Patent Description:
Each surgical tool typically includes an end effector arranged at its distal end. Example end effectors include clamps, graspers, scissors, staplers, and needle holders, and are similar to those used in conventional (open) surgery except that the end effector of each tool is separated from its handle by an approximately <NUM>-inch (<NUM>,<NUM>) long, shaft. A camera or image capture device, such as an endoscope, is also commonly introduced into the abdominal cavity to enable the surgeon to view the surgical field and the operation of the end effectors during operation. The surgeon is able to view the procedure in real-time by means of a visual display in communication with the image capture device.

Surgical staplers are one type of end effector capable of cutting and simultaneously stapling (fastening) transected tissue. Alternately referred to as an "endocutter," the surgical stapler includes opposing jaws capable of opening and closing to grasp and release tissue. Once tissue is grasped or clamped between the opposing jaws, the end effector may be "fired" to advance a cutting element or knife distally to transect grasped tissue. As the cutting element advances, staples contained within the end effector are progressively deployed to seal opposing sides of the transected tissue.

Some surgical staplers include a knife bailout mechanism or system that allows the user to manually retract the knife in the event of an emergency, such as a loss of power. It may be desirable to communicate the status of a manual knife bailout system to the user, but including various sensors in the end effector to sense whether the knife is being manually bailed out may not be feasible.

<CIT> discloses a surgical instrument configured to detect a condition of the surgical instrument such as detecting whether a shaft assembly has been assembled to the handle.

The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

The invention is defined by independent claims <NUM> and <NUM>. Certain optional features of the invention are defined in the dependent claims.

The present disclosure is related to robotic surgical instruments and, more particularly, to systems and methods of sensing when a manual knife bailout system for a robotic surgical tool has been activated or is about to be activated.

Embodiments discussed herein describe a robotic surgical tool that has a tool driver in communication with a computer system, and a drive housing mountable to the tool driver and including one or more component parts made of or including a magnetically responsive material. A first inductor coil may be included on the tool driver and configured to generate a magnetic field, and a second inductor coil may be included on the drive housing and configured to measure an intensity of the magnetic field and a field distortion caused by the one or more component parts. When a change in the field distortion is measured, that may be an indication of movement of the one or more component parts. In some embodiments, the one or more component parts form part of a manual knife bailout system, and measuring the change in the field distortion may provide an indication that the manual knife bailout system has been activated or is about to be activated. When the change in field distortion is measures, the computer system may provide a notification to a user (e.g., a surgeon, a scrub nurse, etc.) of the status change.

<FIG> illustrate the structure and operation of an example robotic surgical system and associated components thereof. While applicable to robotic surgical systems, it is noted that the principles of the present disclosure may alternatively be applied to non-robotic surgical systems, without departing from the scope of the disclosure.

<FIG> is a block diagram of an example robotic surgical system <NUM> that may incorporate some or all of the principles of the present disclosure. As illustrated, the system <NUM> can include at least one master control console 102a and at least one robotic manipulator <NUM>. The robotic manipulator <NUM> may be mechanically and/or electrically coupled to or otherwise include one or more robotic arms <NUM>. In some embodiments, the robotic manipulator <NUM> may be mounted to a transport cart (alternately referred to as an "arm cart") that enables mobility of the robotic manipulator <NUM> and the associated robotic arms <NUM>. Each robotic arm <NUM> may include and otherwise provide a tool driver where one or more surgical instruments or tools <NUM> may be mounted for performing various surgical tasks on a patient <NUM>. Operation of the robotic arms <NUM>, the corresponding tool drivers, and the associated tools <NUM> may be directed by a clinician 112a (e.g., a surgeon) from the master control console 102a.

In some embodiments, a second master control console 102b (shown in dashed lines) operated by a second clinician 112b may also help direct operation of the robotic arms <NUM> and the tools <NUM> in conjunction with the first clinician 112a. In such embodiments, for example, each clinician 112a,b may control different robotic arms <NUM> or, in some cases, complete control of the robotic arms <NUM> may be passed between the clinicians 112a,b. In some embodiments, additional robotic manipulators having additional robotic arms may be utilized during surgery on a patient <NUM>, and these additional robotic arms may be controlled by one or more of the master control consoles 102a,b.

The robotic manipulator <NUM> and the master control consoles 102a,b may communicate with one another via a communications link <NUM>, which may be any type of wired or wireless communications link configured to carry suitable types of signals (e.g., electrical, optical, infrared, etc.) according to any communications protocol. The communications link <NUM> may be an actual physical link or it may be a logical link that uses one or more actual physical links. When the link is a logical link the type of physical link may be a data link, uplink, downlink, fiber optic link, point-to-point link, for example, as is well known in the computer networking art to refer to the communications facilities that connect nodes of a network. Accordingly, the clinicians 112a,b may be able to remotely control operation of the robotic arms <NUM> via the communications link <NUM>, thus enabling the clinicians 112a,b to operate on the patient <NUM> remotely.

<FIG> is one example embodiment of the master control console 102a that may be used to control operation of the robotic manipulator <NUM> of <FIG>. As illustrated, the master control console 102a can include a support <NUM> on which the clinician 112a,b (<FIG>) can rest his/her forearms while gripping one or more user input devices (not shown). The user input devices can comprise, for example, physical controllers such as, but not limited to, hand-held actuator modules, a joystick, exoskeletal gloves, a master manipulator, etc., and may be movable in multiple degrees of freedom to control the position and operation of the surgical tool(s) <NUM> (<FIG>). The master control console 102a may further include one or more foot pedals <NUM> engageable by the clinician 112a,b to change the configuration of the surgical system and/or generate additional control signals to control operation of the surgical tool(s) <NUM>.

