Description:TECHNICAL FIELD
[0001] The present disclosure relates to robotic surgical systems, in particular, the present disclosure relates to a robotic surgical system for robotically actuating a harmonic surgical instrument.
BACKGROUND
[0002] Robotic surgical systems have widespread application in minimally invasive surgical procedures, wherein the robotic surgical systems manipulate surgical instruments at a surgical site with precision and dexterity beyond the capability of direct manual intervention. Among the surgical instruments employed in robotic surgical systems, harmonic surgical instruments, also referred to as ultrasonic surgical instruments, play a critical role by enabling simultaneous tissue cutting and coagulation through high-frequency mechanical oscillations transmitted. The jaw members of a harmonic surgical instrument is required to perform multiple independent functions at the surgical site, including ultrasonic cutting and coagulation through transmission of ultrasonic vibrations to at least one of the jaw members, and angular repositioning of the jaw members about the longitudinal axis of the instrument, referred to as roll rotation, to access tissue at varying orientations within the confined spatial constraints of the surgical site. The concurrent provision of jaw actuation, ultrasonic vibration transmission, and roll rotation within a single harmonic surgical instrument imposes severe mechanical design challenges, principally arising from the requirement to transmit three mechanically independent actuation functions i.e., axial translation for jaw actuation, longitudinal oscillation for ultrasonic vibration, and rotation about the longitudinal axis for roll motion through the same harmonic surgical instrument, without mutual mechanical interference among the three functions and without increasing the outer cross-sectional profile of the harmonic surgical instrument shaft beyond the dimensional constraints imposed by minimally invasive surgical access requirements.
[0003] Existing robotic harmonic surgical instruments have addressed the requirements of jaw actuation and ultrasonic vibration transmission through concentric shaft arrangements, wherein an innermost cutting shaft transmits ultrasonic vibrations and a surrounding motion-transferring tube provides axial translation for jaw actuation. However, such existing harmonic surgical instruments typically lack an internally integrated roll actuation mechanism, instead relying upon external robotic articulation joints positioned proximal to the harmonic surgical instrument or upon proximal wrist mechanisms external to the instrument shaft to achieve angular repositioning of distal end assembly of the harmonic surgical instrument about the longitudinal axis. The reliance on external robotic joints or proximal articulation mechanisms for roll motion introduces several significant drawbacks. The use of external joints increases the overall mechanical complexity of the robotic arm, adds additional degrees of freedom that must be independently controlled and calibrated, and reduces the positional accuracy of the distal end assembly by introducing additional sources of mechanical compliance and backlash in the kinematic chain between the robotic arm and the surgical site. Furthermore, external articulation for roll motion limits the compactness and dexterity of the robotic arm in confined surgical spaces, as the proximal articulation joints must themselves be manoeuvred within the operative field to achieve the desired roll orientation of the distal end assembly, thereby increasing the risk of instrument collisions and reducing the accessible workspace at the surgical site. The existing solutions to integrate roll actuation internally within harmonic surgical instruments are constrained by the severe spatial limitations imposed by the need to maintain the concentric arrangement of the cutting shaft and the motion-transferring tube within the instrument shaft, the requirement to mechanically isolate roll rotation from axial translation of the motion-transferring tube to prevent unintended jaw actuation during roll motion, and the necessity of confining the ultrasonic vibrations to the cutting shaft without transmission of vibrational energy to the roll actuation or jaw actuation components.
[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 for robotically actuating a harmonic surgical instrument. The present disclosure provides a solution to the technical problem of how to provide independent jaw actuation, ultrasonic vibrations and roll rotation within the same harmonic surgical instrument. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art by providing a robotic surgical system for robotically actuating a harmonic surgical instrument.
[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 comprising a patient-side cart comprising a plurality of robotic arms. Moreover, the robotic surgical system comprises a surgeon console configured to receive inputs from an operator to control the plurality of robotic arms. Furthermore, the robotic surgical system comprises a vision cart configured to process and display images from a surgical site. The at least one robotic arm from amongst the plurality of robotic arms comprises a robotically actuated harmonic surgical instrument mounted to a surgical instrument holder, the robotically actuated harmonic surgical instrument comprising a housing. Moreover, the robotically actuated harmonic surgical instrument comprises a distal end assembly comprising a first jaw member and a second jaw member movable relative to the first jaw member. Furthermore, the robotically actuated harmonic surgical instrument comprises a cutting shaft extending from the housing to the distal end assembly along a central longitudinal axis, wherein the cutting shaft is adapted to transmit ultrasonic vibrations to at least one of the first and second jaw members. Furthermore, the robotically actuated harmonic surgical instrument comprises a motion-transferring tube extending from the housing to the distal end assembly, such that the motion-transferring tube circumferentially surrounds the cutting shaft, wherein the motion-transferring tube is operatively coupled to one of the first and second jaw members and adapted to provide axial translation to the one of the first and second jaw members to actuate a relative movement therebetween. Furthermore, the robotically actuated harmonic surgical instrument comprises a roll actuation assembly arranged within the housing and coupled to a coupling shaft of the robotic surgical system, the roll actuation assembly adapted to receive a rotational input about a central longitudinal axis from the coupling shaft and transfer the rotational input to an outer shaft operatively coupled to the roll actuation assembly. Furthermore, the robotically actuated harmonic surgical instrument comprises the outer shaft circumferentially surrounding the motion-transferring tube and operatively coupled to the one of the first and second jaw members, wherein the outer shaft is adapted to produce roll rotation of the first and second jaw members about the central longitudinal axis, using the rotational input received from the roll actuation assembly, without causing the motion-transferring tube to provide the axial translation to the one of the first and second jaw members.
[0008] The robotic surgical system for robotically actuating a harmonic surgical instrument addresses the technical limitations of existing robotically actuated harmonic surgical instruments by provision of the roll actuation assembly arranged within the housing and coupled to the coupling shaft of the robotic surgical system to enable the roll rotation of the first and second jaw members to be generated entirely through an internally housed gear train, eliminating reliance on external robotic articulation joints or proximal wrist mechanisms for angular repositioning of the distal end assembly. The internal integration of roll actuating assembly reduces the overall mechanical complexity of the robotic arm, minimises additional sources of backlash and mechanical compliance in the kinematic chain between the robotic arm and the surgical site, and improves the positional accuracy of the distal end assembly during the roll actuation. The concentric arrangement of the cutting shaft, the motion-transferring tube, and the outer shaft along the central longitudinal axis enables the three independent actuation functions of the robotically actuated harmonic surgical instrument i.e., the ultrasonic vibration transmission, the jaw actuation, and the roll rotation to be delivered through a single compact instrument shaft without increasing the outer cross-sectional profile of the instrument shaft beyond the dimensional constraints of minimally invasive surgical access. The operative coupling of the outer shaft to the roll actuation assembly, such that the roll rotation of the first and second jaw members is produced without causing the motion-transferring tube to provide axial translation to the jaw members, ensures complete mechanical isolation of roll rotation from jaw actuation, preventing unintended opening or closing of the jaw members during roll repositioning of the distal end assembly. The confinement of the ultrasonic vibrations to the cutting shaft, independently of the motion-transferring tube and the outer shaft, ensures uninterrupted ultrasonic energy delivery to the jaw members during concurrent roll actuation and jaw actuation throughout operation.
