Patent ID: 12251107

DETAILED DESCRIPTION

Particular embodiments of the present surgical instruments are described hereinbelow with reference to the accompanying drawings; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure and may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure. Well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in any unnecessary detail.

While the following disclosure is presented with respect to a linear surgical stapler where staples are sequentially fired, it should be understood that features of the presently described surgical instruments may be readily adapted for use in any type of surgical clamping, cutting, or sealing instruments. The surgical clamping and cutting instrument may be a minimally invasive (e.g., laparoscopic) instrument or an instrument used for open surgery.

Additionally, the features of the presently described surgical stapling instruments may be readily adapted for use in surgical instruments that are activated using any technique within the purview of those skilled in the art, such as, for example, manually activated surgical instruments, powered surgical instruments (e.g., electro-mechanically powered instruments), robotic surgical instruments, and the like.

FIG.1is a perspective view of an illustrative surgical instrument100in accordance with embodiments of the present disclosure having a handle assembly102, and an end effector110mounted on an elongated shaft106. End effector110includes a stationary jaw111and a moveable jaw112. Handle assembly102includes a stationary handle102aand a moveable handle102bwhich serves as an actuator for surgical instrument100.

In certain embodiments, handle assembly102may include input couplers (not shown) instead of, or in addition to, the stationary and movable handles. The input couplers provide a mechanical coupling between the drive tendons or cables of the instrument and motorized axes of the mechanical interface of a drive system. The input couplers may interface with, and be driven by, corresponding output couplers (not shown) of a telesurgical surgery system, such as the system disclosed in U.S. Pub. No. 2014/0183244A1, the entire disclosure of which is incorporated by reference herein. The input couplers are drivingly coupled with one or more input members (not shown) that are disposed within the instrument shaft106. The input members are drivingly coupled with the end effector110. Suitable input couplers can be adapted to mate with various types of motor packs (not shown), such as the stapler-specific motor packs disclosed in U.S. Pat. No. 8,912,746, or the universal motor packs disclosed in U.S. Pat. No. 8,529,582, the disclosures of both of which are incorporated by reference herein in their entirety. Further details of known input couplers and surgical systems are described, for example, in U.S. Pat. Nos. 8,597,280, 7,048,745, and 10,016,244. Each of these patents is hereby incorporated by reference in its entirety.

Actuation mechanisms of surgical instrument100may employ drive cables that are used in conjunction with a system of motors and pulleys. Powered surgical systems, including robotic surgical systems that utilize drive cables connected to a system of motors and pulleys for various functions including opening and closing of jaws, as well as for movement and actuation of end effectors are well known. Further details of known drive cable surgical systems are described, for example, in U.S. Pat. Nos. 7,666,191 and 9,050,119 both of which are hereby incorporated by reference in their entireties. While described herein with respect to an instrument configured for use with a robotic surgical system, it should be understood that the wrist assemblies described herein may be incorporated into manually actuated instruments, electro-mechanical powered instruments, or instruments actuated in any other way.

FIG.2shows the distal end portion of surgical instrument100, including an end effector110defining a longitudinal axis X-X and having a first jaw111, a second jaw112, a clevis140for mounting jaws111,112to the instrument, and an articulation mechanism, such as a wrist assembly160. In certain embodiments, second jaw112is a movable jaw configured to move from an open position to a closed position relative to first jaw111. In other embodiments, first jaw111is a movable jaw configured to move between open and closed positions relative to second jaw112. In still other embodiments, both jaws111,112are movable relative to each other. First jaw111includes an anvil115having staple-forming pockets116. In the exemplary embodiment, first jaw112is a movable jaw112configured to move from an open position to a closed position relative to stationary jaw111. In the open position, a fresh stapler cartridge122(sometimes referred to as a fresh or unfired reload) can be loaded into movable jaw112and tissue may be positioned between the jaws111,112. In the closed position, jaws111,112cooperate to clamp tissue such that stapler cartridge122and the anvil115are in close cooperative alignment.

