(12) United States Patent
`(10) Patent N0.:
`US 7,524,320 B2
`(45) Date of Patent:
`Tierney et a].
`*Apr. 28, 2009
`
`USOO7524320B2
`
`MECHANICAL ACTUATOR INTERFACE
`SYSTEM FOR ROBOTIC SURGICAL TOOLS
`
`(56)
`
`(54)
`
`(75)
`
`Inventors: Michael J. Tierney, Pleasanton, CA
`(US); Thomas G. Cooper, Menlo Park,
`CA (US); Chris A. Julian, Los Gatos.
`CA (US); Stephen J. Blumenkranz,
`Redwood City, CA (US); Gary S.
`Gnthart, Foster City, CA (US); Robert
`G. Younge, Portola Valley, CA (US)
`
`(73)
`
`Assignee:
`
`Intuitive Surgical, Inc., Sunnyvale, CA
`(US)
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 1036 days.
`
`This patent is subject to a terminal dis-
`claimer.
`
`(21)
`
`App]. N0.: 10/316,666
`
`(22)
`
`(65)
`
`(60)
`
`(60)
`
`(51)
`
`(52)
`(58)
`
`Filed:
`
`Dec. 10, 2002
`
`Prior Publication Data
`
`May 1, 2003
`US 2003/0083673 Al
`Related U.S. Application Data
`Continuation of application No. 09/929,453, tiled on
`Aug. 13, 2001, now Pat. No. 7,048,745, which is a
`division of application No. 09/418,726, filed on Oct.
`15, 1999, now Pat. No. 6,331,181.
`
`Provisional application No. 60/111,713, tiled on Dec.
`8, 1998.
`Int. Cl.
`(2006.01)
`A613 19/00
`U.S. Cl.
`........................................... 606/130; 606/1
`Field of Classification Search ..................... 606/1,
`606/130; 700/259, 260, 263
`See application file for complete search history.
`
`References Cited
`U.S. PA'I'HN'I' DOCUMENTS
`
`4,038,987 A
`
`3/1977 Komiya
`
`
`
`(Continued)
` FOREIGN PATENT DOCUMENTS
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`JP
`
`(Continued)
`()THHR PUB] .](‘,/\'1'1()NS
`
`Alexander, Arthur D., 111., “Impacts of Telemanipulation on Modern
`Society," International Centrefor Alec/"mica! Sciences, Courses and
`lectures No.201,v01.11,pp. 122-136 (Sep. 5-8, 1973).
`
`(Continued)
`
`Primary Examiner Hduardo C Robert
`Assistant Examinerilames L Swiger, III
`
`(57)
`
`ABSTRACT
`
`Robotic surgical tools, systems, and methods for preparing
`for and performing robotic surgery include a memory
`mounted on the tool. The memory can perform a number of
`functions when the tool is loaded on the tool manipulator:
`first, the memory can provide a signal verifying that the tool
`is compatible with that particular robotic system. Secondly,
`the tool memory may identify the tool-type to the robotic
`system so that the robotic system can recon [igure its program—
`ming. Thirdly, the memory of the tool may indicate tool-
`specific information, including measured calibration offsets
`indicating misalignment of the tool drive system, tool life
`data, or the like. This information may be stored in a read only
`memory (ROM), or in a nonvolatile memory which can be
`written to only a single time. The invention further provides
`improved engagement structures for coupling robotic surgi—
`cal tools with manipulator structures.
`
`31 Claims, 22 Drawing Sheets
`
`108 \
`
`
`
`Ethicon Exhibit 2003.001
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.001
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US 7,524,320 B2
`Page 2
`
`
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`STAN-CS-82-921 (1982)Chapter 9. pp. 67-77.
`Thring, “Robots and telechirs: Manipulators with memory; remote
`manipulators; machine limbs for the handicapped” (1993) M.VV.
