EP4633492A1

EP4633492A1 - Robotic surgical assemblies including surgical instruments having articulatable end effectors

Info

Publication number: EP4633492A1
Application number: EP23832822.3A
Authority: EP
Inventors: Zachary S. HEILIGER; Haralambos P. APOSTOLOPOULOS
Original assignee: Covidien LP
Current assignee: Covidien LP
Priority date: 2022-12-15
Filing date: 2023-12-11
Publication date: 2025-10-22
Also published as: CN120344206A; WO2024127227A1

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, and one or more wave spring coils movably coupling the end effector to a portion of the shaft. Articulation cables adjust the pitch and yaw of the end effector relative to the shaft.

Description

ROBOTIC SURGICAL ASSEMBLIES INCLUDING SURGICAL INSTRUMENTS HAVING ARTICULATABLE END EFFECTORS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/432,764, filed December 15, 2022, the entire content of which is incorporated herein by reference.

BACKGROUND

[0002] 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

[0003] In accordance with an aspect of the disclosure, a surgical instrument of a surgical robotic system is provided. The surgical instrument includes a housing, a shaft extending distally from the housing, an end effector pivotably coupled to a distal end portion of the shaft, first and second articulation cables, and a first wrist assembly. The first and second 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 and second articulation cables articulate the end effector relative to the shaft in a first plane. The first wrist assembly is positioned between the end effector and the distal end portion of the shaft. The first wrist assembly includes a first wave spring coil and a bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil. The bead is configured to maintain the first axial gap.

[0004] In aspects, the bead may be radially offset from the first and second articulation cables.

[0005] In aspects, the surgical instrument may include a plurality of beads longitudinally aligned with one another along a length of the first wrist assembly.

[0006] In aspects, the surgical instrument may further include third and fourth articulation cables configured to articulate the end effector relative to the shaft in a second plane, perpendicular to the first plane.

[0007] In aspects, the surgical instrument may further include a second wrist assembly positioned along the shaft and including a second wave spring coil and at least one bead positioned in a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.

[0008] In aspects, the first and second wrist assemblies may be positioned adjacent one another.

[0009] In aspects, the second wrist assembly may be positioned between a first segment of the shaft and a second segment of the shaft, and the first wrist assembly may be positioned distally of the second segment of the shaft.

[0010] In aspects, the first wave spring coil may be radially offset from the second wave spring coil.

[0011] In aspects, the first wave spring coil may have a plurality of turns each including diametrically opposed first and second crests. The second wave spring may have a plurality of turns each including diametrically opposed first and second crests radially offset from the first and second crests of the first wave spring coil.

[0012] In aspects, the first crests of the first wave spring coil may be axially aligned with one another, the second crests of the first wave spring coil may be axially aligned with one another, the first crests of the second wave spring coil may be axially aligned with one another, and the second crests of the second wave spring coil may be axially aligned with one another.

[0013] In accordance with further aspects of the disclosure, a surgical instrument is provided that includes a shaft, an end effector pivotably coupled to a distal end portion of the shaft, first and second articulation cables extending through the shaft and configured to articulate the end effector to adjust a pitch of the end effector, third and fourth articulation cables extending through the shaft and configured to articulate the end effector to adjust a yaw of the end effector, a first wrist assembly positioned between the end effector and the distal end portion of the shaft, and a second wrist assembly positioned along the shaft. The first wrist assembly includes a first wave spring coil having a plurality of turns. The second wrist assembly includes a second wave spring coil including a plurality of turns.

[0014] In aspects, the first wrist assembly may include a plurality of beads positioned in a respective first axial gap defined between adjacent turns of the plurality of turns of the first wave spring coil and configured to maintain the first axial gaps.

[0015] In aspects, the second wrist assembly may include a plurality of beads positioned in a respective second axial gap defined between adjacent turns of the plurality of turns of the second wave spring coil and configured to maintain the second axial gaps.

[0016] In aspects, the plurality of beads of the first wrist assembly may be axially aligned with one another and the plurality of beads of the second wrist assembly may be axially aligned with one another.

[0017] In aspects, the plurality of beads of the first wrist assembly may be radially offset from the plurality of beads of the second wrist assembly.

