Variable instrument preload mechanism controller

Patent metadata

Field	Value
Publication number	US-2016184036-A1
Application number	US-201414911523-A
Country	US
Kind code	A1
Filing date	Aug 13, 2014
Priority date	Aug 15, 2013
Publication date	Jun 30, 2016
Grant date	—

Abstract

A surgical system ( 200 ) includes a surgical instrument ( 260 ) that is sensitive to backlash that would adversely affect the transmission of controlled torque and position to the surgical instrument. The surgical instrument ( 260 ) is coupled to motors in a surgical instrument manipulator assembly ( 240 ) via a mechanical interface. The combination of the mechanical interface and surgical instrument manipulator assembly ( 240 ) have low backlash, e.g., less than 0.7 degrees. The backlash is controlled in the surgical instrument manipulator assembly ( 240 ). From the drive output disk ( 545 ) in the surgical instrument manipulator assembly to the driven disk ( 964 ) of the surgical instrument, the mechanical interface has zero backlash for torque levels used in surgical procedures.

First claim

We claim:

1 . An apparatus comprising:
a preload track; and a preload assembly configured to ride on the preload track, and the preload assembly configured to couple to a surgical device assembly,
wherein if the preload assembly is positioned at a first location on the preload track, the preload assembly is configured to apply a force proportional to a first force to the surgical device assembly, and
wherein if the preload assembly is positioned at a second location on the preload track, the preload assembly is configured to apply a force proportional to a second force to the surgical device assembly, and
wherein the second force is larger than the first force.

2 . The apparatus of claim 1 , the preload assembly further comprising:
a cam follower assembly configured to ride on the preload track; and an arm comprising a first end and a second end, the first end being configured to couple to the surgical device assembly, and the second end being coupled to the cam follower assembly; wherein if the cam follower assembly is positioned at the first location on the preload track, the arm is configured to transfer the force proportional to the first force from the cam follower assembly to the surgical device assembly; and wherein if the cam follower assembly is positioned at the second location on the preload track, the arm is configured to transfer the force proportional to the second force from the cam follower assembly to the surgical device assembly.

3 . The apparatus of claim 2 , the cam follower assembly further comprising:
a body having a first and a second end, the second end being rotatably coupled to the arm; and a wheel rotatably coupled to the first end of the body, the wheel being configured to ride on the preload track.

4 . The apparatus of claim 1 , further comprising:
an insertion assembly including the preload track.

5 . The apparatus of claim 1 , the surgical device assembly further comprising:
a housing; and a motor pack movably mounted in the housing.

6 . The apparatus of claim 5 , the preload assembly further comprising:
a cam follower assembly configured to ride on the preload track; and an arm comprising a first end, and a second end, the first end being configured to couple to the motor pack, and the second end being coupled to the cam follower assembly; wherein if the cam follower assembly is positioned at the first location on the preload track, the arm is configured to transfer a force proportional to the first force from the cam follower assembly to the motor pack; and wherein if the cam follower assembly is positioned at the second location on the preload track, the arm is configured to transfer a force proportional to the second force from the cam follower assembly to the motor pack.

7 . The apparatus of claim 6 , the cam follower assembly further comprising:
a wheel configured to ride on the preload track; and a body rotatably coupled to the housing, the body having a first and a second end, the second end of the body being rotatably coupled to the second end of the arm, the first end of the body being rotatably coupled to the wheel.

8 . The apparatus of claim 1 , further comprising:
an insertion assembly including the preload track; wherein the surgical device assembly further comprises:
a housing affixed to the insertion assembly; and
a motor pack movably mounted in the housing; and
wherein the preload assembly further comprises:
a cam follower assembly configured to ride the preload track; and
an arm comprising a first end, and a second end, the first end being configured to couple to the motor pack, and the second end being coupled to the cam follower assembly;
wherein if the cam follower assembly is positioned at the first location on the preload track, the arm is configured to transfer a force proportional to the first force from the cam follower assembly to the motor pack; and
wherein if the cam follower assembly is positioned at the second location on the preload track, the arm is configured to transfer a force proportional to the second force from the cam follower assembly to the motor pack.

9 . The apparatus of claim 8 , the cam follower assembly further comprising:
a wheel configured to ride on the preload track; and a body rotatably coupled to the housing, the body having a first and a second end, the second end of the body being rotatably coupled to the second end of the arm, the first end of the body being rotatably coupled to the wheel.

10 . The apparatus of claim 1 , further comprising:
an insertion assembly including the preload track, wherein the insertion assembly comprises a distal end, and wherein the surgical device assembly further comprises:
a surgical instrument manipulator assembly connected to the distal end of the insertion assembly, wherein the surgical instrument manipulator assembly is coupled to the preload assembly.

11 . The apparatus of claim 10 , wherein the surgical instrument manipulator assembly further comprises a drive output disk configured to receive the first force and the second force.

12 . The apparatus of claim 10 , the surgical device assembly further comprising:
a sterile adapter mounted on the surgical instrument manipulator assembly, wherein the sterile adapter comprises an intermediate disk coupled the drive output disk; and wherein if the second force is applied to the drive output disk and the drive output disk is mated to the intermediate disk, the coupling between the intermediate disk and the drive output disk comprises zero backlash.

13 . The apparatus of claim 1 ,
the surgical device assembly comprising, a housing, a motor pack movably mounted in the housing, and a pin coupled to the housing; and the preload assembly further comprising:
a cam following assembly comprising a wheel and a body, the wheel being configured to ride on the preload track, the body being configured to rotatably couple to the pin, the body having a first and a second end, the second end of the body being rotatably coupled to the motor pack, and the first end of the body being rotatably coupled to the wheel.

14 . The apparatus of claim 13 , further comprising:
a preload engagement arm comprising a first end and a second, the first end of the preload engagement arm being rotatably coupled to the pin; and a rolling pin mounted in the second end of the preload engagement arm.

15 . The apparatus of claim 14 , further comprising:
a preload release lever comprising a first end and a second end, the first end of preload release lever being couplable to and decouplable from the rolling pin; and a preload release button coupled to the second end of the preload release lever.

16 . The apparatus of claim 1 , the preload assembly further comprising a preload reset mechanism, the preload reset mechanism being configured to position the preload assembly at the first location on the preload track.

17 . The apparatus of claim 1 :
the preload track being movable; the preload track comprising a ramp, a distal portion, and a preload engagement ridge, the distal portion being distal to the ramp, and the preload engagement ridge extending from the distal portion; and the preload assembly further comprising:
a cam following assembly configured to ride on the preload track, the cam following assembly being rotatably coupled to a pivot pin
a preload engagement arm comprising a first end and a second, the first end of the preload engagement arm being rotatably coupled to the pivot pin, the second end of the preload engagement arm co

Assignees

• Intuitive Surgical Operations

Inventors

• Solomon Todd R
• Mcgrogan Anthony K
• Cooper Thomas G

Classifications

• A61B2034/302

  specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities · CPC title

• A61B34/30 Primary

  Surgical robots · CPC title

• A61B2017/00477

  Coupling (A61B2017/0046 takes precedence) · CPC title

• G05B2219/41032

  Backlash · CPC title

• B25J9/1641

  compensation for backlash, friction, compliance, elasticity in the joints · CPC title