Patent ID: 12257700

DETAILED DESCRIPTION

The present disclosure contemplates various embodiments of rotational stop mechanisms that constrain rotation of components of a tool, such as a shaft of a surgical instrument, within a predefined range of rotational motion. In accordance with the present disclosure, stop mechanisms can exhibit a first state in which rotational motion of the component is permitted in two rotational directions, and a second state in which rotation of the component is constrained in one of the two rotational directions. Movement of the tool component through a predetermined rotational position changes the stop mechanism from the first state to the second state. Stop mechanisms of the present disclosure can further exhibit a third state in which rotational motion of the component is constrained in only the other of the two rotational directions.

Various embodiments of rotational constraint devices of the present disclosure include a rotary device with features configured to interface with one or more complementary features of the rotational component of the tool. In certain embodiments of the disclosure, stop mechanisms optionally include rotary devices that rotate in a direction counter to the direction of rotation of the shaft of the tool, for example, and include one or more features configured to interface with one or more features on the rotating component of the tool, such as the tool shaft. Stop mechanisms according to the present disclosure generally occupy less space circumferentially around the rotating shaft of the tool than other devices for constraining motion. For example, other solutions for constraining rotation of the shaft, such as a collar with one or more inner and outer stop tabs that ride in respective annular grooves in the rotating component and a structure surrounding the rotating component, or a ball bearing that rides in similar grooves, require a structure that entirely surrounds the shaft. In contrast, structures in accordance with the present disclosure do not require a circumferentially surrounding structure and, therefore, portions of the tool can be made smaller in overall diameter compared to other solutions.

In embodiments of the disclosure, the rotary device rotates about an axis parallel to, and offset from, an axis of rotation of the rotatable component of the tool. In other embodiments of the disclosure, the rotary device can be configured to rotate about an axis perpendicular to the axis of rotation of the rotatable component and include similar features and functionality to embodiments in which the rotatable component rotates about an axis parallel to the axis of rotation of the rotatable component.

Referring now toFIG.1, a schematic representing an embodiment of a tool100(such as, for example, a surgical instrument) is shown. While aspects of the present disclosure are discussed in the context of surgical instruments, embodiments of the present disclosure can be used with various tools other than surgical instruments. The tool100includes a transmission mechanism102configured to interface with a manipulating system, such as manipulating systems700or800shown below in connection withFIGS.7and8, respectively. A shaft104extends distally from the transmission mechanism102. An end effector106is coupled to the distal end of the shaft104. In some embodiments, the end effector106can optionally be coupled to the shaft104by one or more articulating joints105that provide one or more degrees of freedom of articulation of the end effector106relative to the shaft104. In embodiments, operation of the end effector106and articulation of the one or more articulating joints105is controlled by the manipulating system (e.g., manipulating system700or800) through the transmission mechanism102, which includes various mechanical and/or electromechanical devices that transmit motion, energy, and/or signals from the manipulating system to the end effector106and/or the one or more articulating joints105.

In embodiments of the present disclosure, the transmission mechanism102is configured to impart a roll motion to the shaft104of the tool100(see, e.g., arrow R depicting rotation of shaft104around its longitudinal axis). In embodiments, a total roll motion of the shaft104must be constrained within a predetermined range of rotational motion to ensure consistent functioning and potentially to avoid damage to components of the transmission mechanism. For example, referring now toFIG.2, in various embodiments, a transmission mechanism202is configured to rotate a shaft204through a system including a capstan210, a pulley212coupled with the shaft204, and at least one drive cable214coupled between the capstan210and the pulley212. In the embodiment ofFIG.2, the capstan210is operably coupled to a motor or other drive device (not shown) in the manipulating system (e.g., manipulating system700or800) when the tool100(FIG.1) is installed on the articulating system.

In some embodiments, such as that ofFIG.2, the at least one drive cable214is attached at a first end to the capstan210and at a second end to the pulley212. The at least one drive cable214can optionally be wrapped at least partially around the capstan210and the pulley212. As the capstan210is rotated by the drive device, the at least one drive cable214pays in or out from the capstan210, rotating the pulley212and the shaft204. Optionally, the at least one drive cable214comprises two drive cables, each wrapped in an opposite direction around the capstan210and pulley212to enable rotation of the pulley212and shaft204in either of two rotational directions. Because the at least one drive cable is not endless (i.e., not in the form of a belt) and is connected at each end to the capstan210and the pulley212, respectively, the shaft204is not capable of continuously rotating as would be possible with a belt-type arrangement. Further, it may be desired to encode the position of the shaft204and provide position information to a user through an interface of the articulating system.

