Surgical device and component having movable plug portions

Abstract

A surgical device (2) having a distal end and a proximal end, and comprising a delivery portion (12) extending from the proximal end and comprising first and second instrument delivery channels, an active portion (4,8) at a distal portion of the device and a plug (10) having a proximal end and a distal end, and engageable with the delivery portion at its proximal end, and with the active portion at its distal end, the plug comprising first and second plug channels (82) each defining a curved path, such that the plug channels diverge from one another towards the distal end of the plug wherein when the plug is engaged with the delivery portion the first plug channel and the first instrument delivery channel form a first instrument channel and the second plug channel and the second instrument delivery channel form a second instrument channel.

Claims

1. A surgical device having a distal end and a proximal end, and comprising: a delivery portion extending from the proximal end; first and second instrument delivery channels formed in, and extending through, the delivery portion; an active portion at a distal portion of the device; and a plug having a proximal end and a distal end, positionable between the delivery portion and the active portion, and engageable with the delivery portion at the proximal end of the plug, and with the active portion at the distal end of the plug, to thereby releasably connect the delivery portion to the active portion, wherein the plug includes a first plug portion in which a first plug channel is formed and a second plug portion in which a second plug channel is formed, the first and second plug channels each defining a curved path, such that the plug channels diverge from one another towards the distal end of the plug, wherein, when the plug is engaged with the delivery portion, the first plug channel and the first instrument delivery channel form a single continuous first instrument channel and the second plug channel and the second instrument delivery channel form a single continuous second instrument channel, and wherein the first and second plug portions are moveable relative to one another.

2. A surgical device according to claim 1 further comprising a first instrument arm adapted to be inserted into the first instrument channel, and a second instrument arm adapted to be inserted into the second instrument channel.

3. A surgical device according to claim 2 wherein each instrument arm comprises three sections: a distal section with two directional flexibility and actuatability in two planes; a middle section with one directional flexibility; and a proximal section.

4. A surgical device according to claim 3 wherein each instrument arm comprises a superelastic Nitinol tube.

5. A surgical device according to claim 4 wherein each instrument arm is driveable by at least one tendon attachable to a distal end of the instrument arm and extending along the arm to the proximal end thereof.

6. A surgical device according to claim 5 wherein each instrument arm accommodates an interchangeable instrument.

7. A surgical device according to claim 6 wherein the interchangeable instrument is flexible while capable of delivering torque using hollow flexible multi-headed shaft.

8. A surgical device according to claim 7 comprising a third instrument delivery channel formed in the delivery portion, and a third plug channel formed in the plug, the third instrument delivery channel and the third plug channel forming a third instrument channel when the plug is engaged with the delivery portion.

9. A surgical device according to claim 7 comprising a further delivery channel formed in the delivery portion, and a further plug channel formed in the plug, the further delivery channel and the further plug channel forming a device channel.

10. A device according to claim 7 wherein the active portion comprises a deployment section and an articulated section.

11. A surgical device according to claim 10 wherein the articulated section comprises a plurality of articulated universal joints and/or single degree freedom joints.

12. A surgical device according to claim 11 wherein the articulated section comprises one or more micromotors embedded in one or more or all of the joints.

13. A surgical device according to claim 12 wherein the deployment section comprises a plurality of joints pivotally linked to one another to form a continuous flexible section.

14. A surgical device according to claim 13 wherein the flexible section comprises one or more tendons adapted to drive the flexible section between a non-deployed position in which the flexible section extends in substantially the same plane as that in the delivery portion, and a shifted, deployed position in which the flexible section extends away from the plane of the delivery portion.

15. A surgical device according to claim 14 wherein the flexible section is adapted to carry a camera and/or light sources at its proximal end.

16. A device according to claim 15 further comprising a locking mechanism for locking the flexible section in any position.

17. A device according to claim 16 wherein the delivery portion is flexible.

18. A device according to claim 17 wherein the delivery portion comprises a plurality of links arranged to allow flexible movement of the delivery portion, and a flexible material adapted to extend between the links.

19. A device according to claim 18 wherein the rotational axes between links are defined by cylindrical surfaces of the delivery portion.

