Geared actuation mechanisms for surgical instruments such as for use in robotic surgical systems

Abstract

A surgical instrument configured for use with a robotic surgical system includes a housing, a shaft extending distally from the housing and including an articulating portion, an end effector assembly extending distally from the shaft and including first and second jaw members, a knife configured for translation between the jaw members, and a gearbox assembly disposed within the housing and operably coupled to the articulating portion of the shaft, the end effector assembly, and the knife. The gearbox assembly includes four rotational input gears each adapted to receive a rotational input from a robotic arm. The gearbox assembly is configured to independently articulate the end effector assembly about a first axis, articulate the end effector assembly about a second axis, move the jaw member(s) relative to the other, and translate the knife between the jaw members based upon the rotational inputs received by the four rotational input gears.

1 - 20 . (canceled) 
     
     
         21 . A gearbox assembly of a surgical instrument configured for use with a robotic surgical system, the gearbox assembly comprising:
 a plurality of input gear assemblies, each input gear assembly of the plurality of input gear assemblies adapted to receive a rotational input;   a plurality of drive shafts, wherein each input gear assembly of the plurality of input gear assemblies is configured to drive rotation of one of the drive shafts of the plurality of drive shafts;   a driver; and   a differential gear system coupled between the plurality of input gear assemblies and the driver and configured to selectively drive rotation of the driver, wherein, in response to rotational inputs of equal direction and magnitude provided to each of the input gear assemblies of the plurality of input gear assemblies, the differential gear system drives rotation of the driver, and wherein, in response to different rotational inputs to at least two input gear assemblies of the plurality of input gear assemblies, the differential gear system does not drive rotation of the driver.   
     
     
         22 . The gearbox assembly according to  claim 21 , wherein the differential gear system includes first and second differential gear assemblies coupled to respective first and second pairs of input gear assemblies of the plurality of input gear assemblies. 
     
     
         23 . The gearbox assembly according to  claim 22 , wherein the differential gear system further includes a third differential gear assembly coupled between the first and second differential gear assemblies and the driver. 
     
     
         24 . The gearbox assembly according to  claim 21 , wherein the plurality of input gear assemblies includes first, second, third, and fourth input gear assemblies. 
     
     
         25 . The gearbox assembly according to  claim 24 , wherein the plurality of drive shafts includes first, second, third, and fourth drive shafts coupled to the first, second, third, and fourth input gear assemblies, respectively. 
     
     
         26 . The gearbox assembly according to  claim 24 , wherein the differential gear system includes:
 a first differential gear assembly coupled to the first and second input gear assemblies and configured to provide a rotational output when the rotational inputs provided to the first and second input gear assemblies are of equal magnitude and direction; and   a second differential gear assembly coupled to the third and fourth input gear assemblies and configured to provide a rotational output when the rotational inputs provided to the third and fourth input gear assemblies are of equal magnitude and direction.   
     
     
         27 . The gearbox assembly according to  claim 26 , wherein the differential gear system further includes a third differential gear assembly coupled between the first and second differential gear assemblies and the driver and configured to drive rotation of the driver when the rotational outputs provided by the first and second differential gear assemblies are of equal magnitude and direction. 
     
     
         28 . The gearbox assembly according to  claim 21 , wherein the driver is a threaded driver coupled to a deployable component such that rotation of the threaded driver translates the deployable component. 
     
     
         29 . The gearbox assembly according to  claim 21 , wherein at least one drive shaft of the plurality of drive shafts is coupled to a lead screw such that rotation of the at least one drive shaft drives rotation of the lead screw. 
     
     
         30 . The gearbox assembly according to  claim 29 , wherein the lead screw includes a hub threadingly engaged thereabout, the hub engaging a cable thereto such that rotation of the at least one drive shaft pushes or pulls the corresponding cable. 
     
     
         31 . A surgical instrument configured for use with a robotic surgical system, the surgical instrument comprising:
 a housing;   a shaft extending distally from the housing, the shaft including an articulating portion;   an end effector assembly extending distally from the shaft; and   a gearbox assembly disposed within the housing, the gearbox assembly including:
 a plurality of input gear assemblies, each input gear assembly of the plurality of input gear assemblies adapted to receive a rotational input from a surgical robot; 
 a plurality of drive shafts, wherein each input gear assembly of the plurality of input gear assemblies is configured to drive rotation of one of the drive shafts of the plurality of drive shafts; 
 a driver; and 
 a differential gear system coupled between the plurality of input gear assemblies and the driver and configured to selectively drive rotation of the driver, wherein, in response to rotational inputs of equal direction and magnitude provided to each of the input gear assemblies of the plurality of input gear assemblies, the differential gear system drives rotation of the driver, and wherein, in response to rotational inputs of different direction or magnitude provided to at least two input gear assemblies of the plurality of input gear assemblies, the differential gear system does not drive rotation of the driver. 
   
