US20110060346A1 - Surgical manipulator for a telerobotic system - Google Patents

Abstract

The invention is directed to a system and method for releasably holding a surgical instrument (14), such as an endoscopic instrument configured for delivery through a small percutaneous penetration in a patient. The instrument comprises an elongate shaft (100) with a pair of mounting pins (116) laterally extending from the shaft between its proximal and distal ends. An instrument holder comprises a support having a central bore (202) and an axially extending slot (204) for receiving the instrument shaft and the mounting pins. A pair of locking slots (206) are cut into the support transversely to and in communication with the axial slot so that the mounting pins can be rotated within the locking slots. The instrument support further includes a latch assembly for automatically locking the mounting pins within the locking slots to releasably couple the instrument to the instrument holder. With this twist-lock motion, the surgeon can rapidly engage and disengage various instruments from the holder during a surgical procedure, such as open surgery, laparoscopy or thoracoscopy.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS
• This application is a continuation of U.S. application Ser. No. 10/265,285 filed Oct. 4, 2002, which is a continuation of U.S. application Ser. No. 09/521,253 filed on Mar. 8, 2000, now U.S. Pat. No. 6,461,372, which is a continuation of U.S. application Ser. No. 09/105,706 filed on Jun. 26, 1998, now U.S. Pat. No. 6,080,181, which is a division of U.S. application Ser. No. 08/848,934, filed on May 1, 1997, now U.S. Pat. No. 5,810,880, which is a division of application Ser. No. 08/485,587, filed on Jun. 7, 1995, now U.S. Pat. No. 5,649,956, all of which are incorporated herein by reference.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
• This invention was made with Government support under contract awarded by the National Institute for Health (NIH) under grant number 5 R01GM-44902-02. The Government has certain rights in this invention.
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
• Not Applicable
BACKGROUND OF THE INVENTION
• This invention relates to surgical manipulators and more particularly to robotic assisted apparatus for use in surgery.
• In standard laparoscopic surgery, a patient's abdomen is insufflated with gas, and trocar sleeves are passed through small (approximately ½ inch) incisions to provide entry ports for laparoscopic surgical instruments. The laparoscopic surgical instruments generally include a laparoscope for viewing the surgical field, and working tools such as clamps, graspers, scissors, staplers, and needle holders. The working tools are similar to those used in conventional (open) surgery, except that the working end of each tool is separated from its handle by an approximately 12 inch long extension tube. To perform surgical procedures, the surgeon passes instruments through the trocar sleeves and manipulates them inside the abdomen by sliding them in and out through the sleeves, rotating them in the sleeves, levering (e.g., pivoting) the sleeves in the abdominal wall, and actuating end effectors on the distal end of the instruments.
• In robotically-assisted and telerobotic surgery (both open surgery and endoscopic procedures), the position of the surgical instruments is controlled by servo motors rather than directly by hand or with fixed clamps. The servo motors follow the motions of a surgeon's hands as he/she manipulates input control devices at a location that may be remote from the patient. Position, force, and tactile feedback sensors may be employed to transmit position, force, and tactile sensations from the surgical instrument back to the surgeon's hands as he/she operates the telerobotic system.
• The servo motors are typically part of an electromechanical device that supports and controls the surgical instruments that have been introduced directly into an open surgical site or through trocar sleeves into the patient's abdomen becomes a body cavity. During the operation, the electromechanical device or instrument holder provides mechanical actuation and control of a variety of surgical instruments, such as tissue graspers, needle drivers, etc, that each perform various functions for the surgeon, i.e., holding or driving a needle, grasping a blood vessel or dissecting tissue.
• This new method of performing telesurgery through remote manipulation will create many new challenges. One such challenge is that different surgical instruments will be attached and detached from the same instrument holder a number of times during an operation. In laparoscopic procedures, for example, the number of entry ports into the patient's abdomen is generally limited during the operation because of space constraints as well as a desire to avoid unnecessary incisions in the patient. Thus, a number of different surgical instruments will typically be introduced through the same trocar sleeve during the operation. Likewise, in open surgery, there is typically not enough room around the surgical site to position more than one or two surgical manipulators, and so the surgeon's assistant will be compelled to frequently remove instruments from the holder and exchange them with other surgical tools.
• What is needed, therefore, is an improved system and method for releasably coupling a surgical instrument to an instrument holder. The system should be configured to quickly and easily engage and disengage the instrument from the holder to minimize the instrument exchange time during endoscopic surgery. Preferably, the system is part of an electromechanical device that can be coupled to a controller mechanism to form a telerobotic system for operating the surgical instrument by remote control.
