Intuitive Surgical Operations, Inc.

Daniel P Saraliev

Matthew Reagan Williams

Gabriel Francis Brisson

Melody Wu

Julie L Berry

David W Weir

Melissa D Lippiatt

Thomas G Cooper

Timothy M Vale

Mathew R Williams

William A McDonald, Iii

Techniques for reducing blade exposures include a computer-assisted device having one or more processors and a drive system comprising one or more drive units configured to be coupled to a cutting instrument. The one or more processors are configured to: measure, using one or more first sensors, a jaw angle between gripping jaws of the cutting instrument; measure, using one or more second sensors, a roll of a shaft of the cutting instrument; correct the jaw angle based on the roll of the shaft; determine a restriction on a cutting operation to be performed using the instrument based on the corrected jaw angle; and perform or prevent the cutting operation according to the restriction.

System and method for reducing blade exposures

A wrist joint comprises first and second joint features, the first joint feature having a first end surface profile defining a central protrusion, a first outer protrusion, a second outer protrusion, a first recess, and a second recess, wherein the first recess and the second recess are on opposite sides of the central protrusion and between the first outer protrusion and the second outer protrusion, and the second joint feature having a second end surface profile defining a central recess, a first outer recess, a second outer recess, a first protrusion between the central recess and the first outer recess, and a second protrusion between the central recess and the second outer recess, wherein the first protrusion and the second protrusion have an end surface profile different from the end surface profile of the first outer protrusion, the second outer protrusion, and the central protrusion.

Mechanical wrist joints with enhanced range of motion, and related devices and methods

Techniques for reducing blade exposures include one or more processors and a drive system configured to be coupled to a cutting instrument. The cutting instrument includes an end effector located at a distal end of the cutting instrument, the end effector comprising opposable gripping jaws and a cutting blade, a shaft configured to be coupled to the drive system, an articulated wrist coupling the end effector to the shaft and one or more drive mechanisms in the shaft for coupling force or torque from the drive system to the end effector and the articulated wrist. The one or more processors are configured to measure a jaw angle between the gripping jaws, measure articulation of the articulated wrist, correct the jaw angle based on the articulation of the articulated wrist, determine a cutting length based on the corrected jaw angle, and perform a cutting operation according to the cutting length.

A wrist joint, such as for a surgical instrument, may include a first disc, a second disc adjacent the first disc, a drive tendon connecting the first disc and the second disc. The first disc and the second disc may include respective opposing gear features that intermesh with one another. The first disc and the second disc may further include opposing load bearing surfaces. In response to tensioning the drive tendon, the first and second discs rotate relative to each other. The first and second discs may have a maximum rotational range of motion greater than about +/&#x2212;45 degrees relative to each other.

A surgical instrument may comprise a shaft; a wrist structure coupled to the shaft; an end effector coupled to the wrist structure; and an actuation element extending through the shaft and the wrist and coupled to the end effector. The wrist structure may be articulatable in multiple degrees of freedom relative to the shaft, and the actuation element may follow a twisted path along at least a portion of a length of the wrist structure, the twisted path having an angular extent of less than 360 degrees over the length of the wrist.

Mechanical joints, and related systems and methods

A system and method of reducing blade exposures includes a surgical cutting. The surgical cutting instrument includes an end effector located at a distal end of the surgical cutting instrument, one or more drive units, a shaft coupled to the drive unit, an articulated wrist coupling the end effector to the shaft, and one or more drive mechanisms in the shaft for coupling force or torque from the drive units to the end effector and the articulated wrist. The end effector includes opposable gripping jaws and a cutting blade. To perform a cutting operation, the surgical cutting instrument measures a jaw angle between the gripping jaws, measures articulation of the articulated wrist, corrects the jaw angle based on the articulation of the articulated wrist, determines a restriction on the cutting operation based on the corrected jaw angle, and performs or prevents the cutting operation based on the restriction.

A wrist joint, such as for a surgical instrument, may include a first disc, a second disc adjacent the first disc, and a drive tendon that extends through the first disc and the second disc. The first disc and the second disc may include respective opposing joint features that intermesh with one another. The first disc and the second disc may further include opposing load bearing surfaces separate from the joint features. The drive tendon may exert a force on at least one of the first and second discs to cause relative rotation between the first and second discs. The first and second discs may have a maximum rotational range of motion greater than about +/&#x2212;45 degrees relative to each other.

A surgical instrument may comprise a shaft comprising a wrist at a first end, an end effector coupled to the wrist, and an actuation element that extends along the shaft and the wrist. The actuation element may follow a twisted path along at least a portion of the wrist. The twisted path may have an angular extent of less than 360 degrees along an entire length of the wrist. A method of configuring a surgical instrument wrist is also contemplated, as well as a support structure for an actuation element of a surgical instrument. The support structure may comprise at least one passage defining a twisted path about a longitudinal axis of the support structure. The passage may have an angular extent of less than 360 degrees from a first end of the passage to a second end of the passage.

An actuation element guide for a surgical instrument comprises a first piece, a second piece, at least one guide channel defining a twisted path about a longitudinal axis of the guide. The guide channel may be between the inner piece and the outer piece. A cross-section of the at least one guide channel, at a location along an axial length of the guide, may be defined by a surface portion of the first piece and by a surface portion of the second piece. Exemplary embodiments further regard medical devices including an actuation element guide and methods of manufacturing an actuation element guide.

Actuation element guide with twisting channels

A surgical end effector includes a clevis and one or more jaws pivotally coupled to the clevis. At least one jaw includes a slot. An axle assembly includes a bearing axle that rotatably supports a bearing, which may be a plain bearing. An actuator coupling is coupled to the bearing axle. The bearing engages the slot such that pushing and pulling on the actuator coupling causes one jaw to close against the other jaw. The bearing axle and the jaws may be made from materials that are prone to galling and the bearing may be made from a material that resists galling. The slot may include a lip that supports the bearings in a spaced apart relationship. The bearing axle may be less than 1.5 millimeters in diameter and each bearing may be less than 3.0 millimeters in diameter.

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Soquel, CA, United States of America

Daniel P Saraliev