[0018] In accordance with another aspect 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 instrument drive unit includes one or more motors and the surgical instrument includes a housing configured to be attached to the instrument drive unit, a shaft extending distally from the housing, an end effector movably coupled to a distal end portion of the shaft, first and second articulation cables each having a proximal end portion operably coupled to the one or more motors of the instrument drive unit, and a distal end portion secured to the end effector, such that the first and second articulation cables articulate the end effector relative to the shaft in a first plane in response to an actuation of the one or more motors. The surgical instrument further includes a first wrist assembly positioned between the end effector and the distal end portion of the shaft. The first wrist assembly includes a first wave spring coil and at least one bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil and configured to maintain the first axial gap.

[0019] In aspects, the bead may be radially offset from the first and second articulation cables.

[0020] In aspects, the surgical instrument of the surgical robotic system may include a plurality of beads longitudinally aligned with one another along a length of the first wrist assembly.

[0021] In aspects, the surgical instrument of the surgical robotic system may further include third and fourth articulation cables configured to articulate the end effector relative to the shaft in a second plane, perpendicular to the first plane.

[0022] In aspects, the surgical instrument of the surgical robotic system may further include a second wrist assembly positioned along the shaft. The second wrist assembly may include a second wave spring coil and a bead positioned in a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.

[0023] Further details and aspects of exemplary embodiments of the disclosure are described in more detail below with reference to the appended figures.

[0024] As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or - 10 degrees from true parallel and true perpendicular.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Embodiments of the disclosure are described herein with reference to the accompanying drawings, wherein:

[0026] FIG. 1 is a schematic illustration of a robotic surgical system in accordance with the disclosure;

[0027] FIG. 2 is a perspective view of a surgical robotic arm of the robotic surgical system of FIG. 1 illustrating a surgical instrument and an instrument drive unit being coupled to the surgical robotic arm;

[0028] FIG. 3 is a side view illustrating a wrist assembly of the surgical instrument shown in FIG. 2 coupled between a shaft and an end effector of the surgical instrument;

[0029] FIG. 4A is a side view illustrating components of the wrist assembly of FIG. 3;

[0030] FIG. 4B is a top view illustrating a shim of the wrist assembly of FIG. 4A;

[0031] FIG. 4C is a perspective view illustrating the components of the wrist assembly of FIG. 4A;

[0032] FIG. 5A is a side view illustrating the components of the wrist assembly of FIG. 4A including a plurality of beads;

[0033] FIG. 5B is a side view illustrating another embodiment of a wrist assembly for use with the surgical instrument of FIG. 2;

[0034] FIG. 6 is a side view illustrating another embodiment of a wrist assembly incorporated into the surgical instrument of FIG. 2;

[0035] FIG. 7 is a side view illustrating a pair of separated wrist assemblies incorporated into the surgical instrument of FIG. 2;

[0036] FIG. 8 is a perspective view illustrating two separated pairs of wrist assemblies incorporated into the surgical instrument of FIG. 2;

[0037] FIG. 9A is a side view illustrating a wrist assembly of a surgical instrument according to another embodiment; and

[0038] FIG. 9B is a perspective view illustrating the components of the wrist assembly of FIG. 9A.

DETAILED DESCRIPTION

[0039] Embodiments of the disclosed robotic surgical system and methods thereof 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 used herein the term “distal” refers to that portion of the robotic surgical system or component thereof that is further from the user, while the term “proximal” refers to that portion of the robotic surgical system or component thereof that is closer to the user.

[0040] A robotically-controlled surgical instrument may include a wrist assembly that allows for articulation of an end effector in a plurality of directions to change, for example, a pitch or yaw of the end effector. However, the wrist assembly may be prone to wear and tear and may have dead space. Accordingly, this disclosure provides a wrist assembly that implements wave spring coils that allow for reduced resistance to articulation of the end effector, limits wear and tear on the wrist assembly, and reduces dead space.

[0041] Referring initially to FIGS. 1 and 2, a robotic surgical system 1 is shown and generally includes a plurality of surgical robotic arms 2, 3 each having a surgical instrument 10 (e.g., an electrosurgical instrument, a surgical stapling instrument, a surgical forceps, a surgical grasper or the like) removably coupled thereto; a control device 4 (e.g., a computer); and an operating console 5 coupled with the control device 4.

