METHOD FOR TRACKING AND REPORTING USAGE EVENTS TO DETERMINE WHEN PREVENTIVE MAINTENANCE IS DUE FOR A MEDICAL ROBOTIC SYSTEM

Abstract

A medical robotic system comprises a number of components that may be monitored to determine their preventive maintenance needs by recording usage-related information for the monitored components into associated non-volatile memories. When usage of the component exceeds a specified usage threshold, the system displays a warning message on its display screen to have preventive maintenance performed for the component. If the usage continues without such maintenance and exceeds a higher usage threshold, the system displays an error message on its display screen and the system transitions into an error state during which medical procedures are not allowed to be performed. The usage-related information may also be communicated to a remote computer which gathers and processes usage-related information from a number of medical robotic systems to estimate resource requirements for timely performing preventive maintenance on the medical robotic systems, and anticipated service revenues from such maintenance.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a top view of an operating room employing a medical robotic system utilizing aspects of the present invention.

FIG. 2 illustrates a perspective view of a patient-side cart included in a medical robotic system, utilizing various aspects of the present invention.

FIG. 3 illustrates a perspective view of a slave manipulator of a patient-side cart incorporating various aspects of the present invention.

FIG. 4 illustrates a perspective view of a patient-side cart with exposed positioning linkages for supporting slave manipulators, utilizing aspects of the present invention.

FIGS. 5˜6 illustrate front and rear perspective views of a vertical structure of the patient-side cart incorporating various aspects of the present invention.

FIG. 7 illustrates a perspective view of a positioning linkage as part of a robotic arm included on a patient-side cart incorporating aspects of the present invention.

FIG. 8 illustrates a perspective view of a patient-side cart with robotic arms holding medical devices including a modified middle arm for holding and positioning an endoscope, utilizing aspects of the present invention.

FIGS. 9˜10 illustrate rear and front perspective views of a surgeon console included in a medical robotic system, utilizing aspects of the present invention.

FIG. 11 illustrates a block diagram of printed circuit assemblies included in a surgeon console and patient-side cart, utilizing aspects of the present invention.

FIG. 12 illustrates a flow diagram of a preventive maintenance method utilizing aspects of the present invention.

FIG. 13 illustrates a flow diagram of a method used for performing optional power down tasks in conjunction with a preventive maintenance method utilizing aspects of the present invention.

FIG. 14 illustrates a block diagram of a medical robotic system including a surgeon console and patient-side cart having removable memory units, utilizing aspects of the present invention.

FIG. 15 illustrates a block diagram of a system for centrally processing usage-related information from a number of remote medical robotic systems for preventive maintenance forecasting and other purposes, utilizing aspects of the present invention.

FIG. 16 illustrates a flow diagram of a method for monitoring preventive maintenance needs for a plurality of medical robotic systems, utilizing aspects of the present invention.

Claims

1. A preventive maintenance method for a medical robotic system, comprising: storing usage-related information for components of the medical robotic system in non-volatile memories respectively associated with the components;determining whether one or more usage thresholds for the components are exceeded according to the stored usage-related information; anddisplaying messages on a display screen of the medical robotic system identifying individual of the components to be recommended for preventive maintenance based upon such determination of whether one or more usage thresholds for the components are exceeded.

2. The preventive maintenance method according to claim 1, wherein the components include subsystems.

3. The preventive maintenance method according to claim 2, wherein the non-volatile memories reside in their respectively associated subsystems.

4. The preventive maintenance method according to claim 2, wherein the subsystems include a patient-side unit and a surgeon console.

5. The preventive maintenance method according to claim 4, wherein the subsystems include a first plurality of slave manipulators included in the patient-side unit, and a second plurality of master manipulators included in the surgeon console.

6. The preventive maintenance method according to claim 4, wherein the subsystems include a first plurality of removable subassemblies included in the patient-side unit, and a second plurality of removable subassemblies included in the surgeon console.

