Patent Grant
9068628
The embodiments of the invention relate generally to robotic surgical systems. More particularly, the embodiments of the invention relate to robotic surgical arms.
Typical robotic surgical arms include a number of joints and links to provide a range of motion to form a work envelope for an end effector coupled thereto. It is desirable to improve the range of motion of robotic surgical arms to increase the work envelope of the end effectors coupled thereto to perform a wider variety of robotic surgical procedures.
Typical robotic surgical arms further include a plurality of metal control cables routed therein which are moved to mechanically control the motion of the links about the joints and the motion in the end effector. The use of the plurality of metal control cables is expensive and complicates the maintenance of the robotic surgical arms. It is desirable to reduce the manufacturing and maintenance costs of robotic surgical arms while at the same time improving its range of motion.
The embodiments of the invention are summarized by the claims that follow below.
It will be appreciated that all the drawings of Figures provide for herein are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the elements being illustrated
In the following detailed description of the embodiments of the invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one skilled in the art that the embodiments of the invention may be practiced without these specific details. In other instances well known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments of the invention.
The embodiments of the invention include methods, apparatus and systems for a robotic surgical system. In one embodiment of the invention a robotic surgical system is provided including one or more robotic surgical arms under the control of at least one multi-layer or multi-ply control strap.
Referring now to
A user or operator O (generally a surgeon) performs a minimally invasive surgical procedure on patient P by manipulating control input devices 160 at a master control console 150. A computer 151 of the console 150 directs movement of robotically controlled endoscopic surgical instruments 101A-101C by means of one or more control cables 159, effecting movement of the instruments using a robotic patient-side system 152 (also referred to as a patient-side cart). The robotic patient-side system 152 has one or more robotic arms 158 with the strap drive. Typically, the robotic patient-side system 152 includes at least three robotic manipulator arms 158A-158C supported by linkages 156,156′, with a central robotic arm 158B supporting an endoscopic camera 101B and the robotic arms 158A,158C to left and right of center supporting tissue manipulation tools 101A,101C.
Generally, the robotic patient-side system 152 includes a positioning portion and a driven portion. The positioning portion of the robotic patient-side system 152 remains in a fixed configuration during surgery while manipulating tissue. The driven portion of the robotic patient-side system 152 is actively articulated under the direction of the operator O generating control signals at the surgeon's console 150 during surgery. The actively driven portion of the robotic patient-side system 152 is generally referred to herein as the robotic arms or alternatively to robotic surgical manipulators. The positioning portion of the robotic patient-side system 152 that is in a fixed configuration during surgery may be referred to as “set up arms” 156, 156′ with positioning linkage and/or “set-up joints”. In an alternate embodiment of the invention, the robotic patient-side system 152 may be replaced by set up arms that couple at one end to left and right sides of the operating table T. The three robotic manipulator arms 158A-158C may then be coupled to the opposite end of the set-up arms to ground to the table T.
For convenience in terminology, manipulators such as robotic surgical arms 158A, 158C actuating the tissue affecting surgical tools 101A,101C are generally referred to herein as a PSM (patient-side manipulator), and a robotic surgical arm 158B controlling an image capture or data acquisition device, such as the endoscopic camera 101B, is generally referred to herein as a ECM (endoscopic-camera manipulator), it being noted that such telesurgical robotic manipulators may optionally actuate, maneuver and control a wide variety of instruments, tools and devices useful in surgery.
An assistant A may assist in pre-positioning of the robotic patient-side system 152 relative to patient P as well as swapping tools or instruments 101 for alternative tool structures, and the like, while viewing the internal surgical site via an assistant's display 154.
Referring now to
The robotic patient-side system 152 generally has dimensions suitable for transporting between operating rooms. It typically can fit through standard operating room doors and onto standard hospital elevators. The robotic patient-side system 152 may have a weight and a wheel (or other transportation) system that allows the cart to be positioned adjacent an operating table by a single attendant. The robotic patient-side system 152 may be sufficiently stable during transport to avoid tipping, and to easily withstand overturning moments that may be imposed at the ends of the robotic arms during use.
Referring now to
The stereo viewer 312 has two displays where stereo three-dimensional images of the surgical site may be viewed to perform minimally invasive surgery. When using the master control console, the operator O typically sits in a chair, moves his or her head into alignment with the stereo viewer 312 to view the three-dimensional images of the surgical site. To ensure that the operator is viewing the surgical site when controlling the robotic surgical tools 101, the master control console 150 may include the viewing sensor 320 disposed adjacent the binocular display 312. When the system operator aligns his or her eyes with the binocular eye pieces of the display 312 to view a stereoscopic image of the surgical worksite, the operator's head sets off the viewing sensor 320 to enable the control of the robotic surgical tools 101. When the operator's head is removed the area of the display 312, the viewing sensor 320 can disable or stop generating new control signals in response to movements of the touch sensitive handles in order to hold the state of the robotic surgical tools.
The arm support 314 can be used to rest the elbows or forearms of the operator O (typically a surgeon) while gripping touch sensitive handles of the control input 160, one in each hand, in the workspace 316 to generate control signals. The touch sensitive handles are positioned in the workspace 316 disposed beyond the arm support 314 and below the viewer 312. This allows the touch sensitive handles to be moved easily in the control space 316 in both position and orientation to generate control signals. Additionally, the operator O can use his feet to control the foot-pedals 318 to change the configuration of the surgical system and generate additional control signals to control the robotic surgical instruments.
The computer 151 may include one or microprocessors 302 to execute instructions and a storage device 304 to store software with executable instructions that may be used to generate control signals to control the robotic surgical system 100. The computer 151 with its microprocessors 302 interprets movements and actuation of the touch sensitive handles (and other inputs from the operator O or other personnel) to generate control signals to control the robotic surgical instruments 101 in the surgical worksite. In one embodiment of the invention, the computer 151 and the stereo viewer 312 map the surgical worksite into the controller workspace 316 so it feels and appears to the operator that the touch sensitive handles are working over the surgical worksite.