[0042] With continued reference to FIG. 1, the operating console 5 includes a display device 6, which is set up to display two-dimensional and three-dimensional images; and manual input devices 7, 8 that serve to enable a user (e.g., a surgeon) to telemanipulate robotic arms 2, 3, as known in principle to a person skilled in the art. Each of the robotic arms 2, 3 may include a plurality of members that are interconnected by joints. The robotic arms 2, 3 may be driven by electric drives (not shown) that are connected to the control device 4. The control device 4 is set up to execute a computer program to activate the electric drives in such a way that the robotic arms 2, 3, their instrument drive units 20, and thus the surgical instrument 10 execute a movement in accordance with a movement of the manual input devices 7, 8. The control device 4 may also be set up in such a way that it regulates the movement of the robotic arms 2, 3 and/or of the electric drives.

[0043] The robotic surgical system 1 is configured for minimally invasive treatment of a patient “P” lying on a surgical table “ST” using a surgical instrument (e.g., surgical instrument 10) coupled to the robotic surgical system 1. In some embodiments of the disclosure, the robotic surgical system 1 may include more than two robotic arms that are likewise coupled to the control device 4 and telemanipulatable by the operating console 5. A surgical instrument (e.g., surgical instrument 10) may also be attached to the additional robotic arm(s).

[0044] The surgical instrument 10 includes an end effector 40 (FIG. 2) for grasping and, in aspects, treating tissue. The control device 4 may control a plurality of motors (Motor l ... n) with each motor configured to drive a relative rotation of drive members of a transmission assembly (not labeled) of the surgical instrument 10 to effect operation and/or movement of the end effector 40 of the surgical instrument 10. It is contemplated that the control device 4 coordinates the activation of the various motors (Motor l ... n) to coordinate a clockwise or counter-clockwise rotation of drive members (not shown) of the instrument drive unit 20 in order to coordinate an operation and/or movement of the end effector 40. In embodiments, each motor can be configured to actuate a drive rod or a lever arm to effect operation and/or movement of the end effector 40 of the surgical instrument 10.

[0045] With specific reference to FIG. 2, the robotic surgical system 1 includes a surgical assembly 12, which includes the robotic arm 2, the surgical instrument 10 coupled to the robotic arm 2, and the instrument drive unit 20 configured to operably couple to the surgical instrument 10. The instrument drive unit 20 is configured for powering the surgical instrument 10. The instrument drive unit 20 transfers power and actuation forces from its motors (not shown) to the transmission assembly of the surgical instrument 10 to ultimately drive movement of components of the end effector 40, for example, a movement of a knife blade 80 (see FIG. 4C) for cutting tissue and a closing and opening of jaw members of the end effector 40 for grasping tissue, and/or drive an articulation of the end effector 40.

[0046] The surgical instrument 10 generally includes a housing 102, a shaft 120 extending distally from the housing 102, and a wrist assembly 30 pivotably coupling the end effector 40 to the shaft 120. The housing 102 is configured to hook, latch, or otherwise attach to a surface of the robotic arm 2, e.g., the distal end 2a of the robotic arm 2, to secure the surgical instrument 10 to the robotic arm 2. In embodiments, the housing 102 may be attached to the surgical robotic arm 2 via various fastening engagements, such as, for example, clips, latches, friction fit engagement, buttons, a variety of fasteners, and/or a bayonet-type connection. The housing 102 houses the transmission assembly that interfaces with the instrument drive unit 20. The transmission assembly translates the motion and torques of the motors of the instrument drive unit 20 into the motion necessary to articulate the wrist assembly 30 of the surgical instrument 10, open and close the jaw members of the end effector 40, and deploy and retract a knife blade 80 to cut tissue grasped between the jaw members of the end effector 40.