[0009] In an implementation, the housing comprises a first base, a second base, and a third base. The housing comprising the first base, the second base, and the third base provides a modular internal structure that creates distinct compartments within the housing for organizing and supporting the components of the roll actuation assembly at defined axial positions.
[0010] In an implementation, the roll actuation assembly comprises:
a driving gear arranged between the second base and the third base, the driving gear being adapted to receive the rotational input from the coupling shaft and to rotate about the central longitudinal axis;
a stepped idler gear rotatably mounted between the second base and the third base, the stepped idler gear having a first gear portion meshing with the driving gear and a second gear portion having a diameter greater than the first gear portion; and
a driven gear arranged between the first base and the second base, such that the driven gear is meshed with the second gear portion of the stepped idler gear;
wherein the rotation of the driving gear is transmitted through the stepped idler gear and the driven gear to the outer shaft.
[0011] The stepped idler gear configuration, wherein the second gear portion has a diameter greater than the first gear portion, introduces a gear ratio between the driving gear and the driven gear that is achievable within a compact spatial envelope inside the housing.
[0012] In an implementation, the roll actuation assembly further comprises:
a first bearing arranged between the driven gear and the second base, wherein the first bearing is adapted to prevent an axial movement of the driven gear in a first direction; and
a second bearing arranged between the driven gear and an outer cover in the housing, wherein the second bearing is adapted to prevent the axial movement of the driven gear in a second direction.
[0013] The dual bearing arrangement, wherein the first bearing constrains the axial movement of the driven gear in the first axial direction and the second bearing constrains the axial movement of the driven gear in the second axial direction opposite the first, ensures that the driven gear and the outer shaft coupled to the driven gear are axially fixed relative to the housing in both axial directions during operation.
[0014] In an implementation, an outer diameter of the driving gear is smaller than an inner diameter of the first bearing. The outer diameter of the driving gear being configured to be smaller than the inner diameter of the first bearing ensures that the driving gear can pass through the bore of the first bearing during assembly of the roll actuation assembly within the housing.
[0015] In an implementation, the stepped idler gear is rotatably mounted between the second base and the third base by a first dowel pin. The stepped idler gear being mounted between the second base and the third base by the first dowel pin provides a precise and stable rotational axis for the stepped idler gear at a fixed location within the housing.
[0016] In an implementation, the driven gear is mechanically coupled to the outer shaft by a second dowel pin. The driven gear being mechanically coupled to the outer shaft by the second dowel pin provides a positive, non-slip torque transmission interface between the driven gear and the outer shaft.
[0017] In an implementation, an outer diameter of the outer shaft is in the range of 8.0 mm to 8.8 mm. The outer diameter of the outer shaft being within the range of 8.0 mm to 8.8 mm ensures that the robotically actuated harmonic surgical instrument maintains an overall instrument profile compatible with minimally invasive surgical access requirements, while providing sufficient wall thickness in the outer shaft to withstand the torsional loads generated during roll actuation.
[0018] In an implementation, the driving gear is mechanically coupled to the coupling shaft by a fastening element. The driving gear being mechanically coupled to the coupling shaft by the fastening element provides a fixed, rigid connection between the coupling shaft and the driving gear, ensuring that the full rotational input delivered by the coupling shaft is transmitted directly to the driving gear without rotational slippage at the interface.
[0019] In an implementation, the robotic surgical system further comprises an ultrasonic transducer mechanically coupled to the cutting shaft and adapted to generate the ultrasonic vibrations in the cutting shaft. The ultrasonic transducer being mechanically coupled to the cutting shaft provides the source of ultrasonic vibrational energy that is transmitted along the cutting shaft to at least one of the first jaw member and the second jaw member at the distal end assembly.
[0020] It is to be appreciated that all the aforementioned implementation forms can be combined.
[0021] 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.
[0022] 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
[0023] 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.
[0024] 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 schematic diagram illustrating a robotic surgical system, in accordance with an embodiment of the present disclosure;
FIGs. 2A and 2B are schematic diagrams illustrating a robotically actuated harmonic surgical instrument, in accordance with the embodiment of the present disclosure;
FIGs. 3A and 3B are schematic diagrams illustrating enlarged views of the distal end assembly, in accordance with the embodiment of the present disclosure; and
FIGs. 4A-E are schematic diagrams illustrating different views of the robotically actuated harmonic surgical instrument, in accordance with the embodiment of the present disclosure.
[0025] 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
[0026] 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.
[0027] FIG. 1 is a schematic diagram illustrating a robotic surgical system 100, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown the robotic surgical system 100 comprising a patient-side cart 110, a vision cart 120, and a surgeon console 130.
[0028] Throughout the present disclosure, the term "patient-side cart" refers to a mobile platform comprising a plurality of robotic arms (depicted as a first robotic arm 112, a second robotic arm 113 and a third robotic arm 114). The patient-side cart 110 are configured to support the plurality of robotic arms 112-114 positioned adjacent to a patient during surgical procedures. Each patient-side cart includes a base mounted on wheels and a vertical column extending upward from the base. The plurality of robotic arms 112-114 extends from the vertical column of the patient-side cart 110. The first robotic arm 112 is configured for surgical instrument manipulation and the second robotic arm 113 is configured for endoscopic imaging. The plurality of robotic arms 112-114 includes primary segments, secondary segments, and tertiary segments connected by rotational joints. The rotational joints contain servo motors enabling precise angular positioning. The plurality of robotic arms 112-114 include surgical instrument holders 115 at distal ends. The surgical instrument holders 115 comprise mechanical interfaces and electrical connectors. The mechanical interfaces include spring-loaded clamps for instrument attachment. In an implementation, the surgical instrument holders 115 includes an actuator configured to attach the surgical instrument 140 to the surgical instrument holder 115 through the help of a sterile adapter. 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 115 at the first robotic arm 112. The surgical instrument 140 includes elongated shafts with end effectors at distal tips. The second robotic arm 113 supports an endoscopic imaging system. Each of the robotic arms 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 second 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.
[0029] 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. 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.
[0030] 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 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. 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 grips provide haptic feedback.
[0031] 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.
[0032] The patient-side cart 110, the vision cart 120, and the surgeon console 130 connect through a communication network. 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.
[0033] The communication network includes redundant data pathways. The communication network transmits control signals from the master control manipulators 132 to the plurality of robotic arms 112-114. 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.
[0034] 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.
[0035] 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 are not limited to, general surgery procedures, gynaecological procedures, urological procedures, cardiothoracic procedures, and otolaryngological procedures.
[0036] FIGs. 2A and 2B are schematic diagrams illustrating a robotically actuated harmonic surgical instrument, in accordance with the embodiment of the present disclosure. FIGs. 2A and 2B are described in conjunction with elements of the FIG. 1. With reference to FIGs. 2A and 2B, there is shown a robotically actuated harmonic surgical instrument 200. The robotically actuated harmonic surgical instrument 200 comprises a housing 202 and a distal end assembly 204.
