Patent Application
20220022978
Robotic surgical systems have been used in minimally invasive medical procedures and can include robotic arm assemblies. Some robotic arm assemblies include a robot arm having an instrument drive assembly coupled thereto for coupling surgical instruments to the robot arm, such as, for example, a pair of jaw members, electrosurgical forceps, cutting instruments, or any other endoscopic or open surgical devices, and a mounting arm coupled thereto for coupling surgical accessories to the robot arm, such as, for example, a surgical port such as a trocar.
Prior to or during use of the robotic surgical system, surgical instruments are selected and connected to the instrument drive assembly of each robot arm, where the instrument drive assembly can drive the actuation of an end effector of the surgical instrument. Such instrument drive assemblies can include many components that add to the cost, size, and energy output of the robotic surgical system.
Under certain procedures, a surgical accessory, such as, for example, a surgical port may be docked or undocked to/from a mounting arm of the robot arm by clamping or unclamping steps. During a procedure, the end effector and/or a portion of the surgical instrument may be inserted through the surgical port, and a small incision or a natural orifice of a patient, to bring the end effector proximate a working site within the body of the patient. Although such surgical ports may provide additional stability and act as a guide channel for the surgical instrument during insertion and actuation of the end effector, the clamping/unclamping steps can prolong or otherwise add to the complexity of the surgical procedure.
Accordingly, the present disclosure describes robotic arm assemblies having a mounting arm that advantageously provides quick and easy connection between a robot arm and a variety of surgical accessories, such as a surgical port. The present disclosure also describes robotic arm assemblies having a small, lightweight instrument drive unit that reduces the complexity of the robotic arm assemblies. The presently disclosed instrument drive unit consolidates five motors into a single unit that shares mounting features and maximizes thermal mass and heat dissipation. Advantageously, the presently disclosed instrument drive unit has a reduced height, simplifies motor mounting, provides a shorter drivetrain, reduces weight, provides a higher power density, reduces overall height of the surgical robot, reduces electronics, provides lower COGS, improves reliability, and reduces manufacturing costs.
According to an aspect of the present disclosure, a robotic arm assembly is provided. The robotic arm assembly includes a robotic arm and an instrument drive unit. The instrument drive unit is configured to provide five degrees of rotational freedom and is coupled to the robotic arm. The instrument drive unit includes a motor housing, motors supported in the motor housing and rotatable with the motor housing, and gear box assemblies coupled to the motors and configured to transmit drive power from the motors to a surgical instrument. In embodiments, the instrument drive unit may include one or more torque sensors that rotate with one or more output shafts of the motors to measure torque as drive power is transmitted form the motors to the surgical instrument.
In some embodiments, the robotic arm assembly may further include the surgical instrument.
In certain embodiments, the robotic arm assembly may further include a sterile interface module that couples the instrument drive unit to the surgical instrument.
In embodiment, the motors may include four or more motors, each motor providing one of the five degrees of rotational freedom of the instrument drive unit. In certain embodiments, the motors may include five (5) motors, four (4) motors of which drive the surgical instrument, and one (1) motor of which rotates the four (4) motors about an instrument axis. The instrument drive unit may define a longitudinal axis and the four motors may be arranged in a circle about the longitudinal axis. The motor housing and the four motors may be configured rotate together about the longitudinal axis. A first motor of the four motors may define a first motor axis. The first motor may be configured to independently rotate about the first motor axis when the motor housing rotates about the longitudinal axis of the instrument drive unit. The first motor axis of the first motor and the longitudinal axis of the instrument drive unit may be parallel to one another.
In some embodiments, a first gear box assembly of the gear box assemblies may include a reduction gear assembly and a coupler secured to the reduction gear assembly. The first motor may include a drive shaft, wherein the reduction gear assembly of the first gear box assembly couples to the drive shaft of the first motor. The reduction gear assembly may be configured to reduce an output from the drive shaft of the first motor to the coupler of the first gear box assembly.
In certain embodiments, the robotic arm assembly may further comprise a motor winding and a magnet supported about the motor housing. The motor winding may be configured to rotate with the motor housing relative to the magnet to act as a motor and provide one of the five degrees of rotational freedom.
According to yet another aspect of the present disclosure, a robotic arm assembly comprises a robotic arm, a surgical port, a sterile interface module, a surgical instrument, and an instrument drive unit. The robotic arm includes a mounting arm that extends distally to an annulus. The surgical port is coupled to the annulus. The surgical instrument is coupled to the sterile interface module. The instrument drive unit is coupled to the sterile interface module and slidably movable along the robotic arm to translate the surgical instrument along the robotic arm and selectively advance the surgical instrument through the surgical port.