`'1'hring/h11is Horwood Ltd. pp. 9-11, 122-131, 194-195, 235-257,
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`
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`VVO
`W0
`W0
`W0
`W0
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`WO
`VVO
`W0
`
`7/1993
`1161994
`64°95
`“/1995
`1261996
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`6999*
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`”000
`
`
`
`4.149178 A
`4.2815447 A
`4.332.066 A
`43677998 A
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`4456960 A
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`4500,065 A
`4511305 A
`4.512,709 A
`4,706.372 A
`4.710.093 A
`4744363 A
`4.751925 A
`4.7667775 A
`4793053 A
`4809,747 A
`4830569 A
`4.8327198 A
`48374703 A
`4928546 A
`4.943939 A
`4.979,949 A
`4996.975 A
`5.018,266 A
`$078,140 A
`5.086,401 A
`5,143.453 A
`5.154.717 A
`$155,693 A
`5.174,300 A
`5.184,601 A
`5217,0031 A
`5221,28} A
`5236,432 A
`5.243,266 A
`5.255.429 A
`5257998 A
`5271,384 A
`5294,209 A
`5305.203 A
`5312,212 A
`5.313935 A
`$337,732 A
`5339799 A
`5,343,385 A
`53,54,314 A
`53555743 A
`5.359.993 A
`5371147 A
`5397323 A
`53995951 A
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`5402.801 A
`514033 19 A
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`54514368 A
`55207578 A
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`5.624,398 A
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`6" 983 Sanche?
`6/ 984 Wakai
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`4/ 985 Hennekes eta].
`11/ 987 Ferrero et a1.
`12/ 987 Zimmer et a1.
`5/ 988 Hasson
`/ 988 Tonmm
`8/ 988 Hodge
`12/ 988 Zuccaro etalv
`3/ 989 Cholyctai
`5/ 989 Jannborg
`5/ 989 Alikhan
`/ 989 Kakazuetal-
`5/ 990 Walters
`7/ 990 Hoover
`12/ 990 Matsen, 111 eta].
`3/ 991 Nakamura
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`1/ 992 Kwoh
`........... 700/259
`2/ 992 Glassman et a1.
`/ 992 \Veynant née Girones
`10/ 992 Matsen. 111 etal
`101’ 992 Altmayeret 91-
`12/ 992 Bales et a1.
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`/ 993 Matsen,111etal.
`/ 993 Kasagarnietal.
`10/ 993 Nishi et a1.
`11/ 993 Our et a1.
`12/ 993 McEwen e161.
`3/ 994 Naka et a1.
`/ 994
`{Mb
`5/ 994 Naumec
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`{ortenbach et al.
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`/ 994
`iamiet 31-
`----------------- 600/117
`/ 994 JOSkOWiCZ 6t 31
`[0/ 994 dardy et al.
`10/ 994 Tesar
`11/ 994 Slater et 31-
`12/ 994
`eathl'opr Jr. et al.
`31/ 995 Taylor
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`navallee ‘51 a1.
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`)enen et al.
`/ 995 Taylor
`/ 995 M38011, HI 0‘ 81
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`:unda et a].
`/ 995 >699
`/ 995 Jacob
`5/ 996
`{CCkCIC Ct a1
`41’ 997 Chaderetal.
`4/ 997 Smith et a1.
`5/ 997 Taylor ~~~~~~~~~~~~~~~~~~~~~~~~ 128/897
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`11/ 997 Baumgarten et 31/
`12/ 997 Taylor et a1.
`12/ 997 Carol eta1.
`
`
`
`
`
`........ 318/5681
`
`* cited by examiner
`
`Ethicon Exhibit 2003.002
`
`Intuitive v. Ethicon
`
`IPR2018-01254
`
`Ethicon Exhibit 2003.002
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 1 of 22
`
`US 7,524,320 B2
`
`l50
`
`/l0
`
`F/GI/.
`
`Ethicon Exhibit 2003.003
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.003
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`A 1.28 2009
`
`Sheet2 0f22
`
`
`
`Ethicon Exhibit 2003.004
`
`UI Ive v.
`
`Icon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.004
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 3 of 22
`
`US 7,524,320 B2
`
`
`
`FIG: 2A.
