Automated end effector component reloading system for use with a robotic system

Abstract

A surgical instrument. The surgical instrument includes an end effector that comprises a staple channel and an anvil that is movably translatable relative to the staple channel. A tool mounting portion is configured to interface with a robotic system and operably communicate with the end effector. The instrument further includes a first sensor that has an output that represents a first condition of a portion of the robotic system. A second sensor has an output that represents a position of the anvil. A third sensor has an output that represents a position of a reciprocating knife within the end effector. An externally accessible memory device communicates with the first, second and third sensors.

What is claimed is: 
     
         1 . An automated reloading system for replacing a spent surgical end effector component in a manipulatable robotic tool portion of a robotic surgical system with a new surgical end effector component, said automated reloading system comprising:
 an extraction system supportable within a work envelope of the manipulatable robotic tool portion of the robotic surgical system, said extraction system configured to automatically dislodge said spent surgical end effector component from a component support portion of said manipulatable robotic tool portion when said manipulatable robotic tool portion moves said spent surgical end effector into extractive engagement therewith; and   a new component support arrangement supportable within the work envelope, said new component support arrangement supporting at least one said new surgical end effector component in a loading orientation such that when said manipulatable robotic tool portion moves said component support portion into loading engagement with one of said at least one new surgical end effector components, said one of said at least one new surgical end effector components is loaded therein.   
     
     
         2 . The automated reloading system of  claim 1  further comprising a collection receptacle adjacent said extraction system such that when said spent surgical end effector components are dislodged from their respective end effector support portions, said spent surgical end effector components automatically collect within said collection receptacle. 
     
     
         3 . The automated reloading system of  claim 1  wherein said extraction system comprises an extraction hook member configured to hookingly engage said spent surgical end effector component when said spent surgical end effector component is brought into extractive engagement therewith. 
     
     
         4 . The automated reloading system of  claim 2  wherein said extraction system comprises an extraction member movably supported adjacent said collection receptacle for selective movable extractive engagement with said spent surgical end effector component. 
     
     
         5 . The automated reloading system of  claim 4  wherein said extraction member comprises an extraction hook member rotatably supported adjacent said collection receptacle. 
     
     
         6 . The automated reloading system of  claim 1  wherein the manipulatable robotic tool comprises a surgical stapling device; wherein said component support portion comprises an elongated channel; and wherein said spent surgical end effector component comprises a spent staple cartridge supported within said elongated channel; wherein at least some staples that were previously supported therein have been discharged therefrom; wherein each of said at least one new surgical end effector component comprises a new surgical staple cartridge operably supporting a plurality of unformed staples therein; and wherein said surgical stapling device comprises an anvil movably supported relative to said elongated channel and being selectively movable between open and closed positions in response to corresponding control motions applied thereto by said manipulatable robotic tool portion. 
     
     
         7 . The automated reloading system of  claim 6  wherein said new component support arrangement comprises a base member configured to support each of said at least one new surgical staple cartridges in said loading orientation, said base member having a pressure pad portion supported adjacent to each said new staple cartridge such that when said end effector is manipulated to locate a new staple cartridge between the anvil and elongated channel thereof, said pressure pad forces said new surgical staple cartridge into seating engagement with the elongated channel as said anvil is moved from an open to a closed position. 
     
     
         8 . An automated reloading system for replacing a spent surgical end effector in a manipulatable robotic tool portion of a robotic surgical system, said automated reloading system comprising a selectively movable support assembly configured to support a plurality of new surgical end effectors in a corresponding loading orientation within a work envelope of the manipulatable robotic tool portion, said selectively movable support member further defining at least one unloading station for receiving a portion of said spent surgical end effector therein while remaining attached to said manipulatable robotic tool portion, said unloading station configured to operably support said spent surgical end effector while being automatically detached from said manipulatable robotic tool portion. 
     
     
         9 . The automated reloading system of  claim 8  wherein at least a rotary detachment motion must be applied to at least one of said spent surgical end effector and said manipulatable robotic tool portion to detach said spent surgical end effector therefrom. 
     
     
         10 . The automated reloading system of  claim 9  wherein at least another rotary attachment motion must be applied to at least one of said new surgical end effector and said manipulatable robotic tool portion to attach said new surgical end effector to said manipulatable robotic tool portion. 
     
     
         11 . The automated reloading system of  claim 8  wherein said movable support assembly comprises a selectively rotatable carrousel supportable within said work envelope and communicating with said robotic system, said carrousel defining a plurality of reloading positions therein, each said reloading position configured to receive a corresponding one of said new surgical end effectors therein and wherein an empty one of said reloading positions comprises said unloading station. 
     
     
         12 . The automated reloading system of  claim 11  wherein each said reloading position is configured to receive a corresponding orientation tube therein, each said orientation tube configured to receive a portion of a corresponding new or spent surgical end effector therein in a non-rotatable predetermined orientation. 
     
     
         13 . The automated reloading system of  claim 12  wherein said movable support assembly further comprises a drive assembly configured to selectively apply at least one rotary detachment motion and at least one rotary attachment motion to said orientation tubes when said orientation tubes are serially brought into engagement therewith. 
     
     
         14 . The automated reloading system of  claim 12  further comprising a portable tray configured to transport a plurality of orientation tubes therein in positions that correspond to loading positions in said rotatable carrousel. 
     
     
         15 . The automated reloading system of  claim 8  wherein said spent and new surgical end effectors comprise disposable loading units. 
     
     
         16 . A method for automatically replacing a spent end effector component operably coupled to a manipulatable robotic tool portion of a robotic system with a new end effector component, said method comprising:
 orienting an automated reloading system within a work envelope of the manipulatable robotic tool portion, the automated reloading system comprising at least one said new end effector oriented in a loading orientation, the automated reloading system defining an unloading position;   activating the robotic system to move the manipulatable robotic tool portion to locate the spent end effector component in the unloading position;   automatically applying an extraction motion to at least one of the spent end effector component and the manipulatable robotic tool portion when in the unloading position to detach the spent end effector component from a corresponding portion of the manipulatable robotic tool portion;   reactivating the robotic system to move the corresponding portion of the manipulatable robotic tool portion into loading engagement with the new end effector component; and   applying a loading motion to at least one of the new end effector component and the corresponding portion of the manipulatable robotic tool portion to operably couple the new end effector component to the corresponding portion of the manipulatable robotic tool portion.   
     
     
         17 . The method of  claim 16  wherein said automatically applying an extraction motion comprises applying a rotary extraction motion to said spent end effector component. 
     
     
         18 . The method of  claim 17  wherein said applying a rotary extraction motion comprises:
 engaging a portion of the spent end effector component with a rotary hook member; and 
 activating the robotic system to apply a rotary motion to the rotary hook member. 
 
     
     
         19 . The method of  claim 16  wherein said applying a loading motion comprises applying a rotary loading motion to at least one of said new end effector component and said manipulatable robotic tool portion. 
     
     
         20 . The method of  claim 16  wherein said end effector component comprises a new surgical staple cartridge configured to be mounted to an elongated channel portion of the manipulatable robotic tool portion and wherein said applying a loading motion comprises applying a closing motion to an anvil movably attached to the elongated channel to force the new surgical staple cartridge into seating engagement with the elongated channel.