Surgical Arm System with Internally Driven Gear Assemblies

Abstract

Embodiments relate to robotic arm assemblies. Embodiments include shoulder segment and upper arm segment having motor drive portion. Embodiments include shoulder coupling joint assembly connecting upper arm segment to shoulder segment. Shoulder coupling joint assembly includes distal shoulder joint subassembly connected to upper arm segment. Distal shoulder joint subassembly includes distal shoulder joint forming first axis. Distal shoulder joint subassembly includes shoulder planetary gear assembly having shoulder sun gear configured to rotate relative to first axis when motor drive portion is driven to rotate. Shoulder planetary gear assembly includes shoulder planetary gear carrier. When shoulder sun gear rotates, shoulder planetary gear carrier drives upper arm segment to rotate relative to first axis. Shoulder coupling joint assembly includes proximal shoulder joint subassembly connecting shoulder segment to distal shoulder joint subassembly. Proximal shoulder joint subassembly includes proximal shoulder joint forming second axis, which rotates distal shoulder joint subassembly relative to second axis.

What is claimed is: 
     
         1 . A robotic arm assembly, the robotic arm assembly comprising:
 an upper arm segment, the upper arm segment formed as an elongated structure with a proximal end and a distal end, the upper arm segment having:
 a first proximal motor, the first proximal motor having a first proximal motor drive portion at the proximal end of the upper arm segment, the first proximal motor drive portion configured to rotate relative to a first axis; 
   a shoulder segment, the shoulder segment having a proximal end and a distal end; and   a shoulder coupling joint assembly, the shoulder coupling joint assembly connecting the proximal end of the upper arm segment to the distal end of the shoulder segment, the shoulder coupling joint assembly having:
 a distal shoulder joint subassembly connected at a distal end to the proximal end of the upper arm segment, the distal shoulder joint subassembly including a distal shoulder joint forming a first main shoulder axis, the distal shoulder joint subassembly including:
 a distal shoulder gear stage, the distal shoulder gear stage having a distal shoulder planetary gear assembly, the distal shoulder planetary gear assembly having:
 a distal shoulder sun gear, the distal shoulder sun gear configured to be driven to rotate relative to the first main shoulder axis when the first proximal motor drive portion is driven to rotate by the first proximal motor; 
 a distal shoulder ring gear configured to not rotate relative to the first main shoulder axis; 
 a plurality of distal shoulder planetary gears drivable by the distal shoulder sun gear; and 
 a distal shoulder planetary gear carrier connected to the plurality of distal shoulder planetary gears in such a way that, when the distal shoulder sun gear is driven to rotate relative to the first main shoulder axis, the distal shoulder planetary gear carrier drives the upper arm segment to rotate relative to the first main shoulder axis; and 
 
 
 a proximal shoulder joint subassembly connecting the distal end of the shoulder segment to the distal shoulder joint subassembly, the proximal shoulder joint subassembly including a proximal shoulder joint forming a second main shoulder axis, the proximal shoulder joint subassembly configurable to be driven in such a way as to pivotally rotate the distal shoulder joint subassembly relative to the second main shoulder axis, the second main shoulder axis being orthogonal to the first main shoulder axis. 
   
     
     
         2 . The robotic arm assembly of  claim 1 , wherein the distal shoulder joint subassembly further comprises:
 a second distal shoulder gear stage, the second distal shoulder gear stage having:
 a first distal shoulder bevel gear configured to be driven by the first proximal motor drive portion of the first proximal motor to rotate relative to the first axis; and 
 a second distal shoulder bevel gear drivable by the first distal shoulder bevel gear, the second distal shoulder bevel gear configured to rotate relative to the first main shoulder axis when driven by the first distal shoulder bevel gear; 
   wherein the distal shoulder sun gear is connected to the second distal shoulder bevel gear.   
     
     
         3 . The robotic arm assembly of  claim 1 , wherein the upper arm segment further comprises:
 a second proximal motor, the second proximal motor having a second proximal motor drive portion at the proximal end of the upper arm segment, the second proximal motor drive portion configured to rotate relative to a second axis, the second axis being parallel to the first axis.   
     
