JP6955518B2 - Robotic surgical assembly and its instrument drive unit - Google Patents

Description

Cross-reference to related applications This application claims the priority benefit of US Provisional Application No. 62 / 345,041 filed June 3, 2016, the entire contents of which are incorporated herein by reference. ..

(Background technology)
Robotic surgical systems have been used in minimally invasive medical procedures. Some robotic surgical systems include a surgical robot arm with at least one end effector (eg, forceps or grip) attached to the robot arm and a console that supports the surgical instrument. The robot arm provides mechanical force to the surgical instrument for its movement and movement.

Manually operated surgical instruments often included a handle assembly to activate the function of the surgical instrument. However, when using a robotic surgical system, there is usually no handle assembly to activate the function of the end effector. Therefore, in order to use each unique surgical instrument with a robotic surgical system, an instrument drive unit is used to connect with the selected surgical instrument to drive the movement of the surgical instrument.

In some systems, the internal motor pack of the instrument drive unit was configured to rotate to provide the corresponding rotation of the attached surgical instrument. However, the rotation of the motor pack, and thus the attached surgical instrument, was limited by the internal circuitry or physical constraints of the instrument drive unit. In addition, the rotation of the motor pack could exceed a predetermined finite threshold and damage the internal circuitry of the appliance drive unit.

Therefore, there is a need for an instrument drive unit capable of increasing the rotation angle of the motor pack without damaging the internal circuits while reducing any resistance to rotation from the motor pack's internal circuits. In addition, feedback to operating room staff regarding the condition of the instrument drive unit needs to be improved.

According to aspects of the present disclosure, an instrument drive unit is provided. The instrument drive unit includes a surgical robot arm, a motor assembly, and a housing configured to be coupled to the flex spool assembly. The motor assembly is rotatably located within the housing and is configured to perform the function of the surgical instrument. The flex spool assembly includes a first printed circuit board mounted on the housing, a second printed circuit board configured to be non-rotatably coupled to the motor assembly and electrically connected, and a first flex. Includes circuit. The first flex circuit has a first end connected to a first printed circuit board, a second end connected to a second printed circuit board, and an intermediate portion. The middle portion is wound around the second printed circuit board so that the rotation of the motor assembly with respect to the housing affects the movement of the second end of the first flex circuit along the annular path.

In some embodiments, the flex spool assembly can include a second flex circuit that communicates with a first printed circuit board. The second flex circuit can have at least one visual indicator placed around the middle of the first flex circuit and placed in an annular array. At least one visual indicator can be configured to indicate the rotational position of the motor assembly with respect to the housing.

The housing may include a transmissive portion arranged around a second flex circuit such that light emitted from at least one visual indicator passes through the transmissive portion.

At least one visual indicator can be configured to indicate the status of the instrument, IDU, system, and / or auxiliary device. At least one visual indicator can also indicate the status of the user, including the surgeon, patient, and operating room staff interacting with the system.

It is envisioned that the instrument drive unit can further include multiple elongated printed circuit boards that co-define the cavities in which the motor assembly is located non-rotatably. The elongated printed circuit board may be in electrical communication with the motor assembly. The first printed circuit board may have a connector for receiving power and data, and the second printed circuit board is a connector configured to connect to the first connector of the elongated printed circuit board. May have. The connector of the second printed circuit board can transmit power from the first printed circuit board to the elongated printed circuit board. The flex spool assembly can further include a third printed circuit board connected to the second end of the first flex circuit. The third printed circuit board may have a connector that is located adjacent to the second printed circuit board and is configured to connect to a second connector on the elongated printed circuit board. The connector of the third printed circuit board can transmit data from the first printed circuit board to the elongated printed circuit board.

It is envisioned that the instrument drive unit can further include an annular member that is non-rotatably coupled to the motor assembly. The annular member can have an intermediate portion of a first flex circuit wound around it. The annular member may be fixed to the second end of the first flex circuit so that the rotation of the annular member causes the movement of the second end of the first flex circuit along the annular path. The instrument drive unit can include a pair of elastic capture members fixed to the second end of the first flex circuit. Each catching member can define a groove. The annular member is configured to be received in each groove of the capture member such that a counterclockwise or clockwise rotation of the annular member results in a corresponding movement of the second end of the first flex circuit. It may have first and second ends.

In some embodiments, the appliance drive unit can include a fan located in the housing adjacent to the flex spool assembly.

It is envisioned that rotation of the motor assembly in the first direction with respect to the housing can reduce the diameter of the middle part of the first flex circuit. Rotation of the motor assembly in the second direction with respect to the housing can increase the diameter of the middle part.

According to another aspect of the present disclosure, a surgical assembly for use with a surgical robotic arm is provided. The surgical assembly includes an instrument drive unit and a carriage. The instrument drive unit includes a surgical robot arm, a motor assembly, and a housing configured to be coupled to the flex spool assembly. The motor assembly is rotatably located within the housing and is configured to perform the function of the surgical instrument. The flex spool assembly includes a first printed circuit board mounted on the housing, a second printed circuit board configured to be non-rotatably coupled to the motor assembly and electrically connected, and a first flex. Includes circuit. The first flex circuit has a first end connected to a first printed circuit board, a second end connected to a second printed circuit board, and an intermediate portion. The middle portion is wound around the second printed circuit board so that the rotation of the motor assembly with respect to the housing affects the movement of the second end of the first flex circuit along the annular path.

The carriage includes a first surface configured to movably engage the surgical robot arm and a second surface configured to non-rotatably support the housing of the instrument drive unit. The carriage includes a motor configured to electrically communicate with the first printed circuit board and rotate the motor assembly.

In some embodiments, the actuation of the carriage motor can rotate the motor assembly relative to the housing.

Further details and aspects of the exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings.

