Note: Descriptions are shown in the official language in which they were submitted.
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ROBOTIC SURGICAL ASSEMBLIES AND INSTRUMENT DRIVE UNITS THEREOF
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of and priority to U.S.
Provisional
Patent Application No. 62/345,041, filed on June 3, 2016, the entire contents
of which are
incorporated by reference herein.
BACKGROUND
[0002] Robotic surgical systems have been used in minimally invasive
medical
procedures. Some robotic surgical systems include a console supporting a
surgical robotic arm
and a surgical instrument, having at least one end effector (e.g., forceps or
a grasping tool),
mounted to the robotic arm. The robotic arm provides mechanical power to the
surgical
instrument for its operation and movement.
[0003] Manually-operated surgical instruments often included a handle
assembly for
actuating the functions of the surgical instrument. However, when using a
robotic surgical
system, no handle assembly is typically present to actuate the functions of
the end effector.
Accordingly, to use each unique surgical instrument with a robotic surgical
system, an
instrument drive unit is used to interface with the selected surgical
instrument to drive operations
of the surgical instrument.
[0004] In some systems, an internal motor pack of the instrument drive
unit was
configured to rotate to effect a corresponding rotation of an attached
surgical instrument.
However, rotation of the motor pack, and in turn the attached surgical
instrument, was limited by
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internal circuitry or physical constraints of the instrument drive unit.
Further, rotation of the
motor pack, beyond predefined finite thresholds, could result in damage to the
internal circuitry
of the instrument drive unit.
[0005] Accordingly, a need exists for an instrument drive unit capable of
increased
degrees of rotation of the motor pack without causing damage to the internal
circuitry while
reducing any resistance to rotation from the internal circuitry thereof In
addition, a need exists
for improved feedback to the operating room staff regarding the status of the
instrument drive
unit.
SUMMARY
[0006] In accordance with an aspect of the present disclosure, an
instrument drive unit is
provided. The instrument drive unit includes a housing configured to be
coupled to a surgical
robotic arm, a motor assembly, and a flex spool assembly. The motor assembly
is rotatably
disposed within the housing and configured to effectuate functions of a
surgical instrument. The
flex spool assembly includes a first printed circuit board mounted to the
housing, a second
printed circuit board configured to be non-rotatably coupled to and
electrically connected to the
motor assembly, and a first flex circuit. The first flex circuit has a first
end portion connected to
the first printed circuit board, a second end portion connected to the second
printed circuit board,
and an intermediate portion. The intermediate portion is coiled about the
second printed circuit
board such that rotation of the motor assembly relative to the housing effects
movement of the
second end portion of the first flex circuit along an annular path.
[0007] In some embodiments, the flex spool assembly may include a second
flex circuit
in communication with the first printed circuit board. The second flex circuit
may be disposed
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about the intermediate portion of the first flex circuit and have at least one
visual indicator
disposed in an annular array. The at least one visual indicator may be
configured to indicate a
rotational position of the motor assembly relative to the housing.
[0008] The housing may include a translucent portion disposed about the
second flex
circuit such that light emitted from the at least one visual indicator passes
through the translucent
portion.
[0009] The at least one visual indicator may be configured to indicate
the status of
instruments, the IDU, systems, and/or ancillary devices. The at least one
visual indicator may
also indicate the status of users, including surgeons, patients, and operating
room staff interacting
with the system.
[0010] It is contemplated that the instrument drive unit may further
include a plurality of
elongate printed circuit boards cooperatively defining a cavity that has the
motor assembly non-
rotatably disposed therein. An elongate printed circuit board may be in
electrical communication
with the motor assembly. The first printed circuit board may have a connector
for receiving
power and data, and the second printed circuit board may have a connector
configured to connect
to a first connector of the elongate printed circuit boards. The connector of
the second printed
circuit board may transfer the power from the first printed circuit board to
an elongate printed
circuit board. The flex spool assembly may further include a third printed
circuit board
connected to the second end portion of the first flex circuit. The third
printed circuit board may
be disposed adjacent the second printed circuit board and have a connector
configured to connect
to a second connector of the elongate printed circuit boards. The connector of
the third printed
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circuit board may transfer the data from the first printed circuit board to an
elongate printed
circuit board.
[0011] It is envisioned that the instrument drive unit may further
include an annular
member non-rotatably coupled to the motor assembly. The annular member may
have the
intermediate portion of the first flex circuit coiled thereabout. The annular
member may be fixed
to the second end portion of the first flex circuit such that rotation of the
annular member effects
movement of the second end portion of the first flex circuit along the annular
path. The
instrument drive unit may include a pair of elastomeric capture members fixed
to the second end
portion of the first flex circuit. The capture members may each define a
groove therein. The
annular member may have first and second ends configured for receipt in
respective grooves of
the capture members such that a counterclockwise rotation or a clockwise
rotation of the annular
member effects a corresponding movement of the second end portion of the first
flex circuit.