[0047] With reference to FIGS. 3, 4A, and 4B, the wrist assembly 30 of the surgical instrument 10 operably couples the end effector 40 to a distal end portion 122 of the shaft 120. The wrist assembly 30 may be positioned along the shaft 120 between a distal end 122b of the distal end portion 122 of the shaft 120 and a proximal end 122a of the distal end portion 122. In aspects, the wrist assembly 30 may be coupled between a proximal end portion of the end effector 40 and the distal end 122b of the shaft 120. The wrist assembly 30 is configured to affect the pivoting motion of the end effector 40 relative to the shaft 120 to adjust the yaw and/or pitch of the end effector 40 utilizing a series of translatable cables “Cl,” “C2,” “C3,” “C4” driven by the motors of the instrument drive unit 20. The articulation cables “Cl,” “C2,” “C3,” “C4” are routed through the wrist assembly 30 and have distal end portions fixed to a distal shim 32 of the wrist assembly 30 and/or proximal end portions fixed to actuators 104 (FIG. 8) of housing 102 of surgical instrument 10, wherein distal/proximal translation of articulation cables “Cl,” “C2,” “C3,” “C4” results in adjustment of a pitch and a yaw of the end effector 40. Each actuator 104 may be connected to a respective motor (not shown) of instrument drive units 20.

[0048] The wrist assembly 30 includes a pair of adjacent, first and second wrist assemblies 30a, 30b each including respective first and second wave spring coils 42, 44. The first wave spring coil 42 is positioned between the distal shim 32b that is fixed to the distal end 122b of the shaft 120, and an intermediate shim 32c positioned between the first and second wave spring coils 42, 44. The second wave spring coil 44 is positioned between a proximal shim 32a, that is fixed to the proximal end 122a of the distal end portion 122 of the shaft 120, and an intermediate shim 32c.

[0049] The first wave spring coil 42 may be a monolithically formed, multi-turn wave spring having a plurality of turns with each turn having diametrically opposed first and second crests 45 (only the first crests are labeled), and diametrically opposed first and second troughs 47 (only the first troughs are labeled). It is contemplated that the first wave spring coil 42 may have more than two crests and two troughs. The first wave spring coil 42 is configured to compress or deform along a longitudinal axis “Al” extending through the first crest 45 of each of the turns during proximal translation of first cable “Cl”, or along a longitudinal axis (not explicitly labeled) that extends through the second crest of each of the turns during proximal translation of second cable “C2.” On the other hand, the first wave spring coil 42 is configured to resist compression or deformation along a longitudinal axis “Bl” extending through the first trough 47 of each of the turns, and along a longitudinal axis “B2” that extends through the second trough of each of the turns during the proximal translation of the first or second cables “Cl,” “C2.”

[0050] The second wave spring coil 44 may be a monolithically formed, multi-turn wave spring having a plurality of turns with each turn having diametrically opposed first and second crests 50, 52, and diametrically opposed first and second troughs 54 (only the first troughs are labeled). It is contemplated that the second wave spring coil 44 may have more than two crests and two troughs. The second wave spring coil 44 is configured to compress or deform along the longitudinal axis “Bl” extending through the first crest 50 of each of the turns during proximal translation of third cable “C3,” or along the longitudinal axis “B2” that extends through the second crest 52 of each of the turns during proximal translation of the fourth cable “C4.” On the other hand, the second wave spring coil 44 is configured to resist compression or deformation along the longitudinal axis “Al” extending through the first trough 54 of each of the turns, and along the longitudinal axis that extends through the second trough of each of the turns during proximal translation of the third or fourth cables “C3,” “C4.” As such, the first and second crests 45 of the first wave spring 42 are radially offset (e.g., by 90 degrees) from the first and second crests 50, 52 of the second wave spring coil 44 and coaxial with the respective first and second troughs 54 of the second wave spring coil 44. That is, the first and second wave spring coils 42, 44 are rotationally or radially offset from one another (e.g., by 90 degrees) about a central longitudinal axis defined through the first and second wrist assemblies 30a, 30b.

[0051] The distal shim 32b (FIG. 4B) defines four channels 46a, 46b, 46c, 46d therethrough that are equidistant from one another about the circumference of the distal shim 32b. The intermediate and proximal shims 32c, 32a also define corresponding channels (not explicitly labeled) therethrough. The first pair of first and second articulation cables “Cl,” “C2” are slidably positioned in the respective first and second channels 46a, 46b, and the second pair of first and second articulation cables “C3,” “C4” are slidably positioned in the respective third and fourth channels 46c, 46d. Each of the cables “Cl,” “C2,” “C3,” “C4” are positioned within a central passageway 48 defined through the first and second wave spring coils 42, 44.

