EP4161428A1

EP4161428A1 - Ball and socket articulation mechanisms for surgical instruments

Info

Publication number: EP4161428A1
Application number: EP21736467.8A
Authority: EP
Inventors: Matthew S. COWLEY
Original assignee: Covidien LP
Current assignee: Covidien LP
Priority date: 2020-06-09
Filing date: 2021-06-08
Publication date: 2023-04-12
Also published as: CN115697237A; WO2021252418A1

Abstract

A surgical instrument includes a housing, a shaft extending from the housing and having proximal and distal segments, a ball and socket joint interconnecting the proximal and distal segments, and an end effector assembly supported at the distal segment. An outer tube surrounds the shaft, may be operably coupled to the end effector assembly, and may be rotatable around the shaft to rotate the end effector assembly about a longitudinal axis defined by the shaft. First, second, and third cables extend about the ball and socket joint. A distal end of the first cable, a distal end of the second cable, and a distal end of the third cable may be equally spaced around an outer surface of a socket of the ball and socket joint. Longitudinal translation of at least one of the first, second, or third cables causes the end effector assembly to articulate relative to the longitudinal axis.

Description

BALL AND SOCKET ARTICULATION MECHANISMS FOR SURGICAL

INSTRUMENTS

FIELD

[0001] The present disclosure relates to surgical instruments and, more specifically, to ball and socket articulation mechanisms for surgical instruments such as, for example, for use in robotic surgical systems.

BACKGROUND

[0002] Robotic surgical systems are increasingly utilized in various surgical procedures.

Some robotic surgical systems include a console supporting a robotic arm. One or more different surgical instruments may be configured for use with the robotic surgical system and selectively mountable to the robotic arm. The robotic arm provides one or more inputs to the mounted surgical instrument to enable operation of the mounted surgical instrument.

[0003] The number, type, and configuration of inputs provided by the robotic arm of a robotic surgical system are constraints in the design of surgical instruments configured for use with the robotic surgical system. That is, in designing a surgical instrument compatible for mounting on, and use with, the robotic arm of a robotic surgical system, consideration should be given as to how to utilize the available inputs provided by the robotic arm to achieve the desired functionality of the surgical instrument.

SUMMARY

[0004] As used herein, the term “distal” refers to the portion that is being described which is further from an operator (whether a surgeon or robotic arm), while the term “proximal” refers to the portion that is being described which is closer to the operator. The terms “about,” substantially,” and the like, as utilized herein, are meant to account for manufacturing, material, environmental, use, and/or measurement tolerances and variations. Further, to the extent consistent, any of the aspects described herein may be used in conjunction with any or all of the other aspects described herein.

[0005] Provided in accordance with aspects of the present disclosure is a surgical instrument including a housing, a shaft extending from the housing and having proximal and distal segments, a ball and socket joint interconnecting the proximal and distal segments of the shaft, and an end effector assembly supported at the distal segment of the shaft. The end effector assembly may include a first jaw member and a second jaw member. An outer tube surrounds the shaft and is operably coupled to the end effector assembly. The outer tube is rotatable around the shaft and is configured to rotate the end effector assembly about the longitudinal axis defined by the shaft. The surgical instrument also includes a first cable, a second cable, and a third cable extending about the ball and socket joint. A distal end of the first cable, a distal end of the second cable, and a distal end of the third cable may be equally spaced around an outer surface of a socket of the ball and socket joint. Proximal longitudinal translation of at least one of the first cable, second cable, or the third cable causes the end effector assembly to articulate relative to a longitudinal axis defined by the shaft.

[0006] In an aspect, at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable may define a collar operably coupled to a post of at least one of a distal segment of the shaft or the second jaw member. Alternatively, at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable may define a ball operably coupled to a post of at least one of the distal segment of the shaft or the second jaw member.

[0007] In an aspect, a distal end of the outer tube may be operably coupled to the first jaw member and longitudinal movement of the outer tube may cause the first jaw member to pivot relative to the second jaw member.

[0008] In an aspect, the second jaw member may be an ultrasonic blade configured to transmit ultrasonic energy, the socket of the ball and socket joint may be defined within a proximal portion of the ultrasonic blade, and a ball of the ball and socket joint may be formed on a distal end of an elongated rod configured to transmit ultrasonic energy to the ultrasonic blade. [0009] In an aspect, proximal longitudinal translation of the second cable and the third cable causes the end effector assembly to articulate in a first direction relative to the longitudinal axis defined by the shaft, and proximal longitudinal translation of the first cable causes the end effector assembly to articulate in a second direction, opposite the first direction, relative to the longitudinal axis defined by the shaft. Additionally, proximal longitudinal translation of the first cable and the second cable causes the end effector assembly to articulate in a third direction relative to the longitudinal axis defined by the shaft and proximal longitudinal translation of the third cable causes the end effector assembly to articulate in a fourth direction, opposite the third direction, relative to the longitudinal axis defined by the shaft.

[0010] In an aspect, an articulation sub-assembly may be disposed within the housing and may be operably coupled to a proximal end of the first cable, a proximal end of the second cable, and a proximal end of the third cable. The articulation sub-assembly is configured to cause longitudinal translation of the first cable, the second cable, and the third cable. The articulation sub-assembly may include a first lead screw and a first nut threadingly coupled to the first lead screw, a second lead screw and a second nut threadingly coupled to the second lead screw, and a third lead screw and a third nut threadingly coupled to the third lead screw. The proximal end of the first cable is coupled to the first nut, the proximal end of the second cable is coupled to the second nut, and the proximal end of the third cable coupled to the third nut.