As shown inFIG.3, stapler cartridge122may include a plurality of staples124supported on corresponding staple drivers126provided within respective staple retention openings127formed in stapler cartridge122. As shown inFIG.8, end effector110may also include a drive member150configured to translate distally and retract proximally through the end effector, the drive member may have a shuttle123integrally formed thereon including an inclined distal portion125that sequentially acts on staple drivers126upon distal movement of the drive member150, camming staple drivers126upwardly, thereby moving staples124into deforming contact with anvil115. In embodiments, shuttle123may be included within stapler cartridge122as a separate component. In embodiments, stapler cartridge122further includes one or more switches configured to engage a slot196formed on the proximal tail195of stapler cartridge122. The functionality of switches191will be described in more detail below. As seen inFIG.8, drive member150includes an upper shoe152that is substantially aligned with and translates through a channel in fixed jaw111(seeFIG.2), while lower shoe154, also seen inFIG.8, of drive member150translates through and underneath jaw112. The details of the drive member and actuation will be described below.

FIG.4shows a portion of an illustrative surgical instrument with an unfired reload installed, including portions of stapler cartridge122, a locking member170, and switch191.

When an unfired reload is installed, as shown inFIG.4, switch191is in a first home (or default) position. In a fresh, unfired reload, switch191is in contact with switch engaging portion172of locking member170, keeping engagement portion174out of channel119. When locking member170is in this disabled position, distal translation of drive member150is permitted, as locking member170will not obstruct movement of drive member150because engagement portion174is held out of alignment with channel119.

FIGS.5and6show a top view of a locking assembly including a locking member170in the unlocked or disabled position and the locked position, respectively with switch191not shown.

Locking member170pivots about a pivot point179that is laterally offset from channel119. Locking member170is configured to move in a direction substantially perpendicular to the longitudinal axis of the end effector. Spring178biases engagement portion174of locking member170into channel119to lock the instrument. In the unlocked position ofFIG.5, switch191(seeFIG.4) engages switch engaging portion172of locking member170, overcoming the bias of spring178and holding engagement portion174out of channel119, permitting distal movement of drive member150. When switch191is no longer in contact with switch engaging portion172of locking member170, spring178forces engagement portion174of locking member into channel119as seen inFIG.6, where engagement portion174obstructs distal movement of drive member150.

FIG.7shows a view of an end effector in accordance with the embodiment ofFIG.4including a lockout assembly in accordance with the embodiment ofFIG.5. InFIG.7, a fresh reload has been installed, and switch191is in the initial position. Locking member170is held by switch191out of channel119so that, upon actuation, drive member150may be advanced distally along channel119. As shown inFIG.7, upon distal translation of drive member150during actuation of the instrument, a chamfered surface131formed on drive member150(as seen inFIG.8) engages a chamfered surface192formed on switch191(as seen inFIG.9). Switch191is then driven through a switch channel129in a direction substantially perpendicular to the longitudinal axis of end effector110.

InFIG.10, switch191is shown in the initial position within switch channel129(seeFIG.7). Switch channel129includes a series of detents132configured to provide mechanical resistance that must be overcome by drive member150in order to slide switch191from the initial position toward the second position, shown inFIG.11. This ensures that the lockout will not unintentionally activate as may happen if switch191freely slides in channel129(e.g., in the absence of detents132). In embodiments, switch191may secured by friction fit within switch channel129. As best seen in previously describedFIG.7, while drive member150translates distally along the longitudinal axis defined by end effector110, switch191moves laterally through channel129in a direction perpendicular to the axis. This allows switch191to be retained the within end effector110on a side that is opposite locking member170, such that switch191and locking member170do not have to compete for space within end effector110, allowing for maintenance of reduced instrument size.

InFIG.12drive member150has translated distally, forcing switch191to the second position thereby enabling locking member170as spring178biases engagement portion174of locking member170into channel119. Drive member150may continue to travel distally to drive staples into tissue and cut the stapled tissue. Upon retraction, drive member150engages a series of proximal ramped surfaces176on locking member170, allowing drive member150to return to a position proximal of locking member170. However, once drive member150is positioned proximally of locking member170, if another attempt is made to actuate the instrument, drive member150will be obstructed by engagement portion174of locking member150, preventing actuation of an unloaded instrument, as best seen inFIGS.13and14.

