Description:TECHNICAL FIELD
[0001] The present disclosure relates to robotic systems, in particular, the present disclosure relates to a robotic surgical system.
BACKGROUND
[0002] Robotic surgical systems have revolutionised modern surgical procedures by enabling minimally invasive approaches with enhanced precision and control. The robotic surgical systems employ robotic arms that manipulate surgical harmonic instruments through small incisions in the body of a patient. The performance of the surgical harmonic instruments is significantly influenced by the mechanism used for actuating the end-effectors, such as jaws, which are responsible for tissue grasping, cutting, or manipulation. Precise and reliable jaw actuation is vital for ensuring surgical safety and effectiveness, particularly during delicate or repetitive tasks.
[0003] Conventional surgical harmonic instruments used in robotic systems often rely on cable-driven or manual mechanical linkages to actuate the jaws. Such mechanisms are limited in precision and subject to variability in actuation force due to friction, backlash, or mechanical wear. Furthermore, manual actuation or tension-based systems may introduce fatigue or inconsistency over time. In certain applications, such as ultrasonic surgical harmonic instruments, the need for accurate and controlled movement of the jaw becomes useful, as improper closure can affect tissue treatment efficacy or lead to unintended damage. Thus, there exists a technical problem of how to implement a compact, precise, and electronically controlled jaw actuation mechanism that provides consistent and repeatable motion.
[0004] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks.
SUMMARY
[0005] The present disclosure provides a robotic surgical system with a surgical harmonic instrument. The present disclosure provides a solution to the technical problem of space constraints and how to transmit ultrasonic mechanical vibrations to a surgical site without energy dissipation and with optimal vibrational coherence within the compact confines of robotic surgical platforms. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art by integrating a coaxially aligned internal transducer mechanism comprising piezoelectric elements, a connector pin, and a stationary jaw within a minimized instrument footprint while maintaining direct energy transmission pathways that preserve phase alignment and amplitude of mechanical vibrations. The disclosed system addresses the limitations of existing ultrasonic surgical instruments that suffer from poor compatibility with robotic and endoscopic platforms due to their oversized mechanical arrangements, energy loss through structural vibrations, inadequate mechanical isolation, and inability to achieve proper concentric alignment of energy transmission components.
[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 robotic surgical system. The robotic surgical system includes a patient-side cart comprising a plurality of robotic arms, the robotic surgical system further includes a surgeon console configured to receive inputs from a surgeon to control the plurality of robotic arms. The robotic surgical system further includes a vision cart configured to process and display images from a surgical site. At least one robotic arm of the plurality of robotic arms comprises a surgical harmonic instrument. The surgical harmonic instrument includes a jaw assembly disposed at a distal end of the surgical instrument, where the jaw assembly includes a stationary jaw and a pivotable jaw and an instrument housing. The instrument housing includes a transducer configured to generate mechanical vibrations and a connector pin disposed between the stationary jaw of the jaw assembly and the transducer. The connector pin is configured to receive the mechanical vibrations from the transducer and transmit the mechanical vibrations to the stationary jaw. The stationary jaw is configured to oscillate at a predetermined ultrasonic frequency in response to the mechanical vibrations received from the connector pin and transmit the mechanical vibrations to a surgical site.
[0008] The integration of the surgical harmonic instrument within the robotic surgical system offers precision of robotic control with the efficiency of ultrasonic energy delivery. The structure of the robotic surgical system enables the surgeon to perform complex surgical manoeuvres with enhanced dexterity, stability, and visualization. Within the integrated framework of the robotic surgical system, the surgical harmonic instrument enhances surgical effectiveness by delivering high-frequency mechanical vibrations directly to the target tissue which allows precise cutting and coagulation with minimal lateral thermal damage.
[0009] The inclusion of an internally aligned energy transfer mechanism ensures that ultrasonic vibrations are delivered seamlessly from the proximal end of the surgical harmonic instrument to the distal end, where the jaws interact with tissue (i.e., the surgical site). The direct energy path enhances vibrational efficiency and reduces losses commonly encountered in modular or misaligned assemblies. As a result, the stationary jaw can oscillate effectively at the ultrasonic frequency. The oscillation at the ultrasonic frequency allows for rapid mechanical disruption of tissue and reliable haemostasis in real-time. The rapid mechanical disruption and reliable haemostasis not only improves the surgical outcome with reduction in bleeding and collateral damage but also minimizes the need for frequent repositioning of the surgical harmonic instrument.
[0010] Furthermore, the integration of the surgical harmonic instrument into the robotic arm enables fine control over jaw actuation and energy delivery with minimal user fatigue. The robotically assisted manipulation of the jaw assembly, combined with ultrasonic action, allows for delicate tissue dissection even in confined anatomical spaces. The synergy between mechanical precision and ultrasonic functionality enhances the overall control, safety, and efficiency of surgical procedures (such as in minimally invasive and endoscopic environments). The compact and co-axial internal structure of the surgical harmonic instrument further supports better balance and ease of integration within robotic platform. The better balance and ease of integration within robotic platform enables scalable and reliable use across a wide range of clinical applications.
[0011] In an implementation, the transducer includes piezoelectric elements and in order to generate mechanical vibrations using the transducer. The piezoelectric elements are configured to receive an electrical signal having alternating voltage. The alternating voltage causes the piezoelectric elements to alternately expand and contract along a longitudinal direction at the same frequency as the electrical signal. The piezoelectric elements are further configured to generate mechanical vibrations via alternate expansion and contraction of the piezoelectric elements. The piezoelectric elements are further configured to oscillate the mechanical vibrations back and forth along the longitudinal axis. The mechanical vibrations are produced at the predetermined ultrasonic frequency matching the frequency of the electrical signal.
[0012] Application of alternating electrical signal makes the piezoelectric elements to undergo controlled expansion and contraction along the longitudinal axis. The direct electromechanical conversion allows the surgical harmonic instrument to generate high-frequency oscillations that closely match the input signal. The matching of the high-frequency oscillations with the input signal ensures consistent and predictable vibrational output. The piezoelectric elements produce mechanical vibrations without requiring complex mechanical linkages or moving parts and hence reduces energy losses, wear, and the need for frequent maintenance. The longitudinal direction of oscillation also enables effective coupling with the connector pin and other downstream components. The effective coupling supports a linear transmission path that preserves amplitude and phase alignment of the ultrasonic waves.
[0013] In an implementation, the mechanical vibrations are longitudinal mechanical vibrations at the predetermined ultrasonic frequency.
[0014] In such an implementation, the use of longitudinal mechanical vibrations at the predetermined ultrasonic frequency enables efficient energy transmission with minimal acoustic loss along the axis of the surgical harmonic instrument. The directional alignment enhances precision at the surgical site, allowing for controlled tissue dissection and coagulation with reduced lateral thermal spread. The directional alignment also improves vibrational coherence and ensures consistent performance across procedures.
[0015] In an implementation, the connector pin is configured to transmit the mechanical vibrations to the stationary jaw through a continuous solid body of the connector pin while preserving phase alignment and amplitude of the mechanical vibrations through acoustic wave transmission.