     
         4 . The robotic arm assembly of  claim 3 , wherein the proximal shoulder joint subassembly includes a gear train system having a plurality of gear stages including:
 a first proximal shoulder gear stage, the first proximal shoulder gear stage having:
 a first proximal shoulder bevel gear configured to be driven by the second proximal motor drive portion of the second proximal motor to rotate relative to the second axis; 
 a second proximal shoulder bevel gear drivable by the first proximal shoulder bevel gear, the second proximal shoulder bevel gear configured to rotate relative to the first main shoulder axis when driven by the first proximal shoulder bevel gear; and 
 a third proximal shoulder bevel gear drivable by the second proximal shoulder bevel gear, the third proximal shoulder bevel gear configured to rotate relative to an axis orthogonal to the first main shoulder axis when the first proximal shoulder bevel gear drives the second proximal shoulder bevel gear to rotate relative to the first main shoulder axis; 
   a second proximal shoulder gear stage, the second proximal shoulder gear stage having:
 a first proximal shoulder spur gear connected to the third proximal shoulder bevel gear, the first proximal shoulder spur gear configured to rotate relative to a same axis of rotation as the third proximal shoulder bevel gear when the third proximal shoulder bevel gear is driven to rotate; and 
 a second proximal shoulder spur gear drivable by the first proximal shoulder spur gear, the second proximal shoulder spur gear configured to rotate relative to an axis of rotation that is parallel to the axis of rotation of the first proximal shoulder spur gear when the second proximal shoulder spur gear is driven by the first proximal shoulder spur gear; 
   a third proximal shoulder gear stage, the third proximal shoulder gear stage having:
 a fourth proximal shoulder bevel gear connected to the second proximal shoulder spur gear, the fourth proximal shoulder bevel gear configured to be driven by the second proximal shoulder spur gear to rotate relative to the same axis of rotation as that of the second proximal shoulder spur gear; and 
 a fifth proximal shoulder bevel gear drivable by the fourth proximal shoulder bevel gear, the fifth proximal shoulder bevel gear configured to rotate relative to the second main shoulder axis when driven by the fourth proximal shoulder bevel gear; and 
   a fourth proximal shoulder gear stage, the fourth proximal shoulder gear stage having a proximal shoulder planetary gear assembly, the proximal shoulder planetary gear assembly having:
 a proximal shoulder sun gear connected to the fifth proximal shoulder bevel gear, the proximal shoulder sun gear configured to be driven by the fifth proximal shoulder bevel gear to rotate relative to the second main shoulder axis; 
 a proximal shoulder ring gear configured to not rotate relative to the second main shoulder axis; 
 a plurality of proximal shoulder planetary gears drivable by the proximal shoulder sun gear; and 
 a proximal shoulder planetary gear carrier connected at one end to the plurality of proximal shoulder planetary gears in such a way that when the proximal shoulder sun gear rotates relative to the second main shoulder axis, the proximal shoulder planetary gear carrier rotates relative to the second main shoulder axis, wherein the proximal shoulder planetary gear carrier is connected at another end to the distal end of the shoulder segment in such a way that when the proximal shoulder sun gear is driven to rotate relative to the second main shoulder axis, the proximal shoulder planetary gear carrier drives the upper arm segment to pivotally rotate relative to the second main shoulder axis. 
   
     
     
         5 . The robotic arm assembly of  claim 4 , wherein one or more of the following apply:
 the first proximal shoulder spur gear and the third proximal shoulder bevel gear are directly connected to one another in such a way that a portion of the first proximal shoulder spur gear is secured to a portion of the third proximal shoulder bevel gear; and/or   the second proximal shoulder spur gear and the fourth proximal shoulder bevel gear are directly connected to one another in such a way that a portion of the second proximal shoulder spur gear is directly secured to a portion of the fourth proximal shoulder bevel gear; and/or   the proximal shoulder sun gear and the fifth proximal shoulder bevel gear are directly coupled to one another in such a way that a portion of the proximal shoulder sun gear is secured to a portion of the fifth proximal shoulder bevel gear; and/or   the first distal shoulder bevel gear is driven by the first proximal motor drive portion of the first proximal motor to rotate relative to the first axis via one or more spur gears provided between the first distal shoulder bevel gear and the first proximal motor drive portion of the first proximal motor.   
     
