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Intuitive surgical, inc.(isi) received the da vinci product to perform failure analysis.The single port (sp) needle driver instrument was analyzed and found to have a broken idler roll gear, and a fragment of the gear was located inside the housing after disassembly.Manual articulation testing showed that the main tube rotated; however, the hard stop was not felt because the broken gear prevented proper articulation.Functional testing on an in-house system confirmed unintuitive motion.The main tube did not rotate when commanded by the master tool manipulator (mtm) on the surgeon side cart (ssc).When the wrist and joggle joint were bent and roll commands were applied, the distal end moved in a circular path rather than remaining in a fixed position while rolling as expected.In certain orientations, the distal tip also moved opposite to the commanded direction.This behavior was consistently observed in 3 of 3 installations, indicating misalignment of the coordinate frames during the engagement sequence.The unintuitive motion was attributed to the broken idler roll gear.The complaint regarding an issue with the instrument was confirmed by failure analysis.The probable root cause of the broken idler roll gear is attributed to improper reprocessing.
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