     
     
         32 . The surgical instrument according to  claim 31 , wherein the plurality of input gear assemblies includes first, second, third, and fourth input gear assemblies, and wherein the plurality of drive shafts includes first, second, third, and fourth drive shafts coupled to the first, second, third, and fourth input gear assemblies, respectively. 
     
     
         33 . The surgical instrument according to  claim 32 , wherein the differential gear system includes:
 a first differential gear assembly coupled to the first and second input gear assemblies and configured to provide a rotational output when the rotational inputs provided to the first and second input gear assemblies are of equal magnitude and direction;   a second differential gear assembly coupled to the third and fourth input gear assemblies and configured to provide a rotational output when the rotational inputs provided to the third and fourth input gear assemblies are of equal magnitude and direction; and   a third differential gear assembly coupled between the first and second differential gear assemblies and the drive and configured to drive rotation of the driver when the rotational outputs provided by the first and second differential gear assemblies are of equal magnitude and direction.   
     
     
         34 . The surgical instrument according to  claim 31 , wherein the driver is a threaded driver coupled to a deployable component extending through the shaft such that rotation of the threaded driver deploys the deployable component through the shaft and relative to the end effector assembly. 
     
     
         35 . The surgical instrument according to  claim 34 , wherein the deployable component is a knife assembly including a knife cable and a knife blade disposed at a distal end portion of the knife cable. 
     
     
         36 . The surgical instrument according to  claim 31 , wherein at least one drive shaft of the plurality of drive shafts is coupled to an articulation cable that extends through the shaft and is operably coupled with the articulating portion of the shaft such that rotation of the at least one drive shaft pushes or pulls the articulation cable to thereby articulate the end effector assembly about the articulating portion of the shaft. 
     
     
         37 . The surgical instrument according to  claim 31 , wherein the end effector assembly includes first and second jaw members, at least the first jaw member movable relative to the second jaw member between a spaced-apart position and an approximated position, and wherein at least one drive shaft of the plurality of drive shafts is coupled to a cable that extends through the shaft and is operably coupled with the first jaw member such that rotation of the at least one drive shaft pushes or pulls the cable to thereby move the first jaw member relative to the second jaw member. 
     
     
         38 . A surgical instrument configured for use with a robotic surgical system, the surgical instrument comprising:
 first, second, third, and fourth input gear assemblies, each of the first, second, third, and fourth input gear assemblies adapted to receive a rotational input;   first, second, third, and fourth drive shafts, wherein the first, second, third, and fourth input gear assemblies are configured to drive rotation of the first, second, third, and fourth drive shafts, respectively;   first, second, third, and fourth cables, wherein the first, second, third, and fourth drive shafts are configured to push or pull the first, second, third, and fourth drive cables, respectively, depending upon a direction of rotation of the respective first, second, third, or fourth drive shaft;   a driver;   a fifth cable, wherein the driver is configured to push or pull the fifth cable depending upon a direction of rotation of the driver; and   a differential gear system coupled between the plurality of input gear assemblies and the driver and configured to selectively drive rotation of the driver, wherein, in response to rotational inputs of equal direction and magnitude provided to each of the input gear assemblies of the plurality of input gear assemblies, the differential gear system drives rotation of the driver to thereby push or pull the fifth cable, and wherein, in response to different rotational inputs to at least two input gear assemblies of the plurality of input gear assemblies, the differential gear system does not drive rotation of the driver such that the fifth cable is not pushed or pulled.   
     
     
         39 . The surgical instrument according to  claim 38 , wherein pushing or pulling at least one of the first, second, third, or fourth cables articulates a portion of the surgical instrument, and wherein pushing or pulling at least one other of the first, second, third, or fourth cables actuates an end effector assembly of the surgical instrument. 
     
     
         40 . is coupled to an articulation  38 , wherein pushing or pulling the fifth cable deploys or retracts a deployable component relative to an end effector assembly of the surgical instrument.