[0052] While wrist assembly 30 is shown as including shims 32a, 32b, 32c, it is envisioned and contemplated that wrist assembly by be constructed with more or less than three shims, and as illustrated in FIGS. 9A and 9B, it is envisioned that wrist assembly 30 may be constructed without any shims at all.

[0053] In operation, to articulate the end effector 40 in a first direction, indicated by arrow “A” in FIG. 3, to adjust a pitch of the end effector 40 relative to the shaft 120, the first articulation cable “Cl” may be translated proximally or distally and the second articulation cable “C2” may be translated the other of proximally or distally. Translation of the articulation cables “Cl,” “C2” may be actuated by a motor or motors of the instrument drive unit 20 (FIG. 2). Translation of the cables “Cl,” “C2” in opposing directions causes the first crests 45 of the first wave spring coil 42 to compress thereby reducing the axial distance therebetween, and the second crests of the first wave spring coil 42 to expand thereby increasing the axial distance therebetween. The first and second troughs 47 of the first wave spring coil 42 may be configured to resist axial compression therebetween to facilitate articulation of the end effector 40 only in the first direction. [0054] To articulate the end effector 40 in a second direction, about a pivot axis indicated by arrow “B” in FIG. 3, to adjust a yaw of the end effector 40 relative to the shaft 120, the third articulation cable “C3” may be translated proximally or distally and the fourth articulation cable “C4” may be translated the other of proximally or distally. Translation of the articulation cables “C3,” “C4” may be actuated by a motor or motors of the instrument drive unit 20 (FIG. 2). Translation of the cables “C3,” “C4” in opposing directions causes either the first crests 50 or the second crests 52 of the second wave spring coil 44 to compress thereby reducing the axial distance therebetween, and the other of the first crests 50 or the second crests 52 of the second wave spring coil 44 to expand thereby increasing the axial distance therebetween. The first and second troughs 54 of the second wave spring coil 44 may be configured to resist axial compression therebetween to facilitate articulation of the end effector 40 only in the second direction. As such, the first wrist assembly 30a is responsible for adjusting the pitch of the end effector 40 whereas the second wrist assembly 30b is responsible for adjusting the yaw of the end effector 40. In aspects, the second wrist assembly 30b may be responsible for adjusting the pitch of the end effector 40 whereas the first wrist assembly 30a may be responsible for adjusting the yaw of the end effector 40.

[0055] With reference to FIGS. 4A and 5A, the distal wrist assembly 30a of the surgical instrument 10 may further include a first set of beads 60 positioned respectively in axial gaps 66 defined between the adjacent first crests 45 of the first wave spring coil 42, and a second set of beads (not explicitly labeled) positioned respectively in axial gaps 66 defined between adjacent second crests of the first wave spring coil 42. The first and second set of beads 60 are incompressible or substantially incompressible to prevent compression/deformation between the first and second crests 45 to maintain the axial gaps 66. However, axial gaps 68 defined between adjacent troughs 47 of the first wave spring coil 42 are devoid of the beads 60 such that axial compression/deformation between the axial gaps 68 is permitted. It is contemplated that the beads 60 may be fabricated from any suitable material, such as, for example, rubber, plastic, or metal, and may assume any suitable shape sufficient to fill or substantially fill the axial gaps 66, such as, for example, rectangular, square, round, triangular, or the like. As illustrated in FIGS. 3, 4A, 7, and 8, the wrist assemblies of the disclosure may be completely devoid of the beads 60. [0056] The proximal wrist assembly 30b of the surgical instrument 10 may also include a first set of beads 62 positioned respectively in axial gaps 70 defined between the adjacent first crests 50 of the second wave spring coil 44, and a second set of beads 64 positioned respectively in axial gaps 72 defined between adjacent second crests 52 of the second wave spring coil 44. As such, the first and second sets of beads 62, 64 of the proximal wrist assembly 30b prevent compression/deformation between the first and second crests 50, 52 to maintain the axial gaps 70, 72 therebetween. However, axial gaps 76 defined between adjacent troughs 54 of the second wave spring coil 44 are devoid of the beads such that axial compression/deformation between the axial gaps 76 is permitted. The first and second sets of beads 62, 64 of the second wave spring coil 44 are radially or rotationally offset (e.g., by 90 degrees) about the central longitudinal axis from the first and second sets of beads 60 of the first wave spring coil 42. In this way, articulation of the end effector 40 in the first direction is facilitated by the distal wrist assembly 30a and articulation of the end effector 40 in the second direction is facilitated by the proximal wrist assembly 30b.