7. The preventive maintenance method according to claim 6, wherein the first plurality of removable subassemblies includes a first plurality of printed circuit assemblies and a battery.

8. The preventive maintenance method according to claim 7, wherein the patient-side unit includes a plurality of robotic arms adapted to hold and manipulate medical devices, and individual of the plurality of robotic arms includes a plurality of setup joints for setting up the robotic arm so that its held medical device is manipulatable about a pivot point and a plurality of active joints for manipulating the robotic arm so as to manipulate its held medical device about the pivot point.

9. The preventive maintenance method according to claim 8, wherein the individual of the plurality of robotic arms further includes a first plurality of motors for breaking corresponding of the plurality of setup joints of the robotic arm, and the first plurality of printed circuit assemblies includes a first printed circuit assembly for gathering setup joint position and setup joint motor data from the plurality of setup joints and corresponding first plurality of motors.

10. The preventive maintenance method according to claim 8, wherein the individual of the plurality of robotic arms further includes a second plurality of motors for moving corresponding of the plurality of active joints of the robotic arm, and the first plurality of printed circuit assemblies includes a second printed circuit assembly for gathering active joint position and active joint motor data from the plurality of active joints and corresponding second plurality of motors.

11. The preventive maintenance method according to claim 2, wherein the storing of usage-related information comprises: determining whether a usage-related countable event has occurred for one of the subsystems; andincrementing a count in a field dedicated to the event in one of the non-volatile memories respectively associated with the subsystem.

12. The preventive maintenance method according to claim 11, wherein the storing of usage-related information further comprises: adding an entry in an event list in conjunction with incrementing of the count, wherein the entry includes a date of the incrementing, and an identification of the usage-related countable event causing the incrementing.

13. The preventive maintenance method according to claim 11, wherein the non-volatile memory respectively associated with the subsystem is an electrically programmable read only memory.

14. The preventive maintenance method according to claim 11, wherein the non-volatile memory respectively associated with the subsystem is a flash electrically erasable and programmable read only memory, and the incrementing of the count is performed so as not to require erasure of any previously programmed bits in the flash electrically erasable and programmable read only memory.

15. The preventive maintenance method according to claim 1, wherein the components include joint related components of the medical robotic system.

16. The preventive maintenance method according to claim 1, wherein the components include a battery.

17. The preventive maintenance method according to claim 1, wherein the usage-related information includes a time that power is on for one of the components.

18. The preventive maintenance method according to claim 1, wherein the usage-related information includes a cycle count of a number of times that one of the components is powered up and down.

19. The preventive maintenance method according to claim 1, wherein the usage-related information includes a measure of time since installation of one of the components.

20. The preventive maintenance method according to claim 19, wherein a calendar date of the installation is stored in the non-volatile memory respectively associated with the component.

21. The preventive maintenance method according to claim 19, wherein a calendar date of the installation is stored along with a serial number of the component in a system configuration file of the medical robotic system.

22. The preventive maintenance method according to claim 1, wherein the usage-related information includes a measure of time since a last preventive maintenance was performed for one of the components.

23. The preventive maintenance method according to claim 22, wherein a calendar date of the last preventive maintenance for the component is stored in the non-volatile memory respectively associated with the component.

24. The preventive maintenance method according to claim 22, wherein a calendar date of the last preventive maintenance for the component is stored in a system configuration file of the medical robotic system.

25. The preventive maintenance method according to claim 1, wherein the usage-related information includes a count of a number of medical procedures performed using one of the components.

26. The preventive maintenance method according to claim 1, wherein the usage-related information includes an accumulated period of time that one of the components is electrically conducting.

27. The preventive maintenance method according to claim 1, wherein the components include a patient-side unit having a spring that is extendable along a vertical direction to assist in setting up a corresponding robotic arm of the patient-side unit, and the usage-related information includes a count of a number of direction changes of the spring in the vertical direction.