[0037] Throughout the present disclosure, the term "robotically actuated harmonic surgical instrument" refers to a surgical instrument mounted to a surgical instrument holder carried by at least one robotic arm (for instance the first robotic arm 112) from amongst the plurality of robotic arms 112-114. The robotically actuated harmonic surgical instrument integrates ultrasonic cutting capability with robotic actuation of jaw movement and the roll rotation within a single, concentrically arranged instrument body. Throughout the present disclosure, the term "housing" refers to a structural enclosure forming the proximal body of the robotically actuated harmonic surgical instrument 200. The housing 202 contains and supports the internal actuation components, including a roll actuation assembly, and serves as the fixed reference frame relative to which internal components operate. The housing 202 provides structural integrity to the robotically actuated harmonic surgical instrument 200 and offers fixed mounting points for other components. Throughout the present disclosure, the term "distal end assembly" refers to the working end of the robotically actuated harmonic surgical instrument 200, situated at the distal side of the robotically actuated harmonic surgical instrument 200 opposite the housing 202. The distal end assembly 204 is responsible to perform tissue grasping, cutting, and coagulation at the surgical site.
[0038] FIGs. 3A and 3B are schematic diagrams illustrating enlarged views of the distal end assembly, in accordance with the embodiment of the present disclosure. FIGs. 3A and 3B are described in conjunction with elements of the FIG. 1 to FIG. 2B. With reference to FIGs. 3A and 3B, there is shown the distal end assembly 204 comprising a first jaw member 300 and a second jaw member 302 movable relative to the first jaw member 300. Moreover, a motion-transferring tube 304 is operatively coupled to one of the first and second jaw members 300 and 302. Furthermore, an outer shaft is operatively coupled to one of the first and second jaw members 300 and 302.
[0039] Throughout the present disclosure, the term "first jaw member" refers to a structural component of the distal end assembly 204 that forms one of a pair of opposing jaw elements for engaging tissue. The first jaw member 300, in conjunction with the second jaw member 302, enables clamping of tissue between the first and second jaw members 300 and 302 to facilitate cutting and coagulation through ultrasonic energy transmitted through a cutting shaft. Throughout the present disclosure, the term "second jaw member" refers to a structural component of the distal end assembly 204 that forms the jaw element opposing the first jaw member. The second jaw member 302 cooperates with the first jaw member 300 to clamp and release tissue during a surgical procedure. The second jaw member 302 being movable relative to the first jaw member 300 implies to the second jaw member 302 being capable of pivoting or translating with respect to the first jaw member 300 to open and close the distal end assembly 204. The movability of the second jaw member 302 being relative to the first jaw member 300 enables the distal end assembly 204 to grasp, clamp, and release tissue in a controlled manner.
[0040] In some embodiments, the distal end assembly 204 further comprises surgical blades, clamps, graspers, scissors, cutting elements, sealing devices, or other end effectors commonly used in minimally invasive surgical procedures.
[0041] FIGs. 4A-E are schematic diagrams illustrating different views of the robotically actuated harmonic surgical instrument, in accordance with the embodiment of the present disclosure. FIGs. 4A-E are described in conjunction with elements of the FIG. 1 to FIG. 3B. With reference to FIGs. 4A-E, there is shown the robotically actuated harmonic surgical instrument 200 comprises a cutting shaft 400 extending from the housing 202 to the distal end assembly 204 along a central longitudinal axis, wherein the cutting shaft 400 is adapted to transmit ultrasonic vibrations to at least one of the first and second jaw members 300 and 302. Moreover, the robotically actuated harmonic surgical instrument 200 comprises the motion-transferring tube 304 extending from the housing 202 to the distal end assembly 204, such that the motion-transferring tube 304 circumferentially surrounds the cutting shaft 400, wherein the motion-transferring tube 304 is operatively coupled to one of the first and second jaw members 300 and 302 and adapted to provide axial translation to the one of the first and second jaw members 300 and 302 to actuate a relative movement therebetween. Furthermore, the robotically actuated harmonic surgical instrument 200 comprises a roll actuation assembly 402 arranged within the housing 202 and coupled to a coupling shaft 404 of the robotic surgical system 100, the roll actuation assembly 402 adapted to receive a rotational input about the central longitudinal axis from the coupling shaft 404 and transfer the rotational input to the outer shaft 306 operatively coupled to the roll actuation assembly 402. Furthermore, the robotically actuated harmonic surgical instrument 200 comprises the outer shaft 306 circumferentially surrounding the motion-transferring tube 304 and operatively coupled to the one of the first and second jaw members 300 and 302, wherein the outer shaft 306 is adapted to produce roll rotation of the first and second jaw members 300 and 302 about the central longitudinal axis, using the rotational input received from the roll actuation assembly 402, without causing the motion-transferring tube 304 to provide the axial translation to the one of the first and second jaw members 300 and 302.
[0042] Throughout the present disclosure, the term "central longitudinal axis" refers to an imaginary axis extending along the length of the robotically actuated harmonic surgical instrument 200 from the housing 202 to the distal end assembly 204. The central longitudinal axis defines the primary reference axis for all concentric tubular and shaft components of the robotically actuated harmonic surgical instrument 200 and also defines the axis about which roll rotation of the distal end assembly 204 is performed. Throughout the present disclosure, the term "cutting shaft" refers to an elongated shaft that serves as the primary structural and vibrational medium for transmitting ultrasonic vibrations generated proximally by an ultrasonic transducer to at least one of the first and second jaw members 300 and 302 at the distal end assembly 204. The cutting shaft 400 is mechanically coupled at a proximal end in the housing 202 to the ultrasonic transducer and extends distally along the central longitudinal axis to the distal end assembly 204, where the cutting shaft 400 terminates in a blade or cutting element positioned at or between the first and second jaw members 300 and 302. Throughout the present disclosure, the term "ultrasonic vibrations" refers to high-frequency mechanical oscillations generated by the ultrasonic transducer and transmitted along the cutting shaft 400 to the at least one of the first and second jaw members 300 and 302 at the distal end assembly 204. The transmission of the ultrasonic vibrations to at least one of the first and second jaw members 300 and 302 enables precise tissue cutting and hemostatic coagulation through ultrasonic mechanical action, minimizing thermal spread to surrounding tissue and reducing the applied cutting force required.
[0043] In an implementation, the robotic surgical system further comprises an ultrasonic transducer mechanically coupled to the cutting shaft 400 and adapted to generate the ultrasonic vibrations in the cutting shaft 400. In this regard, the term "ultrasonic transducer" refers to an electromechanical device mechanically coupled to the cutting shaft 400 at the proximal end of the cutting shaft 400, configured to convert electrical energy into high-frequency mechanical oscillations and to generate the ultrasonic vibrations in the cutting shaft 400 upon application of electrical energy. The ultrasonic transducer is mechanically coupled to the cutting shaft 400 at the proximal end of the cutting shaft 400 via a connector pin that functions as a rigid intermediary component between the ultrasonic transducer and the cutting shaft 400. The ultrasonic transducer being adapted to generate the ultrasonic vibrations in the cutting shaft enables the robotically actuated harmonic surgical instrument 200 to perform tissue cutting and coagulation at the surgical site through ultrasonic mechanical action. The ultrasonic transducer is electrically connected to a power source of the robotic surgical system 100 via a cautery cable, through which electrical energy at the operating frequency of the ultrasonic transducer is delivered to the ultrasonic transducer. Upon receipt of the electrical energy, the ultrasonic transducer converts the electrical energy into high-frequency mechanical oscillations through the piezoelectric or magneto strictive effect, generating ultrasonic vibrations at the operating frequency of the ultrasonic transducer. The ultrasonic vibrations are transmitted from the ultrasonic transducer to the cutting shaft 400 through the connector pin, causing the cutting shaft 400 to oscillate longitudinally at the operating frequency of the ultrasonic transducer. A technical effect of the aforementioned implementation is that a complete and self-contained ultrasonic energy delivery pathway within the robotically actuated harmonic surgical instrument 200 is established.