BRIEF SUMMARY OF THE INVENTION
• According to the invention, a system and method provide for releasably holding a surgical instrument during conventional open surgery or endoscopic procedures, such as laparoscopy. The instrument comprises an elongate shaft with proximal and distal ends and a mounting means having a protrusion extending radially from the shaft between the proximal and distal ends. An instrument holder comprises a support having a body with an axial passage for receiving the instrument shaft and a first hole in communication with the axial passage for receiving the protrusion. A second hole is cut into the body transversely to and in communication with the first hole so that the protrusion can be rotated within the second hole. To prevent the instrument from being accidently twisted and thereby disengaged from the instrument holder during surgery, the holder further includes a locking means coupled to the body for automatically locking the protrusion within the second hole thereby releasably locking the instrument to the instrument holder.
• In a preferred configuration, the protrusion of the mounting means comprises a pair of opposing arms, such as mounting pins, extending outward from the instrument shaft. The first hole is an axially extending slot for receiving the mounting pins and the second hole is a perpendicular locking slot having a first portion aligned with the axial slot and a second portion extending circumferentially around the body of the instrument support. With this configuration, the mounting pins can be slid through the axial slot and rotated into the locking slot to attach the instrument to the holder. The instrument can be removed by performing the same two steps in reverse order. With this twist-lock motion, the surgeon can rapidly engage and disengage various instruments from the instrument holder during a surgical procedure.
• The locking means preferably comprises a releasable latch assembly for locking the mounting pins to the instrument holder. The latch assembly includes a spring-loaded plunger coupled to a latch that normally locks the instrument in place by capturing the mounting pin in the locking slot. The plunger has a button extending outward from the instrument holder for moving the latch away from the locking slot. The button can be depressed manually or automatically to release the mounting pins and allow instrument exchange when the instrument is easily accessible to the surgeon.
• The invention is particularly useful for releasably holding an endoscopic instrument configured for introduction through a small percutaneous penetration into a body cavity, e.g., the abdominal or thoracic cavity. To that end, the instrument preferably includes an end effector, such as a pair of jaws, —coupled to the distal end for engaging a tissue structure within the body cavity. To actuate the end effector, the instrument has a second pair of arms, such as actuator pins, laterally extending from the shaft and operatively coupled to the end effector. Preferably, the actuator pins are axially displaceable with respect to the shaft to actuate the end effector (e.g., open and close the jaws). The instrument holder further includes an actuator driver releasably coupled to the actuator arms and to an external driver for actuating the end effector. The actuator driver preferably includes a twist-lock interface having transverse slots similar to that described for the instrument support so that-the instrument can be simultaneously engaged or disengaged from both the instrument support and the actuator driver.
• Other features and advantages of the invention will appear from the following description in which the preferred embodiment has been set forth in detail in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a partial sectional elevational view of a robotic endoscopic surgical instrument mounted to a manipulator assembly according to the present invention;
• FIG. 1A is a partial sectional elevational view of the manipulator assembly ofFIG. 1 illustrating the removal of an instrument holder from the rest of the assembly;
• FIGS. 2A and 2B are enlarged side and front cross-sectional views, respectively, of the surgical instrument ofFIG. 1;
• FIGS. 3A and 3B are perspective views of an instrument support and an actuator pin catch, respectively, for releasably mounting the surgical instrument to the manipulator assembly;
• FIG. 4 is a front elevational view of the surgical instrument mounted within the instrument support and actuator pin catch ofFIGS. 3A and 3B;
• FIG. 5 is a front elevational view of an actuator driver for providing axial movement of the actuator pin catch ofFIG. 3B;
• FIGS. 6A and 6B are enlarged cross-sectional views of an actuator carriage assembly and a helical actuator of the actuator driver ofFIG. 5;
• FIG. 7 is an enlarged detail of a portion of the frame of the manipulator assembly ofFIG. 1 illustrating a coupling mechanism for removing the shafts from the frame;
• FIG. 8 is a partial cross-sectional view of the instrument support ofFIG. 3A illustrating a locking mechanism for a twist lock interface according to the present invention; and
• FIG. 9 is an elevational view of a remote center positioner for holding the manipulator assembly ofFIG. 1.
• FIG. 10 shows a fragmentary portion of the insertion portion of an endoscope for use with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
• Referring to the drawings in detail, wherein like numerals indicate like elements, amanipulator assembly2 is illustrated according to the principles of the invention.Manipulator assembly2 generally includes an instrument holder4 removably mounted to a base6 and a drive assembly7 for manipulating asurgical instrument14 releasably coupled to instrument holder4.