FIG.15shows a series of illustrative cartridges having a switch191in the initial position at various axial positions on the respective tail195of each stapler cartridge122. In embodiments, the axial position of switch191may function as a mechanism by which a robotic surgical system may identify the type of stapler cartridge installed. As drive member150translates through the end effector, it will encounter the switch at a distinct axial position for a given type of stapler cartridge. When the drive member encounters the switch, the drive member will encounter a detectable amount of resistance. In embodiments, a robotic surgical system may be configured to detect the position along a firing stroke at which the chamfered surface131formed on drive member150engages switch191via detection of a torque spike, allowing the system to determine the type of stapler cartridge installed. This will allow a control unit, operatively coupled with the actuation mechanism, to determine the correct amount of forces to apply to the drive member depending upon the features of the detected type of stapler cartridge, including but not limited to, the number of staples contained therein, the size of the staples contained therein, and the geometry of the staples contained therein. An exemplary surgical stapler including a surgical system including a control unit operatively coupled to the actuation mechanism is described for example in International Application No. PCT/US2017050747, the disclosure of which is hereby incorporated by reference in its entirety.

Jaws111,112are attached to surgical instrument100via clevis140. See,FIG.16. Clevis140includes a proximal surface140aand a distal surface140b. Clevis140further includes upper clevis portion142and lower clevis portion141that cooperate when assembled to form protrusion145(seeFIG.20A) configured to engage tabs113(seen in inFIG.20Aof jaw111to securely mount jaw111in a fixed position on instrument100. As seen inFIG.16, Lower clevis portion141includes a pair of distally extending arms147for supporting movable jaw112. Arms147include opening149for receiving a pivot pin130defining a pivot axis around which jaw112pivots as described in more detail below. Lower clevis portion141also includes ramped groove144configured to guide a portion of an actuation coil120(seeFIG.19A) emerging from wrist160(seeFIG.17). Upper clevis portion142includes a complementary shaped ramped groove146that cooperates with ramped groove144of lower clevis portion141to form an enclosed channel180that guides coil120as it jogs upwards from wrist160towards distal surface157of upper shoe152of drive member150. In embodiments, channel180may include a first end181at a central portion of proximal surface140aand a second end182at a peripheral portion of distal surface140b. In embodiments, enclosed channel180may be substantially “S” shaped. Although shown as a two-part clevis, it should be understood that the clevis may be a unitary structure formed, for example, by molding, machining, 3-D printing, or the like.

End effector110may be articulated in multiple directions by an articulation mechanism. In embodiments, the articulation mechanism may be a wrist160as shown, although other articulation mechanisms are contemplated. As seen inFIG.17, wrist160includes a plurality of articulation joints162,164,166, etc. that define a bore167through which an actuation mechanism (in embodiments, coil120and drive cable171, see FIG.19A) may pass. Upon exiting articulation wrist160, coil120enters and passes through channel180of clevis140(seeFIG.18), ultimately engaging proximal surface153of upper shoe152of drive member150. Other articulation mechanisms within the purview of those skilled in the art may substitute for wrist160. One suitable articulation mechanism is described for example in U.S. Publication No. 2015/0250530, the disclosure of which is hereby incorporated by reference in its entirety.

Upon actuation of the surgical instrument, drive member150is advanced distally through end effector110to move jaws111,112from the open position to the closed position, after which shuttle123and knife128are advanced distally through cartridge122to staple and cut tissue grasped between jaws111,112. Drive member150may be any structure capable of pushing at least one of a shuttle or a knife of a surgical stapling instrument with the necessary force to effectively sever or staple human tissue. Drive member150may be an I-beam, an E-beam, or any other type of drive member capable of performing similar functions. Drive member150is movably supported on the surgical stapling instrument100such that it may pass distally through cartridge122and upper fixed jaw111and lower jaw112when the surgical stapling instrument is fired (e.g., actuated).