     
         6 . The robotic arm assembly of  claim 4 , wherein one or more of the following apply:
 the first proximal shoulder spur gear and the third proximal shoulder bevel gear are connected to one another via a first common elongated member connected at one end to the first proximal shoulder spur gear and at another end to the third proximal shoulder bevel gear, the first proximal shoulder spur gear, the third proximal shoulder bevel gear, and the first common elongated member having a common central axis of rotation; and/or   the second proximal shoulder spur gear and the fourth proximal shoulder bevel gear are connected to one another via a second common elongated member connected at one end to the second proximal shoulder spur gear and at another end to the fourth proximal shoulder bevel gear, the second proximal shoulder spur gear, the fourth proximal shoulder bevel gear, and the second common elongated member having a common central axis of rotation; and/or   the proximal shoulder sun gear and the fifth proximal shoulder bevel gear are connected to one another via a third common elongated member connected at one end to the proximal shoulder sun gear and at another end to the fifth proximal shoulder bevel gear, the proximal shoulder sun gear, the fifth proximal shoulder bevel gear, and the third common elongated member having a common central axis of rotation.   
     
     
         7 . The robotic arm assembly of  claim 1 , wherein the distal end of the forearm segment is securable to an end effector assembly via a wrist joint. 
     
     
         8 . The robotic arm assembly of  claim 1 , further comprising an elbow coupling joint assembly, the elbow coupling joint assembly connecting a forearm section to the distal end of the upper arm segment via a serial arrangement of a proximal elbow joint and a distal elbow joint. 
     
     
         9 . A robotic arm assembly, the robotic arm assembly comprising:
 an upper arm segment, the upper arm segment formed as an elongated structure with a proximal end and a distal end, the upper arm segment having:
 a first proximal motor, the first proximal motor having a first proximal motor drive portion at the proximal end of the upper arm segment, the first proximal motor drive portion configured to rotate relative to a first axis; 
   a shoulder segment, the shoulder segment having a proximal end and a distal end; and   a shoulder coupling joint assembly, the shoulder coupling joint assembly connecting the proximal end of the upper arm segment to the distal end of the shoulder segment, the shoulder coupling joint assembly having:
 a distal shoulder joint subassembly connected at a distal end to the proximal end of the upper arm segment, the distal shoulder joint subassembly including a distal shoulder joint forming a first main shoulder axis, the distal shoulder joint subassembly configurable to be driven in such a way as to pivotally rotate the upper arm segment relative to the first main shoulder axis; 
 a proximal shoulder joint subassembly connecting the distal end of the shoulder segment to the distal shoulder joint subassembly, the proximal shoulder joint subassembly including a proximal shoulder joint forming a second main shoulder axis, the second main shoulder axis orthogonal to the first main shoulder axis, the proximal shoulder joint subassembly including:
 a proximal shoulder gear stage, the proximal shoulder gear stage having a proximal shoulder planetary gear assembly, the proximal shoulder planetary gear assembly having:
 a proximal shoulder sun gear configured to be driven to rotate relative to the second main shoulder axis when the first proximal motor drive portion is driven by the first proximal motor; 
 a proximal shoulder ring gear configured to not rotate relative to the second main shoulder axis; 
 a plurality of proximal shoulder planetary gears drivable by the proximal shoulder sun gear; and 
 a proximal shoulder planetary gear carrier connected to the plurality of proximal shoulder planetary gears in such a way that, when the proximal shoulder sun gear is driven to rotate relative to the second main shoulder axis, the proximal shoulder planetary gear carrier drives the distal shoulder joint assembly to rotate relative to the second main shoulder axis. 
 