[0057] With reference to FIG. 5B, another embodiment of a wrist assembly 130 for incorporation into the surgical instrument 10 is illustrated. The wrist assembly 130 is substantially similar to the wrist assembly 30 of FIG. 5 A. Accordingly, only selected differences of the wrist assembly 130 from the wrist assembly 30 will be described in detail herein.

[0058] The wrist assembly 130 includes a single, multi-turn wave spring coil 142 positioned between proximal and distal shims 132a, 132b. The wrist assembly 130 further includes a first set of beads 160 axially aligned with one another and positioned in alternating first axial gaps defined between adjacent turns of the wave spring coil 142. A second set of beads (not explicitly labeled) is provided that are axially aligned with one another and positioned in the alternating first axial gaps defined between adjacent turns of the wave spring coil 142. The second set of beads are in diametric opposition to the first set of beads 160.

[0059] The wrist assembly 130 further includes a third set of beads 162 axially aligned with one another and positioned in alternating second axial gaps defined between adjacent turns of the wave spring coil 142. A fourth set of beads 164 is provided that are axially aligned with one another and positioned in the alternating second axial gaps defined between adjacent turns of the wave spring coil 142. The fourth set of beads 164 are in diametric opposition to the third set of beads 162. The third and fourth sets of beads 162, 164 are radially or rotationally offset (e.g., by 90 degrees) about the central longitudinal axis from the first and second sets of beads 160.

[0060] While beads 60, 62, 64, 160, 162, 164 are shown as being rectangular, it is envisioned and within the scope of the disclosure that beads can have any profile, including, and not limited to circular, oblong, triangular, ovoid, etc.

[0061] With reference to FIG. 6, the surgical instrument 10 of FIG. 2 is illustrated incorporating an alternative embodiment of a wrist assembly 230. The wrist assembly 230 includes two pairs of the wrist assemblies 30a, 30b of FIG. 5 A stacked on top of one another.

[0062] With reference to FIG. 7, the surgical instrument 10 of FIG. 2 is illustrated incorporating the first and second wrist assemblies 30a, 30b of FIG. 3. However, the wrist assemblies 30a, 30b of the surgical instrument 10 of FIG. 7 are separated from one another along the shaft 120 and radially offset from one another. More specifically, first wrist assembly 30a is positioned between a proximal segment 125 of the shaft 120 and an intermediate segment 123 of the shaft 120, and the second wrist assembly 30b is positioned between the intermediate segment 123 of the shaft 120 and the distal end 122b of the shaft 122. As such, the end effector 40 is configured to articulate relative to the intermediate segment 123 about the second wrist assembly 30b to adjust one of the pitch or the yaw of the end effector 40, and the end effector 40, along with the intermediate segment 123, are configured to articulate relative to the proximal segment 125 about the first wrist assembly 30a to adjust the other of the pitch or yaw of the end effector 40.

[0063] With reference to FIG. 8, the surgical instrument 10 of FIG. 2 is illustrated incorporating two pairs of the first and second wrist assemblies 30a, 30b of FIG. 3. A first or proximal pair of the first and second wrist assemblies 30a, 30b is positioned between the proximal segment 125 of the shaft 120 and the intermediate segment 123 of the shaft 120, and a second or distal pair of the first and second wrist assemblies 30a, 30b is positioned between the intermediate segment 123 of the shaft 120 and the distal end 122b of the shaft 120. As such, the end effector 40 is configured to articulate relative to the intermediate segment 123 about the distal pair of wrist assemblies 30a, 30b to adjust the pitch and/or the yaw of the end effector 40, and the end effector 40, along with the intermediate segment 123, are configured to articulate relative to the proximal segment 125 about the proximal pair of the first and second wrist assemblies 30a, 30b to adjust the pitch and/or yaw of the end effector 40.

