SURGICAL PLATFORM WITH MOTORIZED ARMS

TECHNICAL FIELD

The systems and methods disclosed herein are directed to medical devices, and more particularly to robotic systems.

BACKGROUND

Robotic systems can assist physicians in performing medical procedures. Various medical procedures involve localization of a three-dimensional position of a medical instrument within a patient's body in order to provide diagnosis and/or treatment. Articulated robotic arms can be operated under the control of a physician, partially autonomously, or completely autonomously to position the medical instrument at the correct location. Due to use of robotic systems, procedures may be performed with greater precision, smaller incisions, decreased blood loss, and quicker healing time, to name a few examples.

SUMMARY

One challenge with medical robotic systems is that there are a wide variety of medical procedures, with each procedure having its own set of kinematic requirements for a robotic arm usable during the procedure. For instance, the requirements for robotic-assisted endoscopy differ from the requirements for robotic-assisted laparoscopy with respect to system bandwidth, stiffness, workspace range and positioning, and speeds, among other differences. As a result, existing medical robotic systems are typically purpose-built for a specific medical procedure and are unable to perform other types of medical procedures. Accordingly, hospitals or other medical clinics seeking to use such robotic systems have increased costs relating to acquisition (e.g., purchase or rental) and storage of multiple systems. This can, in turn, result in increased costs passed on to patients undergoing such procedures.

Some embodiments disclosed herein can implement robotic arm kinematic layouts for performing laparoscopic surgery on a bed-based surgical robotics platform. For example, in accordance with some embodiments disclosed herein is the realization that current robotic systems continue to face certain limitations and challenges including the available reach of the robotic arms, potential access and maneuverability of the robotic arms, stiffness of the robotic arms and support architecture, and performance of the system, among other things.

Moreover, in accordance with some embodiments disclosed herein is the realization and recognition of the increased complexity of robotic systems that utilize a software-constrained remote center of motion. Indeed, these and other challenges can be particularly acute in robotic systems that use six robotic arms. Accordingly, some embodiments disclosed herein can be configured to address these and other considerations to provide a robotic system that utilizes a common mounting platform for the robotic arms, a robotic setup joint, and a distal manipulator linkage that uses a hardware-constrained remote center of motion.

These and other optional features can be implemented in a robotic system to provide improved rigidity, reduce collisions, and increase the maneuverability and positioning of the robotic arms of the system. Further, some embodiments can optionally implement a hardware-constrained center of motion for one or more robotic arms of the system in order to reduce the complexity, increase the reliability, and streamline operation of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed aspects will hereinafter be described in conjunction with the appended drawings, provided to illustrate and not to limit the disclosed aspects, wherein like designations denote like elements.

FIG. 1 illustrates an embodiment of a cart-based robotic system arranged for diagnostic and/or therapeutic bronchoscopy procedure(s).

FIG. 2 depicts further aspects of the robotic system of FIG. 1.

FIG. 3 illustrates an embodiment of the robotic system of FIG. 1 arranged for ureteroscopy.

FIG. 4 illustrates an embodiment of the robotic system of FIG. 1 arranged for a vascular procedure.

FIG. 5 illustrates an embodiment of a table-based robotic system arranged for a bronchoscopy procedure.

FIG. 6 provides an alternative view of the robotic system of FIG. 5.

FIG. 7 illustrates an example system configured to stow robotic arm(s).

FIG. 8 illustrates an embodiment of a table-based robotic system configured for a ureteroscopy procedure.

FIG. 9 illustrates an embodiment of a table-based robotic system configured for a laparoscopic procedure.

FIG. 10 illustrates an embodiment of the table-based robotic system of FIGS. 5-9 with pitch or tilt adjustment.

FIG. 11 provides a detailed illustration of the interface between the table and the column of the table-based robotic system of FIGS. 5-10.

FIG. 12 illustrates an exemplary instrument driver.

FIG. 13 illustrates an exemplary medical instrument with a paired instrument driver.

FIG. 14 illustrates an alternative design for an instrument driver and instrument where the axes of the drive units are parallel to the axis of the elongated shaft of the instrument.

FIG. 15 depicts a block diagram illustrating a localization system that estimates a location of one or more elements of the robotic systems of FIGS. 1-10, such as the location of the instrument of FIGS. 13-14, in accordance to some embodiments.

FIG. 16 illustrates an example command console for a medical robotic system as depicted in FIGS. 1-5 and 8-10, according to some embodiments.

FIG. 17 is an end view of an embodiment of a robotic system that includes two single-link motorized arms for positioning arm supports.

FIG. 18 is an isometric view of an embodiment of a motorized arm and an arm support.

FIGS. 19A and 19B show perspective and end views, respectively, of an embodiment of a robotic system that includes two single-link motorized arms in a stowed configuration.

FIG. 20 is a perspective view of an embodiment of a robotic system that includes two single-link motorized arms and six robotic arms in a stowed configuration.

FIG. 21 is an isometric view of a robotic arm according to one embodiment.

FIGS. 22A and 22B illustrate perspective views of an embodiment of a dual-link motorized arm in extended and stowed configurations, respectively.

FIG. 23 is a perspective view of an embodiment of an arm support linkage and attached arm support.

FIG. 24 illustrates an example of a robotic arm usable with the systems and components depicted in FIGS. 1-23.

FIG. 25 illustrates another example of a robotic arm usable with the systems and components depicted in FIGS. 1-23.

FIG. 26A depicts the robotic arm of FIG. 24 begin actuated in a first mode of operation.

FIG. 26B depicts a table-based robotic system including a number of robotic arms as depicted in FIG. 24 configured for operating in the first mode for a laparoscopic procedure.

FIG. 27A depicts a number of the robotic arms of FIG. 24 configured in a second mode of operation.

FIG. 27B depicts the table-based robotic system of FIG. 26B including some of the robotic arms configured as shown in FIG. 27A for operating in the second mode for an endoscopic procedure.

FIGS. 28A and 28B depict a range of positions for an instrument driver mounted to the robotic arm of FIG. 24.

FIGS. 29A-29D depict a series of example steps for setting up the robotic arm of FIG. 24 to operate in the first mode depicted in FIG. 26A.

FIGS. 30A-30C depict different sub-modes for operating the robotic arm of FIG. 25 in the first mode depicted in FIG. 26A.

FIGS. 31A and 31B depict different sub-modes for operating the robotic arm of FIG. 24 in the first mode depicted in FIG. 26A.

FIGS. 32A and 32B depict addition of a second instrument driver to the robotic arm of FIG. 25 during operation in the second mode depicted in FIG. 27A.

FIG. 33 depicts the robotic arm of FIG. 25 in a storage configuration.

FIG. 34 depicts a robotic system having a plurality of robotic arms, according to some embodiments.

FIG. 35 depicts optional features of a robotic arm for use with the robotic system of FIG. 35, according to some embodiments.

FIG. 36 depicts optional features of a robotic arm for use with the robotic system of FIG. 35, according to some embodiments.

FIG. 37 depicts a table-based robotic system of FIG. 17 including some of the robotic arms configured as shown in FIG. 27A for operating in the second mode for an endoscopic procedure

FIG. 38 depicts various examples of robotic arms according to the present disclosure.

FIG. 39 depicts a flowchart of an example process for operating the robotic arms of FIGS. 24-38.

DETAILED DESCRIPTION
1. Overview

Aspects of the present disclosure may be integrated into a robotically enabled medical system capable of performing a variety of medical procedures, including both minimally invasive, such as laparoscopy, and non-invasive, such as endoscopy, procedures. Among endoscopy procedures, the system may be capable of performing bronchoscopy, ureteroscopy, gastroscopy, etc.

In addition to performing the breadth of procedures, the system may provide additional benefits, such as enhanced imaging and guidance to assist the physician. Additionally, the system may provide the physician with the ability to perform the procedure from an ergonomic position without the need for awkward arm motions and positions. Still further, the system may provide the physician with the ability to perform the procedure with improved ease of use such that one or more of the instruments of the system can be controlled by a single user.

Various embodiments will be described below in conjunction with the drawings for purposes of illustration. It should be appreciated that many other implementations of the disclosed concepts are possible, and various advantages can be achieved with the disclosed implementations. Headings are included herein for reference and to aid in locating various sections. These headings are not intended to limit the scope of the concepts described with respect thereto. Such concepts may have applicability throughout the entire specification.