Accordingly, embodiments of the disclosure include mechanisms configured to constrain rotation of the shaft between known rotational endpoints. Various embodiments of rotational constraint devices of the present disclosure include a rotary device with features configured to interface with one or more complementary features of the shaft. As the shaft rotates, the one or more complementary features of the shaft interact with the rotary device to rotate the rotary device between various positions.

For example, referring now toFIG.3, a perspective view of a rotational constraint mechanism316according to an embodiment of the present disclosure is shown. The rotational constraint mechanism includes a rotary device318with a rotational axis AR oriented parallel to and offset from a rotational axis Asof a shaft portion304. The rotary device318includes a first stop surface320, a second stop surface322, and a notch324between the first stop surface320and the second stop surface322. Between the first stop surface320and the notch324is a first profiled portion330, and a second profiled portion332is between the notch324and the second stop surface322. Each of the first and second profiled portions330and332can optionally feature a profile that is complementary to a partial profile of the shaft portion304, as discussed further below. The shaft portion304includes a protrusion326extending from the shaft portion304normal to the rotational axis Asof the shaft portion304. Recesses328are positioned on either side of the protrusion326to facilitate rotation of the rotary device318by allowing portions of the rotary device318around the notch324to enter the recesses328as the rotary device rotates.

Referring now toFIGS.4A-4E, the rotational constraint mechanism316according to the embodiment ofFIG.3is shown in an end view in various states. InFIG.4A, the rotary device318is in a center position. The shaft portion304is also in a center position, i.e., at a rotational midpoint between endpoints of the rotational range of rotational motion of the shaft portion304. In this position, the protrusion326is positioned within the notch324of the rotary device318. The position shown inFIG.4Acan be referred to as a first state in which the shaft portion304is free to rotate in either the clockwise or counter-clockwise directions.

As the shaft portion304begins turning counter-clockwise, as shown in the view ofFIG.4B, the protrusion326bears against an interior surface of the notch324and turns the rotary device318clockwise until the protrusion326exits the notch324. In this position of the rotary device318, the first profiled portion330rests against the outer surface of the shaft portion304. In certain embodiments, the first profiled portion330can have a radiused profile having a radius of curvature equal to the radius of the shaft portion304. This configuration maintains the position of the rotary device318relative to the shaft portion304as the shaft portion304continues to rotate counter-clockwise.

As the shaft portion304turns counter-clockwise beyond the position shown inFIG.4B, the protrusion326eventually contacts the first stop surface320of the rotary device318. Mechanical interference between the protrusion326and the rotary device318at the first stop surface320prevents further rotation of the shaft portion304in the counter-clockwise direction, and the shaft portion304has reached a constrained orientation in which rotation in one direction (i.e., the counter-clockwise direction as viewed inFIG.4C) is prevented. In other words, in the position shown inFIG.4C, rotation of the shaft portion304is constrained to a maximum rotation in at least one rotational direction (i.e., the counter-clockwise direction). The position shown inFIG.4Ccan be referred to as a second state, in which rotation of the shaft portion304is constrained to a maximum rotation in one rotational direction.

A clockwise rotation of the shaft portion304from the orientation shown inFIG.4Creturns the shaft portion304and the rotary device318to the configuration shown inFIG.4A. Rotating the shaft portion304clockwise further from theFIG.4Aposition results in the protrusion326exiting the notch324, and the rotary device318rotates counter-clockwise to the position shown inFIG.4D. The second profiled portion332rests against the shaft portion304, and the rotary device318maintains this position while the shaft portion304is rotated further clockwise to the position shown inFIG.4E. In the position ofFIG.4E, the protrusion326contacts the second stop surface322, and the shaft portion304is prevented from turning further in the clockwise direction. In other words, in the position ofFIG.4E, rotation of the shaft portion304is constrained from rotating further in the clockwise direction. The position ofFIG.4Ecan be referred to as a third state of the stop mechanism, in which rotation of the shaft portion304is constrained to a maximum rotation in the other of the two rotational directions as compared to the second state.

A total distance of rotation between rotational endpoints depends on the configuration of the protrusion326and the rotary device318. In the embodiment ofFIGS.4A-4E, a total distance of rotation between the position shown inFIG.4Cand the position shown inFIG.4Ecan be nearly 720 degrees (two full rotations), such as, for example, 1.5 revolutions (540 degrees) or more, 1.75 revolutions (630 degrees) or more, 690 degrees, or more. Lesser or greater amounts of rotation are within the scope of the disclosure.