• Referring toFIG. 1, base6 comprises aframe16 having proximal and distalelongate support members17,19 and first and second ball-spline shafts18,20 rotatably coupled to supportmembers17,19 viabearings22.Frame16 further includes asupport bracket24 for attachingmanipulator assembly2 to aremote center positioner300, as discussed in more detail below (seeFIG. 9). Drive assembly7 comprises first, second andthird drives8,10,12, which are mounted to frame16 and configured to provide three degrees of freedom tosurgical instrument14. In the preferred embodiment, first drive8 rotatesinstrument14 around its own axis,second drive10 actuates anend effector120 on the distal end ofinstrument14 andthird drive12 axially displacesinstrument14 with respect to frame16. Of course, it will be readily recognized by those skilled in the art that other configurations are possible. For example,assembly2 may include additional drives for providing additional degrees of freedom tosurgical instrument14, such as rotation and flexion of an instrument wrist.
• First drive8 comprises arotation drive motor26 fixed to frame16 and coupled tofirst shaft18 by adrive belt28 for rotatingfirst shaft18 with respect to frame16.Second drive10 comprises agripper drive motor30 fixed to frame16, and coupled tosecond shaft20 by a drive belt-32 for rotatingsecond shaft20 with respect to frame16. Third drive12 comprises avertical drive motor34 coupled to instrument holder4 via adrive belt36 and twopulleys38 for axially displacing instrument holder4 with respect to frame16. Drivemotors26,30,34 are preferably coupled to a controller mechanism via servo-control electronics (not shown) to form a telerobotic system for operatingsurgical instrument14 by remote control. The drive motors follow the motions of a surgeon's hands as he/she manipulates input control devices at a location that may be remote from the patient. A suitable telerobotic system for controlling the drive motors is described in commonly assigned co-pending application Ser. No. 08/623,932 filed Jan. 21, 1992 TELEOPERATOR SYSTEM AND METHOD WITH TELEPRESENCE, which is incorporated herein by reference.
• The above described telerobotic servo system preferably has a servo bandwidth with a 3 dB cut off frequency of at least 10 hz so that the system can quickly and accurately respond to the rapid hand motions used by the surgeon. To operate effectively with this system, instrument holder4 has a relatively low inertia and drivemotors26,30,34 have relatively low ratio gear or pulley couplings.
• In a specific embodiment,surgical instrument14 is an endoscopic instrument configured for introduction through a percutaneous penetration into a body cavity, such as the abdominal or thoracic cavity. In this embodiment,manipulator assembly2 supports acannula50 ondistal support member19 offrame16 for placement in the entry incision during an endoscopic surgical procedure (note thatcannula50 is illustrated schematically inFIG. 1 and will typically be much longer).Cannula50 is preferably a conventional gas sealing trocar sleeve adapted for laparoscopic surgery, such as colon resection and Nissen fundoplication.
• As shown inFIG. 1,cannula50 preferably includes aforce sensing element52, such as a strain gauge or force-sensing resistor, mounted to anannular bearing54 withincannula50.Bearing54 supportsinstrument14 during surgery, allowing the instrument to rotate and move axially through the central bore of bearing54.Bearing54 transmits lateral forces exerted by theinstrument14 to forcesensing element52, which is operably connected to the controller mechanism for transmitting these forces to the input control devices (not shown) held by the surgeon in the telerobotic system. In this manner, forces acting oninstrument14 can be detected without disturbances from forces acting oncannula50, such as the tissue surrounding the surgical incision, or by gravity and inertial forces acting onmanipulator assembly2. This facilitates the use of manipulator assembly in a robotic system because the surgeon will directly sense the forces acting against the end ofinstrument14. Of course, the gravitational forces acting on the distal end ofinstrument14 will also be detected byforce sensing element52. However, these forces would also be sensed by the surgeon during direct manipulation of the instrument.
• As shown inFIG. 1, instrument holder4 comprises achassis60 mounted onshafts18, via ball-spline bearings62,64 so thatchassis60 may move axially with respect toshafts18,20, but is prevented from rotating withshafts18,20.Chassis60 is preferably constructed of a material that will withstand exposure to high temperature sterilization processes, such as stainless steel, so thatchassis60 can be sterilized after a surgical procedure.Chassis60 includes acentral cavity66 for receivingsurgical instrument14 and anarm68 laterally extending fromchassis60.Arm68 is fixed to drivebelt36 so that rotation ofdrive belt36 moves instrument holder4 in the axial direction alongshafts18;20.
• Instrument holder4 is removably coupled to base6 and the drive motors so that the entire holder4 can be removed and sterilized by conventional methods, such as steam, heat and pressure, chemicals, etc. In the preferred configuration,arm68 includes atoggle switch69 that can be rotated to releasearm68 from drive belt36 (FIG. 1). In addition,shafts18,20 are removably coupled tobearings22 so that the shafts can be axially withdrawn fromsupport members17,19 offrame16, as shown inFIG. 1A. To this end, thedistal bearings22 preferably include a coupling mechanism for allowing the removal ofshafts18,20. As shown inFIG. 7,distal support member19 includes asupport collar71 within eachdistal bearing22 having aninner bore72 for passage of one of theshafts18,20. Eachsupport collar71 has aninternal groove73 andshafts18,20 each have an annular groove74 (seeFIG. 1A) near their lower ends that is aligned withinternal grooves73 when the shafts are suitably mounted within frame16 (FIG. 1). Aspring clip75 is positioned within eachinternal groove73 to hold eachshaft18,20 within therespective support collar71.Spring clip74 has a discontinuity (not shown) to allow removal ofshafts18,20 upon the application of a threshold axial force on the shafts.