[0016] The use of the continuous solid connector pin to transmit mechanical vibrations from the transducer to the stationary jaw integrity of the acoustic wave throughout the energy transfer path. The uninterrupted solid structure ensures that both the amplitude and phase of the ultrasonic vibrations are preserved. The preservation of the amplitude and phase of the ultrasonic vibrations minimizes energy loss and avoiding signal distortion. Such preservation helps to maintain consistent oscillatory behaviour at the distal end, which directly impacts the precision and effectiveness of tissue cutting and coagulation. Additionally, the solid-body design improves mechanical stability, reduces the potential for micro-movements or misalignments.
[0017] In an implementation, the oscillation of the stationary jaw causes rapid mechanical displacement. The rapid mechanical displacement generates localized heating through friction and mechanical disruption of cellular structures at the surgical site.
[0018] The rapid mechanical displacement of the stationary jaw enables efficient tissue cutting and coagulation by generating localized heating through friction and cellular disruption. The targeted energy delivery minimizes thermal spread to adjacent tissues, enhances surgical precision, and reduces the need for additional haemostatic tools. As a result, targeted energy delivery improves procedural efficiency and patient safety.
[0019] In an implementation, the surgical harmonic instrument further includes further comprises a transducer cover coaxially surrounding the transducer and configured to provide mechanical isolation.
[0020] The coaxial transducer cover provides mechanical isolation, which helps prevent vibration loss to surrounding components and reduces interference within the instrument housing. The reduction in interference enhances vibrational efficiency, improves safety, and supports consistent ultrasonic performance during surgical procedures.
[0021] In an implementation, the transducer cover, connector pin, and stationary jaw are arranged concentrically along the longitudinal axis of the surgical harmonic instrument.
[0022] The concentric arrangement of the transducer cover, connector pin, and stationary jaw along the longitudinal axis ensures precise alignment and efficient transmission of ultrasonic energy with minimal vibrational loss. The streamlined configuration enhances mechanical stability, reduces complexity in assembly, and allows for a more compact profile of the surgical harmonic instrument ideal for integration into the robotic surgical system.
[0023] In an implementation, the surgical harmonic instrument further includes an electrical connector configured to receive electrical power for energizing the transducer.
[0024] The electrical connector provides standardized power interface compatibility across different robotic surgical platforms while enabling hot-swappable instrument changes during procedures. The configuration of the electrical connector eliminates the need for hardwired connections and allows for rapid instrument replacement without interrupting surgical workflow. The dedicated electrical pathway ensures consistent power delivery to the transducer, maintaining stable ultrasonic frequency generation throughout extended surgical procedures.
[0025] In an implementation, the pivotable jaw is configured to move between an open position and a closed position.
[0026] The mechanism of the pivotable jaw enables precise tissue grasping and manipulation capabilities essential for delicate surgical procedures and allows surgeons to securely hold tissue while simultaneously applying ultrasonic energy for cutting and coagulation. The dual functionality eliminates the need for separate grasping instruments, reduces instrument exchanges and streamline surgical workflow. The controlled jaw positioning provides variable compression force application, optimizing tissue treatment effectiveness based on specific surgical requirements.
[0027] In an implementation, the surgical harmonic instrument further comprises a cam connected to a coupling shaft and a follower arm having a guide element positioned within a groove of the cam, such that rotation of the cam causes linear displacement of the follower arm to actuate the pivotable jaw.
[0028] The cam-driven actuation system converts rotational input motion into precise linear displacement and provides mechanical advantage and enhanced control precision for jaw positioning. The mechanism of the cam enables smooth, predictable jaw movement with reduced backlash and improved positional accuracy. The follower arm configuration distributes mechanical loads evenly and reduces wear and extending instrument lifespan. The follower arm configuration maintains consistent jaw closing forces throughout the operational life of the surgical harmonic instrument.
[0029] In an implementation, the surgical harmonic instrument further comprises a push rod mechanically connected to the follower arm and extending along the longitudinal axis. Linear motion of the follower arm is transmitted through the push rod to actuate the pivotable jaw.
[0030] The mechanism push rod provides direct mechanical coupling between the actuator and jaw assembly that eliminates compliance and ensuring immediate response to surgeon input commands. The rigid transmission system maintains precise positional control and force feedback that enables surgeons to feel tissue resistance and adjust grasping pressure accordingly. The longitudinal axis alignment minimizes mechanical complexity while maximizing force transmission efficiency, reducing power requirements and improving overall system reliability.
[0031] In an implementation, the concentric alignment of the transducer, the connector pin, and the stationary jaw provides a direct energy transmission path that maintains vibrational coherence from the transducer to the surgical site.
[0032] The concentric alignment of the transducer eliminates energy dissipation through structural vibrations and maintains phase coherence of ultrasonic waves throughout the transmission path. The phase coherence of ultrasonic waves maximizes cutting efficiency and coagulation effectiveness. The configuration of the transducer prevents unwanted resonance modes and vibration dampening that may otherwise reduce surgical performance and increase heat generation. The direct energy transmission pathway reduces power requirements and ensures consistent ultrasonic amplitude delivery to the surgical site, improving procedural outcomes and reducing tissue thermal damage.
[0033] It is to be appreciated that all the aforementioned implementation forms can be combined.
[0034] 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.
[0035] 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
[0036] 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.
[0037] 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 isometric view of an exemplary surgical harmonic instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 3 is a diagram illustrating a proximal and distal end of the surgical harmonic instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 4 is a diagram illustrating a base of the surgical harmonic instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 5 is a diagram illustrating a jaw assembly of the surgical harmonic instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure; and
FIG. 6 is a diagram illustrating a cross-sectional view of the surgical harmonic instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure.; and
FIG. 7 is a diagram illustrating a process for generation of mechanical vibrations within the surgical harmonic instrument, in accordance with an embodiment of the present disclosure.
[0038] 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
[0039] 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.
[0040] 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.
[0041] The patient-side cart 110 refers to a mobile platform and comprises a plurality of robotic arms. The patient-side cart 110 is configured to support the plurality of robotic arms positioned adjacent to a patient during surgical procedures. The patient-side cart 110 includes a base mounted on wheels. The patient-side cart 110 further includes a vertical column extending upward from the base. The plurality of robotic arms extends from the vertical column of the patient-side cart 110. In some implementations, the plurality of robotic arms includes 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.
[0042] The electrical connectors transmit power and signals to mounted instruments. The patient-side cart 110 further includes at least one surgical harmonic instrument (e.g., a surgical harmonic instrument 140) mounted to the surgical instrument holders 114 at one of the robotic arms 112. The surgical harmonic instrument 140 includes elongated shafts with end effectors at distal tips. 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.
[0043] 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 display 122 mounted at an upper portion of the vertical housing, wherein the display 122 comprises a high-definition LCD monitor with anti-glare coating. In some other embodiments, the vision cart 120 may include multiple displays. 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.
[0044] 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 for displaying real-time surgical site images in high resolution, providing enhanced depth perception and clarity. The stereoscopic display system 134 includes dual display panels and optical elements. The optical elements include focusing mechanisms and eye tracking sensors. In an implementation, the stereoscopic display system 134 is secured by a monitor mounting assembly, which enables adjustable positioning for optimal viewing angles. The monitor mounting assembly 136 may be referred to as an adjustable support system that securely holds and enables the controlled positioning of the stereoscopic display system 134 within a workstation or operational environment.