`
`Ethicon Exhibit 2003.005
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.005
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 4 of 22
`
`US 7,524,320 B2
`
`
`
`
`Ethicon Exhibit 2003.006
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.006
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 5 of 22
`
`US 7,524,320 B2
`
`
`
`Ethicon Exhibit 2003.007
`
`Intuitive v. Ethicon
`
`IPR2018-01254
`
`Ethicon Exhibit 2003.007
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 6 of 22
`
`US 7,524,320 B2
`
`
`
`
`
`Ethicon Exhibit 2003.008
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.008
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 7 of 22
`
`US 7,524,320 B2
`
`
`
`Ethicon Exhibit 2003.009
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.009
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 8 of 22
`
`US 7,524,320 B2
`
`FIG.48.
`
`Ethicon Exhibit 2003.010
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.010
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 9 of 22
`
`US 7,524,320 B2
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`
`
`Ethicon Exhibit 2003.011
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.011
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 10 of 22
`
`US 7,524,320 B2
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`
`
`Ethicon Exhibit 2003.012
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.012
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 11 0f 22
`
`US 7,524,320 B2
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`
`
`Ethicon Exhibit 2003.013
`
`Intuitive v. Ethicon
`
`IPR2018-01254
`
`Ethicon Exhibit 2003.013
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 12 0f 22
`
`US 7,524,320 B2
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`
`
`Ethicon Exhibit 2003.014
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.014
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 13 of 22
`
`US 7,524,320 B2
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`
`
`Ethicon Exhibit 2003.015
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.015
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 14 0f 22
`
`US 7,524,320 B2
`
`mow POE
`LE) E36 -RED 5:57
`MH-IBBLK £53
`
`WWII-mm
`
`:HALF BRIDGE
`YEL £41
`warm m
`FORCE ssusom
`mamas PCB
`I24
`N0 “3 Ian m [42
`mum-m.‘ m .3 ._ .0
`'fi-gmlrfl g3 "m
`
`£25
`
`FWD—4A 43
`
`‘
`
`.
`
`um
`
`WI
`
`ROLUNG LOOP
`
`REED/'47
`swncu
`
`'44
`
`DALLAS CHlP
`[26
`
` (STERILE ADAPTOR}
`
`+ SIG)
`
`- SIG)
`BET)
`SHIELD‘
`
`+sm>
`
`-$G>
`RET>
`SHIELD
`
`DALLAS
`- STERIL E>
`(5N0>
`SHIELD)
`DA
`.TOOL
`cuo>
`5mm»
`
`mm-
`E3I
`“2
`
`'
`
`V
`.
`
`I
`TOOL-EXPIRED)SEE E23E!
`
`TOOL-EXPIRED)
`
`E43
`RED
`,
`TOOL-CHAN-5w >
`[ILL-23f
`TOOLcum-Gun.swap
`TOOL-CHANGE-an “E“ [Ellin-
`am» an: “ES!- 1"”
`I 1001.CHANGE swncn
`
`'
`
`E47
`SLAVLCLUTDH SW> RED E25
`‘
`BK -[Z1':- '7
`“"0 - SLAVE CLUTGHING SWITCH
`
`FIG. 8.
`
`Ethicon Exhibit 2003.016
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.016
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 15 of 22
`
`US 7,524,320 B2
`
`
`
`FIG 8A.
`
`Ethicon Exhibit 2003.017
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.017
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 16 0f 22
`
`US 7,524,320 B2
`
`126
`
`TOOL
`
`DALLAS
`
`N
`
`MAGNET
`
`SA DALLAS
`
`144
`
`REED'
`
`SWITCH.
`
`147
`
`—>
`
`RIA
`
`->
`
`RIA
`
`FIG.9.