A. Robotic System-Cart.

The robotically enabled medical system may be configured in a variety of ways depending on the particular procedure. FIG. 1 illustrates an embodiment of a cart-based robotically enabled system 10 arranged for a diagnostic and/or therapeutic bronchoscopy procedure. During a bronchoscopy, the system 10 may comprise a cart 11 having one or more robotic arms 12 to deliver a medical instrument, such as a steerable endoscope 13, which may be a procedure-specific bronchoscope for bronchoscopy, to a natural orifice access point (i.e., the mouth of the patient positioned on a table in the present example) to deliver diagnostic and/or therapeutic tools. As shown, the cart 11 may be positioned proximate to the patient's upper torso in order to provide access to the access point. Similarly, the robotic arms 12 may be actuated to position the bronchoscope relative to the access point. The arrangement in FIG. 1 may also be utilized when performing a gastro-intestinal (GI) procedure with a gastroscope, a specialized endoscope for GI procedures. FIG. 2 depicts an example embodiment of the cart in greater detail.

With continued reference to FIG. 1, once the cart 11 is properly positioned, the robotic arms 12 may insert the steerable endoscope 13 into the patient robotically, manually, or a combination thereof. As shown, the steerable endoscope 13 may comprise at least two telescoping parts, such as an inner leader portion and an outer sheath portion, each portion coupled to a separate instrument driver from the set of instrument drivers 28, each instrument driver coupled to the distal end of an individual robotic arm. This linear arrangement of the instrument drivers 28, which facilitates coaxially aligning the leader portion with the sheath portion, creates a “virtual rail” 29 that may be repositioned in space by manipulating the one or more robotic arms 12 into different angles and/or positions. The virtual rails described herein are depicted in the Figures using dashed lines, and accordingly the dashed lines do not depict any physical structure of the system. Translation of the instrument drivers 28 along the virtual rail 29 telescopes the inner leader portion relative to the outer sheath portion or advances or retracts the endoscope 13 from the patient. The angle of the virtual rail 29 may be adjusted, translated, and pivoted based on clinical application or physician preference. For example, in bronchoscopy, the angle and position of the virtual rail 29 as shown represents a compromise between providing physician access to the endoscope 13 while minimizing friction that results from bending the endoscope 13 into the patient's mouth.

The endoscope 13 may be directed down the patient's trachea and lungs after insertion using precise commands from the robotic system until reaching the target destination or operative site. In order to enhance navigation through the patient's lung network and/or reach the desired target, the endoscope 13 may be manipulated to telescopically extend the inner leader portion from the outer sheath portion to obtain enhanced articulation and greater bend radius. The use of separate instrument drivers 28 also allows the leader portion and sheath portion to be driven independent of each other.

For example, the endoscope 13 may be directed to deliver a biopsy needle to a target, such as, for example, a lesion or nodule within the lungs of a patient. The needle may be deployed down a working channel that runs the length of the endoscope to obtain a tissue sample to be analyzed by a pathologist. Depending on the pathology results, additional tools may be deployed down the working channel of the endoscope for additional biopsies. After identifying a nodule to be malignant, the endoscope 13 may endoscopically deliver tools to resect the potentially cancerous tissue. In some instances, diagnostic and therapeutic treatments may need to be delivered in separate procedures. In those circumstances, the endoscope 13 may also be used to deliver a fiducial to “mark” the location of the target nodule as well. In other instances, diagnostic and therapeutic treatments may be delivered during the same procedure.

The system 10 may also include a movable tower 30, which may be connected via support cables to the cart 11 to provide support for controls, electronics, fluidics, optics, sensors, and/or power to the cart 11. Placing such functionality in the tower 30 allows for a smaller form factor cart 11 that may be more easily adjusted and/or re-positioned by an operating physician and his/her staff. Additionally, the division of functionality between the cart/table and the support tower 30 reduces operating room clutter and facilitates improving clinical workflow. While the cart 11 may be positioned close to the patient, the tower 30 may be stowed in a remote location to stay out of the way during a procedure.

In support of the robotic systems described above, the tower 30 may include component(s) of a computer-based control system that stores computer program instructions, for example, within a non-transitory computer-readable storage medium such as a persistent magnetic storage drive, solid state drive, etc. The execution of those instructions, whether the execution occurs in the tower 30 or the cart 11, may control the entire system or sub-system(s) thereof. For example, when executed by a processor of the computer system, the instructions may cause the components of the robotics system to actuate the relevant carriages and arm mounts, actuate the robotics arms, and control the medical instruments. For example, in response to receiving the control signal, the motors in the joints of the robotics arms may position the arms into a certain posture.

The tower 30 may also include a pump, flow meter, valve control, and/or fluid access in order to provide controlled irrigation and aspiration capabilities to system that may be deployed through the endoscope 13. These components may also be controlled using the computer system of tower 30. In some embodiments, irrigation and aspiration capabilities may be delivered directly to the endoscope 13 through separate cable(s).

The tower 30 may include a voltage and surge protector designed to provide filtered and protected electrical power to the cart 11, thereby avoiding placement of a power transformer and other auxiliary power components in the cart 11, resulting in a smaller, more moveable cart 11.

The tower 30 may also include support equipment for the sensors deployed throughout the robotic system 10. For example, the tower 30 may include opto-electronics equipment for detecting, receiving, and processing data received from the optical sensors or cameras throughout the robotic system 10. In combination with the control system, such opto-electronics equipment may be used to generate real-time images for display in any number of consoles deployed throughout the system, including in the tower 30. Similarly, the tower 30 may also include an electronic subsystem for receiving and processing signals received from deployed electromagnetic (EM) sensors. The tower 30 may also be used to house and position an EM field generator for detection by EM sensors in or on the medical instrument.

The tower 30 may also include a console 31 in addition to other consoles available in the rest of the system, e.g., console mounted on top of the cart. The console 31 may include a user interface and a display screen, such as a touchscreen, for the physician operator. Consoles in system 10 are generally designed to provide both robotic controls as well as pre-operative and real-time information of the procedure, such as navigational and localization information of the endoscope 13. When the console 31 is not the only console available to the physician, it may be used by a second operator, such as a nurse, to monitor the health or vitals of the patient and the operation of system, as well as provide procedure-specific data, such as navigational and localization information.

The tower 30 may be coupled to the cart 11 and endoscope 13 through one or more cables or connections (not shown). In some embodiments, the support functionality from the tower 30 may be provided through a single cable to the cart 11, simplifying and de-cluttering the operating room. In other embodiments, specific functionality may be coupled in separate cabling and connections. For example, while power may be provided through a single power cable to the cart, the support for controls, optics, fluidics, and/or navigation may be provided through a separate cable.

FIG. 2 provides a detailed illustration of an embodiment of the cart from the cart-based robotically enabled system shown in FIG. 1. The cart 11 generally includes an elongated support structure 14 (often referred to as a “column”), a cart base 15, and a console 16 at the top of the column 14. The column 14 may include one or more carriages, such as a carriage 17 (alternatively “arm support”) for supporting the deployment of one or more robotic arms 12 (three shown in FIG. 2). The carriage 17 may include individually configurable arm mounts that rotate along a perpendicular axis to adjust the base of the robotic arms 12 for better positioning relative to the patient. The carriage 17 also includes a carriage interface 19 that allows the carriage 17 to vertically translate along the column 14.

The carriage interface 19 is connected to the column 14 through slots, such as slot 20, that are positioned on opposite sides of the column 14 to guide the vertical translation of the carriage 17. The slot 20 contains a vertical translation interface to position and hold the carriage at various vertical heights relative to the cart base 15. Vertical translation of the carriage 17 allows the cart 11 to adjust the reach of the robotic arms 12 to meet a variety of table heights, patient sizes, and physician preferences. Similarly, the individually configurable arm mounts on the carriage 17 allow the robotic arm base 21 of robotic arms 12 to be angled in a variety of configurations.

In some embodiments, the slot 20 may be supplemented with slot covers that are flush and parallel to the slot surface to prevent dirt and fluid ingress into the internal chambers of the column 14 and the vertical translation interface as the carriage 17 vertically translates. The slot covers may be deployed through pairs of spring spools positioned near the vertical top and bottom of the slot 20. The covers are coiled within the spools until deployed to extend and retract from their coiled state as the carriage 17 vertically translates up and down. The spring-loading of the spools provides force to retract the cover into a spool when carriage 17 translates towards the spool, while also maintaining a tight seal when the carriage 17 translates away from the spool. The covers may be connected to the carriage 17 using, for example, brackets in the carriage interface 19 to ensure proper extension and retraction of the cover as the carriage 17 translates.

The column 14 may internally comprise mechanisms, such as gears and motors, that are designed to use a vertically aligned lead screw to translate the carriage 17 in a mechanized fashion in response to control signals generated in response to user inputs, e.g., inputs from the console 16.

The robotic arms 12 may generally comprise robotic arm bases 21 and end effectors 22, separated by a series of linkages 23 that are connected by a series of joints 24, each joint comprising an independent actuator, each actuator comprising an independently controllable motor. Each independently controllable joint represents an independent degree of freedom available to the robotic arm. Each of the arms 12 have seven joints, and thus provide seven degrees of freedom. A multitude of joints result in a multitude of degrees of freedom, allowing for “redundant” degrees of freedom. Redundant degrees of freedom allow the robotic arms 12 to position their respective end effectors 22 at a specific position, orientation, and trajectory in space using different linkage positions and joint angles. This allows for the system to position and direct a medical instrument from a desired point in space while allowing the physician to move the arm joints into a clinically advantageous position away from the patient to create greater access, while avoiding arm collisions.