The user input devices and/or the foot pedals <NUM> may be manipulated while the clinician 112a,b (<FIG>) views the procedure via a visual display <NUM>. Images displayed on the visual display <NUM> may be obtained from an endoscopic camera or "endoscope. " In some embodiments, the visual display <NUM> may include or otherwise incorporate a force feedback meter or "force indicator" that provides the clinician 112a,b with a visual indication of the magnitude of force being assumed by the surgical tool (i.e., a cutting instrument or dynamic clamping member) and in which direction. As will be appreciated, other sensor arrangements may be employed to provide the master control console 102a with an indication of other surgical tool metrics, such as whether a staple cartridge has been loaded into an end effector or whether an anvil has been moved to a closed position prior to firing, for example.

<FIG> depicts one example of the robotic manipulator <NUM> that may be used to operate a plurality of surgical tools <NUM>, according to one or more embodiments. As illustrated, the robotic manipulator <NUM> may include a base <NUM> that supports a vertically extending column <NUM>. A plurality of robotic arms <NUM> (three shown) may be operatively coupled to the column <NUM> at a carriage <NUM> that can be selectively adjusted to vary the height of the robotic arms <NUM> relative to the base <NUM>, as indicated by the arrow A.

The robotic arms <NUM> may comprise manually articulable linkages, alternately referred to as "set-up joints. " In the illustrated embodiment, a surgical tool <NUM> is mounted to corresponding tool drivers <NUM> provided on each robotic arm <NUM>. Each tool driver <NUM> may include one or more drivers or motors used to interact with a corresponding one or more drive inputs of the surgical tools <NUM>, and actuation of the drive inputs causes the associated surgical tool <NUM> to operate.

One of the surgical tools <NUM> may comprise an image capture device <NUM>, such as an endoscope, which may include, for example, a laparoscope, an arthroscope, a hysteroscope, or may alternatively include some other imaging modality, such as ultrasound, infrared, fluoroscopy, magnetic resonance imaging, or the like. The image capture device <NUM> has a viewing end located at the distal end of an elongate shaft, which permits the viewing end to be inserted through an entry port into an internal surgical site of a patient's body. The image capture device <NUM> may be communicably coupled to the visual display <NUM> (<FIG>) and capable of transmitting images in real-time to be displayed on the visual display <NUM>.

The remaining surgical tools may be communicably coupled to the user input devices held by the clinician 112a,b (<FIG>) at the master control console 102a (<FIG>). Movement of the robotic arms <NUM> and associated surgical tools <NUM> may be controlled by the clinician 112a,b manipulating the user input devices. As described in more detail below, the surgical tools <NUM> may include or otherwise incorporate an end effector mounted on a corresponding articulable wrist pivotally mounted on a distal end of an associated elongate shaft. The elongate shaft permits the end effector to be inserted through entry ports into the internal surgical site of a patient's body, and the user input devices also control movement (actuation) of the end effector.

In use, the robotic manipulator <NUM> is positioned close to a patient requiring surgery and is then normally caused to remain stationary until a surgical procedure to be performed has been completed. The robotic manipulator <NUM> typically has wheels or casters to render it mobile. The lateral and vertical positioning of the robotic arms <NUM> may be set by the clinician 112a,b (<FIG>) to facilitate passing the elongate shafts of the surgical tools <NUM> and the image capture device <NUM> through the entry ports to desired positions relative to the surgical site. When the surgical tools <NUM> and image capture device <NUM> are so positioned, the robotic arms <NUM> and carriage <NUM> can be locked in position.

<FIG> is an isometric side view of an example surgical tool <NUM> that may incorporate some or all of the principles of the present disclosure. The surgical tool <NUM> may be the same as or similar to at least one of the surgical tools <NUM> of <FIG> and <FIG> and, therefore, may be used in conjunction with a robotic surgical system, such as the robotic surgical system <NUM> of <FIG>. As illustrated, the surgical tool <NUM> includes an elongated shaft <NUM>, an end effector <NUM>, an articulable wrist <NUM> (alternately referred to as a "wrist joint") that couples the end effector <NUM> to the distal end of the shaft <NUM>, and a drive housing <NUM> coupled to the proximal end of the shaft <NUM>. In applications where the surgical tool <NUM> is used in conjunction with a robotic surgical system, the drive housing <NUM> can include coupling features that releasably couple the surgical tool <NUM> to the robotic surgical system. The principles of the present disclosure, however, are equally applicable to surgical tools that are non-robotic and otherwise capable of manual manipulation.

The terms "proximal" and "distal" are defined herein relative to a robotic surgical system having an interface configured to mechanically and electrically couple the surgical tool <NUM> (e.g., the drive housing <NUM>) to a robotic manipulator. The term "proximal" refers to the position of an element closer to the robotic manipulator and the term "distal" refers to the position of an element closer to the end effector <NUM> and thus further away from the robotic manipulator. Moreover, the use of directional terms such as above, below, upper, lower, upward, downward, left, right, and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward or upper direction being toward the top of the corresponding figure and the downward or lower direction being toward the bottom of the corresponding figure.