[0011] Provided in accordance with another aspect of the present disclosure is a surgical system including a robotic surgical system, having a control device and a robotic arm, and a surgical instrument configured to operably couple to the robotic arm. The surgical instrument includes a housing, a shaft extending from the housing and defining a longitudinal axis, an elongated rod extending through the shaft and defining a ball at a distal end of the elongated rod, and an end effector assembly including a socket operably coupled to the ball of the elongated rod. The end effector assembly may include a first jaw member and a second jaw member. An outer tube surrounds the shaft and is operably coupled to the end effector assembly. The outer tube is rotatable around the shaft and is configured to rotate the end effector assembly about the longitudinal axis defined by the shaft. The surgical instrument may also include a first cable, a second cable, and a third cable extending through the shaft and operably coupled to the end effector assembly. A distal end of the first cable, a distal end of the second cable, and a distal end of the third cable may be equally spaced around an outer surface of the socket. Proximal longitudinal translation of at least one of the first cable, second cable, or the third cable causes the end effector assembly to articulate relative to the longitudinal axis defined by the shaft,

[0012] In an aspect, at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable may define a collar operably coupled to a post of at least one of a distal segment of the shaft or the second jaw member. Alternatively, at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable may define a ball operably coupled to a post of at least one of the distal segment of the shaft or the second jaw member.

[0013] In an aspect, a distal end of the outer tube may be operably coupled to the first jaw member and longitudinal movement of the outer tube causes the first jaw member to pivot relative to the second jaw member.

[0014] In an aspect, the second jaw member may be an ultrasonic blade configured to transmit ultrasonic energy and the first jaw member is a clamp arm.

[0015] In an aspect, proximal longitudinal translation of the second cable and the third cable causes the end effector assembly to articulate in a first direction relative to the longitudinal axis defined by the shaft, and proximal longitudinal translation of the first cable causes the end effector assembly to articulate in a second direction, opposite the first direction, relative to the longitudinal axis defined by the shaft. Additionally, proximal longitudinal translation of the first cable and the second cable causes the end effector assembly to articulate in a third direction relative to the longitudinal axis defined by the shaft and proximal longitudinal translation of the third cable causes the end effector assembly to articulate in a fourth direction, opposite the third direction, relative to the longitudinal axis defined by the shaft.

[0016] In an aspect, an articulation sub-assembly may be disposed within the housing and may be operably coupled to a proximal end of the first cable, a proximal end of the second cable, and a proximal end of the third cable. The articulation sub-assembly is configured to cause longitudinal translation of the first cable, the second cable, and the third cable. The articulation sub-assembly may include a first lead screw and a first nut threadingly coupled to the first lead screw, a second lead screw and a second nut threadingly coupled to the second lead screw, and a third lead screw and a third nut threadingly coupled to the third lead screw. The proximal end of the first cable is coupled to the first nut, the proximal end of the second cable is coupled to the second nut, and the proximal end of the third cable coupled to the third nut.

[0017] Provided in accordance with another aspect of the present disclosure is a surgical instrument including a housing, a shaft extending from the housing and defining a longitudinal axis, an elongated rod extending through the shaft and defining a ball at a distal end of the elongated rod, and an end effector assembly defining a socket operably coupled to the ball of the elongated rod. The surgical instrument further includes a first cable, a second cable, and a third cable extending through the shaft and operably coupled to the end effector assembly. A distal end of the first cable, a distal end of the second cable, and a distal end of the third cable are equally spaced around an outer surface of the socket of the end effector assembly. Proximal longitudinal translation of the second cable and the third cable causes the end effector assembly to articulate in a first direction relative to the longitudinal axis defined by the shaft, and proximal longitudinal translation of the first cable causes the end effector assembly to articulate in a second direction, opposite the first direction, relative to the longitudinal axis defined by the shaft. [0018] In an aspect, proximal longitudinal translation of the first cable and the second cable causes the end effector assembly to articulate in a third direction relative to the longitudinal axis defined by the shaft, and proximal longitudinal translation of the third cable causes the end effector assembly to articulate in a fourth direction, opposite the third direction, relative to the longitudinal axis defined by the shaft.

[0019] In an aspect, the surgical instrument further includes an articulation sub-assembly disposed within the housing and operably coupled to a proximal end of the first cable, a proximal end of the second cable, and a proximal end of the third cable. The articulation sub-assembly is configured to cause longitudinal translation of the first cable, the second cable, and the third cable.

[0020] In an aspect, at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable defines a collar operably coupled to a post of at least one of a distal segment of the shaft or the end effector assembly. Alternatively, at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable defines a ball operably coupled to a post of at least one of the distal segment of the shaft or the end effector assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Various aspects and features of the present disclosure are described hereinbelow with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views.

