belt <NUM> in the opposite direction. In the embodiment where the locking feature <NUM> fixes the carriage <NUM> to the top end portion 106b of the outer sleeve <NUM> of the slide <NUM>, the downward force exerted on the carriage <NUM>, via the belt <NUM>, causes the outer sleeve <NUM> to retract relative to the inner shaft <NUM>. The outer sleeve <NUM> may be retracted until the bottom end portion 106a of the outer sleeve <NUM> bottoms out on the bottom end portion 104a of the inner shaft <NUM>. At this point, to further lower the carriage <NUM>, the belt <NUM>, via the motor <NUM>, exerts a force great enough to unlock the carriage <NUM> from the top end portion 106a of the outer sleeve <NUM>, whereby the carriage <NUM> descends along the track <NUM> of the outer sleeve <NUM> toward the descended position, as shown in <FIG>.

With reference to <FIG>, the slide <NUM> may further include a motor release mechanism <NUM> for manually disengaging the main pulley <NUM> of the belt and pulley system <NUM> (<FIG>) from the drive motor <NUM> to allow a clinician to manually move the carriage <NUM> and associated instrument drive unit <NUM> and surgical instrument <NUM> to a safe position away from the position during an emergency situation (e.g., a power outage).

The motor release mechanism <NUM> generally includes a hub <NUM> and a knob <NUM>. The hub <NUM> is threadedly coupled to a threaded outer surface <NUM> of a motor output member <NUM>, and the knob <NUM> is slidably coupled to the hub <NUM>. The knob <NUM> protrudes outwardly from the slide <NUM> to provide access to the knob <NUM>. To activate the motor release mechanism <NUM>, the knob <NUM> is pushed inwardly, in the direction indicated by arrow "B" in <FIG>, which non-rotationally fixes the knob <NUM> to the hub <NUM> in a friction fit engagement. With the knob <NUM> non-rotationally fixed to the hub <NUM>, a rotation of the knob <NUM> rotates the hub <NUM> relative to the motor output member <NUM>. As the motor release mechanism <NUM> is rotated, the motor release mechanism <NUM> is pulled along the motor output member <NUM>, in the direction indicated by arrow "C. " In embodiments, the knob <NUM> may be permanently non-rotatably coupled to the hub <NUM> to remove the safety step of pushing the knob <NUM> into engagement with the hub <NUM> prior to activating the motor release mechanism <NUM>.

The hub <NUM> of the motor release mechanism <NUM> is axially retained within a proximal end 123a of the pulley <NUM> while also being permitted to rotate relative to the pulley <NUM>. A thrust bearing <NUM> may be provided to facilitate rotation of the hub <NUM> within and relative to the pulley <NUM>. Due to the hub <NUM> being axially retained within the pulley <NUM>, as the hub <NUM> of the motor release mechanism <NUM> is moved in direction "C," so is the pulley <NUM>.

The motor output member <NUM> of the belt and pulley system <NUM> includes a casing 132a and a shaft 132b extending from the casing 132a. The shaft 132b is non-rotationally fixed to a motor gearbox output shaft <NUM> of the drive motor <NUM> and extends axially through the pulley <NUM>. A pair of torque transfer pins 134a, 134b are fixed to the casing 132a and extend through corresponding bores 127a, 127b defined through a distal end 123b of the pulley <NUM>. In embodiments, there may be more or less than two pins 134a, 134b. The torque transfer pins 134a, 134b drivingly couple the pulley <NUM> to the motor output member <NUM>, such that the pulley <NUM> rotates with the motor output member <NUM> in response to an activation of the drive motor <NUM>.

The pulley <NUM> is slidable relative to and along the pins 134a, 134b to adjust an axial position of the pulley <NUM> relative to the motor output member <NUM>. In particular, the pulley <NUM> is axially movable along the torque transfer pins 134a, 134b, in response to an activation of the motor release mechanism <NUM>, between a first axial position, as shown in <FIG>, and a second axial position, as shown in <FIG>. In the first axial position, the torque transfer pins 134a, 134b extend through the bores 127a, 127b of the pulley <NUM>, non-rotationally fixing the pulley <NUM> with the motor output member <NUM>. In the second axial position, the pulley <NUM> is disengaged from the torque transfer pins 134a, 134b, whereby the pulley <NUM> is decoupled from the motor output member <NUM> and independently rotatable relative to the motor output member <NUM>. The slide <NUM> may include a spring <NUM> (e.g., a wave spring) that resiliently biases the pulley <NUM> toward the first position. A thrust bearing <NUM> may be provided to facilitate rotation of the pulley <NUM> relative to the spring <NUM>.