Surgical instruments 101A,101C on the robotic surgical arms 158A,158C with the strap drive typically include elongated shafts, with proximal and distal ends. End effectors are generally mounted on wrist-like mechanisms pivotally mounted on the distal ends of the shafts, for enabling the instruments to perform one or more surgical tasks. Generally, the elongated shafts of surgical instruments allow the end effectors to be inserted through entry ports in a patient's body so as to access the internal surgical site. Movement of the end effectors is generally controlled via master controls on the control console 150.
Referring now to
With reference to
Referring now to
Referring now to
The robotic surgical arms 158A,158C further include a mounting base 540 that allows them to be mounted and supported by set-up arms/joints of a cart mount, ceiling mount, floor/pedestal mount, or other mounting surface of a patient side system. The mounting base 540 is pivotally coupled to the first link 541 to yaw the serial linkage of the robotic surgical arm about a yaw axis.
The third link 543 has a bend with respect to the pitch axis that is offset from center. The bend in the third link allows the links 542-544 to be brought more closely together and provide a greater range of pitch in the robotic arm, as is illustrated in
Referring now to
As discussed previously, alternate terms may be applied to the links 541-542 herein. The first link 541 may be referred to as an offset yaw link 541 or a parallelogram linkage base 541. The second link 542 may be referred to as a lowered vertical link 542 or drive link 542. The third link 543 may be referred to as the main bent link 543. The fourth link 544 may be referred to as the instrument holder link 544. Links 541-543 may also be referred to as rigid links. Additionally, the term “joint” may be used interchangeably herein with the term “pivot”.
In robotic surgical systems for minimally invasive surgery, it is desirable to move and constrain a robotic surgical tool substantially at a single fixed remote center point 666. Typically the fixed remote center point 666 is near the point of insertion of the surgical tool into the patient P. The center of rotation 666 may be aligned with the incision point to the internal surgical site, for example, by a trocar or cannula at an abdominal or thoracic wall during laparoscopic or thorascopic surgery. As the fixed remote center point 666 is on an insertion axis 574 of the surgical tool and the robotic camera and is offset and remote from ground, the embodiments of the robotic surgical arm may also be referred as an offset remote center manipulator instead of robotic surgical arm or surgical manipulator.
The robotic surgical arms 158A-158C have a strap and pulley drive train system to control the pivoting of the links about the joints 512-514. The term “strap” may be used interchangeably with the terms “belt” and “band” herein to mean a segment of one or more material layers that are not formed in a continuous loop. If a continuous loop of one or more material layers is to be referenced herein, the phrase “continuous belt” or loop may be used. As the links of the robotic surgical arms 158A-158C do not rotate more than three hundred sixty degrees about the joints 512-514, instead pivoting less than three hundred sixty degrees about the joints 512-514, straps may be used to couple to the pulleys of the drive train system.
Referring now to
While the robotic surgical arm 600 includes links and joints as described herein, the strap drive train of the robotic surgical arm 600 includes six pulleys 604, 608A, 608B, 610, 612A, 612B and four straps 624A, 624B, 626A, 626B in one embodiment of the invention. The six pulleys 604, 608A, 608B, 610, 612A, 612B and four straps 624A, 624B, 626A, 626B are configured with the links and joints or the robotic surgical arm 600 to constrain the motion of the shaft 430 of the surgical tool or endoscopic camera relative to the center of rotation 666.
In the second link 542, straps 624A-624B are coupled between pulleys 604 and 608A. In the third link 543, the straps 626A-626B are coupled between pulleys 608B,610 and ride over the idler pulleys 612A,612B, respectively, in one embodiment of the invention. At the second joint, pulley 604 is rigidly coupled to the first link 541. At the third joint 513 as is illustrated in the
As illustrated better in
Referring now to
The strap drive train of the robotic surgical arm 600′ includes five pulleys 604, 608A, 608B, 610, 612′ and five straps 624A, 624B, 626A, 627, 628 in one embodiment of the invention. The five pulleys 604, 608A, 608B, 610, 612′ and five straps 624A, 624B, 626A, 627,628 are configured with the links and joints of the robotic surgical arm 600′ to constrain the motion of the shaft 430 of the surgical tool or endoscopic camera relative to the center of rotation 666.
In the second link 542, straps 624A-624B are coupled between pulleys 604 and 608A. In the third link 543′, a single idler pulley 612′ may be used. In the third link 543′, the strap 626A is coupled between pulleys 608B, 610 and rides over the idler pulley 612′; the strap 627 is coupled between pulleys 612′, 610; and strap 628 is coupled between pulleys 608B, 612′, in this embodiment of the invention. At the third joint 513 the separation between pulleys 608A and 608B allows them to freely rotate about each other even though pulley 608A is rigidly coupled to the third link 543′ and pulley 608B is rigidly coupled to the second link 542. As is illustrated in
With the exception of the third link 543′ and the straps and pulleys therein, the robotic surgical arm 600′ is substantially similar to the robotic surgical arm 600 and its description is incorporated here by reference as the same reference numbers are used,
The straps 624A, 624B, 626A, 626B in the robotic surgical arms 600 and the straps 624A, 624B, 626A, 627,628 in robotic surgical arm 600′ may also be referred to as flexible elements and may include straps, belts, chains, or cables connected around the pulleys 604, 608A, 608B, 610, and 612A, 612B or 612′. As described in greater detail with reference to FIGS. 9B,10B, the straps comprise multiple layers of multiple plies of metal. In one embodiment of the invention, the multiple plies of metal are formed out of stainless steel belts having a breaking strength of approximately 800 lbs or more and being about a quarter inch wide. The belts are preferably multi-layered utilizing at least two or three plies, preferably five or six plies to be strong enough to carry an adequate tension load yet sufficiently thin enough to not fatigue when repeatedly bent around the pulleys.