`
`Ethicon Exhibit 2003.018
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`(2
`a)
`0)
`<1:
`
`
`
`Io
`
`54
`
`TOOL 149
`
`SA
`
`CARRIAGE
`
`RIA
`
`58128
`
`56
`
`152
`
`Ethicon Exhibit 2003.018
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 17 of 22
`
`US 7,524,320 B2
`
`
`
`
`MIDDLEMAN (CTP)
`
`
`
`CONTRgthbOG'CAL
`INSTRUCTIONS FROM
`
`
`
`
`SUPERVISOR (UMC)
`
`EXECUTES
`
`
`
`SUPERVISOR
`
`
`
`PROCEDURE
`
`
`
` KERNEL (CTP AND CES)
`MANAGEMENT/DATA
`
`
`
`HANDLER (MDC)
`
`
`
`
`
`LOCAL TOOL
`
`
`DETECTION (RIA)
`
`
`FIG. 10.
`
`Ethicon Exhibit 2003.019
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.019
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 18 of 22
`
`US 7,524,320 B2
`
`SEQUENCE FLOW
`
`DETAILED SEQUENCE
`BLOCKS
`
`® 147
`
`
`REED
`SWITCH
`LOSED*
`
`REED
`SWITCH
`OPEN
`
`
`
`* - SIGN|F|ES MESSAGE SENT @
`HARDWARE STATE ®
`
`TO INDICATE CHANGE IN
`
`CHECK
`FOR
`TOOL
`
`TOOL DALLAS
`PRESET’
`
`
`
`TOOL DALLAS
`NOT PRESENT‘
`
`148
`
`
`
`
`FIG. 11.
`
`Ethicon Exhibit 2003.020
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.020
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 19 of 22
`
`US 7,524,320 B2
`
`POWER ON
`
`INITIALIZATION
`
`
`
`
`
`
` TOOL IS
`BEING INSERTED
`
`(S4)
`
`
` TOOL IS
`Initialization
`OUT (52)
`
`complete
`Sterile ad .ter engaged
`
`
`
`Sadapter D chip
`
`
`
`
`STERILE
`ADAPTER
`
`OFF (31)
`
`111
`
`D = Dallas chip ( 1 = present, 0 = not present)
`E = End of use indicator (0 = Open, 1 = Shorted)
`R = Reed Switch ( 0: open, 1 = shorted)
`
`
`
`
`Events occur in DER order
`
`9.9. 101 means Dallas chip present, End of use
`indicator is open, Reed switch is closed)
`
`
`
`
`A=110,100,010,110,101,111
`B=011, 101,001
`C=001,010,011,100,101, 110,111
`FIG. 12.
`
`
`Logging occurs if the situation
`
`persists for more than 1 second
`
`
`
`Ethicon Exhibit 2003.021
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.021
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 20 Of 22
`
`US 7,524,320 B2
`
`TOOL
`CHANGE
`
`B
`
`CAM
`CHANGE
`DONE
`
`CHK 2
`
`CHANGE
`DONE
`
`TOOL
`FOLLOW
`CHK1
`
`TOOL
`FOLLOW
`
`Ethicon Exhibit 2003.022
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.022
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 21 0f 22
`
`US 7,524,320 B2
`
`
`
`Ethicon Exhibit 2003.023
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.023
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`U.S. Patent
`
`Apr. 28, 2009
`
`Sheet 22 0f 22
`
`US 7,524,320 B2
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`166
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`ALGORITHM
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`162
`
`
`
`1
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`64
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`TOOL PRODUCTION
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`TOOL COMPATIBILITY VERIFICATION
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`166
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`ALGORITHM
`
`
`
`170
`
`TOOL
`
`PROCESSOR
`
`FIG. 15.
`
`Ethicon Exhibit 2003.024
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.024
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US 7,524,320 B2
`
`1
`MECIIANICAL ACTUATOR INTERFACE
`SYSTEM FOR ROBOTIC SURGICAL TOOLS
`
`
`CROSS-REFERENCES TO RELATED
`APPLICATIONS
`
`The present application is a continuation of US. patent
`application Ser. No. 09/929,453 filed onAug. 13, 2001, and is
`a divisional application of U.S. patent application Ser. No.