As seen inFIG.18, drive member150may include a body151, upper shoe152, lower shoe154, and central portion156. Upper shoe152of drive member150is substantially aligned with and translates through a channel118in fixed jaw111, while lower shoe154of drive member150is substantially aligned with and translates through a channel119and below jaw112. Bore158is formed through upper shoe152to receive drive cable171as will be described in more detail below. Proximal surface153of upper shoe152is configured to be engaged by a coil120of actuation assembly190such that coil120may apply force to upper shoe152to advance drive member150distally, i.e., in the direction of arrow “A” inFIG.19B. A knife128may be formed on drive member150along the distal edge between upper shoe152and central portion156. In embodiments, inclined distal portions125may be formed on either side of drive member150.

Actuation assembly190includes a drive cable171, a coil120, a sheath121surrounding coil120, and a drive rod175. Drive cable171includes an enlarged distal end173.

As seen inFIGS.19A and19B, upper shoe152of drive member150includes a bore158into which drive cable171is routed. When assembling illustrative surgical instrument100, coil120and a protective sheath121are slipped over the free end of drive cable171. The free end of drive cable171is attached to a drive rod175securing coil120and the protective sheath121between drive member150and drive rod175as seen inFIG.19B. Sheath121may function to promote stability, smooth movement, and prevent buckling upon actuation of surgical instrument100. Sheath121may be made from polyimide, or any other suitable material having the requisite strength requirements such as various reinforced plastics, a nickel titanium alloy such as NITINOL™, poly para-phenyleneterphtalamide materials such as KEVLAR™ commercially available from DuPont. Other suitable materials may be envisioned by those of skill in the art. Enlarged distal end173of drive cable171resides within an enlarged distal portion159of bore158in upper shoe152of body150, such that the proximal face157of enlarged distal end173may apply a retraction force on upper shoe152when the drive cable171is pulled proximally, i.e., in the direction of arrow “B” inFIG.19B. Drive rod175is operationally connected to an actuator (e.g., movable handle102b), which allows distal translation and proximal retraction of actuation assembly190. Those skilled in the art will recognize that in a manually actuated instrument, the actuator may be a movable handle, such as moveable handle102bshown inFIG.1; in a powered instrument the actuator may be a button (not shown) that causes a motor to act on the drive rod; and in a robotic system, the actuator may be a control device such as the control devices described below in connection withFIG.28. Any suitable backend actuation mechanism for driving the components of the surgical stapling instrument may be used. For additional details relating to exemplary actuation mechanisms using push/pull drive cables see, e.g., commonly owned International Application WO 2018/049217, the disclosure of which is hereby incorporated by reference in its entirety.

During actuation of illustrative surgical instrument100, drive rod175applies force to coil120, thereby causing coil120to apply force to upper shoe152of drive member150, translating it distally (i.e., in the direction of arrow “A” inFIG.19B) initially closing jaws111,112and then ejecting staples124from cartridge122to staple tissue. After stapling is complete, drive rod175applies a force in the proximal direction to effect retraction of drive member. During retraction, enlarged distal end173of drive cable171is obstructed by wall157of enlarged portion159of bore158, causing drive cable171to apply force to upper shoe152of drive member150, thereby translating drive member150in the proximal direction. In certain embodiments, the surgical instrument may be designed such that the drive member150is not retracted in the proximal direction after the staples have been fired. One of ordinary skill in the art will appreciate that drive member150, drive cable171, and drive rod175all move in unison and remain in the same relative position to each other.

In the preferred embodiment, drive cable171advances drive member150through fixed jaw111(instead of through the staple cartridge jaw as in conventional surgical stapling instruments). Eliminating the internal channel for the actuation mechanism from the staple cartridge provides more space in the cartridge for the staples and for the reinforcing wall discussed above. In alternative embodiments, coil120of actuation assembly190may be coupled with lower shoe154instead of upper shoe152. In these embodiments, coil120applies force to lower shoe153to advance drive member150distally through a channel (not shown) in the lower jaw112. In these embodiments, coil120will advance at least through a portion of lower jaw112and staple cartridge122.

FIGS.20A-Cdepict fixed jaw111and movable jaw112of illustrative surgical instrument100sequentially moving from an open configuration to a closed configuration. As shown inFIG.20A, in the open configuration, drive member150is positioned proximally of cam surface114formed on movable jaw112. As drive member150translates in the distal direction “A” movable jaw112will rotate towards the closed position around pivot117.