[0012] In some embodiments, the instrument drive unit may include a fan
disposed
within the housing adjacent the flex spool assembly.
[0013] It is contemplated that rotation of the motor assembly relative to
the housing in a
first direction may decrease a diameter of the intermediate portion of the
first flex circuit.
Rotation of the motor assembly relative to the housing in a second direction
may increase the
diameter of the intermediate portion.
[0014] In accordance with another aspect of the present disclosure, a
surgical assembly
for use with a surgical robotic arm is provided. The surgical assembly
includes an instrument
drive unit, and a carriage. The instrument drive unit includes a housing
configured to be coupled
to a surgical robotic arm, a motor assembly, and a flex spool assembly. The
motor assembly is
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rotatably disposed within the housing and configured to effectuate functions
of a surgical
instrument. The flex spool assembly includes a first printed circuit board
mounted to the
housing, a second printed circuit board configured to be non-rotatably coupled
to and electrically
connected to the motor assembly, and a first flex circuit. The first flex
circuit has a first end
portion connected to the first printed circuit board, a second end portion
connected to the second
printed circuit board, and an intermediate portion. The intermediate portion
is coiled about the
second printed circuit board such that rotation of the motor assembly relative
to the housing
effects movement of the second end portion of the first flex circuit along an
annular path.
[0015] The carriage includes a first side configured for movable
engagement with a
surgical robotic arm, and a second side configured for non-rotatably
supporting the housing of
the instrument drive unit. The carriage includes a motor in electrical
communication with the
first printed circuit board and configured to effect a rotation of the motor
assembly.
[0016] In some embodiments, actuation of the motor of the carriage may
rotate the motor
assembly relative to the housing.
[0017] Further details and aspects of exemplary embodiments of the
present disclosure
are described in more detail below with reference to the appended figures.
[0018] As used herein, the terms parallel and perpendicular are
understood to include
relative configurations that are substantially parallel and substantially
perpendicular up to about
+ or ¨ 10 degrees from true parallel and true perpendicular.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Embodiments of the present disclosure are described herein with
reference to the
accompanying drawings, wherein:
[0020] FIG. 1 is a schematic illustration of a robotic surgical system
including a robotic
surgical assembly in accordance with the present disclosure;
[0021] FIG. 2 is a perspective view of the robotic surgical assembly of
FIG. 1 including a
holder, an instrument drive unit coupled to the holder, and a surgical
instrument coupled to the
instrument drive unit;
[0022] FIG. 3 is a cross-sectional view, taken along lines 3-3 of FIG. 2,
of the surgical
assembly;
[0023] FIG. 4 is a perspective view of an integrated circuit of the
instrument drive unit of
FIG. 2;
[0024] FIG. 5A is a perspective view, with parts removed, of the
instrument drive unit of
FIG. 2;
[0025] FIG. 5B is a cross-sectional view, taken along lines 5B-5B of FIG.
5A, of the
instrument drive unit;
[0026] FIG. 6 is an exploded view of components of the instrument drive
unit of FIG. 2;
[0027] FIG. 7 is a top, plan view of a flex spool assembly of the
instrument drive unit of
FIG. 2 coupled to a motor assembly of the instrument drive unit;
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[0028] FIG. 8 is a top, perspective view of the flex spool assembly of
FIG. 7;
[0029] FIG. 9 is a bottom, perspective view of the flex spool assembly of
FIG. 7; and
[0030] FIG. 10 is a plan view of the flex spool assembly of FIG. 7 is an
uncoiled state.
DETAILED DESCRIPTION
[0031] Embodiments of the presently disclosed robotic surgical assembly
including an
IDU holder, an instrument drive unit, and a surgical instrument, and methods
of making and
using such surgical assemblies, are described in detail with reference to the
drawings, in which
like reference numerals designate identical or corresponding elements in each
of the several
views. As used herein the term "distal" refers to that portion of the IDU
holder, instrument drive
unit, and/or surgical instrument, that is closer to the patient, while the
term "proximal" refers to
that portion of the IDU holder, instrument drive unit, and/or surgical
instrument, that is farther
from the patient.