The surgical tool <NUM> can have any of a variety of configurations capable of performing one or more surgical functions. In the illustrated embodiment, the end effector <NUM> comprises a surgical stapler, alternately referred to as an "endocutter," configured to cut and staple (fasten) tissue. As illustrated, the end effector <NUM> includes opposing jaws <NUM>, <NUM> configured to move (articulate) between open and closed positions. The opposing jaws <NUM>, <NUM>, however, may alternately form part of other types of end effectors that include jaws such as, but not limited to, tissue graspers, surgical scissors, advanced energy vessel sealers, clip appliers, needle drivers, a babcock including a pair of opposed grasping jaws, bipolar jaws (e.g., bipolar Maryland grasper, forceps, a fenestrated grasper, etc.), etc. One or both of the jaws <NUM>, <NUM> may be configured to pivot to actuate the end effector <NUM> between the open and closed positions. In the illustrated example, the second jaw <NUM> is rotatable (pivotable) relative to the first jaw <NUM> to move between an open, unclamped position and a closed, clamped position. In other embodiments, however, the first jaw <NUM> may move (rotate) relative to the second jaw <NUM>, without departing from the scope of the disclosure.

In the illustrated example, the first jaw <NUM> may be characterized or otherwise referred to as a "cartridge" jaw, and the second jaw <NUM> may be characterized or otherwise referred to as an "anvil" jaw. The first jaw <NUM> may include a frame that houses or supports a staple cartridge, and the second jaw <NUM> is pivotally supported relative to the first jaw <NUM> and defines a surface that operates as an anvil to deform staples ejected from the staple cartridge during operation.

The wrist <NUM> enables the end effector <NUM> to articulate (pivot) relative to the shaft <NUM> and thereby position the end effector <NUM> at desired orientations and locations relative to a surgical site. <FIG> illustrates the potential degrees of freedom in which the wrist <NUM> may be able to articulate (pivot). The wrist <NUM> can have any of a variety of configurations. In general, the wrist <NUM> comprises a joint configured to allow pivoting movement of the end effector <NUM> relative to the shaft <NUM>. The degrees of freedom of the wrist <NUM> are 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 effector <NUM>) with respect to a given reference Cartesian frame. As depicted in <FIG>, "surge" refers to forward and backward translational movement, "heave" refers to translational movement up and down, and "sway" refers to translational movement left and right. With regard to the rotational terms, "roll" refers to tilting side to side, "pitch" refers to tilting forward and backward, and "yaw" refers to turning left and right.

The pivoting motion can include pitch movement about a first axis of the wrist <NUM> (e.g., X-axis), yaw movement about a second axis of the wrist <NUM> (e.g., Y-axis), and combinations thereof to allow for <NUM>° rotational movement of the end effector <NUM> about the wrist <NUM>. In other applications, the pivoting motion can be limited to movement in a single plane, e.g., only pitch movement about the first axis of the wrist <NUM> or only yaw movement about the second axis of the wrist <NUM>, such that the end effector <NUM> moves only in a single plane.

Referring again to <FIG>, the surgical tool <NUM> may incorporate or include an actuation system designed to facilitate articulation of the wrist <NUM> and actuation (operation) of the end effector <NUM> (e.g., clamping, firing, rotation, articulation, energy delivery, etc.). The actuation system may include a plurality of drive members or the like (obscured in <FIG>) that extend from the drive housing <NUM> to the wrist <NUM>, and selective actuation of these drive members causes the end effector <NUM> to articulate (pivot) relative to the shaft <NUM> at the wrist <NUM>. The end effector <NUM> is depicted in <FIG> in the unarticulated position where a longitudinal axis A<NUM> of the end effector <NUM> is substantially aligned with the longitudinal axis A<NUM> of the shaft <NUM>, such that the end effector <NUM> is at a substantially zero angle relative to the shaft <NUM>. In the articulated position, the longitudinal axes A<NUM>, A<NUM> would be angularly offset from each other such that the end effector <NUM> is at a non-zero angle relative to the shaft <NUM>.

Other drive members may extend to the end effector <NUM>, and selective actuation of those drive members may cause the end effector <NUM> to actuate (operate). Actuating the end effector <NUM> may include closing and/or opening the second jaw <NUM> relative to the first jaw <NUM> (or vice versa), thereby enabling the end effector <NUM> to grasp (clamp) onto tissue. Once tissue is grasped or clamped between the opposing jaws <NUM>, <NUM>, actuating the end effector <NUM> may further include "firing" the end effector <NUM>, which may refer to causing a cutting element or knife (not visible) to advance distally within a slot <NUM> defined in the second jaw <NUM>. As it moves distally, the cutting element may transect any tissue grasped between the opposing jaws <NUM>, <NUM>. Moreover, as the cutting element advances distally, a plurality of staples contained within the staple cartridge (e.g., housed within the first jaw <NUM>) may be urged (cammed) into deforming contact with corresponding anvil surfaces (e.g., pockets) provided on the second jaw <NUM>. The deployed staples may form multiple rows of staples that seal opposing sides of the transected tissue.

In some applications, the surgical tool <NUM> may also be configured to apply energy to tissue, such as radio frequency (RF) energy. In such cases, actuating the end effector <NUM> may further include applying energy to tissue grasped or clamped between two opposing jaws to cauterize or seal the captured tissue, following which the tissue may be transected.

The surgical tool <NUM> may further include a manual jaw bailout system that enables a user to manually open and close the jaws <NUM>, <NUM>. In the illustrated embodiment, the manual jaw bailout system may include a bailout tool <NUM> accessible to a user on the exterior of the drive housing <NUM>. The bailout tool <NUM> may be operatively coupled to various gears and/or drive members located within the drive housing <NUM> to allow a clinician to manually open and close the jaws <NUM>, <NUM>. By rotating the bailout tool <NUM> in either angular direction, a clinician may be able to fully clamp and fully unclamp the jaws <NUM>, <NUM>. The bailout tool <NUM> may be particularly useful to a clinician when the surgical tool <NUM> is detached from a surgical robot, since having the capability to open and close the jaws <NUM>, <NUM> may eliminate the need to place inadvertent stress on internal drive members or components. In the event that a clinician desires to manually open the jaws <NUM>, <NUM> when the surgical tool <NUM> is still attached to a surgical robot, the clinician can rotate the bailout tool <NUM> in an attempt to open the end effector <NUM>.