As used herein, the terms parallel and vertical are understood to include substantially parallel and substantially vertical relative configurations from true parallel and true vertical to about + or -10 degrees.
The present invention provides, for example,:
(Item 1)
An instrument drive unit for use with robotic surgical systems
With a housing configured to be coupled to a surgical robot arm,
With a motor assembly rotatably supported within the housing and configured to perform the function of a surgical instrument.
Flex spool assembly
The first printed circuit board attached to the housing and
A second printed circuit board configured to be non-rotatably coupled and electrically connected to the motor assembly.
The rotation of the motor assembly with respect to the first end connected to the first printed circuit board, the second end connected to the second printed circuit board, and the housing along an annular path. A flex spool assembly comprising a first flex circuit having an intermediate portion wound around the second printed circuit board to provide movement of the second end of the first flex circuit. Equipment drive unit equipped with.
(Item 2)
An item comprising a second flex circuit in which the flex spool assembly communicates with the first printed circuit board and is located around the middle portion of the first flex circuit and has at least one visual indicator. The appliance drive unit according to 1.
(Item 3)
The appliance drive unit of item 2, wherein the at least one visual indicator is configured to indicate a rotational position of the motor assembly with respect to the housing.
(Item 4)
The appliance drive unit according to item 2, wherein the housing has a translucent portion arranged around the second flex circuit so that light emitted from the visual indicator passes through the transmissive portion.
(Item 5)
Further, a plurality of elongated printed circuit boards for cooperatingly defining cavities configured to accept the motor assembly in a non-rotatable manner are provided, and at least one of the plurality of elongated printed circuit boards is the motor assembly and the plurality of elongated printed circuit boards. The appliance drive unit according to item 1, which is electrically connected.
(Item 6)
The first printed circuit board has a connector for receiving at least one of power and data, and the second printed circuit board is from the first printed circuit board to the plurality of elongated printed circuit boards. 5. The appliance drive according to item 5, wherein the appliance drive has a connector configured to connect to a first connector on the plurality of elongated printed circuit boards so as to transmit at least one of power or data to at least one of them. unit.
(Item 7)
The flex spool assembly comprises a third printed circuit board connected to the second end of the first flex circuit and located adjacent to the second printed circuit board. The printed circuit board is connected to a second connector of the plurality of elongated printed circuit boards to transmit the data from the first printed circuit board to at least one of the plurality of elongated printed circuit boards. Item 6. The appliance drive unit according to item 6, which has a connector configured to do so.
(Item 8)
Further, the first is provided with an annular member that is non-rotatably coupled to the motor assembly and in which the intermediate portion of the first flex circuit is wound around the annular member, the rotation of the annular member along the annular path. The appliance drive unit according to item 1, wherein the annular member is fixed to the second end of the first flex circuit so as to bring about the movement of the second end of the flex circuit.
(Item 9)
Further, a pair of elastic trapping members fixed to the second end of the first flex circuit and defining a groove therein are provided, and the annular member is such that the rotation of the annular member is the rotation of the first flex. Item 8. Instrument drive unit.
(Item 10)
The appliance drive unit of item 1, further comprising a fan disposed in the housing adjacent to the flex spool assembly.
(Item 11)
Rotation of the motor assembly with respect to the housing in the first direction reduces the diameter of the intermediate portion of the first flex circuit, and rotation of the motor assembly with respect to the housing in the second direction is intermediate. The appliance drive unit according to item 1, which increases the diameter of the portion.
(Item 12)
A surgical assembly for use with a surgical robot arm
It is an instrument drive unit
A housing coupled to the surgical robot arm and
With a motor assembly rotatably supported within the housing and configured to perform the function of a surgical instrument.
Flex spool assembly
The first printed circuit board attached to the housing and
A second printed circuit board configured to be non-rotatably coupled and electrically connected to the motor assembly.
The rotation of the motor assembly with respect to the first end connected to the first printed circuit board, the second end connected to the second printed circuit board, and the housing along an annular path. A flex spool assembly comprising a first flex circuit having an intermediate portion wound around the second printed circuit board to provide movement of the second end of the first flex circuit. ,
A first surface configured to movably engage the surgical robot arm and a second surface configured to non-rotatably support the housing of the instrument drive unit, said. A surgical assembly comprising a carriage comprising a motor configured to electrically communicate with a first printed circuit board and provide rotation of the motor assembly.
(Item 13)
The flex spool assembly of the instrument drive unit comprises a second flex circuit that communicates with the first printed circuit board and is located around the middle portion of the first flex circuit. The surgical assembly of item 12, wherein the flex circuit has at least one visual indicator arranged in an annular array.
(Item 14)
13. The surgical assembly according to item 13, wherein the at least one visual indicator of the second flex circuit is configured to indicate the rotational position of the motor assembly with respect to the housing.
(Item 15)
13. The surgery of item 13, wherein the housing has a translucent portion arranged around the second flex circuit such that light emitted from the at least one visual indicator passes through the transmissive portion. For assembly.
(Item 16)
The instrument drive unit comprises a plurality of elongated printed circuit boards that jointly define a cavity configured to accept the motor assembly non-rotatably, and at least one of the plurality of elongated printed circuit boards. The surgical assembly according to item 12, which is electrically connected to the motor assembly.
(Item 17)
The first printed circuit board of the flex spool assembly has a connector for receiving at least one of power or data, and the second printed circuit board is from the first printed circuit board. The item having a connector configured to connect to a first connector of the plurality of elongated printed circuit boards so as to transmit at least one of power or data to at least one of the elongated printed circuit boards of the. 16. The surgical assembly according to 16.
(Item 18)
The flex spool assembly of the appliance drive unit includes a third printed circuit board connected to the second end of the first flex circuit and located adjacent to the second printed circuit board. The third printed circuit board is connected to the second connector of the plurality of elongated printed circuit boards, and the first printed circuit board is connected to at least one of the plurality of elongated printed circuit boards. 17. The surgical assembly according to item 17, which has a connector configured to carry data.
(Item 19)
The instrument drive unit includes an annular member having the intermediate portion of the first flex circuit that is non-rotatably coupled to and wound around the motor assembly, the rotation of the annular member into the annular path. 12. The surgery of item 12, wherein the annular member is secured to the second end of the first flex circuit so as to provide movement of the second end of the first flex circuit along. For assembly.
(Item 20)
The instrument drive unit comprises a pair of elastic trapping members fixed to the second end of the first flex circuit and internally grooved to allow counterclockwise or clockwise rotation of the annular member. The first and second ends configured such that the annular member is received in each groove of the pair of capture members so as to provide the corresponding movement of the second end of the first flex circuit. 19. The surgical assembly according to item 19, which has a portion.
(Item 21)
12. The surgical assembly of item 12, wherein the instrument drive unit comprises a fan placed in the housing adjacent to the flex spool assembly.
(Item 22)
The actuation of the motor of the carriage causes the motor assembly to rotate relative to the housing, and rotation of the motor assembly in the first direction reduces the diameter of the intermediate portion of the first flex circuit, the housing. 12. The surgical assembly according to item 12, wherein rotation of the motor assembly in a second direction with respect to the motor assembly increases the diameter of the intermediate portion.