`09/759,542 filed Jan. 12, 2001, now U.S. Pat. No. 6,491,701,
`which is a continuation application ofU.S. patent application
`Ser. No. 09/418,726 filed Dec. 6, 1999, and in tum also claims
`priority to U.S. Provisional Patent Application No. 60/111,
`713 filed on Dec. 8, 1998; U.S. patent application Ser. No.
`09/398,958 filed Sep. 17, 1999, now U.S. Pat. No. 6,394,998;
`and U.S. Provisional Patent Application No. 60/1 16,844 filed
`on Jan. 2, 1999, entitled “Surgical Tools For Use In Mini—
`mally Invasive Telesurgical Applications”. The entirety ofthe
`above-referenced applications is herein incorporated by ref-
`erence.
`
`This application also incorporates by references the fol-
`lowing U.S. Design patent application Ser. Nos. 29/097,544
`filed on Dec. 8, 1998, entitled “Portion OfAn Interface ForA
`Medical Instrument”; 29/097,552 filed on Dec. 8, 1998,
`entitled “Interface For A Medical Instrument”; 29/097,550
`filed on Dec. 8, 1998, entitled “Portion OfAnAdaptor ForA
`Medical Instrument”; and 29/097,551 filed on Dec, 8, 1998,
`entitled “Adaptor For A Medical Instrument”.
`
`BACKGROUND OF THE INVENTION
`
`This invention relates to robotically assisted surgery, and
`more particularly provides surgical tools having improved
`mechanical and/or data interface capabilities to enhance the
`safety, accuracy, and speed of minimally invasive and other
`robotically enhanced surgical procedures.
`In robotically assisted surgery, the surgeon typically oper-
`ates a master controller to remotely control the motion of
`surgical instruments at the surgical site. The controller may be
`separated from the patient by a significant distance (e.g.,
`across the operating room, in a different room, or in a corn—
`pletely different building than the patient). Altematively, a
`controller may be positioned quite near the patient in the
`operating room. Regardless,
`the controller will typically
`include one or more hand input devices (such as joysticks,
`exoskeletol gloves, master manipulators, or the like) which
`are coupled by a servo mechanism to the surgical instrument.
`More specifically, servo motors move a manipulator or
`“slave” supporting the surgical instrument based on the sur—
`geon’s manipulation of the hand input devices. During an
`operation, the surgeon may employ, via the robotic surgery
`system, a variety of surgical instruments such as tissue grasp—
`ers, needle drivers, electrosurgical cautery probes, etc. Each
`of these structures perfonns functions for the surgeon, for
`example, holding or driving a needle, grasping a blood vessel,
`or dissecting, cauterizing, or coagulating tissue.
`This new method of performing robotic surgery has, of
`course, created many new challenges, One such challenge is
`that a surgeon will typically employ a significant number of
`different surgical instruments during each surgical procedure.
`The number of independent surgical manipulators will often
`be limited due to space constraints and cost. Additionally,
`patient trauma can generally be reduced by eliminating the
`number of tools used at any given time. More specifically, in
`minimally invasive procedures, the number ofentry ports into
`a patient is generally limited because of space constraints, as
`well as a desire to avoid umiecessary incisions in the patient.
`
`I 0
`
`15
`
`30
`
`35
`
`40
`
`45
`
`mm
`
`60
`
`2
`Hence, a number of different surgical instruments will typi-
`cally be introduced through the same trocar sleeve into the
`abdomen during,
`for example,
`laparoscopic procedures.
`Likewise, in open surgery, there is typically not enough room
`adjacent the surgical site to position more than a few surgical
`manipulators, particularly where each manipulator/tool com—
`bination has a relatively large range of motion. As a result, a
`number of surgical instruments will often be attached and
`detached from a single instrument holder of a manipulator
`during an operation.