As the straps 624A, 624B and 626A, 626B or 626A,627,628 are only segments and are offset from each other, they provide stress reduction, particularly at the attachment points, thus minimizing failures. Further, the straps allow for convenient tension and position adjustments as is further described below. It will further be appreciated that straps 624A, 624B as well as straps 626A, 626B may each optionally comprise a continuous single belt. Additionally, the metal straps may be loosely coupled to flat flex cables that carry electrical signals along the manipulator arm as further described in U.S. provisional patent application No. 60/752,788. Moreover, while the straps are preferably formed of multiple plies of metal, multi-ply belts of other materials, single-ply belts of other materials, mechanical cables, multiple mechanical cables, timing belts with teeth, or other types of drive straps may be used.
Pulleys 604 and 608A have approximately the same diameter, e.g., 2.2 inches. Smaller pulleys 608B and 610 have approximately the same diameter, e.g., 1.8 inches. In one embodiment of the invention, there are two idler pulleys 612A, 612B at the bend of the main link 543 to facilitate running of straps 626A, 626B in opposite directions so as to allow for attachment of the belts ends to be more robust. In another embodiment there is one idler pulley 612′ at the bend of the main link 543′ as the straps 626A,627,628 turn the pulley 612′ in the same direction even though the midspans of the straps 626A,627,628 may be moving in opposite directions. However, as the three straps 626A,627,628 ride on or wrap around the idler pulley 612′, it is wider at the bend than the two idler pulleys 612A,612B. It will be appreciated that the term pulley 604, 608A, 608B, 610, 612A, 612B, 612′ can include wheels, gears, sprockets, pulleys with bullnose pins, and the like.
Besides straps/belts/bands and pulleys there are other drive train means that may be used in the robotic surgical arm such as a continuous toothed timing belt with a timing gear, mechanical cables (one or more in parallel together) with shouldered pulleys, chains with sprockets, continuous perforated metal tapes around pulleys with bull nose pins, as well as other like drive train.
As discussed previously, the robotic surgical manipulator or robotic surgical arm 600 includes a plurality of links 541-544 coupled together through a series of joints 511-514. The first link 541 also referred to as the parallelogram linkage base 541 supports the instrument holder link 546 through the rigid links 542, 543 coupled together by the rotational pivot joints 512, 513, 514.
Using alternate terminology, the links of the robotic surgical arm include an offset yaw link 541, a lowered vertical link 542, and a main bent link 543. The main link 543 is bent at an angle so as to provide clearance for the vertical link 542 to rest on the main bent link 543. This clearance prevents inter-linkage collisions between the vertical link 542 and the main bent link 543. For example, the main link 543 may be bent at an angle of about twenty-two degrees to allow clearance over a pitch dive 872 as shown in
At the center of rotation 666, three axes intersect and may be defined for the robotic arm 600. A yaw axis 656 about which the robotic arm rotates, a pitch axis (which is perpendicular to the page) about which the robotic arm pitches, and an insertion axis 674 along which the shaft 430 is moved intersect with each other at the remote center 666.
The surgical tool 428 can be pivotally rotated though desired yaw angles 658 around the yaw axis 656 and pivotally rotated though desired pitch angles 872 around the pitch axis (see
Referring now momentarily to
A top long side 868A of the parallelogram 864 is defined as the distance between axes of rotation at joints 513 and 514 generally defined by the third link 543. A left short side 867A of the parallelogram is defined as the distance between axes of rotation at joints 512 and 513 generally defined by the second link 542. The strap drive train is assembled in the robotic arm with the pulleys in proper positions in order to define the bottom long side 868B and the right short side 867B of the parallelogram.
Note that the yaw axis 656 and the parallelogram 864 intersect the insertion axis 674 of the shaft 430 at the remote center of rotation 666. Also note that the parallelogram 864 is angularly offset from the yaw axis 656 by an angle Alpha. That is, the robotic arm 600 offsets or decouples the first joint 512 and the first side 868B of the parallelogram 864 from the yaw axis 656 by the angle Alpha. The angle Alpha may be in a range from about two degrees to about forty five degrees and preferably falls in a range from about two degrees to about thirty five degrees. This offset enhances the range of motion in the instrument 428 about the remote center point 666 relative to the pitch axis, as indicated by arrow 872. The manipulator 600 further allows for an enhanced range of motion relative to the yaw axis 656, as indicated by arrow 658. An improved pivot range of motion along pitch and yaw axes in turn enhances the efficiency and ease of use of the robotic surgical arm in a robotic surgical system.
As
The second link 542 and the fourth link 544 are likewise kept from rotating relative to each other. In one embodiment of the invention, this is accomplished by the straps 626A, 626B coupled between pulleys 608B and 610 and running over the idler pulleys 612A, 612B; and by pulley 608B being rigidly fixed to the second link 542 and by the pulley 610 being rigidly fixed to the fourth link 544. In another embodiment of the invention, this is accomplished by the strap 626A coupled between pulleys 608B and 610 running over the idler pulley 612′; and strap 628 coupled between pulleys 608B, 612′ and strap 627 coupled between pulleys 612′,610; with pulley 608B being rigidly fixed to the second link 542 and pulley 610 being rigidly fixed to the fourth link 544.
Hence, links 541 and 543 can translate but not rotate relative to each other to maintain the parallelogram shape 864. Likewise, links 542 and 544 can translate but not rotate relative to each other to maintain the parallelogram shape 864.
The mounting base 540 includes a motor 601 illustrated in
The second link 542 includes a motor 602 coupled to the pulley 604 to pitch the robotic arm 600 as illustrated in
At least one of the rigid links 541, 542, 543 coupled together by rotational pivot joints 512, 513, 514 are not completely balanced, relative to gravity, in at least one degree of freedom. As such, a brake system may be coupled to the articulate linkage assembly 600. The brake system releasably inhibits articulation of at least one of the joints 512, 513, 514. It will be appreciated that the offset remote center manipulator 600 may comprise a lighter system as the linkage is free of any counter-balancing weights. As such, the links 541, 542, 543 will preferably comprise sufficiently rigid and stiff structures so as to support any vibration issues associated with a lighter surgical manipulator 600. It will further be appreciated that the offset remote center manipulator 600 may optionally be balanced by the use of weights, tension springs, gas springs, torsion springs, compression springs, air or hydraulic cylinders, torque motors, or combinations thereof.