The cart base 15 balances the weight of the column 14, carriage 17, and arms 12 over the floor. Accordingly, the cart base 15 houses heavier components, such as electronics, motors, power supply, as well as components that either enable movement and/or immobilize the cart. For example, the cart base 15 includes rollable wheel-shaped casters 25 that allow for the cart to easily move around the room prior to a procedure. After reaching the appropriate position, the casters 25 may be immobilized using wheel locks to hold the cart 11 in place during the procedure.

Positioned at the vertical end of column 14, the console 16 allows for both a user interface for receiving user input and a display screen (or a dual-purpose device such as, for example, a touchscreen 26) to provide the physician user with both pre-operative and intra-operative data. Potential pre-operative data on the touchscreen 26 may include pre-operative plans, navigation and mapping data derived from pre-operative computerized tomography (CT) scans, and/or notes from pre-operative patient interviews. Intra-operative data on display may include optical information provided from the tool, sensor and coordinate information from sensors, as well as vital patient statistics, such as respiration, heart rate, and/or pulse. The console 16 may be positioned and tilted to allow a physician to access the console from the side of the column 14 opposite carriage 17. From this position the physician may view the console 16, robotic arms 12, and patient while operating the console 16 from behind the cart 11. As shown, the console 16 also includes a handle 27 to assist with maneuvering and stabilizing cart 11.

FIG. 3 illustrates an embodiment of a robotically enabled system 10 arranged for ureteroscopy. In a ureteroscopic procedure, the cart 11 may be positioned to deliver a ureteroscope 32, a procedure-specific endoscope designed to traverse a patient's urethra and ureter, to the lower abdominal area of the patient. In a ureteroscopy, it may be desirable for the ureteroscope 32 to be directly aligned with the patient's urethra to reduce friction and forces on the sensitive anatomy in the area. As shown, the cart 11 may be aligned at the foot of the table to allow the robotic arms 12 to position the ureteroscope 32 for direct linear access to the patient's urethra. From the foot of the table, the robotic arms 12 may insert the ureteroscope 32 along the virtual rail 33 directly into the patient's lower abdomen through the urethra.

After insertion into the urethra, using similar control techniques as in bronchoscopy, the ureteroscope 32 may be navigated into the bladder, ureters, and/or kidneys for diagnostic and/or therapeutic applications. For example, the ureteroscope 32 may be directed into the ureter and kidneys to break up kidney stone build up using laser or ultrasonic lithotripsy device deployed down the working channel of the ureteroscope 32. After lithotripsy is complete, the resulting stone fragments may be removed using baskets deployed down the ureteroscope 32.

FIG. 4 illustrates an embodiment of a robotically enabled system similarly arranged for a vascular procedure. In a vascular procedure, the system 10 may be configured such the cart 11 may deliver a medical instrument 34, such as a steerable catheter, to an access point in the femoral artery in the patient's leg. The femoral artery presents both a larger diameter for navigation as well as relatively less circuitous and tortuous path to the patient's heart, which simplifies navigation. As in a ureteroscopic procedure, the cart 11 may be positioned towards the patient's legs and lower abdomen to allow the robotic arms 12 to provide a virtual rail 35 with direct linear access to the femoral artery access point in the patient's thigh/hip region. After insertion into the artery, the medical instrument 34 may be directed and inserted by translating the instrument drivers 28. Alternatively, the cart may be positioned around the patient's upper abdomen in order to reach alternative vascular access points, such as, for example, the carotid and brachial arteries near the shoulder and wrist.

B. Robotic System-Table.

Embodiments of the robotically enabled medical system may also incorporate the patient's table. Incorporation of the table reduces the amount of capital equipment within the operating room by removing the cart, which allows greater access to the patient. FIG. 5 illustrates an embodiment of such a robotically enabled system arranged for a bronchoscopy procedure. System 36 includes a support structure or column 37 for supporting platform 38 (shown as a “table” or “bed”) over the floor. Much like in the cart-based systems, the end effectors of the robotic arms 39 of the system 36 comprise instrument drivers 42 that are designed to manipulate an elongated medical instrument, such as a bronchoscope 40 in FIG. 5, through or along a virtual rail 41 formed from the linear alignment of the instrument drivers 42. In practice, a C-arm for providing fluoroscopic imaging may be positioned over the patient's upper abdominal area by placing the emitter and detector around table 38.

FIG. 6 provides an alternative view of the system 36 without the patient and medical instrument for discussion purposes. As shown, the column 37 may include one or more carriages 43 shown as ring-shaped in the system 36, from which the one or more robotic arms 39 may be based. The carriages 43 may translate along a vertical column interface 44 that runs the length of the column 37 to provide different vantage points from which the robotic arms 39 may be positioned to reach the patient. The carriage(s) 43 may rotate around the column 37 using a mechanical motor positioned within the column 37 to allow the robotic arms 39 to have access to multiples sides of the table 38, such as, for example, both sides of the patient. In embodiments with multiple carriages, the carriages may be individually positioned on the column and may translate and/or rotate independent of the other carriages. While carriages 43 need not surround the column 37 or even be circular, the ring-shape as shown facilitates rotation of the carriages 43 around the column 37 while maintaining structural balance. Rotation and translation of the carriages 43 allows the system to align the medical instruments, such as endoscopes and laparoscopes, into different access points on the patient.

The arms 39 may be mounted on the carriages through a set of arm mounts 45 comprising a series of joints that may individually rotate and/or telescopically extend to provide additional configurability to the robotic arms 39. Additionally, the arm mounts 45 may be positioned on the carriages 43 such that, when the carriages 43 are appropriately rotated, the arm mounts 45 may be positioned on either the same side of table 38 (as shown in FIG. 6), on opposite sides of table 38 (as shown in FIG. 9), or on adjacent sides of the table 38 (not shown).

The column 37 structurally provides support for the table 38, and a path for vertical translation of the carriages. Internally, the column 37 may be equipped with lead screws for guiding vertical translation of the carriages, and motors to mechanize the translation of said carriages based the lead screws. The column 37 may also convey power and control signals to the carriage 43 and robotic arms 39 mounted thereon.

The table base 46 serves a similar function as the cart base 15 in cart 11 shown in FIG. 2, housing heavier components to balance the table/bed 38, the column 37, the carriages 43, and the robotic arms 39. The table base 46 may also incorporate rigid casters to provide stability during procedures. Deployed from the bottom of the table base 46, the casters may extend in opposite directions on both sides of the base 46 and retract when the system 36 needs to be moved.

Continuing with FIG. 6, the system 36 may also include a tower (not shown) that divides the functionality of system 36 between table and tower to reduce the form factor and bulk of the table. As in earlier disclosed embodiments, the tower may provide a variety of support functionalities to table, such as processing, computing, and control capabilities, power, fluidics, and/or optical and sensor processing. The tower may also be movable to be positioned away from the patient to improve physician access and de-clutter the operating room. Additionally, placing components in the tower allows for more storage space in the table base for potential stowage of the robotic arms. The tower may also include a console that provides both a user interface for user input, such as keyboard and/or pendant, as well as a display screen (or touchscreen) for pre-operative and intra-operative information, such as real-time imaging, navigation, and tracking information.

In some embodiments, a table base may stow and store the robotic arms when not in use. FIG. 7 illustrates a system 47 that stows robotic arms in an embodiment of the table-based system. In system 47, carriages 48 may be vertically translated into base 49 to stow robotic arms 50, arm mounts 51, and the carriages 48 within the base 49. Base covers 52 may be translated and retracted open to deploy the carriages 48, arm mounts 51, and arms 50 around column 53, and closed to stow to protect them when not in use. The base covers 52 may be sealed with a membrane 54 along the edges of its opening to prevent dirt and fluid ingress when closed.

FIG. 8 illustrates an embodiment of a robotically enabled table-based system configured for a ureteroscopy procedure. In a ureteroscopy, the table 38 may include a swivel portion 55 for positioning a patient off-angle from the column 37 and table base 46. The swivel portion 55 may rotate or pivot around a pivot point (e.g., located below the patient's head) in order to position the bottom portion of the swivel portion 55 away from the column 37. For example, the pivoting of the swivel portion 55 allows a C-arm (not shown) to be positioned over the patient's lower abdomen without competing for space with the column (not shown) below table 38. By rotating the carriage 35 (not shown) around the column 37, the robotic arms 39 may directly insert a ureteroscope 56 along a virtual rail 57 into the patient's groin area to reach the urethra. In a ureteroscopy, stirrups 58 may also be fixed to the swivel portion 55 of the table 38 to support the position of the patient's legs during the procedure and allow clear access to the patient's groin area.