• To remove instrument holder4 from base6, the operator rotatestoggle switch69 to releasearm68 fromdrive belt36 and removesdrive belts28,32 fromdrives8,10. As shown inFIG. 1A, the operator holds instrument holder4 and pullsshafts18,20 upwards, providing enough force to release spring clips75.Shafts18,20 will disengage fromdistal bearings22 and slide through ball-spline bearings62,64 so that instrument holder4 is disconnected from base6. It should be understood that the invention is not limited to the above described means for removably coupling instrument holder4 to base6 and drive assembly7. For example,distal support member19 may be removably coupled to the rest offrame16 so that the surgeon simply removesmember19 and slides holder down and offshafts18,20.Proximal support member17 may be removably coupled toframe16 in a similar manner. Alternatively, the drive motors may be housed in a separate servo-box (not shown) that is removably attached to base6. In this configuration, the servo-box would be removed from base6 so that the entire base6, together with holder4, can be sterilized.
• The lower portion of base6 (including distal support member19) may also be sterilized to decontaminate those parts that come into contact with holder4 or instrument14 (e.g., by dipping the lower portion of base6 into a sterilizing bath). To facilitate this type of sterilization,shafts18,20 will preferably be somewhat longer than shown inFIG. 1 so that the upper portion of base6, including drive assembly7, is disposed sufficiently away from holder4 andinstrument14. In this manner, the surgical manipulator can be easily sterilized after a surgical procedure without damaging the drive motors or the electrical connections required for the telerobotic system.
• Instrument holder4 further includes an instrument support70 (see detail inFIG. 3A), for releasably couplingsurgical instrument14 to the manipulator assembly.Instrument support70 is rotatably mounted withinchassis60 via mountingbearings74 so thatsupport70 and the instrument can be rotated therein. As shown inFIG. 1,support70 is circumscribed by anannular ring gear76 having teeth that mesh with the teeth of adrive gear78 mounted tofirst shaft18.Drive gear78 is configured aroundfirst shaft18 such that it will rotate withfirst shaft18, thereby rotatinginstrument support70 and the surgical instrument therewith.Drive gear78 is also configured to move axially with respect tofirst shaft18 to allow axial movement of instrument holder4 with respect to frame16.
• Instrument holder4 further includes an actuator driver80 (see detail inFIG. 5) movably mounted withinaxial guide slots82 on either side ofchassis60.Actuator driver80 comprises a helical actuator84 (see detail inFIG. 6B) having a ring gear86 that meshes with agripper drive gear88 mounted tosecond shaft20. Rotation ofsecond shaft20 causes rotation ofgripper drive gear88, thereby rotating ring gear86 andhelical actuator84 withinchassis60.Actuator driver80 further includes an actuator carriage assembly90 (see detail inFIG. 6A) for releasably coupling an end effector actuator ofsurgical instrument14 to instrument holder4 (seeFIG. 2).Carriage assembly90 is mounted withinhelical actuator84 andchassis60 such that rotation ofhelical actuator84 causes. a corresponding axial movement ofcarriage assembly90 with respect tochassis60, as discussed in greater detail below.
• FIGS. 2A and 2B illustrate a specific embodiment of an endoscopicsurgical instrument14 capable of being operated by a motorized manipulator, such asmanipulator assembly2, for telerobotic surgery.Surgical instrument14 can be a variety of conventional endoscopic instruments adapted for delivery through a percutaneous penetration into a body cavity, such as tissue graspers, needle drivers, microscissors, electrocautery dissectors, etc. In the preferred embodiment,instrument14 is a tissue grasper comprising ashaft100 having aproximal end102, adistal end104 and alongitudinal axis106 therebetween. Aknurled handle114 is attached toproximal end102 ofshaft100 to facilitate manipulation ofinstrument14.
• Shaft100 is preferably a stainless steel tube having an outer diameter in the range of 2-10 mm, usually 4-8 mm, so as to fit within a cannula having an internal diameter in the range of 2-15 mm.Shaft100 can also be introduced directly through a percutaneous incision in the patient.Shaft100 has a length selected to reach a target site in a body cavity, such as the abdomen, and to extend sufficiently out of the body cavity to facilitate easy manipulation ofsurgical instrument14. Thus,shaft100 should be at least between 10 cm and 40 cm and is preferably between 17 cm and 30 cm. It should be noted that althoughshaft100 is shown as having a circular cross-sectional shape in the drawings,shaft100 could alternatively have a rectangular, triangular, oval or channel cross-sectional shape.
• In a specific configuration,shaft100 includes a mounting means for releasably couplingsurgical instrument14 toinstrument support70 and first drive8 ofmanipulator assembly2. In the preferred embodiment, mounting means comprises a pair of opposed mountingpins116 extending laterally outward fromshaft100. Mountingpins116 are rigidly connected toshaft100 and are adapted for engaging a twist-lock interface oninstrument support70, as discussed in detail below. It should be understood that the invention is not limited to a pair of opposing pins and mounting means can include a single mounting pin or a plurality of pins extending circumferentially around shaft. Alternatively, pins116 may have a variety of other shapes, such as spherical or annular, if desired.