[0022] FIG. 1A is a perspective view of a surgical instrument provided in accordance with the present disclosure configured for mounting on a robotic arm of a robotic surgical system; [0023] FIG. IB is a rear, perspective view of a proximal portion of the surgical instrument of FIG. 1A; [0024] FIG. 2 is a schematic illustration of an exemplary robotic surgical system configured to releasably receive the surgical instrument of FIG. 1A;

[0025] FIG. 3 is a side, perspective view of the surgical instrument of FIG. 1A with an outer shell removed;

[0026] FIG. 4A is a rear, perspective view of a ball and socket configuration for use with the surgical instrument of FIG. 1A according to one aspect of the disclosure;

[0027] FIG. 4B is a rear, perspective view of another ball and socket configuration for use with the surgical instrument of FIG. 1A according to another aspect of the disclosure;

[0028] FIG. 5 A is a side view of a distal portion of the surgical instrument of FIG. 1A with an end effector assembly thereof articulated;

[0029] FIG. 5B is a top view of the distal portion of the surgical instrument of FIG. 1A with the end effector assembly articulated;

[0030] FIG. 6 is a side view of the distal portion of the surgical instrument of FIG. 1A with the end effector assembly articulated and with an outer tube removed;

[0031] FIG. 7A is a front view of the end effector assembly of the surgical instrument of FIG. 1A;

[0032] FIG. 7B is a side view of the end effector assembly of the surgical instrument of FIG. 1A;

[0033] FIGS. 8A-8D are front views of the end effector assembly of the surgical instrument of FIG. 1A in various articulated positions; and

[0034] FIG. 9 is a front, side perspective view illustrating an articulation envelope of the end effector assembly of the surgical instrument of FIG. 1A.

DETAILED DESCRIPTION

[0035] The present disclosure relates to surgical instruments and, more specifically, to ball and socket articulation mechanisms for surgical instruments such as, for example, for use in robotic surgical systems.

[0036] Robotic devices typically utilize one or more articulating joints to increase dexterity and access of the surgical instruments within the abdominal cavity. The articulating joints are controlled by cables that are coupled to respective motors. For example, a typical robot may have four motors to control four cables that could be used for articulation, jaw pivoting, blade throws, and/or any other mechanical action that would be needed for an end effector. With wristed joints, this often requires two motors for achieving movement within just two degrees of freedom.

[0037] This disclosure provides an articulation mechanism utilizing a ball and socket joint with three articulation cables coupled to the socket. The end effector assembly (e.g., ultrasonic blade and clamping jaw, grasping jaws, bipolar jaws, electrosurgical vessel sealing jaws, monopolar electrode, etc.) can spin on the ball and socket joint with three co-located degrees of freedom, allowing the articulation to take place within a three-dimensional cone envelope as opposed to a plane and with a compact configuration. The end effector assembly is rotatable around its central axis, enabling the positioning of the end effector assembly in any orientation necessary to grasp or treat tissue.

[0038] The disclosed articulation mechanism having a ball and socket joint has an advantage over traditional hinged joints at least because of its compactness and its ability to reach any point in its movement envelope with fewer motions, fewer cables, and/or fewer motors. In particular, the disclosed ball and socket articulation configuration requires only three articulation cables and reduces the number of control motors needed to actuate (e.g., articulate). As described in detail below, each of the three articulation cables is independently controlled by pulling on, or relaxing (e.g., pushing), one or more of the three articulation cables. The three articulation cables are the minimal number of wires needed to articulate a spherical joint to any location in its articulation envelope. Additional or alternative aspects and features of the disclosure are also detailed hereinbelow.

[0039] In aspects, the actuation cables are coupled to the socket portion of the joint in such a manner that enables movement and can be coupled to the socket portion of the joint via another ball and socket joint, a pin and collar joint, or any other type of joint that couples the actuation cables to the socket, but still allows for independent motion. A flexible outer tube, in aspects, is rotatable to rotate the end effector assembly. This enables the range of articulation of the end effector assembly to reach any orientation in its articulation envelope. The outer tube may be articulated via segmentations, helical U-joints, or other configurations, while maintaining torsional and linear integrity.

[0040] Referring to FIGS. 1A-1B, 2, and 3, a surgical instrument 10 provided in accordance with the present disclosure generally includes a housing 20, a shaft 30 extending distally from housing 20, an end effector assembly 40 extending distally from shaft 30, and a gearbox assembly 100 (FIG.3) disposed within housing 20 and operably associated with end effector assembly 40. Surgical instrument 10 is detailed herein as an articulating electrosurgical forceps configured for use with a robotic surgical system, e.g., robotic surgical system 1000 (FIG. 2). However, the aspects and features of surgical instrument 10 provided in accordance with the present disclosure, detailed below, are equally applicable for use with other suitable surgical instruments and/or in other suitable surgical systems.

[0041] With particular reference to FIG. 1A, housing 20 of surgical instrument 10 includes a first body portion 22a, a second body portion 22b, and a proximal face plate 24 that cooperate to enclose gearbox assembly 100 (FIG. 3) therein. Proximal face plate 24 includes apertures defined therein through which first input 110, second input 120, third input 130, and fourth input 140 (FIG. IB) of gearbox assembly 100 extend for coupling to drivers (e.g., motors) of a robotic surgical system 1000 (FIG. 2). A pair of latch levers 26 (only one of which is illustrated in FIG. 1A) extend outwardly from opposing sides of housing 20 and enable releasable engagement of housing 20 with a robotic arm of a surgical system, e.g., robotic surgical system 1000 (FIG. 2). [0042] Shaft 30 of surgical instrument 10 includes a proximal segment 34 and a distal segment 32. Distal segment 32 is operably coupled to end effector assembly 40 and is configured to articulate relative to the proximal segment 34. An outer tube 45 surrounds the proximal segment 34 and distal segment 32 of shaft 30 and is operably coupled to at least a portion of end effector assembly 40. At least a portion of the outer tube 45 is flexible to enable articulation of the end effector assembly 40 relative to proximal segment 34 of shaft 30. Additionally, or alternatively, a portion of outer tube 45 may have a spiral-shaped cut or other flexibility-enhancing feature or structure, to enable articulation of end effector assembly 40. In configurations, outer tube 45 is rotatable relative to shaft 30 and a distal end of outer tube 45 is fixedly coupled to at least a portion of end effector assembly 40 (e.g., fixedly coupled to first jaw member 42) such that rotation of outer tube 45 causes corresponding rotation of the at least a portion of end effector assembly 40 (e.g., first jaw member 42) about longitudinal axis “L” of surgical instrument 10.