In a laparoscopic procedure, through small incision(s) in the patient's abdominal wall, minimally invasive instruments (elongated in shape to accommodate the size of the one or more incisions) may be inserted into the patient's anatomy. After inflation of the patient's abdominal cavity, the instruments, often referred to as laparoscopes, may be directed to perform surgical tasks, such as grasping, cutting, ablating, suturing, etc. FIG. 9 illustrates an embodiment of a robotically enabled table-based system configured for a laparoscopic procedure. As shown in FIG. 9, the carriages 43 of the system 36 may be rotated and vertically adjusted to position pairs of the robotic arms 39 on opposite sides of the table 38, such that laparoscopes 59 may be positioned using the arm mounts 45 to be passed through minimal incisions on both sides of the patient to reach his/her abdominal cavity.

To accommodate laparoscopic procedures, the robotically enabled table system may also tilt the platform to a desired angle. FIG. 10 illustrates an embodiment of the robotically enabled medical system with pitch or tilt adjustment. As shown in FIG. 10, the system 36 may accommodate tilt of the table 38 to position one portion of the table at a greater distance from the floor than the other. Additionally, the arm mounts 45 may rotate to match the tilt such that the arms 39 maintain the same planar relationship with table 38. To accommodate steeper angles, the column 37 may also include telescoping portions 60 that allow vertical extension of column 37 to keep the table 38 from touching the floor or colliding with base 46.

FIG. 11 provides a detailed illustration of the interface between the table 38 and the column 37. Pitch rotation mechanism 61 may be configured to alter the pitch angle of the table 38 relative to the column 37 in multiple degrees of freedom. The pitch rotation mechanism 61 may be enabled by the positioning of orthogonal axes 1, 2 at the column-table interface, each axis actuated by a separate motor 2, 4 responsive to an electrical pitch angle command. Rotation along one screw 5 would enable tilt adjustments in one axis 1, while rotation along the other screw 6 would enable tilt adjustments along the other axis 2.

For example, pitch adjustments are particularly useful when trying to position the table in a Trendelenburg position, i.e., position the patient's lower abdomen at a higher position from the floor than the patient's lower abdomen, for lower abdominal surgery. The Trendelenburg position causes the patient's internal organs to slide towards his/her upper abdomen through the force of gravity, clearing out the abdominal cavity for minimally invasive tools to enter and perform lower abdominal surgical procedures, such as laparoscopic prostatectomy.

Other features and aspects of the systems and robotic arms disclosed in Applicant's own U.S. Patent Pub. Nos. 2019/0000576 and 2020/0268460, the entireties of each of which are incorporated herein by reference.

C. Instrument Driver & Interface.

The end effectors of the system's robotic arms comprise (i) an instrument driver (alternatively referred to as “instrument drive mechanism” or “instrument device manipulator”) that incorporate electro-mechanical means for actuating the medical instrument and (ii) a removable or detachable medical instrument which may be devoid of any electro-mechanical components, such as motors. This dichotomy may be driven by the need to sterilize medical instruments used in medical procedures, and the inability to adequately sterilize expensive capital equipment due to their intricate mechanical assemblies and sensitive electronics. Accordingly, the medical instruments may be designed to be detached, removed, and interchanged from the instrument driver (and thus the system) for individual sterilization or disposal by the physician or the physician's staff. In contrast, the instrument drivers need not be changed or sterilized, and may be draped for protection.

FIG. 12 illustrates an example instrument driver. Positioned at the distal end of a robotic arm, instrument driver 62 comprises of one or more drive units 63 arranged with parallel axes to provide controlled torque to a medical instrument via drive shafts 64. Each drive unit 63 comprises an individual drive shaft 64 for interacting with the instrument, a gear head 65 for converting the motor shaft rotation to a desired torque, a motor 66 for generating the drive torque, an encoder 67 to measure the speed of the motor shaft and provide feedback to the control circuitry, and control circuitry 68 for receiving control signals and actuating the drive unit. Each drive unit 63 being independent controlled and motorized, the instrument driver 62 may provide multiple (four as shown in FIG. 12) independent drive outputs to the medical instrument. In operation, the control circuitry 68 would receive a control signal, transmit a motor signal to the motor 66, compare the resulting motor speed as measured by the encoder 67 with the desired speed, and modulate the motor signal to generate the desired torque.

For procedures that require a sterile environment, the robotic system may incorporate a drive interface, such as a sterile adapter connected to a sterile drape, that sits between the instrument driver and the medical instrument. The chief purpose of the sterile adapter is to transfer angular motion from the drive shafts of the instrument driver to the drive inputs of the instrument while maintaining physical separation, and thus sterility, between the drive shafts and drive inputs. Accordingly, an example sterile adapter may comprise of a series of rotational inputs and outputs intended to be mated with the drive shafts of the instrument driver and drive inputs on the instrument. Connected to the sterile adapter, the sterile drape, comprised of a thin, flexible material such as transparent or translucent plastic, is designed to cover the capital equipment, such as the instrument driver, robotic arm, and cart (in a cart-based system) or table (in a table-based system). Use of the drape would allow the capital equipment to be positioned proximate to the patient while still being located in an area not requiring sterilization (i.e., non-sterile field). On the other side of the sterile drape, the medical instrument may interface with the patient in an area requiring sterilization (i.e., sterile field).

D. Medical Instrument.

FIG. 13 illustrates an example medical instrument with a paired instrument driver. Like other instruments designed for use with a robotic system, medical instrument 70 comprises an elongated shaft 71 (or elongate body) and an instrument base 72. The instrument base 72, also referred to as an “instrument handle” due to its intended design for manual interaction by the physician, may generally comprise rotatable drive inputs 73, e.g., receptacles, pulleys or spools, that are designed to be mated with drive outputs 74 that extend through a drive interface on instrument driver 75 at the distal end of robotic arm 76. When physically connected, latched, and/or coupled, the mated drive inputs 73 of instrument base 72 may share axes of rotation with the drive outputs 74 in the instrument driver 75 to allow the transfer of torque from drive outputs 74 to drive inputs 73. In some embodiments, the drive outputs 74 may comprise splines that are designed to mate with receptacles on the drive inputs 73.

The elongated shaft 71 is designed to be delivered through either an anatomical opening or lumen, e.g., as in endoscopy, or a minimally invasive incision, e.g., as in laparoscopy. The elongated shaft 66 may be either flexible (e.g., having properties similar to an endoscope) or rigid (e.g., having properties similar to a laparoscope) or contain a customized combination of both flexible and rigid portions. When designed for laparoscopy, the distal end of a rigid elongated shaft may be connected to an end effector comprising a jointed wrist formed from a clevis with an axis of rotation and a surgical tool, such as, for example, a grasper or scissors, that may be actuated based on force from the tendons as the drive inputs rotate in response to torque received from the drive outputs 74 of the instrument driver 75. When designed for endoscopy, the distal end of a flexible elongated shaft may include a steerable or controllable bending section that may be articulated and bent based on torque received from the drive outputs 74 of the instrument driver 75.

Torque from the instrument driver 75 is transmitted down the elongated shaft 71 using tendons within the shaft 71. These individual tendons, such as pull wires, may be individually anchored to individual drive inputs 73 within the instrument handle 72. From the handle 72, the tendons are directed down one or more pull lumens within the elongated shaft 71 and anchored at the distal portion of the elongated shaft 71. In laparoscopy, these tendons may be coupled to a distally mounted end effector, such as a wrist, grasper, or scissor. Under such an arrangement, torque exerted on drive inputs 73 would transfer tension to the tendon, thereby causing the end effector to actuate in some way. In laparoscopy, the tendon may cause a joint to rotate about an axis, thereby causing the end effector to move in one direction or another. Alternatively, the tendon may be connected to one or more jaws of a grasper at distal end of the elongated shaft 71, where tension from the tendon cause the grasper to close.

In endoscopy, the tendons may be coupled to a bending or articulating section positioned along the elongated shaft 71 (e.g., at the distal end) via adhesive, control ring, or other mechanical fixation. When fixedly attached to the distal end of a bending section, torque exerted on drive inputs 73 would be transmitted down the tendons, causing the softer, bending section (sometimes referred to as the articulable section or region) to bend or articulate. Along the non-bending sections, it may be advantageous to spiral or helix the individual pull lumens that direct the individual tendons along (or inside) the walls of the endoscope shaft to balance the radial forces that result from tension in the pull wires. The angle of the spiraling and/or spacing there between may be altered or engineered for specific purposes, wherein tighter spiraling exhibits lesser shaft compression under load forces, while lower amounts of spiraling results in greater shaft compression under load forces, but also exhibits limits bending. On the other end of the spectrum, the pull lumens may be directed parallel to the longitudinal axis of the elongated shaft 71 to allow for controlled articulation in the desired bending or articulable sections.