20. A component for a surgical device the component comprising a delivery portion comprising first and second instrument delivery channels extending through the delivery portion, and a plug engageable with the delivery portion at a proximal end of the plug, which plug comprises first and second plug channels each defining a curved path, such that the plug channels diverge from one another towards a distal end of the plug when the plug is engaged with the delivery portion, and wherein the first plug channel and the first instrument delivery channel form a first instrument channel and the second plug channel and the second instrument delivery channel form a second instrument channel, wherein the plug comprises a first plug portion in which a first plug channel is formed and a second plug portion in which a second plug channel is formed, the first and second plug channels each defining a curved path, such that the plug channels diverge from one another toward the distal end of the plug and wherein, when the plug is engaged with the delivery portion, the first plug channel and the first instrument delivery channel form a single continuous first instrument channel and the second plug channel and the second instrument delivery channel form a single continuous second instrument channel, and wherein the first and second plug portions are moveable relative to one another.

21. A component according to claim 20 wherein the delivery portion is flexible.

22. A component according to claim 21 wherein the delivery portion comprises a plurality of links arranged to allow flexible movement of the delivery portion, and a flexible material adapted to extend between the links.

23. A component according to claim 22 wherein the rotational axes between links are defined by cylindrical surfaces of the delivery portion.

Description

(1) The invention will now be further described by way of example only with reference to the accompanying drawings in which:

(2) FIG. 1 is a schematic representation of surgical tool according to an embodiment of the invention;

(3) FIGS. 2a and 2b are schematic representations showing details of an articulated robotic section forming part of the device of FIG. 1;

(4) FIG. 3 is a schematic representation showing more details of a drive unit forming part of the device of FIG. 1;

(5) FIG. 4a is a schematic representation of a plug forming part of the device of FIG. 1 showing details of the path along which motor and signal wires extend;

(6) FIG. 4b is schematic representation of the plug shown in FIG. 4a showing details of two instrument channels extending along the plug; and

(7) FIG. 4c is a cross section representation of the plug of FIG. 4a showing an additional channel;

(8) FIG. 5 is a schematic representation of a plug according to another embodiment of the invention and formed from two plug portions;

(9) FIG. 6 is schematic representation showing how axial translation of one plug portion relative to the other of the plug shown in FIG. 5 can result in independent movement of instruments carried in the plug;

(10) FIG. 7 is a cross section representation of a delivery portion forming part the device of FIG. 1;

(11) FIGS. 8 to 10 are partial schematic representations of a portion of delivery portions according to embodiments of the invention resulting in different levels of flexibility of the delivery portion;

(12) FIGS. 11 and 12 are schematic representations showing in more detail a cross-section of the delivery portion and showing a possible link design;

(13) FIG. 13 is a schematic representation of an instrument in the form of an overtube forming part of the device of FIG. 1;

(14) FIG. 14 is a schematic representation showing a portion of the over tube of FIG. 6 forming part of a manipulator that may be used with the device of FIG. 1;

(15) FIG. 15 is a schematic representation of an instrument comprising gripper that may form part of the device of FIG. 1;

(16) FIG. 16 is a schematic representation of a hollow flexible shaft may be used for the instrument of FIG. 15; and

(17) FIG. 17 is a schematic representation showing in more detail lights and cameras forming part of the device of FIG. 1.

(18) A device according to an embodiment of the invention is shown schematically in FIG. 1 and is designated generally by the reference numeral 2. The device 2 comprises a surgical device suitable for use by a surgeon or other skilled person in minimally invasive surgery.

(19) The device 2 comprises a proximal end 3 and a distal end 5. An active portion of the device comprising an articulated robotic section 4 is formed at the distal end 5 of the device 2 and comprises a tendon driven flexible section 8. During use of the device, a surgeon manipulates the active portion remotely in order to carry out MIS. The device 2 further comprises a delivery portion comprising a hollow shaft 12, a back interface unit 14, and a plug 10 forming an interface between the active portion and the delivery portion. As will be described in more detail below, the delivery portion delivers signals, wires and instruments, for example, to the active portion of the device 2 in order that the active portion may be operated remotely. The plug 10 serves to connect the delivery portion to the active portion.

