Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of robotic surgical systems and, more particularly, to a surgical robotic instrument with distributed locking mechanism for secure coupling
BACKGROUND
[0002] In the field of robotic-assisted surgery and medical instrumentation, ensuring a sterile and stable connection between surgical instruments and their robotic actuation systems is desirable. Sterile adapters are commonly used to provide a contamination-free interface between the instrument and the drive system, allowing for precise control while maintaining aseptic conditions. However, the connection between the sterile adapter and the medical instrument must be robust enough to endure mechanical stresses while still allowing for quick and efficient assembly and disassembly.
[0003] Existing technologies for securing sterile adapters to surgical instruments primarily rely on snap-fit mechanisms or winches that suffer from significant drawbacks. The traditional locking mechanisms can become unstable under bending forces due to their limited contact area and the stress concentration at specific points. Additionally, the existing mechanisms may require complex assembly procedures, leading to increased time for instrument setup and a higher likelihood of failure during critical surgical procedures. Furthermore, conventional locking methods may not provide sufficient tactile feedback to confirm successful engagement, leading to potential operational inefficiencies and safety concerns.
[0004] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks of existing surgical robotic instruments.
SUMMARY
[0005] The present disclosure provides a surgical robotic instrument. The present disclosure provides a solution to the technical problem of how to securely and reliably attach a surgical instrument to a robotic arm while maintaining sterility and allowing for precise control during surgical procedures. Existing attachment mechanisms may suffer from insufficient stability at connection points, leading to unwanted movement during delicate surgical manoeuvres. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art by offering a distributed locking mechanism that ensures secure engagement between the surgical instrument and sterile adapter. The present disclosure specifically aims to improve stability during surgical procedures through a multi-point locking system positioned at corner regions of the instrument housing while simultaneously enhancing the user experience through an intuitive, spring-loaded switching mechanism that provides reliable tactile feedback during engagement.
[0006] One or more objectives of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
[0007] In one aspect, the present disclosure provides a surgical robotic instrument. The surgical robotic instrument includes an elongate shaft defining a longitudinal axis. Further, the surgical robotic instrument includes an end effector disposed at a distal portion of the surgical robotic instrument. The surgical robotic instrument further includes an instrument housing at a proximal portion of the surgical robotic instrument configured to couple with a sterile adapter that interfaces with an actuator drive system. The instrument housing includes a plurality of lock switches movably mounted at corner regions of the instrument housing. The instrument housing further includes a plurality of locking projections extending from the respective lock switches of the plurality of lock switches and drive transfer interfaces configured to receive rotary motion from the actuator drive system through the sterile adapter. The plurality of locking projections simultaneously engages with corresponding slots in the sterile adapter upon movement of the plurality of lock switches to create a distributed securing force at the corner regions for maintaining connection between the surgical robotic instrument and the sterile adapter during transmission of rotary motion from the actuator drive system to the end effector.
[0008] The surgical robotic instrument integrates an advanced locking system with multiple locking projections at the corner regions of the instrument housing. The configuration of the surgical robotic instrument creates a distributed securing force that enhances the mechanical stability and reliability of the attachment. By reducing stress concentration points and evenly distributing load forces, the surgical robotic instrument significantly improves the durability of the locking mechanism and ensures long-term operational integrity. Further, the multiple locking projections simultaneously engage with the sterile adapter, ensuring a secure and vibration-resistant connection. The multiple engagement prevents unintended disengagement due to mechanical stress, external forces, or prolonged operational usage, which is beneficial in maintaining precision during delicate surgical tasks.
[0009] Furthermore, the drive transfer interfaces are configured to efficiently transmit rotary motion from the actuator drive system to the end effector. The configuration of drive transfer interfaces eliminates mechanical slippage, ensuring precise motion control, which is essential for executing complex surgical movements with high accuracy. The combination of secure attachment and precise drive transmission significantly improves the overall performance of the robotic surgical instrument.
[0010] Moreover, upon successful engagement, the surgical robotic instrument provides a perceptible confirmation signal, ensuring that users can verify secure attachment without the need for additional inspection. The additional inspection feature enhances user confidence and reduces the likelihood of operational errors, ultimately improving the safety and efficiency of robotic-assisted surgeries. Additionally, the alignment features integrated into the instrument housing ensure precise orientation during coupling with the sterile adapter. The precise orientation prevents misalignment issues that could impact the effectiveness of the locking mechanism or interfere with surgical procedures. The design enables fast, error-free attachment, reducing preparation time and improving workflow efficiency in surgical environments. Even in the event of partial failure, such as a single lock switch malfunction, the remaining locking projections maintain the secure attachment, preventing accidental detachment. The redundancy feature enhances the reliability of the system, ensuring continuous operation without interruptions or safety risks.
[0011] In an implementation, the sterile adapter includes an outer housing, an inner housing; and drive transfer elements extending between the outer housing and the inner housing for transmitting the rotary motion while maintaining a sterile barrier. In such an implementation, by using the outer housing, the inner housing, and drive transfer elements, the sterile adapter not only safeguards sterility but also enhances operational efficiency, allowing for quick instrument changes and reducing the requirement for excessive sterilization procedures.
[0012] In another implementation, each of the plurality of lock switches comprises a switch body and a user engagement surface extending laterally from the switch body. The plurality of locking projection extends perpendicularly from the switch body. In such an implementation, the switch body, the user engagement surface, and the perpendicular locking projection work together to provide a robust, intuitive, and fail-safe locking mechanism for the surgical robotic instrument. The ergonomic design enhances the ease of use and efficiency, making it simpler to lock and unlock the surgical robotic instrument during surgical procedures.
[0013] In implementation, the instrument housing comprises spring slots, wherein spring members are disposed in the spring slots to bias the plurality of lock switches toward an engaged position. In such an implementation, the integration of spring slots and the spring members within the instrument housing creates an automated, self-securing locking system that enhances stability, ease of use, and safety in robotic-assisted surgeries. The spring-biased lock switches ensure automatic engagement, secure attachment, and intuitive feedback, ultimately improving workflow efficiency and procedural reliability in high-precision surgical applications.