[0032] As will be described in detail below, an instrument drive unit is
provided, which
drives the various operations of an attached surgical instrument. The
instrument drive unit
includes a flex spool printed circuit board assembly (sometimes referred to
herein as a "flex
spool assembly") that transfers power and communications (e.g., in the form of
electrical signals)
to various components of the instrument drive unit and the attached surgical
instrument. The
flex spool assembly, inter alia, permits an increased degree of rotation of a
motor assembly of
the instrument drive unit relative to a housing of the instrument drive unit
with relatively low
friction loss (e.g., to communication and power signals) and while limiting
damage (e.g., to
internal components of the instrument drive unit) even after prolonged use.
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[0033] Referring initially to FIG. 1, a surgical system, such as, for
example, a robotic
surgical system 1, generally includes a plurality of surgical robotic arms 2,
3 having a robotic
surgical assembly 100, which generally includes an instrument drive unit
(hereinafter "IDU")
110 removably coupled to a slide rail 40 of surgical robotic arms 2, 3, and an
electromechanical
surgical instrument 300 operably coupled to IDU 110; a control device 4; and
an operating
console 5 coupled with control device 4.
[0034] Operating console 5 includes a display device 6, which is set up in
particular to
display three-dimensional images; and manual input devices 7, 8, by means of
which a person
(not shown), for example a surgeon, is able to telemanipulate robotic arms 2,
3 in a first
operating mode, as known in principle to a person skilled in the art. Each of
the robotic arms 2,
3 may be composed of a plurality of members, which are connected through
joints. Robotic
arms 2, 3 may be driven by electric drives (not shown) that are connected to
control device 4.
Control device 4 (e.g., a computer) may be set up to activate the drives, in
particular by means of
a computer program, in such a way that robotic arms 2, 3, the attached robotic
surgical assembly
100, and thus electromechanical surgical instrument 300 (including an
electromechanical end
effector (not shown)) execute a desired movement according to a movement
defined by means of
manual input devices 7, 8. Control device 4 may also be set up in such a way
that it regulates the
movement of robotic arms 2, 3.
[0035] Robotic surgical system 1 is configured for use on a patient "P"
lying on a
surgical table "ST" to be treated in a minimally invasive manner by means of a
surgical
instrument, e.g., electromechanical surgical instrument 300. In embodiments,
robotic arms 2, 3
may be coupled to a robotic arm cart (not shown) rather than surgical table
"ST." Robotic
surgical system 1 may also include more than two robotic arms 2, 3, the
additional robotic arms
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likewise being connected to control device 4 and being telemanipulatable by
means of operating
console 5. A surgical instrument, for example, electromechanical surgical
instrument 300
(including the electromechanical end effector), may also be attached to the
additional robotic
arm.
[0036] Control device 4 may control a plurality of motors, e.g., motors
(Motor 1 . . .n),
with each motor configured to drive movement of robotic arms 2, 3 in a
plurality of directions.
Further, control device 4 may control a motor assembly 114 (FIGS. 3 and 5B) of
IDU 110 of
robotic surgical assembly 100 that drives various operations of surgical
instrument 300. In
addition, control device 4 may control the operation of a rotation motor, such
as, for example, a
canister motor "M" (FIG. 3) of an instrument drive unit ("IDU") holder 102 of
surgical assembly
100, configured to drive a relative rotation of motor assembly 114 (FIGS. 3
and 5B) of IDU 110
and in turn electromechanical surgical instrument 300, as will be described in
detail below. In
embodiments, each motor "M1-M4" of the IDU 110 can be configured to actuate a
drive
rod/cable or a lever arm to effect operation and/or movement of
electromechanical surgical
instrument 300.
[0037] For a detailed discussion of the construction and operation of a
robotic surgical
system, reference may be made to U.S. Patent No. 8,828,023, filed on November
3, 2011,
entitled "Medical Workstation," the entire contents of which are incorporated
by reference
herein.
[0038] With reference to FIGS. 1-3, surgical assembly 100 of surgical
system 1, which is
configured to be coupled with or to robotic arm 2 or 3, generally includes the
IDU holder 102,
the IDU 110, and the electromechanical surgical instrument 300. As briefly
mentioned above,
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IDU 110 transfers power and actuation forces from its motors to driven members
(not shown) of
electromechanical surgical instrument 300 to ultimately drive movement of
components of the
end effector of electromechanical surgical instrument 300, for example, a
movement of a knife
blade (not shown) and/or a closing and opening of jaw members of the end
effector, the actuation
or firing of a stapler, and/or the activation or firing of an electrosurgical
energy-based
instrument, or the like. Motor assembly 114 (FIGS. 3 and 5B) of IDU 110 is
rotated by a motor
"M" supported in IDU holder 102 and transfers its rotational motion to
electromechanical
surgical instrument 300.