Embodiments of the present disclosure are described herein with reference to the accompanying drawings.
FIG. 1 is a schematic view of a robotic surgical system including the robotic surgical assembly according to the present disclosure. FIG. 2 is a perspective view of the robotic surgical assembly of FIG. 1 including a holder, an instrument drive unit coupled to the holder, and a surgical instrument coupled to the instrument drive unit. FIG. 3 is a cross-sectional view of the surgical assembly along line 3-3 of FIG. FIG. 4 is a perspective view of the integrated circuit of the instrument drive unit of FIG. FIG. 5A is a perspective view in which a part of the instrument drive unit of FIG. 2 is removed. FIG. 5B is a cross-sectional view of the instrument drive unit along line 5B-5B of FIG. 5A. FIG. 6 is an exploded view of the components of the instrument drive unit of FIG. FIG. 7 is a plan view of the flex spool assembly of the instrument drive unit of FIG. 2 coupled to the motor assembly of the instrument drive unit. FIG. 8 is a plan perspective view of the flex spool assembly of FIG. 9 is a bottom perspective view of the flex spool assembly of FIG. 7. FIG. FIG. 10 is a plan view of the flex spool assembly of FIG. 7 in the unwound state.

Robotic surgical assemblies disclosed herein, including IDU holders, instrument drive units, and surgical instruments, and embodiments of methods of manufacturing and using such surgical assemblies are described in detail with reference to the drawings. A similar reference code specifies the same or corresponding element in each of several views. As used herein, the term "tip" refers to the IDU holder, instrument drive unit, and / or surgical instrument closer to the patient, and the term "base" refers to the IDU holder, instrument drive unit, and / or surgical instrument. / Or refers to the part of the surgical instrument far from the patient.

Instrument drive units are provided that drive various movements of the attached surgical instrument, as described in detail below. The instrument drive unit is a flex spool printed circuit board assembly that transmits power and communications (eg, in the form of electrical signals) to various components of the instrument drive unit and attached surgical instruments (in the present specification, "flex spool". Includes (sometimes called "assembly"). The flex spool assembly increases the degree of rotation of the instrument drive unit motor assembly, especially with respect to the instrument drive unit housing with relatively low friction loss (eg for communication and power signals), and is after long-term use. Even the damage (eg to the internal components of the instrument drive unit) can be limited.

First, referring to FIG. 1, a surgical system such as the robot surgical system 1 is an instrument drive unit (hereinafter, “IDU”) removably coupled to a sliding rail 40 of the surgical robot arms 2 and 3. A plurality of surgical robot arms 2, 3 having an electromechanical surgical instrument 300 operably coupled to a robotic surgical assembly 100, generally including 110, and an IDU 110, a controller 4, and a controller 4. The operation console 5 and the like are generally included.

As is known to those skilled in the art in principle, the operation console 5 includes a display device 6 set to display a three-dimensional image in particular, and robot arms 2 and 3 by a human being (not shown) such as a surgeon. Includes manual input devices 7 and 8 that can be remotely controlled in the first operating mode. Each robot arm 2, 3 may be composed of a plurality of members connected via a joint. The robot arms 2 and 3 can be driven by an electric drive device (not shown) connected to the control device 4. The control device 4 (for example, a computer) is manually input by robot arms 2, 3, an attached robot surgical assembly 100, and thus an electromechanical surgical instrument 300 (including an electromechanical end effector (not shown)). The drive unit can be set to operate, especially by a computer program, to perform the desired operation according to the operation defined by the devices 7 and 8. The control device 4 can also be set to adjust the movements of the robot arms 2 and 3.

The robotic surgical system 1 is configured for use on a patient "P" lying on a surgical table "ST" to be minimally invasively treated by a surgical instrument such as an electromechanical surgical instrument 300. ing. In embodiments, the robot arms 2 and 3 may be coupled to a robot arm cart (not shown) instead of the surgical table "ST". The robotic surgical system 1 may also include three or more robot arms 2, 3, and similarly, an additional robot arm is connected to the control device 4 and can be remotely controlled by the operating console 5. Surgical instruments such as electromechanical surgical instruments 300 (including electromechanical end effectors) may also be attached to additional robot arms.

The control device 4 can control a plurality of motors, for example, a motor (motor 1). Each motor is configured to drive the movement of the robot arms 2 and 3 in a plurality of directions. Further, the control device 4 can control the motor assembly 114 (FIGS. 3 and 5B) of the IDU 110 of the robotic surgical assembly 100 that drives various movements of the surgical instrument 300. Further, the control device 4 is configured to drive the relative rotation of the motor assembly 114 (FIGS. 3 and 5B) of the IDU 110 and thus the electromechanical surgical instrument 300, as described in detail below, for example. It is possible to control the operation of a rotary motor such as the canister motor “M” (FIG. 3) of the instrument drive unit (“IDU”) holder 102 of the surgical assembly 100. In embodiments, each of the IDU 110 motors "M1-M4" may be configured to actuate a drive rod / cable or lever arm to perform and / or move the electromechanical surgical instrument 300. can.

