US-12617078-B2 - Robotic surgical assemblies including surgical instruments having articulatable wrist assemblies

Abstract

A surgical instrument for use in a robotic surgical system includes an end effector, a housing configured to be operably coupled to an instrument drive unit, a shaft extending distally from the housing, a tensegrity wrist assembly movably coupling the end effector to a distal end portion of the shaft, and articulation cables that adjust the pitch and yaw of the end effector relative to the shaft.

Inventors

• Zachary S. Heiliger

Assignees

• COVIDIEN LP

Dates

Publication Date

20260505

Application Date

20230606

Claims (20)

1. 1 . A surgical instrument of a surgical robotic system, the surgical instrument comprising: a housing; a shaft extending distally from the housing, the shaft having a distal end portion; a tensegrity wrist assembly including: a proximal coupler secured to the distal end portion of the shaft and having an extension extending distally relative to the distal end portion of the shaft; a distal coupler secured to the end effector and having an arm extending proximally relative to the end effector; and a link coupled to and extending between the extension of the proximal coupler and the arm of the distal coupler, wherein the link is configured to apply opposing axial forces on the proximal and distal couplers; an end effector pivotably coupled to a distal end of the distal coupler of the tensegrity wrist assembly; and a first pair of first and second articulation cables each having a proximal end portion operably coupled to an actuator, and a distal end portion secured to the end effector, such that the first pair of first and second articulation cables articulate the end effector relative to the shaft.
2. 2 . The surgical instrument according to claim 1 , wherein the extension of the proximal coupler has a distal end secured to a distal end of the link, and the arm of the distal coupler has a proximal end secured to a proximal end of the link.
3. 3 . The surgical instrument according to claim 2 , wherein the distal end of the extension of the proximal coupler is in overlapping alignment with and distal of the proximal end of the arm of the distal coupler.
4. 4 . The surgical instrument according to claim 3 , wherein the distal end of the extension of the proximal coupler and the proximal end of the arm of the distal coupler are positioned on a central longitudinal axis defined by the tensegrity wrist assembly.
5. 5 . The surgical instrument according to claim 2 , wherein the distal end of the extension of the proximal coupler is coaxial with and distal of the proximal end of the arm of the distal coupler.
6. 6 . The surgical instrument according to claim 1 , wherein the link is a rigid or flexible rod defining a link longitudinal axis, wherein the link longitudinal axis extends in a proximal to distal direction and is positioned on a central longitudinal axis defined by the tensegrity wrist assembly.
7. 7 . The surgical instrument according to claim 1 , wherein the proximal coupler includes: a hub secured to the distal end portion of the shaft; and the extension, the extension including first and second arms extending distally from the hub, the link having a distal end secured to a distal end of each of the first and second arms of the extension and prevented from moving proximally relative to the first and second arms of the proximal coupler.
8. 8 . The surgical instrument according to claim 7 , wherein the distal coupler includes: a hub secured to the end effector; and the arm, the arm extending proximally from the hub of the distal coupler, the link having a proximal end secured to a proximal end of the arm and prevented from moving distally relative to the arm of the distal coupler.
9. 9 . The surgical instrument according to claim 8 , wherein the hub of each of the proximal and distal couplers defines a first pair of first and second channels having the first pair of first and second articulation cables slidably positioned therein.
10. 10 . The surgical instrument according to claim 9 , further comprising a second pair of first and second articulation cables, wherein the hub of each of the proximal and distal couplers defines a second pair of first and second channels having the second pair of first and second articulation cables slidably positioned therein.
11. 11 . A surgical robotic system, comprising: a surgical robotic arm; an instrument drive unit configured to be supported on the surgical robotic arm; and a surgical instrument configured to be coupled to and driven by the instrument drive unit, the surgical instrument including; a housing configured to be attached to the instrument drive unit; a shaft extending distally from the housing, the shaft having a distal end portion; a tensegrity wrist assembly including: a proximal coupler secured to the distal end portion of the shaft and having a pair of first and second arms extending distally relative to the distal end portion of the shaft; a distal coupler secured to the end effector and having an arm extending proximally relative to the end effector; and a link including a proximal end secured to a proximal end of the arm of the distal coupler, and a distal end secured to a distal end of each of the first and second arms of the proximal coupler, wherein the link is configured to apply opposing axial forces on the proximal and distal couplers; an end effector pivotably coupled to a distal end of the distal coupler of the tensegrity wrist assembly; and a first pair of first and second articulation cables each having a proximal end portion operably coupled to an actuator of the instrument drive unit, and a distal end portion secured to the end effector, such that the first pair of first and second articulation cables articulate the end effector relative to the shaft.
12. 12 . The surgical robotic system according to claim 11 , wherein the distal end of each of the first and second arms of the proximal coupler is in overlapping alignment with and distal of the proximal end of the arm of the distal coupler.
13. 13 . The surgical robotic system according to claim 11 , wherein the distal end of each of the first and second arms of the proximal coupler is coaxial with and distal of the proximal end of the arm of the distal coupler.
14. 14 . The surgical robotic system according to claim 11 , wherein the link is a rigid or flexible rod defining a link longitudinal axis, wherein the link longitudinal axis extends in a proximal to distal direction and is positioned on a central longitudinal axis defined by the tensegrity wrist assembly.
15. 15 . The surgical robotic system according to claim 11 , wherein the proximal coupler includes a hub defining a pair of channels having the first pair of first and second articulation cables slidably positioned therein, the first and second arms extending distally from the hub, wherein the distal coupler includes a hub defining a pair of channels having the first pair of first and second articulation cables slidably positioned therein, the arm extending proximally from the hub of the distal coupler.
16. 16 . A surgical instrument of a surgical robotic system, the surgical instrument comprising: a housing; a shaft extending distally from the housing, the shaft having a distal end portion; a tensegrity wrist assembly including: a proximal coupler including: a hub secured to the distal end portion of the shaft; and an extension extending distally from the hub; a distal coupler including: a hub secured to the end effector; and an arm extending proximally from the hub of the distal coupler; and a link defining a link longitudinal axis, wherein the link longitudinal axis extends in a proximal to distal direction, the link including a proximal end secured to a proximal end of the arm of the distal coupler, and a distal end secured to a distal end of the extension of the proximal coupler, the proximal end of the link being prevented from moving distally relative to the arm of the distal coupler and the distal end of the link being prevented from moving proximally relative to the extension of the proximal coupler such that the link is configured to maintain an axial separation between the proximal and distal couplers; and an end effector pivotably coupled to a distal end of the distal coupler of the tensegrity wrist assembly.
17. 17 . The surgical instrument according to claim 16 , wherein the distal end of the extension of the proximal coupler is in overlapping alignment with and distal of the proximal end of the arm of the distal coupler.
18. 18 . The surgical instrument according to claim 16 , further comprising a first pair of first and second articulation cables each including a distal end portion secured to the end effector, such that the first pair of first and second articulation cables articulate the end effector relative to the shaft.
19. 19 . The surgical instrument according to claim 18 , wherein the hub of each of the proximal and distal couplers defines a first pair of first and second channels having the first pair of first and second articulation cables slidably positioned therein.
20. 20 . The surgical instrument according to claim 19 , further comprising a second pair of first and second articulation cables, wherein the hub of each of the proximal and distal couplers defines a second pair of first and second channels having the second pair of first and second articulation cables slidably positioned therein.