• Instrument14 includes anend effector120 extending fromdistal end104 for engaging a tissue structure on the patient, such as the abdomen during laparoscopic surgery. In the preferred embodiment,end effector120 comprises a pair ofjaws122,124 that are movable between open and closed positions for grasping a blood vessel, holding a suture, etc.Jaws122,124 preferably have transverse grooves or other textural features (not shown) on opposing surfaces to facilitate gripping of the tissue structure. To avoid the possibility of damaging the tissue to whichjaws122,124 are applied, the jaws may also include atraumatic means (not shown), such as elastomeric sleeves made of rubber, foam or surgical gauze wrapped aroundjaws122,124.
• To movejaws122,124 between the open and closed positions,instrument14 includes an end effector actuator releasably coupled toactuator driver80 andsecond drive10 of manipulation assembly2 (seeFIG. 4). In the preferred embodiment, end effector actuator comprises a pair of opposed actuator pins132 laterally protruding from axially extendingslots134 inshaft100. Actuator pins132 are coupled to anelongate rod136 slidably disposed within an inner lumen138 ofshaft100. Actuator pins132 are slidable withinslots134 so thatrod136 is axially movable with respect toshaft100 and mountingpins116 to open andclose jaws122,124, as is conventional in the art.Elongate rod136 has aproximal portion140 that is disposed within aninner lumen142 withinshaft100 to preventactuator pins132 from moving in the laterally direction and to ensure thatrod136 remains generally centered withinshaft100 during a surgical procedure.
• Jaws122,124 are preferably biased into the closed positioned by anannular compression spring144 positioned withinshaft100 betweenactuator pins132 and anannular disc146 fixed to the inside surface ofshaft100. Dining endoscopic procedures, this allows the surgical team to introducejaws122,124 through cannula50 (or any other type of percutaneous penetration) and into the body cavity without getting stuck withincannula50 or damaging surrounding tissue.
• FIGS. 3A,3B and4 illustrate a twist lock mechanism for releasably connectingsurgical instrument14 tomanipulator assembly2 so that different instruments may be rapidly changed during an endoscopic surgical procedure. As shown inFIG. 3A,instrument support70 comprises anannular collar200 defining a.central bore202 for receivingshaft100 ofsurgical instrument14.Collar200 further defines anaxially extending slot204 in communication withbore202 and sized to allow mounting and actuator pins116,132 ofinstrument14 to slide therethrough (seeFIG. 4). Two lockingslots20′6 are cut intoannular collar200 at a transverse angle, preferably about 90°, to axially extending slot204 (note that only one of the locking slots are shown inFIG. 3A). Lockingslots206 intersect slot2.04 near the center ofannular collar200 and extend circumferentially around bore202, preferably about 90°, to allow rotation of both mountingpins116 therethrough, as discussed below.
• As shown inFIGS. 3A and 8,instrument support70 further comprises means for locking mountingpins116 into lockingslots206 so that the instrument cannot be accidently twisted and thereby disengaged frominstrument support70 during surgery. Preferably, the locking means comprises a latch assembly having aplunger210 slidably disposed within ahole212 incollar200, as shown inFIG. 3A.Plunger210 comprises an L-shapedlatch213 coupled to arelease button214 by arod215 extending throughhole212.Plunger210 is movable between a first position, wherelatch213 is not disposed within lockingslots206 so that mountingpins116 are free to rotate therethrough, and a second position, wherelatch213 is at least partially disposed within one of the lockingslots206 so as to prevent rotation of mounting pins116:Latch213 is preferably biased into the second or locked position by acompression spring216.
• Button214 is disposed on the upper surface ofsupport70 for manual actuation by the surgeon or automatic actuation by base6. Preferably, when instrument holder4 is moved to its most proximal position (seeFIG. 1),proximal support member17 offrame16 depressesrelease switch214 to movelatch213 into the first or open position. With this configuration, instruments can be exchanged only when the instrument holder4 is in the most proximal position, whereshaft100 ofinstrument14 is easily accessible. In addition, this prevents the accidental release of the instrument when its distal end has penetratedcannula50 and is disposed within the body cavity.
• The intersecting axial and lockingslots204,206 form an interface for releasablycoupling mounting pins116 ofsurgical instrument14 to instrument holder4. To insertinstrument14, the surgeon aligns mountingpins116 withaxial slot204 and slides the instrument throughbore202 ofannular collar200 until mountingpins116 are aligned with lockingslots206, as shown inFIG. 4. The instrument is then rotated a sufficient distance, preferably about a ¼ turn, through lockingslots206 so that the pins are no longer aligned withaxial slot204. Wheninstrument14 is moved distally,switch214 is released (FIG. 1) and latch213 moves into lockingslots206 to prevent mountingpins116 from rotating back into alignment withaxial slot204 so thatinstrument14 is secured toinstrument support70. It should be noted that a single mounting pin may be utilized with the above described configuration to lock the surgical instrument to the support. However, two opposing pins are preferred because this configuration reduces torsional forces on the inner surface of lockingslots206.