Rotations greater than two rotations (720 degrees) are possible by increasing the number of notches and profiled portions of the rotary device. For example, referring now toFIG.5, a rotary device518according to another embodiment includes two notches536,537positioned between first and second stop surfaces520and522. Three profiled portions538are arranged between the first stop surface and the notch536, between the notches536,537, and between the notch537and the second stop surface522. Function of the rotary device518is similar to that of the rotary device318shown inFIGS.4A-4E, but a protrusion (such as protrusion326inFIGS.3and4A-4E) passes through both notches536,537between stop surfaces520and522, and the rotary device518thereby permits a rotational range of rotational motion of greater than two rotations (720 degrees) and can be nearly three rotations (1080 degrees). Greater rotational ranges are possible by further increasing the number of notches and profiled portions, such as 3 notches, 4 notches, 5 notches, etc. Each additional notch and associated profile surface positioned therebetween provides an additional single rotation (i.e., 360 degrees) to the total range of rotational motion.

Referring now toFIGS.6A-6C, another embodiment of a tool600including a rotation stop mechanism is shown in top view. Functionally the embodiment ofFIGS.6A-6Cis similar to the embodiments ofFIGS.3and4A-4E, but in the embodiment ofFIGS.6A-6C, a rotational axis AR of a rotary device618is perpendicular to a rotational axis ASof a tool shaft640. The rotational axis of the rotary device618is fixed relative to the tool shaft640. The rotary device618includes a notch642and first and second stop surfaces644and646. The tool shaft640includes a protrusion648. In a central orientation, as shown inFIG.6A, the protrusion648is positioned within the notch642of the rotary device618, and the rotary device618is in a centered orientation. As the tool shaft640rotates in direction R1to the orientation shown inFIG.6B, the protrusion648pushes the rotary device618away from the centered orientation. As the tool shaft640continues to rotate, the protrusion648contacts the first stop surface644. The rotary device618is limited in rotational range, e.g., by contact with another component of the tool600, as shown inFIG.6B. Once the protrusion648contacts the stop surface644and the rotary device618is constrained from further rotation, e.g., by contact with another component of the tool600as shown inFIG.6B, the tool shaft640is constrained from further rotation in direction R1. The tool shaft640is free to rotate in a direction opposite R1, and as shown inFIG.6C, if the tool shaft640is rotated in direction R2, the protrusion648returns to the notch742in the rotary device618, and moves the rotary device618from the orientation shown in FIG.6B to the orientation shown inFIG.6C, in which further rotation of the rotary device618is constrained by contact between the rotary device618and a portion of the tool600. Continued rotation of the tool shaft640in direction R2results in the protrusion648contacting second stop surface646, and, because rotation of the rotary device618is constrained, the tool shaft640is prevented from rotating further in direction R2.

Optionally, the rotary device618can include a contoured portion that matches the profile of the tool shaft640and prevents the rotary device618from rotating back to the central orientation shown inFIG.6A. For example, the rotary device618can include portions analogous to the first and second profiled portions330and332discussed in connection with the rotary device318ofFIGS.3and4A-4E.

Additionally, or alternatively, the tool600can include a biasing element that biases the rotary device618to one of the two positions shown inFIG.6BandFIG.6C. For example, as shown inFIG.10, a tool1000includes components similar to the tool600described in connection withFIGS.6A-6C, such as a tool shaft1040and a rotary device1018, and also includes a biasing element1050that biases the rotary device1018to an over-center position, such as the position shown inFIG.10. Likewise, when the shaft1040is rotated such that the rotary device1018is in the position shown inFIG.6C, the biasing element1050provides a biasing force that holds the rotary device1018in the position corresponding to the position ofFIG.6C. The biasing element1050can be or include, for example, an extension spring or other resilient member, and can comprise a metal such as stainless steel or other alloy, a polymer, a composite material, or other material.

Referring now toFIG.9, a flow chart showing a workflow900for constraining rotational range of a tool shaft of a tool is shown. At902, the workflow includes rotating a shaft through a range of rotational motion in a first direction. At904the workflow includes, moving a stop mechanism from a first position to a second position by engaging the stop mechanism with a protrusion extending from the shaft during rotation of the shaft through a midpoint of the range of rotational motion.