For a detailed description of the configuration and operation of the robotic surgical system, see US Pat. No. 8,828,023, entitled "Medical Workstation," filed November 3, 2011. , The entire contents of which are incorporated herein by reference.

Referring to FIGS. 1 to 3, the surgical assembly 100 of the surgical system 1 configured to be coupled to the robot arm 2 or 3 generally includes an IDU holder 102, an IDU 110, and an electromechanical surgical instrument 300. including. As briefly described above, the IDU 110 transmits power and operating force from its motor to a driven member (not shown) of the electromechanical surgical instrument 300 and is an end effector of the electromechanical surgical instrument 300. Movement of components, such as movement of a knife blade (not shown) and / or closing and opening of a jaw member of an end effector, activation or firing of a stapler, and / or activation or firing of an electrosurgical energy-based instrument. And finally drive. The motor assembly 114 (FIGS. 3 and 5B) of the IDU 110 is rotated by a motor "M" supported by the IDU holder 102 and transmits the rotational motion to the electromechanical surgical instrument 300.

Referring to FIGS. 2 and 3, the IDU holder 102 of the surgical assembly 100 activates the rotation of the motor assembly 114 (FIGS. 3 and 5B) of the IDU 110 and axes the IDU 110 along the rail 40 of the robot arm 2. It works to translate in the direction. The IDU holder 102 includes a back member or carriage 104 and an outer member or outer housing 106 extending laterally (eg, vertically) from the tip 107 of the carriage 104. In some embodiments, the housing 106 may extend from different parts of the carriage 104 at different angles with respect to the carriage 104. The carriage 104 has a first surface 108a and a second surface 108b facing the first surface 108a. The first surface 108a of the carriage 104 can be detachably connected to the rail 40 of the robot arm 2 (FIG. 1), allowing the IDU holder 102 to slide or translate along the rail 40 of the robot arm 2. To. The second surface 108b of the carriage 104 is configured to support the housing 112 and the like of the IDU 110.

The carriage 104 of the IDU holder 102 supports or accommodates a motor such as the canister motor "M". The motor "M" receives control and power from the control device 4 (FIG. 1) and finally rotates the internal motor assembly 114 of the IDU 110. The carriage 104 includes a printed circuit board 109 that electrically communicates with the motor "M" of the carriage 104 in order to control the operation of the motor "M" of the carriage 104. The carriage 104 further includes a belt or gear drive mechanism 111 extending in the distal direction from the motor "M". The drive mechanism 111 is configured to operably interface with the motor assembly 114 of the IDU 110 to rotate the motor assembly 114 when the motor "M" of the carriage 104 is activated.

Continuing with reference to FIGS. 2 and 3, the housing 112 of the IDU 110 engages with the second surface 108b of the carriage 104 of the IDU holder 102 so as to cover, cover, and protect the internal components of the IDU 110 and the carriage 104. It fits. The housing 112 of the IDU 110 can generally have a cylindrical configuration, but in some embodiments the housing 112 has various configurations such as square, triangular, elongated, curved, semi-cylindrical and the like. Can be taken. As mentioned above, the housing 112 protects or shields various components of the IDU 110, including the motor assembly 114 and the flex spool assembly 200, in order to transmit power and data to the components of the IDU 110. The housing 112 also provides a platform 116 on which the internal components of the IDU 110 are mounted.

The IDU 110 includes a fan 150 located above it and is located above the flex spool assembly 200. The fan 150 is connected to the flex spool assembly 200 via a connector (not specified) to supply adjustable power to the fan 150. The top 112a of the housing 112 may define a plurality of vents or slits 152 to allow air to be transmitted from the IDU 110. The fan 150 is configured to draw air from the top 112a of the housing 112 via the flex spool assembly 200 and through the slit 152 to cool the electronics during its operation and maintain a negative pressure through the IDU 110. Has been done. The flex spool assembly 200 is configured to adjust the amount of power supplied to the fan 150 based on the temperature in the IDU 110. A speed controller (not shown) associated with the flex spool assembly 200 and / or integrated circuit 120 can be provided to control the speed of the fan 150 to adjust the cooling rate. For example, the speed control device can adjust the speed by adjusting the current supplied to the fan 150.

Referring to FIGS. 2-6, the IDU 110 includes an integrated circuit 120 and a motor assembly 114 rotatably arranged therein, respectively. In some embodiments, the IDU 110 is configured to compensate for loads directed at the motor assembly 114 and / or integrated circuit 120 perpendicular or lateral to the longitudinal axis defined by the IDU 110. Or it can include a stop. The integrated circuit 120 includes an upper rigid printed circuit board or nexus 122 and four elongated rigid printed circuit boards 124a, 124b, 126a, 126b extending vertically from the upper printed circuit board 122. The upper printed circuit board 122 has first and second male electrical connectors 128, 130 for coupling to the first and second female electrical connectors 214a, 216a of the flex spool assembly 200.

The elongated printed circuit boards 124a, 124b, 126a, 126b are parallel to each other and are arranged along the longitudinal axis of the IDU 110. The elongated printed circuit boards 124a, 124b, 126a, 126b include a first pair of elongated printed circuit boards 124a, 124b facing each other and a second pair of elongated printed circuit boards 126a, 126b facing each other. The elongated printed circuit boards 124a, 124b, 126a, 126b work together to form a rectangular configuration in which a cavity 132 configured for slidable acceptance of the motor assembly 114 is defined. The circuit boards 124a, 124b, 126a, 126b and the nexus 122 of the integrated circuit 300 are, for example, arbitrary numbers such as the first, second, third and fourth circuit boards 124a, 124b, 126a, 126b connected side by side. One of the first, second, third or fourth circuit boards 124a, 124b, 126a, 126b may further be composed of the first, second, first, second, 126b of the nexus 122. It should be understood that it is coupled to one side of the third or fourth surface. In some embodiments, the integrated circuit 300 connects various connectors, flex cables, or wires used to interconnect elongated printed circuit boards 124a, 124b, 126a, 126b to and / or to the nexus 122. Can have.