In some embodiments, the annulus may be an enclosed ring defining a central opening therethrough.
In certain embodiments, the annulus may be configured to couple the surgical port to the annulus by bottom-loading. The annulus may include an inner surface and the surgical port may include a housing and a cannula that extends distally from the housing. The annulus and the housing of the surgical port may be threadably coupled.
In embodiments, the instrument drive unit may include a motor housing, motors supported in the motor housing and rotatable with the motor housing, and gear box assemblies coupled to the motors and configured to transmit drive power from the motors to the surgical instrument. The motors may include four motors. The instrument drive unit may define a longitudinal axis and the four motors may be arranged in a circle about the longitudinal axis. The motor housing and the four motors may be configured rotate together about the longitudinal axis. A first motor of the four motors may define a first motor axis. The first motor may be configured to independently rotate about the first motor axis when the motor housing rotates about the longitudinal axis of the instrument drive unit.
In certain embodiments, the robotic arm assembly may further include a motor winding and a magnet supported about the motor housing. The motor winding may be configured to rotate with the motor housing relative to the magnet.
Other aspects, features, and advantages will be apparent from the description, the drawings, and the claims that follow.
Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:
Embodiments of the presently disclosed robotic arm assembly are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As commonly known, the term “clinician” refers to a doctor, a nurse, or any other care provider and may include support personnel. Further, as is used in the art, the term “distal” refers to a position, a direction, and/or a structure, which is farther from the user, and the term “proximal” refers to a position, a direction, and/or a structure, which is closer to the user. In addition, directional terms such as front, rear, upper, lower, top, bottom, and the like are used simply for convenience of description and are not intended to limit the disclosure attached hereto.
In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.
With brief reference to
Robotic surgical system 10 employ various robotic elements to assist the clinician and allow remote operation (or partial remote operation) of surgical instrumentation such as surgical instrument 30. Various robotic arms, gears, cams, pulleys, electric and mechanical motors, etc. may be employed for this purpose and may be designed with robotic surgical system 10 to assist the clinician during the course of an operation or treatment. Such robotic systems may include remotely steerable systems, automatically flexible surgical systems, remotely flexible surgical systems, remotely articulating surgical systems, wireless surgical systems, modular or selectively configurable remotely operated surgical systems, etc.
Robotic surgical system 10 includes a medical work station (not shown) that may be employed with one or more consoles positioned next to the operating theater or located in a remote location. In this instance, one team of clinicians may prep the patient for surgery and configure robotic surgical system 10 with surgical instrument 30 while another clinician (or group of clinicians) remotely controls surgical instrument 30 via robotic surgical system 10. As can be appreciated, a highly skilled clinician may perform multiple operations in multiple locations without leaving his/her remote console which can be both economically advantageous and a benefit to the patient or a series of patients. For a detailed description of exemplary medical work stations and/or components thereof, reference may be made to U.S. Patent Application Publication No. 2012/0116416 and PCT Application Publication No. WO2016/025132, the entire contents of each of which are incorporated by reference herein.
With continued reference to
Slide rail 40 of robotic arm assembly 20 further includes a mounting arm 60 secured to distal end portion 40b of slide rail 40. Mounting arm 60 supports a surgical portal 70 for advancing surgical instrument 30 through surgical portion 70 to selectively access a surgical site. Mounting arm 60 is releasably attachable to slide rail 40. For more detailed description of how mounting arm 60 releasably attaches to slide rail 40, reference can be made to a similar mounting arm disclosed in U.S. Provisional Application Ser. No. 62/613,601, filed Jan. 4, 2018, the entire contents of which are incorporated by reference herein.
Turning now to
In some embodiments, an outer surface of upper housing 72a and an inner surface of annulus 64 may be threaded to enable housing assembly 72 of surgical port 70 to be threadably secured to annulus 64 of mounting arm 60.
Turning now to
IDU 50 of robotic arm assembly 20 includes internal components 100 arranged with integrated electronics and motors (e.g., in the form of a cluster motor) to maximize output per volume and weight. Internal components 100 of IDU 50 include a slip ring 102, electronic disc assembly 104 (e.g., magnetic and/or optical encoders), upper ring 106, upper ring bearing 108, upper plate 110, electronic boards 112, motors 114, lower plate 116, gear box assemblies 118, lower ring bearing 120, gear box housing 122, motor housing 124, torque sensors 126, magnet 128, magnet housing 130, motor winding 132, and base 134.