[0039] With reference to FIGS. 2 and 3, IDU holder 102 of surgical
assembly 100
functions both to actuate a rotation of motor assembly 114 (FIGS. 3 and 5B) of
IDU 110 and to
effect axial translation of IDU 110 along rail 40 of robotic arm 2. IDU holder
102 includes a
back member or carriage 104, and an outer member or outer housing 106
extending laterally
(e.g., perpendicularly) from a distal end 107 of carriage 104. In some
embodiments, housing 106
may extend at various angles relative to carriage 104 and from various
portions of carriage 104.
Carriage 104 has a first side 108a and a second side 108b, opposite first side
108a. First side
108a of carriage 104 is detachably connectable to rail 40 (FIG. 1) of robotic
arm 2 to enable IDU
holder 102 to slide or translate along rail 40 of robotic arm 2. Second side
108b of carriage 104
is configured to support a housing 112 or the like of IDU 110.
[0040] Carriage 104 of IDU holder 102 supports or houses a motor, such
as, for example,
canister motor "M" therein. Motor "M" receives controls and power from control
device 4 (FIG.
1) to ultimately rotate internal motor assembly 114 of IDU 110. Carriage 104
includes a printed
circuit board 109 in electrical communication with motor "M" of carriage 104
to control an
operation of motor "M" of carriage 104. Carriage 104 further includes a belt
or gear drive
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mechanism 111 that extends distally from motor "M." Drive mechanism 111 is
configured to
operably interface with motor assembly 114 of IDU 110 to effect a rotation of
motor assembly
114 upon actuation of motor "M" of carriage 104.
[0041] With continued reference to FIGS. 2 and 3, housing 112 of IDU 110
is engaged to
second side 108b of carriage 104 of IDU holder 102 so as to shroud, cover and
protect the inner
components of IDU 110 and carriage 104. Housing 112 of IDU 110 may have a
generally
cylindrical configuration, but in some embodiments, housing 112 may assume a
variety of
configurations, such as, for example, squared, triangular, elongate, curved,
semi-cylindrical or
the like. As mentioned above, housing 112 protects or shields various
components of IDU 110
including motor assembly 114 and a flex spool assembly 200 for transferring
power and data to
components of IDU 110. Housing 112 also provides a platform 116 on which the
inner
components of IDU 110 are attached.
[0042] IDU 110 includes a fan 150 disposed within a top portion thereof,
and is located
above flex spool assembly 200. Fan 150 is connected to flex spool assembly 200
via a connector
(not explicitly shown) to provide adjustable power to fan 150. A top portion
112a of housing
112 may define a plurality of vents or slits 152 therein to allow for air to
transfer out of IDU 110.
Fan 150 is configured to draw air through flex spool assembly 200 and out of
top portion 112a of
housing 112 through slits 152 to cool electronics during operation thereof,
and to maintain a
negative pressure through IDU 110. The flex spool assembly 200 is configured
to adjust the
amount of power delivered to fan 150 based on the temperature within IDU 110.
Speed
controllers (not shown) associated with flex spool assembly 200 and/or
integrated circuit 120
may be provided to control a speed of fan 150 to adjust a cooling rate. For
example, the speed
control may adjust the electrical current that is delivered to fan 150 to
adjust a speed thereof.
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[0043] With reference to FIGS. 2-6, IDU 110 includes the integrated
circuit 120 and the
motor assembly 114 each rotatably disposed therewithin. In some embodiments,
IDU 110 may
include brackets and/or stops configured to compensate for loads directed on
motor assembly
114 and/or integrated circuit 120 in a direction that is perpendicular or
transverse to the
longitudinal axis defined by IDU 110. Integrated circuit 120 includes a top
rigid printed circuit
board or nexus 122, and four elongate rigid printed circuit boards 124a, 124b,
126a, 126b that
extend perpendicularly from top printed circuit board 122. Top printed circuit
board 122 has
first and second male electrical connectors 128, 130 for coupling to first and
second female
electrical connectors 214a, 216a of flex spool assembly 200.