[0014] In another implementation, each spring member comprises a first portion engaging with the respective spring slot, a second portion engaging with the respective lock switch, and a biasing portion between the first and second portions. In such an implementation, the inclusion of the three-part structure of the spring member comprising the first portion for anchoring, the second portion for engaging with the lock switch, and the biasing portion for force application—creates a robust, self-securing and fail-safe locking mechanism for the surgical robotic instrument.
[0015] In an implementation, the plurality of lock switches are configured to provide tactile feedback upon successful engagement with the sterile adapter. In such an implementation, by integrating tactile feedback, the locking mechanism provides a physical response, such as a noticeable click or resistance change, signalling to the user that the instrument is properly secured. Providing an immediate physical confirmation upon successful engagement ensures quick instrument attachment, reduces procedural errors, and improves overall workflow efficiency.
[0016] In an implementation, the plurality of lock switches is configured to automatically move to an engaged position when aligned with the corresponding slots in the sterile adapter. In such an implementation, the automatic engagement of the lock switches enhances efficiency, safety, and precision in robotic-assisted surgeries. Eliminating the requirement for manual locking reduces attachment errors, improves workflow efficiency, and ensures a stable and reliable instrument connection.
[0017] In an implementation, the corner regions comprise four corner regions symmetrically arranged around the instrument housing. In such an implementation, the symmetrically arranged four-corner locking mechanism enhances stability, even force distribution, and fail-safe redundancy in robotic-assisted surgery. The balanced structural configuration also allows for smooth engagement and disengagement, making the system more user-friendly and dependable in high-precision surgical applications.
[0018] In an implementation, the plurality of locking projections maintains secure engagement between the surgical robotic instrument and the sterile adapter upon failure of any single lock switch of the plurality of lock switches. In such an implementation, the redundant locking projection ensures that the surgical robotic instrument remains securely engaged with the sterile adapter, even if a single lock switch fails. This enhances surgical safety, system reliability, and operational efficiency, reducing the risk of unintended instrument detachment and minimizing the requirement for procedural interruptions.
[0019] In an implementation, each lock switch of the plurality of lock switches requires deliberate manual actuation to disengage from the sterile adapter. In such an implementation, requiring deliberate manual actuation for disengagement enhances safety, prevents accidental detachment, and ensures controlled instrument removal. This feature improves procedural reliability and efficiency by ensuring that the instrument remains securely locked during operation while still allowing for quick and easy removal when required.
[0020] In an implementation, the instrument housing comprises alignment features configured to ensure proper orientation between the surgical robotic instrument and the sterile adapter during coupling. In such an implementation, the integration of alignment features in the instrument housing ensures precise and automatic positioning of the surgical robotic instrument during coupling with the sterile adapter. By guiding the surgical robotic instrument into the correct orientation without requiring manual adjustments, these features significantly reduce setup time, improve engagement accuracy, and ensure seamless instrument operation, ultimately contributing to safer and more efficient robotic-assisted surgical procedures.
[0021] In an implementation, the drive transfer interfaces comprise a plurality of drive cable interfaces, cable routing features, and connection interfaces configured to engage with corresponding drive transfer elements of the sterile adapter. In such an implementation, by incorporating the plurality of drive cable interfaces, cable routing features, and connection interfaces, the instrument achieves a seamless, secure, and reliable connection that not only transmits motion accurately but also protects against mechanical wear and maintains stability. The careful coordination of these elements ultimately enhances the overall functionality and safety of the robotic system, ensuring that each surgical movement is executed with high precision and efficiency.
[0022] In an implementation, each lock switch of the plurality of lock switches is movable between an engaged position where the respective locking projection extends into the corresponding slot, a disengaged position where the respective locking projection is withdrawn from the corresponding slot, and an intermediate position providing tactile feedback. In such an implementation, the three-position movement of the lock switch enhances surgical safety, precision, and user control. The engaged position ensures a secure and stable connection, the intermediate position provides tactile confirmation for controlled engagement or disengagement, and the disengaged position allows for intentional removal.
[0023] In an implementation, the instrument housing further comprises peripheral walls, retention features integrated into the peripheral walls, and guide features for directing movement of the plurality of lock switches. In such an implementation, the integration of peripheral walls, retention features, and guide features within the instrument housing enhances the stability, durability, and reliability of the locking mechanism. These elements ensure that the lock switches move consistently along their intended path, remain securely retained in the housing, and engage properly with the sterile adapter.
[0024] In an implementation, the end effector comprises articulation joints for multi-axis movement; and drive cables extending through the elongate shaft from the drive transfer interfaces to actuate the end effector. In such an implementation, the articulation joints and the drive cables work together to provide multi-axis movement, precise force transmission, and enhanced manoeuvrability for the surgical robotic instrument. This allows for greater dexterity in confined surgical spaces, smoother instrument control, and increased procedural accuracy, making it a significant advancement in robotic-assisted surgery.
[0025] It is to be appreciated that all the aforementioned implementation forms can be combined.