The first pair of elongated printed circuit boards 124a, 124b have a first end that electrically communicates with the nexus 122 and a printed circuit that electrically communicates with the motor assembly 114, as described in detail below. It has a second end that transfers power from the assembly 200 to the motor assembly 114. A second pair of elongated printed circuit boards 126a, 126b electrically communicates with a first end that electrically communicates with the nexus 122 and with various electrical components of the IDU 110 and / or surgical instrument 300. It has a tip that transmits communication signals and / or power to the IDU 110 and various electrical components of the surgical instrument 300.

The electrical components of the IDU 110 are, but are not limited to, transducers, encoders, gyroscopes, accelerometers, distal limit sensors, pressure sensors, twist sensors, load cells, optical sensors, position sensors, thermal sensors, etc. It can include lighting elements, cameras, speakers, audible radiation components, motor controllers, LED components, microprocessors, sensory transducers, accelerometers, switches for monitoring, limiting and controlling position limits and the like. In some embodiments, each of these electrical components may be integrated into the IDU 110 flex spool assembly 200 (FIGS. 7-10).

The motor assembly 114 of the IDU 110 is non-rotatably arranged in the cavity 132 of the integrated circuit 120. The motor assembly 114 has drive shafts 138, 140 (only the drive shafts of two motors of the motors "M1-M4" are shown), each of which has a non-circular cross-sectional profile (eg, substantially D-shaped). It can include four motors "M1-M4" such as a canister motor having. The four motors "M1-M4" are arranged in a rectangular shape so that the drive shafts 138 and 140 are all parallel to each other and all extend in a common direction. When the motor "M1-M4" of the motor assembly 114 is activated, the rotation of each drive shaft 138, 140 of the motor "M1-M4" causes each drive transmission shaft to operate various functions of the surgical instrument 300. Is transmitted to the gear or coupler of the drive assembly of the surgical instrument 300 via.

With reference to FIGS. 2-10, especially with reference to FIGS. 6-10, the flex spool assembly 200 of the IDU 110 powers and informs the integrated circuit 120 of the IDU 110 from controller 4 (FIG. 1) (eg, IDU 110 and surgery). It is configured to transmit (a signal instructing the operation of a specific function of the appliance 300). The flex spool assembly 200 generally includes a first flex circuit 210 and a second flex circuit 220. The first flex circuit 210 electrically interconnects the controller 4 with a plurality of electrical components (eg, motors, various sensors, transducers, etc.) of the IDU 110 and / or the surgical instrument 300. It is configured.

The first flex circuit 210 of the flex spool assembly 200 is located on the platform 116 of the housing 112 of the IDU 110 and has a first end 210a, a second end 210b, and first and second ends 210a. , An intermediate portion or a coil portion 210c that interconnects 210b. The intermediate portion 210c is wound around itself to form a plurality of concentric layers. The concentric layers of the intermediate portion 210c of the first flex circuit 210 are radially separated from each other so as to define a gap between them. The gap between the concentric layers of the intermediate 210c of the first flex circuit 210 allows the intermediate 210c to contract towards its center and then re-expand to its original expansion position. The first flex circuit 210 is expected to provide sufficient clearance to allow the first flex circuit 210 to move slightly along the longitudinal axis defined by the IDU 110.

The first end 210a of the first flex circuit 210 extends tangentially from the intermediate 210c and is located outside the intermediate 210c. The second end 210b of the first flex circuit 210 extends radially inward from the innermost layer 211 (see FIG. 8) of the intermediate 210c. As described in detail below, the rotation of the IDU 110 motor assembly 114 with respect to the IDU 110 housing 112 is the movement of the second end 210b of the first flex circuit 210 along the annular path "P" (FIG. 8). The intermediate portion 210c of the first flex circuit 210 is contracted or expanded thereby.

The first flex circuit 210 exhibits low resistance to contraction and / or expansion of the intermediate 210c, has very low torsional resistance, high thermal resistance (eg, greater than about 280 ° C.), UL V- Manufactured from materials or material hybrids that have a 0 frame rate and / or comply with the Restriction of Hazardous Substances (ROHS). The first flex circuit 210 can be manufactured from a highly ductile copper clad laminate, polyamide, polyester, polytetrafluoroethylene, and / or polyimide film Kapton ™. The first flex circuit 210 can be formed from one or more layers, for example about six layers. In some embodiments, the lower end of the first flex circuit 210 is a lubricated coating, eg, one of the lubricated coatings disclosed herein, to account for or reduce wear over time and with use. Can have. Additional or alternative, platform 116 may have a lubricious coating to reduce wear on the flex spool assembly 200. In some embodiments, the first flex circuit 210 may be preformed as a wound structure. The first flex circuit 210 may be a pure flex circuit or a rigid flex circuit.

The first flex circuit 210 incorporates or is placed on one or more mechanical protrusions or stops (not specified) made from any suitable material such as, for example, elastomers, epoxies or plastics. Can be In some embodiments, the inner and / or outer surfaces of the first flex circuit 210 may have a high hardness or low friction coating or material to reduce wear on the first flex circuit 210. Various parts of the first flex circuit 210 can define holes or openings to facilitate the passage of air for cooling the first flex circuit 210. It is envisioned that the flex spool assembly 200 can incorporate diagnostic ports, various sensors, actuators, connectors for connecting to external devices, microcontrollers, Ethernet® connections and the like.