[0044] The elongate printed circuit boards 124a, 124b, 126a, 126b are
parallel with one
another and are disposed along a longitudinal axis of IDU 110. Elongate
printed circuit boards
124a, 124b, 126a, 126b include a first pair of elongate printed circuit boards
124a, 124b that
oppose one another, and a second pair of elongate printed circuit boards 126a,
126b that oppose
one another. Elongate printed circuit boards 124a, 124b, 126a, 126b
cooperatively form a
rectangular configuration and define a cavity 132 therein configured for
slidable receipt of motor
assembly 114. It should be appreciated that circuit boards 124a, 124b, 126a,
126b and nexus 122
of integrated circuit 300 may be configured in any number of structural
combinations, such as,
for example, first, second, third, and fourth circuit boards 124a, 124b, 126a,
126b being coupled,
side-by-side, where one of first, second, third, or fourth circuit board 124a,
124b, 126a, 126b is
further coupled to one side of a first, second, third, or fourth side of nexus
122. In some
embodiments, integrated circuit 300 may have various connectors, flex cables,
or wires used to
interconnect elongate printed circuit boards 124a, 124b, 126a, 126b to one
another and/or to
nexus 122.
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[0045] First pair of elongate printed circuit boards 124a, 124b have a
first end portion in
electrical communication with nexus 122, and a second end portion in
electrical communication
with motor assembly 114 to transfer power from printed circuit assembly 200 to
motor assembly
114, as will be described in detail below. Second pair of elongate printed
circuit boards 126a,
126b have a first end portion in electrical communication with nexus 122, and
a distal end in
electrical communication with various electrical components of IDU 110 and/or
surgical
instrument 300 to transfer communication signals and/or power to the various
electrical
components of IDU 110 and surgical instrument 300.
[0046] The electrical components of IDU 110 may include, but are not
limited to,
transducers, encoders, gyroscopes, magnetometers, distal limit sensors,
pressure sensors,
torsional sensors, load cells, optical sensors, position sensors, heat
sensors, illumination
elements, cameras, speakers, audible emission components, motor controllers,
LED components,
microprocessors, sense resistors, accelerometers, switches to monitor, limit
and control
positional limits, etc. In some embodiments, each of these electrical
components may be
incorporated into flex spool assembly 200 (FIGS. 7-10) of IDU 110.
[0047] Motor assembly 114 of IDU 110 is non-rotatably disposed within
cavity 132 of
integrated circuit 120. Motor assembly 114 may include four motors "M1-M4,"
for example,
canister motors or the like, each having a drive shaft 138, 140 (only drive
shafts of two motors of
motors "M1-M4" being shown) having a non-circular transverse cross-sectional
profile (e.g.,
substantially D-shaped, or the like). The four motors "M1-M4" are arranged in
a rectangular
formation such that respective drive shafts 138, 140 thereof are all parallel
to one another and all
extending in a common direction. As the motors "M1-M4" of the motor assembly
114 are
actuated, rotation of the respective drive shafts 138, 140 of the motors "M1-
M4" is transferred to
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gears or couplers of drive assemblies of surgical instrument 300 via
respective drive transfer
shafts to actuate various functions of surgical instrument 300.
[0048] With reference to FIGS. 2-10, and with particular reference to
FIGS. 6-10, flex
spool assembly 200 of IDU 110 is configured to transfer power and information
(e.g., signals
that direct actuation of certain functions of IDU 110 and surgical instrument
300) from control
device 4 (FIG. 1) to an integrated circuit 120 of IDU 110. Flex spool assembly
200 generally
includes a first flex circuit 210 and a second flex circuit 220. First flex
circuit 210 is configured
to electrically interconnect control device 4 and a plurality of electrical
components (e.g.,
motors, various sensors, transducers, etc.) of IDU 110 and/or surgical
instrument 300.
[0049] First flex circuit 210 of flex spool assembly 200 is disposed on
platform 116 of
housing 112 of IDU 110 and has a first end portion 210a, a second end portion
210b, and an
intermediate portion or coiled portion 210c that interconnects first and
second end portions 210a,
210b. Intermediate portion 210c is coiled about itself to form a plurality of
concentric layers.
The concentric layers of intermediate portion 210c of first flex circuit 210
are radially spaced
from one another to define gaps therebetween. The gaps between concentric
layers of
intermediate portion 210c of first flex circuit 210 allow for intermediate
portion 210c to constrict
towards its center and then expand back to its original, expanded position. It
is contemplated
that first flex circuit 210 is provided with adequate clearance to allow for
first flex circuit 210 to
move slightly along a longitudinal axis defined by IDU 110
[0050] First end portion 210a of first flex circuit 210 extends
tangentially from
intermediate portion 210c and is disposed outside of intermediate portion
210c. Second end
portion 210b of first flex circuit 210 extends radially inward from an
innermost layer 211 (See
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FIG. 8) of intermediate portion 210c. As will be described in detail below, a
rotation of motor
assembly 114 of IDU 110 relative to housing 112 of IDU 110 results in a
movement of second
end portion 210b of first flex circuit 210 along an annular pathway "P" (FIG.