The straps in each link, drive the pitch axis of the robotic surgical arm. The first set of straps 624A-624B in the second link 542 are used to connect pulley 604 to pulley 608A in a 1:1 ratio (i.e., pulleys are of the same diameter). As discussed previously, joint pulley 604 is rigidly connected to the first link (Link 1) 541 and joint pulley 608A is rigidly connect to the third link (Link 3) 543. Thus, one unit of rotation of the second link (Link 2) about the second joint 512 in one direction (e.g., clockwise) causes one unit of rotation of the third link (Link 3) about the third joint 513 in an opposite direction (e.g., counter clockwise). Thus, the first set of straps ensures that the third link 543 maintains the same angle relative to the first link 541, as the robotic surgical arm's pitch axis is moved.
The second set of straps in the third link 543 are used to connect joint pulley 608B to joint pulley 610 in a 1:1 ratio. Joint pulleys 608A and 608B are free to rotate about each other at the third joint 513. As discussed previously, pulley 608B is rigidly connected to the second link (Link 2) 542 and pulley 610 is rigidly connected to the fourth link (Link 4) 544. One unit of rotation of the second link (Link 2) about the second joint 512 causes one unit of rotation of the fourth link (Link 4) about the fourth joint 514. Thus, the first and second set of straps ensures that the fourth link (Link 4) 544 maintains the same angle relative to the second link (Link 2) 542, as the robotic surgical arm's pitch axis is moved.
To provide a strap drive system linking pulleys at the joints of the bent third link 543 (the hockey stick shaped link), a pair of idler pulleys are provided near the bend in the link in one embodiment of the invention. The pair of idler pulleys direct one or more of the straps of the strap drive system in the link housing from one end to the other through the bend of the link. Thus, one or more of the straps may bend around the idler pulleys of the third link 543 to facilitate the hockey-stick shape and provide the proper kinematics and range of motion for the robotic surgical arm. As discussed previously, a two-strap drive system is used for connecting pulleys in the third link 543 in one embodiment of the invention. Alternatively, a three-strap drive system is used for connecting pulleys in the third link 543 in another embodiment of the invention.
Referring now to
Because the third link (Link 3) 543 has a bend in it (e.g., the third link may be referred to being hockey-stick shaped), each strap 626A-626B wraps around it's own respective idler pulley 612A-612B, because the belts rotate in opposite directions about them. The idler pulleys 612A, 612B allow the straps 626A, 626B to navigate around the bend in the third link 543. In one embodiment of the invention, the idler pulleys are also used to tension the straps as discussed further below. Otherwise, the idler pulleys are passive idlers.
The system 900 may be advantageous for single-ply straps or cables, as it requires only two straps. However in a number of embodiments of the invention, the straps are formed of a plurality of layers or plies of material. In a preferred embodiment of the invention, each of the straps includes a plurality of metal layers or plies. The plurality of layers or plies provides a safety redundancy over that of a single cable or single ply strap or belt. If any single ply breaks in a multi-ply strap due to a manufacturing defect, fatigue, or overload for example, the remaining plies prevent the robotic surgical arm from collapsing.
Referring now to
In the two belt system, strap 626B is reverse bent over the idler pulley in comparison with how it wraps around the joint pulleys. That is, one side of the strap wraps around the joint pulleys while the opposite side wraps around the idler pulley. This can cause increased fatigue in the strap 626B unless alleviated by its design.
Referring now to
The multi-ply metal straps are an enabling technology for the robotic surgical arm due to their high stiffness and strength, zero backlash, low hysteresis, low friction, compact packaging, and redundant construction for safety. Their ability to bend around idler pulleys in third link (Link 3) 543 also enables the hockey-stick shape for proper kinematics and range of motion.
In a preferred embodiment of the invention, three straps are used in the third link to couple between the joint pulleys to avoid use of an antifriction layer between plies of the strap 626B.
Referring now to
The idler pulley 612′ is used in the system 1000 to negotiate the bend in the third link (Link 3) 543 (i.e.—hockey-stick shaped link). In one embodiment of the invention, one end of the straps may be used to generate tension in each strap between the pulleys. In another embodiment of the invention, the idler pulley 612′ may be used to tension the straps. In this case, the idler pulley 612′ is a passive idler.
Referring now to
As alluded to previously, the three strap system 1000 has some advantages. For any strap or cable (single ply or multi ply), the three-strap configuration eliminates reverse bending, to avoid fatigue caused by alternating stresses. In the case of multiple plies or layers, the three strap system eliminates pinching and stretching of plies at the idler pulley due to reverse bending, further allowing the anti-friction layer to be avoided in the formation of the straps. Another advantage of the three strap system is that a single idler pulley may be used, since all straps are being rotated in the same direction at the idler pulley 612′. Moreover, a single idler pulley may be used to tension all three straps in the system 1000.
Additionally, multi-layer or multi-ply metal straps in the drive train of the robotic surgical arm has a number of advantages over using metal mechanical cables. The multi-ply straps are more reliable, have a greater stiffness, have an excellent ability to maintain tension, and have superior strength than cables. Moreover, using conductive metal or alloy materials for the plies or layers of the metal straps assists in grounding the robotic surgical arm since they are electrically conductive.
Referring now to
Referring now to
To receive the end of the strap 1110, the pulley 1101 further includes a recess 1103 in its circumference that is at least as wide as the strap 1110. The recess 1103 becomes progressively deeper until it joins with the pocket 1102. The recess ends at the lip 1105.