[0043] A plurality of articulation cables 38 (FIG. 4A), e.g., three (3) articulation cables, or other suitable actuators, extend through shaft 30 and are coupled at their distal ends to distal segment 32 of shaft 30 or second jaw member 44 (e.g., where second jaw member is an ultrasonic blade). More specifically, articulation cables 38 are operably coupled to distal segment 32 of shaft 30, or second jaw member 44, at the distal ends thereof and extend proximally from distal segment 32 of shaft 30, or second jaw member 44, through proximal segment 34 of shaft 30, and into housing 20, wherein articulation cables 38 operably couple to an articulation sub-assembly 200 of gearbox assembly 100 to enable selective articulation of distal segment 32 (and, thus end effector assembly 40) relative to proximal segment 34 and housing 20. [0044] Continuing with reference to FIG. 1 A, end effector assembly 40 includes a first jaw member 42 and a second jaw member 44 where the first jaw member 42 is pivotably coupled relative to the second jaw member 44 about a pivot 50. Jaw member 42 may be pivotably coupled to distal segment 32 of shaft 30 and/or to outer tube 45. Such a configuration enables pivoting of jaw member 42 relative to jaw member 44 and distal segment 32 of shaft 30 between a spaced-apart position (e.g., an open position of end effector assembly 40) and an approximated position (e.g., a closed position of end effector assembly 40) for grasping tissue therebetween, for example, by linear motion of outer tube 45.

[0045] In some configurations, the first, movable jaw member 42 includes a more-rigid structural body supporting a more-compliant jaw liner (defining a tissue-contacting surface 46) and the second jaw member 44 is an ultrasonic blade (defining a tissue-contacting surface 48) wherein, in the closed position, the jaw liner and ultrasonic blade cooperate to grasp tissue between the tissue-contacting surfaces 46, 48 thereof. In such configurations, an ultrasonic transducer (not shown) may be positioned proximally of the articulating portion, e.g., within proximal segment 34 of shaft 30 or within housing 20 and a waveguide (not shown) including one or more articulating portions, e.g., flexible portions, joint portions, linkage portions, etc., is provided to extend through the articulating portion to interconnect an ultrasonic horn extending from the ultrasonic transducer with the blade such that ultrasonic energy produced by the ultrasonic transducer may be transmitted along the waveguide to the blade to treat tissue therewith regardless of the articulation of the articulating portion. Alternatively, the ultrasonic transducer may be disposed within distal segment 32 of shaft 30, e.g., distally of the articulating portion, and may connect to the blade via the ultrasonic horn (with or without and ultrasonic waveguide therebetween) such that ultrasonic energy produced by the ultrasonic transducer is transmitted along the ultrasonic horn (and waveguide, where provided) to the blade for treating tissue with ultrasonic energy. [0046] In other configurations, as noted above, jaw members 42, 44 may be configured for supplying other energy, e.g., monopolar RF, bipolar RF, microwave, thermal laser, etc., and/or for other purposes, e.g., grasping, stapling, clipping. For example, with respect to bipolar RF energy, a tissue-contacting surface 46 of first jaw member 42 and tissue-contacting surface 48 of second jaw member 44 are at least partially formed from an electrically conductive material and are energizable to different potentials to enable the conduction of electrical energy through tissue grasped therebetween. In such configurations, surgical instrument 10 defines a conductive pathway (not shown) through housing 20 and shaft 30 to end effector assembly 40 that may include lead wires, contacts, and/or electrically-conductive components to enable electrical connection of at least one of tissue-contacting surface 46 of first jaw member 42 or tissue contacting surface 48 of second jaw member 44 to an energy source (not shown), e.g., an electrosurgical generator, for supplying energy to at least one of tissue-contacting surface 46 or tissue-contacting surface 48 to treat, e.g., seal, tissue grasped between first jaw member 42 and second jaw member 44.

[0047] As an alternative to unilateral movement, bilateral movement may be enabled whereby both of first jaw member 42 and second jaw member 44 are pivotable relative to one another and distal segment 32 of shaft 30.

[0048] In aspects, regardless of the particular energy modality and/or configuration of the jaw members 42, 44, a drive rod (not shown) is operably coupled to at least one of the first jaw member 42 or second jaw member 44 such that longitudinal actuation of the drive rod (not shown) pivots first jaw member 42 relative to second jaw member 44 between the spaced-apart (e.g., open) and approximated (e.g., closed) positions (or vice versa). However, other suitable mechanisms and/or configurations for pivoting first jaw member 42 relative to second jaw member 44 between the spaced-apart and approximated positions are also contemplated. For example, in an aspect, a distal end of outer tube 45 is coupled to at least one of first jaw member 42 or second jaw member 44 and distal longitudinal translation of the outer tube 45 pivots at least one of the first jaw member 42 or the second jaw member 44 relative to the other.