[0026] It has to be noted that all devices, elements, circuitry, units and means described in the present application could be implemented in the software or hardware elements or any kind of combination thereof. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. Even if, in the following description of specific embodiments, a specific functionality or step to be performed by external entities is not reflected in the description of a specific detailed element of that entity which performs that specific step or functionality, it should be clear for a skilled person that these methods and functionalities can be implemented in respective software or hardware elements, or any kind of combination thereof. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
[0027] Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
[0029] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a diagram illustrating a robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 2 is a diagram illustrating an exemplary surgical instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 3 is a diagram illustrating an isometric view of an engagement of an instrument housing, a sterile adapter, and an actuator top casing, in accordance with an embodiment of the present disclosure
FIG. 4 is a diagram illustrating an exploded view of an engagement of the instrument housing, the sterile adapter, and the actuator top casing, in accordance with an embodiment of the present disclosure;
FIG. 5 is a diagram illustrating an isometric view of a lock switch mechanism of the surgical robotic instrument, in accordance with an embodiment of the present disclosure;
FIG. 6 is a diagram illustrating a top view of the lock switch mechanism of the surgical robotic instrument, in accordance with an embodiment of the present disclosure;
FIG. 7 is a diagram illustrating a section of the instrument housing, in accordance with an embodiment of the present disclosure; and
FIGs. 8A and 8B are diagrams illustrating an assembly arrangement of an engagement of the instrument housing, the sterile adapter, and the actuator top casing, in accordance with an embodiment of the present disclosure.
[0030] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[0031] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[0032] FIG. 1 is a diagram illustrating a robotic surgical system, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown a robotic surgical system 100, including a patient-side cart 110, a vision cart 120, and a surgeon console 130.
[0033] The patient-side cart 110 is a mobile unit having a base mounted on wheels. The base includes locking mechanisms for securing the patient-side cart 110 in position. The patient-side cart 110 includes a vertical column extending upward from the base. The vertical column comprises a linear actuator enabling height adjustment. The patient-side cart 110 includes multiple robotic arms that extend from the vertical column. In some implementations, the multiple robotic arms include four robotic arms in which three robotic arms 112 are configured for surgical instrument manipulation and one robotic arm 113 is configured for endoscopic imaging. The robotic arms 112 include primary segments, secondary segments, and tertiary segments connected by rotational joints. The rotational joints contain servo motors enabling precise angular positioning. The robotic arms 112 include surgical instrument holders 114 at distal ends. The surgical instrument holders 114 comprise mechanical interfaces and electrical connectors. The mechanical interfaces include spring-loaded clamps for instrument attachment. The electrical connectors transmit power and signals to mounted instruments. The patient-side cart 110 further includes at least one surgical instrument 140 mounted to the surgical instrument holders 114 at one of the robotic arms 112. The surgical instrument includes elongated shafts with end effectors at distal tips. The end effectors include articulation mechanisms enabling pitch and yaw movements. The surgical robotic instrument 140 includes internal drive cables connecting to motor units in the instrument holders. The drive cables actuate the end effector movements. The robotic arm 113 supports an endoscopic imaging system. Each of the robotic arms 112 includes additional degrees of freedom for camera positioning. The endoscopic imaging system includes dual high-definition camera sensors mounted at a distal end of the robotic arm 113. The dual camera sensors enable stereoscopic image capture. The endoscopic imaging system includes fibre optic light transmission bundles surrounding the camera sensors for illuminating the surgical field. The endoscopic imaging system enables both white light imaging and near-infrared fluorescence visualization. The endoscopic imaging system comprises glass rod lenses for controlling chromatic aberration and enhancing image quality.
[0034] The vision cart 120 is a mobile unit comprising a base with wheels and a vertical housing. The base contains power supply units and cooling systems. The vertical housing contains processing units and displays. The vertical housing includes ventilation channels for thermal management. The vision cart 120 includes a primary display 122 mounted at an upper portion of the vertical housing, wherein the primary display 122 comprises a high-definition LCD monitor with anti-glare coating. The vision cart 120 includes an electrosurgical unit (ESU) 124 mounted within the vertical housing. The vision cart 120 further includes endoscope light sources. The endoscope light sources comprise one or two light source units mounted within the vertical housing. The vision cart 120 includes an insufflator unit mounted within the vertical housing for creating and maintaining pneumoperitoneum. The vision cart 120 includes an uninterruptible power supply (UPS) system mounted within the base for providing backup power. The vision cart 120 further includes a video processing unit and a central processing unit within the vertical housing. The video processing unit includes dedicated graphics processors. The central processing unit comprises multiple processing cores. The vision cart 120 further includes data storage devices mounted within the vertical housing. In some implementations, the vision cart 120 comprises image enhancement processors for contrast adjustment and noise reduction. In some implementations, the vision cart 120 includes fluorescence imaging processors for tissue identification. In some implementations, the vision cart 120 includes augmented reality processors for data overlay generation.
[0035] The surgeon console 130 includes a base structure supporting an operator seat and control interfaces. The base structure includes levelling mechanisms for stable positioning. The operator seat comprises height adjustment mechanisms and lumbar support systems. A display housing extends upward and forward from the base structure. The display housing contains a stereoscopic display system 134. The stereoscopic display system 134 includes dual display panels and optical elements. The optical elements include focusing mechanisms and eye tracking sensors. The surgeon console 130 further includes head control manipulators 132 mounted on sides of the base structure in front of the operator seat. The master control manipulators 132 include primary arms, secondary arms, and tertiary arms connected by joints. The joints include force feedback actuators and position sensors. The master control manipulators 132 terminate in ergonomic hand grips. The hand grips contain pressure sensors and multi-function triggers. In some implementations, the surgeon console 130 further includes foot pedals mounted on a lower portion of the base structure. The foot pedals include position sensors and tactile feedback mechanisms. A user interface comprising touchscreens mounts on the base structure between the master control manipulators 132. The touchscreens display system status information and configuration controls.
[0036] The patient-side cart 110, the vision cart 120, and the surgeon console 130 connect through a communication network. The communication network comprises fiber optic cables for high-speed data transmission. The communication network includes redundant data pathways. The communication network transmits control signals from the master control manipulators 132 to the robotic arms 112. The control signals include position commands and gripper actuation commands. In some implementations, the communication network transmits imaging data from the endoscopic imaging system to the stereoscopic display system 134. The imaging data includes calibration parameters and camera position data. The robotic surgical system 100 includes monitoring systems connected to the communication network. The monitoring systems comprise voltage sensors, current sensors, temperature sensors, and position sensors.