<FIG> is an enlarged isometric view of the drive housing <NUM>. In some embodiments, the surgical tool <NUM> may include a manual knife bailout system that allows a user to manually retract the knife (cutting element) at the end effector <NUM> (<FIG>). The manual knife bailout system includes various component parts, such as a bailout tool <NUM> accessible to a user and configured to mate with a bailout cap <NUM> to cause knife retraction. The bailout cap <NUM> may include or otherwise provide one or more surface features <NUM> configured to interact with corresponding engagement features (not shown) provided on the bottom of the bailout tool <NUM>. Each surface feature <NUM> may be ramped in one angular direction and terminate at a raised shoulder. The engagement features of the bailout tool <NUM> may be configured to engage the raised shoulders of the surface features <NUM> when the bailout tool <NUM> is rotated in a first direction (e.g., counter-clockwise), thus transmitting torque from the bailout tool <NUM> to the bailout cap <NUM>. In contrast, when the bailout tool <NUM> is rotated in a second direction (e.g., clockwise), the engagement features may traverse (ride up) and ratchet over the surface features <NUM>. Accordingly, the bailout cap <NUM> may operate as a unidirectional transfer member.

In example use of the manual knife bailout system, a user rotating the bailout tool <NUM> in the first direction (e.g., counter-clockwise) will drive the bailout cap <NUM> in the same direction and thereby cause the gears of the firing system to rotate, which will rotate the firing pinion and thereby retract a firing rack so that an interconnected firing rod (not shown) can retract the knife at the end effector <NUM> (<FIG>). When the bailout tool <NUM> is rotated in the second direction (e.g., clockwise), however, the bailout tool <NUM> will ratchet over the surface features <NUM> and otherwise rotate relative to the bailout cap <NUM>, thus not affecting the position of the firing rod or the knife.

In the illustrated embodiment, the bailout tool <NUM> comprises a separate component part stored within the drive housing <NUM> and is accessible to the user by first removing a bailout panel <NUM> from the body of the drive housing <NUM>. As illustrated, the bailout tool <NUM> may be seated within a pocket <NUM> and the user may remove the bailout tool <NUM> from the pocket <NUM> and mate it with the bailout cap <NUM> to manually retract the knife. In other embodiments, however, the bailout tool <NUM> may be located on the exterior of the drive housing <NUM> and extend through the bailout panel <NUM> of the drive housing <NUM> to be operatively coupled to the bailout cap <NUM>. In yet other embodiments, the bailout tool <NUM> may be attached to or form part of the bottom (underside) of the bailout panel <NUM>. In such embodiments, the clinician may remove the bailout panel <NUM> and align the interconnected bailout tool <NUM> with the bailout cap <NUM>, thus converting the removable bailout panel <NUM> into a type of wrench.

<FIG> is a bottom view of the drive housing <NUM>, according to one or more embodiments. As illustrated, the drive housing <NUM> may include a tool mounting portion <NUM> used to operatively couple the drive housing <NUM> to a tool driver <NUM>. The tool driver <NUM> may be the same as or similar to the tool drivers <NUM> of <FIG>, and may thus be operable in conjunction with the robotic manipulator <NUM> of <FIG> and <FIG>. Mounting the drive housing <NUM> to the tool driver <NUM> places the drive housing <NUM> in communication with a computer system <NUM>, which may communicate with or otherwise form part of the master controllers 102a,b (<FIG>). The computer system <NUM> monitors and directs operation of the drive housing <NUM> via operation of the tool driver <NUM>, thus enabling a user (e.g., the clinicians 112a,b of <FIG>) to control operation of the drive housing <NUM> by working through the master controller 102a,b.

The tool mounting portion <NUM> includes and otherwise provides an interface that mechanically, magnetically, and/or electrically couples the drive housing <NUM> to the tool driver <NUM>. In at least one embodiment, the tool mounting portion <NUM> couples the drive housing <NUM> to the tool driver <NUM> via a sterile barrier (not shown). As illustrated, the interface can include and support a plurality of inputs, shown as drive inputs 708a, 708b, 708c, 708d, 708e, and 708f. Each drive input 708a-f may comprise a rotatable disc configured to align (mate) with and couple to a corresponding driver 710a, 710b, 710c, 710d, 710e, and 710f of the tool driver <NUM>. Each drive input 708a-f and corresponding driver 710a-f provide or define one or more matable surface features <NUM> and <NUM>, respectively, configured to facilitate mating engagement between the opposing surface features <NUM>, <NUM> such that movement (rotation) of a given driver 710a-f correspondingly moves (rotates) the associated drive input 708a-f.

Each driver 710a-f may include or otherwise comprise a motor <NUM> configured to actuate the corresponding driver 710a-f, and actuation of a given driver 710a-f correspondingly causes actuation of the mated drive input 708a-f, which facilitates operation of the mechanics of the drive housing <NUM>. More specifically, actuation of a given motor <NUM> may cause rotational movement of the corresponding driver 710a-f, which, in turn, rotates the associated drive input 708a-f operatively coupled thereto. Each motor <NUM> may be in communication with the computer system <NUM> and, based on input signals provided by a user (e.g., a surgeon), the computer system <NUM> may selectively cause any of the motors <NUM> to actuate and thereby drive the corresponding driver 710a-f to operate the mechanical systems of the drive housing <NUM>.