[0049] With momentary reference to FIGS. 4A and 4B, a proximal portion of second jaw member 44 may extend through distal segment 32 of shaft 30 and define a socket 442 which is coupled to a ball 444 formed on a distal end of an elongated rod 446 or other suitable support extending through shaft 30 to form a ball and socket joint between the second jaw member 44 and the elongated rod 446. In configurations where second jaw member 44 is an ultrasonic blade and the ultrasonic transducer is proximal of the articulating portion, the socket 442 may be defined within a proximal end portion of the ultrasonic blade, and the elongated rod 446 (including the ball 444 formed on the distal end portion thereof) may be a waveguide articulatably coupled to, and configured to transmit ultrasonic energy to, the blade by way of the ball and socket joint, regardless of an articulated position of the blade relative to the waveguide. Alternatively, the socket 442 may be formed on distal segment 32 of shaft 30 or another structure fixed in engagement therewith and/or the ball 442 may be formed on proximal segment 32 of shaft 30 or another structure fixed in engagement therewith. Additionally, or alternatively, the ball and socket 444, 442 may be reversed.

[0050] With reference to FIG. 3, gearbox assembly 100 is disposed within housing 20 and includes an articulation sub-assembly 200 and a jaw drive sub-assembly 400. Articulation sub- assembly 200 is operably coupled between first input 110, second input 120, and third input 130 (FIG. IB), respectively, of gearbox assembly 100 and articulation cables 38 (FIG. 1A) such that, upon receipt of appropriate inputs into first input 110, second input 120, and/or third input 130, articulation sub-assembly 200 manipulates articulation cables 38 (FIG. 1A) to articulate end effector assembly 40 in a desired direction relative to a longitudinal axis “L” defined by shaft 30, e.g., to pitch and/or yaw end effector assembly 40.

[0051] Rotation of a lead screw of articulation sub-assembly 200 causes corresponding longitudinal translation of a respective nut along a length of the lead screw. Each cable 38 is coupled to a respective nut such that proximal longitudinal translation of a nut causes proximal longitudinal translation of the respective cable 38 and distal longitudinal translation of the nut causes slack to be provided to the corresponding cable 38 coupled thereto. With this configuration, rotation of first input 110, second input 120, and third input 130 effects longitudinal translation of the respective nuts which are coupled to proximal portions of respective articulation cables 38 (FIG. 1A) to articulate end effector assembly 40 relative to a longitudinal axis “L” defined by shaft 30. In particular, articulation sub-assembly 200 of gearbox assembly 100 includes first lead screw 111, second lead screw 112, and third lead screw 113 respectively coupled to first input 110, second input 120, and third input 130. A first nut 210 is threadingly coupled to first lead screw 111, a second nut 220 is threadingly coupled to second lead screw 112, and a third nut 230 is threadingly coupled to third lead screw 113. Rotation of first input 110, second input 120, and third input 130 causes respective rotation of first lead screw 111, second lead screw 112, and third lead screw 113, which in turn, causes corresponding respective longitudinal translation of first nut 210, second nut 220, or third nut 230.

[0052] Jaw drive sub-assembly 400 is operably coupled between fourth input 140 (FIG. IB) of gearbox assembly 100 and a drive rod (not shown) or other suitable structure (e.g., outer tube 45), such that, upon receipt of appropriate input into fourth input 140, jaw drive sub-assembly 400 pivots first jaw member 42 and/or second jaw member 44 between spaced-apart and approximated positions to grasp tissue therebetween and apply a closure force within an appropriate closure force range. In aspects, jaw drive sub-assembly 400 is operably coupled to outer tube 45 such that jaw drive sub-assembly 400 can both longitudinally translate outer tube 45 (e.g., to pivot second jaw member 45) and rotate outer tube 45 (e.g., to rotate end effector assembly 40 or a portion thereof about longitudinal axis “L”).

[0053] Gearbox assembly 100 is configured to operably interface with a robotic surgical system 1000 (FIG. 2) when surgical instrument 10 is mounted on robotic surgical system 1000 (FIG. 2), to enable robotic operation of gearbox assembly 100 to provide the above-detailed functionality. That is, robotic surgical system 1000 (FIG. 2) selectively provides inputs to first input 110, second input 120, third input 130, and fourth input 140 of gearbox assembly 100 to articulate end effector assembly 40, grasp tissue between first jaw member 42 and second jaw member 44, and/or treat grasped tissue. However, it is also contemplated that gearbox assembly 100 may be configured to interface with any other suitable surgical system, e.g., a manual surgical handle, a powered surgical handle, etc. For the purposes herein, robotic surgical system 1000 (FIG. 2) is generally described.

[0054] Turning to FIG. 2, robotic surgical system 1000 is configured for use in accordance with the present disclosure. Aspects and features of robotic surgical system 1000 not germane to the understanding of the present disclosure are omitted to avoid obscuring the aspects and features of the present disclosure in unnecessary detail.