Optionally, and not shown in workflow900, such a workflow can further include continuing to rotate the shaft in the first direction until the protrusion engages the stop mechanism while the stop mechanism is in the second position, which prevents further rotation of the shaft in the first direction and indicates the shaft has reached a first endpoint of the range of rotational motion. Further optionally, a workflow can include rotating the shaft in a second direction opposite the first direction and moving the stop mechanism from the first position to a third position by engaging the stop mechanism with the protrusion extending from the shaft during rotation of the shaft, in the second direction, through the midpoint of the range of rotational motion. Such a workflow can also optionally include continuing to rotate the shaft in the second direction until the protrusion engages the stop mechanism while the stop mechanism is in the third position, which prevents further rotation of the shaft in the second direction and indicates the shaft has reached a second endpoint of the range of rotational motion.

Embodiments of the disclosure provide rotation stop mechanisms that provide reliable constraints on the rotational motion of the tool shaft without occupying excess space around the circumference of the tool shaft.

Tools including the embodiments described herein may be used, for example, with remotely operated, computer-assisted systems (such, for example, teleoperated surgical systems) such as those described in, for example, U.S. Pat. No. 9,358,074 (filed May 31, 2013) to Schena et al., entitled “Multi-Port Surgical Robotic System Architecture,” U.S. Pat. No. 9,295,524 (filed May 31, 2013) to Schena et al., entitled “Redundant Axis and Degree of Freedom for Hardware-Constrained Remote Center Robotic Manipulator” and U.S. Pat. No. 8,852,208 (filed Aug. 12, 2010) to Gomez et al., entitled “Surgical System Instrument Mounting,” each of which is hereby incorporated by reference in its entirety. Further, the embodiments described herein may be used, for example, with a da Vinci® Surgical System, such as the da Vinci Si® Surgical System (model no. IS3000) or the da Vinci Xi® Surgical System (model no. IS4000), both with or without Single-Site® single orifice surgery technology, all commercialized by Intuitive Surgical, Inc. of Sunnyvale, California. Although various embodiments described herein are discussed with regard to surgical instruments used with a manipulating system of a teleoperated surgical system, the present disclosure is not limited to use with surgical instruments for a teleoperated surgical system. For example, various embodiments described herein can optionally be used in conjunction with hand-held, manual surgical instruments, or other surgical and non-surgical tools.

As discussed above, in accordance with various embodiments, surgical instruments of the present disclosure are configured for use in teleoperated, computer-assisted surgical systems (sometimes referred to as robotic surgical systems). Referring now toFIG.7, an embodiment of a manipulating system700of a teleoperated, computer-assisted surgical system, to which surgical instruments are configured to be mounted for use, is shown. Such a surgical system may further include a user control system, such as a surgeon console (not shown) for receiving input from a user to control instruments of manipulating system700, as well as an auxiliary system, such as a control/vision cart (not shown), as described in, for example, U.S. Pat. Nos. 9,358,074 and 9,295,524, incorporated above.

As shown in the embodiment ofFIG.7, a manipulating system700includes a base720, a main column740, and a main boom760connected to main column740. Manipulating system700also includes a plurality of arms710,711,712,713, which are each connected to main boom760. Arms710,711,712,713each include an instrument mount portion722to which an instrument730may be mounted, which is illustrated as being attached to arm710. Portions of arms710,711,712,713may be manipulated during a surgical procedure according to commands provided by a user at the surgeon console. In an embodiment, signal(s) or input(s) transmitted from a surgeon console are transmitted to the control/vision cart, which may interpret the input(s) and generate command(s) or output(s) to be transmitted to the manipulating system700to cause manipulation of the instrument730(only one such instrument being mounted inFIG.7) and/or portions of arm710to which the instrument730is coupled at the manipulating system700.

Instrument mount portion722comprises a drive assembly723and a cannula mount724, with a force transmission mechanism734of the instrument730connecting with the drive assembly723, according to an embodiment. Cannula mount724is configured to hold a cannula736through which a shaft732of instrument730may extend to a surgery site during a surgical procedure. drive assembly723contains a variety of drive and other mechanisms that are controlled to respond to input commands at the surgeon console and transmit forces to the force transmission mechanism734to actuate the instrument730, as those skilled in the art are familiar with.

Although the embodiment ofFIG.7shows an instrument730attached to only arm710for ease of viewing, an instrument may be attached to any and each of arms710,711,712,713. An instrument730may be a surgical instrument with an end effector as discussed herein. A surgical instrument with an end effector may be attached to and used with any of arms710,711,712,713. The embodiments described herein are not limited to the embodiment ofFIG.7and various other teleoperated, computer-assisted surgical system configurations may be used with the embodiments described herein.