`Published PCT application WO98/25 666, filed on Dec. 10,
`1997 and assigned to the present assignee (the full disclosure
`of which is incorporated herein by reference) describes a
`Multicomponent Telepresence System and Method which
`significantly improves the safety and speed with which
`robotic surgical tools can be removed and replaced during a
`surgical procedure. While this represents a
`significant
`advancement of the art, as is often true, still further improve-
`ments would be desirable. In particular, each tool change
`which occurs during a surgical procedure increases the over—
`all surgery time. While still further improvements in the
`mechanical tool/manipulator interface may help reduce a por-
`tion of this tool change time, work in connection with the
`present invention has shown that the mechanical removal and
`replacement ofthe tool may represent only one portion ofthe
`total interruption for a tool change. U.S. Pat. No. 5,400,267
`describes a memory feature for electrically powered medical
`equipment. and is also incorporated herein by reference.
`As more and more different surgical tools are provided for
`use with a robotic system, the differences between the tool
`structures (and the interaction between the tool and the other
`components of the robotic system) become more pro-
`nounced. Many of these surgical tools will have one or more
`degrees of motion between the surgical end effectors and the
`proximal interface which engages the tool to the holder ofthe
`manipulator. The desired and/or practicable ranges ofmotion
`for an electrosurgical scalpel may be significantly different
`than those of a clip applier, for example. Work in connection
`with the present invention has found that even after a tool is
`properly placed on the surgical manipulator,
`the time
`involved in reconfiguring the robotic system to take advan—
`tage of a different tool. and to perfect the master eontroller’ s
`effective control over the degrees of motion of the tool, may
`add significantly to the total tool change delay.
`In light of the above,
`it would be desirable to provide
`improved robotic surgery tools, systems, and method. It
`would further be desirable to provide teclmiques for reducing
`the total delay associated with each tool change. It would be
`especially desirable if these enhanced, and often more rapid,
`robotic tool change techniques resulted in still
`further
`improvement in the safety and reliability of these promising
`surgical systems.
`
`BRIEF SUMMARY OF THE INVENTION
`
`The present invention generally provides improved robotic
`surgical devices, systems, and methods for preparing for and
`performing robotic surgery. The robotic tools of the present
`invention will often make use of a memory structure mounted
`on a tool, manipulator ann, or movable support structure. The
`memory can, for example, perform a number of important
`functions when a tool is loaded on the tool manipulator: first.
`the memory can provide a signal verifying that the tool is
`compatible with that particular robotic system. Secondly, the
`tool memory may identify the tool-type (whether it is a seal-
`pel, needle grasper, jaws, scissors, clip applier, electrocautery
`blade, or the like) to the robotic system so that the robotic
`
`Ethicon Exhibit 2003.025
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.025
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US 7,524,320 B2
`
`
`
`4
`3
`In many embodiments, compatibility of the component
`system can reconfigure its programming to take full advan-
`with the robotic surgical system will be verified using the
`tage of the tools’ specialized capabilities. This tool-type data
`signal transmitted from the component to the processor. This
`may simply be an identification signal referencing firrther
`can be accomplished by providing unique identification data
`data in a look-up table ofthe robotic system. Alternatively, the
`5 on the component, and deriving verification data from the
`tool-type signal provided by the tool may define the tool
`identification data according to an algorithm. The verification
`characteristics in sufficient detail to allow reconfiguration of
`data is stored with a memory of the component, the signal
`the robotic programming without having to resort to an exter-
`transmitted to the processor including both the identification
`nal table. Thirdly, the memory of the tool may indicate tool-
`and verification data. The algorithm may then be performed
`specific information, including (for example) measured cali-
`10 onthe transmitted uniqueidentification data withthe proces—
`bration offsets indicating misalignment between the tool
`sor, and the results compared with the verification data.
`drive system and the tool end effector elements, tool life data
`Advantageously, this method can take advantage of unique
`(such as the number of times the tool has been loaded onto a
`identification data which is often unalterably stored in a
`surgical system,
`the number of surgical procedures per—
`memory of commercially available integrated circuits.
`formed with the tool, and/or the total time the tools has been
`In another aspect, the invention provides arobotic surgical
`used), or the like. The information may be stored in some 15
`tool for use in robotic surgical systems having a processor.