The tab 1112 is a rectangularly shaped geometric solid (e.g., rectangular prism) in one embodiment of the invention including a front side, a back side, and left and right sides formed by a thickness of the tab. The tab 1112 further includes a bottom surface and an opposing top surface to couple to a bottom surface of the strap 1110. The width of the tab may be substantially similar to the width of the strap.
In a preferred embodiment of the invention, the strap 1110 is a metal strap having one or more layers or plies as discussed previously with reference to
The pocket in the pulley is shaped to receive the tab 1112. The pocket 1102 includes a lip 1105 at the back of the pocket to retain the tab therein. The strap is sufficiently stiff enough to behave as a beam, which is relaxed when it is straight. When the strap is deformed around the circumference of the pulley and the tab 1112 is inserted into the pocket, the lip 1105 exerts a force on the tab to retain it in the pocket. In the strap's deformed state, it wants to straighten and exerts a load on the tab that attempts to rotate the tab clockwise with reference to the view of
The tab 1112 and strap 1110 hook into and unhook from the pocket 1102 around the circumference of the pulley 1101, in contrast to being slid out through a side of the pulley. This allows easier replacement of the belts where sides of the pulley are constrained to a limited area.
With the tab 1112 in the pocket 1122 and the strap under tension, there is a first gap 1121 between an edge of the lip 1105 and the end of the strap 1110 and a second gap 1123 between a back stop of the pocket 1102 and the tab 1112 as illustrated best by
As illustrated in
As discussed previously, the straps 1110 in the robotic surgical arm are metal straps having one or more layers or plies in a preferred embodiment of the invention and may be coupled to the tab 1102 by welding as illustrated by the welds 1114. The welds 1114 form a heat-affected zone that locally reduce the strap's material strength. That is, the “heat affected zone” surrounding the welds is weaker than the as-rolled condition of the portion of the straps sufficiently away from the welds.
A reliable and safe design for the straps calls for a breaking load at the straight portion of the strap between pulleys (e.g., midspan) to be less than or equal to the breaking load at the end tabs. Because the strength of the welds 1114 have more variation at the ends of the strap than at the midspan of the strap, a sensible design to consider for the wrap angle of the straps is one where the straps nearly always break not at the welds 1114 but well away from the welds (at midspan, for example). In the embodiments of the invention, the wrap angle was increased to sufficiently meet this criteria in a majority of the cases.
Testing on sample lots of straps wrapped around pulleys at each end with a worst case wrap angle indicates that a vast majority of ultimate failures occur not at but away from the welds 1114 so as to have a safe and reliable design. Theoretical calculations have also been made and show that a minimum wrap angle (worst case) of one hundred six degrees (1.85 radians) is sufficient for five or six ply metal belts with welded tabs/blocks to withstand 2025 pounds of force in the straight portion between pulleys.
In one embodiment of the invention, an idler pulley is pivotally coupled to a swing arm tensioner to automatically set and maintain the correct tension in the straps. In another embodiment of the invention, a strap tensioner is part of a pin, tab, or block coupling the strap to a pulley and includes a manually adjustable screw.
Referring now to
Referring now to
The base 1210 of the tensioner couples to the housing or frame of the link for support in order to apply a force against the one or more straps.
The swing-arm tensioner automatically sets and maintains correct tension in bands when assembly is completed. The tension T in the straps is set by torsional spring 1215 and provides for automatic adjustment of the tension in the straps. The torsional spring 1215 is selected with a spring constant to set the desired tension in the straps at a given idler pulley or pulleys. With the tension being automatically set by the torsional spring, there is no need for tension calibration by a service person and thus no risk of an incorrect tension adjustment. Alternatively, a tension spring, compression spring, leaf spring, or other means of applying a force could be used in place of the torsional spring 1215.
However in one embodiment of the invention, the arm of the tensioner may be locked in place by a fastener, such as a screw 1231, so that the torsional spring does not adjust tension during normal operation. The screw 1231 would pass through a slot 1230 in arm 1212, and screw into a threaded hole in third link 543, thus locking the arm. Instead, the tension on the straps may be periodically recalibrated in the field. The fastener can lock the position of the arm 1212 relative to the base 1210 after the strap system is assembled together. To recalibrate the tension on the straps in the field, the fastener is simply removed or loosened to free the arms to swing and allow the spring to adjust the tension and then replaced or retightened. In the case of a screw, it may be unscrewed to release and then screwed in to retighten after automatic adjustment of the tension by the torsional spring. The advantage of locking the tensioner in place is that the compliance of the tensioner spring 1215 then does not affect the stiffness of the strap drivetrain. A stiffer drivetrain results in improved performance, due to less vibration of the robot.
In an alternative embodiment of the invention, an electrically engagable brake 1250 that locks the pivotal axis through the pivotable shaft 1211 so that the torsional spring does not adjust tension during normal operation. The brake 1250 may be periodically unlocked by computer 151, to allow the tension in the strap to be automatically reset. The brake 1250 is locked during surgery. The electrically engagable brake 1250 may reduce maintenance costs in that a maintenance person would not be required to periodically release a fastener to adjust tension as it is automatically performed by the computer 151. In other embodiments of the invention, the brake 1250 is not an electrically engagable brake but a brake that is pneumatically, hydraulically, or engaged by other means.
In the example geometry above, the reaction force “R” that acts between the pulley and the straps is congruent to two and one half times the tension “T” on the straps. Changes in geometry will alter the amount of reaction force and/or tension. However because both straps 626A,626B are automatically tensioned on the parallel idler pulleys 612A,612B, “slack” that develops in the straps and system will be taken up approximately by both straps being self-adjusted for tension by the tensioner 1201. Thus, the tensioner 1201 minimizes the rotation of the pulleys at the ends of the link as slack develops. Minimizing the rotation of pulleys in response to slackening minimizes error in the position of the remote center of motion (RCM) 666 in comparison with one idler pulley tensioner being used to tension a single strap in the link.