[0037] In some implementations, the robotic surgical system 100 includes emergency stop mechanisms mounted on each component. The emergency stop mechanisms include physical switches and software-triggered stops. The robotic surgical system 100 includes power backup systems within each component. The power backup systems include batteries and uninterruptible power supplies. The robotic surgical system 100 includes fault detection processors within the vision cart 120. The fault detection processors monitor system parameters and component status.
[0038] In some implementations, the robotic surgical system 100 executes autonomous and semi-autonomous functions. In some implementations, the robotic surgical system 100 enables system upgrades through modular component replacement. The modular component replacement includes instrument interface upgrades and processing unit upgrades.
[0039] The robotic surgical system 100 enables minimally invasive surgical procedures. Exemplary surgical procedures may include, but not limited to, general surgery procedures, gynaecological procedures, urological procedures, cardiothoracic procedures, and otolaryngological procedures.
[0040] FIG. 2 is a diagram illustrating an exemplary surgical instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure. FIG. 2 is described in conjunction with the elements of FIG. 1. With reference to FIG. 2, there is shown the surgical robotic instrument 140 for use with the robotic surgical system 100 described in FIG. 1. The surgical robotic instrument 140 comprises an instrument housing 200 and an end effector 210 connected by an elongate shaft 220. The instrument housing 200 includes a generally rectangular configuration with rounded edges for ergonomic handling. The instrument housing 200 comprises a top surface 230 having access apertures. The instrument housing 200 further includes side panels 232 with mounting fixtures positioned for secure attachment to instrument holders on the robotic arms 112. The instrument housing 200 contains internal drive mechanisms for actuating the end effector 210. In some implementations, the instrument housing 200 includes electronic components for receiving control signals from the robotic surgical system 100.
[0041] The instrument housing 200 comprises a circular coupling interface 234 located on a front face. The circular coupling interface 234 includes mechanical registration features ensuring precise alignment during instrument mounting. The circular coupling interface 234 contains RFID enabling signal transmission between the surgical robotic instrument 140 and the robotic arm 112. In some other implementations, any other wireless transmission can be used to enable transmission between the surgical robotic instrument 140 and the robotic arm 112.
[0042] The elongate shaft 220 extends from the circular coupling interface 234 of the instrument housing 200. The elongate shaft 220 comprises a rigid cylindrical structure having a substantially uniform diameter. The elongate shaft 220 includes an outer sheath fabricated from biocompatible materials. The elongated shaft 220 may contains internal drive cables, electrical wiring, and mechanical linkages for transmitting forces and signals from the instrument housing 200 to the end effector 210. In an implementation, for monopolar and bipolar instruments, there will be electrical wirings. But, for non-energized instruments, there will not be any electrical wirings. In some implementations, the elongate shaft 220 includes articulation segments enabling angular positioning of the end effector 210.
[0043] The end effector 210 mounts to a distal end of the elongate shaft 220. In an implementation, the end effector 210 comprises articulation joints for multi-axis movement. The articulation joints are arranged in series and/or parallel configurations to enable controlled manipulation of the end effector 210 in multiple degrees of freedom. The articulation joints include, but are not limited to, rotational joints for yaw, and pitch and roll movements, and translational joints for linear displacements, thereby allowing the end effector 210 to be precisely positioned and oriented relative to target tissue during surgical procedures. The articulation joints are configured to provide a wide range of motion while maintaining structural rigidity when under load. In some implementations, the actuator itself rotates to produce the roll movement entirely for the instrument by using rotation from robot’s last joint.
[0044] The end effector further comprises drive cables extending through the elongate shaft 220 from the drive transfer interfaces to actuate the end effector 210. The drive cables are operatively connected at their proximal ends to the drive transfer interfaces and at their distal ends to the articulation joints and/or functional elements of the end effector 210. The drive cables are arranged in a predetermined pattern within the elongate shaft 220 and are configured to transmit tensile and compressive forces generated by the rotational motion of the actuator drive system. Each drive cable is individually tensioned and routed through dedicated channels or lumens within the elongate shaft 220 to minimize friction and interference between adjacent cables, thereby ensuring smooth and precise actuation of the end effector 210 during surgical manipulations. The arrangement and number of drive cables correspond to the specific degrees of freedom and functional capabilities of the end effector 210.
[0045] In some implementations, the end effector 210 comprises a wrist mechanism 250 providing additional degrees of freedom. The wrist mechanism 250 includes articulation joints enabling pitch and yaw movements of grasping jaws 252. In some implementations, the wrist mechanism 250 contains gearing assemblies for converting linear actuation into rotational movement. The grasping jaws 252 include opposed members with tissue-interfacing surfaces. The tissue-interfacing surfaces comprise grip-enhancing textures for secure tissue manipulation. In some implementations, the grasping jaws 252 include integrated sensors for force feedback. In some implementations, the grasping jaws 252 incorporate electrosurgical elements for tissue coagulation.
[0046] The surgical robotic instrument 140 includes mechanical registration features ensuring proper orientation when mounted to the robotic arm 112. The surgical robotic instrument 140 comprises sealing elements preventing fluid ingress during surgical procedures. The surgical robotic instrument 140 includes sterilization-compatible materials enabling repeated reprocessing cycles.
[0047] In some implementations, the surgical robotic instrument 140 comprises specialized end effectors for specific surgical tasks, including tissue cutting, needle driving, clip application, and suturing. In some implementations, the surgical robotic instrument 140 includes integrated cameras for additional visualization capabilities. The surgical robotic instrument 140 operates under the control of the surgeon console 130 via the robotic arm 112 to enable precise tissue manipulation during minimally invasive surgical procedures.