 
   
     
     
         10 . The robotic arm assembly of  claim 1 , wherein the proximal shoulder joint subassembly further comprises:
 a second proximal shoulder gear stage, the second proximal shoulder gear stage having:
 a first proximal shoulder bevel gear configured to be driven by the first proximal motor drive portion of the first proximal motor to rotate relative to the first axis; 
 a second proximal shoulder bevel gear drivable by the first proximal shoulder bevel gear, the second proximal shoulder bevel gear configured to rotate relative to a first main shoulder axis when driven by the first proximal shoulder bevel gear, the first main shoulder axis being orthogonal to the first axis; and 
 a third proximal shoulder bevel gear drivable by the second proximal shoulder bevel gear, the third proximal shoulder bevel gear configured to rotate relative to an axis orthogonal to the first main shoulder axis when the first proximal shoulder bevel gear drives the second proximal shoulder bevel gear to rotate relative to the first main shoulder axis; 
   a third proximal shoulder gear stage, the third proximal shoulder gear stage having:
 a first proximal shoulder spur gear connected to the third proximal shoulder bevel gear, the first proximal shoulder spur gear configured to rotate relative to a same axis of rotation as the third proximal shoulder bevel gear when the third proximal shoulder bevel gear is driven to rotate; and 
 a second proximal shoulder spur gear drivable by the first proximal shoulder spur gear, the second proximal shoulder spur gear configured to rotate relative to an axis of rotation that is parallel to the axis of rotation of the first proximal shoulder spur gear when the second proximal shoulder spur gear is driven by the first proximal shoulder spur gear; 
   a fourth proximal shoulder gear stage, the fourth proximal shoulder gear stage having:
 a fourth proximal shoulder bevel gear connected to the second proximal shoulder spur gear, the fourth proximal shoulder bevel gear configured to be driven by the second proximal shoulder spur gear to rotate relative to the same axis of rotation as that of the second proximal shoulder spur gear; and 
 a fifth proximal shoulder bevel gear drivable by the fourth proximal shoulder bevel gear, the fifth proximal shoulder bevel gear configured to rotate relative to a second main shoulder axis when driven by the fourth proximal shoulder bevel gear, the second main shoulder axis being orthogonal to the first main shoulder axis; 
   wherein the proximal shoulder gear stage is driven by the fourth proximal shoulder bevel gear to rotate relative to the second main shoulder axis.   
     
     
         11 . The robotic arm assembly of  claim 9 , wherein the upper arm segment further comprises:
 a second proximal motor, the second proximal motor having a second proximal motor drive portion at the proximal end of the upper arm segment, the second proximal motor drive portion configured to rotate relative to a second axis, the second axis being parallel to the first axis.   
     
     
         12 . The robotic arm assembly of  claim 11 , wherein the distal shoulder joint subassembly includes a gear train system having a plurality of gear stages including:
 a first distal shoulder gear stage, the first distal shoulder gear stage having:
 a first distal shoulder bevel gear configured to be driven by the second proximal motor drive portion of the second proximal motor to rotate relative to the second axis; and 
 a second distal shoulder bevel gear drivable by the first distal shoulder bevel gear, the second distal shoulder bevel gear configured to rotate relative to the first main shoulder axis when driven by the first distal shoulder bevel gear, the first main shoulder axis being orthogonal to the first axis; and 
   a second distal shoulder gear stage, the second distal shoulder gear stage having a distal shoulder planetary gear assembly, the distal shoulder planetary gear assembly having:
 a distal shoulder sun gear connected to the second distal shoulder bevel gear, the distal shoulder sun gear configured to be driven by the second distal shoulder bevel gear to rotate relative to the first main shoulder axis; 
 a distal shoulder ring gear configured to not rotate relative to the first main shoulder axis; 
 a plurality of distal shoulder planetary gears drivable by the distal shoulder sun gear; and 
 a distal shoulder planetary gear carrier connected at one end to the plurality of distal shoulder planetary gears in such a way that when the distal shoulder sun gear rotates relative to the first main shoulder axis, the distal shoulder planetary gear carrier rotates relative to the first main shoulder axis. 
   
     
     
         13 . The robotic arm assembly of  claim 9 , wherein the distal end of the forearm segment is securable to an end effector assembly via a wrist joint. 
     
     
         14 . The robotic arm assembly of  claim 10 , wherein one or more of the following apply:
 the first proximal shoulder spur gear and the third proximal shoulder bevel gear are directly connected to one another in such a way that a portion of the first proximal shoulder spur gear is secured to a portion of the third proximal shoulder bevel gear; and/or   the second proximal shoulder spur gear and the fourth proximal shoulder bevel gear are directly connected to one another in such a way that a portion of the second proximal shoulder spur gear is directly secured to a portion of the fourth proximal shoulder bevel gear; and/or   the proximal shoulder sun gear and the fifth proximal shoulder bevel gear are directly coupled to one another in such a way that a portion of the proximal shoulder sun gear is secured to a portion of the fifth proximal shoulder bevel gear; and/or   the first proximal shoulder bevel gear is driven by the first proximal motor drive portion of the first proximal motor to rotate relative to the first axis via one or more spur gears provided between the first proximal shoulder bevel gear and the first proximal motor drive portion of the first proximal motor.   
     