The swing arm tensioners may further include one or more swing arm sensors to quickly detect if a strap slackens indicating fatigue or if the strap fails or breaks. In this manner, the swing arm sensors provide a safety mechanism to protect a patient from harm. Sensor 1232 is a through-beam sensor, and it's beam would be broken if arm 1212 moved to block it's line-of-sight. Alternatively, other types of sensors to detect position of arm 1212 could be used.
Referring now to
In the preferred embodiment of the invention,
The pocket 1302 in the pulley 1301 is shaped to receive the tensioning block 1312. The tensioning block 1312 hooks into the pocket 1302. The pocket 1302 includes a lip 1305 at a back thereof to retain the tensioning block 1312 therein against longitudinal forces (i.e., the tension) placed on the strap. Additionally when no tension is being applied, a spring force in the metal strap 1310 keeps the block 1312 locked in place within the pocket so that it cannot be readily unhooked. In the event that a strap is slackened, removal of the block 1312 from the pocket is avoided so that the robotic surgical arm does not completely collapse and wildly move a surgical tool and injure a patient. The pocket further includes a stop 1306 at the front of the pocket 1302. The pocket 1302 further includes a side restraining protrusion 1307 extending from the stop 1306 to retain the front portion of the block therein against side forces that may be placed on the strap 1310.
To tension the strap 1310, the strap tensioning system 1300 further includes a fastener 1331. The fastener 1331 has significant forces applied to it from tensioning and coupling the strap to the pulley. The fastener 1331, such as a screw or bolt, has male threads 1332 at one end and a head 1333 at an opposite end with a tool receiver. The tool receiver in the head receives a tool to rotate the fastener. The tool receiver may be a slot, a hex socket, a cross, other type of indentation in the head, or the shape of the head itself, such as a hex head.
The tensioning block 1312 has a cylindrical opening 1335 with female threads 1336 to receive the fastener 1331 and mate with its male threads 1332. In one embodiment of the invention, the female threads 1336 may include a screw-lock helical coil to keep the fastener from rotating and changing the tension. The tensioning block has a limited distance to travel when being tensioned before its back side hits the front stop 1322. This distance between the block 1312 and the front stop 1322 is referred to as the tension travel distance DTT 1321.
The tensioning block 1312 generally includes a rectangularly shaped geometric solid (e.g., rectangular prism) portion at a front end and a cube shaped portion with the threaded opening 1335 at a back end, in one embodiment of the invention. The rectangularly shaped solid portion of the block 1312 further includes a bottom surface and an opposing top surface to couple to a bottom surface of the strap 1310. The width of the block may be substantially similar to the width of the strap.
In a preferred embodiment of the invention, the strap 1310 is a metal strap having one or more layers or plies as discussed previously with reference to
To receive the end of the strap 1310, the pulley 1301 includes a recess 1303 in its circumference that is at least as wide as the strap 1310. The recess 1303 becomes progressively deeper until it joins with the pocket 1302. The recess ends at the lip 1305 of the pulley 1301.
In addition to the recess 1303 and pocket 1302, the pulley 1301 has a cutout 1342 to receive the fastener 1331 and allow its head 1333 to rotate therein. In one embodiment of the invention, a clearance between the head 1333 and sides of the cutout 1342 are sufficient to attach a tool, such as a socket, to the head 1333 of the fastener 1331 so that it may be turned. The pulley 1301 further has a cylindrical opening 1340, that is slightly larger in diameter than the fastener 1331, that extends from the cutout 1342 into pocket 1302 to allow the fastener 1331 to pass into the pocket and mate with the threaded opening 1335 in the block 1312.
Without the fastener 1331, the tensioning block 1312 and strap 1310 hook into and unhook from the pocket 1302 through the recess 1303 in the circumference of the pulley 1301, as illustrated by
With the block 1312 in the pocket 1302 and the strap under tension, there is a gap between a back stop 1306 of the pocket 1302 and the block 1312, as illustrated in
To change the tension on the strap 1310, the fastener may be manually turned by a hand tool, such as by a screw driver, socket wrench, or nut driver; or an automated tool, such as a speed driving drill with a torque clutch. To increase the tension on the strap 1310, the fastener 1331 is tightened by turning clockwise for standard threads and counter clockwise for reverse threads. This pulls on the tensioning block 1312 in the pocket to increase the tension on the strap. To decrease the tension on the strap 1310, the fastener 1331 loosened by turning counter clockwise for standard threads and clockwise for reverse threads. This pushes on the tensioning block 1312 in the pocket to release the tension in the strap. The tension is set using a sonic tension meter, which measures the transverse frequency of vibration of the straps, when strummed. The screw 1331 is adjusted until the frequency that corresponds to the desired tension is achieved. This is substantially similar to using a sonic frequency guitar tuner to set the desired tension of guitar strings.
Referring now to
In
As the tension on the strap 1410 may be insufficient to keep the tensioning fastener 1431 from backing out on its own and reducing the tension, the system 1400 may include a locking fastener coupled to the tensioning fastener 1431. In this case to receive the locking fastener, the pulley 1401 includes an opening 1454A starting at its circumference or an opening 1454B starting from a side down to the opening 1340. In either case, the opening 1454A,1454B is threaded to receive a locking fastener 1456, such as a puck or set screw. A distal end of the fastener 1456 couples against the tensioning fastener 1431 to lock it and keep it from rotating and altering the tension in the strap 1410. The locking fastener 1456 may be formed of brass, such as a brass tip set screw or a brass puck.
The hook 1451 of the tensioning block 1412 mates with the hook 1452 of the end tab 1450. The end tab 1450 is preferably welded to the strap 1410. With the strap under tension, the end tab 1450 is captured within the pocket 1402. Additionally, as was previously discussed in greater detail, without any tension a spring force in the metal strap 1410 may keep the hooks 1451-1452 mated together within the pocket so that they cannot be readily unhooked from each other. In the event that the tensioning fastener fails due to overloading of the arm and the strap is completely slackened, the hooks 1451-1452 may remain mated together so that the robotic surgical arm does not completely collapse and wildly move a surgical tool and injure a patient. The pocket further includes a stop 1406 at the front of the pocket 1402.