[0045] The surgeon console 130 further includes master control manipulators 132 mounted on sides of the base structure in front of the operator seat. The master control manipulators 132 terminate in ergonomic hand grips. The hand grips contain pressure sensors and multi-function triggers. In some other embodiments, the hand grip provides haptic feedback.
[0046] 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.
[0047] The patient-side cart 110, the vision cart 120, and the surgeon console 130 connect through a communication network. The communication network comprises ethernet cables. In an implementation, the communication network may be through wired or wireless communication protocol. In an implementation, the communication between the patient-side cart 110, the vision cart 120, and the surgeon console 130 is established through etherCAT or ethernet. In some other embodiments, the communication may be through any wireless communication protocol.
[0048] 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.
[0049] In some implementations, the robotic surgical system 100 includes emergency stop mechanisms mounted on each component. The emergency stops 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.
[0050] 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. 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.
[0051] FIG. 2 is a diagram illustrating an isometric view of an exemplary surgical harmonic 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 harmonic instrument 140 mounted to the surgical instrument holder 114 for use with the robotic surgical system 100 described in FIG. 1. The surgical harmonic instrument 140 includes an elongated shaft 202 comprising a proximal end 204 and a distal end 206. The surgical harmonic instrument 140 further includes a jaw assembly 208 disposed at the distal end 206 of the elongated shaft 202. The surgical harmonic instrument 140 further includes an instrument housing 210 disposed at the proximal end 204 and configured to cover the internal components of the surgical harmonic instrument 140. The internal components of the surgical harmonic instrument 140, introduced as a structural element of the robotic surgical system, are described in greater detail with reference to FIG. 3. The instrument housing 210 includes an electrical interface port 212 for power supply and a clutch 214.
[0052] The elongated shaft 202 forms a central structural backbone of the surgical harmonic instrument 140. The elongated shaft 202 is configured to provide mechanical support and housing for the internal components of the surgical harmonic instrument 140. The elongated shaft 202 is configured to facilitate minimally invasive surgical access while maintaining sufficient structural rigidity to transmit mechanical forces and ultrasonic vibrations from the proximal end 204 to the distal end 206 without loss of precision or power.
[0053] The jaw assembly 208 refers to a functional end-effector of the surgical harmonic instrument 140. The jaw assembly 208 comprises a stationary jaw and a pivotable jaw. The jaw assembly 208 is configured to perform surgical tasks such as grasping, cutting, and coagulating tissue. The jaw assembly 208 is positioned at the distal end 206 to provide suitable surgical access while receiving both ultrasonic energy and mechanical actuation forces transmitted through the elongated shaft 202.
[0054] The instrument housing 210 refers to a structural enclosure for the internal components disposed at the proximal end 204. The instrument housing 210 is configured to maintain sterile boundaries while accommodating the internal components and electrical connections useful for the integration of the surgical harmonic instrument 140 with the robotic surgical system 100 to ensure reliable operation in surgical environments.
[0055] The electrical interface port 212 (hereinafter referred to as “the port 212”) refers to a connector configured to establish the power supply connection for the surgical harmonic instrument 140. The port 212 is configured for secure, sterile connection to a power distribution network of the robotic surgical system 100 while and maintains appropriate electrical isolation and safety standards.
[0056] The clutch 214 refers to an electromechanical device operatively coupled between a motor and a jaw actuation mechanism, configured to enable selective engagement and disengagement of the drive power of the motor from jaw actuation components. The clutch 214 allows the motor to drive the pivotable jaw under automated control when engaged and permits manual operation or safe disconnection of the actuation mechanism when disengaged, such as during instrument setup, emergency override, or maintenance procedures.
[0057] FIG. 3 is a diagram illustrating the proximal end and distal end of the surgical harmonic instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure. FIG. 3 is described in conjunction with the elements of FIGs. 1 to 2. With reference to FIG. 3, there is shown the proximal end 204 of the surgical harmonic instrument 140. In the illustrated embodiment of FIG. 3, the instrument housing 210 (not shown) of the surgical harmonic instrument 140 includes internal components include a cam 304 coupled to a base 302 of the surgical harmonic instrument 140. The cam 304 includes a groove 306 and a coupling shaft 312 coupled along a longitudinal axis 318 to the cam 304. The internal components further include a guide body 308 positioned around a follower arm 314. In an implementation the surgical harmonic instrument 140 includes a cam 304 connected to a coupling shaft 312 and a follower arm 314 having a guide element positioned within a groove of the cam, such that rotation of the cam causes linear displacement of the follower arm 314 to actuate the pivotable jaw.
[0058] The guide body 308 comprises a plurality of guide channels (for example a first guide channel 310) coupled to the base 302 of the surgical harmonic instrument 140. The follower arm 314 comprises a plurality of guide pins (for example, a first guide pin 316). The surgical harmonic instrument 140 includes a cap 320 to cover all the internal components present at the proximal end 204 of the surgical harmonic instrument 140. In an implementation, the surgical harmonic instrument 140 further comprises the elongated shaft 202 extending between the base 302 and the jaw assembly 208.
[0059] The base 302 refers to a foundational mounting structure of the surgical harmonic instrument 140. The base 302 is configured to provide a stable platform for securing and aligning the internal components. The base 302 is structurally integrated with the proximal end 204 of the elongated shaft 202 and serves as the primary attachment point for the cam 304 and the guide body 308. The base 302 ensures precise positioning and mechanical stability of the motor while providing interface mounting for connection to the surgical instrument holder 114 of the robotic surgical system 100.
[0060] The cam 304 refers to a rotating mechanical element configured to convert rotational motion into linear displacement. In an implementation, the cam 304 is mechanically coupled to the base 302 through the coupling shaft 312 that extends along the longitudinal axis 318 of the surgical harmonic instrument. The coupling shaft 312 is secured within a journal bore formed in the base 302, using a press-fit mechanism to allow smooth rotational movement while preventing axial displacement. The cam 304 receives rotational input through the coupling shaft 312 and transmits converted linear motion to the follower arm 314 via the groove 306.
[0061] In an implementation, the cam 304 is operatively coupled to the motor configured to provide rotational input. The motor is positioned within or adjacent to the base 302 and mechanically connected to the coupling shaft 312 through appropriate coupling mechanisms such as direct shaft connection, gear reduction systems, or flexible couplings. The motor provides controlled rotational motion to the cam 304, enabling precise speed and position control of the jaw actuation system.
[0062] The groove 306 refers to a precision machined pathway formed within the cam 304, configured with a specific geometric profile to guide the linear translation of the follower arm 314 during rotation of the cam 304. In an implementation, the groove 306 of the cam 304 comprises a cam profile configured to control a motion ratio between rotational input and linear displacement output. In such implementations, the groove 306 has a helical profile configured to control a motion ratio between rotational input and linear displacement output. In other words, the helical profile determines how much linear displacement of the follower arm 314 occurs for each degree of rotational input applied to the cam 304 through the coupling shaft 312. The motion ratio control is achieved through the variable pitch and depth characteristics of the helical profile. For example, when the groove 306 features a steep helical angle, a small rotational input of the cam 304 produces a large linear displacement of the guide pin and consequently the follower arm 314. Furthermore, when the groove 306 exhibits a shallow helical angle, the small rotational input results in a small linear displacement. The helical profile of the groove 306 is useful for different phases of jaw operation, such as rapid opening and closing movements followed by precise positioning for delicate tissue manipulation.