(20) A universal joint 7 having multiple degrees of freedom is located at a distal end of the robotic section and allows relative motion between the delivery portion and the active portion.

(21) A yaw joint 9 is located at the proximal end of the robotic section 4 and allows one degree of freedom of movement.

(22) The robotic section can also be formed of two or more universal joints, or any combination of universal joints and single degree of freedom joints.

(23) The active section may, in one embodiment comprise a two degrees of freedom universal joint and a single degree of freedom yaw joint. In such an embodiment, each degree of freedom can be actuated by 45.

(24) The purpose of the active section to visualise the operation site or to deliver additional instruments to the site.

(25) This means that the neutral position of the universal joint is arranged to angle downwards by 30. As a result, the travel range of the universal joint is +15 to 75 in a vertical plane and 45 in the horizontal plane. The yaw joint may also travel 45 and therefore the travel range of the articulated robotic section 4 is 90 horizontally and +15 to 75 vertically in such an embodiment.

(26) In other embodiments, different arrangements may be appropriate.

(27) The device further comprises interchangeable instruments 20 which form part of the active device during deployment of the device.

(28) The active portion of the device further comprises cameras 22, 24 for enabling visualization of the area in which the procedure is carried out within a patient's body, for example. One camera, or group of cameras 22 is located at a distal tip of the articulated robotic section 4, whist the other camera or group of cameras 24 is located at an opposite end of the flexible section 8 to provide a broader view of the operation site.

(29) Illumination is provided by LEDs 26, 28 although of course other light sources could be used if appropriate.

(30) The LEDs 26, 28 may be positioned at any convenient location, and this embodiment are positioned at a proximal end of the flexible section 8, and the distal end of the articulated section respectively.

(31) The device 2 as illustrated in FIG. 1 is shown in a deployed position in which the flexible section 8 of the robotic section 4 is positioned generally above the body of the device 2 and is in the form of a Goose Neck. Further, the inter-changeable instruments 20 are ready for use.

(32) Before the device 2 is placed in a deployed position, the robotic section 4 may lie substantially in the same plane as the hollow shaft 12, and the inter-changeable instruments 20 may either have not yet been inserted, or if inserted remain within the hollow shaft 12.

(33) Once the device has been inserted into the patient's body, and sufficient workspace has been created, the device may be placed in its deployed position by lifting the flexible section 8 and positioning the instruments 20 so that they are exposed and ready for use.

(34) Each of the components of the device 2 will now be described in more detail with reference to the appropriate drawings.

(35) Referring now to FIGS. 2a and 2b the flexible section 8 also known as the Goose Neck is shown in more detail. In FIG. 2a the flexible section 8 is in the un-deployed position, and in FIG. 2b it is in the deployed position. The flexible section 8 comprises a plurality of modules 40 linked together by pivot pins 42 joining two adjacent modules 40.

(36) The device 2 further comprises tendons 44, which extend from the tendon driving unit 16 to the flexible section 8 for driving the flexible section 8. A first pair of tendons 44 extends to fixation points 46, 48 on the flexible section 8; whilst a second pair of tendons 44 extends to fixation points 50, 52 also on the flexible section. As can be seen from FIG. 2a particularly, the fixation points 46, 48 are located in a middle portion of the flexible section 8, and the fixation points 50, 52 are located at a distal end of the flexible section 8.

(37) By actuating the two pairs of tendons individually, an S shape may be formed. This lifts the distal section 54 of the device 2 creating the so called Goose Neck, and placing the device in the deployed position.

(38) Referring now to FIG. 3, the tendon driving unit 16 is shown in more detail. The driving unit comprises a plurality of sub-units that each drives one pair of tendons. One sub unit is described in more detail with reference to FIG. 3. The sub-unit comprises a driving knob 60 a first gear 64 attached to a driving rod 66, and a second gear 70 attached to a body 72 of the unit 16. As can be seen from the Figures, there is a gap 62 along the teeth of the knob 60. This means that any gear positioned in the knob and located in this gap will be disengaged. The dimensions of the knob and the dimensions and positions of the gears 64, 70 are such that when the driving knob is engaged with the gear 64 the gear 70 will be located in the gap and will therefore be disengaged. This means that the rod 66 will rotate with the driving knob. As a result it drives the tendons 44 which are wrapped around the rod 66 to actuate the flexible section 8 and to place it to the deployed position shown in FIG. 2b.