As previously mentioned, the strap tensioning system 1400 includes the tensioning fastener 1431 to tension the strap 1410. The tensioning fastener 1431, such as a screw or bolt, has male threads 1432 at one end and a head 1433 at an opposite end with a tool receiver. The tool receiver in the head receives a tool to rotate the fastener. The tool receiver may be a slot, a hex socket, a cross, other type of indentation in the head, or the shape of the head itself, such as a hex head. The tensioning fastener 1431 has significant forces applied to it from tensioning and coupling the strap to the pulley. The first fastener, the tensioning fastener 1431, may be a silver plated fastener, such as a silver plated screw, to minimize galling that might otherwise be caused by dissimilar metals.
To keep the tensioning fastener 1431 from rotating and tension changing, use of the locking fastener 1456, such as a set screw, was described previously. In the preferred embodiment of the invention, the tensioning block 1412 and 1312 includes a screw-lock helical coil 1446 in the opening 1335 with its threads 1336 to receive the tensioning fastener 1431,1331. The screw-lock helical coil 1446 includes a couple of straight segments to squeeze on the screw and hold it in position. This increases the torque required to rotate the fastener 1431,1331 and screw it in or out of the opening 1335 in the block 1412,1312. This increased torque prohibits the tensioning fastener 1431,1331 from rotating on its own and changing the tension in the strap.
A washer 1458 may be inserted on the tensioning fastener 1431. The washer may be a star washer or a lock washer to further hold the position of the tensioning fastener 1431 when set.
The tensioning systems 1300 and 1400 each have a failsafe mechanism in case of failure of the fastener 1331, 1441. That is, if the tensioning fastener 1331,1431 breaks, the strap will not become free from the pulley 1301. The tensioner blocks 1312, 142 are captive in their respective pockets 1302,1402 in which they reside by a moment generated by the metal strap which was discussed previously with respect to the tab 1112. If the tensioning fastener 1331,1431 breaks free from the blocks, the block and strap will only move a small distance to the back stop 1306,1406 in the pocket, such as the fail distance 1352 illustrated in
Referring momentarily to
At block 1902, the tensioners of straps inside the third link 543 are adjusted to calibrate the length of the long side 868B of the parallelogram. To calibrate the length of the long side 868 of the parallelogram 864, the tensioning system of straps in the third link 543 can be adjusted. Tensioning blocks for strap 626A and strap 626B can adjusted in opposite directions to calibrate the length of the long side 868, in the case of a two strap system in the third link 543. In the case of a three strap system in the third link 543, Tensioning blocks for strap 626A and strap 627 or 628 may be adjusted in opposite directions to calibrate the length of the long side 868. This slightly rotates the fourth link (Link 4) 544 about the fourth joint 514 to achieve the desired length in the long side 868B of the parallelogram 864. That is, the tensioning blocks in the third link 543 can be adjusted to set the desired length of the long side 868B from the second joint 512 to the remote center 666.
If, for example, long side 868B is too long, as illustrated by erroneous long side 868B′ in
At block 1904, the tensioners of straps inside the second link 542 are adjusted to calibrate the remote center error. In this case, the third link 543 needs to be rotated clockwise about the axis of rotation at joint 513, relative to
As discussed previously, the second link 542 and the fourth link 544 are kept from rotating relative to each other by straps 626A, 626B. Thus, when adjustment to remote center error 1801 is made, the parallelogram 864 is maintained and the length of long side 868B is not affected. Regardless, the length of the long side 868B of the parallelogram is verified after the remote center error has been removed.
At block, 1906, a determination is made if the length of the long side 868B of the parallelogram is correct. If not, the method returns to block 1902 and the length of the long side 868B of the parallelogram is calibrated again. If so, the method goes to block 1908.
At block 1908, a determination is made if the remote center error 1801 has been substantially removed. If not, the method returns to block 1904 and the remote center error is calibrated out once again. If the remote center error 1801 has been substantially removed, the method of calibration ends at block 1910.
In a situation where straps or belts span long distances and pass over idler pulleys, they must be controlled laterally so that they do not wander off of pulleys. Due to variation in manufacturing tolerances of the straps, pulleys and other components, they sometimes wander off of a pulley that is not sufficiently wide enough to handle the variation.
To provide a compact and narrow robotic surgical arm to avoid collisions with other equipment, it is desirable to use narrow idler pulleys. With narrow idler pulleys, proper tracking of straps over idler pulleys is key to avoid strap failure. To keep straps properly tracking on narrow pulleys, a strap guide bearing system may be used.
Referring now to
Referring now to
The anti-friction pad 1514 is coupled up against the mounting block 1512 by the fasteners 1516. The anti-friction pad 1514 reduces abrasion of strap 626A and any flat flex cables and ground straps riding thereon by keeping them all from puffing up too much over the idle pulley 612′ when they are under stress. The length of the anti-friction pad 1514 is substantially parallel to the length of the belt. The anti-friction or anti-abrasion pad 1514 may be a PTFE pad, a Teflon pad, or a material having a surface with a low coefficient of friction. The flat flex cables and ground straps riding on strap 626A through the third link is more fully described in U.S. provisional patent application Ser. No. 60/752,788 entitled “FLAT ELECTRICAL CONDUCTORS OVER PULLEYS IN A STRAP DRIVE-TRAIN OF A ROBOTIC SURGICAL ARM”, filed on Dec. 21, 2005 by Todd Solomon.
Ordinarily the metal belts 626A, 626B do not ride up against the anti-friction pad 1514. Normally there is a gap 1530A between the anti-friction pad 1514 and the metal strap 626A, 626B. However if there is slack in a strap, the gap 1530A may become zero and the anti-friction pad 1514 may press back on the strap.
