Systems to apply preload tension for surgical instruments and related methods

Patent metadata

Field	Value
Publication number	US-12426974-B2
Application number	US-202117488881-A
Country	US
Kind code	B2
Filing date	Sep 29, 2021
Priority date	Oct 14, 2016
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

A surgical system includes a dynamic preload tension feature for a tensioning element that actuates a distal end component of a surgical instrument. The surgical instrument includes a chassis at a proximal end of the surgical instrument, drive components mounted in the chassis, a distal end component at a distal end of the surgical instrument, a flexible tensioning element coupled between a first of the drive components and the distal end component, and a dynamic preload tensioner mounted in the chassis and coupled to a second of the drive components. The flexible tensioning element extends along a path. The dynamic preload tensioner is configured to be driven by the second of the drive components to be moved relative to the chassis and is positioned to change the path of the flexible tensioning element as the dynamic preload tensioner moves relative to the chassis.

First claim

What is claimed is:

1. A surgical instrument comprising:
a chassis at a proximal end;
a distal end component at a distal end;
a tubular member coupled to the chassis and extending from the chassis to the distal end component, the tubular member having a longitudinal axis;
a drive component mounted in the chassis;
a flexible tensioning element coupled to the drive component, extending through the tubular member, and coupled to the distal end component; and
a dynamic preload tensioner engaged with the tubular member, the dynamic preload tensioner configured to move the tubular member in translation along the longitudinal axis of the tubular member and relative to the chassis to change a path of the flexible tensioning element.

2. The surgical instrument of claim 1 , wherein:
the dynamic preload tensioner is located on a proximal end of the tubular member.

3. The surgical instrument of claim 1 , further comprising:
a rotatable member through which the flexible tensioning element extends, the rotatable member configured to be rotated to cause rotation of the tubular member and the distal end component.

4. The surgical instrument of claim 3 , wherein:
the rotatable member comprises a gear portion.

5. The surgical instrument of claim 3 , wherein:
the rotatable member is a first rotatable member, and
the dynamic preload tensioner comprises a second rotatable member movable in translation along the longitudinal axis of the tubular member to cause the tubular member and the first rotatable member to move in translation along the longitudinal axis to change the path of the flexible tensioning element.

6. The surgical instrument of claim 5 , wherein:
the second rotatable member is rotatable relative to a portion of the chassis, and
the second rotatable member is movable in translation along the longitudinal axis in response to rotating about relative to the portion of the chassis.

7. The surgical instrument of claim 6 , wherein:
the first rotatable member is configured to engage with the second rotatable member at a predefined orientation such that the second rotatable member rotates relative to the portion of the chassis.

8. The surgical instrument of claim 6 , wherein:
the second rotatable member is movable along a ramp formed on the portion of the chassis as the second rotatable member is rotated relative to the portion of the chassis.

9. The surgical instrument of claim 6 , wherein:
the second rotatable member comprises a locking portion configured to engage a corresponding locking portion on the portion of the chassis to lock a position of the second rotatable member.

10. The surgical instrument of claim 5 , wherein:
the second rotatable member is lockable to one of multiple discrete positions.

11. The surgical instrument of claim 5 , wherein:
the first rotatable member is configured to contact the second rotatable member to cause the second rotatable member to move from a first axial position to a second axial position to change the path of the flexible tensioning element and is further configured to contact the second rotatable member to move the second rotatable member from the second axial position to the first axial position.

12. The surgical instrument of claim 5 , wherein:
the first rotatable member is positioned distal to the second rotatable member, and
the tubular member is positioned distal to the second rotatable member.

13. The surgical instrument of claim 3 , wherein:
the rotatable member is rotatable within a first predefined range and a second predefined range such that rotation of the rotatable member in the first predefined range causes rotation of the tubular member and the distal end component and such that rotation of the rotatable member in the second predefined range causes movement of the tubular member and the distal end component in translation along the longitudinal axis of the tubular member in a distal direction to change the path of the flexible tensioning element.

14. The surgical instrument of claim 1 , wherein:
the flexible tensioning element extends through the dynamic preload tensioner.

15. The surgical instrument of claim 8 , wherein:
the ramp follows a helical path.

16. The surgical instrument of claim 1 , wherein:
the drive component is a first drive component,
the surgical instrument comprises a second drive component mounted in the chassis and configured to drive rotation of the tubular member and distal end component about the longitudinal axis of the tubular member, and
the dynamic preload tensioner is configured to be driven in rotation by the second drive component.

17. A method comprising:
causing a tubular member coupled to and extending from a chassis of a surgical instrument to move in translation along a longitudinal axis of the tubular member and relative to the chassis to adjust a preload tension in a flexible tensioning element of the surgical instrument, wherein the flexible tensioning element of the surgical instrument is coupled to a drive component mounted in the chassis of the surgical instrument, extends through the tubular member, and is coupled to a distal end component of the surgical instrument coupled to a distal end of the tubular member; and
causing the distal end component of the surgical instrument to move using the drive component and the flexible tensioning element.

18. The method of claim 17 , wherein:
causing the tubular member to move comprises:
causing a dynamic preload tensioner coupled to a proximal end portion of the tubular member to move in translation relative to the chassis of the surgical instrument.

19. The method of claim 17 , wherein causing the distal end component of the surgical instrument to move using the drive component and the flexible tensioning element comprises causing the distal end component to move while maintaining a position of the tubular member.

Assignees

• Intuitive Surgical Operations

Inventors

• Wixey Matthew Aaron
• Burbank William
• Cooper Thomas Grosvenor
• Flanagan Patrick
• Ragosta Nicholas H
• Wilson Jr Donald Frank

Classifications

• A61B2034/715

  Cable tensioning mechanisms for removing slack · CPC title

• A61B2017/00477

  Coupling (A61B2017/0046 takes precedence) · CPC title

• A61B34/30

  Surgical robots · CPC title

• A61B90/08

  Accessories or related features not otherwise provided for · CPC title

• A61B34/71 Primary

  Manipulators operated by drive cable mechanisms · CPC title