[0048] FIG. 3 is a diagram illustrating an isometric view of an engagement of the instrument housing, the sterile adapter, and the actuator top casing, in accordance with an embodiment of the present disclosure. FIG. 3 is explained in conjunction with elements of FIGs. 1 to 2. With reference to FIG. 3, there is shown an isometric view of an engagement of the instrument housing, the sterile adapter, and the actuator top casing. FIG. 3 includes the surgical robotic instrument 140 (connected to the surgical instrument holders 114 of FIG. 1) inside a cover 300 and a sterile adapter 302. The surgical robotic instrument 140 is configured to be removably coupled to the sterile adapter 302 through a plurality of engagement interfaces. The sterile adapter 302 is situated near a rear end 310 of the surgical robotic instrument 140. The sterile adapter 302 acts as an intermediary connection mechanism between the surgical robotic instrument 140 and an actuator drive system 304, facilitating sterile operation while enabling precise motion control and power transmission. The sterile adapter 302 includes specialized coupling mechanisms that maintain a sterile barrier while allowing mechanical power transmission between the actuator drive system 304 and the surgical robotic instrument 140. In an implementation, the instrument housing 200 comprises the alignment features configured to ensure proper orientation between the surgical robotic instrument 140 and the sterile adapter 302 during coupling. The alignment features include complementary geometric structures for example, keyed protrusions, asymmetric recesses, and orientation-specific tabs strategically positioned on the periphery of the instrument housing 200. The alignment features correspond to matching structures on the sterile adapter 302, thereby permitting coupling only when the surgical robotic instrument 140 is correctly oriented relative to the sterile adapter 302. The alignment features function to prevent misalignment of the drive transfer interfaces with the corresponding drive transfer elements of the sterile adapter 302, which may otherwise result in mechanical failure, incomplete engagement of the locking mechanism, or damage to sensitive components. Additionally, the alignment features facilitate rapid and intuitive coupling by providing visual and tactile cues to the operator, thereby reducing procedural time, and minimizing the risk of improper instrument attachment during surgical preparation.
[0049] The actuator drive system 304 refers to a main motorized system that powers the surgical robotic instrument 140 connected to the sterile adapter 302. In some implementations, the actuator drive system 304 refers to a system or mechanism that provides the power and control required to operate the surgical robotic instrument 140, typically involving components such as motors, controllers, and transmission elements, often integrated with processors and memory for precise control and automation. The actuator drive system 304 includes an actuator top casing 306. The actuator top casing 306 that houses a plurality of drive motors and associated transmission components. The actuator top casing 306 is configured to protect the internal drive components while providing structural support for the entire actuator assembly. In some implementations, the actuator top casing 306 is fabricated from a rigid material, such as a medical-grade polymer or metal alloy, designed to withstand sterilization procedures and maintain dimensional stability during operation.
[0050] In some implementations, the actuator top casing 306 comprises mounting features for secure attachment to the robotic arm and includes precisely positioned openings through which drive transfer elements extend to interface with the sterile adapter 302. In yet another implementation, the actuator top casing 306 is further configured with heat dissipation structures to manage thermal output from the drive motors during extended surgical procedures, thereby ensuring optimal performance and longevity of the electronic components.
[0051] The instrument housing 200 further includes a plurality of lock switches movably mounted at corner regions 314 of the instrument housing 200 plurality of locking projections extending from respective lock switches of the plurality of lock switches. In an implementation, the corner regions comprise four corner regions symmetrically arranged around the instrument housing 200. For example, as illustrated in the embodiment of FIG. 3, the instrument housing 200 incorporates a plurality of lock switches, such as lock switch 308, strategically positioned at the corner regions thereof to establish a distributed securing mechanism. The lock switch 308, as depicted in FIG. 3, comprises a pressable movable body portion that is pivotally or slidably mounted to the instrument housing 200, permitting controlled displacement between engaged and disengaged positions. The lock switch 308 includes a user engagement surface extending laterally from the switch body, configured to receive manual actuation force from an operator. Extending perpendicularly from the lock switch 308, which is dimensioned and oriented to engage with a corresponding slot or recess in the sterile adapter 302 when the lock switch 308 is in the engaged position. As illustrated in the embodiment of FIG. 3, the lock switch 308 has the plurality of locking projections 312, i.e., the locking projection 312A and the locking projection 312B.
[0052] During operation, the lock switch 308 is biased toward the engaged position by a spring member disposed in a dedicated spring slot within the instrument housing 200, such that when the surgical instrument is properly aligned with the sterile adapter 302, the plurality of locking projections 312 automatically extends into the corresponding slot, creating an audible and tactile feedback that signals successful engagement to the operator. The lock switch 308 and the plurality of locking projection 312 function cooperatively with the other lock switches and other projections positioned at the remaining corner regions to create a distributed securing force that maintains precise alignment between the surgical robotic instrument 140 and the sterile adapter 302 throughout the surgical procedure, even under conditions of mechanical stress or vibration, while simultaneously allowing for deliberate disengagement when required through intentional actuation of the lock switches against their spring bias.
[0053] FIG. 4 is a diagram illustrating an exploded view of the engagement of the instrument housing, the sterile adapter, and the actuator top casing, in accordance with an embodiment of the present disclosure. FIG. 4 is described in conjunction with the elements of FIGs. 1 to 3. With reference to FIG. 4, there is shown an exploded view of engagement of the instrument housing, the sterile adapter, and the actuator top casing, depicting the hierarchical arrangement of components in their relative assembly positions. As illustrated in the embodiment of FIG. 4, the instrument housing 200 includes, from top to bottom, the actuator drive system 304 positioned at the proximal end of the instrument housing 200, which the actuator drive system 304 houses the drive motors and control mechanisms; the actuator top casing 306 that provides structural support and protection for the internal drive components; the sterile adapter 302 functioning as the intermediary connector that maintains sterility while enabling mechanical power transmission; the rear end 310 containing the drive transfer interfaces; the lock switch 308 and the plurality of locking projections 312 positioned at the corner regions for secure engagement; and the cover 300 at the distal portion that encloses and protects the components of the surgical robotic instrument 140.