In some embodiments, actuation of the first drive input 708a via the first driver 710a may control rotation of the shaft <NUM> about its longitudinal axis A<NUM>. Depending on the rotational direction of the first drive input 708a, the shaft <NUM> can be rotated clockwise or counter-clockwise, thus correspondingly rotating the end effector <NUM> (<FIG>) in the same direction. Actuation of the second and third drive inputs 708b,c via the second and third drivers 710a,b, respectively, may control articulation of the end effector <NUM> at the wrist <NUM> (<FIG>). Actuation of the fourth and fifth drive inputs 708d,e via the fourth and fifth drivers 710d,e, respectively, may cause an outer portion of the shaft <NUM> (referred to herein as a "closure tube") to advance and retract, which closes and opens the jaws <NUM>, <NUM> (<FIG>). Lastly, actuation of the sixth drive input 708f via the sixth driver 710f may cause the end effector <NUM> to fire, which may entail distal deployment of a knife (cutting element) to transect tissue grasped by the jaws <NUM>, <NUM> and simultaneous deployment of staples contained within the staple cartridge housed within the first jaw <NUM>.

The drive housing <NUM> may house or otherwise include an internal computer <NUM> that may include a memory <NUM> and/or a microprocessor <NUM>. The memory <NUM> may include one or more databases or libraries that store data relating to the drive housing <NUM> and, more particularly, to the surgical tool <NUM> (<FIG>). In some embodiments, the memory <NUM> may include non-transitory, computer-readable media such as a read-only memory (ROM), which may be PROM, EPROM, EEPROM, or the like.

Mounting (coupling) the tool mounting portion <NUM> to the tool driver <NUM> facilitates communication and power transfer between the tool driver <NUM> and the drive housing <NUM>. More specifically, mating the drive housing <NUM> to the tool driver <NUM> places the internal computer <NUM> in communication with the computer system <NUM>, which allows the computer system <NUM> to identify and authenticate the surgical tool <NUM> (<FIG>) or otherwise associate the surgical tool <NUM> with data stored elsewhere in the robotic surgical system. In some embodiments, to facilitate communication and power transfer between the tool mounting portion <NUM> and the tool driver <NUM>, the tool mounting portion <NUM> may include one or more electrical connectors <NUM> (two shown) configured to mate with corresponding electrical connections <NUM> (two shown) provided by the tool driver <NUM> to.

Alternately, or in addition thereto, the drive housing <NUM> can be inductively (or "magnetically) coupled to the tool driver <NUM> to facilitate wireless communication and power transfer between the two structures. In at least one embodiment, for example, the drive housing <NUM> may be inductively coupled to the tool driver <NUM> using a near field communication (NFC) connection or protocol. In other embodiments, however, the drive housing <NUM> may be inductively coupled to the tool driver <NUM> via other wireless communication protocols.

In the illustrated embodiment, a first or "transmitting" inductor coil 728a (shown in dashed lines) may be included on the tool driver <NUM>, and a corresponding second or "receiving" inductor coil 728b (shown in dashed lines) may be included on the drive housing <NUM>, such as being arranged on the tool mounting portion <NUM>. The first inductor coil 728a may be communicably coupled to the computer system <NUM>, and the second inductor coil 728b may be communicably coupled to the internal computer <NUM> of the drive housing <NUM>. Once the first and second inductor coils 728a,b are inductively coupled, data may be transferred between the computer system <NUM> and the internal computer <NUM>.

The first inductor coil 728a may be operated and powered by the computer system <NUM> and configured to generate (emit) a magnetic field, which induces an electromotive force (i.e., a voltage or a current) in the adjacent second inductor coil 728b. Based on the changing intensity of the magnetic field, the generated electromotive force can be interpreted by the internal computer <NUM> to transmit data between the two structures. Moreover, the generated electromotive force may be harvested in the form of electrical power, which may be used to power the circuitry of the internal computer <NUM>.

According to embodiments of the present disclosure, the inductive coupling between the drive housing <NUM> and the tool driver <NUM> may also be used to determine when the manual knife bailout system of the surgical tool <NUM> (<FIG>) is activated or about to be activated. More specifically, embodiments of the present disclosure rely on the effect that a magnetically responsive material (e.g., conductive or ferrous materials) can have on the magnetic field generated by the inductive coupling. One or more component parts of the drive housing <NUM> used to activate the manual knife bailout system may include or otherwise be made of a magnetically responsive material. When such component parts are physically moved, a disturbance in the magnetic field may be detected, and that may provide a positive indication that the manual knife bailout system is being activated. In some embodiments, once the disturbance is detected, the user (i.e., a surgeon, a scrub nurse, etc.) may be informed of the status change and subsequently provided with instructions on how to complete the knife bailout procedure or otherwise instructions on how to reverse commencement of the knife bailout procedure.

<FIG> are cross-sectional side views of the drive housing <NUM> inductively coupled to the tool driver <NUM>, according to one or more embodiments. <FIG> also depict various component parts of the manual knife bailout system, including the bailout tool <NUM> and the bailout cap <NUM>. In the illustrated embodiment, the bailout tool <NUM> is stored within the drive housing <NUM> and seated (received) within the pocket <NUM>. The user can access the bailout tool <NUM> by first removing the bailout panel <NUM>. The bailout tool <NUM> can then be removed from the pocket <NUM> and mated to the bailout cap <NUM> to rotate the bailout cap <NUM> and thereby manually retract the knife (not shown). As mentioned above, rotating (driving) the bailout cap <NUM> in the first direction (e.g., counter-clockwise) will cause an interconnected firing rod <NUM> (shown in dashed lines) to retract proximally, as indicated by the arrow A in <FIG>. The knife may be operatively coupled to the distal end of the firing rod <NUM> at the end effector <NUM> (<FIG>), and proximal movement of the firing rod <NUM> correspondingly retracts the knife in the proximal direction A.