With reference to FIGS. 5A-9, the IDU 110 further includes a spindle assembly 230 for transmitting rotational motion from the motor assembly 114 to the first flex circuit 210. The spindle assembly 230 includes an outer annular member 232 and an inner annular member or ring member 234. The outer annular member 232 is fixed to the proximal end of the motor assembly 114 via fasteners 236. The inner annular member 234 is fixed to the outer annular member 232 via a fastener 238 and is rotatable with respect to the platform 116 so that the outer annular member 234 rotates with respect to the platform 116. In embodiments, the outer and inner annular members 232 and 234 of the spindle assembly 230 may have a single integral structure. A lubricating coating can be applied to the surface of the platform 116 in contact with the spindle assembly 230 or the surface of the spindle assembly 230 in contact with the surface of the platform 116 so that the spindle assembly 230 rotates relative to a friction-limited platform. .. Thus, the lubricating coating can include any suitable material such as, for example, ultra high molecular weight polyethylene, nylon, acetal, or polytetrafluoroethylene.

The inner annular member 234 of the spindle assembly 230 is concentrically arranged in the intermediate portion 210c of the first flex circuit 210. The inner annular member 234 is in the form of a C-clamp having a first end 234a and a second end 234b. The first and second ends 234a, 234b of the inner annular member 234 face each other and have a fitting portion, such as a male fitting portion or protrusions 240a, 240b, respectively. The protrusions 240a and 240b are configured to be fixed to the capture members 218a and 218b of the first flex circuit 210.

In particular, the first flex circuit 210 has a pair of elastic capture members 218a, 218b fixed to opposite sides of the second end 210b of the first flex circuit 210. The catching members 218a and 218b are C-shaped so as to define the female fitting portions or grooves 224a and 224b in the trapping members 218a and 218b, respectively. The grooves 224a and 224b of the capture members 218a and 218b are the second end of the first flex circuit 210 in which the rotation of the inner annular member 234 (eg, counterclockwise or clockwise rotation) is along the annular path "P". The protrusions 240a, 240b of the inner annular member 234 are received so as to bring about the corresponding movement of the portion 210b.

With reference to FIGS. 2 to 10 and particularly with reference to FIGS. 7 to 10, the flex spool assembly 200 includes a first printed circuit board 212, a second printed circuit board 214, and a third printed circuit board. 216 and is included. The first, second, and third printed circuit boards 212, 214, and 216 are rigid circuit boards rather than flex circuits. In some embodiments, the first, second and third printed circuit boards 212, 214, 216 may be flex circuits and / or may be monolithically formed with the first flex circuit 210. good. The first printed circuit board 212 is connected to the printed circuit board 109 of the IDU holder 102 so that the first printed circuit board 212 is fixed to the IDU 110. The first printed circuit board 212 is connected to the first end 210a of the first flex circuit 210 and transmits power and data to the first flex circuit 210. The first printed circuit board 212 has an electrical connector, eg, a female connector 212a, configured to be coupled to a corresponding male electrical connector (not specified) of the printed circuit board 109 of the IDU holder 102. In some embodiments, wires may be used instead of the female connector 212a. It is assumed that any of the disclosed electrical connectors may be zero insertion force (“ZIF”) connectors.

The second and third printed circuit boards 214 and 216 of the flex spool assembly 200 are respectively arranged in the intermediate portion 210c of the first flex circuit 210 and at the second end 210b of the first flex circuit 210, respectively. Be connected. The second printed circuit board 214 is configured to transmit power from the first printed circuit board 212 to the motor assembly 114 of the IDU 110. The second printed circuit board 214 has an electrical connector, eg, a female connector 214a, configured to be coupled to the first male electrical connector 128 of the integrated circuit 120. The third printed circuit board 216 is located adjacent to the second printed circuit board 214 so as to transmit data from the first printed circuit board 212 to the IDU 110 and / or various components of the surgical instrument 300. It is configured in. The third printed circuit board 216 has an electrical connector configured to be coupled to a second male electrical connector 130 of the integrated circuit 120, such as a female connector 216a. The female and male connectors 214a and 216a may be pin / position connectors such as, for example, a 40-pin connector.

Continuing with reference to FIGS. 7-10, the second flex circuit 220 of the flex spool assembly 200 is a first printed circuit board so as to define a U-shaped intermediate portion 220c surrounding the first flex circuit 210. It has a first end 220a connected to the first end of the 212 and a second end 220b arranged adjacent to the second end of the first printed circuit board 212. The first and second ends 220a, 220b of the second flex circuit 220 are fixed to the platform 116 of the IDU 110.

The second flex circuit 220 has one or more visual indicators 222, such as LEDs, LCDs, and the like. The visual indicator 222 is arranged in an annular array on the outer surface of the U-shaped intermediate portion 220c. In some embodiments, the visual indicator 222 can be arranged in a linear array or any other suitable pattern. The visual indicator 222 is coplanar or aligned with the translucent portion 117 (FIG. 2) of the housing cover of the IDU 110. In this way, the light emitted from the visual indicator 222 can be visually recognized from the outside of the IDU 110. In some embodiments, the translucent portion 117 may be completely transparent.

The second flex circuit 220 receives information related to the state of the IDU 110 or a plurality of states from the first printed circuit board 212. One state of the IDU 110 can be the rotational position of the motor assembly 114 with respect to the IDU 110, and thus the rotational position of the attached surgical instrument 300. Therefore, the visual indicator 222 of the second flex circuit 220 is actuated or operated by the integrated circuit 120 of the IDU 110 and / or control device 4 (FIG. 1) to provide a visual indication of the rotational position of the surgical instrument 300. Can be irradiated. The visual indicator 222 of the second flex circuit 220 can be operated in an order commensurate with some rotation of the motor assembly 114. For example, another light of the visual indicator 222 can be activated for each threshold of rotation of the motor assembly 114 with respect to the IDU 110. Full rotation of the motor assembly 114 can be indicated by activating all of the visual indicators 222.

In some embodiments, the visual indicator 222 may vary in color and / or intensity to indicate various states of the IDU 110 and / or surgical instrument 300. In some embodiments, the visual indicator 222 may be configured to indicate the state of any component of the surgical system 1.