8), thereby
constricting or expanding intermediate portion 210c of first flex circuit 210.
[0051] First flex circuit 210 is fabricated from a material, or a hybrid
of materials, that
exhibit low resistance to constricting and/or expanding of intermediate
portion 210c, have an
extremely low torsional resistance, a high thermal resistance (e.g., greater
than about 280 C), a
UL V-0 flame rating, and/or be Restriction of Hazardous Substances (ROHS)
compliant. First
flex circuit 210 may be fabricated from high ductile copper clad laminate,
polyamide, polyester,
polytetrafluoroethylene, and/or the polyimide film KaptonTm. First flex
circuit 210 may be
formed from one or more layers, for example, about six layers. In some
embodiments, a lower
edge of first flex circuit 210 may have a lubricious coating, for example, any
of the lubricious
coatings disclosed herein, to account for or reduce wear over time and use.
Additionally or
alternatively, the platform 116 may have a lubricious coating for reducing
wear on flex spool
assembly 200. In some embodiments, first flex circuit 210 may be pre-formed as
a wound
structure. First flex circuit 210 may be a pure flex circuit or a rigidized
flex circuit.
[0052] First flex circuit 210 may incorporate or have disposed thereon
one or more
mechanical projections or stops (not explicitly shown) fabricated from any
suitable material, for
example, elastomers, epoxy, or plastics. In some embodiments, inner and/or
outer surfaces of
first flex circuit 210 may have a high hardness, or low friction coating or
material, to reduce
wear on first flex circuit 210. Various portions of first flex circuit 210 may
define holes or
openings therethrough to facilitate passage of air for cooling of first flex
circuit 210. It is
contemplated that flex spool assembly 200 may incorporate diagnostics ports,
various sensors,
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actuators, connectors for connection to external devices, microcontrollers,
Ethernet connections,
or the like.
[0053] With reference to FIGS. 5A-9, IDU 110 further includes a spindle
assembly 230
for transferring rotational motion from motor assembly 114 to first flex
circuit 210. Spindle
assembly 230 includes an outer annular member 232, and an inner annular member
or ring
member 234. Outer annular member 232 is fastened to a proximal end portion of
motor
assembly 114 via fasteners 236. Inner annular member 234 is fastened to outer
annular member
232 via fasteners 238 and is rotatable relative to platform 116 such that
outer annular member
234 rotates relative to platform 116. In embodiments, outer and inner annular
members 232, 234
of spindle assembly 230 may be of a single integral construction. A lubricious
coating may be
applied to surfaces of spindle assembly 230 that contact platform 116 or to
the surfaces of
platform 116 that contact spindle assembly 230, such that spindle assembly 230
rotates relative
to platform with limited friction. Accordingly, the lubricious coating may
include any suitable
material, such as, for example, ultra high molecular weight polyethylene,
nylon, acetal, or
polytetrafluoroethylene.
[0054] Inner annular member 234 of spindle assembly 230 is disposed
concentrically
within intermediate portion 210c of first flex circuit 210. Inner annular
member 234 is in the
form of a C-clamp having a first end portion 234a and a second end portion
234b. First and
second end portions 234a, 234b of inner annular member 234 face one another
and each have a
mating part, for example, a male mating part or projection 240a, 240b.
Projections 240a, 240b
are configured to be secured to respective capture members 218a, 218b of first
flex circuit 210.
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[0055] In particular, first flex circuit 210 has a pair of elastomeric
capture members 218a,
218b fixed to opposing lateral surfaces of second end portion 210b of first
flex circuit 210.
Capture members 218a, 218b are each C-shaped to define a respective female
mating part or
groove 224a, 224b therein. Grooves 224a, 224b of capture members 218a, 218b
receive
respective projections 240a, 240b of inner annular member 234 such that a
rotation (e.g.,
counterclockwise or clockwise rotation) of inner annular member 234 effects a
corresponding
movement of second end portion 210b of first flex circuit 210 along an annular
path "P."
[0056] With continued reference to FIGS. 2-10, and with particular
reference to FIGS. 7-
10, flex spool assembly 200 includes a first printed circuit board 212, a
second printed circuit
board 214, and a third printed circuit board 216. First, second, and third
printed circuit boards
212, 214, 216 are rigid circuit boards rather than flex circuits. In some
embodiments, first,
second, and third printed circuit boards 212, 214, 216 may be flex circuits
and/or may be
monolithically formed with first flex circuit 210. First printed circuit board
212 is connected to
printed circuit board 109 of IDU holder 102 such that first printed circuit
board 212 is fixed
relative to IDU 110. First printed circuit board 212 is connected to first end
portion 210a of first
flex circuit 210 to transfer power and data to first flex circuit 210. First
printed circuit board 212
has an electrical connector, for example, a female connector 212a, configured
to be coupled to a
corresponding male electrical connector (not explicitly shown) of printed
circuit board 109 of
IDU holder 102. In some embodiments, a wire may be used in place of female
connector 212a.