[0054] The instrument housing 200 is configured to ensure proper alignment and secure connection between the components of the surgical robotic instrument 140 and the actuator drive system 304. The sterile adapter 302 serves as an interface between the actuator drive system 304 and the sterile surgical instrument components. The strategic positioning of the lock switch mechanism including the plurality of lock switches (for example, the lock switch 308) and the plurality of locking projections (for example, the plurality of locking projections 312), which engages with corresponding slots in the sterile adapter 302 when assembled. The instrument housing 200 encompasses the entire assembly, providing structural integrity and proper orientation through specialized alignment features that correspond to complementary structures on the sterile adapter 302. The arrangement of the instrument housing 200 ensures that mechanical force is efficiently transmitted from the actuator drive system 304 through the sterile adapter 302 to the surgical instrument while maintaining the sterile barrier required for surgical procedures.
[0055] FIG. 5 is a diagram illustrating an isometric view of lock switch mechanism of the surgical robotic instrument, in accordance with an embodiment of the present disclosure. FIG. 5 is described in conjunction with the elements of FIGs. 1 to 4. With reference to FIG. 5, there is shown a diagram 500 depicts an isometric view of a lock switch mechanism of the surgical robotic instrument 140 (shown in FIG. 2). The diagram 500 highlights the lock switch mechanism integrated with the instrument housing 200 (a shown in FIG. 2). The diagram 500 depicts the cover 300 which forms the outer shell of the surgical robotic instrument 140 (as shown in FIG. 2), providing protection and structural integrity to the internal components. The rear end 310 is configured with a plurality of circular apertures 502 arranged in a predetermined pattern to accommodate drive transfer interfaces for transmitting rotary motion from the actuator drive system 304 (as shown in FIG. 3) to the end effector 210.
[0056] As illustrated in embodiment of FIG. 5, the lock switch 308 and the lock projection 312A are positioned at the corner region of the instrument housing 200. The spatial relationship between the lock switch 308 and the plurality of locking projections, demonstrating how the lock switch 308, when actuated, controls the position of the projection for engagement or disengagement with the sterile adapter 302. The integration of the lock switch 308 with the instrument housing 200 allows for controlled movement while maintaining structural integrity. The lock switch 308 is strategically positioned to ensure that when the surgical robotic instrument 140 is properly aligned with the sterile adapter 302, the plurality of locking projection automatically engages with the corresponding slot, establishing a secure mechanical connection.
[0057] FIG. 6 is a diagram illustrating a top view of the lock switch mechanism of the surgical robotic instrument, in accordance with an embodiment of the present disclosure. FIG. 6 is described in conjunction with the elements of FIGs. 1 to 5. With reference to FIG. 6, there is shown a diagram 600 illustrating a top view of the rear end 310 of the instrument housing 200, showcasing the spring-loaded switch mechanism used to securely lock the surgical robotic instrument 140 (as shown in FIG. 1) with the sterile adapter 302 (as shown in FIG. 3). The diagram 600 presents a planar view that clearly depicts the spatial arrangement of the components that facilitate secure coupling between the surgical robotic instrument 140 and the sterile adapter 302. The rear end 310 features a substantially rectangular configuration with rounded corners, where the central portion comprises the plurality of circular apertures 502 arranged in a symmetrical pattern. The plurality of circular apertures 502 serve as drive transfer interfaces configured to receive rotary motion from the actuator drive system 304 through the sterile adapter 302 comprises couplers to receive the rotary motion from actuator drive system and drive the drive components of the surgical robotic instrument 140 to actuate the end effector 210.
[0058] Further, the plurality of lock switches, as illustrated in the embodiment of the FIG. 6, the lock switch 308 and the lock switch 602 movably mounted at the corner regions of the instrument housing 200 (as shown in FIG. 2), positioned symmetrically on opposing lateral sides of the rear end 310. Each lock switch (for example, the lock switch 308 and the lock switch 602) is configured with a user engagement surface extending laterally outward from the peripheral edge of the rear end 310, thereby facilitating ergonomic manipulation by the operator during coupling and decoupling operations. As illustrated in the embodiment of FIG. 6, the lock switch 308 has the plurality of locking projections 312 i.e., the locking projection 312A and the locking projection 312B. Similarly, the lock switch 602 has plurality of locking projections i.e., the locking projection 604A and the locking projection 604B. The diagram 600 effectively demonstrates the strategic positioning of the plurality of lock switches, which enables the distributed securing force at the corner regions for maintaining a stable connection between the surgical robotic instrument 140 and the sterile adapter 302 during surgical procedures.
[0059] The top view as depicted by the diagram 600, further reveals the structural configuration of the rear end 310, which incorporates precision-engineered features designed to ensure proper alignment with the sterile adapter 302. The symmetrical arrangement of the drive transfer interfaces and lock switches 308 enhances the structural integrity of the connection, ensuring that forces generated during surgical procedures are evenly distributed across the coupling interface. The configuration is essential for preventing unwanted movement or misalignment during delicate surgical manoeuvres, thereby contributing to improved surgical outcomes through enhanced stability and precision.
[0060] FIG. 7 is a diagram illustrating a section of the instrument housing, in accordance with an embodiment of the present disclosure. FIG. 7 is described in conjunction with the elements of FIGs. 1 to 6. With reference to FIG. 7, there is shown a diagram 700 depicting a section of the instrument housing 200, specifically depicting the integration of the plurality of lock switches and the plurality of locking projections. In an implementation, each of the plurality of lock switches comprises a switch body (as illustrated in the embodiment of the FIG. 7, a switch body 704 of the lock switch 308 and a switch body 708 of the lock switch 602).
[0061] Each of the plurality of lock switches further comprises a user engagement surface extending laterally from the switch body. For example, a user engagement surface 702 of the lock switch 308. In an implementation, the plurality of locking projection, for example, the locking projection 312A and the locking projection 314A extends perpendicularly from the switch body 704. It is to be noted that lock switch 602 has similar functionalities and configuration as that of the lock switch 308. In some other implementations, there may be more than two lock switches having similar structure and functionalities as that of the lock switch 308 and the the locking projection 312A and the locking projection 314A.