`form of non—volatile memory such as one—tilne program—
`The tool comprises a shaft having a proximal end and a distal
`mable EPROM, Flash EPROM, EEPROM, battery—backed—
`end.A surgical end effector is disposed adjacent the distal end
`up SRAM, or similar memory technology where data can be
`of the shaft. The end effector has a plurality of degrees of
`updated and retained in either a serial or random access
`methor , or with any ofa wide variety ofalternative hardware, 20 motion relative to the proximal end. An interface is disposed
`firmware, or software. The invention further provides
`adjacent the proximal end of the shaft. The interface can be
`improved engagement structures for coupling robotic surgi-
`releasably coupled with a robotic probe holder. The interface
`cal tools with manipulator structures.
`comprises a plurality of driven elements. A plurality of tool
`In a first aspect, the invention provides a robotic surgical
`drive systems couple the driven elements to the degrees of
`tool for use in a robotic surgical system. The robotic surgical
`motion of the end effector. The tool drive system has calibra-
`system has a processor which directs movement of a tool
`tion offsets between a nominal relative position of the end
`effector and the driven elements, and a measured relative
`holder. The tool comprises a probe having a proximal end and
`a distal end. A surgical end effector is disposed adjacent the
`position of the end effector and driven elements. A memory
`distal end ofthe probe. A11 interface is disposed adjacent to the
`stores data indicating the offsets. The memory is coupled to
`proximal end of the probe. The interface can be releasably
`the interface so as to transmit the offsets to the processor.
`coupled with the tool holder. Circuitry is mounted on the
`In yet another aspect, the invention provides a robotic
`probe. The circuitry defines a signal for transmitting to the
`surgical system comprising a plurality of tools of different
`
`processor so as to indicate compatibility of the tool with the
`tool-types. Each tool comprises an elongate shaft with a
`system.
`cross—section suitable for introduction into an internal surgi—
`The tool will often comprise a surgical instrtunent suitable 35 cal site within a patient body via a minimally invasive open-
`for manipulating tissue, an endoscope or other image capture
`ing. A distal surgical end effector is coupled to the shaft by at
`device, or the like. Preferably, the signal willcomprise unique
`least one joint. The joint is drivingly coupled to a proximal
`tool identifier data. The processor of the robotic surgical
`interfaceby atool drive system. Circuitry ofthe tool transmits
`system may include programming to manipulate the tool
`a tool-type via the interface. The tool types may optionally
`identifier according to a pre—deterrnined function or algorithm 40 differ in at least one characteristic such as joint geometry, end
`so as to derive verification data. The signal transmitted to the
`effector geometry, drive system characteristics, end effector
`processor will often include the verification data. Altemative
`or drive system strength, or the like. The system also includes
`compatibility signals may include a signal which is listed in a
`a robotic manipulator including a linkage supporting a tool
`table accessible to the processor, an arbitrary compatibility
`holder. The tool holder releasably receives the interface. A
`data string. or the like.
`manipulator drive motor drivingly engages the linkage so as
`In another aspect, the invention provides a robotic surgical
`to move the tool holder relative to the opening and position
`component for use in a robotic surgical system having a
`the shaft within the surgical site. A tool drive motor is coupled
`processor and a component holder. The component comprises
`to the tool holder so as to drivingly engage the tool drive
`a component body having an interface mountable to the com-
`system and articulate the joint. A processor is coupled to the
`ponent holder. The body supports a surgical end effector, and
`tool holder. The processor has programming that effects a
`a drive system is coupled to the body for moving the end
`desired movement of the end effector by transmitting drive
`effector per commands from the processor. Circuitry is
`signals to the tool drive motors of the manipulator. The pro-
`mounted on the body and defines a signal for transmitting to
`cessor reconfigures the program for the different joint geom-
`the processor. The signal may indicate compatibility of the
`etries based on the tool—type signals.
`component with the system, may define a component type of
`In another aspect, the invention provides a robotic surgical
`the component, may indicate coupling of the component to
`system comprising a surgical tool having a surgical end effec-
`the system, and/or may indicate calibration ofthe component.