• As shown inFIG. 8, the locking means preferably includes aball detent217 disposed withincollar200.Ball detent217 is biased upward into one of the lockingslots206 by aspring218.Ball detent217 serves to temporarily capture mountingpins116 in a position rotated about 90° from alignment withaxial slot204. This ensures that the mounting pins will be completely rotated into the proper position (i.e., out of the way of latch213) wheninstrument14 is twisted into instrument holder. Otherwise, whenswitch214 is released,latch213 could become engaged with mountingpins216 so that the latch is unable to move completely into the locked position, thereby potentially causing the accidental release ofinstrument14 during surgery.
• As shown inFIGS. 3B,4 and5,actuator driver80 of instrument holder4 further comprises anactuator pin catch220 for releasably holding and movingactuator pins132 ofinstrument14.Actuator pin catch220 is constructed similarly to instrument support70 (FIG. 3A), comprising anannular collar222 that defines abore224 for receivingshaft100 and anaxially extending slot226 for receiving actuator pins132. Alocking slot228 is cut intoactuator pin catch220 at a 90° angle so that actuator pins can be rotated into the lock slot to coupleactuator pins132 toactuator driver66, as discussed above in reference to the mounting pins. It should be noted thatslot226 need not extend completely throughcollar222 since actuator pins132 are located distally of mounting pins116 (the instrument is preferably inserted jaws first). Of course, actuator and mountingpins132,116 may be reversed so that the mounting pins are distal to the actuator pins, if desired.
• Referring toFIG. 6A,actuator pin catch220 is rotatably mounted on aball bearing230 inactuator carriage assembly90. Bearing230 allows thepin catch220 to rotate freely incarriage assembly90 while preventing relative axial motion. Therefore, wheninstrument14 is rotated by first drive8, actuator pins132 will rotate withincarriage assembly90.Carriage assembly90 further comprises two sets of axles232 for rotatably supporting a pair ofinner rollers236 and a pair ofouter rollers238. As shown inFIG. 1,outer rollers238 are slidably disposed withinaxial guide slots82 ofchassis60 to prevent rotation ofcarriage assembly90 with respect tochassis60. Inner andouter rollers236,238 cooperate withhelical actuator84 andchassis60 of instrument holder4 to move axially with respect to the holder, thereby axially movingpin catch220 andactuator pins132 therewith relative toshaft100 of instrument14 (which actuatesjaws122,124, as discussed above).
• As shown inFIG. 6B,helical actuator84 includes acentral bore240 for receivingcarriage assembly90 andsurgical instrument14 and two opposinghelical tracks242,244 each extending circumferentially around helical actuator84 (preferably slightly less than 180°) for receivinginner rollers236 ofcarriage assembly90, as shown inFIG. 5. Withouter rollers238 constrained inaxial guide slots82 ofchassis60, rotation ofhelical actuator84 causes carriage assembly90 (and actuator pin catch220) to move up or down, depending on the sense of the rotation. Because of the symmetrical design ofhelical actuator84, the actuation force applied bysecond driver10 will not generate any effective side loads oninstrument14, which avoids frictional coupling with other degrees of freedom such as axial (third driver12) and rotation (first driver8). In the preferred embodiment;helical tracks242,244 have a pitch selected such that the mechanism can be easily back-driven, allowing grip forces to be sensed in a position-served teleoperation system.
• As shown inFIGS. 3A and 3B, instrument holder4 further includes a pair of axial guide pins250,252 fixed toinstrument support70.Actuator pin catch220 has a pair ofopenings254,256 for receiving guide pins250,252. Guide pins250,252 prevent relative rotation betweenpin catch220 and support70 (so that actuator and mountingpins116,132 can both rotate with the instrument) and allow axial movement relative to each other (so thatend effector120 can be actuated by axial movement of actuator pins132).
• FIG. 9 is an elevational view of aremote center positioner300 which can be used to supportmanipulator assembly2 above the patient (note thatsupport manipulator2 is not shown inFIG. 8).Remote center positioner300 provides two degrees of freedom forpositioning manipulator assembly2, constraining it to rotate about apoint308 coincident with the entry incision. Preferably,point308 will be approximately the center of bearing54 in cannula50 (FIG. 1). A more complete description ofremote center positioner300 is described in commonly assigned co-pending application Ser. No. 08/062,404 filed May 14, 1993 REMOTE CENTER POSITIONER, which is incorporated herein by reference.
• A first linkage means is indicated generally by the numeral321 and a second linkage in the form of a parallelogram is indicated by the numeral323. The first linkage means is pivotally mounted on a base plate for rotation about an x-x axis. The second linkage means is pivotally connected to the first linkage means and is adapted to move in a plane parallel to the first linkage. Five link members (including extensions thereof),311,312,313,314, and315 are connected together with pivot joints316-320. A portion ofelement313 extends beyondpivot320 of the parallelogram linkage. The parallelogram linkage has an operating end atlink member313 and a driving end atlink member312. Theelongated element313 may, as desired later, carry a surgical instrument or other device, such assupport bracket24 ofmanipulator assembly2. The pivot joints allow relative motion of the link members only in the plane containing them.