(39) If the driving knob 60 is driven further in, both the gear 64 and gear 70 are engaged with the knob. Because the gear 70 is attached to the body 72 of the driving unit 16, the rod 66 and the driving knob 60 are locked with the gear 70. This results in the flexible section being locked.

(40) In further embodiments of the invention, there may be more than two pairs of tendons 44, which may terminate at different locations to create multiple bends.

(41) In some embodiments of the invention, by arranging the axle in other planes, 3D bends can be created.

(42) In some embodiments of the invention the knob 60 is replaced by a motor which drives the flexible section 8. In some embodiments there may be a plurality of motors.

(43) Turning now to FIGS. 4a, 4b and 4c the plug 10 is shown in more detail.

(44) The plug 10 serves to connect the delivery portion to the active portion and provides a path 80 in the form of a flexible internal channel, for the motor and signal wires to extend along to connect the motor to the flexible section 8.

(45) The plug 10 also provides triangulation for the inter-changeable instruments 20, which are inserted from the back interface unit 14 and run along side each other within the hollow shaft 12 until they arrive at the plug 10. At the plug, the instruments 20 are split by means of two curved channels 82 formed within the plug 10. The instruments enter the plug 10 from the hollow shaft 12 at inlets 84, 86 and emerge from outlets 88, 90 along a curved trajectory thus providing the desired triangulation.

(46) As shown in FIG. 4c, the plug further comprises a further channel 400 which forms a path for various endoscopic instruments.

(47) Turning now to FIGS. 5 and 6, a plug according to another embodiment in the invention is designated generally by the reference numeral 510. In this embodiment the plug 510 comprises a first plug portion 520 and a second plug portion 530. Each plug portion 520, 530 extends along the length of the plug 510. Further, each plug portion comprises a curved channel 82 along which instruments may extend.

(48) The plug portions 520, 530 are moveable axially relative to one another. The result of this is that the instruments carried in the channels 82 may be positioned axially independently from one another as shown in FIG. 6.

(49) Turning now to FIG. 7, the hollow shaft 12 is shown in more detail. The shaft comprises a thin wall 98, two channels 100, 102 and two instrument arms 104, 106.

(50) Channel 100 carries signal, motor power, light source and camera wires and channel 102 forms a path for various endoscopic instruments. Channel 102 aligns with channel 400 of plug 10 described hereinabove and with particular reference to FIG. 4c, thus enabling endoscopic instruments to extend through to the active portion of the device. The instrument arms each carries an inter-changeable instrument.

(51) In some embodiment of the invention the hollow shaft may be formed from a continuous sleeve. In other examples however the shaft may be formed from a plurality of short sections, which may be actuated by tendons in a similar manner to the actuation of the flexible section 8 which has been described herein above.

(52) Such embodiments facilitate navigation of the device around obstacles within a patient's body, and also facilitate the reaching of certain sites that may be difficult to reach without articulation. In a similar manner to that described hereinabove with reference to the flexible section 8, the tendons may be arranged in pairs and each pair may terminate at different location along the hollow shaft 12.

(53) FIGS. 8, 9 and 10 show various embodiments of the invention in which the hollow shaft 12 has different levels of flexibility.

(54) In FIG. 8, the hollow shaft 12 comprises a plurality of links 610 connected to one another, and separated by a flexible material 620.

(55) In FIG. 8, the arrangement of the links is such that the delivery portion is flexible in a single plane only.

(56) In FIG. 9, the delivery portion is flexible in more than one plane, and sections 630, 640 have different levels of flexibility.

(57) In FIG. 10, the delivery shaft has links 610 that are arranged in an alternating manner such that orthogonal, or other angles of flexibility are periodically repeated.