`tor and an interface. A manipulator assembly has a base and a
`Typically, the component will comprise a surgical tool, a
`tool holder for releasably engaging the interface. A plurality
`manipulator arm, a pre-positioning linkage supporting the
`of tool engagement sensors are coupled to the tool holder.
`manipulator ami, or the like.
`Each tool sensor produces a signal when the interface engages
`In another aspect, the invention provides a method for
`the holder. A processor is coupled to the tool engagement
`installing a robotic surgical component in a robotic surgical
`sensors. The processor has a tool change mode and a tissue
`system. The method comprises mounting the component to a
`manipulation mode. The processor requires tool signals from
`component holder. A signal is transmitted from the cornpo—
`each of the sensors before changing the tool change mode to
`nent to a processor of the robotic surgical system. The com-
`the tissue manipulation mode. The processor remains in the
`ponent is articulated in response to the signal per commands
`tissue manipulation mode when at least one, but not all, ofthe
`of the processor.
`tool signals is lost.
`
`30
`
`45
`
`mm
`
`60
`
`Ethicon Exhibit 2003.026
`
`Intuitive v. Ethicon
`
`lPR2018-01254
`
`Ethicon Exhibit 2003.026
`Intuitive v. Ethicon
`IPR2018-01254
`
`

`

`US 7,524,320 B2
`
`5
`The tools used in robotic surgery will be subjected to
`significant structural stress during use. The stress may result
`in temporary loss of an engagement signal from an engage—
`ment sensor. By providing at least two, and preferably three
`engagement sensors,
`the surgical procedure can continue
`safely with the loss of an engagement signal from an indi—
`vidual sensor so long as the system can still verify proper
`engagement between the manipulator and tool. This arrange-
`ment results in a robust tool engagement sensing system that
`avoids frequent delays during the surgical procedure as might
`occur from the loss of an individual signal.
`In yet another aspect, the invention provides a robotic
`surgical system comprising a manipulator assembly having a
`base and tool holder which moves relative to the base, The
`tool holder has a plurality of drive elements. A sterile drape
`covers at least a portion of the manipulator. A sterile tool has
`a proximal interface and distal end effector. The distal end
`effector has a plurality of degrees of motion relative to the
`proximal interface. The degrees of motion are coupled to
`drive elements of the interface An adapter is disposed adja—
`cent the sterile drape between the holder and the interface.
`The adapter comprises a plurality of movable bodies. Each
`movable body has a first surface driven by the drive elements
`of the holder, and a second surface driving the driven ele-
`ments of the tool.
`In yet another aspect, the invention provides a robotic
`surgical tool for use with a robotic manipulator having a tool
`holder. The tool holder has magnetically aetuatable circuitry.
`The tool comprises a probe having a proximal end and a distal
`end. A surgical end effector is disposed adjacent the distal end
`of the probe. An interface adjacent the proximal end of the
`probe is re easably coupleable with the holder. The interface
`comprises a magnet positioned so as to actuate the circuitry of
`the holder.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`
`
`FIG. 1 i lustrates a robotic surgical procedure in which a
`surgeon at a master station directs movement of robotic sur—
`gical tools effected by a slave manipulator, and shows an
`assistant preparing to change a tool mounted to a tool holder
`of the slave.
`FIG. 2 is a perspective view of a robotic surgical arm cart
`system in which a series of passive set-up joints support
`robotically actuated manipulators (typically, the center arm
`would support a camera).
`FIG. 2A is a perspective view of a robotic surgical manipu-
`lator for use in the cart system of FIG. 2.
`FIGS. 2B and C are side and front views, respectively, of
`the linkage ofthe robotic manipulator ofFIG. 2, showing how
`the manipulator maintains a remote center ofrotation along a
`shaft of the surgical tool.
`FIGS. 3 and 3A are perspective views of exemplary cart
`structures with positioning linkages which support
`the
`robotic manipulators in the system of FIG. 2.
`FIG. 4 is a perspec