Description

CROSS-REFERENCE TO RELATED APPLICATION The present application claims priority to and the benefit of U.S. Patent Provisional Application No. 63/352,302, filed on Jun. 15, 2022. The entire contents of the foregoing application are incorporated by reference herein. BACKGROUND Some surgical robotic systems include a console supporting a surgical robotic arm and a surgical instrument or at least one end effector (e.g., forceps or a grasping tool) mounted to the robotic arm. The robotic arm provides mechanical power to the surgical instrument for its operation and movement. Each robotic arm may include an instrument drive unit operatively connected to the surgical instrument and coupled to the robotic arm via a rail. In operation, the robotic arm is moved to a position over a patient and then guides the surgical instrument into a small incision via a surgical trocar or a natural orifice of a patient to position the end effector at a work site within the patient's body. The instrument drive unit drives a rotation of each corresponding driven member of the attached surgical instrument to perform a surgical treatment. The instrument drive unit may be configured to articulate the end effector in a plurality of directions to adjust its pitch and/or yaw within a surgical site, to open/close jaw members, and/or to fire features thereof. SUMMARY In accordance with an aspect of the disclosure, a surgical instrument of a surgical robotic system is provided and includes a housing, a shaft extending distally from the housing, an end effector pivotably coupled to a distal end portion of the shaft, a first pair of first and second articulation cables, and a tensegrity wrist assembly. The articulation cables each have a proximal end portion operably coupled to an actuator, and a distal end portion secured to the end effector, such that the first pair of first and second articulation cables articulate the end effector relative to the shaft. The tensegrity wrist assembly includes a proximal coupler secured to the distal end portion of the shaft, a distal coupler secured to the end effector, and a link. The proximal coupler has an extension extending distally relative to the distal end portion of the shaft, and the distal coupler has an arm extending proximally relative to the end effector. The link is coupled to and extends between the extension of the proximal coupler and the arm of the distal coupler. The link is configured to apply opposing axial forces on the proximal and distal couplers. In aspects, the extension of the proximal coupler may have a distal end secured to a distal end of the link, and the arm of the distal coupler may have a proximal end secured to a proximal end of the link. In aspects, the distal end of the extension of the proximal coupler may be in overlapping alignment with and distal of the proximal end of the arm of the distal coupler. In aspects, the distal end of the extension of the proximal coupler and the proximal end of the arm of the distal coupler may be positioned on a central longitudinal axis defined by the tensegrity wrist assembly. In aspects, the distal end of the extension of the proximal coupler may be coaxial with and distal of the proximal end of the arm of the distal coupler. In aspects, the link may be a rigid or flexible rod and/or may be positioned on a central longitudinal axis defined by the tensegrity wrist assembly. In aspects, the proximal coupler may include a hub secured to the distal end portion of the shaft, and the extension. The extension may include first and second arms extending distally from the hub. The link may have a distal end secured to a distal end of each of the first and second arms of the extension. The distal end of the link may be prevented from moving proximally relative to the first and second arms of the proximal coupler. In aspects, the distal coupler may include a hub secured to the end effector, and the arm. The arm may extend proximally from the hub of the distal coupler. The link may have a proximal end secured to a proximal end of the arm and may be from moving distally relative to the arm of the distal coupler. In aspects, the hub of each of the proximal and distal couplers may define a first pair of first and second channels having the first pair of first and second articulation cables slidably positioned therein. In aspects, the surgical instrument may include a second pair of first and second articulation cables. The hub of each of the proximal and distal couplers may define a second pair of first and second channels having the second pair of first and second articulation cables slidably positioned therein. In accordance with further aspects of the disclosure, a surgical robotic system is provided that includes a surgical robotic arm, an instrument drive unit configured to be supported on the surgical robotic arm, and a surgical instrument configured to be coupled to and driven by the instrument drive unit. The surgical instrument includes a h