[0044] Throughout the present disclosure, the term "motion-transferring tube" refers to a tubular component that extends from the housing 202 to the distal end assembly 204. The motion-transferring tube 304 converts the axial linear displacement generated within the housing 202 into jaw actuation at the distal end assembly 204. The motion-transferring tube 304 extends from the housing 202 to the distal end assembly 204, spanning the full length of the robotically actuated harmonic surgical instrument 200 from the housing 202 to the distal end assembly 204. The extension of the motion-transferring tube 304 from the housing 202 to the distal end assembly 204 provides the mechanical linkage necessary to transmit axial translation from the proximal actuation mechanism to the first and second jaw members 300 and 302 at the distal end assembly 204. The motion-transferring tube 304 is disposed along the central longitudinal axis, extending from within the housing 202 through the instrument body to the distal end assembly 204. The cutting shaft 400 being circumferentially surrounded by the motion-transferring tube 304 implies to the coaxial arrangement in which the motion-transferring tube 304 is positioned radially outward of and encircles the cutting shaft 400 along the common length of both components. The circumferential surrounding of the cutting shaft 400 by the motion-transferring tube 304 enables independent operation of the two components within a compact concentric configuration, with the cutting shaft 400 transmitting ultrasonic vibrations and the motion-transferring tube 304 providing axial translation, without mutual mechanical interference. The motion-transferring tube 304 is dimensioned with an inner diameter greater than the outer diameter of the cutting shaft 400, such that the cutting shaft 400 is received within the bore of the motion-transferring tube 304 along the central longitudinal axis, permitting the circumferential surrounding of the cutting shaft by the motion-transferring tube 304.
[0045] The motion-transferring tube 304 being operatively coupled to the one of the first and second jaw members 300 and 302 implies to the mechanical linkage between the distal end of the motion-transferring tube 304 and the one of the first and second jaw members 300 and 302 at the distal end assembly 204. The operative coupling ensures that axial translation of the motion-transferring tube 304 is effectively converted into a controlled opening or closing motion of the second jaw 302 member relative to the first jaw member 300. Throughout the present disclosure, the term "axial translation" refers to the linear displacement of the motion-transferring tube 304 along the central longitudinal axis, generated by the actuation mechanism within the housing and transmitted distally to the one of the first or second jaw members 300 and 302. The axial translation of the motion-transferring tube 304 provides the mechanical input required to actuate relative movement between the first and second jaw members 300 and 302, enabling tissue grasping and release at the surgical site. The axial translation of the motion-transferring tube 304 is generated by a cam and follower mechanism within the housing 202, wherein rotation of a coupling shaft causes a cylindrical cam to rotate, driving a follower in linear motion along the central longitudinal axis, and the linear motion of the follower is transmitted as the axial translation to the motion-transferring tube 304, which in turn actuates one of the first or second jaw members 300 and 302. The axial translation being provided to the one of the first and second jaw members 300 and 302 enables to cause the relative movement between the first and second jaw members 300 and 302. The axial translation of the motion-transferring tube 304, transmitted to the one of the first and second jaw members 300 and 302 causes the second jaw member 302 to pivot about the hinge axis at the distal end assembly 204, producing controlled opening and closing of the distal end assembly 204 in form of the relative movement between the first and second jaw members 300 and 302.
[0046] In an implementation, the axial translation is provided by the motion-transferring tube by employing a cam and follower mechanism via a cam and a follower coupled to the coupling shaft 404 of the robotic surgical system 200. The coupling shaft 404 is configured to rotate the cam arranged within the housing 202 about the central longitudinal axis. The cam comprises a contoured groove configured to engage the follower positioned adjacent to the cam. The follower is guided within the housing 202 such that the follower is constrained to move along the central longitudinal axis while being prevented from rotating relative to the housing 202. Upon rotation of the cam by the coupling shaft 404, the engagement between the groove of the cam and the follower causes the follower to translate linearly along the central longitudinal axis. The linear movement of the follower is transmitted to the motion-transferring tube 304 operatively coupled to the follower, thereby producing axial translation of the motion-transferring tube 304. The axial translation of the motion-transferring tube 304 is transmitted to the one of the first and second jaw members 300 and 302 in form of rotational motion at the distal end assembly 204 to actuate the relative movement between the first and second jaw members 300 and 302.
[0047] In other implementations, the axial translation is provided by rotary-to-linear conversion mechanisms such as lead screws, ball screws, rack-and-pinion mechanisms, or linkage-based actuation mechanisms.
[0048] Throughout the present disclosure, the term "roll actuation assembly" is a gear-based mechanical assembly arranged within the housing 202 that receives the rotational input from the coupling shaft 404 and transmits the rotational input to the outer shaft 306, producing the roll rotation of the first and second jaw members 300 and 302 about the central longitudinal axis. The roll actuation assembly 402 enables internal roll motion of the distal end assembly 204 about the central longitudinal axis without reliance on external robotic articulation joints, improving distal dexterity and reducing overall instrument complexity while maintaining the outer form factor of the robotically actuated harmonic surgical instrument 200. The arrangement of the roll actuation assembly 402 within the housing 202 provides a compact, protected, and concentrically aligned configuration of actuation components, enabling internal roll motion without increasing the outer diameter of the robotically actuated harmonic surgical instrument 200.
[0049] Throughout the present disclosure, the term "coupling shaft" refers to a drive shaft of the robotic surgical system 100 that provides the rotational input to the roll actuation assembly 402 arranged within the housing 202. The coupling of the roll actuation assembly 402 to the coupling shaft 404 enables the roll actuation assembly 402 to receive and use the rotational input from the coupling shaft 404 to produce the roll rotation. The roll actuation assembly 402 is mechanically coupled to the coupling shaft 404, such that rotation of the coupling shaft 404 is directly imparted to the roll actuation assembly 402, initiating torque transmission through the roll actuation assembly 402 to the outer shaft 306. Throughout the present disclosure, the term "rotational input" is the torque or rotary motion delivered by the coupling shaft 404 to the roll actuation assembly 402 about the central longitudinal axis. The rotational input is the primary mechanical actuation signal that drives the gear train of the roll actuation assembly 402 to produce roll rotation of the outer shaft 306. The transfer of the rotational input to the outer shaft 306 refers to the transmission of torque from a driven gear of the roll actuation assembly 402 to the outer shaft 36, where the outer shaft 306 is operatively coupled to the roll actuation assembly 402. The transfer of the rotational input to the outer shaft 306 enables the outer shaft 306 to rotate about the central longitudinal axis and produce roll rotation of the first and second jaw members 300 and 302 at the distal end assembly 204 in response to the rotational input received from the coupling shaft 404.