It is contemplated that any of the disclosed electrical connectors may be zero
insertion force
("ZIF") connectors.
[0057] Second and third printed circuit boards 214, 216 of flex spool
assembly 200 are
each disposed within intermediate portion 210c of first flex circuit 210 and
are each connected to
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second end portion 210b of first flex circuit 210. Second printed circuit
board 214 is configured
to transfer power from first printed circuit board 212 to motor assembly 114
of IDU 110. Second
printed circuit board 214 has an electrical connector, for example, a female
connector 214a,
configured to be coupled to first male electrical connector 128 of integrated
circuit 120. Third
printed circuit board 216 is disposed adjacent second printed circuit board
214 and is configured
to transfer data from first printed circuit board 212 to various components of
IDU 110 and/or
surgical instrument 300. Third printed circuit board 216 has an electrical
connector, for
example, a female connector 216a, configured to be coupled to second male
electrical connector
130 of integrated circuit 120. Female and male connectors 214a, 216a may be
pin/position
connectors, such as, for example, 40-pin connectors.
[0058] With continued reference to FIGS. 7-10, second flex circuit 220 of
flex spool
assembly 200 has a first end portion 220a connected to a first end portion of
first printed circuit
board 212, and a second end portion 220b disposed adjacent a second end
portion of first printed
circuit board 212 to define a U-shaped intermediate portion 220c that
surrounds first flex circuit
210. First and second ends 220a, 220b of second flex circuit 220 are fixed to
platform 116 of
IDU 110.
[0059] Second flex circuit 220 has one or more visual indicators 222, for
example, LEDs,
LCDs, or the like. Visual indicators 222 are disposed in an annular array on
an outer surface of
U-shaped intermediate portion 220c. In some embodiments, visual indicators 222
may be
disposed in a linear array or in any other suitable pattern. Visual indicators
222 are coplanar or
in registration with a translucent portion 117 (FIG. 2) of housing cover of
IDU 110. In this way,
light emitted from visual indicators 222 is visible from outside of IDU 110.
In some
embodiments, translucent portion 117 may be completely transparent.
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[0060] Second flex circuit 220 receives information from first printed
circuit board 212
related to a condition or conditions of IDU 110. One condition of IDU 110 may
be a rotational
position of motor assembly 114, and thus the attached surgical instrument 300,
relative to IDU
110. As such, visual indicators 222 of second flex circuit 220 may be
activated or illuminated by
integrated circuit 120 of IDU 110 and/or control device 4 (FIG. 1) to provide
a visual indication
of the rotational position of surgical instrument 300. Visual indicators 222
of second flex circuit
220 may be activated in sequential order commensurate with a degree of
rotation of motor
assembly 114. For example, for every threshold degree of rotation of motor
assembly 114
relative to IDU 110, another light of visual indicators 222 may be activated.
A complete rotation
of motor assembly 114 may be indicated by all of visual indicators 222 being
activated.
[0061] In some embodiments, visual indicators 222 may change in color
and/or intensity
to indicate various conditions of IDU 110 and/or surgical instrument 300. In
some embodiments,
visual indicators 222 may be configured to indicate a status of any component
of surgical system
1.
[0062] In operation, integrated circuit 120 of IDU 110, with motor
assembly 114
disposed therein, is electromechanically coupled to flex spool assembly 200 of
IDU 110. In
particular, first and second male electrical connectors 128, 130 of integrated
circuit 120 are
mated with respective first and second female electrical connectors 214a, 216a
of first flex
circuit 210 of flex spool assembly 200. Upon electromechanically coupling
integrated circuit
120 with flex spool assembly 200, power and data may be transferred from
control device 4 to
integrated circuit 120 and motor assembly 114 via flex spool assembly 200.