[0064] According to 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; 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 and second articulation cables articulate the end effector relative to the shaft in a first plane; and a first wrist assembly positioned between the end effector and the distal end portion of the shaft. The first wrist assembly includes a first wave spring coil; and at least one bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil and configured to maintain the first axial gap.

[0065] The at least one bead may be radially offset from the first and second articulation cables.

[0066] The at least one bead may be a plurality of beads longitudinally aligned with one another along a length of the first wrist assembly.

[0067] The surgical instrument may further include third and fourth articulation cables configured to articulate the end effector relative to the shaft in a second plane, perpendicular to the first plane.

[0068] The surgical instrument may further include a second wrist assembly positioned along the shaft. The second wrist assembly may include a second wave spring coil; and at least one bead positioned in a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.

[0069] The first and second wrist assemblies may be positioned adjacent one another.

[0070] The second wrist assembly may be positioned between a first segment of the shaft and a second segment of the shaft, and the first wrist assembly is positioned distally of the second segment of the shaft.

[0071] The first wave spring coil may be radially offset from the second wave spring coil.

[0072] The first wave spring coil may have a plurality of turns each including diametrically opposed first and second crests, and the second wave spring has a plurality of turns each including diametrically opposed first and second crests radially offset from the first and second crests of the first wave spring coil.

[0073] The first crests of the first wave spring coil may be axially aligned with one another, the second crests of the first wave spring coil may be axially aligned with one another, the first crests of the second wave spring coil may be axially aligned with one another, and the second crests of the second wave spring coil may be axially aligned with one another.

[0074] According to a further aspect of the disclosure, a surgical instrument is provided and includes a shaft; an end effector pivotably coupled to a distal end portion of the shaft; first and second articulation cables extending through the shaft and configured to articulate the end effector to adjust a pitch of the end effector; third and fourth articulation cables extending through the shaft and configured to articulate the end effector to adjust a yaw of the end effector; a first wrist assembly positioned between the end effector and the distal end portion of the shaft and including a first wave spring coil including a plurality of turns; and a second wrist assembly positioned along the shaft and including a second wave spring coil including a plurality of turns.

[0075] The first wrist assembly may include a plurality of beads positioned in a respective first axial gap defined between adjacent turns of the plurality of turns of the first wave spring coil and configured to maintain the first axial gaps, and the second wrist assembly including a plurality of beads positioned in a respective second axial gap defined between adjacent turns of the plurality of turns of the second wave spring coil and configured to maintain the second axial gaps.

[0076] The plurality of beads of the first wrist assembly may be axially aligned with one another and the plurality of beads of the second wrist assembly may be axially aligned with one another.

[0077] The plurality of beads of the first wrist assembly may be radially offset from the plurality of beads of the second wrist assembly.

[0078] The first and second wrist assemblies may be positioned adjacent one another or separated from one another along the shaft.

[0079] According to a further aspect of the disclosure, a surgical robotic system is provided and includes a surgical robotic arm; an instrument drive unit configured to be supported on the surgical robotic arm, the instrument drive unit including at least one motor; and a surgical instrument configured to be coupled to and driven by the instrument drive unit, the surgical instrument described above, wherein the housing is configured to be attached to the instrument drive unit; the proximal end portion of each of first and second articulation cables are operably coupled to the at least one motor of the instrument drive unit, wherein the first and second articulation cables articulate the end effector relative to the shaft in response to an actuation of the at least one motor of the instrument drive unit.

[0080] It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto.

Claims

WHAT IS CLAIMED IS:

1. A surgical instrument of a surgical robotic system, the surgical instrument comprising: a housing; a shaft extending distally from the housing; an end effector pivotably coupled to a distal end portion of the shaft; 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 and second articulation cables articulate the end effector relative to the shaft in a first plane; and a first wrist assembly positioned between the end effector and the distal end portion of the shaft, the first wrist assembly including: a first wave spring coil; and at least one bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil and configured to maintain the first axial gap.

2. The surgical instrument according to claim 1 , wherein the at least one bead is radially offset from the first and second articulation cables.

3. The surgical instrument according to claim 2, wherein the at least one bead is a plurality of beads longitudinally aligned with one another along a length of the first wrist assembly.