[0050] Throughout the present disclosure, the term "outer shaft" refers to an elongate tubular member arranged coaxially outward of the motion-transferring tube 304 and operatively coupled to the roll actuation assembly 402 at a proximal end and to one of the first and second jaw members 300 and 302 of the distal end assembly 204 at a distal end. The outer shaft 306 transmits roll rotation from the roll actuation assembly 402 to the first and second jaw members 300 and 302 at the distal end assembly 204, enabling internal roll motion about the central longitudinal axis in the first and second jaw members 300 and 302 without affecting jaw actuation or ultrasonic vibration transmission. The motion-transferring tube 304 being circumferentially surrounded by the outer shaft 306 implies to the coaxial arrangement in which the outer shaft 306 is positioned radially outward of and encircles the motion-transferring tube 304 along the common length of both components. The circumferential surrounding of the motion-transferring tube 304 by the outer shaft 306 enables both components to operate independently within a compact concentric configuration, with the outer shaft 306 transmitting the roll rotation and the motion-transferring tube 304 providing axial translation, without mutual mechanical interference. The outer shaft 306 is dimensioned with an inner diameter greater than the outer diameter of the motion-transferring tube 304, such that the motion-transferring tube 304 is received within the bore of the outer shaft 306 along the central longitudinal axis, permitting the circumferential surrounding of the motion-transferring tube 304 by the outer shaft 306.
[0051] In an implementation, an outer diameter of the outer shaft 306 is in the range of 8.0 mm to 8.8 mm. In this regard, the term "outer diameter of the outer shaft" refers to the diametric dimension measured across the outermost surface of the outer shaft 306, defining the maximum radial extent of the outer shaft 306 about the central longitudinal axis along the length of the outer shaft 306 extending from the housing 202 to the distal end assembly 204. The outer diameter of the outer shaft being in the range of 8.0 mm to 8.8 mm enables to the outer diameter of the outer shaft 306 to be sufficiently large to provide adequate bore dimensions to accommodate the motion-transferring tube 304 and the cutting shaft 400 concentrically within the outer shaft 306 and provide sufficient wall thickness to withstand the torsional loads generated by roll actuation transmitted through the outer shaft 306 from the driven gear 416 to the distal end assembly 204, without structural deformation of the outer shaft 306 that compromises roll rotation accuracy. A technical effect of the aforementioned implementation is that the concentric assembly of the outer shaft 306, the motion-transferring tube 304, and the cutting shaft 400 is enabled to be achieved within a compact shaft cross-section that simultaneously satisfies the dimensional requirements for internal accommodation of the motion-transferring tube 304 and the cutting shaft 400, and structural integrity of the outer shaft 306 under roll actuation torsional loads
[0052] Throughout the present disclosure, the term "roll rotation" refers to the rotary motion of the first and second jaw members 300 and 302 about the central longitudinal axis, produced by transmission of the rotational input from the roll actuation assembly 402 through the outer shaft 306 to the distal end assembly 204. The roll rotation of the first and second jaw members 300 and 302 enables the distal end assembly 204 to be angularly repositioned about the central longitudinal axis during a surgical procedure, improving the dexterity and reach of the robotically actuated harmonic surgical instrument 200 at the surgical site without requiring external articulation joints. The roll rotation of the first and second jaw members 300 and 302 being produced about the central longitudinal axis, using the rotational input received from the roll actuation assembly 402 implies to the process by which torque from the coupling shaft 404 is transmitted through the gear train of the roll actuation assembly 402 to the outer shaft 306 and the distal end assembly 204, rotating the first and second jaw members 300 and 302 together about the central longitudinal axis. The rotational input from the coupling shaft 404 is transmitted through the roll actuation assembly 402 to the outer shaft 306, which is mechanically connected to the distal end assembly 204, causing both the first and second jaw members 300 and 302 to rotate about the central longitudinal axis. The roll rotation of the first and second jaw members 300 and 302 being produced, without causing the motion-transferring tube 304 to provide the axial translation to the one of the first and second jaw members 300 and 302 implies to the mechanical independence of the roll rotation from the jaw actuation mechanism, such that rotation of the outer shaft 306 about the central longitudinal axis does not impart axial displacement to the motion-transferring tube 304. The roll rotation of the first and second jaw members 300 and 302 is produced, without causing the motion-transferring tube 304 to provide the axial translation to the one of the first and second jaw members 300 and 302 as the outer shaft 306 is arranged coaxially around and independently of the motion-transferring tube 304, such that rotation of the outer shaft 306 about the central longitudinal axis does not impose axial forces on the motion-transferring tube 204.
[0053] In an implementation, the housing 202 comprises a first base 406, a second base 408, and a third base 410. In this regard, the term "first base" refers to the lowermost structural member among the three bases of the housing 202, positioned at a first axial location within the housing 202 and forming one of the two axial boundaries within the housing 202. The housing 202 comprising the first base 406 provides one of the structural references within the housing 202 for maintaining correct spatial alignment of components within the housing 202 relative to the central longitudinal axis during operation. Throughout the present disclosure, the term "second base" refers to the intermediate structural member in the housing 202, positioned between the first base 406 and the third base 410 along the central longitudinal axis, and forming a shared structural boundary between two axially adjacent compartments within the housing 202. The housing 202 comprising the second base 408 enables the second base 408 to serve as the common dividing structure in the housing 202, ensuring that each component of the roll actuation assembly 402 is maintained within its designated spatial zone. Throughout the present disclosure, the term "third base" refers to the uppermost structural member in the housing 202, positioned at the second axial extremity of the housing 202 beyond the second base 408, and forming one of the two axial boundaries within the housing 202 opposite to the first base 406. The housing 202 comprising the third base 410 provides the structural boundary and mounting reference required to retain the components within the housing 202. A technical effect of the aforementioned implementation is that a compact, precisely segmented, and rigid internal framework is enabled that spatially organises the components of the roll actuation assembly 402 into distinct axial compartments.
[0054] In an implementation, wherein the roll actuation assembly 402 comprises:
a driving gear 412 arranged between the second base 408 and the third base 410, the driving gear 412 being adapted to receive the rotational input from the coupling shaft 404 and to rotate about the central longitudinal axis;
a stepped idler gear 414 rotatably mounted between the second base 408 and the third base 410, the stepped idler gear 414 having a first gear portion meshing with the driving gear 412 and a second gear portion having a diameter greater than the first gear portion; and
a driven gear 416 arranged between the first base 406 and the second base 408, such that the driven gear 416 is meshed with the second gear portion of the stepped idler gear 414;
wherein the rotation of the driving gear 412 is transmitted through the stepped idler gear 414 and the driven gear 416 to the outer shaft 404.
