Drive cable brake assembly for robotic surgical tool

1. A surgical tool, comprising:

a drive housing;

an elongate shaft that extends from the drive housing;

a plurality of drive cables extending within the elongate shaft between the drive housing and an end effector coupled to a distal end of the elongate shaft; and

a cable brake assembly at least partially arranged within a cavity defined in the drive housing or the elongate shaft, the cable brake assembly having one or more brakes and a brake pad engageable with one or more of the plurality of drive cables,

wherein the cable brake assembly is actuatable between a first position, where the plurality of drive cables are free to move longitudinally within the elongate shaft, and a second position, where the one or more brakes and the brake pad engage and prevent the one or more of the plurality of drive cables from moving.

2. The surgical tool of claim 1 , wherein the cable brake assembly further includes a brake chassis and the one or more brakes are arranged on the brake chassis, and wherein the brake chassis is movable in a direction transverse to a longitudinal direction of the plurality of drive cables to laterally align the one or more brakes with the one or more of the plurality of drive cables.

3. The surgical tool of claim 2 , wherein the brake chassis includes a first leg and a second leg, and wherein at least one of the one or more brakes is arranged on each of the first and second legs.

4. The surgical tool of claim 2 , wherein an end of the brake chassis is receivable within a pocket defined in an inner sidewall of the cavity upon actuation of the cable brake assembly.

5. The surgical tool of claim 4 , further comprising a key arranged at the end and matable with the pocket to prevent the brake chassis from rotating.

6. The surgical tool of claim 2 , further comprising a locking assembly arranged at an end of the brake chassis to lock the cable brake assembly in the second position.

7. The surgical tool of claim 6 , wherein the locking assembly comprises one or more locking tabs having a projection formed thereon, and wherein the one or more locking tabs flex inward as the cable brake assembly moves to the second position.

8. The surgical tool of claim 6 , wherein the locking assembly comprises:

a bullnose provided at the end of the brake chassis and receivable into a pocket defined in a sidewall of the cavity; and

one or more lugs arranged within corresponding recesses defined in the sidewall and movable relative to the bullnose to lock the assembly in the second position.

9. The surgical tool of claim 8 , wherein the one or more lugs are spring-loaded.

10. The surgical tool of claim 1 , wherein the one or more brakes are selected from the group consisting of a geared or toothed structure, a rotatable cam, and a structure having a knurled outer surface.

11. The surgical tool of claim 1 , wherein the brake pad provides an outer profile comprising one or more projections engageable with the one or more of the plurality of drive cables.

12. The surgical tool of claim 1 , wherein the cable brake assembly comprises:

at least one support attached to a sidewall of the cavity, wherein the one or more brakes are rotatably mounted to the at least one support at an axle; and

a brake chassis movable in a direction transverse to a longitudinal direction of the plurality of drive cables and including a leg that terminates with a key matable with a profile provided on the one or more brakes,

wherein the key mates with the profile upon actuating the cable brake assembly to the second position to prevent rotation of the one or more brakes on the axle.

13. A method of operating a surgical tool, comprising:

triggering actuation of one or more actuation devices in a drive housing and thereby moving a plurality of drive cables extending within an elongate shaft extending from the drive housing to an end effector coupled to a distal end of the elongate shaft;

actuating a cable brake assembly from a first position, where the plurality of drive cables are free to move longitudinally within the elongate shaft, and to a second position, where one or more brakes and a brake pad of the cable brake assembly engage and prevent the one or more of the plurality of drive cables from moving,

wherein the cable brake assembly is at least partially arranged within a cavity defined in the drive housing or the elongate shaft.

14. The method of claim 13 , wherein the cable brake assembly further includes a brake chassis and the one or more brakes are arranged on the brake chassis, and wherein actuating the cable brake assembly comprises:

moving the brake chassis in a direction transverse to a longitudinal direction of the plurality of drive cables; and

laterally aligning the one or more brakes with the one or more of the plurality of drive cables.

15. The method of claim 14 , wherein actuating the cable brake assembly further comprises receiving an end of the brake chassis within a pocket defined in an inner sidewall of the cavity.

16. The method of claim 15 , further comprising mating a key arranged at the end with the pocket and thereby preventing the brake chassis from rotating.

17. The method of claim 14 , wherein laterally aligning the one or more brakes with the one or more of the plurality of drive cables comprises:

driving the one or more of the plurality of drive cables against an adjacent outer surface of the brake pad with the one or more brakes; and

binding the one or more of the plurality of drive cables in place with the one or more brakes to prevent axial movement of the one or more of the plurality of drive cables.

18. The method of claim 13 , further comprising locking the cable brake assembly in the second position with a locking assembly arranged at an end of the brake chassis.

19. The method of claim 13 , wherein the cable brake assembly includes at least one support attached to a sidewall of the cavity and having the one or more brakes rotatably mounted thereto at an axle, and further includes a brake chassis including a leg that terminates with a key matable with a profile provided on the one or more brakes, and wherein actuating the cable brake assembly comprises:

moving the brake chassis in a direction transverse to a longitudinal direction of the plurality of drive cables;

mating the key with the profile and thereby preventing rotation of the one or more brakes on the axle; and

binding the one or more of the plurality of drive cables in place with the one or more brakes to prevent axial movement of the one or more of the plurality of drive cables.

20. A cable brake assembly for a surgical tool operable with a plurality of drive cables, the cable brake assembly comprising:

a brake chassis;

one or more brakes engageable with one or more of the plurality of drive cables; and

a brake pad engageable with one or more of the drive cables,

wherein the brake chassis is movable between a first position, where the plurality of drive cables are free to move longitudinally within the elongate shaft, and a second position, where the one or more brakes and the brake pad engage and prevent the one or more of the plurality of drive cables from moving.