• A parallelogram linkage is formed by correspondinglink members314,315 andlink members312 and313. The portions oflink members314 and315 of the parallelogram are of equal length as are the portions ofmembers312 and313 of the parallelogram. These members are connected together in a parallelogram for relative movement only in the plane formed by the members. A rotatable joint generally indicated by the numeral322 is connected to asuitable base324. The rotatable joint322 is mounted on abase plate326 adapted to be fixedly mounted to the base support means324. A pivot plate328 is pivotally mounted tobase plate326 by suitable means at, such as, pivots330,332. Thus pivot plate328 may be rotated about axis x-x through a desiredangle62. This may be accomplished manually or by a suitablepivot drive motor334.
• A first linkage is pivotally mounted on the pivot plate328 of the rotatable joint322. Thelinkage elements311,312 and the link members are relatively stiff or inflexible so that they may adequately support an instrument used in surgical operations. Rods made of aluminum or other metal are useful as such links. Thelinkage elements311 and312 are pivotally mounted on base plate328 for rotation with respect to the rotatable joint bypivots336 and338. At least one of the -pivots336,338 is positioned so that its axis of rotation is normal to and intersects the x-x axis. Movement may occur manually or may occur using alinkage drive motor340. The first linkage is also shaped in the form of a parallelogram formed bylinkage elements311, and312; the portion oflink member315 connected thereto bypivots316,318; and base plate328. One of thelink members315 is thus utilized in both the first321 and second323 linkage means.Linkage element312 also forms a common link of both the first linkage means321 and the second linkage means323. In accordance with the invention, a remote center ofspherical rotation308 is provided by the above described embodiment of apparatus when thelinkage element311 is rotated and/or when pivot plate328 is rotated about axis x-x. Thus, the end ofelement313 can be moved through desired angles81 and92 or rotated about its own axis, while the remote center of rotation remains at the same location.
• FIG. 9 also shows an inclinometer350 attached to the base ofremote center positioner300. The remote center positioner may be mounted at an arbitrary orientation with respect to vertical depending on the particular surgery to be performed, and inclinometer350 can be used to measure this orientation. The measured orientation can be used to calculate and implement servo control signals necessary to control the telerobotic system so as to prevent gravitational forces acting on the system mechanisms from being felt by the surgeon.
• Reference now is made toFIG. 10 wherein the distal end portion or tip,260 of the insertion section of an endoscope is shown which is a substantially the same type as shown in the above-mentioned publication entitled “Introduction to a New Project for National Research and Development Program (Large-Scale Project) in FY 1991” which endoscope may be used in the practice of the present invention. The insertion end of the endoscope includes a pair of spacedviewing windows262R and262L and anillumination source264 for viewing and illuminating a workspace to be observed. Light received at the windows is focused by objective lens means, not shown, and transmitted through fiber-optic bundles to a pair of cameras at the operating end of the endoscope, now shown. The camera outputs are converted to a three-dimensional image of the workspace which image is located adjacent hand-operated means at the operator's station, now shown. Right and leftsteerable catheters268R and268L pass through accessory channels in the endoscope body, which catheters are adapted for extension form the distal end portion, as illustrated.End effectors270R and270L are provided at the ends of the catheters which may comprise conventional endoscopic instruments. Force sensors, not shown, also are inserted through the endoscope channels. Steerable catheters which include control wires for controlling bending of the catheters and operation of an end effector suitable for use with this invention are well known. Control motors for operation of the control wires are provided at the operating end of the endoscope, which motors are included in a servomechanism of a type described in U.S. patent application Ser. No. 07/823,932 for operation of the steerable catheters and associated end effectors from a remote operator's station. As with the other embodiments described in U.S. patent application Ser. No. 07/823,932, the interfacing computer in the servomechanism system remaps the operator's hand motion into the coordinate system of the end effectors, and images of the end effectors are viewable adjacent the hand-operated controllers. With this embodiment, the operator has the sensation of reaching through the endoscope to put his hands directly on the end effectors for control thereof. Endoscopes of different types may be employed in this embodiment of the invention so long as they include one or more accessory channels for use in control of end effectors means, and suitable viewing means for use in providing a visual display of the workspace. For example, gastric, colonscopic, and like type, endoscopes may be employed.
• Variations and changes may be made by others without departing from the spirit of the present invention. For example, it should be understood that the present invention is not limited to endoscopic surgery. In fact, instrument holder4, along with a telerobotic control mechanism, would be particularly useful during open surgical procedures, allowing a surgeon to perform an operation from a remote location, such as a different room or a completely different hospital.