InFIG.20B, drive member150has come into contact with cam surface114of movable jaw112. As lower portion154of drive member150rides underneath cam surface114, drive member150pushes movable jaw112, causing it to pivot towards the closed position.

FIG.20Cillustrates jaws111,112in the closed position. Drive member150has translated distally past cam surface114. In this position, tissue is clamped, and further advancement of the drive member will sever and staple tissue.

FIG.21illustrates an alternative embodiment in which an illustrative end effector210has a stapler cartridge222installed therein. Stapler cartridge222includes an annular pin280configured to be engaged by an inclined distal portion225of an illustrative shuttle223. It is envisioned that shuttle223may be a separate component contained in stapler cartridge222, or integrally formed on a drive member250as seen inFIG.22.

FIGS.22-26sequentially depict actuation of a surgical instrument including the illustrative end effector and reload shown inFIG.21.

InFIG.22, stapler cartridge222includes annular pin280in an unraised position corresponding to a freshly installed reload. Upon actuation, a drive member250(as shown inFIG.27) is driven distally through end effector210. Drive member250may have an integrated shuttle component223having inclined distal portions225attached thereto. InFIG.23, an inclined distal portion225of shuttle223engages a lower ramped portion282of annular pin280applying sufficient force to cause annular pin280to be pushed through a cartridge channel290towards a raised position.

InFIG.24, drive member250has translated distally such that shuttle223has fully engaged and moved annular pin280into the raised position. When annular pin280is in the raised position, drive member250may pass under annular pin280to continue to translate distally to sequentially fire staples and cut tissue.

FIGS.25and26show the mechanism by which annular pin280is retained within cartridge222once moved into the raised position. Annular pin280may have one or more undercuts284formed on either side of annular pin280. In embodiments, annular pin280may include an upper undercut285, a middle undercut286, and a lower undercut287. Before being contacted by inclined distal portion225, annular pin280is retained within cartridge channel290by engagement of the upper undercut285with an upper edge293of an interference ring295formed within cartridge channel290. In embodiments, any interferences structure of a suitable shape or size may be used to retain annular pin280in channel290. Channel281may include one or more interference rings295as desired. InFIG.20, as inclined distal portion225urges annular pin280upwards, an amount of force is needed to push middle undercut286upward with enough force to be driven past a lower edge292of interference ring295.

InFIG.26, annular pin280has been moved into the raised position in which middle undercut286is now above and resting on upper edge293of interference ring295, retaining annular pin280within cartridge channel290out of the path of shuttle223of drive member250.

In embodiments, robotic surgical system may be configured to detect the position along a firing stroke at which the inclined distal portion225of shuttle223engages annular pin280via detection of a torque spike, allowing the system to determine the type of reload presently installed. Based on the detected torque spike, a control unit, operatively coupled with the actuation mechanism, may read and process the detectable force to determine the correct amount of force to apply to the drive member in a similar fashion as described above in connection with previously described embodiments. In embodiments, the position of the annular pin and the position of channel291and its associated retention features may be moved proximally within different types of reload configured to be installed within cartridge222to provide for a unique contact point between annular pin280and inclined distal portion225as best seen inFIG.26A. Thus, a surgical system may identify the detectable force at a different axial position along the firing stroke, thus allowing the system to differentiate between different types of reloads installed in a given cartridge222based on the position of annular pin280. It is envisioned that drive member250may include any structure capable of engaging annular pin280at a given axial position to create a detectable resistance, so long as the accompanying interference structure described above is modified to complement the direction in which annular pin280is driven upon engagement by drive member250. It is also envisioned that an annular pin may engage and maintain a locking member in a disabled position in a similar manner as switch191described in connection with previous embodiments in a first position, and may then disengage with the locking member upon actuation to allow the locking member to pivot to a locked position, prevent actuation in the presence of a spent cartridge.FIGS.27and28illustrate a feature for stabilizing drive member250upon actuation of a surgical instrument including an annular pin280. As inclined distal portion225engages annular pin280as described above, shuttle223and drive member250experience a downward force that causes shuttle223to deflect away from annular pin280. When drive member250and shuttle223experience vertical load, a protrusion255formed on shuttle223pushes against an inner wall221formed within a channel of jaw member211(above lower shoe254) providing a counter force. Inner wall221and the counter force it provides reduces the deflection of shuttle223and drive member250, ensuring more controlled engagement between annular pin280and shuttle223and limiting potential stress or damage to drive member250from excessive deflection or bending.