[0063] The guide body 308 refers to a structural housing component that provides linear guidance and support for the follower arm 314 during the translation motion. The guide body 308 is mechanically coupled to the base 302 and positioned to surround and constrain the follower arm 314, ensuring precise linear movement without lateral deflection or binding. In an implementation, the guide body 308 is mechanically secured to the base 302 using a snap-fit interface. In another implementation, the guide body 308 is mechanically secured to the base 302 using precision screws. The guide body 308 incorporates the plurality of guide channels (including the first guide channel 310) that serve as linear bearings for the motion of the follower arm 314. The first guide channel 310 refers to a linear pathway within the guide body 308 that provides guided motion constraint for the follower arm 314 during actuation cycles. The first guide channel 310 is one component of the plurality of guide channels that collectively ensure stable and accurate linear translation of the follower arm 314 in response to cam rotation. The first guide channel 310 is coupled to the base 302 through integration within the guide body 308 and maintains fixed positioning relative to the cam 304.
[0064] The coupling shaft 312 refers to a rotational transmission element that mechanically connects the cam 304 to an external rotational drive source (such as the motor) and defines the rotational axis for cam operation. The coupling shaft 312 is aligned along the longitudinal axis 318 and provides the mechanical interface for receiving rotational input from the motor. In an implementation, the cam is operatively coupled to the motor configured to provide rotational input. The motor that provides rotational input to the coupling shaft can be implemented as a servo motor. The coupling shaft 312 ensures precise rotational positioning and torque transmission to the cam 304 while maintaining proper alignment with the base 302 and the guide body 308.
[0065] The follower arm 314 refers to a mechanical element that serves as the primary motion transmission component between the cam 304 and the jaw assembly 208. The follower arm 314 is configured to convert the rotational motion of the cam 304 into linear displacement. The follower arm 314 incorporates the plurality of guide pins. Each guide pin of the plurality of guide pins is a protrusion on a curved surface of the follower arm 314. The plurality of guide pins is configured to travel within the corresponding guide channel of the plurality of guide channels within the guide body 308, providing stable guidance during linear translation. In an implementation, the guide pin is configured to follow a helical path within the groove 306 during cam rotation. A guide pin (not shown) is configured to engage with the groove 306 of the cam 304, following the helical pathway defined by the groove 306 during cam rotation. The rotational motion of the cam 304 produces a linear motion in the guide pin (not shown) engaged with the groove 306, which subsequently generates coordinated linear movement for the plurality of guide pins. The coordinated linear movement of the plurality of guide pins provides controlled linear motion of the follower arm 314 along the longitudinal axis 318, enabling precise actuation of the pivotable jaw 504 for surgical operations.
[0066] In an implementation, the surgical harmonic instrument 140 further comprises the instrument housing 210 configured to enclose the cam 304 and the follower arm 314. The instrument housing 210 provides comprehensive environmental protection and structural enclosure for the cam 304, the follower arm 314, and the guide body 308. The instrument housing 210 is configured to maintain sterile boundaries while accommodating the cam-follower mechanism, electrical connections, and interface elements necessary for robotic system integration. The instrument housing 210 prevents contamination of moving parts while maintaining the compact instrument geometry required for minimally invasive surgical procedures, thereby ensuring reliable operation in surgical environments and facilitating standard cleaning and sterilization protocols without compromising the precision of the internal actuation mechanism.
[0067] The cap 320 refers to a structural cover component configured to enclose and retain internal elements of the surgical harmonic instrument 140 at the proximal end 204 of the elongated shaft 202. In an implementation, the cap 320 is secured to a top portion of the follower arm 314 using fasteners or a snap-fit engagement. The cap 320 provides mechanical protection and prevents the ingress of contaminants.
[0068] FIG. 4 is a diagram illustrating the base of the surgical harmonic instrument of the robotic surgical system, 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 the base 302 of the surgical harmonic instrument 140 of the robotic surgical system 100 highlighting the arrangement of coupling shaft 312. The base 302 includes a plurality of perforations 402 at a bottom surface of the base 302. The bottom surface of the base 302 is opposite to a surface on which the cam 304, the guide body 308 and the follower arm 314 are positioned. The plurality of perforations 402 are configured to receive the corresponding coupling shaft. Each perforation of the plurality of perforations 402 includes a bearing 404. The bearing 404 refers to a rotational support element disposed within each of the perforations of the plurality of perforations 402 at the bottom surface of the base 302. In an implementation, the bearing 404 is a radial ball bearing configured to support the coupling shaft 312, allowing free and smooth rotational motion while minimizing friction and axial displacement. The bearing 404 is press-fitted into the perforation 402 to ensure a secure, vibration-resistant interface, thereby maintaining concentric alignment between the coupling shaft 312 and the base 302.
[0069] In another implementation, the bearing 404 may comprise a sleeve bearing or journal bearing formed of a biocompatible polymer or ceramic composite, selected based on sterilization compatibility and wear resistance. The bearings 404, when used in conjunction with the coupling shaft 312, ensure precise alignment of a rotational axis across the cam 304. The alignment is useful for translating rotational motion into linear motion without introducing lateral deviation, backlash, or motion lag.
[0070] Each coupling shaft is configured to extend vertically through a corresponding perforation of the plurality of perforations 402 and engage one or more rotating components located on the opposite side of the base 302, such as the cam 304. In some implementations, the coupling shaft 312 is fixedly mounted to the cam using a mechanical key, flat, or set screw, thereby transmitting rotational input from the clutch 214 positioned below the base 302.
[0071] The bottom surface of the base 302 serves as an interface plane for mounting the motor. In an implementation, the clutch 214 is positioned adjacent to or integrated with the motor and operatively coupled to the coupling shaft 312 to provide selective engagement and disengagement of rotational input. The integration of the clutch 214 ensures that when the clutch 214 is disengaged, the cam 304 remains decoupled from the motor output, thereby enabling manual override or safety lockout.
[0072] FIG. 5 is a diagram illustrating the jaw assembly of the surgical harmonic instrument of the robotic surgical system, 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 the jaw assembly 208 of the surgical harmonic instrument 140 of the robotic surgical system 100. The jaw assembly 208 includes a stationary jaw 502 and a pivotable jaw 504. The jaw assembly 208 is mounted to the elongated shaft 202 of the surgical harmonic instrument 140. The pivotable jaw 504 is mechanically linked to a push rod 508 configured to slide linearly within the elongated shaft 202.
[0073] In an implementation, the surgical harmonic instrument 140 further comprises a push rod 508 mechanically connected to the follower arm 314 and extending along the longitudinal axis. Linear motion of the follower arm 314 is transmitted through the push rod 508 to actuate the pivotable jaw 504. The push rod 508 receives linear input from the follower arm 314 and transmits the linear motion to the pivotable jaw 504. The connection of the follower arm 314, the push rod 508 and the pivotable jaw 504 ensure synchronized actuation, enabling predictable opening and closing of the pivotable jaw 504 during surgical procedures.