The slide <NUM> further includes a one way bearing <NUM> disposed within the pulley <NUM> and captured between the pulley <NUM> and the shaft 132b of the motor output member <NUM>. The bearing <NUM> may be non-rotationally fixed to the shaft 132b of the motor output member <NUM>. The bearing <NUM> may be any suitable one way bearing or clutch, such as, for example, a one way bearing having rollers, sprags, or spring elements. The bearing <NUM> is configured to resist rotation of the pulley <NUM> relative to the motor output member <NUM> in the direction corresponding to a movement of the carriage <NUM>/instrument drive unit <NUM> in a downward direction along the slide <NUM>, as described below.

In operation, when the pulley <NUM> is in the first or operational position, as shown in <FIG>, an activation of the drive motor <NUM> rotates the motor output member <NUM>, the bearing <NUM>, and the pulley <NUM> as one integral unit in either rotational direction (i.e., clockwise or counter-clockwise). As described above, a rotation of the pulley <NUM> results in a movement of the surgical instrument <NUM> along the slide <NUM> in a selected direction. For example, a clockwise rotation of the pulley <NUM> may result in an upward movement of the surgical instrument <NUM> along the slide <NUM>, whereas a counter-clockwise rotation of the pulley <NUM> may result in a downward movement of the surgical instrument <NUM> along the slide.

During an emergency (e.g., a power outage), a clinician may desire to move the surgical instrument <NUM> out of and away from the patient. However, during a power outage, the drive motor <NUM> will be locked out and prevent a manual movement of the surgical instrument <NUM> along the slide <NUM>. Accordingly, to move the surgical instrument <NUM>/carriage <NUM>/instrument drive unit <NUM>, the carriage <NUM> may need to be operably disengaged from the drive motor <NUM>.

To disengage the drive motor <NUM> from the carriage <NUM>, the motor release mechanism <NUM> may be actuated by pushing the knob <NUM> thereof into non-rotational engagement with the hub <NUM> thereof. With the knob <NUM> and hub <NUM> of the motor release mechanism <NUM> non-rotationally coupled to one another, the knob <NUM> and hub <NUM> are rotated together about the motor output member <NUM> to draw the pulley <NUM> away from the casing 132a of the motor output member <NUM> toward the second position, whereby the belt and pulley system <NUM> (<FIG>) is disengaged from the drive motor <NUM>.

When the pulley <NUM> is in the second or safety position, as shown in <FIG>, the bearing <NUM> permits a rotation of the pulley <NUM> relative thereto and relative to the motor output member <NUM> in the direction corresponding to movement of the carriage <NUM>/instrument drive unit <NUM>/surgical instrument <NUM> in an upward direction along the slide <NUM>. Accordingly, the surgical instrument <NUM> may be manually moved up and out of the patient to a selected position along the slide <NUM>. In contrast, an attempt to move the carriage <NUM>/instrument drive unit <NUM>/surgical instrument <NUM> in the downward direction is thwarted due to the one way bearing <NUM> preventing rotation of the pulley <NUM> relative to the bearing <NUM> in the corresponding rotational direction. Further, since the drive motor <NUM> is in a locked state (e.g., due to a power outage), the drive motor <NUM> prevents the bearing <NUM> and the motor output member <NUM> from being rotated by the applied force on the carriage <NUM>/instrument drive unit <NUM>/surgical instrument <NUM>.

Claim 1:
A surgical robotic system (<NUM>), comprising:
an elongated slide (<NUM>) defining a longitudinal axis ("X");
a carriage (<NUM>) for supporting an instrument drive unit (<NUM>), wherein the carriage is coupled to the slide and movable relative thereto along the longitudinal axis, the carriage (<NUM>) being fixed to a belt, such that movement of the belt drives movement of the carriage along the slide;
a drive motor (<NUM>) operably coupled to the carriage (<NUM>) and configured to drive the movement of the carriage relative to the slide (<NUM>);
a motor release mechanism (<NUM>) configured to selectively disengage the drive motor from the carriage to permit a manual movement of the carriage along the slide characterised by the belt (<NUM>) being operably coupled to a pulley (<NUM>) operably coupling the drive motor (<NUM>) and the carriage (<NUM>), wherein an activation of the motor release mechanism (<NUM>) disengages the pulley (<NUM>) from the drive motor; and
a motor output member (<NUM>) rotatable by the drive motor (<NUM>), wherein an activation of the motor release mechanism (<NUM>) slides the pulley (<NUM>) relative to the motor output member from a first position, in which the pulley and the motor output member are rotatable with one another, to a second position, in which the pulley is independently rotatable relative to the motor output member.