4. The surgical instrument according to claim 1 , further comprising third and fourth articulation cables configured to articulate the end effector relative to the shaft in a second plane, perpendicular to the first plane.

5. The surgical instrument according to claim 4, further comprising a second wrist assembly positioned along the shaft, the second wrist assembly including: a second wave spring coil; and at least one bead positioned in a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.

6. The surgical instrument according to claim 5, wherein the first and second wrist assemblies are positioned adjacent one another.

7. The surgical instrument according to claim 5, wherein the second wrist assembly is positioned between a first segment of the shaft and a second segment of the shaft, and the first wrist assembly is positioned distally of the second segment of the shaft.

8. The surgical instrument according to claim 5, wherein the first wave spring coil is radially offset from the second wave spring coil.

9. The surgical instrument according to claim 8, wherein the first wave spring coil has a plurality of turns each including diametrically opposed first and second crests, and the second wave spring has a plurality of turns each including diametrically opposed first and second crests radially offset from the first and second crests of the first wave spring coil.

10. The surgical instrument according to claim 8, wherein the first crests of the first wave spring coil are axially aligned with one another, the second crests of the first wave spring coil are axially aligned with one another, the first crests of the second wave spring coil are axially aligned with one another, and the second crests of the second wave spring coil are axially aligned with one another.

11. A surgical instrument, comprising: a shaft; an end effector pivotably coupled to a distal end portion of the shaft; first and second articulation cables extending through the shaft and configured to articulate the end effector to adjust a pitch of the end effector; third and fourth articulation cables extending through the shaft and configured to articulate the end effector to adjust a yaw of the end effector; a first wrist assembly positioned between the end effector and the distal end portion of the shaft and including a first wave spring coil including a plurality of turns; and a second wrist assembly positioned along the shaft and including a second wave spring coil including a plurality of turns.

12. The surgical instrument according to claim 11, wherein the first wrist assembly includes a plurality of beads positioned in a respective first axial gap defined between adjacent turns of the plurality of turns of the first wave spring coil and configured to maintain the first axial gaps, and the second wrist assembly including a plurality of beads positioned in a respective second axial gap defined between adjacent turns of the plurality of turns of the second wave spring coil and configured to maintain the second axial gaps.

13. The surgical instrument according to claim 12, wherein the plurality of beads of the first wrist assembly are axially aligned with one another and the plurality of beads of the second wrist assembly are axially aligned with one another.

14. The surgical instrument according to claim 13, wherein the plurality of beads of the first wrist assembly are radially offset from the plurality of beads of the second wrist assembly.

15. The surgical instrument according to claim 11, wherein the first and second wrist assemblies are positioned adjacent one another or separated from one another along the shaft.

16. A surgical robotic system, comprising: a surgical robotic arm; an instrument drive unit configured to be supported on the surgical robotic arm, the instrument drive unit including at least one motor; 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; an end effector movably coupled to a distal end portion of the shaft; first and second articulation cables each having a proximal end portion operably coupled to the at least one motor of the instrument drive unit, and a distal end portion secured to the end effector, such that the first and second articulation cables articulate the end effector relative to the shaft in a first plane in response to an actuation of the at least one motor of the instrument drive unit; and a first wrist assembly positioned between the end effector and the distal end portion of the shaft, the first wrist assembly including: a first wave spring coil; and at least one bead positioned in a first axial gap defined between adjacent first and second turns of the first wave spring coil and configured to maintain the first axial gap.

17. The surgical robotic system according to claim 16, wherein the at least one bead is radially offset from the first and second articulation cables.

18. The surgical robotic system according to claim 17, wherein the at least one bead is a plurality of beads longitudinally aligned with one another along a length of the first wrist assembly.

19. The surgical robotic system according to claim 17, wherein the surgical instrument further includes a pair of third and fourth articulation cables configured to articulate the end effector relative to the shaft in a second plane, perpendicular to the first plane.

20. The surgical robotic system according to claim 19, wherein the surgical instrument further includes a second wrist assembly positioned along the shaft, the second wrist assembly including: a second wave spring coil; and at least one bead positioned in a second axial gap defined between adjacent first and second turns of the second wave spring coil and configured to maintain the second axial gap.