(58) Turning now to FIGS. 13 to 16, parts of the distal portion of the device 2 are shown in more details. As can be seen from these figures in particular, the device 2 comprises instrument arms in the form of sleeves 30 comprising tendon actuated overtubes. Each of the sleeves 30 accommodates one of the inter-changeable instruments 20 such that when the device is in the deployed position at least a tip of each of the interchangeable instruments protrudes from a distal end of a respective sleeve 30. Each overtube extends through the hollow tube 12 along a respective instrument arm to the drive unit 16.

(59) Each sleeve 30 may be made of any convenient material, but in this embodiment the sleeves are made of super elastic Nitinol. A sleeve 30 may be regarded as comprising three sections: a first section 90 extends from the plug 10 and is the distal section from which at least a tip of an interchangeable instrument accommodated in the sleeve will protrude when in the deployed position; a second section 92 that extends through the plug 10; and a third section 94 that extends along the hollow tube 12 to the driving unit.

(60) Each of these sections has different requirements. The first, distal section must be flexible so as not to restrict movement of the instrument carried by it. Cuts 110, 120 are therefore formed in the sleeve in a way to enable the sleeve to be actuated in two orthogonal planes. This results in actuation being possible in any direction by combining the actuating force in the two planes appropriately.

(61) The second section must be able to follow the curved path of a channel 82 in the plug 10 and is cut in one plane. This means that the second section is less flexible than the first section but is still able to curve as required to pass through the plug 10.

(62) The third section is required to be even less flexible but to be able to follow the bend of the external shaft. This section is loosely cut in two planes.

(63) A plurality of tendons (in this case four) in the form of Nitinol wires are attached to the distal end of each sleeve 30 at approximately 90 separation and extend along the overtube 30 to the driving unit 16. Each tendon (not shown) is paired with an opposite tendon. In use, one tendon pulls back while the opposite tendon pays out. This results in the sleeve 30 bending towards the pulling tendon side.

(64) The primary requirement for each sleeve 30 is to combine flexibility in a radial direction with rigidity along an axial direction so that the sleeve is not compressed while it is actuated. This is achieved by means of cut outs which result in a thin wall along the spine (axially) and a thick wall across the sleeve (transversely).

(65) Because the distal section 90 is cut into planes as shown particularly in FIG. 14, there is no backbone to support the structure. This means that the driving of the tendons causes compression along the axis of the overtube 30. By means of the carefully designed cuts 110, 120 in the distal portion of the overtube, axially force may be a relatively thin wall may still be able to withstand the axial forces exerted during use, enabling easy bending. Given a maximum bending of 90, the length difference between the compressed edge and the spine is l=*r/2, where r is the radius of the tube. The maximum which is l is the amount of compression when all the slots are completely compressed. Therefore each slot width can be l/n where n is the number of slots in one plane. Using this slot width gives a maximum capability for withstanding the axial forces created when driving the tendons whilst still fulfilling the actuation range requirements of the device.

(66) The results taken from a simulation show that the actuation of one tendon may create a 4N pulling force. This results in approximately 30 mm displacement.

(67) The overtubes 30 may be cut using wire-cut Electrical Discharge Machine.

(68) The instrument tip design varies according to the requirement of the clinical procedure to be carried out.

(69) A schematic representation of one instrument is shown schematically in FIG. 15. The instrument comprises a gripper 120 that can open and close and rotate about its axis and translate along the sleeve 30.

(70) In the illustrated embodiment the instrument tip is delivered to the distal end of the device for deployment by means of an instrument overtube comprising a flexible hollow shaft 122 which provides the flexibility to follow the sleeve 30 bending, and also to transmit torque to enable the instrument to rotate.

(71) In order to transmit sufficient torque, the hollow shaft 122 is made of multiple wire coil with a flexible coating as shown in FIG. 16. The multiple wire coil significantly improves the torque transmission capability compared with a single wire coil. Further, the flexibility of the shaft is not significantly affected. The flexible coating prevents misplacement of the wires forming the shaft.

(72) The central channel of the flexible shaft provides a path for the tendons actuating the instrument tip.

(73) The gripper also features a section cylindrical feature that is longer than the desired instrument translation stroke within the over tube.