Slip ring 102 of IDU 50 is secured to electronic disc assembly 104 in upper cavity 52e of outer housing 52 and is configured to transfer power and/or data by electrical signals to/from IDU 50 and/or surgical instrument 30 (and/or sterile interface module 80 coupled between IDU 50 and surgical instrument 30). Slip ring 102 includes a flanged tube 102a that mounts to electronic disc assembly 104 and an inner shaft 102b about which flanged tube 102a rotates. Inner shaft 102b couples to electrical wiring (not shown) for providing electrical communication to/from surgical instrument 30 through IDU 50. The electrical wiring, which can electrically couple one or more of the presently disclosed electrical components together, can support drive and/or encoder electronics. Inner shaft 102b has a proximal portion 102c that connects to a first cable (not shown) for communicating power and/or data to/from console of robotic surgical system 10, and a distal portion 102d that connects to a second cable (not shown) for communicating power and/or data through IDU 50 and to/from surgical instrument 30 (and/or sterile interface module 80).
Electronic disc assembly 104 of IDU 50 is supported in upper cavity 52e of outer housing 52 and includes a plurality of circuit discs 104a that are coupled together by ribbons 104r and folded in a stacked and spaced-apart relation to one another. The plurality of circuit discs 104a defines a central lumen 104b therethrough that receives slip ring 102 therein so that flanged tube 102a of slip disc 102 secures to the plurality of circuit discs 104a. The plurality of circuit discs 104a includes a bottom circuit disc 104c that defines a plurality of apertures 104e therethrough. The plurality of apertures 104d of bottom circuit disc 104c align with motors 114 (e.g., four apertures, each aperture circumferentially spaced, for example, 90 degrees out-of-phase from adjacent apertures).
Upper ring 106 of IDU 50 is mounted to outer housing 52 and defines an annular channel 106a that supports upper ring bearing 108 therein. Upper ring bearing 108 is coupled to upper plate 110 for rotatably supporting upper plate 110 relative to upper ring 106. Upper plate 110 includes an outer ledge 110a that supports upper ring bearing 108 on an outer surface of upper plate 110. Upper plate 110 further defines a plurality of annular openings 110b therethrough that aligns with motors 114. Upper plate 110 also defines a central aperture 110c and a plurality of cable apertures 110e that are configured to receive electrical wiring therethrough (e.g., from slip ring 102 and/or torque sensors 126) and to facilitate air flow through IDU 50.
Motor housing 124 of IDU 50, which may be formed of any suitable iron-based and/or soft magnetic material), supports upper ring 106 and includes an outer ring 124a that supports a plurality of sleeves 124b. Each sleeve 124b is configured to function as a motor stator for a respective one of the motors 114. Sleeves 124b are positioned to receive motors 114 therein. Motor housing 124 defines a plurality of elongated channels 124c between adjacent sleeves 124b. Elongated channels 124c are positioned to support electronic boards 112 (and/or electrical wiring) therein and facilitate air flow therethrough. Motor housing 124 further defines a central aperture 124d that is configured to receive electrical wiring therethrough (e.g., from slip ring 102). Motor housing 124 is configured to rotate about central axis “L” of IDU 50 with motor winding 132, upper plate 110, lower plate 116, motors 114, electronic boards 112, electronic disc assembly 104, and flanged tube 102a of slip ring 102. Motor winding 132 of IDU 50, which includes any number and/or arrangement of conductive coils (not shown) therein, is positioned to surround motor housing 124 and is secured to motor housing 124 for rotating with motor housing 124 about central axis “L” of IDU 50 relative to magnet 128. Rotation of motor winding 132 about central axis “L” functions as another motor 115 of IDU 50 (e.g., the 5th motor where the four motors 114 constitute the first four motors such that IDU 50 provides five (5) degrees of freedom).
Motor winding 132 is disposed between an outer surface of outer ring 124a of motor housing 124 and an inner surface of magnet 128. Magnet 128 is fixedly secured to motor housing 128, and motor housing 128 is fixedly secured to outer housing 52 of IDU 50 (e.g., bonded).