[0074] In another implementation, the jaw assembly 208 is configured such that when the push rod 508 is pushed forward, the pivotable jaw 504 open , and when the push rod 508 is retracted, the pivotable jaw 504 closes . When the push rod 508 is pushed forward (toward the distal end 206), the push rod 508 applies force to the pivotable jaw 504 through a pivot point 506. The forward linear motion by the push rod 508 causes the pivotable jaw 504 to rotate about the pivot point 506 in a opening direction, bringing a surface of the pivotable jaw 504 into contact with the stationary jaw 502. The jaw assembly 208 is configured such that the forward motion of the push rod 508 translates into an opening rotational movement of the pivotable jaw 504. The opening rotational movement of the pivotable jaw 504 creates the clamping action necessary for secure tissue holding during ultrasonic cutting and coagulation. Similarly, when the push rod 508 is retracted (pulled backwards toward the proximal end 204), the push rod 508 reverses the motion translation, causing the pivotable jaw to rotate in the opposite direction about the pivot point 506. The retraction motion of the push rod 508 closes the jaw assembly 208 by moving the pivotable jaw 504 away from the stationary jaw 502. The linear displacement of the push rod 508 causes angular displacement of the pivotable jaw 504 about the pivot point 506, thereby enabling the pivotable jaw 504 to transition between an open position and a closed position.
[0075] In an implementation, the pivotable jaw 504 is configured to pivot about the pivot point 506 to provide variable clamping force based on the linear position of the push rod 508. The pivotable jaw 504 is configured to pivot about the pivot point 506, which serves as a rotational axis. The pivoting motion is controlled by the linear position of the push rod 508, such that intermediate positions of the rod correspond to variable jaw openings. The controlled pivoting motion of the jaw assembly 208 allows the surgeon to apply variable clamping forces depending on the position of the push rod 508, enabling gentle handling of delicate tissue or firmer clamping when needed. For example, slight movement of the push rod 508 enables gentle grasping for coagulation, intermediate movement allows controlled dissection, and further movement provides firm clamping for cutting.
[0076] FIG. 6 is a diagram illustrating a cross-sectional view of the surgical harmonic instrument of the robotic surgical system, 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 the cross-sectional view of the surgical harmonic instrument 140 of the robotic surgical system 100. The surgical harmonic instrument 140 includes the instrument housing 210 includes a transducer cover 604 coaxially surrounding the transducer 602 and configured to provide mechanical isolation.
[0077] The transducer 602 refers to an ultrasonic component integrated within the surgical harmonic instrument and configured to generate high-frequency mechanical vibrations suitable for tissue dissection, coagulation, or cutting. The transducer 602 constitutes an ultrasonic energy generation component that converts electrical energy into mechanical vibrations at ultrasonic frequencies. In an implementation, the ultrasonic frequencies are ranging from 20 kHz to 55 kHz. The transducer 602 is mechanically coupled to the base 302 through a secure mounting arrangement that ensures efficient energy transmission while maintaining proper alignment with the longitudinal axis 318 of the surgical harmonic instrument 140. The transducer 602 incorporates piezoelectric elements that expand and contract in response to alternating electrical signals, generating high-frequency mechanical oscillations suitable for ultrasonic surgical applications.
[0078] The transducer cover 604 refers to a structural enclosure element configured to house and protect the transducer 602 within the surgical harmonic instrument 140. The transducer cover 604 provides a protective enclosure and environmental sealing for the transducer 602, preventing contamination and ensuring sterile operation within the surgical environment. The transducer cover 604 maintains the precise positioning of the transducer 602 and facilitates proper energy transmission through the connector pin 606 to the stationary jaw 502 which acts as a surgical end-effector.
[0079] The connector pin 606 refers to an elongated ultrasonic transmission element that forms a mechanical link between the transducer 602 and the stationary jaw 502 of the jaw assembly 208. The connector pin 606 is configured to propagate high-frequency mechanical vibrations from the transducer 602 to a surgical site with minimal signal attenuation.
[0080] In an implementation, the surgical harmonic instrument 140 is an ultrasonic surgical harmonic instrument comprising the transducer 602 configured to vibrate the stationary jaw 502. The transducer 602 generates controlled high-frequency mechanical vibrations that are transmitted through the connector pin 606 to the stationary jaw 502, causing the surface of the stationary jaw 502 to oscillate at ultrasonic frequencies during surgical procedures. The oscillation of the stationary jaw 502 enables simultaneous cutting, coagulation, and sealing of tissue through frictional heating generated by the ultrasonic vibrations.
[0081] FIG. 7 is a diagram illustrating a process for generation of mechanical vibrations within the surgical harmonic instrument, in accordance with an embodiment of the present disclosure. With reference to FIG. 7, there is shown a process 700 for generation of mechanical vibrations within the surgical harmonic instrument 140. The surgical harmonic instrument 140 includes the transducer 602, which further includes piezoelectric elements 704. The piezoelectric elements 704 refers to ceramic or crystalline materials (for example, ceramic compounds composed of lead zirconate titanate (PZT)), that exhibit the property of mechanical deformation when subjected to electrical voltage and conversely generate electrical charge when mechanically stressed. The piezoelectric elements 704 are configured as thin wafers, discs, or layered stacks arranged within the transducer 602.
[0082] In operation, a surgeon actuates the jaw assembly 208 of the surgical harmonic instrument 140 by input commands through the surgeon console 130 of the robotic surgical system 100. The manipulation of the surgeon console 130 controlled by the surgeon is translated into digital control signals that are transmitted to the robotic arm 112. The transmitted digital signals are delivered to a motor within the base 302 of the surgical harmonic instrument 140 through the port 212. The port 212 establishes the electrical connection between a power distribution network of the robotic arm 112 and the motor. The transmitted digital signals initiate rotation of the cam 304 through the coupling shaft 312. The transmitted digital signals are delivered to the transducer 602within the base 302 of the surgical harmonic instrument 140 through the port 212, which serves as a multi-function interface for both mechanical control and electrical power distribution. The port 212 establishes the electrical connection between the power distribution network of the robotic arm 112 and the transducer 602 , while simultaneously providing pathways for ultrasonic power delivery. The transmitted digital signals initiate rotation of the cam 304 through the coupling shaft 312. Further, the rotational motion of the cam 304 is converted to linear displacement through the follower arm 314. The linear motion is transmitted through the push rod 508 that extends along the longitudinal axis, causing the pivotable jaw to move between open and closed positions for precise tissue grasping and manipulation.
[0083] A power source 702 is configured to provide electrical signal 706 to the transducer 602 via the port 212. The power source 702 may be referred to as an electrical power supply, AC power generator, ultrasonic generator, or electrosurgical unit (ESU). The power source 702 is configured to provide electrical signals (for example, an electrical signal 704) to the transducer 602. The power source 702 may be referred to as an electrical power supply, AC power generator, ultrasonic generator, or electrosurgical unit (ESU). In some implementations, the power source 702 may include an alternating current generator specifically designed to produce frequency electrical signals in the ultrasonic range of 50-60 kHz. In an implementation, the surgical harmonic instrument 140 further comprises an electrical connector configured to receive electrical power for energizing the transducer 602. The electrical connector is connected to the port 212 through which the electrical signal 706 is delivered to the transducer 602 for generating ultrasonic mechanical vibrations. The transducer 602 converts the electrical signal 706 into mechanical vibrations 710, which are transmitted through the connector pin 606 to the stationary jaw 502. Separately, the coupling shaft 312 provides mechanical actuation for jaw movement. The coupling shaft 312 operates independently from the ultrasonic vibration pathway. The electrical connector of the surgical harmonic instrument 140 is configured to receive electrical signal 706 for energizing the transducer 602 through the port 212. The electrical connector establishes electrical continuity with a power distribution network of the surgical harmonic instrument 140. The electrical signal 706 from the power source 702 is routed through the port 212 to the transducer 602 via dedicated internal electrical pathways. The dedicated internal electrical pathways are electrically isolated from the mechanical components including the coupling shaft 312, which is used solely for mechanical jaw actuation. The dual pathway ensures that both mechanical actuation signals for jaw movement and electrical power for ultrasonic generation reach their respective components within the instrument housing 210 without interference.