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[0063] After electromechanically coupling integrated circuit 120 with
flex spool
assembly 200, a clinician operating manual input devices 7, 8 of surgical
system 1 may actuate
motor "M" of IDU holder 102 to ultimately effect rotation of surgical
instrument 300 to orient
surgical instrument 300 in a particular position within a surgical site. In
particular, an actuation
of manual input devices 7, 8 of surgical system 1 sends a signal from control
device 4 of surgical
system 1 to first printed circuit board 212 of flex spool assembly 200, which
transmits the signal
to printed circuit board 109 of carriage 104. Printed circuit board 109 of
carriage 104 transmits
the signal to motor "M" of IDU holder 102 to actuate motor "M." Actuation of
motor "M" of
IDU holder 102 drives rotation of motor assembly 114 of IDU 110 relative to
housing 112 of
IDU 110 due to the operable connection of motor assembly 114 with drive
mechanism 111 of
IDU holder 102. With proximal end 302 of surgical instrument 300 non-rotatably
coupled to
motor assembly 114 of IDU 110, rotation of motor assembly 114 of IDU 110
results in rotation
of surgical instrument 300 about its longitudinal axis.
[0064] In addition to a rotation of motor assembly 114 causing a rotation
of surgical
instrument 300, a rotation of motor assembly 114 causes outer annular member
232 of spindle
assembly 230 of IDU 110 to rotate due to outer annular member 232 of spindle
assembly 230
being fastened to proximal portion 114a of motor assembly 114. Due to inner
annular member
234 of spindle assembly 230 being secured to second end portion 210b of first
flex circuit 210 of
flex spool assembly 200, second end portion 210b of first flex circuit 210
moves along an
annular pathway "P" (FIG. 8) around a central longitudinal axis defined by IDU
110 in response
to the rotation of spindle assembly 230.
[0065] As second end portion 210b of first flex circuit 210 moves along
the annular
pathway "P," intermediate portion 210c of first flex circuit 210 constricts
about itself, thereby
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decreasing the outer diameter of intermediate portion 210c and reducing the
spacing between
individual coils of intermediate portion 210c of first flex circuit 210.
Rotation of motor
assembly 114 is continued, for example, up to about 270 degrees or until
intermediate portion
210c of first flex circuit 210 cannot be safely constricted any further. In
some embodiments,
motor assembly 114 may be rotated more than 270 degrees, for example, about
360 degrees or
more. The degree of rotation depends on the length of first flex circuit, and
more particularly the
number of coils of intermediate portion 210c of first flex circuit 210.
[0066] Platform 116 further includes a hard stop 121 projecting downwardly
therefrom,
and IDU 110 further includes a ring 123 disposed between platform 116 and
outer annular
member 232 of IDU 110. Ring 123 has an H-shaped transverse cross-sectional
configuration
and has stops 121 (FIG. 5B) disposed in upper and lower portions thereof. Hard
stop 121 of
platform 116 is configured to cease rotation of motor assembly 114 upon motor
assembly 114
achieving a threshold amount of rotation. In particular, as motor assembly 114
rotates relative to
platform 116, a projection or hard stop 121 extending upwardly from outer
annular member 232
of motor assembly 114 engages the hard stop (not shown) disposed in the lower
portion of ring
123 to rotate ring 123. Continued rotation of motor assembly 114 causes the
hard stop 121
disposed in the upper portion of ring 123 to engage hard stop 121 of platform
116 such that
motor assembly 114 is prevented from further rotation.
[0067] After motor assembly 114 rotates about 270 degrees, drive mechanism
111 of
IDU holder 102 may be actuated to reverse the direction of rotation of motor
assembly 114 to
return motor assembly 114 to its starting position. As motor assembly 114 is
rotated in the
reverse direction toward its starting position, intermediate portion 210c of
first flex circuit 210
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uncoils to expand the outer diameter of intermediate portion 210c without
providing resistance to
rotation of motor assembly 114.
[0068] During rotation of motor assembly 114 of IDU 110 relative to
housing 112 of
IDU 110, information regarding the amount or degree of rotation of motor
assembly 114 may be
transmitted to second flex circuit 220 of flex spool assembly 200. The annular
array of visual
indicators 222 disposed on second flex circuit 220 may illuminate sequentially
based on the
amount motor assembly 114 rotates. For example, if motor assembly 114 achieves
90 degrees of
rotation relative to its starting position, only an outermost light of the
visual indicators 222 may
illuminate, whereas if motor assembly 114 achieves 270 degrees of rotation
relative to its starting
position, all of visual indicators 222 may illuminate. As such, visual
indicators 222 give a
clinician an indication of how much motor assembly 114, and in turn, surgical
instrument 300,
has rotated.
[0069] It will be understood that various modifications may be made to
the embodiments
disclosed herein. Therefore, the above description should not be construed as
limiting, but
merely as exemplifications of various embodiments. Those skilled in the art
will envision other
modifications within the scope and spirit of the claims appended thereto.
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