US-12616543-B2 - Disabling surgical tools due to manual bailout

US12616543B2US 12616543 B2US12616543 B2US 12616543B2US-12616543-B2

Abstract

A surgical tool includes a drive housing removably coupled to a tool driver of a robotic surgical system, a shaft extending from the drive housing, an end effector arranged at an end of the shaft, and a computer system. The computer system is programmed to send a command signal to a motor of the tool driver to drive rotation of a drive shaft mounted within the drive housing, monitor torque and rotational motion of the motor with a torque sensor and a rotary encoder, respectively, in communication with the computer system, measure an unexpected change in the torque or the rotational motion of the motor with the torque sensor or the rotary encoder when the surgical tool is manually bailed out by manually rotating the drive shaft and backdriving the motor, report the unexpected change as a bailout signal, and disable the surgical tool once the bailout signal is received.

Inventors

Mark D. Overmyer
Benjamin Lawrence Bertram
Christopher A. Denzinger
Robert Louis Koch, JR.

Assignees

CILAG GMBH INTERNATIONAL

Dates

Publication Date: 20260505
Application Date: 20241210

Claims (20)

1 . A surgical tool, comprising: a drive housing with a drive shaft rotatably mounted therein; a shaft extending from the drive housing and terminating with an end effector arranged at an end of the shaft; a tool driver configured to receive the drive housing and including: a motor operatively coupled to the drive shaft when the drive housing is mounted to the tool driver; and a torque sensor configured to monitor a torque of the motor; and a computer system including a memory and a processor operable to execute commands stored on the memory, the computer system being programmed to: generate a bailout signal after measuring an unexpected change in the torque with the torque sensor when the surgical tool is manually bailed out by manually rotating the drive shaft and backdriving the motor; and disable the surgical tool once the bailout signal is received.
2 . The surgical tool of claim 1 , wherein, by disabling the surgical tool, the computer system is further programmed to render the surgical tool unavailable for future procedures.
3 . The surgical tool of claim 2 , wherein rendering the surgical tool unavailable for future procedures comprises at least one of: allowing a knife located at the end effector to be retracted to a home position; preventing the knife from extending; permitting actuation of opposing jaws of the end effector; permitting articulation of a wrist interposing the end effector and the shaft; and permitting rotation of the shaft.
4 . The surgical tool of claim 1 , wherein, by disabling the surgical tool, the computer system is further programmed to: generate an alert perceivable by a user that the surgical tool has been bailed out; and override the alert and thereby allowing the user to proceed with operation of the surgical tool.
5 . The surgical tool of claim 1 , wherein the robotic surgical system is a first robotic surgical system and the surgical tool further includes an internal computer housed within the drive housing and including an internal computer memory, and wherein the computer system is further programmed to: communicate the bailout signal to the internal computer such that the bailout signal is stored in the internal computer memory; upon installing the surgical tool on a tool driver of a second robotic surgical system, query the internal computer memory with the second robotic surgical system and determine that the surgical tool was previously bailed out; and initiate one or more remedial actions to ensure safe operation of the surgical tool on the second robotic surgical system.
6 . The surgical tool of claim 5 , wherein initiating the one or more remedial actions comprises disabling the surgical tool and thereby rendering the surgical tool unavailable for future procedures.
7 . The surgical tool of claim 5 , wherein initiating the one or more remedial actions comprises generating an alert that informs a user that the surgical tool was previously bailed out.
8 . The surgical tool of claim 1 , wherein the surgical tool is manually bailed out using a bailout mechanism that includes: a key mounted within the drive housing; and a transfer drive shaft interconnected by gearing to the drive shaft and a firing member, the firing member being longitudinally movable within the drive housing and operatively coupled to a knife located at the end effector, wherein a user accesses the key and manually couples the key to the transfer drive shaft, and wherein manually rotating the key in a first angular direction drives the firing member and the knife in a first longitudinal direction.
9 . The surgical tool of claim 1 , wherein the surgical tool is manually bailed out using a bailout mechanism that includes: a bailout tool arranged on an exterior of the drive housing and operatively coupled to a primary gear mounted within the drive housing, the primary gear being interconnected by gearing to the drive shaft and rotatably mounted to a closure yoke, wherein the closure yoke is coupled to a closure tube of the shaft and movable to actuate opposing jaws of the end effector, and wherein manually rotating the bailout tool drives the closure yoke and the closure tube in a longitudinal direction to actuate the opposing jaws.
10 . The surgical tool of claim 1 , wherein the computer system is further programmed to communicate the bailout signal to a central database to disable the surgical tool.
11 . The surgical tool of claim 1 , wherein the unexpected change is the torque being inconsistent with a command signal sent to the motor by the computer system.
12 . A surgical tool, comprising: a drive housing configured to be removably coupled to a tool driver of a robotic surgical system; a shaft extending from the drive housing and terminating with an end effector arranged at an end of the shaft; and a computer system including a memory and a processor operable to execute commands stored on the memory, the computer system being programmed to: set a bailout Boolean value to “true” in the computer system once a command signal is sent to a motor of the tool driver to commence a firing sequence of the surgical tool; set the bailout Boolean value to “false” in the computer system if the firing sequence is fully completed; and maintain the bailout Boolean value as “true” if the surgical tool is manually bailed out before completing the firing sequence.
13 . The surgical tool of claim 12 , wherein the computer system is further programmed to disable the surgical tool when the bailout Boolean value is “true” following the surgical tool being manually bailed out.