Mounting the drive housing <NUM> to the tool driver <NUM> places the second inductor coil 728b of the drive housing <NUM> in proximity to the first inductor coil 728a of the tool driver <NUM>. As controlled by the computer system <NUM> (<FIG>, the first inductor coil 728a may be configured to generate (emit) a magnetic field <NUM> that propagates radially outward. As briefly described above, the magnetic field <NUM> may be received or otherwise sensed by the second inductor coil 728b to facilitate data transmission and electrical power transfer (i.e., voltage or current) to the circuitry of the internal computer <NUM> (<FIG>).

In some embodiments, as illustrated, one or more component parts of the manual knife bailout system may be made of or otherwise include a magnetically responsive material <NUM> that causes field distortions <NUM> in the magnetic field <NUM>. The magnetically responsive material <NUM> may comprise any magnetically responsive material capable of distorting or disrupting the magnetic field <NUM>. The magnetically responsive material <NUM> may comprise, for example, a conductive metal such as, but not limited to, silver, copper, gold, aluminum, zinc, nickel, brass, bronze, a ferrous metal (e.g., iron, carbon steel, stainless steel, etc.), platinum, lead, any alloy thereof, or any combination thereof. The magnetically responsive material <NUM> may alternatively comprise a conductive polymer, graphite, carbon fibers, or any combination thereof.

In some embodiments, all or a portion of one or more of the bailout tool <NUM>, the bailout panel <NUM>, and the firing rod <NUM> may be made of the magnetically responsive material <NUM>. In other embodiments, the magnetically responsive material <NUM> may be included with or otherwise attached to one or more of the bailout tool <NUM>, the bailout panel <NUM>, and the firing rod <NUM>. The magnetically responsive materials <NUM> will distort the magnetic field <NUM> and generate field distortions <NUM> that may be measured or otherwise sensed by the second inductor coil 728b.

More specifically, the second inductor coil 728b may be configured to measure the electromotive force (i.e., a voltage or a current) generated within the second inductor coil 728b; i.e., how much electrical potential is resulting in the second inductor coil 728b due to the magnetic field <NUM>. Because the electrical potential is driven by how much magnetic flux is driven through the second inductor coil 728b, the measured electrical potential can also serve as a measurement of the magnetic flux in the second inductor coil 728b. The magnetically responsive materials <NUM> will distort the magnetic flux of the magnetic field <NUM> depending on the position of the magnetically responsive materials <NUM> within the magnetic field <NUM>. If the physical position of the magnetically responsive materials <NUM> changes, the magnetic flux of the magnetic field <NUM> will correspondingly change and the second inductor coil 728b will be able to detect the alteration and position change.

Referring to <FIG>, the component parts of the manual knife bailout system are properly stowed and otherwise in position for normal use of the surgical tool <NUM> (<FIG>). When the drive housing <NUM> is first installed on the tool driver <NUM>, the intensity of the magnetic field <NUM> and the resulting field distortions <NUM> generated by the magnetically responsive materials <NUM> included with the component parts of the manual knife bailout system may be measured and recorded. This data may be stored (logged) by the computer system <NUM> (<FIG>) or the internal computer <NUM> (<FIG>) to provide a normal operating state for the surgical tool <NUM>, and any variation from this normal operating state may provide an indication that the manual knife bailout system has been activated or is about to be activated. Alternatively, the memory <NUM> of the internal computer <NUM> may already have stored therein known field distortions <NUM> generated in the magnetic field <NUM> when the drive housing <NUM> is coupled to the tool driver <NUM> and in the normal operating state. In such embodiments, the computer system <NUM> (<FIG>) may interpret the measured magnetic field <NUM> and associated field distortions <NUM> and recognize the surgical tool <NUM> based on the measured magnetic field <NUM> and associated field distortions <NUM>.

The intensity of the magnetic field <NUM> may then be continuously monitored and measured by one or both of the computer system <NUM> (<FIG>) and the internal computer <NUM> (<FIG>). In some embodiments, the real-time intensity of the magnetic field <NUM> may then be compared against the intensity corresponding to the normal operating state and one or more predetermined intensity thresholds. The predetermined intensity thresholds may correspond to a known magnetic field <NUM> and associated field distortion <NUM> resulting from a predetermined position (status) of the one or more component parts, which may might indicate when the manual knife bailout system of the surgical tool <NUM> (<FIG>) has been activated or is about to be activated. The predetermined intensity thresholds that may be stored in the memory of the computer system <NUM> or the internal memory <NUM> (<FIG>) of the internal computer <NUM>. The predetermined position of the one or more component parts can include, but is not limited to, <NUM>) the bailout tool <NUM> and the bailout panel <NUM> are present, <NUM>) the bailout tool <NUM> is present but the bailout panel <NUM> is removed, <NUM>) the bailout panel <NUM> is present but the bailout tool <NUM> is removed, <NUM>) both the bailout tool <NUM> and the bailout panel <NUM> are removed, <NUM>) the firing rod <NUM> is located in an extended position, and <NUM>) the firing rod <NUM> is located in an retracted position.