[0055] Robotic surgical system 1000 generally includes a plurality of robot arms 1002, 1003; a control device 1004; and an operating console 1005 coupled with control device 1004. Operating console 1005 may include a display device 1006, which may be set up in particular to display three-dimensional images; and manual input devices 1007, 1008, by means of which a person, e.g., a surgeon, may be able to telemanipulate robot arms 1002, 1003 in a first operating mode. Robotic surgical system 1000 may be configured for use on a patient 1013 lying on a patient table 1012 to be treated in a minimally invasive manner. Robotic surgical system 1000 may further include a database 1014, in particular coupled to control device 1004, in which are stored, for example, pre-operative data from patient 1013 and/or anatomical atlases.

[0056] Each of the robot arms 1002, 1003 may include a plurality of members, which are connected through joints, and mounted devices which may be, for example, a surgical tool “ST.” One or more of the surgical tools “ST” may be surgical instrument 10 (FIG. 1 A), thus providing such functionality on a robotic surgical system 1000.

[0057] Robot arms 1002, 1003 may be driven by electric drives, e.g., motors, connected to control device 1004. Control device 1004, e.g., a computer, may be configured to activate the motors, in particular by means of a computer program, in such a way that robot arms 1002, 1003, and, thus, their mounted surgical tools “ST” execute a desired movement and/or function according to a corresponding input from manual input devices 1007, 1008, respectively. Control device 1004 may also be configured in such a way that it regulates the movement of robot arms 1002, 1003 and/or of the motors.

[0058] Referring to FIGS. 1 A-1B, 3, and 4A-4B, as described above, with respect to articulation of end effector assembly 40 relative to proximal segment 34 of shaft 30, actuation of articulation cables 38 may be effected by rotation of first input 110, second input 120, or third input 130. In particular, a proximal end of a first cable 381 is operably coupled to first input 110 via first nut 210, a proximal end of a second cable 382 is operably coupled to second input 120 via second nut 220, and a proximal end of a third cable 383 is operably coupled to third input 130 via a third nut 230. A distal end 381b of first cable 381, a distal end 382b of second cable 382, and a distal end 383b of third cable 383 are each operably coupled to distal segment 32 of shaft 30 or the second jaw member 44 (e.g., where second jaw member is an ultrasonic blade), for example, being equally spaced around a circumference of the distal segment 32 or being equally spaced around an outer surface of socket 442 of second jaw member 44. In particular, distal ends 381b, 382b, and 383 b of first, second, and third wires 381, 382, and 383, may define respective collars 391, 392, and 393 to have a collared configuration (FIG. 4 A) for pivotably coupling to corresponding posts (or balls) of distal segment 32 of shaft 30 or second jaw member 44. Alternatively, distal ends 381b, 382b, and 383b of first, second, and third wires 381, 382, and 383, may define respective balls 395, 396, 397 to have a ball and socket configuration (FIG. 4B) for pivotably coupling to corresponding sockets of distal segment 32 of shaft 30 or second jaw member 44.

[0059] With reference to FIGS. 5A-5B, 7A-7B, 8A-8D, and 9, articulation of end effector assembly 40 to a desired orientation is caused by coordinated actuation (e.g., longitudinal movement) of first cable 381, second cable 382, and/or third cable 383, and/or rotation of outer tube 45. The end effector assembly 40 is articulatable about a range of motion defining an articulation envelope 40e.

[0060] To achieve a first direction, e.g., vertical upward, articulation of end effector assembly 40 (FIG. 8A), simultaneous and substantially equal proximal longitudinal translation of second cable 382 and third cable 383 in the direction of arrow “D” (FIG. 5B), met with corresponding distal longitudinal translation of first cable 381 in the direction of arrow Έ” (FIG. 5B), or slack provided to first cable 381, causes the end effector assembly 40 to articulate in the direction of arrow “DD” (FIG. 5A and FIG. 8A). On the other hand, proximal longitudinal translation of first cable 381, in an opposite direction than that of arrow “E” (FIG. 5B), met with corresponding simultaneous and substantially equal distal longitudinal translation of second cable 382 and third cable 383 in a direction opposite than that of arrow “D” (FIG. 5B), or slack provided to second cable 382 and third cable 383, cases end effector assembly 40 to articulate in the direction of arrow “EE” (FIG. 8A), e.g., a second, opposite (vertical downward) direction. [0061] To achieve third and fourth directions, e.g., horizontal articulation, of end effector assembly 40 (FIG. 8B), proximal longitudinal translation of second cable 382 in the direction of arrow “D” (FIG. 5B) met with simultaneous distal longitudinal translation of third cable 383 in the direction opposite that of arrow “D” (FIG. 5B), or slack provided to third cable 383, causes the end effector assembly 40 to articulate horizontally in the direction of arrow “FF” (FIG. 8B). On the other hand, proximal longitudinal translation of third cable 383 in the direction of arrow “D” (FIG. 5B) met with simultaneous distal longitudinal translation of second cable 382 in the direction opposite that of arrow “D” (FIG. 5B), or slack provided to second cable 382, causes the end effector assembly 40 to articulate horizontally in the direction of arrow “GG” (FIG. 8B). In both cases, that is, when it is desired to articulate end effector assembly 40 in only a horizontal direction of either arrows “FF” or “GG”, and not be caused to have any vertical movement, first cable 381 is caused to longitudinally translate and/or outer tube 45 is caused to rotate a certain degree to ensure true horizontal articulation of the end effector assembly 40.