(74) The device according to the invention may be used with any suitable instruments, and particularly with interchangeable instruments which are adapted to be inserted and removed as necessary in order that a surgical procedure may be efficiently and safely carried out.

(75) In general, these instruments should have simple open/closed activation, capable of rotation and translation within the over tube, and have flexibility to be manipulated by the over tubes.

(76) Each of these requirements may be achieved with some basic knowledge of standard laparoscopic instruments or endoscopic instruments. Further design of such instruments is however desirable in order to ensure that the instruments are compatible with the other components of the device.

(77) Turning now to FIG. 17, the positions of cameras 22, 24 and LEDs 26, 28 are shown in more detail.

(78) In the embodiment shown in FIG. 17 the device comprises five LEDs 28 positioned towards a proximal end of the flexible section 8 and two LEDs 26 positioned at a distal end of the active portion 4.

(79) The power of the distal LEDs 26 can be adjusted so that the illuminated field is not too bright when the distal end of the active portion 4 is close to the tissue on which the device will be operating.

(80) Two approaches to the adjustment of the LEDs may be taken.

(81) A first approach is by sensing the distance between the distal tip 4a and the tissue.

(82) The second approach is by analysing images acquired from the distal camera 22.

(83) The device comprises a proximal camera 24 and a distal camera 22.

(84) One way of visualise the operation site is to use two cameras, one mounted at the distal tip of the active portion, and the other at a proximal end of the flexible portion 8. Such an arrangement provides a broader view of the surrounding area and enhances the visualisation of the operation site.

(85) In the embodiment illustrated in FIG. 16, two or more cameras 22 or an advanced stereo camera can be mounted to provide stereo vision (only one is shown in the figure) in conjunction with the two LEDs 26.

(86) The plurality of LEDs 26, 28 provide illumination from a plurality of points, the position of which is known at all times through the use of potentiometers placed within the device 2, giving complete control over the physical image formation process.

(87) Stereo camera are traditionally autonomously employed for 3D reconstruction, where traditional algorithms are penalised by the lack of colour constancy cross views. This condition applies to endoscopic data sets, where the highly localised illumination causes colours to appear differently between the left and right video channels.

(88) The complete setup consists of two stereo cameras on the tip of the robot with two LEDs for frontal illumination and a variable number of LEDs along the body of the robot.

(89) The LEDs placed along the body of the robot provide illumination from multiple points whose position is known at all time through the potentiometers placed within the robot itself, giving complete control over the physical image formation process.

(90) Stereo cameras are traditionally autonomously employed for 3D reconstruction, where traditional algorithms are penalised by the lack of colour constancy across views. This condition applies to endoscopic datasets, where the highly localised illumination causes colours to appear differently between the left and right video channels.

(91) The LEDs physical configuration is exploited to reconstruct the 3D structure of the visualised scene by explicitly taking into account shading information. Given complete knowledge of the camera and light positional information, it is possible to correlate the perceived brightness of every point visualised with its 3D position and surface orientation according to the Lambertian formation model:
l(x,y)=1n(x,y)E(l)R(x,y,l)S(l)dl
where l is the image brightness for pixel coordinates x and y, l is the known light source direction vector, n is the surface normal and the integral represents the surface reflectance properties. When at least 3 source LEDs are present in the system, it is possible to solve for the unknown surface normals and, when two cameras are present, for the unknown surface depth values using exact variational calculus methods.

(92) Three LEDs are placed along the robot body that simultaneously illuminate the scene. To distinguish which LED is contributing to the perceived brightness, the chosen wavelengths are spaced as equally as possible along the visible spectrum: 447 nm, 530 nm and 627 nm for blue, green and red LEDs respectively. The wavelengths corresponds to the sensitivities of the RGB CCD cameras used, so that the contribution to the overall image brightness from each light source can be isolated and used together for a fully dense reconstruction of the scene.

(93) The flexible section 8 may be driven in any convenient manner and may for example be driven using a thumb stick and an embedded button which allows toggling between the joints.

(94) The device according to embodiments of the invention thus provides a versatile surgical device particularly suitable for use in minimal invasive surgery. The device may comprise one or more slave devices that may be controlled by a master device.