[0055] In this regard, the term "driving gear" refers to the input gear of the gear train of the roll actuation assembly 402, mechanically coupled to the coupling shaft 404 and arranged within the housing 202 between the second base 408 and the third base 410. The driving gear 412 serves as the first stage of the gear train of the roll actuation assembly 402, for receiving the rotational input from the coupling shaft 404. The arrangement of the driving gear 412 between the second base 408 and the third base 410 within the housing 202 ensures that the driving gear 412 is axially constrained and spatially aligned with the stepped idler gear 414 within the same compartment, enabling accurate and stable gear meshing between the driving gear 412 and the first gear portion of the stepped idler gear 414 during roll actuation. The rotational input being received by the driving gear 412 from the coupling shaft 404 enables the driving gear 412 to serve as the mechanical entry point of the roll actuation assembly 402, converting the externally delivered rotational input from the robotic surgical system 100 into the rotation of the driving gear 412. The rotation of the driving gear 412 about the central longitudinal axis ensures that the axis of rotation of the driving gear 412 is coaxially aligned with the central longitudinal axis of the robotically actuated harmonic surgical instrument 200, enabling the gear train of the roll actuation assembly 402 to transmit torque in a configuration that ultimately produces roll rotation of the outer shaft 306 about the same central longitudinal axis.
[0056] In this regard, the term "stepped idler gear" refers to an intermediate gear of the gear train of the roll actuation assembly 402, rotatably mounted between the second base 408 and the third base 410 and configured with two gear portions of different diameters to transmit and modify the rotation between the driving gear 412 and the driven gear 416. The stepped idler gear 414 serves as the intermediate torque transmission element within the roll actuation assembly 402, enabling a stepped gear ratio between the driving gear 412 and the driven gear 416 within a compact spatial envelope. The stepped configuration of the stepped idler gear 414 enables the gear train to transmit torque from the driving gear 412 to the driven gear 416 with a controlled speed and torque relationship, accommodating the spatial constraints of the housing 202 without increasing the outer diameter of the robotically actuated harmonic surgical instrument 200.
[0057] In this regard, the term "first gear portion" refers to the smaller-diameter gear section of the stepped idler gear 414, positioned on the stepped idler gear 414 to mesh with the driving gear 412 and receive the rotational input from the driving gear 412. The first gear portion being meshed with the driving gear establishes the mechanical linkage between the driving gear 412 and the stepped idler gear 414, enabling the rotational input received by the driving gear 412 from the coupling shaft 404 to be transmitted to the stepped idler gear 414 as the first gear mesh of the roll actuation assembly gear train. The first gear portion of the stepped idler gear 414 is positioned adjacent to the driving gear 412 within the compartment defined by the second base 408 and the third base 410 such that the teeth of the first gear portion and the teeth of the driving gear 412 are in continuous engagement. The term "second gear portion" refers to the larger-diameter gear section of the stepped idler gear 414, formed integrally with the first gear portion and positioned on the stepped idler gear to mesh with the driven gear 416 and transmit the rotational input from the stepped idler gear 414 to the driven gear 416. The greater diameter of the second gear portion relative to the first gear portion implies to the stepped configuration of the stepped idler gear 414 in which the second gear portion has a larger pitch circle diameter than the first gear portion, the two gear portions being formed as a single integral stepped gear body. The greater diameter of the second gear portion relative to the first gear portion establishes a stepped gear ratio between the driving gear 412 and the driven gear 416, enabling torque amplification or speed reduction across the gear train of the roll actuation assembly 402 within the compact spatial envelope of the housing 202, without the need for additional intermediate gear stages.
[0058] In this regard, the term "driven gear" refers to the output gear of the gear train of the roll actuation assembly 402, arranged between the first base 406 and the second base 408, meshed with the second gear portion of the stepped idler gear 414, and mechanically coupled to the outer shaft 306 to transmit the roll rotation to the distal end assembly 204. The driven gear 416 being arranged between the first base 406 and the second base 408 ensures that the driven gear 416 is axially retained and spatially separated from the driving gear 412 and the stepped idler gear 414, maintaining structural rigidity and precise alignment of the driven gear 416 relative to the outer shaft 306 during roll actuation. The driven gear 416 being meshed with the second gear portion enables the rotational input transmitted through the stepped idler gear 414 to be delivered to the driven gear 416 as the final gear mesh stage of the roll actuation assembly 402, completing the torque transmission path from the coupling shaft 404 to the outer shaft 302. The driven gear 416 is positioned within the compartment defined by the first base 406 and the second base 408 such that the teeth of the driven gear 416 engage with the teeth of the second gear portion of the stepped idler gear 414 across the shared boundary at the second base 408. The transmission of the rotation of the driving gear 412 through the stepped idler gear 414 and the driven gear 416 to the outer shaft 306 implies to the sequential propagation of torque along the gear train of the roll actuation assembly 402 from the driving gear 412, through the stepped idler gear 414, then through the driven gear 416, and finally to the outer shaft 306, producing the roll rotation of the outer shaft 306 and the distal end assembly 204 about the central longitudinal axis. The driving gear 412 receives the rotational input from the coupling shaft 404 and meshes with the first gear portion of the stepped idler gear 414, causing the stepped idler gear to rotate about the central longitudinal axis. The second gear portion of the stepped idler gear 414 simultaneously meshes with the driven gear 416, transmitting the rotational input to the driven gear 416. The driven gear 416 is mechanically coupled to the outer shaft 306, such that rotation of the driven gear 416 is directly imparted to the outer shaft 306, causing the outer shaft 306 to rotate about the central longitudinal axis and produce the roll rotation of the first and second jaw members 300 and 302 at the distal end assembly 204. A technical effect of the aforementioned implementation is that compact, multi-stage torque transmission from the coupling shaft 404 to the outer shaft 306 within the confined spatial envelope of the housing 202, without increasing the outer diameter of the robotically actuated harmonic surgical instrument 200.
[0059] In this regard, the driving gear 412 is mechanically coupled to the coupling shaft 404 by a fastening element. In this regard, the term "fastening element" refers to a discrete mechanical connecting component, such as a fixing screw, engaged within aligned engagement features of the coupling shaft 404 and the driving gear 412, mechanically coupling the coupling shaft 404 to the driving gear 412 such that the coupling shaft 404 and the driving gear 412 are constrained to rotate together as a unified assembly about the central longitudinal axis. The fastening element is provided to establish a positive, secure, and non-slip torque transmission connection between the coupling shaft 404 and the driving gear 412. The fastening element is engaged within aligned features of the coupling shaft 404 and the driving gear 412, with the fastening element bearing against both the coupling shaft 404 and the driving gear 412 to create a positive mechanical interlock between the coupling shaft 404 and the driving gear 412. The driving gear 412 being mechanically coupled to the coupling shaft 404 by the fastening element ensures a compact, axially constrained, and play-free interface between the coupling shaft 404 and the driving gear 412 that is suited to the confined spatial envelope of the compartment defined by the second base 408 and the third base 410 within the housing 202, and maintains coupling integrity under the cyclic torque loads and vibration conditions generated during concurrent roll actuation, jaw actuation, and ultrasonic vibration transmission. A technical effect of the aforementioned implementation is that a compact, positive, axially constrained, and play-free torque input interface is established at the entry point of the roll actuation assembly 402, ensuring that the full rotational input delivered by the coupling shaft 404 of the robotic surgical system is directly and reliably transmitted to the driving gear 412 without rotational slippage.