14 . The surgical tool of claim 12 , wherein the robotic surgical system is a first robotic surgical system and the surgical tool further includes an internal computer housed within the drive housing and including an internal computer memory, and wherein the computer system is further programmed to: communicate the bailout Boolean value as “true” to the internal computer and store the bailout Boolean value in the internal computer memory; upon manually bailing out the surgical tool before completing the firing sequence and subsequently installing the surgical tool on a tool driver of a second robotic surgical system, query the internal computer memory with the second robotic surgical system and determine that the surgical tool was previously bailed out; and initiate one or more remedial actions to ensure safe operation of the surgical tool on the second robotic surgical system.
15 . A method of operating a surgical tool coupled to a motor, the surgical tool having a drive housing, a shaft extending from the drive housing, and an end effector arranged at an end of the shaft, the method comprising: manually bailing out the surgical tool via a bailout mechanism included in the surgical tool and thereby manually rotating a drive shaft of a motor coupled to the surgical tool; and disabling the surgical tool after measuring an unexpected change in one or more operational parameters of the motor with one or more monitoring devices as the drive shaft is manually rotated.
16 . The method of claim 15 , further comprising generating a bailout signal after measuring the unexpected change, wherein the surgical tool is disabled once the bailout signal is received.
17 . The method of claim 15 , wherein the unexpected change in the one or more operational parameters comprises a measured operational parameter that is inconsistent with a command signal sent to the motor prior to manually bailing out the surgical tool.
18 . The method of claim 15 , wherein the unexpected change in the one or more operational parameters comprises at least one of a measured torque and a measured motion of the motor that is inconsistent with the command signal send to the motor prior to manually bailing out the surgical tool.
19 . A surgical tool, comprising: a drive housing with a drive shaft rotatably mounted therein; a shaft extending from the drive housing and terminating with an end effector arranged at an end of the shaft; a tool driver configured to receive the drive housing and including: a motor operatively coupled to the drive shaft when the drive housing is mounted to the tool driver; and a rotary encoder configured to monitor a rotational motion of the motor; and a computer system including a memory and a processor operable to execute commands stored on the memory, the computer system being programmed to: generate a bailout signal after measuring an unexpected change in the rotational motion of the motor with the rotary encoder when the surgical tool is manually bailed out by manually rotating the drive shaft and backdriving the motor; and disable the surgical tool once the bailout signal is received.
20 . The surgical tool of claim 19 , wherein, by disabling the surgical tool, the computer system is further programmed to render the surgical tool unavailable for future procedures.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 18/506,000, entitled “Disabling Surgical Tools Due to Manual Bailout,” filed Nov. 9, 2023, and issued as U.S. Pat. No. 12,178,536 on Dec. 31, 2024, which is a continuation of U.S. patent application Ser. No. 17/563,530, entitled “Disabling Surgical Tools Due to Manual Bailout,” filed Dec. 28, 2021, and issued as U.S. Pat. No. 11,813,032 on Nov. 14, 2023, which is a continuation of U.S. patent application Ser. No. 16/427,818, entitled “Disabling Surgical Tools Due to Manual Bailout,” filed May 31, 2019, and issued as U.S. Pat. No. 11,219,495 on Jan. 11, 2022. BACKGROUND Minimally invasive surgical (MIS) instruments are often preferred over traditional open surgical devices due to the reduced post-operative recovery time and minimal scarring. The most common MIS procedure may be endoscopy, and the most common form of endoscopy is laparoscopy, in which one or more small incisions are formed in the abdomen of a patient and a trocar is inserted through the incision to form a pathway that provides access to the abdominal cavity. The trocar is used to introduce various instruments and tools into the abdominal cavity, as well as to provide insufflation to elevate the abdominal wall above the organs. The instruments can be used to engage and/or treat tissue in a number of ways to achieve a diagnostic or therapeutic effect. 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 12-inch 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 tools include manual bailout mechanisms that allow a user to manually manipulate various portions of the tools in the event of an emergency, such as a loss of power or malfunction of the tool. For example, some surgical staplers include manual bailout mechanisms that enable a user to manually open the jaws or retract a knife. With some types of surgical tools, however, manually bailing out the surgical tool can damage internal gearing and may otherwise require that the surgical tool be precisely reset before subsequent use. What is needed is a way to accurately track when a surgical tool is subjected to a manual bailout. BRIEF DESCRIPTION OF THE DRAWINGS 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. FIG. 1 is a block diagram of an example robotic surgical system that may incorporate some or all of the principles of the present disclosure. FIG. 2 is an example embodiment of one of the master control consoles of FIG. 1. FIG. 3 depicts one example of the robotic manipulator of FIG. 1, according to one or more embodiments. FIG. 4 is an isometric side view of an example surgical tool that may incorporate some or all of the principles of the present disclosure. FIG. 5 illustrates potential degrees of freedom in which the wrist of FIG. 4 may be able to articulate (pivot). FIG. 6 is a bottom view of the drive housing of FIG. 4, according to one or more embodiments. FIGS. 7A and 7B are exposed isometric views of the interior of the drive housing of FIG. 4, according to one or more embodiments. FIG. 8 is a schematic diagram of one example of the primary drive gear of FIGS. 7A-7B as intermeshed with the spur gears of FIGS. 7A-7B. FIG. 9 is a flowchart diagram of an example method of operating the surgical tool of FIG. 4, according to one or more embodiments. FIG. 10 is a flowchart diagram of another example method of operating the surgical tool of FIG. 4, according to one or more embodiments. FIG. 11 is a flowchart diagram of another example method