     
         15 . The robotic arm assembly of  claim 10 , wherein one or more of the following apply:
 the first proximal shoulder spur gear and the third proximal shoulder bevel gear are connected to one another via a first common elongated member connected at one end to the first proximal shoulder spur gear and at another end to the third proximal shoulder bevel gear, the first proximal shoulder spur gear, the third proximal shoulder bevel gear, and the first common elongated member having a common central axis of rotation; and/or   the second proximal shoulder spur gear and the fourth proximal shoulder bevel gear are connected to one another via a second common elongated member connected at one end to the second proximal shoulder spur gear and at another end to the fourth proximal shoulder bevel gear, the second proximal shoulder spur gear, the fourth proximal shoulder bevel gear, and the second common elongated member having a common central axis of rotation; and/or   the proximal shoulder sun gear and the fifth proximal shoulder bevel gear are connected to one another via a third common elongated member connected at one end to the proximal shoulder sun gear and at another end to the fifth proximal shoulder bevel gear, the proximal shoulder sun gear, the fifth proximal shoulder bevel gear, and the third common elongated member having a common central axis of rotation.   
     
     
         16 . The robotic arm assembly of  claim 9 , further comprising an elbow coupling joint assembly, the elbow coupling joint assembly connecting a forearm section to the distal end of the upper arm segment via a serial arrangement of a proximal elbow joint and a distal elbow joint. 
     
     
         17 . A robotic arm assembly, the robotic arm assembly comprising:
 an upper arm segment, the upper arm segment formed as an elongated structure with a proximal end and a distal end, the upper arm segment having:
 a first proximal motor, the first proximal motor having a first proximal motor drive portion at the proximal end of the upper arm segment, the first proximal motor drive portion configured to rotate relative to a first axis of rotation; 
   a shoulder segment, the shoulder segment having a proximal end and a distal end; and   a shoulder coupling joint assembly, the shoulder coupling joint assembly connecting the proximal end of the upper arm segment to the distal end of the shoulder segment, the shoulder coupling joint assembly having:
 a distal shoulder joint subassembly connected at a distal end to the proximal end of the upper arm segment, the distal shoulder joint subassembly including a distal shoulder joint forming a first main shoulder axis, the distal shoulder joint subassembly including:
 a distal shoulder gear stage, the distal shoulder gear stage having a distal shoulder planetary gear assembly, the distal shoulder planetary gear assembly having:
 a distal shoulder sun gear, the distal shoulder sun gear configured to be driven to rotate relative to the first main shoulder axis when the first proximal motor drive portion is driven to rotate by the first proximal motor; 
 a distal shoulder ring gear configured to not rotate relative to the first main shoulder axis; 
 a plurality of distal shoulder planetary gears drivable by the distal shoulder sun gear; and 
 a distal shoulder planetary gear carrier connected to the plurality of distal shoulder planetary gears in such a way that, when the distal shoulder sun gear is driven to rotate relative to the first main shoulder axis, the distal shoulder planetary gear carrier drives the upper arm segment to rotate relative to the first main shoulder axis; and 
 
 
 a proximal shoulder joint subassembly connecting the distal end of the shoulder segment to the distal shoulder joint subassembly, the proximal shoulder joint subassembly including a proximal shoulder joint forming a second main shoulder axis, the second main shoulder axis orthogonal to the first main shoulder axis, the proximal shoulder joint subassembly including:
 a proximal shoulder gear stage, the proximal shoulder gear stage having a proximal shoulder planetary gear assembly, the proximal shoulder planetary gear assembly having:
 a proximal shoulder sun gear configured to be driven to rotate relative to the second main shoulder axis when the first proximal motor drive portion is driven by the first proximal motor; 
 a proximal shoulder ring gear configured to not rotate relative to the second main shoulder axis; 
 a plurality of proximal shoulder planetary gears drivable by the proximal shoulder sun gear; and 
 a proximal shoulder planetary gear carrier connected to the plurality of proximal shoulder planetary gears in such a way that, when the proximal shoulder sun gear is driven to rotate relative to the second main shoulder axis, the proximal shoulder planetary gear carrier drives the distal shoulder joint assembly to rotate relative to the second main shoulder axis. 
 