[0060] In an implementation, the stepped idler gear 414 is rotatably mounted between the second base 408 and the third base 410 by a first dowel pin. In this regard, the term "first dowel pin" refers to a cylindrical precision fastening element received within aligned bores in the second base 408 and the third base 410, about which the stepped idler gear 414 is rotatably mounted within the compartment defined by the second base 408 and the third base 410. The first dowel pin is provided to define a fixed, precisely located rotational axis for the stepped idler gear 414 within the housing 202, ensuring that the stepped idler gear 414 is maintained in correct spatial alignment relative to the driving gear 412 and the driven gear 416 throughout roll actuation. The stepped idler gear being rotatably mounted between the second base and the third base by the first dowel pin enables to maintain the stepped idler gear 414 in a fixed, precisely located radial and axial position relative to the driving gear 412 and the driven gear 416 within the housing 202. The precise positioning of the stepped idler gear 414 by the first dowel pin ensures continuous and stable tooth engagement between the first gear portion of the stepped idler gear 414 and the driving gear 412, and between the second gear portion of the stepped idler gear 414 and the driven gear 416, throughout the roll actuation. A technical effect of the aforementioned implementation is that a compact, structurally stable, and precisely located intermediate gear support is provided within the housing 202 that maintains consistent gear meshing between the first gear portion of the stepped idler gear 414 and the driving gear 412, and between the second gear portion of the stepped idler gear 414 and the driven gear 416.
[0061] In an implementation, the roll actuation assembly 402 comprises a plurality of stepped idler gears arranged in a series or as a part of a multi-stage gear train in the roll actuation assembly 402. The use of the plurality of stepped idler gears may enable improved transmission precision, smoother roll motion, or enhanced distribution of mechanical loads within the housing 202 of the harmonic surgical instrument 200. For example, two or more stepped idler gears may be arranged sequentially between the driving gear 412 and the driven gear 416 to provide a more effective transmission ratio while maintaining compact packaging within the housing 202. Moreover, the use of the plurality of stepped idler gears facilitates improved mechanical alignment and reduced localized stress within individual gear components in the roll actuation assembly 402. Furthermore, by distributing torque transmission across the plurality of stepped idler gears, the roll actuation assembly 402 achieve improved durability, reduced wear, and enhanced operational stability during prolonged surgical procedures. The number, size, and arrangement of the stepped idler gears in the roll actuation assembly 402 may therefore be selected according to design requirements such as torque capacity, motion smoothness, and available internal space.
[0062] In some implementations, the roll actuation assembly 402 comprises one or more of: compound gears, bevel gears, and the like, instead of the stepped idler gear 414 to provide rotational actuation within the constrained spatial envelope of the housing 202. The selection of gear geometry and gear ratio in the roll actuation assembly 402 may be determined based on factors including available packaging volume, desired rotational speed of the distal end assembly 204, and the mechanical load associated with the roll actuation.
[0063] In an implementation, the driven gear 416 is mechanically coupled to the outer shaft 306 by a second dowel pin. In this regard, the term "second dowel pin" refers to a cylindrical precision fastening element received within aligned transverse bores in the driven gear 416 and the outer shaft 306, mechanically coupling the driven gear 416 to the outer shaft 306 such that rotational motion of the driven gear 416 about the central longitudinal axis is directly and rigidly transmitted to the outer shaft 306. The driven gear 416 being mechanically coupled to the outer shaft 306 by the second dowel pin implies to the positive torque transmission connection established between the driven gear 416 and the outer shaft 306 through the engagement of the second dowel pin within aligned transverse bores in the driven gear 416 and the outer shaft 306, such that the driven gear 416 and the outer shaft 306 are constrained to rotate together as a unified assembly about the central longitudinal axis. The mechanical coupling of the driven gear 416 to the outer shaft 306 by the second dowel pin is required to ensure that the rotational output of the gear train of the roll actuation assembly 402 is transmitted from the driven gear 416 to the outer shaft 306. A technical effect of the aforementioned implementation is that a compact, positive, and play-free torque transmission interface is established between the driven gear 416 of the roll actuation assembly 402 and the outer shaft 306.
[0064] In an implementation, the roll actuation assembly 402 further comprises:
a first bearing 418 arranged between the driven gear 416 and the second base 408, wherein the first bearing 418 is adapted to prevent an axial movement of the driven gear 416 in a first direction; and
a second bearing 420 arranged between the driven gear 416 and an outer cover in the housing 202, wherein the second bearing 420 is adapted to prevent the axial movement of the driven gear 416 in a second direction.
[0065] In this regard, the term "first bearing" refers to a rotary support element arranged between the driven gear 416 and the second base 408 within the housing 202, configured to permit rotational motion of the driven gear 416 about the central longitudinal axis while constraining the axial movement of the driven gear 416 in the first direction. The first bearing 418 is disposed between the driven gear 416 and the second base 408, with the first bearing 418 seated against the second base 408 on one side and against the driven gear 416 on the other side. The first bearing 418 rotatably supports the driven gear 416, allowing the driven gear 416 to rotate about the central longitudinal axis in response to the rotational input transmitted from the stepped idler gear 414, while the bearing reaction force at the interface between the first bearing 418 and the second base 408 prevents the driven gear 416 from displacing in the first direction along the central longitudinal axis. For example, the first bearing 418 is one of: a ball bearing, a roller bearing, a needle bearing, or a hybrid bearing comprising combinations of metallic and ceramic elements. Notably, the selection of the bearing type as the first bearing 418 is based on factors such as rotational speed, load capacity, friction characteristics, and durability under repeated sterilization cycles. In some embodiments, a low-friction precision bearing may be employed as the first bearing 418 to minimize mechanical resistance and improve roll actuation responsiveness. In other embodiments, a high-load bearing may be employed as the first bearing 418 to support increased torsional loads generated during instrument manipulation. The term "axial movement" refers to the linear displacement of the driven gear 416 along the central longitudinal axis of the robotically actuated harmonic surgical instrument 200, in either the first direction or the second direction. The axial movement of the driven gear 416, if unconstrained, would cause unintended displacement of the outer shaft 306 and the distal end assembly 204 along the central longitudinal axis, potentially interfering with jaw actuation and ultrasonic vibration transmission and compromising the structural integrity of the roll actuation assembly 402. The term "first direction" refers to one of the two opposing axial directions along the central longitudinal axis in which the driven gear is susceptible to the axial movement, corresponding to the axial direction toward the second base 408 from the driven gear 416. For example, the first direction is negative z-direction. The prevention of the axial movement of the driven gear 416 in the first direction by the first bearing 418 ensures that the driven gear 416, the outer shaft 306, and the distal end assembly 204 are maintained in correct axial alignment within the robotically actuated harmonic surgical instrument 200, preventing unintended axial displacement of said components from interfering with the jaw actuation, the roll rotation, or the ultrasonic vibration transmission during operation.