In endoscopy, the elongated shaft 71 houses a number of components to assist with the robotic procedure. The shaft may comprise of a working channel for deploying surgical tools, irrigation, and/or aspiration to the operative region at the distal end of the shaft 71. The shaft 71 may also accommodate wires and/or optical fibers to transfer signals to/from an optical assembly at the distal tip, which may include of an optical camera. The shaft 71 may also accommodate optical fibers to carry light from proximally located light sources, such as light emitting diodes, to the distal end of the shaft.

At the distal end of the instrument 70, the distal tip may also comprise the opening of a working channel for delivering tools for diagnostic and/or therapy, irrigation, and aspiration to an operative site. The distal tip may also include a port for a camera, such as a fiberscope or a digital camera, to capture images of an internal anatomical space. Relatedly, the distal tip may also include ports for light sources for illuminating the anatomical space when using the camera.

In the example of FIG. 13, the drive shaft axes, and thus the drive input axes, are orthogonal to the axis of the elongated shaft. This arrangement, however, complicates roll capabilities for the elongated shaft 71. Rolling the elongated shaft 71 along its axis while keeping the drive inputs 73 static results in undesirable tangling of the tendons as they extend off the drive inputs 73 and enter pull lumens within the elongate shaft 71. The resulting entanglement of such tendons may disrupt any control algorithms intended to predict movement of the flexible elongate shaft during an endoscopic procedure.

FIG. 14 illustrates an alternative design for an instrument driver and instrument where the axes of the drive units are parallel to the axis of the elongated shaft of the instrument. As shown, a circular instrument driver 80 comprises four drive units with their drive outputs 81 aligned in parallel at the end of a robotic arm 82. The drive units, and their respective drive outputs 81, are housed in a rotational assembly 83 of the instrument driver 80 that is driven by one of the drive units within the assembly 83. In response to torque provided by the rotational drive unit, the rotational assembly 83 rotates along a circular bearing that connects the rotational assembly 83 to the non-rotational portion 84 of the instrument driver. Power and controls signals may be communicated from the non-rotational portion 84 of the instrument driver 80 to the rotational assembly 83 through electrical contacts may be maintained through rotation by a brushed slip ring connection (not shown). In other embodiments, the rotational assembly 83 may be responsive to a separate drive unit that is integrated into the non-rotatable portion 84, and thus not in parallel to the other drive units. The rotational mechanism 83 allows the instrument driver 80 to rotate the drive units, and their respective drive outputs 81, as a single unit around an instrument driver axis 85.

Like earlier disclosed embodiments, an instrument 86 may comprise of an elongated shaft portion 88 and an instrument base 87 (shown with a transparent external skin for discussion purposes) comprising a plurality of drive inputs 89 (such as receptacles, pulleys, and spools) that are configured to receive the drive outputs 81 in the instrument driver 80. Unlike prior disclosed embodiments, instrument shaft 88 extends from the center of instrument base 87 with an axis substantially parallel to the axes of the drive inputs 89, rather than orthogonal as in the design of FIG. 13.

When coupled to the rotational assembly 83 of the instrument driver 80, the medical instrument 86, comprising instrument base 87 and instrument shaft 88, rotates in combination with the rotational assembly 83 about the instrument driver axis 85. Since the instrument shaft 88 is positioned at the center of instrument base 87, the instrument shaft 88 is coaxial with instrument driver axis 85 when attached. Thus, rotation of the rotational assembly 83 causes the instrument shaft 88 to rotate about its own longitudinal axis. Moreover, as the instrument base 87 rotates with the instrument shaft 88, any tendons connected to the drive inputs 89 in the instrument base 87 are not tangled during rotation. Accordingly, the parallelism of the axes of the drive outputs 81, drive inputs 89, and instrument shaft 88 allows for the shaft rotation without tangling any control tendons.

E. Navigation and Control.

Traditional endoscopy may involve the use of fluoroscopy (e.g., as may be delivered through a C-arm) and other forms of radiation-based imaging modalities to provide endoluminal guidance to an operator physician. In contrast, the robotic systems contemplated by this disclosure can provide for non-radiation-based navigational and localization means to reduce physician exposure to radiation and reduce the amount of equipment within the operating room. As used herein, the term “localization” may refer to determining and/or monitoring the position of objects in a reference coordinate system. Technologies such as pre-operative mapping, computer vision, real-time EM tracking, and robot command data may be used individually or in combination to achieve a radiation-free operating environment. In other cases, where radiation-based imaging modalities are still used, the pre-operative mapping, computer vision, real-time EM tracking, and robot command data may be used individually or in combination to improve upon the information obtained solely through radiation-based imaging modalities.

FIG. 15 is a block diagram illustrating a localization system 90 that estimates a location of one or more elements of the robotic system, such as the location of the instrument, in accordance with an example embodiment. The localization system 90 may be a set of one or more computer devices configured to execute one or more instructions. The computer devices may be embodied by a processor (or processors) and computer-readable memory in one or more components discussed above. By way of example and not limitation, the computer devices may be in the tower 30 shown in FIG. 1, the cart shown in FIGS. 1-4, the beds shown in FIGS. 5-10, etc.

As shown in FIG. 15, the localization system 90 may include a localization module 95 that processes input data 91-94 to generate location data 96 for the distal tip of a medical instrument. The location data 96 may be data or logic that represents a location and/or orientation of the distal end of the instrument relative to a frame of reference. The frame of reference can be a frame of reference relative to the anatomy of the patient or to a known object, such as an EM field generator (see discussion below for the EM field generator).

The various input data 91-94 are now described in greater detail. Pre-operative mapping may be accomplished through the use of the collection of low dose CT scans. Pre-operative CT scans generate two-dimensional images, each representing a “slice” of a cutaway view of the patient's internal anatomy. When analyzed in the aggregate, image-based models for anatomical cavities, spaces and structures of the patient's anatomy, such as a patient lung network, may be generated. Techniques such as center-line geometry may be determined and approximated from the CT images to develop a three-dimensional volume of the patient's anatomy, referred to as preoperative model data 91. The use of center-line geometry is discussed in U.S. patent application Ser. No. 14/523,760, the contents of which are herein incorporated in its entirety. Network topological models may also be derived from the CT-images and are particularly appropriate for bronchoscopy.

In some embodiments, the instrument may be equipped with a camera to provide vision data 92. The localization module 95 may process the vision data to enable one or more vision-based location tracking. For example, the preoperative model data may be used in conjunction with the vision data 92 to enable computer vision-based tracking of the medical instrument (e.g., an endoscope or an instrument advance through a working channel of the endoscope). For example, using the preoperative model data 91, the robotic system may generate a library of expected endoscopic images from the model based on the expected path of travel of the endoscope, each image linked to a location within the model. Intra-operatively, this library may be referenced by the robotic system in order to compare real-time images captured at the camera (e.g., a camera at a distal end of the endoscope) to those in the image library to assist localization.

Other computer vision-based tracking techniques use feature tracking to determine motion of the camera, and thus the endoscope. Some feature of the localization module 95 may identify circular geometries in the preoperative model data 91 that correspond to anatomical lumens and track the change of those geometries to determine which anatomical lumen was selected, as well as the relative rotational and/or translational motion of the camera. Use of a topological map may further enhance vision-based algorithms or techniques.

Optical flow, another computer vision-based technique, may analyze the displacement and translation of image pixels in a video sequence in the vision data 92 to infer camera movement. Through the comparison of multiple frames over multiple iterations, movement and location of the camera (and thus the endoscope) may be determined.

The localization module 95 may use real-time EM tracking to generate a real-time location of the endoscope in a global coordinate system that may be registered to the patient's anatomy, represented by the preoperative model. In EM tracking, an EM sensor (or tracker) comprising of one or more sensor coils embedded in one or more locations and orientations in a medical instrument (e.g., an endoscopic tool) measures the variation in the EM field created by one or more static EM field generators positioned at a known location. The location information detected by the EM sensors is stored as EM data 93. The EM field generator (or transmitter) may be placed close to the patient to create a low intensity magnetic field that the embedded sensor may detect. The magnetic field induces small currents in the sensor coils of the EM sensor, which may be analyzed to determine the distance and angle between the EM sensor and the EM field generator. These distances and orientations may be intra-operatively “registered” to the patient anatomy (e.g., the preoperative model) in order to determine the geometric transformation that aligns a single location in the coordinate system with a position in the pre-operative model of the patient's anatomy. Once registered, an embedded EM tracker in one or more positions of the medical instrument (e.g., the distal tip of an endoscope) may provide real-time indications of the progression of the medical instrument through the patient's anatomy.