As mentioned previously, in the three strap system of link three 543, only one strap guide system 1500 is needed for strap 626A. In the two strap system of link three 543, two strap guide systems 1500 are utilized as both straps cover a long distance between pulleys. One strap guide system 1500 is provided for strap 626A and a second strap guide system 1500 is provided for strap 626B.
The mounting block 1512 is formed of aluminum in one embodiment of the invention. The rollers 1510A-1510B are ball bearings or roller bearings in one embodiment of the invention. The dowel pins 1511A-1511B are press fit and/or glued into the center race of the bearings to rotatably couple the rollers 1510A-1510B to the mounting block 1512. Alternately, the dowel pins could be an integral part of the rollers 1510A-1510B.
Referring now to
The belt guide bearing system 1500 is compact and reliably keeps the straps tracking on the narrow idler pulley or pulleys. The belt guide bearing system 1500 may also be used to control the tracking of flat flex cables and a beryllium copper ground strap along with the tensioned metal straps in a robotic surgical arm, as is more fully discussed in U.S. provisional patent application Ser. No. 60/752,788 entitled “FLAT ELECTRICAL CONDUCTORS OVER PULLEYS IN A STRAP DRIVE-TRAIN OF A ROBOTIC SURGICAL ARM”, filed on Dec. 21, 2005 by Todd Solomon.
Instead of or in addition to using a strap guide system to keep the straps tracking on the idler pulleys, a camber adjustment system may be used. The camber adjustment system provides means of adjusting the camber angle of the idler pulleys in order to keep the belts tracking.
Referring now to
To adjust the camber of each pulley 612A, 612B, pivoting or camber adjustment screws 1706A, 1706B are provided. Each of the idler pulleys 612A, 612B are respectively supported by bearings 1710A, 1710B and pivotable pulley mounts 1712A, 1712B. Each of the pivotable pulley mounts 1712A, 1712B include a pair of pivot points 1714A, 1714B, near a center of the pulley axis of each pulley 1612A, 1612B. Bracket 1702 has a pair of pivot valleys 1716A, 1716B to receive the pair of pivot points 1714A, 1714B, respectively. As illustrated, the pair of pivot valleys 1716A, 1716B are spaced apart to provide sufficient space in the bracket for the pair of straps, the pair of pulleys, the pair of pivotable pulley mounts, the pair of bearings, and the camber adjustment range,
An open region 1750 illustrated in
Referring now to
The camber adjustment screw 1706B is allowed to turn in a non-threaded opening 1725A in the third link 543. Camber adjustment screw 1706A is allowed to turn a non-threaded opening 1725B in bracket 1702. As a result, each camber adjustment screw 1706A, 1706B has a snap ring 1720A, 1720B to retain the head of the screws within the respective openings 1725A, 1725B.
Additionally, each of the camber adjustment screws 1706A, 1706B are preloaded by a spring washer 1722A, 1722B coupled between the pivoting pulley mount 1712B and the third link 543, in between the bracket 1702 in the pivoting pulley mount 1712A. The spring washers 1722A, 1722B apply pressure to the pivoting pulley mounts 1712A and 1712B to force them away from bracket 1702 and the link 543 respectively. Additionally, the spring washers 1722A, 1722B apply a pressure between the screw threads 1726A, 1726B and the female thread of threaded openings 1728A, 1728B in the pulley mounts 1712A, 1712B so as to deter the screws 1706A, 1706B from turning freely. That is, the camber settings of the pulleys 626A,626B are maintained by deterring movement in the camber adjustment screws 1706A,1706B.
The elements previously described of a strap drive train system in a robotic surgical arm provide a number of advantages. The strap drive train provides a reduction in friction of pitch movement of the robotic surgical arm so as to reduce the required motor power and improve back-drive-ability. The strap drive train provides a high degree of stiffness in the robotic surgical arm to reduce vibrations and deflections thereof. The strap drive train provides a high degree of strength in the robotic surgical arm high to increase safety to patients and assistants around the arm. The strap drive train allows easy adjustment of remote center of in the robotic surgical arm to reduce manufacturing and maintenance costs. The strap drive train provides a light and compact robot surgical arm that increases the range of motion and makes it easier to set up and use.
While certain exemplary embodiments of the invention have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that the embodiments of the invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art after reading this disclosure. For example, the embodiments of the invention have been described with reference to a robotic surgical arm. However, the embodiments of the invention are equally applicable to other types of robotic arms and not just robotic surgical arms. Instead, the embodiments of the invention should be construed according to the claims that follow below.
This non-provisional patent application is a divisional application claiming the benefit of U.S. patent application Ser. No. 11/611,849 entitled MULTI-PLY STRAP DRIVE TRAINS FOR ROBOTIC ARMS, filed by Todd R. Solomon et al on Dec. 6, 2006 pending. U.S. patent application Ser. No. 11/611,849 claims the benefit of provisional patent application No. 60/752,514, entitled MULTI-PLY STRAP DRIVE TRAIN FOR ROBOTIC SURGICAL ARM filed by Todd R. Solomon et al on Dec. 20, 2005, incorporated herein by reference, and provisional U.S. patent application Ser. No. 60/752,788 entitled FLAT ELECTRICAL CONDUCTORS OVER PULLEYS IN A STRAP DRIVE-TRAIN OF A ROBOTIC SURGICAL ARM, filed on Dec. 21, 2005 , by Todd R. Solomon. U.S. patent application Ser. No. 11/611,849 is further a continuation in part (CIP) and claims the benefit of U.S. patent application Ser. No. 10/957,077, entitled OFFSET REMOTE CENTER MANIPULATOR FOR ROBOTIC SURGERY, filed on Sep. 30, 2004 by Thomas G. Cooper and Todd R. Solomon.
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| Number | Date | Country | |
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| 20130239735 A1 | Sep 2013 | US |
| Number | Date | Country | |
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| 60752514 | Dec 2005 | US | |
| 60752788 | Dec 2005 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11611849 | Dec 2006 | US |
| Child | 13890233 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10957077 | Sep 2004 | US |
| Child | 11611849 | US |