During operation, the integrated circuit 120 of the IDU 110 having the motor assembly 114 disposed internally is electromechanically coupled to the flex spool assembly 200 of the IDU 110. In particular, the first and second male electrical connectors 128 and 130 of the integrated circuit 120 fit into the first and second female electrical connectors 214a and 216a of the first flex circuit 210 of the flex spool assembly 200, respectively. When the integrated circuit 120 is electromechanically coupled to the flex spool assembly 200, power and data can be transmitted from the controller 4 to the integrated circuit 120 and the motor assembly 114 via the flex spool assembly 200.

After electromechanically coupling the integrated circuit 120 to the flex spool assembly 200, the surgeon-operated manual input devices 7 and 8 of the surgical system 1 actuate the motor “M” of the IDU holder 102 to identify within the surgical site. The rotation of the surgical instrument 300 can finally be brought about to orient the surgical instrument 300 at the position of. In particular, the operation of the manual input devices 7 and 8 of the surgical system 1 is a first printed circuit board of the flex spool assembly 200 that transmits a signal from the control device 4 of the surgical system 1 to the printed circuit board 109 of the carriage 104. Send a signal to 212. The printed circuit board 109 of the carriage 104 transmits a signal to the motor "M" of the IDU holder 102 to operate the motor "M". The operation of the motor "M" of the IDU holder 102 drives the rotation of the motor assembly 114 of the IDU 110 with respect to the housing 112 of the IDU 110 due to the operable connection of the motor assembly 114 with the drive mechanism 111 of the IDU holder 102. When the proximal end 302 of the surgical instrument 300 is rotatably coupled to the motor assembly 114 of the IDU 110, the rotation of the motor assembly 114 of the IDU 110 results in the rotation of the surgical instrument 300 about its longitudinal axis.

In addition to the rotation of the motor assembly 114 that causes the rotation of the surgical instrument 300, the rotation of the motor assembly 114 is due to the outer annular member 232 of the spindle assembly 230 being secured to the proximal end 114a of the motor assembly 114. The outer annular member 232 of the spindle assembly 230 of the IDU 110 is rotated. The second end 210b of the first flex circuit 210 is due to the inner annular member 234 of the spindle assembly 230 fixed to the second end 210b of the first flex circuit 210 of the flex spool assembly 200. In response to the rotation of the spindle assembly 230, it moves along an annular path "P" (FIG. 8) around a central longitudinal axis defined by the IDU 110.

As the second end 210b of the first flex circuit 210 moves along the annular path "P", the middle 210c of the first flex circuit 210 contracts around itself, thereby causing the middle 210c. The outer diameter of the first flex circuit 210 is reduced, and the distance between the individual coils of the intermediate portion 210c of the first flex circuit 210 is reduced. Rotation of the motor assembly 114 continues, for example, up to about 270 degrees, or until the intermediate portion 210c of the first flex circuit 210 can no longer be safely contracted. In some embodiments, the motor assembly 114 can be rotated by 270 degrees or more, eg, about 360 degrees or more. The degree of rotation depends on the length of the first flex circuit, more specifically the number of coils in the middle 210c of the first flex circuit 210.

The platform 116 further includes a hard stop 121 projecting downward from it, and the IDU 110 further includes a ring 123 disposed between the platform 116 and the outer annular member 232 of the IDU 110. The ring 123 has an H-shaped cross-sectional shape and has stops 121 (FIG. 5B) arranged at positions above and below the ring 123. The hard stop 121 of the platform 116 is configured to stop the rotation of the motor assembly 114 when the motor assembly 114 reaches a threshold amount of rotation. In particular, as the motor assembly 114 rotates with respect to the platform 116, a protrusion or hard stop 121 extending upward from the outer annular member 232 of the motor assembly 114 is a hard stop (not shown) located below the ring 123. Engage with to rotate the ring 123. The continuous rotation of the motor assembly 114 engages the hard stop 121 located on top of the ring 123 with the hard stop 121 of the platform 116 so as to prevent the motor assembly 114 from rotating further.

After the motor assembly 114 has rotated about 270 degrees, the drive mechanism 111 of the IDU holder 102 can be actuated to reverse the direction of rotation of the motor assembly 114 and return the motor assembly 114 to its starting position. When the motor assembly 114 is rotated in the opposite direction towards its starting position, the intermediate portion 210c of the first flex circuit 210 expands the outer diameter of the intermediate portion 210c without providing resistance to the rotation of the motor assembly 114. Rewind as you do.

During the rotation of the motor assembly 114 of the IDU 110 with respect to the housing 112 of the IDU 110, information regarding the amount or angle of rotation of the motor assembly 114 can be transmitted to the second flex circuit 220 of the flex spool assembly 200. The annular array of visual indicators 222 arranged on the second flex circuit 220 can be sequentially illuminated based on the amount of rotation of the motor assembly 114. For example, if the motor assembly 114 achieves a 90 degree rotation with respect to its starting position, only the outermost light of the visual indicator 222 may be illuminated, whereas the motor assembly 114 is at its starting position. All visual indicators 222 may be illuminated if a rotation of 270 degrees is achieved. Therefore, the visual indicator 222 gives the surgeon an indication of how much the motor assembly 114 and thus the surgical instrument 300 have rotated.

It is understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as a limitation, but merely as an example of various embodiments. Those skilled in the art envision other changes within the scope and intent of the claims attached herein.