28. The preventive maintenance method according to claim 1, wherein the components include a patient-side unit having a spring that is extendable along a vertical direction to assist in setting up a corresponding robotic arm of the patient-side unit, and the usage-related information includes a count of a number of times the spring changes direction in each of a plurality of zones defined along the vertical direction.

29. The preventive maintenance method according to claim 1, further comprising: updating a system configuration file of the medical robotic system with the usage-related information stored in the non-volatile memories.

30. The preventive maintenance method according to claim 29, wherein the updating of the system configuration file is performed during a power up process of the medical robotic system.

31. The preventive maintenance method according to claim 29, wherein the updating of the system configuration file is performed during a power down process of the medical robotic system.

32. The preventive maintenance method according to claim 29, wherein the determination of whether one or more usage thresholds for the components are exceeded, comprises: reading an item from the system configuration file; anddetermining whether the item has exceeded one or more usage thresholds for one of the components related to the item.

33. The preventive maintenance method according to claim 1, wherein the determination of whether one or more usage thresholds for the components are exceeded is performed during a power up process performed by the medical robotic system.

34. The preventive maintenance method according to claim 1, wherein the messages are displayed during a power up process performed by the medical robotic system.

35. The preventive maintenance method according to claim 1, further comprising: copying a snapshot of the contents of the non-volatile memories to a removable memory unit during a power down process performed by the medical robotic system.

36. The preventive maintenance method according to claim 35, wherein the removable memory unit is insertable into a memory slot in a surgeon console of the medical robotic system.

37. The preventive maintenance method according to claim 1, further comprising: communicating the stored usage-related information to a remote location over a communication medium.

38. The preventive maintenance method according to claim 37, wherein the communication medium is the Internet.

39. The preventive maintenance method according to claim 37, wherein the communication medium is a telephone line.

40. The preventive maintenance method according to claim 1, wherein the displaying of messages on the display screen of the medical robotic system comprises: displaying an error message if a first usage threshold is exceeded; anddisplaying a warning message if a second usage threshold that is lower than the first usage threshold is exceeded.

41. The preventive maintenance method according to claim 40, further comprising: transitioning the medical robotic system into an error state so that a medical procedure may not be performed using the medical robotic system if the error message is to be displayed as a result of the first usage threshold being exceeded.

42. In a medical robotic system including a patient-side unit having robotic arms adapted to hold and manipulate medical devices, and a surgeon console having a display screen and a processor configured to control movement of the robotic arms and manipulation of the medical devices, the patient-side unit and surgeon console each including a plurality of subassemblies, wherein the improvement comprises: individual of the plurality of subassemblies configured to store its usage-related information in a non-volatile memory included in the subassembly; andthe processor is further configured to determine whether one or more usage thresholds have been exceeded according to the usage-related information, and display one or more messages on the display screen identifying individual of the subassemblies requiring preventive maintenance according to such determination.

43. The medical robotic system according to claim 41, wherein the plurality of subassemblies are removable subassemblies.

44. The medical robotic system according to claim 41, wherein the individual of the plurality of subassemblies is configured to store its usage-related information in the non-volatile memory by: determining whether a usage-related countable event has occurred for the subassembly; andincrementing a count in a field dedicated to the event in the non-volatile memory.

45. The medical robotic system according to claim 44, wherein the non-volatile memory is a flash electrically erasable and programmable read only memory, and the incrementing of the count is performed so as not to require erasure of any previously programmed bits in the flash electrically erasable and programmable read only memory.

46. The medical robotic system according to claim 44, wherein the usage-related information includes a time that power is on for the subassembly.

47. The medical robotic system according to claim 44, wherein the usage-related information includes a cycle count of a number of times the subassembly is powered up and down.

48. The medical robotic system according to claim 44, wherein the usage-related information includes a measure of time since installation of the subassembly.