[0062] End effector assembly 40 may also be caused to articulate in any one of an infinite number of mixed vertical-horizontal directions (FIG. 8C) by adjusting the relative degree of longitudinal movement (length of actuation) of each of first cable 381, second cable 382, and third cable 383. For example, as illustrated in FIG. 8C, end effector assembly 40 is articulated vertically in the direction of arrow “DD” and horizontally in the direction of arrow “GG.” Such a mixed articulation is accomplished by unequal proximal longitudinal translation of second cable 382 and third cable 383 in the direction of arrow “D” (FIG. 5B), where the degree to which third cable 383 is longitudinally translated is greater than that of second cable 382. The proximal longitudinal translation of both of second cable 382 and third cable 383 in the direction of arrow “D”, although unequal, is met with simultaneous distal translation of first cable 381 in the direction of arrow Έ” (FIG. 5B), or slack provided to first cable 381. Such a specific description is merely exemplary, and it is understood that any combination of actuation between first cable 381, second cable 382, and third cable 383, and/or rotation of outer tube 45, may be adjusted to cause the end effector assembly 40 to articulate in the vertical, horizontal, or combined vertical and horizontal directions within the articulation envelope 40e (FIG. 9).

[0063] In addition to the articulation of end effector assembly 40 described above, rotation of outer tube 45 around shaft 30 also causes end effector assembly 40 to rotate about the central longitudinal axis “F” defined by shaft 30, for example, in the direction of arrow “R” (FIGS. 7A- 7B and 8D). Such a rotation of end effector assembly 40 may be possible while end effector assembly 40 is not articulated (when end effector assembly 40 is longitudinally aligned with longitudinal axis “F”) and also when end effector assembly 40 is articulated in any of the vertical, horizontal, or combined vertical-horizontal directions. Rotation of outer tube 45 orients one or both of jaw members 42, 44 in a desired orientation. In some configurations, rotation of outer tube 45 rotates both jaw members 42, 44 in conjunction with one another. Alternatively, rotation of outer tube 45 may rotate jaw member 42 about jaw member 44 to orient jaw member 42 at different radial positions about jaw member 44 for clamping tissue therebetween at the corresponding radial position. The combination of the articulation of end effector assembly 40, enabled by longitudinal translation of the first cable 381, second cable 382, and/or third cable 383, with the rotation of end effector assembly 40 (or a portion thereof), enabled by rotation of outer tube 45, permits a range of motion for end effector assembly 40 anywhere within the articulation envelope 40e (FIG. 9).

[0064] While several specific versions of devices in accordance with the present disclosure are 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. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular aspects. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

[0065] It should be understood that various features of the devices disclosed herein may be combined in different combinations than the combinations specifically presented in the description and accompanying drawings. It should also be understood that, depending on the example, certain acts or events of any of the processes or methods described herein may be performed in a different sequence, may be added, merged, or left out altogether (e.g., all described acts or events may not be necessary to carry out the techniques). In addition, while certain features of devices in accordance with the present disclosure are described as being performed by a single module or unit for purposes of clarity, it should be understood that the techniques of this disclosure may be performed by a combination of units or modules associated with, for example, a medical device.

Claims

WHAT IS CLAIMED IS:

1. A surgical instrument comprising: a housing; a shaft extending from the housing and defining a longitudinal axis, the shaft including a proximal segment and a distal segment; a ball and socket joint interconnecting the proximal and distal segments of the shaft; an end effector assembly supported at the distal segment of the shaft; an outer tube surrounding the shaft and operably coupled to the end effector assembly, wherein the outer tube is rotatable around the shaft and configured to rotate the end effector assembly about the longitudinal axis defined by the shaft; and a first cable, a second cable, and a third cable extending about the ball and socket joint, wherein proximal longitudinal translation of at least one of the first cable, second cable, or the third cable causes the end effector assembly to articulate relative to the longitudinal axis defined by the shaft.

2. The surgical instrument of claim 1, wherein at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable defines at least one of: a collar operably coupled to a post of at least one of a distal segment of the shaft or the second jaw member; or a ball operably coupled to a post of at least one of the distal segment of the shaft or the second jaw member.

3. The surgical instrument of claim 1, wherein the end effector assembly includes a first jaw member and a second jaw member.

4. The surgical instrument of claim 3, wherein a distal end of the outer tube is operably coupled to the first jaw member and longitudinal movement of the outer tube causes the first jaw member to pivot relative to the second jaw member.

5. The surgical instrument of claim 3, wherein the second jaw member is an ultrasonic blade configured to transmit ultrasonic energy, the socket of the ball and socket joint is defined within a proximal portion of the ultrasonic blade, and a ball of the ball and socket joint is formed on a distal end of an elongated rod configured to transmit ultrasonic energy to the ultrasonic blade.

6. The surgical instrument of claim 1, wherein: proximal longitudinal translation of the second cable and the third cable causes the end effector assembly to articulate in a first direction relative to the longitudinal axis defined by the shaft; and proximal longitudinal translation of the first cable causes the end effector assembly to articulate in a second direction, opposite the first direction, relative to the longitudinal axis defined by the shaft.

7. The surgical instrument of claim 6, wherein: proximal longitudinal translation of the first cable and the second cable causes the end effector assembly to articulate in a third direction relative to the longitudinal axis defined by the shaft; and proximal longitudinal translation of the third cable causes the end effector assembly to articulate in a fourth direction, opposite the third direction, relative to the longitudinal axis defined by the shaft.