In embodiments, an illustrative end effector210may include both an annular pin280for reload detection, and a switch261for engaging a locking member270. InFIGS.29and30, an illustrative end effector210including an annular pin280on one side of a stapler cartridge222, and a switch261on the opposing side of stapler cartridge222. Annular pin280functions as described above in connection withFIGS.24-26. InFIG.29, a locking member270includes an engagement portion274that is being held out of channel219through which drive member250travels distally. A spring278biases locking member270towards channel219, however, switch261engages a distal portion272of locking member270, retaining the proximal engagement portion out of alignment with channel219.FIG.30depicts locking member270with engagement portion274protruding into channel219to obstruct drive member250after actuation of the instrument. Switch261has been moved into a raised position, and distal portion272of locking member has now moved out of channel219towards a position below switch261, thereby causing engagement portion274to translate towards channel219. In this configuration, an attempt to actuate the instrument again would cause drive member250to be obstructed by engagement portion274of lock270.

FIGS.31and32show cross sectional views depicting actuation within the end effector ofFIGS.29and30.

InFIG.31, drive member250is able to translate through channel219(as seen inFIG.30) unobstructed, as locking member270is being held out of engagement with channel219by switch261as it sits in the unraised position.FIG.31further shows inclined distal portion225aligned with, and about to engage, a cutout262formed on switch261. InFIG.32, switch261has been driven to the raised position, allowing distal portion272of locking member270to swing underneath switch261, causing the proximal engagement portion274of locking member270to swing in an opposing direction towards channel219. Should a user retract drive member250and attempt to actuate the surgical instrument, engagement portion274(now aligned with drive member250within channel219) of locking member270would obstruct drive member250and prevent cutting of tissue or firing of staples.

In embodiments, surgical instruments in accordance with this disclosure may alternatively include switches configured to be sheared along an axis, or switches having vertical cutouts designed to be engaged by an inclined distal portion of a drive member for purposes of engaging a lockout assembly, providing for reload recognition, or both, as described in U.S. Provisional Application No. 62/783,429, the entire disclosure of which is incorporated herein by reference.

FIG.33illustrates, as an example, a top view of an operating room employing a robotic surgical system. The robotic surgical system in this case is a robotic surgical system300including a Console (“C”) utilized by a Surgeon (“S”) while performing a minimally invasive diagnostic or surgical procedure, usually with assistance from one or more Assistants (“A”), on a Patient (“P”) who is lying down on an Operating table (“O”).

The Console includes a monitor304for displaying an image of a surgical site to the Surgeon, left and right manipulatable control devices308and309, a foot pedal305, and a processor302. The control devices308and309may include any one or more of a variety of input devices such as joysticks, gloves, trigger-guns, hand-operated controllers, or the like. The processor302may be a dedicated computer that may be integrated into the Console or positioned next to it.

The Surgeon performs a minimally invasive surgical procedure by manipulating the control devices308and309(also referred to herein as “master manipulators”) so that the processor302causes their respectively associated robotic arm assemblies,328and329, (also referred to herein as “slave manipulators”) to manipulate their respective removably coupled surgical instruments338and339(also referred to herein as “tools”) accordingly, while the Surgeon views the surgical site in 3-D on the Console monitor304as it is captured by a stereoscopic endoscope340.

Each of the tools338and339, as well as the endoscope340, may be inserted through a cannula or other tool guide (not shown) into the Patient so as to extend down to the surgical site through a corresponding minimally invasive incision such as incision366. Each of the robotic arms is conventionally formed of links, such as link362, which are coupled together and manipulated through motor controlled or active joints, such as joint363.