49. The medical robotic system according to claim 48, wherein a calendar date of the installation is stored in the non-volatile memory.

50. The medical robotic system according to claim 48, wherein a calendar date of the installation is stored along with a serial number of the subassembly in a system configuration file of the medical robotic system.

51. The medical robotic system according to claim 44, wherein the usage-related information includes a measure of time since a last preventive maintenance of the one of the subassembly.

52. The medical robotic system according to claim 51, wherein a calendar date of the last preventive maintenance is stored in the non-volatile memory.

53. The medical robotic system according to claim 51, wherein a calendar date of the last preventive maintenance is stored in a system configuration file of the medical robotic system.

54. The medical robotic system according to claim 44, wherein the usage-related information includes a count of a number of medical procedures performed using the subassembly.

55. The medical robotic system according to claim 44, wherein the usage-related information includes an accumulated period of time that the subassembly is electrically conducting.

56. The medical robotic system according to claim 44, wherein the plurality of subassemblies includes a subassembly for the patient-side unit having a spring extendable along a vertical direction to assist in setting up a corresponding one of the robotic arms, and the usage-related information includes a count of a number of direction changes in the vertical direction of the spring.

57. The medical robotic system according to claim 44, wherein the plurality of subassemblies includes a subassembly for the patient-side unit having a spring extendable along a vertical direction to assist in setting up a corresponding one of the robotic arms, and the usage-related information includes a count of a number of times the spring changes direction in each of a plurality of zones defined along the vertical direction.

58. The medical robotic system according to claim 41, wherein the processor is further configured to: update a system configuration file of the medical robotic system with the usage-related information stored in the non-volatile memories.

59. The medical robotic system according to claim 58, wherein the updating of the system configuration file is performed during a power up process of the medical robotic system.

60. The medical robotic system according to claim 58, wherein the updating of the system configuration file is performed during a power down process of the medical robotic system.

61. The medical robotic system according to claim 58, wherein the processor is configured to determine whether one or more usage thresholds for the subassembly are exceeded by: reading an item from the system configuration file; anddetermining whether the item has exceeded the one or more usage thresholds for the subassembly related to the item.

62. The medical robotic system according to claim 41, wherein the one or more messages are displayed during a power up process performed by the medical robotic system.

63. The medical robotic system according to claim 41, wherein the one or more messages are displayed by: displaying an error message if a first usage threshold is exceeded; anddisplaying a warning message if a second usage threshold that is lower than the first usage threshold is exceeded.

64. The medical robotic system according to claim 63, wherein the processor is further configured to transition into an error state wherein a medical procedure may not be performed if the error message is to be displayed as a result of the first usage being exceeded.

65. The medical robotic system according to claim 41, wherein the processor is further configured to: copy a snapshot of the contents of the non-volatile memories to a removable memory board during a power down process performed by the medical robotic system.

66. The medical robotic system according to claim 41, wherein the processor is further configured to: communicate the stored usage-related information to a remote location over a communication medium.

67. The medical robotic system according to claim 66, wherein the communication medium is the Internet.

68. The medical robotic system according to claim 66, wherein the communication medium is a telephone line.

69. A method for monitoring preventive maintenance needs for a plurality of medical robotic systems, comprising: periodically receiving usage-related information for monitored components from each of the plurality of medical robotic systems; andprocessing the periodically received usage-related information to estimate when preventive maintenance will be required for each of the monitored components of the plurality of medical robotic systems.

70. The method according to claim 69, wherein the usage-related information includes counts of usages, and the estimation of when preventive maintenance will be required for each of the monitored components comprises: estimating when the count of each usage for each monitored component will reach a corresponding usage threshold.

71. The method according to claim 69, further comprising: estimating resource needs for performing preventive maintenance for the plurality of medical robotic systems.

72. The method according to claim 69, further comprising: estimating service revenues generated by performing preventive maintenance for the plurality of medical robotic systems.