In <FIG>, the bailout tool <NUM>, the bailout panel <NUM>, and the firing rod <NUM> have each been physically moved relative to the drive housing <NUM> and the magnetic field <NUM>, and the field distortions <NUM> caused by the magnetically responsive material <NUM> corresponding to each component part has correspondingly changed. In the illustrated scenario, the bailout tool <NUM> and the bailout panel <NUM> have each been moved out of the range of the magnetic field <NUM>, thus eliminating any field distortions <NUM> that might be attributable to the presence of the bailout tool <NUM> and the bailout panel <NUM>. In such cases, the measured intensity of the magnetic field <NUM> will correspondingly change, which may provide a positive indication that the bailout tool <NUM> and the bailout panel <NUM> have each been removed from the drive housing <NUM>. Moreover, in the illustrated scenario, the firing rod <NUM> has moved proximally A, which also alters the resulting field distortions <NUM> and the measured intensity of the magnetic field <NUM>, which may provide a positive indication that the firing rod <NUM> has moved to the retracted position (state).

If the computer system <NUM> (<FIG>) determines that the manual knife bailout system has been activated, the computer system <NUM> (<FIG>) may be programmed and otherwise configured to notify the user (i.e., a surgeon, a scrub nurse, etc.) of the status change. In some embodiments, the notification may comprise a visual notification provided on the visual display <NUM> (<FIG>), but in other embodiments the notification may be audible or tactile (i.e., felt through the user input devices held by the surgeon). In at least one embodiment, the notification may provide the user with instructions on how to successfully complete the manual knife bailout procedure or otherwise instructions on how to reverse commencement of the bailout procedure (e.g., instructions on how to replace the bailout tool <NUM> and/or the bailout panel <NUM>).

If it is determined that one or more of the component parts of the manual knife bailout system is missing and otherwise outside of the range of the magnetic field <NUM>, the computer system <NUM> (<FIG>) may further be programmed and otherwise configured to send an alert or notice to ensure an accurate accounting for the missing objects. This may prove advantageous in avoiding potential loss of tool objects or parts in the patient.

While the preceding discussion mentions the bailout tool <NUM>, the bailout panel <NUM>, and the firing rod <NUM> as component parts of the manual knife bailout system that may affect the magnetic field <NUM>, the manual knife bailout system may include additional component parts including, but not limited to various gears, racks, levers, etc. included within the drive housing <NUM>. Accordingly, the present disclosure contemplates that any of the gears, racks, levers, etc. may be made of the magnetically responsive material <NUM>, or alternatively, the magnetically responsive material <NUM> may be attached thereto and equally affect the magnetic field <NUM> to indicate activation of the manual knife bailout system. Moreover, the principles of the present disclosure are not limited to monitoring the manual knife bailout system, but may alternatively be applied to other mechanisms or devices included in the drive housing <NUM>. In such embodiments, each mechanism or device may have its own predetermined intensity thresholds that will trigger tool-dependent responses when the magnetic field <NUM> is distorted.

Instead of measuring the intensity of the magnetic field <NUM> on the second inductor coil 728b to determine when the component parts of the manual knife bailout system are present or removed, it is also contemplated herein to measure the electromotive force (i.e., voltage or current) generated in the second inductor coil 728b. Alternatively, the phase delay of the magnetic field <NUM> may be measured to determine when the component parts of the manual knife bailout system are present or removed.

<FIG> illustrates an example embodiment of the computer system <NUM> of <FIG>. As shown, the computer system <NUM> includes one or more processors <NUM>, which can control the operation of the computer system <NUM>. "Processors" are also referred to herein as "controllers. " The processor(s) <NUM> can include any type of microprocessor or central processing unit (CPU), including programmable general-purpose or special-purpose microprocessors and/or any one of a variety of proprietary or commercially available single or multi-processor systems. The computer system <NUM> can also include one or more memories <NUM>, which can provide temporary storage for code to be executed by the processor(s) <NUM> or for data acquired from one or more users, storage devices, and/or databases. The memory <NUM> can include read-only memory (ROM), flash memory, one or more varieties of random access memory (RAM) (e.g., static RAM (SRAM), dynamic RAM (DRAM), or synchronous DRAM (SDRAM)), and/or a combination of memory technologies.

The various elements of the computer system <NUM> can be coupled to a bus system <NUM>. The illustrated bus system <NUM> is an abstraction that represents any one or more separate physical busses, communication lines/interfaces, and/or multi-drop or point-to-point connections, connected by appropriate bridges, adapters, and/or controllers. The computer system <NUM> can also include one or more network interface(s) <NUM>, one or more input/output (IO) interface(s) <NUM>, and one or more storage device(s) <NUM>.

The network interface(s) <NUM> can enable the computer system <NUM> to communicate with remote devices, e.g., other computer systems, over a network, and can be, for non-limiting example, remote desktop connection interfaces, Ethernet adapters, and/or other local area network (LAN) adapters. The IO interface(s) <NUM> can include one or more interface components to connect the computer system <NUM> with other electronic equipment. For non-limiting example, the IO interface(s) <NUM> can include high speed data ports, such as universal serial bus (USB) ports, <NUM> ports, Wi-Fi, Bluetooth, etc. Additionally, the computer system <NUM> can be accessible to a human user, and thus the IO interface(s) <NUM> can include displays, speakers, keyboards, pointing devices, and/or various other video, audio, or alphanumeric interfaces. The storage device(s) <NUM> can include any conventional medium for storing data in a non-volatile and/or non-transient manner. The storage device(s) <NUM> can thus hold data and/or instructions in a persistent state, i.e., the value(s) are retained despite interruption of power to the computer system <NUM>. The storage device(s) <NUM> can include one or more hard disk drives, flash drives, USB drives, optical drives, various media cards, diskettes, compact discs, and/or any combination thereof and can be directly connected to the computer system <NUM> or remotely connected thereto, such as over a network. In an exemplary embodiment, the storage device(s) <NUM> can include a tangible or non-transitory computer readable medium configured to store data, e.g., a hard disk drive, a flash drive, a USB drive, an optical drive, a media card, a diskette, a compact disc, etc..