The number of surgical tools used at one time and consequently, the number of robotic arms being used in the system300will generally depend on the diagnostic or surgical procedure and the space constraints within the operating room, among other factors. If it is necessary to change one or more of the tools being used during a procedure, the Assistant may remove the tool no longer being used from its robotic arm, and replace it with another tool331from a Tray (“T”) in the operating room.

The monitor304may be positioned near the Surgeon's hands so that it will display a projected image that is oriented so that the Surgeon feels that he or she is actually looking directly down onto the operating site. To that end, images of the tools338and339may appear to be located substantially where the Surgeon's hands are located.

The processor302performs various functions in the system300. One function that it performs is to translate and transfer the mechanical motion of control devices308and309to their respective robotic arms328and329through control signals over bus310so that the Surgeon can effectively manipulate their respective tools338and339. Another important function is to implement various control system processes as described herein.

Although described as a processor, it is to be appreciated that the processor302may be implemented in practice by any combination of hardware, software and firmware. Also, its functions as described herein may be performed by one unit, or divided up among different components, each of which may be implemented in turn by any combination of hardware, software and firmware.

For additional details on robotic surgical systems, see, e.g., commonly owned U.S. Pat. Nos. 6,493,608, 6,671, and International Application WO 2017/132611. Each of these disclosures is herein incorporated in its entirety by this reference.

FIG.34illustrates, as an example, a side view of a simplified (not necessarily in proportion or complete) illustrative robotic arm assembly400(which is representative of robotic arm assemblies328and329) holding a surgical instrument450(which is representative of tools338and339) for performing a surgical procedure. The surgical instrument450is removably held in tool holder440. The arm assembly400is mechanically supported by a base401, which may be part of a patient-side movable cart or affixed to the operating table or ceiling. It includes links402and403which are coupled together and to the base401through setup joints404and405.

The setup joints404and405in this example are passive joints that allow manual positioning of the arm400when their brakes are released. For example, setup joint404allows link402to be manually rotated about axis406, and setup joint405allows link403to be manually rotated about axis407.

Although only two links and two setup joints are shown in this example, more or less of each may be used as appropriate in this and other robotic arm assemblies in conjunction with the present disclosure. For example, although setup joints404and405are useful for horizontal positioning of the arm400, additional setup joints may be included and useful for limited vertical and angular positioning of the arm400. For major vertical positioning of the arm400, however, the arm400may also be slidably moved along the vertical axis of the base401and locked in position.

The robotic arm assembly400also includes three active joints driven by motors. A yaw joint410allows arm section430to rotate around an axis461, and a pitch joint420allows arm section430to rotate about an axis perpendicular to that of axis461and orthogonal to the plane of the drawing. The arm section430is configured so that sections431and432are always parallel to each other as the pitch joint420is rotated by its motor. As a consequence, the instrument450may be controllably moved by driving the yaw and pitch motors so as to pivot about the pivot point462, which is generally located through manual positioning of the setup joints404and405so as to be at the point of incision into the patient. In addition, an insertion gear445may be coupled to a linear drive mechanism (not shown) to extend or retract the instrument450along its axis463.

Although each of the yaw, pitch and insertion joints or gears,410,420and445, is controlled by an individual joint or gear controller, the three controllers are controlled by a common master/slave control system so that the robotic arm assembly400(also referred to herein as a “slave manipulator”) may be controlled through user (e.g., surgeon) manipulation of its associated master manipulator.

While several embodiments have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. For example, the invention is not limited to the mechanisms described herein for identifying and/or deactivating stapler cartridges. Other suitable devices or mechanisms are described in co-pending and co-owned International Patent Application No. PCT/US19/66513, filed Dec. 16, 2019 and entitled “SURGICAL INSTRUMENTS WITH SWITCHES FOR DEACTIVATING AND/OR IDENTIFYING STAPLER CARTRIDGES”, the complete disclosure of which is herein incorporated by reference in its entirety for all purposes. Therefore, the above description should not be construed as limiting, but merely as exemplifications of presently disclosed embodiments. Thus, the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances. As well, one skilled in the art will appreciate further features and advantages of the present disclosure based on the above-described embodiments. Accordingly, the present disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.