[0062] Further, the plurality of circular apertures 502 are designed to align with corresponding drive transfer elements of the sterile adapter 302. This alignment ensures precise motion transmission while maintaining a secure and sterile interface. The locking mechanism includes lock switches positioned at strategic locations to facilitate secure engagement. In an implementation, the instrument housing 200 comprises spring slots, and wherein spring members are disposed in the spring slots to bias the plurality of lock switches toward an engaged position. For example, the lock switch 308 incorporate spring slots (i.e., a first spring slot 706A and a second spring 706B), which house biasing elements that provide a controlled force during the locking and unlocking process. The spring slots allow the locking projection 312A, and the locking projection 312B to engage securely with the corresponding features of the sterile adapter 302, ensuring a firm and vibration-resistant connection.
[0063] In an implementation, each spring member comprises a first portion engaging with the respective spring slot; a second portion engaging with the respective lock switch; and a biasing portion between the first and second portions. The first portion of the spring member is specifically configured to engage with the respective spring slot formed in the instrument housing. The engagement is achieved through a complementary geometric relationship between the first portion of the spring member and the spring slot, ensuring stable positioning during operation. The first portion is typically characterized by a substantially flat segment or hook-like structure that firmly seats within the spring slot, preventing displacement during actuation of the lock switch mechanism. The precise geometry of this first portion is optimized to distribute contact forces evenly within the spring slot, minimizing localized stress concentrations and enhancing durability over repeated operational cycles. The second portion of the spring member is specifically designed to engage with the respective lock switch. The engagement is typically achieved through direct contact with a designated feature on the underside or inner surface of the lock switch body. The second portion maintains constant contact with the lock switch throughout its range of motion, ensuring continuous force application. The geometry of the second portion is carefully engineered to provide a controlled contact interface with the lock switch, optimizing force transmission while minimizing friction and wear. Between the first and second portions exists the biasing portion, which constitutes the primary force-generating element of the spring member. The biasing portion typically takes the form of a curved, bent, or coiled segment that undergoes elastic deformation during operation of the lock switch. When the lock switch is moved from an engaged position to a disengaged position, the biasing portion of the spring member is compressed or otherwise elastically deformed, storing potential energy.
[0064] The stored potential energy creates a restoring force that continuously biases the lock switch toward the engaged position where the locking projection extends into the corresponding slot in the sterile adapter 302. The biasing portion is specifically designed to provide sufficient force to maintain secure engagement during normal operation while allowing for deliberate manual actuation when disengagement is required. The material selection and geometric configuration of the biasing portion are optimized to maintain consistent performance over numerous actuation cycles and to withstand the environmental conditions encountered during sterilization procedures. The three-portion configuration of each spring member represents an elegant engineering solution that facilitates reliable operation of the locking mechanism while accommodating the dimensional constraints of the instrument housing. The configuration enables the distributed securing force at the corner regions, significantly enhancing the stability of the connection between the surgical robotic instrument and the sterile adapter 302 during transmission of rotary motion from the actuator drive system 304 to the end effector 210.
[0065] FIGs. 8A and 8B are diagrams illustrating an assembly arrangement of an engagement of the instrument housing, the sterile adapter, and the actuator top casing, in accordance with an embodiment of the present disclosure. FIGs. 8A and 8B are described in conjunction with the elements of FIGs. 1 to 7. With reference to FIGs. 8A and 8B, there is shown an exploded view of an assembly arrangement of an engagement of the instrument housing 200, the sterile adapter 302, and the actuator top casing, the FIG. 8A depicts a front elevation view of the individual components of the instrument housing 200 and FIG 8B depicts a corresponding isometric view of the same components of the instrument housing 200. FIGs. 8A and 8B illustrate the structural arrangement of the sterile adapter 302 that facilitates secure connection between the surgical robotic instrument 140 and the actuator drive system 304. In an implementation, the sterile adapter 302 comprises an outer housing 802A, an inner housing 804A, and drive transfer elements extending between the outer housing 802A and the inner housing 804A for transmitting the rotary motion while maintaining a sterile barrier. By using the outer housing 802A, the inner housing 804A, and drive transfer elements, the sterile adapter 302 not only safeguards sterility but also enhances operational efficiency, allowing for quick instrument changes and reducing the requirement for excessive sterilization procedures.
[0066] In operations, prior to the surgical procedure, the sterile adapter 302 is securely mounted onto the actuator drive system 304. The connection establishes the interface through which rotary motion will be transmitted while maintaining the critical sterile barrier. The sterile adapter 302 comprises the inner housing 804A and the inner housing 804A, with drive transfer elements extending between them to transmit motion while preserving stability.
[0067] When preparing to use the surgical robotic instrument 140, the surgeon or surgical assistant positions the instrument housing 200 at the proximal portion of the surgical robotic instrument140 in alignment with the sterile adapter 302. The alignment features of the instrument housing 200 engage with corresponding structures on the sterile adapter 302, permitting connection only when correctly oriented, thereby preventing potential damage from misalignment. As the instrument housing 200 approaches full engagement with the sterile adapter 302, the plurality of lock switches positioned at the corner regions of the instrument housing 200 come into proximity with the corresponding slots in the sterile adapter 302. The spring members housed within the spring slots of the instrument housing continuously bias the lock switches toward the engaged position through the action of their biasing portions. Upon proper alignment, the plurality of locking projections extending from respective lock switches automatically engage with the corresponding slots in the sterile adapter 302. The engagement occurs simultaneously at all corner regions, creating a distributed securing force that evenly stabilizes the connection. The engagement is accompanied by tactile feedback, confirming to the operator that a proper connection has been achieved without requiring visual verification. During the surgical procedure, the secure connection established by the locking mechanism maintains precise alignment between the drive transfer interfaces of the surgical instrument and the corresponding drive transfer elements of the sterile adapter 302. The alignment ensures efficient transmission of rotary motion from the actuator drive system 304 to the end effector 210 at the distal portion of the surgical robotic instrument 140. The rotary motion is transmitted through the drive transfer interfaces, which comprise the plurality of drive cable interfaces and connection interfaces. The motion is then conveyed through drive cables extending through the elongate shaft to actuate the end effector 210, which may include articulation joints for multi-axis movement.