Robotic command and kinematics data 94 may also be used by the localization module 95 to provide localization data 96 for the robotic system. Device pitch and yaw resulting from articulation commands may be determined during pre-operative calibration. Intra-operatively, these calibration measurements may be used in combination with known insertion depth information to estimate the position of the instrument. Alternatively, these calculations may be analyzed in combination with EM, vision, and/or topological modeling to estimate the position of the medical instrument within the network.

As FIG. 15 shows, a number of other input data can be used by the localization module 95. For example, although not shown in FIG. 15, an instrument utilizing shape-sensing fiber can provide shape data that the localization module 95 can use to determine the location and shape of the instrument.

The localization module 95 may use the input data 91-94 in combination(s). In some cases, such a combination may use a probabilistic approach where the localization module 95 assigns a confidence weight to the location determined from each of the input data 91-94. Thus, where the EM data may not be reliable (as may be the case where there is EM interference) the confidence of the location determined by the EM data 93 can be decrease and the localization module 95 may rely more heavily on the vision data 92 and/or the robotic command and kinematics data 94.

As discussed above, the robotic systems discussed herein may be designed to incorporate a combination of one or more of the technologies above. The robotic system's computer-based control system, based in the tower, bed and/or cart, may store computer program instructions, for example, within a non-transitory computer-readable storage medium such as a persistent magnetic storage drive, solid state drive, or the like, that, upon execution, cause the system to receive and analyze sensor data and user commands, generate control signals throughout the system, and display the navigational and localization data, such as the position of the instrument within the global coordinate system, anatomical map, etc.

2. Medical Robotics Systems and Techniques

Embodiments of the disclosure relate to versatile robotic systems and operational techniques associated with a single robotic system to be capable of performing multiple types of medical procedures. As described above, due to the varying requirements of different medical procedures, robotic systems may be designed and built specifically for performing a single medical procedure, and as a result may be unable to satisfy the requirements for performing other medical procedures.

For example, one existing system is purpose-built for laparoscopic surgery. The existing system is designed with robotic arm kinematics including a mechanically constrained remote center provided so that the robotic arm inserts, pitches, and yaws a medical instrument with respect to the remote center. The mechanically constrained remote center is effected by multiple joints that are connected to one another by bands, such that all joints can be controlled by a single motor. While the inertia of the robotic arm is generally low and the robotic arm is able to maintain the remote center even under loss of power, a potential drawback of this design is that it is not used for performing non-laparoscopic procedures. For example, due to the mechanical remote center it may be difficult to utilize the robotic arm for endoscopic procedures because the mechanically constrained remote center makes it hard to align the robotic arm along a virtual rail. In addition, the bands used to create the mechanical remote center prevent compact storage of the robotic arm.

Similarly, existing serial link manipulators used for endoscopic procedures do not convert to laparoscopy well because it is hard to meet the stiffness and speed requirements for laparoscopy while maintaining a low inertia arm.

The above-described problems, among others, are addressed by the multipurpose robotics systems and associated operating techniques described herein that are able to accommodate a wide range of procedures. For example, a robotic arm according to the present disclosure includes a versatile kinematic chain and is controlled by computer-implemented instructions that enable the robotic arm to operate in a variety of modes, with different modes usable for different types of medical procedures. The kinematic chain includes a number of motorized joints coupled by linkages in a serial fashion, with a revolute motorized joint at the proximal end of the robotic arm (e.g., closest to setup joints or a base of the robotic system), a prismatic motorized joint at the distal end of the robotic arm (e.g., closest to the medical instrument), and a number of additional motorized joints positioned serially between the first and second motorized joints. The additional motorized joints can be either revolute or prismatic as explained in more detail below. The robotic arm can be operated in a first mode with respect to a remote center to perform laparoscopic procedures and can be operated in a second mode with respect to a virtual rail to perform endoscopic procedures. While the present disclosure provides examples of first and second operating modes for laparoscopic and endoscopic procedures, respectively, the disclosed robotic systems can also be used to perform other types of medical procedures.

The disclosed robotic systems can be controlled by a physician or other operator in order to perform medical procedures according to the disclosed modes. FIG. 16 illustrates an example command console 200 for a medical robotics system as described herein, for example in a medical robotic system as depicted in FIGS. 1-5 and 8-10. The command console 200 that can be used, for example, as the command console 105 in the example operating environment 100. The command console 200 includes a console base 201, display modules 202, e.g., monitors, and control modules, e.g., a keyboard 203 and joystick 204. In some embodiments, one or more of the command console 200 functionality may be integrated into a base of a medical robotic system as depicted in FIGS. 1-5 and 8-10 or another system communicatively coupled to the medical robotic system. A user 205, e.g., a physician, remotely controls the medical robotic system from an ergonomic position using the command console 200.

The console base 201 may include controller 206 including one or more processors and memories, and optionally one or more data buses and associated data communication ports. Controller 206 is responsible for interpreting and processing signals such as robotic position data, camera imagery, and tracking sensor data, e.g., from a medical instrument such as endoscope 13, ureteroscope 32, medical instrument 34, laparoscope 59, gastroscope, bronchoscope, or another procedure-specific medical instrument. The memory of the controller 206 can store instructions for operation of the medical instruments and robotic systems described herein. In some embodiments, both the console base 201 and the base of the medical robotic system can perform signal processing for load-balancing, and thus the controller 206 may be split between different system components. The controller 206 may also process commands and instructions provided by the user 205 through the control modules 203 and 204. In addition to the keyboard 203 and joystick 204 shown in FIG. 16, the control modules may include other devices, for example, computer mice, trackpads, trackballs, control pads, controls such as handheld remote controllers, and sensors (e.g., motion sensors or cameras) that capture hand gestures and finger gestures. For example, for some laparoscopic robotic systems the control modules include a pair of seven degree-of-freedom (“7 DOF”) haptic masters. A haptic master is a force controlled haptic interface that translates input (e.g., force applied by a human user) to output (e.g., displacement of the end effector of the robotic system) and also provides tactile feedback back to the user. A 7 DOF haptic master can provide three degrees of motion in the X, Y, Z directions and four degrees of motion of the pitch, yaw, roll and articulation. A control can include a set of user inputs (e.g., buttons, joysticks, directional pads, etc.) mapped to an operation of the instrument (e.g., articulation, driving, water irrigation, etc.).

The user 205 can control a medical instrument via a robotic arm as described herein using the command console 200 in a velocity mode or position control mode. In velocity mode, the user 205 directly controls pitch and yaw motion of a distal end of the medical instrument based on direct manual control using the control modules. For example, movement on the joystick 204 may be mapped to yaw and pitch movement in the distal end of the medical instrument. The joystick 204 can provide haptic feedback to the user 205. For example, the joystick 204 may vibrate to indicate that the medical instrument cannot further translate or rotate in a certain direction. The command console 200 can also provide visual feedback (e.g., pop-up messages) and/or audio feedback (e.g., beeping) to indicate that the medical instrument has reached maximum translation or rotation.

In position control mode, the command console 200 uses a 3D map of a patient luminal network and input from navigational sensors as described herein to control a medical instrument. The command console 200 provides control signals to robotic arms of the medical robotic system to manipulate the medical instrument to a target location. Due to the reliance on the 3D map, position control mode may require accurate mapping of the anatomy of the patient.

In some embodiments, users 205 can manually manipulate robotic arms of the medical robotic system without using the command console 200. During setup in a surgical operating room, the users 205 may move the robotic arms, medical instruments, and other surgical equipment to access a patient. The medical robotic system may rely on force feedback and inertia control from the users 205 to determine appropriate configuration of the robotic arms and equipment.

The displays 202 may include electronic monitors (e.g., LCD displays, LED displays, touch-sensitive displays), virtual reality viewing devices, e.g., goggles or glasses, and/or other display devices. For example, for some procedures (e.g., laparoscopy) the display can include a compact stereo viewer having a pair of apertures through which a user can view a stereoscopic image without the aid of glasses or goggles. This can be used, for example, to display a stereoscopic laparoscopic image. In some embodiments, the display modules 202 are integrated with the control modules, for example, as a tablet device with a touchscreen. In some embodiments, one of the displays 202 can display a 3D model of the patient's luminal network and virtual navigation information (e.g., a virtual representation of the end of the endoscope within the model based on EM sensor position) while the other of the displays 202 can display image information received from the camera or another sensing device at the end of the medical instrument. In some implementations, the user 205 can both view data and input commands to the medical robotic system using the integrated displays 202 and control modules. The displays 202 can display 2D renderings of 3D images and/or 3D images using a stereoscopic device, e.g., a visor or goggles. The 3D images provide an “endo view” (i.e., endoscopic view), which is a computer 3D model illustrating the anatomy of a patient. The “endo view” provides a virtual environment of the patient's interior and an expected location of a medical instrument inside the patient. A user 205 compares the “endo view” model to actual images captured by a camera to help mentally orient and confirm that the medical instrument is in the correct—or approximately correct—location within the patient. The “endo view” provides information about anatomical structures, e.g., the shape of airways, circulatory vessels, or an intestine or colon of the patient, around the distal end of the medical instrument. The display modules 202 can simultaneously display the 3D model and CT scans of the anatomy the around distal end of the medical instrument. Further, the display modules 202 may overlay the already determined navigation paths of the medical instrument on the 3D model and CT scans.