8. The surgical instrument of claim 1, further comprising an articulation sub-assembly disposed within the housing and operably coupled to a proximal end of the first cable, a proximal end of the second cable, and a proximal end of the third cable, the articulation sub-assembly configured to cause longitudinal translation of the first cable, the second cable, and the third cable.

9. The surgical instrument of claim 8, wherein the articulation sub-assembly includes: a first lead screw and a first nut threadingly coupled to the first lead screw, the proximal end of the first cable coupled to the first nut; a second lead screw and a second nut threadingly coupled to the second lead screw, the proximal end of the second cable coupled to the second nut; and a third lead screw and a third nut threadingly coupled to the third lead screw, the proximal end of the third cable coupled to the third nut.

10. The surgical instrument of claim 1, wherein a distal end of the first cable, a distal end of the second cable, and a distal end of the third cable are equally spaced around an outer surface of a socket of the ball and socket joint.

11. A surgical system comprising: a robotic surgical system including a control device and a robotic arm; and a surgical instrument configured to operably couple to the robotic arm of the robotic surgical system, the surgical instrument comprising: a housing; a shaft extending from the housing and defining a longitudinal axis; an elongated rod extending through the shaft and defining a ball at a distal end of the elongated rod; an end effector assembly including a first jaw member and a second jaw member, the second jaw member defining a socket operably coupled to the ball of the elongated rod; an outer tube surrounding the shaft and operably coupled to the end effector assembly, wherein the outer tube is rotatable around the shaft and configured to rotate the end effector assembly about the longitudinal axis defined by the shaft; and a first cable, a second cable, and a third cable extending through the shaft and operably coupled to the end effector assembly, wherein a distal end of the first cable, a distal end of the second cable, and a distal end of the third cable are equally spaced around an outer surface of the socket of the second jaw member and wherein proximal longitudinal translation of at least one of the first cable, second cable, or the third cable causes the end effector assembly to articulate relative to the longitudinal axis defined by the shaft.

12. The surgical system of claim 11, wherein at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable defines at least one of: a collar operably coupled to a post of at least one of a distal segment of the shaft or the second jaw member; or a ball operably coupled to a post of at least one of the distal segment of the shaft or the second jaw member.

13. The surgical system of claim 11, wherein a distal end of the outer tube is operably coupled to the first jaw member and longitudinal movement of the outer tube causes the first jaw member to pivot relative to the second jaw member.

14. The surgical system of claim 11, wherein the second jaw member is an ultrasonic blade configured to transmit ultrasonic energy and the first jaw member is a clamp arm.

15. The surgical system of claim 11, wherein: proximal longitudinal translation of the second cable and the third cable causes the end effector assembly to articulate in a first direction relative to the longitudinal axis defined by the shaft; and proximal longitudinal translation of the first cable causes the end effector assembly to articulate in a second direction, opposite the first direction, relative to the longitudinal axis defined by the shaft.

16. The surgical system of claim 15, wherein: proximal longitudinal translation of the first cable and the second cable causes the end effector assembly to articulate in a third direction relative to the longitudinal axis defined by the shaft; and proximal longitudinal translation of the third cable causes the end effector assembly to articulate in a fourth direction, opposite the third direction, relative to the longitudinal axis defined by the shaft.

17. The surgical system of claim 11, further comprising an articulation sub-assembly disposed within the housing and operably coupled to a proximal end of the first cable, a proximal end of the second cable, and a proximal end of the third cable, the articulation sub-assembly configured to cause longitudinal translation of the first cable, the second cable, and the third cable.

18. The surgical system of claim 17, wherein the articulation sub-assembly includes: a first lead screw and a first nut threadingly coupled to the first lead screw, the proximal end of the first cable coupled to the first nut; a second lead screw and a second nut threadingly coupled to the second lead screw, the proximal end of the second cable coupled to the second nut; and a third lead screw and a third nut threadingly coupled to the third lead screw, the proximal end of the third cable coupled to the third nut.

19. A surgical instrument comprising: a housing; a shaft extending from the housing and defining a longitudinal axis; an elongated rod extending through the shaft and defining a ball at a distal end of the elongated rod; an end effector assembly defining a socket operably coupled to the ball of the elongated rod; and a first cable, a second cable, and a third cable extending through the shaft and operably coupled to the end effector assembly, wherein a distal end of the first cable, a distal end of the second cable, and a distal end of the third cable are equally spaced around an outer surface of the socket of the end effector assembly, wherein: proximal longitudinal translation of the second cable and the third cable causes the end effector assembly to articulate in a first direction relative to the longitudinal axis defined by the shaft; proximal longitudinal translation of the first cable causes the end effector assembly to articulate in a second direction, opposite the first direction, relative to the longitudinal axis defined by the shaft; proximal longitudinal translation of the first cable and the second cable causes the end effector assembly to articulate in a third direction relative to the longitudinal axis defined by the shaft; and proximal longitudinal translation of the third cable causes the end effector assembly to articulate in a fourth direction, opposite the third direction, relative to the longitudinal axis defined by the shaft.

20. The surgical instrument of claim 19, wherein at least one of the distal end of the first cable, the distal end of the second cable, or the distal end of the third cable defines at least one of: a collar operably coupled to a post of at least one of a distal segment of the shaft or the end effector assembly; or a ball operably coupled to a post of at least one of the distal segment of the shaft or the end effector assembly.