[0068] Throughout the surgical procedure, the distributed securing force created by the plurality of locking projections at the corner regions maintains stability even during complex surgical manoeuvres. The strategic placement of the lock switches at four symmetrically arranged corner regions ensures that the connection remains secure even if subjected to various directional forces. Furthermore, the plurality of locking projections maintains secure engagement between the surgical robotic instrument and the sterile adapter even upon failure of any single lock switch, providing redundancy and enhancing operational safety.
[0069] When instrument exchange is required during surgery, the surgeon or assistant must deliberately actuate each lock switch to disengage the locking projections from their corresponding slots. The deliberate action prevents accidental disconnection during surgical procedures. The lock switches move against the biasing force provided by the spring members, transitioning from the engaged position to the disengaged position through an intermediate position that provides additional tactile feedback. Upon disengagement, the surgical robotic instrument 140 can be safely removed from the sterile adapter 302 without compromising the sterile barrier. A new instrument can then be connected following the same procedure, enabling versatile application of various end effectors throughout the surgical intervention while maintaining system integrity and sterility.
[0070] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure. 
, Claims:Claims
We Claim:
1. A surgical robotic instrument (140) comprising:
an elongate shaft (220) defining a longitudinal axis;
an end effector (210) disposed at a distal portion of the surgical robotic instrument;
an instrument housing (200) at a proximal portion of the surgical robotic instrument (140) configured to couple with a sterile adapter that interfaces with an actuator drive system (304), wherein the instrument housing (200) comprises:
a plurality of lock switches (308, 602) movably mounted at corner regions of the instrument housing;
a plurality of locking projections (312A, 312B, 604A, 604B) extending from respective lock switches of the plurality of lock switches (308, 602);
drive transfer interfaces configured to receive rotary motion from the actuator drive system (304) through the sterile adapter (302);
wherein the plurality of locking projections simultaneously engage with corresponding slots in the sterile adapter (302) upon movement of the plurality of lock switches to create a distributed securing force at the corner regions (314) for maintaining connection between the surgical robotic instrument and the sterile adapter (302) during transmission of rotary motion from the actuator drive system (304) to the end effector (210).
2. The surgical robotic instrument (140) as claimed in claim 1, wherein the sterile adapter (302)comprises:
an outer housing (802A);
an inner housing (804A); and
drive transfer elements extending between the outer housing (802A) and the inner housing (804A) for transmitting the rotary motion while maintaining a sterile barrier.
3. The surgical robotic instrument (140) as claimed in claim 1, wherein each of the plurality of lock switches comprises:
a switch body (704); and
a user engagement surface (702) extending laterally from the switch body (704),
wherein the plurality of locking projection extends perpendicularly from the switch body (704).
4. The surgical robotic instrument (140) as claimed in claim 1, wherein the instrument housing (210) comprises spring slots (706A, 706B), and wherein spring members are disposed in the spring slots (706A, 706B) to bias the plurality of lock switches toward an engaged position.
5. The surgical robotic instrument (140) as claimed in claim 4, wherein each spring member comprises:
a first portion engaging with the respective spring slot;
a second portion engaging with the respective lock switch; and
a biasing portion between the first and second portions.
6. The surgical robotic instrument (140) as claimed in claim 1, wherein the plurality of lock switches are configured to provide tactile feedback upon successful engagement with the sterile adapter (302).
7. The surgical robotic instrument (140) as claimed in claim 1, wherein the plurality of lock switches are configured to automatically move to an engaged position when aligned with the corresponding slots in the sterile adapter (302).
8. The surgical robotic instrument (140) as claimed in claim 1, wherein the corner regions (314) comprise four corner regions symmetrically arranged around the instrument housing (200).
9. The surgical robotic instrument (140) as claimed in claim 1, wherein the plurality of locking projections maintains secure engagement between the surgical robotic instrument (140) and the sterile adapter (302) upon failure of any single lock switch of the plurality of lock switches.
10. The surgical robotic instrument (140) as claimed in claim 1, wherein each lock switch of the plurality of lock switches requires deliberate manual actuation to disengage from the sterile adapter (302).
11. The surgical robotic instrument (140) as claimed in claim 1, wherein the instrument housing (140) comprises alignment features configured to ensure proper orientation between the surgical robotic instrument (140) and the sterile adapter (302) during coupling.
12. The surgical robotic instrument (140) as claimed in claim 1, wherein the drive transfer interfaces comprise:
a plurality of drive cable interfaces;
cable routing features; and
connection interfaces configured to engage with corresponding drive transfer elements of the sterile adapter (302).
13. The surgical robotic instrument (140) as claimed in claim 1, wherein each lock switch of the plurality of lock switches is movable between:
an engaged position where the respective locking projection extends into the corresponding slot;
a disengaged position where the respective locking projection is withdrawn from the corresponding slot; and
an intermediate position providing tactile feedback.
14. The surgical robotic instrument (140) as claimed in claim 1, wherein the instrument housing (200) further comprises:
peripheral walls;
retention features integrated into the peripheral walls; and
guide features for directing movement of the plurality of lock switches.
15. The surgical robotic instrument (140) as claimed in claim 1, wherein the end effector (210) comprises:
articulation joints for multi-axis movement; and
drive cables extending through the elongate shaft (220) from the drive transfer interfaces to actuate the end effector (210).