 
   
     
     
         18 . The robotic arm assembly of  claim 17 , wherein the distal shoulder joint subassembly further comprises:
 a second distal shoulder gear stage, the second distal shoulder gear stage having:
 a first distal shoulder bevel gear configured to be driven by the first proximal motor drive portion of the first proximal motor to rotate relative to the first axis; and 
 a second distal shoulder bevel gear drivable by the first distal shoulder bevel gear, the second distal shoulder bevel gear configured to rotate relative to the first main shoulder axis when driven by the first distal shoulder bevel gear; 
   wherein the distal shoulder sun gear is connected to the second distal shoulder bevel gear.   
     
     
         19 . The robotic arm assembly of  claim 17 , wherein the proximal shoulder joint subassembly further comprises:
 a second proximal shoulder gear stage, the second proximal shoulder gear stage having:
 a first proximal shoulder bevel gear configured to be driven by the first proximal motor drive portion of the first proximal motor to rotate relative to the first axis; 
 a second proximal shoulder bevel gear drivable by the first proximal shoulder bevel gear, the second proximal shoulder bevel gear configured to rotate relative to a first main shoulder axis when driven by the first proximal shoulder bevel gear, the first main shoulder axis being orthogonal to the first axis; and 
 a third proximal shoulder bevel gear drivable by the second proximal shoulder bevel gear, the third proximal shoulder bevel gear configured to rotate relative to an axis orthogonal to the first main shoulder axis when the first proximal shoulder bevel gear drives the second proximal shoulder bevel gear to rotate relative to the first main shoulder axis; 
   a third proximal shoulder gear stage, the third proximal shoulder gear stage having:
 a first proximal shoulder spur gear connected to the third proximal shoulder bevel gear, the first proximal shoulder spur gear configured to rotate relative to a same axis of rotation as the third proximal shoulder bevel gear when the third proximal shoulder bevel gear is driven to rotate; and 
 a second proximal shoulder spur gear drivable by the first proximal shoulder spur gear, the second proximal shoulder spur gear configured to rotate relative to an axis of rotation that is parallel to the axis of rotation of the first proximal shoulder spur gear when the second proximal shoulder spur gear is driven by the first proximal shoulder spur gear; 
   a fourth proximal shoulder gear stage, the fourth proximal shoulder gear stage having:
 a fourth proximal shoulder bevel gear connected to the second proximal shoulder spur gear, the fourth proximal shoulder bevel gear configured to be driven by the second proximal shoulder spur gear to rotate relative to the same axis of rotation as that of the second proximal shoulder spur gear; and 
 a fifth proximal shoulder bevel gear drivable by the fourth proximal shoulder bevel gear, the fifth proximal shoulder bevel gear configured to rotate relative to a second main shoulder axis when driven by the fourth proximal shoulder bevel gear, the second main shoulder axis being orthogonal to the first main shoulder axis; 
   wherein the proximal shoulder gear stage is driven by the fourth proximal shoulder bevel gear to rotate relative to the second main shoulder axis.   
     
     
         20 . The robotic arm assembly of  claim 17 , wherein the upper arm segment further comprises:
 a second proximal motor, the second proximal motor having a second proximal motor drive portion at the proximal end of the upper arm segment, the second proximal motor drive portion configured to rotate relative to a second axis of rotation, the second axis of rotation being parallel to the first axis of rotation.   
     
     
         21 . The robotic arm assembly of  claim 17 , wherein the distal end of the forearm segment is securable to an end effector assembly via a wrist joint. 
     
     
         22 . The robotic arm assembly of  claim 17 , further comprising an elbow coupling joint assembly, the elbow coupling joint assembly connecting a forearm section to the distal end of the upper arm segment via a serial arrangement of a proximal elbow joint and a distal elbow joint.