Claims (22)

1. A manipulator assembly comprising:

a base,

an instrument holder removably mounted on the base, and

a drive assembly for manipulating a surgical instrument releasably coupled to the instrument holder through the instrument holder in at least two degrees of freedom comprising rotating the surgical instrument about a longitudinal axis and actuating an end effector of the surgical instrument.

2. The manipulator assembly according toclaim 1, wherein the surgical instrument is releasably coupled to the instrument holder through a twist lock mechanism.

3. The manipulator assembly according toclaim 1, wherein the surgical instrument comprises:

an elongate shaft with one or more mounting pins laterally extending from the shaft; and

the instrument holder comprises a support having a central bore, an axially extending slot for receiving the elongate shaft and the one or more mounting pins of the surgical instrument, and one or more locking slots cut into the support transversely to and in communication with the axial slot so that the one or more mounting pins can be rotated within corresponding of the one or more locking slots when received therein.

4. The manipulator assembly according toclaim 3, wherein the support further has a latch assembly for automatically locking the one or more mounting pins with the corresponding one or more locking slots to releasably couple the surgical instrument to the instrument holder.

5. The manipulator assembly according toclaim 4, wherein the latch assembly includes a latch element that is at least partially disposed within at least one of the locking slots so as to prevent rotation of the mounting pin received therein when the latch element is in a biased position, and is not disposed within any one the locking slots so that the one or more mounting pins received therein are free to rotate therethrough when latch element is in a release position.

6. The manipulator assembly according toclaim 5, wherein the latch element is maintained in the biased position by a compression spring and moved into the release position by compressing the compression spring.

7. The manipulator assembly according toclaim 1, wherein the surgical instrument comprises a shaft having a proximal end and a distal end, and a longitudinal axis defined therebetween; and the drive assembly comprises a first drive for rotating the surgical instrument around the longitudinal axis, a second drive for actuating an end effector on the distal end of the surgical instrument, and a third drive for displacing the surgical instrument along the longitudinal axis.

8. The manipulator assembly according toclaim 7, wherein the first drive, second drive and third drive are coupled to a controller mechanism via servo-control electronics for form a telerobotic system for operating the surgical instrument by remote control.

9. The manipulator assembly according toclaim 7, wherein the base comprises a frame; and the first drive comprises a rotation drive motor fixed to the frame and coupled to a first shaft by a first drive belt for rotating the first shaft with respect to the frame.

10. The manipulator assembly according toclaim 9, wherein the second drive comprises a gripper drive motor fixed to the frame and coupled to a second shaft by a second drive belt for rotating the second shaft with respect to the frame.

11. The manipulator assembly according toclaim 9, wherein the third drive comprises a vertical drive motor coupled to the instrument holder via a third drive belt and at least one pulley for axially displacing the instrument holder with respect to the frame.

12. The manipulator assembly according toclaim 10, wherein the instrument holder comprises a chassis mounted on the first shaft and the second shaft respectively via first bearings and second bearings so that the chassis may move axially with respect to the first shaft and the second shaft, but is prevented from rotating with the first shaft and the second shaft.

13. The manipulator assembly according toclaim 12, wherein the chassis includes a central cavity for receiving the surgical instrument, and a chassis arm laterally extending from the chassis and coupled to the third drive belt so that rotation of the third drive belt moves the instrument holder in the axial direction along the first shaft and the second shaft.

14. The manipulator assembly according toclaim 13, wherein the chassis arm includes a toggle switch that can be rotated to release the chassis arm from the third drive belt.

15. The manipulator assembly according toclaim 14, wherein the first bearings includes a first coupling mechanism for coupling and decoupling of the first shaft from the first bearings, and the second bearings includes a second coupling mechanism for coupling and decoupling of the second shaft from the second bearings.

16. The manipulator assembly according toclaim 15, wherein the first coupling mechanism includes a first spring clip inserted between an annular groove formed on a distal end of the first shaft and an internal groove formed in a first support collar of the first bearings so as to hold the first shaft within the first support collar, and the second coupling mechanism includes a second spring clip inserted between an annular groove formed on a distal end of the second shaft and an internal groove formed in a second support collar of the second bearings so as to hold the second shaft within the second support collar.

17. A manipulator assembly comprising:

a surgical instrument,

an instrument holder releasably coupled through a twist lock mechanism to the surgical instrument, and

a drive assembly coupled to the surgical instrument through the instrument holder for manipulating the surgical instrument in at least two degrees of freedom comprising rotating the surgical instrument about a longitudinal axis and actuating an end effector of the surgical instrument.

18. The manipulator assembly according toclaim 17, wherein the surgical instrument comprises an elongate shaft with one or more mounting pins laterally extending from the shaft; and the instrument holder comprises a support having a central bore, an axially extending slot for receiving the elongate shaft and the one or more mounting pins of the surgical instrument, and one or more locking slots cut into the support transversely to and in communication with the axial slot so that the one or more mounting pins can be rotated within corresponding of the one or more locking slots when received therein.

19. The manipulator assembly according toclaim 18, wherein the support further has a latch assembly for automatically locking the one or more mounting pins with the corresponding one or more locking slots to releasably couple the surgical instrument to the instrument holder.

20. The manipulator assembly according toclaim 19, wherein the latch assembly includes a latch element that is at least partially disposed within at least one of the locking slots so as to prevent rotation of the mounting pin received therein when the latch element is in a biased position, and is not disposed within any one the locking slots so that the one or more mounting pins received therein are free to rotate therethrough when latch element is in a release position.

21. The manipulator assembly according toclaim 20, wherein the latch element is maintained in the biased position by a compression spring and moved into the release position by compressing the compression spring.

22. (canceled)

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