Lower plate 116 of IDU 50 supports motor housing 124 and includes a plurality of stands 116a that rotatably support motors 114 in a bolt circle “B” (e.g., 25.6 mm diameter) (see
Motors 114 (e.g., four motors) of IDU 50 include drive shafts 114a that extend between upper and lower plates 110, 116 of IDU 50. Proximal end portions of drive shafts 114a are coupled to the plurality of apertures 104d of bottom circuit disc 104c by disc bearings 114b. Drive shafts 114a further support shaft bearings 114c that enable drive shafts 114a to rotate within sleeves 124b of motor housing 124. Distal end portions of drive shafts 114a of motors 114 are coupled to gear box assemblies 118. Each motor 114 defines its own longitudinal axis (e.g., motor axes “M1,” “M2,” etc.) about which the respective drive shafts 114a are configured to rotate (e.g., independently and/or with the other motors 114).
Each gear box assembly 118 of IDU 50 includes a gear box 118a, a reduction gear assembly 118b (e.g., planetary or harmonic drive gear box) supported in gear box 118a, and a coupler 118c.
Gear box 118a of gear box assembly 118 is seated in, and secured to, gear box housing 122 of gear box assembly 118. Gear box 118 supports reduction gear assembly 118b between a distal end portion of drive shaft 114a of a respective one of motors 114 and a proximal end portion of coupler 118c. Reduction gear assembly 118b can include any number and/or arrangement of gears sufficient to reduce rotational output from motor 114 to coupler 118c of gear box assembly 118 for effectuating desired rotational output of coupler 118c as motor 114 rotates, regardless of whether respective couplers 118c and motors 114 are configured with aligned or misaligned arrangements. With reduction gear assembly 118b capable of having any suitable configuration, couplers 118c can be aligned with and/or offset from respective motors 114 as desired. Each gear box assembly 118 further includes coupler bearings 118d that facilitate rotational movement of couplers 118c relative to gear box 118a.
Each coupler 118c of gear box assemblies 118 defines its own longitudinal axis (e.g., coupler axes “C1,” “C2,” etc.) about which the respective coupler 118c rotates. Couplers 118c include an upper flange 118e and a lower flange 118f that can be encoded to facilitate torque sensing with torque sensors 126 of IDU 50. For example, torque sensors 126 can be configured to determine deflection differences between upper and lower flanges 118e, 118f as coupler 118c rotates about its respective coupler axis for measuring and/or comparing torque. Torque may also be measured by sensing and/or analyzing data indicating variation in field lines due to stress. Couplers 118c further include a drive tip 118g that is configured to engage a drive assembly (not shown) of sterile interface module 80 (
Gear box housing 122 of gear box assembly 118 includes a platform 122a and a plurality of gear box casings 122b that extends distally from platform 122a. Gear box housing 122 defines a bores 122c that extend through platform 122a and into gear box casings 122b for receiving gear boxes 118a of gear box assemblies 118 therein. Gear box housing 122 also defines a central aperture 122d and a plurality of cable apertures 122e that are configured to receive electrical wiring therethrough (e.g., from slip ring 102 and/or torque sensors 126) and to facilitate air flow through IDU 50.
Base 134 of IDU 50 couples to motor winding 132 of IDU 50 and encloses internal components 100 of IDU 50 within outer housing 52 of IDU 50. Base 134 defines a plurality of coupler openings 134a configured to receive drive tips 118g of couplers 118c therethrough. Base 134 further defines a central opening 134b configured to receive electrical wiring therethrough (e.g., from slip ring 102) and to facilitate air flow through IDU 50.
With reference to
In embodiments, IDU 50 of robotic arm assembly 20 may have the following specifications:
As can be appreciated, securement of any of the components of the presently disclosed apparatus can be effectuated using known securement techniques such welding, crimping, gluing, fastening, etc.
Persons skilled in the art will understand that the structures and methods specifically described herein and illustrated in the accompanying figures are non-limiting exemplary embodiments, and that the description, disclosure, and figures should be construed merely as exemplary of particular embodiments. It is to be understood, therefore, that the present disclosure is not limited to the precise embodiments described, and that various other changes and modifications may be effected by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, it is envisioned that the elements and features illustrated or described in connection with one exemplary embodiment may be combined with the elements and features of another without departing from the scope of the present disclosure, and that such modifications and variations are also intended to be included within the scope of the present disclosure. Indeed, any combination of any of the presently disclosed elements and features is within the scope of the present disclosure. Accordingly, the subject matter of the present disclosure is not to be limited by what has been particularly shown and described.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2019/062840 | 11/22/2019 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62780358 | Dec 2018 | US |