Claims (22)

An instrument drive unit for use with robotic surgical systems
With a housing configured to be coupled to a surgical robot arm,
With a motor assembly rotatably supported within the housing and configured to perform the function of a surgical instrument.
Flex spool assembly
The first printed circuit board attached to the housing and
A second printed circuit board configured to be non-rotatably coupled and electrically connected to the motor assembly.
The rotation of the motor assembly with respect to the first end connected to the first printed circuit board, the second end connected to the second printed circuit board, and the housing along an annular path. A flex spool assembly comprising a first flex circuit having an intermediate portion wound around the second printed circuit board to provide movement of the second end of the first flex circuit. Equipment drive unit equipped with. A claim comprising a second flex circuit in which the flex spool assembly communicates with the first printed circuit board and is located around the middle portion of the first flex circuit and has at least one visual indicator. Item 2. The appliance drive unit according to item 1. The appliance drive unit of claim 2, wherein the at least one visual indicator is configured to indicate a rotational position of the motor assembly with respect to the housing. The appliance drive unit according to claim 2, wherein the housing has a transmissive portion arranged around the second flex circuit so that light emitted from the visual indicator passes through the transmissive portion. Further, a plurality of elongated printed circuit boards for coordinating and defining cavities configured to non-rotatably accept the motor assembly are provided, and at least one of the plurality of elongated printed circuit boards is the motor assembly and the plurality of elongated printed circuit boards. The appliance drive unit according to claim 1, which is electrically connected. The first printed circuit board has a connector for receiving at least one of electric power and data, and the second printed circuit board is from the first printed circuit board to the plurality of elongated printed circuit boards. The appliance of claim 5, comprising a connector configured to connect to a first connector on the plurality of elongated printed circuit boards so as to transmit at least one of power or data to at least one of them. Drive unit. The flex spool assembly comprises a third printed circuit board connected to the second end of the first flex circuit and located adjacent to the second printed circuit board. The printed circuit board is connected to a second connector of the plurality of elongated printed circuit boards to transmit the data from the first printed circuit board to at least one of the plurality of elongated printed circuit boards. The appliance drive unit according to claim 6, further comprising a connector configured to. Further, the first is provided with an annular member that is non-rotatably coupled to the motor assembly and in which the intermediate portion of the first flex circuit is wound around the annular member, the rotation of the annular member along the annular path. The instrument drive unit according to claim 1, wherein the annular member is fixed to the second end of the first flex circuit so as to bring about the movement of the second end of the flex circuit. Further, a pair of elastic trapping members fixed to the second end of the first flex circuit and defining a groove therein are provided, and the annular member is such that the rotation of the annular member is the rotation of the first flex. 8. The eighth aspect of the circuit, wherein the first and second ends are configured to be received within each groove of the pair of capture members so as to provide the corresponding movement of the second end of the circuit. Equipment drive unit. The appliance drive unit of claim 1, further comprising a fan disposed in the housing adjacent to the flex spool assembly. Rotation of the motor assembly with respect to the housing in the first direction reduces the diameter of the intermediate portion of the first flex circuit, and rotation of the motor assembly with respect to the housing in the second direction is intermediate. The appliance drive unit according to claim 1, wherein the diameter of the portion is increased. A surgical assembly for use with a surgical robot arm
It is an instrument drive unit
A housing coupled to the surgical robot arm and
With a motor assembly rotatably supported within the housing and configured to perform the function of a surgical instrument.
Flex spool assembly
The first printed circuit board attached to the housing and
A second printed circuit board configured to be non-rotatably coupled and electrically connected to the motor assembly.
The rotation of the motor assembly with respect to the first end connected to the first printed circuit board, the second end connected to the second printed circuit board, and the housing along an annular path. A flex spool assembly comprising a first flex circuit having an intermediate portion wound around the second printed circuit board to provide movement of the second end of the first flex circuit. ,
A first surface configured to movably engage the surgical robot arm and a second surface configured to non-rotatably support the housing of the instrument drive unit, said. A surgical assembly comprising a carriage comprising a motor configured to electrically communicate with a first printed circuit board and provide rotation of the motor assembly. The flex spool assembly of the instrument drive unit comprises a second flex circuit that communicates with the first printed circuit board and is located around the middle portion of the first flex circuit. 12. The surgical assembly of claim 12, wherein the flex circuit has at least one visual indicator arranged in an annular array. 13. The surgical assembly of claim 13, wherein the at least one visual indicator of the second flex circuit is configured to indicate the rotational position of the motor assembly with respect to the housing. 13. Surgical assembly. The appliance drive unit comprises a plurality of elongated printed circuit boards that jointly define a cavity configured to accept the motor assembly non-rotatably, and at least one of the plurality of elongated printed circuit boards. The surgical assembly according to claim 12, which is electrically connected to the motor assembly. The first printed circuit board of the flex spool assembly has a connector for receiving at least one of power or data, and the second printed circuit board is from the first printed circuit board. A claim having a connector configured to connect to a first connector on the plurality of elongated printed circuit boards so as to transmit at least one of power or data to at least one of the elongated printed circuit boards of the. Item 16. The surgical assembly according to item 16. The flex spool assembly of the appliance drive unit includes a third printed circuit board connected to the second end of the first flex circuit and located adjacent to the second printed circuit board. The third printed circuit board is connected to the second connector of the plurality of elongated printed circuit boards, and the first printed circuit board is connected to at least one of the plurality of elongated printed circuit boards. 17. The surgical assembly according to claim 17, which has a connector configured to carry data. The instrument drive unit includes an annular member having the intermediate portion of the first flex circuit that is non-rotatably coupled to and wound around the motor assembly, the rotation of the annular member into the annular path. 12. The 12. Surgical assembly. The instrument drive unit comprises a pair of elastic trapping members fixed to the second end of the first flex circuit and internally grooved to allow counterclockwise or clockwise rotation of the annular member. The first and second ends configured such that the annular member is received in each groove of the pair of capture members so as to provide the corresponding movement of the second end of the first flex circuit. 19. The surgical assembly according to claim 19, which has a portion. 12. The surgical assembly of claim 12, wherein the instrument drive unit comprises a fan placed in the housing adjacent to the flex spool assembly. The actuation of the motor of the carriage causes the motor assembly to rotate relative to the housing, and rotation of the motor assembly in the first direction reduces the diameter of the intermediate portion of the first flex circuit, the housing. 12. The surgical assembly according to claim 12, wherein rotation of the motor assembly in a second direction with respect to the motor assembly increases the diameter of the intermediate portion.

Images