In some embodiments, a model of the medical instrument is displayed with the 3D models to help indicate a status of a surgical procedure. For example, the CT scans identify a lesion in the anatomy where a biopsy may be necessary. During operation, the display modules 202 may show a reference image captured by the medical instrument corresponding to the current location of the medical instrument. The display modules 202 may automatically display different views of the model of the medical instrument depending on user settings and a particular surgical procedure. For example, the display modules 202 show an overhead fluoroscopic view of the medical instrument during a navigation step as the medical instrument approaches an operative region of a patient. Such user-guided movement of the medical instrument can be constrained according to various pre-defined operating modes for a robotic arm as described herein.

2. Adjustable Mount Platforms

According to some embodiments, robotic systems can include one or more mount platform(s), such as adjustable arm supports, for supporting and positioning robotic arms for use during robotic medical or surgical procedures. For example, an adjustable arm support can include a bar or rail on which one or more robotic arms can be mounted. In this example, the bar or rail can be coupled to a column of a table by a bar or rail connector and a carriage, as described in Applicant's U.S. Patent Pub. No. 2020/0268460, the entirety of which is incorporated herein by reference. The adjustable arm support can be adjustable in several degrees of freedom that allow the bar or rail of the adjustable arm support to be positioned at a large number of positions relative to the table. The adjustable arm support may also be configured to transition to a stowed position, wherein the adjustable arm support and robotic arms mounted thereto are stowed below the surface of the table.

In some embodiments, a connector of the system can comprise various features and structures to connect the bar or rail of an adjustable arm support to the column of the table. For example, as will be described below, the connector can include a motorized arm that connects a rail or bar of the adjustable arm support to a column of the table. In some embodiments, the motorized arm may include, for example, the carriage and rail or bar connector described above. In some embodiments, the motorized arm may include, alternatively or additionally, one or more of the additional features described in this section with reference to FIGS. 17-23.

As will be described more fully below, the motorized arms can include one or more links that are configured to raise, lower, tilt, and/or otherwise position the arm supports (e.g., the bars or rails of the adjustable arm supports) that support the robotic arms. In some instances, the motorized arms can be considered base or set-up arms or joints because they can be designed and configured to position the arm supports prior to actuation of the robotic arms during a medical procedure. For example, in some instances, the motorized arms are configured to move the arm supports (and robotic arms mounted thereto) from a stowed position to a set-up position. In some instances, in the set-up position, the motorized arms and arm supports may remain stationary while the robotic arms mounted on the arm supports move to perform the medical procedure. In some instances, the motorized arms and/or arm supports also move during the medical procedure. Accordingly, in some embodiments, the motorized arms are configured to raise, lower, and angulate the arm supports, and can move the attached robotic arms from a lower, stowed position into a raised position in preparation for surgery. In some embodiments, the motorized arms can enable clinicians or physicians to have better access to the head or foot of the patient, thereby enabling procedures such as urologic and gastrointestinal (GI) procedures.

As described in this section and above, various embodiments for the motorized arms that support the arm supports are possible and some examples are provided below. For example, FIGS. 17-20 provide a first example, wherein the motorized arm comprises a single link. FIGS. 21-23 relate to a second example, wherein the motorized arm comprises a dual link design. These two examples, which are described in detail below, and further in Applicant's U.S. Patent Pub. No. 2020/0268460, the entirety of which is incorporated herein by reference, are provided by way of illustration and not limitation. Those of ordinary skill in the art will appreciate, upon consideration of this disclosure, that various features described in relation to the illustrated examples can be modified and combined in various ways. For example, features of the first illustrated example can be combined with features of the second illustrated example and vice versa.

2 (A). Single Link Motorized Arms.

FIG. 17 illustrates an end view of a medical robotic system 2200 that includes two motorized arms 2205 that position the robotic arm supports or rails 2207. In this example, each motorized arm 2205 comprises a single link 2211 that extends between a shoulder 2209 and an arm support 2207. The term “link” as used throughout this application can refer to any link and its associated structures that are kinematically associated with one or more degrees of freedom and/or joint movements. In some embodiments, a single “link” can comprise two or more structural pieces that a coupled together. For example, as shown in FIG. 18 (described in more detail below) the link 2211 comprises a first lateral side piece 2223 and a second lateral side piece 2225 that are structurally coupled together to form the single link 2211. The arm supports 2207 may comprise a bar or rail on which one or more robotic arms can be mounted as discussed above. As will be discussed below, the link 2211 can be configured to rotate about the shoulder 2209 in a sweeping or “bicep curl” type motion. This bicep curl type motion of the link 2211 in conjunction with the additional degrees of freedom of the motorized arm 2205 can advantageously provide a significant range of motion that can provide a high number of possible positions for the arm support 2207. For example, in some embodiments, the motorized arm comprises a significant range of motion to adequately achieve many or all positions required for robotic medical procedures or surgery, such as robotic laparoscopic surgery.

In the illustrated embodiment, the two motorized arms 2205 are positioned on opposite sides of a column 2202 that supports a table 2201 above a base 2203. That is, one motorized arm 2205 is positioned on a first lateral side of the column 2202 and the other motorized arm 2205 is positioned on a second lateral side of the column 2202 opposite the first lateral side. In this configuration, one motorized arm 2205 can be configured to position the connected arm support 2207 on the first lateral side of the table 2201 and the other motorized arm 2205 can be configured to position the connected arm support 2207 on the second lateral side of the table 2201. As illustrated in the example of FIG. 17, each motorized arm 2205 can be independently controllable and positionable, such that arm supports 2207 can be positioned at different positions on each side of the table 2201. While the two motorized arms 2205 can be independently controllable and positionable, they may comprise similar features. Thus, the following discussion will focus on one of the motorized arms 2205 with the understanding that the other motorized arm 2205 can be similar. In some embodiments, the robotic system 2200 includes only one motorized arm 2205. In some embodiments, the robotic system 2200 includes more than one motorized arm 2205. For example, the robotic system 2200 can include two motorized arms 2205 (as illustrated), three motorized arms 2205, four motorized arms 2205, etc.

A single link motorized arm 2205, for example, as illustrated in FIG. 17, may comprise one or more innovative features that allow it to perform effective bed-mounted robotic laparoscopic or endoscopic surgery (or other robotic medical procedures) while also stowing to a compact form within or proximal to the base 2203 to, for example, allow access for manual surgery. To be useable for a wide variety of medical procedures, the arm supports 2207 must be capable of being positioned in multiple positions or configurations relative to the table 2201. As noted previously, the motorized arm 2205 provides significant range of motion to adequately achieve these positions.

As noted above, the link 2211 of the motorized arm 2205 extends between the shoulder 2209 and the arm support 2207. The link 2211 can extend between a proximal end 2213 and a distal end 2215. The proximal end 2213 of the link 2211 can be coupled to the shoulder 2209. In some embodiments, the proximal end 2213 of the link 2211 is coupled to the shoulder 2209 with a rotational joint. The rotational joint that couples the proximal end 2213 of the link 2211 to the shoulder 2209 can provide a rotational degree of freedom 2217 as shown, which permits the link 2211 to rotate relative to the shoulder 2209. The rotational joint between the shoulder 2209 and the link 2211 may be configured to allow rotation about an axis that extends through the shoulder 2209 and the proximal end 2213 of the link 2211 and that is parallel to a longitudinal axis of the about the table 2201 so as to provide the rotational degree of freedom 2217.

In some embodiments, the rotational degree of freedom 2217 is configured to allow at least 120 degrees, at least 140 degrees, at least 150 degrees, at least 160 degrees, at least 170 degrees, at least 180 degrees of rotation, or more. The rotational degree of freedom 2217 can be measured from the fully lowered position, wherein the arm support 2207 is positioned proximal to the base 2203. In some embodiments, the link 2211 wraps around the column 2202, as discussed below) allowing additional rotation. In some embodiments, the rotational range can be as large as possible, while still avoiding collision with the table 2201 or other structures.

Such rotation can allow the link 2211 to rotate relative to the shoulder 2209 to deploy the arm support 2207 in the sweeping or bicep curl type motion discussed above. In some embodiments, the rotation of the joint between the link 2211 and shoulder 2209 allows the arm support 2207 to be placed laterally close or far away from the table 2201 or column 2202, but only at specific angles of rotation. Thus, in some embodiments, the motorized arm 2205 can include an additional degree of freedom 2219 that allows the height of the arm support 2207 to also be adjusted at various angles of rotation. This can effectively allow the user or the system to have vertical and lateral positional control of the arm support 2207 location relative to the table 2201, which advantageously allows for the flexible positioning of the arm support 2207 to accommodate different surgical or medical procedures, as well as to clear patient positioning accessories and accommodate various patient widths.