Other configurations of surgical systems, such as surgical systems configured for single-port surgery, are also contemplated. For example, with reference now toFIG.8, a portion of an embodiment of a manipulator arm2140of a manipulating system with two surgical instruments2300,2310in an installed position is shown. For example, the embodiments described herein may be used with a da Vinci SPR Surgical System (model no. IS1098), commercialized by Intuitive Surgical, Inc. of Sunnyvale, California. A teleoperated robotic surgical system, including a manipulating system comprising manipulator arm2140, may be configured according to the embodiments described in U.S. Patent App. Pub. No. US 2014/0128886 A1 (filed No. 1, 2013), to Holop et al. and titled “Flux disambiguation for teleoperated surgical systems,” the disclosure of which is incorporated by reference herein. The schematic illustration ofFIG.8depicts only two surgical instruments for simplicity, but more than two surgical instruments may be received in an installed position at a manipulating system as those having ordinary skill in the art are familiar with. Each surgical instrument2300,2310includes an instrument shaft2320,2330that at a distal end has a moveable end effector or an endoscope, camera, or other sensing device, and may or may not include a wrist mechanism (not shown) to control the movement of the distal end.

In the embodiment ofFIG.8, the distal end portions of the surgical instruments2300,2310are received through a single port structure2380to be introduced into the patient. As shown, the port structure includes a cannula and an instrument entry guide inserted into the cannula. Individual instruments are inserted into the entry guide to reach a surgical site. Other configurations of manipulating systems that can be used in conjunction with the present disclosure can use several individual manipulator arms. In addition, individual manipulator arms may include a single instrument or a plurality of instruments. Further, an instrument may be a surgical instrument with an end effector or may be a camera instrument or other sensing instrument utilized during a surgical procedure to provide information, (e.g., visualization, electrophysiological activity, pressure, fluid flow, and/or other sensed data) of a remote surgical site.

Force transmission mechanisms2385,2390are disposed at a proximal end of each shaft2320,2330and connect through a sterile adaptor2400,2410with drive assemblies2420,2430. Drive assemblies2420,2430contain a variety of internal mechanisms (not shown) that are controlled by a controller (e.g., at a control cart of a surgical system) to respond to input commands at a surgeon side console of a surgical system to transmit forces to the force transmission mechanisms2385,2390to actuate instruments2300,2310. The diameter or diameters of an instrument shaft, wrist mechanism, and end effector are generally selected according to the size of the cannula with which the instrument will be used and depending on the surgical procedures being performed. In various embodiments, a shaft and/or wrist mechanism has a diameter of about 4 mm, 5 mm, or 8 mm in diameter, for example, to match the sizes of some existing cannula systems.

This description and the accompanying drawings that illustrate embodiments should not be taken as limiting. Various mechanical, compositional, structural, and operational changes may be made without departing from the scope of this description and the invention as claimed, including equivalents. In some instances, well-known structures and techniques have not been shown or described in detail so as not to obscure the disclosure. Like numbers in two or more figures represent the same or similar elements. Furthermore, elements and their associated features that are described in detail with reference to one embodiment may, whenever practical, be included in other embodiments in which they are not specifically shown or described. For example, if an element is described in detail with reference to one embodiment and is not described with reference to a second embodiment, the element may nevertheless be claimed as included in the second embodiment.

For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages, or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about,” to the extent they are not already so modified. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” and any singular use of any word, include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

Further, this description's terminology is not intended to limit the invention. For example, spatially relative terms—such as “beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, and the like—may be used to describe one element's or feature's relationship to another element or feature as illustrated in the figures. These spatially relative terms are intended to encompass different positions (i.e., locations) and orientations (i.e., rotational placements) of a device in use or operation in addition to the position and orientation shown in the figures. For example, if a device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be “above” or “over” the other elements or features. Thus, the exemplary term “below” can encompass both positions and orientations of above and below. A device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Further modifications and alternative embodiments will be apparent to those of ordinary skill in the art in view of the disclosure herein. For example, the devices and methods may include additional components or steps that were omitted from the diagrams and description for clarity of operation. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the present teachings. It is to be understood that the various embodiments shown and described herein are to be taken as exemplary. Elements and materials, and arrangements of those elements and materials, may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the present teachings may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of the description herein. Changes may be made in the elements described herein without departing from the spirit and scope of the present teachings and following claims.

It is to be understood that the particular examples and embodiments set forth herein are non-limiting, and modifications to structure, dimensions, materials, and methodologies may be made without departing from the scope of the present teachings.

Other embodiments in accordance with the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the following claims being entitled to their fullest breadth, including equivalents, under the applicable law.