The elements illustrated in <FIG> can be some or all of the elements of a single physical machine. In addition, not all of the illustrated elements need to be located on or in the same physical machine. Exemplary computer systems include conventional desktop computers, workstations, minicomputers, laptop computers, tablet computers, personal digital assistants (PDAs), mobile phones, and the like.

The computer system <NUM> can include a web browser for retrieving web pages or other markup language streams, presenting those pages and/or streams (visually, aurally, or otherwise), executing scripts, controls and other code on those pages/streams, accepting user input with respect to those pages/streams (e.g., for purposes of completing input fields), issuing HyperText Transfer Protocol (HTTP) requests with respect to those pages/streams or otherwise (e.g., for submitting to a server information from the completed input fields), and so forth. The web pages or other markup language can be in HyperText Markup Language (HTML) or other conventional forms, including embedded Extensible Markup Language (XML), scripts, controls, and so forth. The computer system <NUM> can also include a web server for generating and/or delivering the web pages to client computer systems.

In an exemplary embodiment, the computer system <NUM> can be provided as a single unit, e.g., as a single server, as a single tower, contained within a single housing, etc. The single unit can be modular such that various aspects thereof can be swapped in and out as needed for, e.g., upgrade, replacement, maintenance, etc., without interrupting functionality of any other aspects of the system. The single unit can thus also be scalable with the ability to be added to as additional modules and/or additional functionality of existing modules are desired and/or improved upon.

The computer system <NUM> can also include any of a variety of other software and/or hardware components, including by way of non-limiting example, operating systems and database management systems. Although an exemplary computer system is depicted and described herein, it will be appreciated that this is for the sake of generality and convenience. In other embodiments, the computer system may differ in architecture and operation from that shown and described here.

Each of embodiments A, B, and C may have one or more of the following additional elements in any combination: Element <NUM>: wherein the magnetically responsive material comprises a magnetically responsive material selected from the group consisting of conductive metal, a conductive polymer, graphite, carbon fibers, and any combination thereof. Element <NUM>: wherein the drive housing further includes an internal computer in communication with the second inductor coil and programmed to process the intensity of the magnetic field and the change in the field distortion. Element <NUM>: wherein the computer system is programmed to provide a notification when the change in the field distortion is detected. Element <NUM>: wherein the notification comprises a visual notification provided on a visual display. Element <NUM>: wherein the notification comprises an audible or tactile notification. Element <NUM>: wherein the one or more component parts of the drive housing form part of a manual knife bailout system, and wherein the measuring the change in the field distortion provides an indication that the manual knife bailout system has been activated.

Element <NUM>: wherein the drive housing further includes an internal computer in communication with the second inductor coil, the method further comprising processing the intensity of the magnetic field and the change in the field distortion with the internal computer. Element <NUM>: further comprising providing a notification with the computer system when the change in the field distortion is detected. Element <NUM>: further comprising providing a visual notification on a visual display in communication with the computer system. Element <NUM>: wherein providing the notification comprises providing an audible or tactile notification. Element <NUM>: wherein measuring the intensity of the magnetic field and the field distortion comprises measuring the intensity and the field distortion upon inductively coupling the drive housing to the tool driver. Element <NUM>: wherein measuring the intensity of the magnetic field and the field distortion comprises measuring the intensity and the field distortion prior to inductively coupling the drive housing to the tool driver, and storing the intensity and the field distortion within a memory of an internal computer included in the drive housing. Element <NUM>: wherein detecting the change in the field distortion comprises comparing the change in the field distortion with a predetermined intensity threshold corresponding to a known magnetic field and a known field distortion resulting from a predetermined position of the one or more component parts, and matching the change in the field distortion with the predetermined intensity threshold.

Element <NUM>: wherein the magnetically responsive material comprises a magnetically responsive material selected from the group consisting of conductive metal, a conductive polymer, graphite, carbon fiber, and any combination thereof. Element <NUM>: wherein the bailout tool is stored within the drive housing and accessible by removing the bailout panel. Element <NUM>: wherein the drive housing further includes a bailout cap and the bailout tool is matable with the bailout cap, and wherein rotating the bailout tool correspondingly rotates the bailout cap, which causes the firing rod to translate longitudinally. Element <NUM>: wherein the computer system is programmed to provide a notification when the change in the field distortion is detected.

By way of non-limiting example, exemplary combinations applicable to A, B, and C include: Element <NUM> with Element <NUM>; Element <NUM> with Element <NUM>; Element <NUM> with Element <NUM>; and Element <NUM> with Element <NUM>.

Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of" or "consist of" the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the elements that it introduces.

Claim 1:
A robotic surgical tool (<NUM>), comprising:
a tool driver (<NUM>) in communication with a computer system (<NUM>);
a drive housing (<NUM>) mountable to the tool driver and including one or more component parts made of or including a magnetically responsive material, characterized in that the surgical tool further comprises:
a first inductor coil (728a) included on the tool driver and configured to generate a magnetic field;
a second inductor coil (728b) included on the drive housing and configured to measure an intensity of the magnetic field and a field distortion caused by the one or more component parts,
wherein a change in the field distortion provides an indication of movement of the one or more component parts.