[0084] Further, the piezoelectric elements 704 are configured to generate mechanical vibrations. The piezoelectric elements 704 composed of lead zirconate titanate (PZT) ceramics arranged in layered stacks or disc configurations, receive the electrical signal 706 having alternating voltage from the power source 702 through the internal electrical distribution network.
[0085] In an implementation, the piezoelectric elements 704 are further configured to generate corresponding mechanical vibrations 710 via alternate expansion and contraction of the piezoelectric elements 704. The alternating voltage causes the piezoelectric elements 704 to alternately expand and contract along the longitudinal direction at precisely the same frequency as the electrical signal 706. The alternate expansion and contraction create dimensional changes that convert electrical energy into mechanical motion. The piezoelectric elements 704 generate corresponding mechanical vibrations via this alternate expansion and contraction mechanism, with the transducer cover providing mechanical isolation to prevent unwanted vibrations from affecting other instrument components. The mechanical vibrations oscillate back and forth along the longitudinal axis of the surgical harmonic instrument 140. The mechanical vibrations produce mechanical vibrations at the predetermined ultrasonic frequency that exactly matches the frequency of the electrical signal 706.
[0086] The connector pin 606, positioned between the stationary jaw 502 and the transducer 602, is configured to receive the longitudinal mechanical vibrations from the transducer and serve as the primary energy transmission element within the vibration pathway. The connector pin 606 transmits the mechanical vibrations to the stationary jaw 502 through its continuous solid body construction, which preserves phase alignment and amplitude of the mechanical vibrations through efficient acoustic wave transmission along the material structure of the connector pin 606. The concentric alignment of the transducer 602, the connector pin 604, and the stationary jaw 502 provides a direct energy transmission path that maintains vibrational coherence and minimizes energy loss from the transducer 602 to the surgical site that ensures maximum efficiency in ultrasonic energy delivery.
[0087] During active surgical operation, the surgeon maintains independent control over both mechanical jaw actuation and ultrasonic energy delivery through separate control of the surgeon console 130, allowing for precise coordination of tissue manipulation and treatment. When ultrasonic cutting or coagulation is activated, the stationary jaw 502 receives the transmitted mechanical vibrations and begins oscillating at the predetermined ultrasonic frequency, causing rapid mechanical displacement with amplitudes typically measured in micrometres.
[0088] The rapid mechanical displacement generates localized heating through friction between the oscillating jaw surface and tissue structures, while simultaneously creating mechanical disruption of cellular structures at the surgical site. The combination of thermal energy from friction and mechanical energy from ultrasonic vibrations enables precise tissue cutting with simultaneous coagulation of blood vessels, minimizing bleeding and providing enhanced surgical precision. Throughout the process, the coupling shafts 312 continue to provide independent mechanical actuation for jaw positioning and tissue grasping, while the dedicated electrical pathways deliver uninterrupted ultrasonic power to the transducer assembly. This integrated design allows the surgeon to maintain simultaneous control over both tissue manipulation through mechanical jaw movement and tissue treatment through ultrasonic energy delivery, providing comprehensive surgical functionality through the coordinated operation of the robotic harmonic instrument 140 while ensuring optimal energy transmission, mechanical isolation, and surgical effectiveness in minimally invasive robotic procedures.
[0089] The alternating voltage causes the piezoelectric elements 704 to alternately expand and contract along a longitudinal direction at the same frequency as the electrical signal 706. alternating voltage causes the piezoelectric elements 704 to alternately expand and contract along the longitudinal direction through the inverse piezoelectric effect, where the applied electric field induces mechanical strain within the crystalline structure of the piezoelectric ceramic materials. When the positive half-cycle of the electrical signal 706 is applied across the piezoelectric elements 704, the electric field aligns with the polarization direction of the ceramic material, typically lead zirconate titanate (PZT), causing the crystal dipoles to reorient and the unit cells to elongate along the longitudinal axis. The electric field-induced deformation results in physical expansion of the piezoelectric elements 704, where the material dimensions increase proportionally to the applied voltage magnitude, typically achieving longitudinal strain values of 0.1% to 0.3% of the original length.
[0090] During the negative half-cycle of the electrical signal 706, the electric field reverses direction and opposes the polarization direction of the piezoelectric material, causing the crystal dipoles to reorient in the opposite direction and the unit cells to compress along the longitudinal axis. The reverse electric field application results in physical contraction of the piezoelectric elements 704, where the material dimensions decrease below their neutral state, creating negative strain that mirrors the expansion characteristics but in the opposite direction. The expansion and contraction process occurs at precisely the same frequency as the electrical signal 706 because the piezoelectric response is instantaneous, with the mechanical deformation directly following the electrical field variations without significant phase lag.
[0091] The alternating expansion and contraction create a cyclic dimensional change where each piezoelectric element 704 oscillates between its maximum expanded state during positive voltage peaks and its maximum contracted state during negative voltage peaks. The magnitude of expansion and contraction is directly proportional to the applied voltage amplitude, while the frequency of the alternating dimensional changes matches exactly the frequency of the electrical signal 706. The piezoelectric elements 704 arranged in series or parallel configurations within the transducer assembly undergo synchronized expansion and contraction, creating cumulative mechanical displacement that amplifies the overall longitudinal motion. The continuous alternating expansion and contraction process converts the electrical energy of the alternating voltage into mechanical energy in the form of longitudinal vibrations, with the piezoelectric elements 704 serving as electromechanical transducers that maintain precise frequency and phase correspondence between the electrical signal 706 and the resulting mechanical vibrations along the longitudinal direction.
[0092] In an implementation, the piezoelectric elements 704 are further configured to the oscillate the mechanical vibrations back and forth along the longitudinal axis. The piezoelectric elements 704 oscillate the mechanical vibrations back and forth along the longitudinal axis through a continuous electromechanical conversion process where the alternating electrical signal causes the piezoelectric ceramic materials to undergo cyclic dimensional changes in synchronized fashion. When the positive half-cycle of the alternating voltage is applied, the piezoelectric elements 704 expand longitudinally due to the inverse piezoelectric effect, where the electric field induces mechanical strain within the crystal lattice structure, causing the piezoelectric elements 704 to lengthen along their polarization axis. During the negative half-cycle of the alternating voltage, the piezoelectric elements 704 contract longitudinally, returning to their original dimensions or compressing below their neutral state, depending on the applied voltage amplitude. The alternating expansion and contraction creates a reciprocating motion where the piezoelectric elements 704 continuously oscillate between their maximum expanded and contracted states at the same frequency as the applied electrical signal, typically 50-60 kHz. The mechanical vibrations are oscillated back and forth along the longitudinal axis as the cumulative effect of all piezoelectric elements 704 working in phase, where their synchronized dimensional changes create a net displacement motion that propagates through the transducer assembly as acoustic waves. The oscillating mechanical vibrations maintain consistent amplitude and frequency characteristics that correspond directly to the electrical signal parameters, creating a faithful electromechanical conversion where the electrical energy is transformed into longitudinal mechanical vibrations that oscillate continuously along the longitudinal axis of the surgical harmonic instrument for transmission to the surgical components.