[0066] In this regard, the term "second bearing" refers to a rotary support element arranged between the driven gear 416 and the outer cover in the housing 202, configured to permit rotational motion of the driven gear 416 about the central longitudinal axis while constraining the axial movement of the driven gear 416 in the second direction. The second bearing 420 is disposed between the driven gear 416 and the outer cover within the housing 202, with the second bearing 420 seated against the outer cover on one side and against the driven gear 416 on the other side. The second bearing 420 rotatably supports the driven gear 416, allowing the driven gear 416 to rotate about the central longitudinal axis, while the bearing reaction force at the interface between the second bearing 420 and the outer cover prevents the driven gear 416 from displacing in the second direction along the central longitudinal axis. For example, the second bearing 420 is one of: a ball bearing, a roller bearing, a needle bearing, or a hybrid bearing comprising combinations of metallic and ceramic elements. Notably, the selection of the bearing type as the second bearing 420 is based on factors such as rotational speed, load capacity, friction characteristics, and durability under repeated sterilization cycles. In some embodiments, a low-friction precision bearing may be employed as the second bearing 420 to minimize mechanical resistance and improve roll actuation responsiveness. In other embodiments, a high-load bearing may be employed as the second bearing 420 to support increased torsional loads generated during instrument manipulation. The term "second direction" refers to the axial direction along the central longitudinal axis opposing the first direction, corresponding to the axial direction toward the outer cover from the driven gear 416. For example, the second direction is positive z-direction. The prevention of the axial movement of the driven gear 416 in the second direction by the second bearing 420, in conjunction with the prevention of the axial movement in the first direction by the first bearing 418, ensures complete bilateral axial constraint of the driven gear 416 within the housing 402. The bilateral axial constraint isolates roll rotation of the outer shaft 306 from any axial displacement along the central longitudinal axis, ensuring that roll actuation does not cause unintended axial movement of the driven gear 416 that would otherwise propagate to the outer shaft 306 and the distal end assembly 204. A technical effect of the aforementioned implementation is that complete bilateral axial constraint of the driven gear 416 is achieved within the housing 202.
[0067] In an implementation, an outer diameter of the driving gear 412 is smaller than an inner diameter of the first bearing 418. In this regard, the term "outer diameter of the driving gear" refers to the diametric dimension measured across the outermost toothed periphery of the driving gear 412, defining the maximum radial extent of the driving gear 416 about the central longitudinal axis. The term "inner diameter of the first bearing" refers to the diametric dimension of the bore defined by the inner race of the first bearing 418, representing the maximum diameter of any component that may pass axially through the first bearing 418 during assembly of the roll actuation assembly 402 within the housing 202. The outer diameter of the driving gear 412 being smaller than the inner diameter of the first bearing 418 enable the assembly of the roll actuation assembly 402 within the housing 202 in the correct sequence. Since the driving gear 412 and the driven gear 416 are arranged in axially adjacent compartments separated by the second base 408, and since the coupling shaft 404 connected to the driving gear 412 must be introduced from the same axial direction as the first bearing 418, the outer diameter of the driving gear 412 must be smaller than the inner diameter of the first bearing 418 to permit the driving gear 412 and the coupling shaft 404 to be assembled past the first bearing 418 into the compartment defined by the second base 408 and the third base 410 without disassembling or displacing the first bearing 418 from the compartment defined by the first base 406 and the second base 408. A technical effect of the aforementioned implementation is that a simplified and conflict-free assembly sequence for the roll actuation assembly 402 is enabled within the housing 202, eliminating the need for additional assembly access features.
[0068] 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.
, C , Claims:CLAIMS
We claim:
1. A robotic surgical system (100) comprising:
a patient-side cart (110) comprising a plurality of robotic arms (112-114);
a surgeon console (130) configured to receive inputs from an operator to control the plurality of robotic arms; and
a vision cart (120) configured to process and display images from a surgical site.
wherein at least one robotic arm from amongst the plurality of robotic arms (112-114) comprises a robotically actuated harmonic surgical instrument (200) mounted to a surgical instrument holder, the robotically actuated harmonic surgical instrument (200) comprising:
a housing (202),
a distal end assembly (204) comprising a first jaw member (300) and a second jaw member (302) movable relative to the first jaw member (300),
a cutting shaft (400) extending from the housing (202) to the distal end assembly (204) along a central longitudinal axis, wherein the cutting shaft (400) is adapted to transmit ultrasonic vibrations to at least one of the first and second jaw members (300, 302),
a motion-transferring tube (304) extending from the housing (202) to the distal end assembly (204), such that the motion-transferring tube (304) circumferentially surrounds the cutting shaft (400), wherein the motion-transferring tube (304) is operatively coupled to one of the first and second jaw members (300, 302) and adapted to provide axial translation to the one of the first and second jaw members (300, 302) to actuate a relative movement therebetween,
a roll actuation assembly (402) arranged within the housing (202) and coupled to a coupling shaft (404) of the robotic surgical system, the roll actuation assembly (402) adapted to receive a rotational input about the central longitudinal axis from the coupling shaft (404) and transfer the rotational input to an outer shaft (306) operatively coupled to the roll actuation assembly (402), and
the outer shaft (306) circumferentially surrounding the motion- transferring tube (304) and operatively coupled to the one of the first and second jaw members (300, 302), wherein the outer shaft (306) is adapted to produce roll rotation of the first and second jaw members (300, 302) about the central longitudinal axis, using the rotational input received from the roll actuation assembly (402), without causing the motion-transferring tube (304) to provide the axial translation to the one of the first and second jaw members (300, 302).
2. The robotic surgical system (100) as claimed in claim 1, wherein the housing (202) comprises a first base (406), a second base (408), and a third base (410).
3. The robotic surgical system (100) as claimed in claim 2, wherein the roll actuation assembly (402) comprises:
a driving gear (412) arranged between the second base (408) and the third base (410), the driving gear (412) being adapted to receive the rotational input from the coupling shaft (404) and to rotate about the central longitudinal axis;
a stepped idler gear (414) rotatably mounted between the second base (408) and the third base (410), the stepped idler gear (414) having a first gear portion meshing with the driving gear (412) and a second gear portion having a diameter greater than the first gear portion; and
a driven gear (416) arranged between the first base (406) and the second base (408), such that the driven gear (416) is meshed with the second gear portion of the stepped idler gear (414);
wherein the rotation of the driving gear (412) is transmitted through the stepped idler gear (414) and the driven gear (416) to the outer shaft (306).
4. The robotic surgical system (100) as claimed in claim 3, wherein the roll actuation assembly (402) further comprises:
a first bearing (418) arranged between the driven gear (416) and the second base (408), wherein the first bearing (418) is adapted to prevent an axial movement of the driven gear (416) in a first direction; and
a second bearing (420) arranged between the driven gear (416) and an outer cover in the housing (202), wherein the second bearing (420) is adapted to prevent the axial movement of the driven gear (416) in a second direction.
5. The robotic surgical system (100) as claimed in claim 4, wherein an outer diameter of the driving gear (412) is smaller than an inner diameter of the first bearing (418).
6. The robotic surgical system (100) as claimed in claim 3, wherein the stepped idler gear (414) is rotatably mounted between the second base (408) and the third base (410) by a first dowel pin.
7. The robotic surgical system (100) as claimed in claim 3, wherein the driven gear (416) is mechanically coupled to the outer shaft (306) by a second dowel pin.
8. The robotic surgical system (100) as claimed in claim 1, wherein an outer diameter of the outer shaft (306) is in the range of 8.0 mm to 8.8 mm.
9. The robotic surgical system (100) as claimed in claim 3, wherein the driving gear (412) is mechanically coupled to the coupling shaft (404) by a fastening element.
10. The robotic surgical system (100) as claimed in claim 1, further comprising an ultrasonic transducer mechanically coupled to the cutting shaft (400) and adapted to generate the ultrasonic vibrations in the cutting shaft (400).