[0093] The connector pin 606 is configured to receive the mechanical vibrations 710 from the transducer 602 and transmit the mechanical vibrations to the stationary jaw 502. The connector pin 606 receives the mechanical vibrations 710 from the transducer 602 through direct mechanical coupling at the interface between the output face the transducer 602 and input end of the connector pin 606. The transducer 602 generates longitudinal mechanical vibrations through the expansion and contraction of its piezoelectric elements. The connector pin 606 is mechanically connected to this output surface through a rigid coupling interface, typically achieved through threaded connection, press-fit assembly, or welded joint that ensures intimate contact between the transducer output face and proximal end of the connecter pin 606.
[0094] The mechanical vibrations 710 are transferred from the transducer 602 to the connector pin 606 through solid-state acoustic wave propagation at the coupling interface. When the piezoelectric elements 704 within the transducer 602 undergo alternating expansion and contraction, they create compressive and tensile forces that are transmitted directly to the connector pin 606 through the physical contact at their interface.
[0095] The reception process involves acoustic impedance matching between the output of the transducer 602 and the input of the connector pin 606 to ensure efficient energy transfer without reflection losses. The connector pin 606 is designed with specific cross-sectional area and material properties that provide acoustic impedance matching with the transducer output, minimizing energy reflection at the interface and maximizing vibration transmission efficiency. The coupling interface maintains constant mechanical contact under varying load conditions through proper preload forces or mechanical clamping mechanisms that prevent separation or slippage during oscillation. The connector pin 606 receives the mechanical vibrations as coherent acoustic waves that maintain the same frequency, phase, and amplitude characteristics as generated by the transducer 602, enabling faithful transmission of the ultrasonic energy through the pin's solid body structure to the stationary jaw 502.
[0096] In an implementation, the connector pin 606 is configured to transmit the mechanical vibrations to the stationary jaw 502 through a continuous solid body of the connector pin 606 while preserving phase alignment and amplitude of the mechanical vibrations through acoustic wave transmission. The connector pin 606 (may be manufactured from a homogeneous metallic material such as titanium alloy or surgical-grade stainless steel), with uniform density and acoustic properties throughout its entire length to ensure consistent wave transmission characteristics. The continuous solid body design eliminates any joints, welds, or material discontinuities that may create acoustic impedance mismatches, reflection points, or energy dissipation zones that would degrade the transmission efficiency of the mechanical vibrations.
[0097] The connector pin 606 is dimensionally configured with specific geometric parameters including length, diameter, and surface finish that are precisely calculated to achieve acoustic resonance at the predetermined ultrasonic frequency of 50-60 kHz. The cross-sectional area and length of the connector pin 606 are optimized to create a quarter-wave or half-wave resonator that amplifies the mechanical vibrations while maintaining phase coherence throughout the transmission path. The solid body construction provides a direct mechanical coupling between the transducer 602 output face and the stationary jaw 502 input interface, creating an uninterrupted pathway for acoustic wave propagation.
[0098] The connector pin 606 transmits mechanical vibrations through acoustic wave transmission, where the longitudinal vibrations from the transducer 602 create compression and rarefaction waves that propagate through the crystalline structure of the connector pin 606 at the speed of sound within the material. The continuous solid body ensures that these acoustic waves maintain their phase alignment by eliminating any phase shifts or delays that may occur at material interfaces or structural discontinuities. The uniform material properties of the connector pin 606 provide consistent acoustic impedance throughout its length, allowing the mechanical vibrations to travel from the transducer end to the stationary jaw end without significant amplitude loss or frequency distortion.
[0099] The preservation of phase alignment is achieved through precise geometric design of the connector pin 606, where the pin length is calculated as an integer multiple of the acoustic wavelength at the operating frequency, ensuring that the vibrations arrive at the stationary jaw 502 in phase with the original transducer output. The amplitude preservation is maintained through the cross-sectional area of the connector pin 606, which is designed to minimize acoustic losses while providing sufficient mechanical strength for surgical applications. The connector pin 606 may incorporate stress concentration relief features such as gradual diameter transitions or radiused corners to prevent acoustic reflection and maintain smooth energy flow. Additionally, the surface of the connector pin 606 is precisely controlled to minimize acoustic scattering and ensure laminar wave propagation. The internal grain structure material is optimized during manufacturing to provide consistent acoustic properties and minimize internal energy dissipation, resulting in efficient transmission of mechanical vibrations from the transducer 602 to the stationary jaw 502 with preserved phase alignment and amplitude characteristics essential for effective ultrasonic surgical operation.
[0100] In an implementation, the oscillation of the stationary jaw 502 causes rapid mechanical displacement. The rapid mechanical displacement generates localized heating through friction and mechanical disruption of cellular structures at the surgical site. The rapid mechanical displacement of the stationary jaw 502 at ultrasonic frequencies provides precise surgical cutting with simultaneous haemostasis. The simultaneous haemostasis eliminates the need for separate coagulation instruments and reduces procedure time while minimizing blood loss. The localized heating generated through controlled friction creates targeted thermal coagulation of blood vessels and tissues within a narrow zone and prevents collateral thermal damage to surrounding healthy tissue structures compared to traditional electrocautery methods. The mechanical disruption of cellular structures at the surgical site enables clean tissue separation with reduced tissue charring and improved healing characteristics, while the ultrasonic energy denatures proteins to form a natural biological seal that promotes faster wound healing. The dual-action mechanism of thermal coagulation and mechanical cutting provides superior surgical precision, reduced operative bleeding, faster tissue healing, and enhanced surgical outcomes compared to conventional cutting instruments or electrosurgical devices.
[0101] In an implementation, the concentric alignment of the transducer 602, the connector pin 604, and the stationary jaw 502 provides a direct energy transmission path that maintains vibrational coherence from the transducer 602 to the surgical site. The concentric alignment of the transducer 602, connector pin 604, and stationary jaw 502 eliminates energy losses through parasitic vibrations and off-axis mechanical coupling and ensures maximum ultrasonic power delivery to the surgical site 716 with minimal heat generation in non-functional components. The direct energy transmission path maintains phase coherence and amplitude consistency throughout the vibration pathway, preventing destructive interference patterns that would reduce cutting efficiency and surgical precision. The coaxial configuration minimizes mechanical stress concentrations and acoustic reflections that could cause instrument fatigue or failure, while providing predictable and consistent surgical performance across varying tissue types and surgical loads. The maintained vibrational coherence from transducer to surgical site ensures optimal energy utilization, reduced power consumption, enhanced instrument longevity, and superior surgical outcomes through precise and efficient ultrasonic energy delivery.
[0102] The stationary jaw 502 is configured to oscillate at a predetermined ultrasonic frequency 712 in response to the mechanical vibrations 710 received from the connector pin 606 and transmit the mechanical vibrations to the surgical site 716. The stationary jaw 502 is configured to oscillate at the predetermined ultrasonic frequency 712 through a precise mechanical resonance mechanism where the jaw structure acts as an acoustic horn or waveguide that receives, amplifies, and transmits the mechanical vibrations 710 from the connector pin 606. When the mechanical vibrations 710 are transmitted from the connector pin 606 to the stationary jaw 502, the jaw's geometric design and material properties are specifically engineered to resonate at the predetermined ultrasonic frequency 712, typically within the 50-60 kHz range. The stationary jaw 502 undergoes rapid longitudinal oscillation with microscopic displacement amplitudes (ranging from 10 to 100 micrometres) to create predefined frequency mechanical motion along the cutting edge of the stationary jaw 502 and contact surfaces.
[0103] The oscillation mechanism of the stationary jaw 502 involves the conversion of the transmitted mechanical vibrations into controlled displacement motion where the distal cutting edge of the stationary jaw 502 the stationary jaw 502 moves back and forth along the longitudinal axis at the ultrasonic frequency. The stationary jaw 502 may incorporate geometric features such as tapered sections, step transitions, or curved profiles that function as acoustic impedance transformers, progressively amplifying the vibration amplitude from the connector pin interface to the cutting-edge contact point with tissue.
[0104] During tissue cutting operation, the oscillating stationary jaw 502 transmits the mechanical vibrations to the surgical site 716 through direct contact between the cutting edge of the stationary jaw 502 and the target tissue structures. The tissue cutting process occurs through a combination of mechanical disruption and thermal coagulation mechanisms working simultaneously at the cellular level. The rapid oscillation of the stationary jaw 502 creates high-frequency mechanical stress within the tissue fibers, causing cellular membranes to rupture and protein structures to denature through cavitation effects, where microscopic bubbles form and collapse within the tissue's fluid components. The mechanical vibrations generate internal friction within the tissue matrix, particularly at interfaces between different tissue types, creating localized heating that reaches temperatures sufficient for protein coagulation.
[0105] The cutting action is achieved through the combined effect of mechanical disruption and controlled thermal coagulation, where the oscillating jaw edge physically separates tissue fibers while simultaneously sealing blood vessels and lymphatic channels through protein denaturation and thermal coagulation. The ultrasonic frequency creates a cavitation effect within tissue fluids, where the rapid pressure variations cause microscopic vapor bubbles to form and collapse, creating mechanical shock waves that disrupt cellular structures and facilitate clean tissue separation. The localized heating generated by internal friction denatures collagen and other proteins, creating a coagulated zone around the cutting path that provides haemostasis and reduces bleeding. The controlled thermal effect remains confined to a narrow zone immediately adjacent to the cutting edge (1-2 millimetres), preventing collateral thermal damage to surrounding healthy tissue while ensuring effective coagulation of severed blood vessels. The dual-action mechanism enables the stationary jaw 502 to perform precise tissue cutting with simultaneous haemostasis and clean tissue separation, reduced bleeding, minimal thermal damage, and enhanced surgical precision at the surgical site 716 through the efficient transmission and application of ultrasonic mechanical vibrations.
[0106] 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 robotic surgical system (100) comprising:
a patient-side cart (110) comprising a plurality of robotic arms;
a surgeon console (130) configured to receive inputs from a surgeon to control the plurality of robotic arms;
a vision cart (120) configured to process and display images from a surgical site (716);
wherein at least one robotic arm of the plurality of robotic arms comprises a surgical harmonic instrument (140) comprising:
a jaw assembly disposed at a distal end (206) of the surgical harmonic instrument (140), wherein the jaw assembly comprises a stationary jaw (502) and a pivotable jaw (504); and
an instrument housing (210) comprising:
a transducer (602) configured to generate mechanical vibrations (710);
a connector pin (606) disposed between the stationary jaw (502) of the jaw assembly and the transducer (602), and configured to receive the mechanical vibrations (710) from the transducer (602) and transmit the mechanical vibrations (710) to the stationary jaw (502); and
wherein the stationary jaw (502) configured to oscillate at a predetermined ultrasonic frequency in response to the mechanical vibrations (710) received from the connector pin (606) and transmit the mechanical vibrations to a surgical site (716).
2. The robotic surgical system (100) as claimed in claim 1, wherein the transducer (602) comprises piezoelectric elements (704) and in order to generate the mechanical vibrations using the transducer (602), the piezoelectric elements (704) are configured to:
receive an electrical signal (706) having alternating voltage, wherein the alternating voltage causes the piezoelectric elements (704) to alternately expand and contract along a longitudinal direction at the same frequency as the electrical signal (706);
generate the mechanical vibrations (710) via alternate expansion and contraction of the piezoelectric elements (704); and
oscillate the mechanical vibrations (710) back and forth along the longitudinal axis, wherein the mechanical vibrations (710) are produced at the predetermined ultrasonic frequency matching the frequency of the electrical signal (706).
3. The robotic surgical system (100) as claimed in claim 1, wherein the mechanical vibrations are longitudinal mechanical vibrations at the predetermined ultrasonic frequency.
4. The robotic surgical system (100) as claimed in claim 1, wherein ultrasonic frequency is in the range of 50-60 kHz.
5. The robotic surgical system (100) as claimed in claim 1, wherein the connector pin (606) is configured to transmit the mechanical vibrations to the stationary jaw (502) through a continuous solid body of the connector pin (606) while preserving phase alignment and amplitude of the mechanical vibrations through acoustic wave transmission.
6. The robotic surgical system (100) as claimed in claim 1, wherein the oscillation of the stationary jaw (502) causes rapid mechanical displacement, wherein the rapid mechanical displacement generates localized heating through friction and mechanical disruption of cellular structures at the surgical site.
7. The robotic surgical system (100) as claimed in claim 1, wherein the surgical harmonic instrument further comprises a transducer cover (604) coaxially surrounding the transducer (602) and configured to provide mechanical isolation.
8. The robotic surgical system (100) according to claim 7, wherein the transducer cover (604), connector pin (606), and stationary jaw (502) are arranged concentrically along the longitudinal axis of the surgical harmonic instrument (140).
9. The robotic surgical system as claimed in claim 1, wherein the surgical harmonic instrument (140) further comprises an electrical connector configured to receive electrical power for energizing the transducer.
10. The robotic surgical system (100) as claimed in claim 1, wherein the pivotable jaw (504) is configured to move between an open position and a closed position.
11. The robotic surgical system (100) as claimed in claim 10, wherein the surgical harmonic instrument (140) further comprises a cam connected to a coupling shaft and a follower arm having a guide element positioned within a groove of the cam, such that rotation of the cam causes linear displacement of the follower arm to actuate the pivotable jaw.
12. The robotic surgical system (100) as claimed in claim 10, wherein the surgical harmonic instrument (140) further comprises a push rod (508) mechanically connected to the follower arm and extending along the longitudinal axis, wherein linear motion of the follower arm is transmitted through the push rod (508) to actuate the pivotable jaw.
13. The robotic surgical system (100) as claimed in claim 1, wherein the concentric alignment of the transducer, the connector pin, and the stationary jaw provides a direct energy transmission path that maintains vibrational coherence from the transducer to the surgical site.