As illustrated in FIG. 17, the degree of freedom 2219 may comprise a translational degree of freedom 2219 along an axis that is parallel to the axis of the column 2202. This translational degree of freedom 2219 can be provided by the connection or joint of the shoulder 2209 to the column 2202. For example, the shoulder 2209 can be coupled to the column 2202 with a joint that translates vertically along the column 2202. The joint between the shoulder 2209 and the column 2202 can comprise a linear, sliding, or prismatic joint so as to allow for the translational degree of freedom 2219 for the motorized arm 2205. In some embodiments, this joint can be referred to as a “z-lift” mechanism because it translates along the z-axis. In some embodiments, the translational degree of freedom 2219 is configured translate along a length of the column 2202. In some embodiments, the translational degree of freedom 2219 is configured to allow translation along 30%, 40%, 50%, 60%, 70%, 80%, 90%, or more of the length of the column 2202. In some embodiments, the translational degree of freedom 2219 is configured to allow at least 20 cm, at least 30 cm, at least 40 cm, at least 50 cm or more of translation along the length of the column 2202.

In combination, the shoulder 2209, the link 2211, the rotational degree of freedom 2217 (provided by the rotational joint between the shoulder 2209 and the link 2211), and the translational degree of freedom 2219 (provided by the joint between the shoulder 2209 and the column 2202) can provide the motorized arm 2205 with a high range of motion that allows the arm support 2207 (positioned at the distal end 2215 of the link 2211) to be positioned at many horizontal and vertical distances relative to the table 2201. Specifically, rotation of the link 2211 about the shoulder 2209 (with the rotational degree of freedom 2219) can allow the arm support 2207 to be positioned at different horizontal and vertical distances relative to the table 2201, and translation of the shoulder 2209 along the column 2202 (with the translational degree of freedom 2219) can allow the arm support 2207 to be positioned at different vertical distances relative to the table 2201. In some embodiments, rotation of the link 2211 about the shoulder 2209 (with the rotational degree of freedom 2219) can allow the arm support 2207 to have a circular sweep about a pivot point at the shoulder 2209.

As illustrated in FIG. 17, the distal end 2215 of the link 2211 can be coupled to the arm support 2207. In some embodiments, the distal end 2215 of the link 2211 can be coupled to the arm support 2207 with a rotational joint that provides a rotational degree of freedom 2221. The rotational degree of freedom 2221 can be configured to enable the motorized arm 2205 to tilt or rotate the arm support 2207 that supports the robotic arms. In some embodiments, an additional mechanism is provided at the distal end 2215 of the link 2211, thereby allowing the arm support 2207 to translate relative to the link 2211 (an example is shown in FIGS. 22 and 23, described below).

In some embodiments, the rotational degree of freedom 2221 can be constrained to the rotational degree of freedom 2217 so as to maintain an orientation of the arm support 2207 during rotation of the link 2211 about the shoulder 2209. For example, in some embodiments, it may be beneficial to maintain the arm support 2207 such that an upper surface of the arm support 2207 remains level (e.g., parallel to a surface of the table 2201 or the floor) regardless of the rotational position of the link 2211. A mechanism can be configured and implemented for constraining the rotational degree of freedom, according to some embodiments.

In some embodiments, an actuator comprising a motor and a gearbox can be positioned in the proximal end of the link 2211 to control rotation of the motorized arm 2205 (i.e., the sweep or bicep curl motion of the link 2211). Further, in some embodiments, additional features may be incorporated to increase the stiffness of the motorized arm 2205 to allow for accurate robotic arm use. For example, in some embodiments, a high torsional stiffness brake can be added to the link 2211 at the proximal end 2213 and/or the distal ends 2213, as shown in FIG. 18.

FIG. 18 illustrates an isometric view of an embodiment of the motorized arm 2205 that includes a proximal torsional stiffness mechanism 2402 (illustrated as an arbor) and a distal tortional stiffness mechanism 2404 (illustrated as an arbor). The proximal torsional stiffness mechanism 2402 and the distal torsional stiffness mechanism 2405 can be configured to increase the stiffness of the motorized arm 2205. As shown in FIG. 18, in some embodiments, the link 2211 can include a first lateral side 2223 and an opposite second lateral side 2225. In some embodiments, an actuator 2405 including one or more of a motor, brake, sensor and/or gearbox can be positioned in the proximal end 2213 of the link 2211 at the first lateral side 2223. In some embodiments, the actuator 2405 can include a brake in the form of an electromagnetic brake. On the second lateral side 2225, the proximal end 2213 of the link 2211 can include the proximal torsional stiffness mechanism 2402. Thus, the actuator 2405 including a motor can be positioned on one lateral side and the proximal torsional stiffness mechanism 2402 can be positioned on the other lateral side of the link 2211. The proximal torsional stiffness mechanism 2402 can be a high torsional stiffness brake. In some embodiments, the proximal torsional stiffness mechanism 2402 can be part of a hydraulic arbor brake system. The proximal torsional stiffness mechanism 2402 can be configured to increase the stiffness of the motorized arm 2205 when actuated.

For example, in some embodiments, the actuator 2405, including the motor, is used to rotate the link 2211 to a rotational position. The torsional stiffness mechanism brake 2402 can be disengaged before rotation of the link 2211. Once in position, the proximal torsional stiffness mechanism 2402 can be engaged to increase the stiffness of the motorized arm 2205. In some embodiments, the proximal torsional stiffness mechanism 2402 or braking system can be considered part of a hydraulic expansion arbor brake system. The distal torsional stiffness mechanism 2404 can similarly be used to increase the torsional stiffness of the motorized arm 2205 at the joint between the link 2211 and the arm support 2207. Other types of brakes can also be used.

For example, in some embodiments, one or both of the proximal torsional stiffness mechanism 2402 and the distal torsional stiffness mechanism 2404 can be an arbor (as described below); a spring engaged, electromagnetic tooth brake; or a spring engaged, hydraulic released tooth brake. In some embodiments, alternatively or additionally, a higher stiffness gearbox in the actuator 2405 (such as a cycloidal gearbox in place of the harmonic gearbox) could also be used to increase torsional stiffness.

FIG. 18 also illustrates that a second, or distal brake 2404 may be included in the distal end 2215 of the link 2211. In the illustrated embodiment, the distal brake 2404 can be included on the second lateral side 2225 of the link 2211. That is, in some embodiments, both the proximal and distal brakes 2402, 2404 are on the same lateral side of the link 2211. This need not be the case in all embodiments. For example, the distal brake 2404 can be included on the first lateral side 2223. The distal brake 2404 can operate in a manner similar to the proximal brake 2402. For example, the distal brake 2404 can be configured to increase the stiffness of the motorized arm 2205. In some embodiments, like the proximal brake 2402, the distal brake 2404 can be part of a hydraulic expansion arbor brake system as described further below. Other types of brakes can be used instead a hydraulic expansion arbor brake system, including a spring engaged, electromagnetic tooth brake system or a spring engaged, hydraulic released tooth brake system.

The motorized arm 2205 described herein with reference to FIGS. 17-18 can also be configured to provide unique advantages for compactly stowing the robotic arms that are attached to the patient platform. For example, the motorized arm 2205 can lower the arm supports 2207 (and attached robotic arms) to a position below the table 2201 and proximal to the base 2203 or the floor to stow the robotic arms. This can allow, for example, access to the patient for manual surgery, as well as access for additional systems (e.g., a fluoroscopic c-arm), to be provided near the patient platform. To facilitate stowage, in some embodiments, the motorized arm 2205 is configured such that the link 2211 wraps around the column 2202, thereby bringing the motorized arm 2205 as close to the column 2250 as possible so as to remain within the footprint of the table 2201. This can be advantageous from a clinical perspective as may not limit patient-side access when the robotic system is not in use. These features are shown, for example, in FIGS. 19A, 19B, and 20.

2(B). Dual Link Motorized Arms.

Some embodiments of a medical robotic system can be implemented that include two motorized arms. For example, FIGS. 21-23 illustrated a medical robotic system in which a motorized arm 2705 comprises a dual-link configuration that includes a first link 2711 and a second link 2712. As shown, the first link 2711 is connected to a shoulder 2709. The shoulder 2709 can be connected to a column 2702 as previously described. The column 2702 extends between a table 2701 and a base 2703. The first link 2711 is also connected to the second link 2712. The second link 2712 is connected to an arm support 2707. The arm support 2707 may comprise a bar or rail on which one or more robotic arms can be mounted as discussed above (e.g., bar or rail 1307). In contrast with the single link design of the motorized arm 2205 of FIGS. 17-20, the dual-link design of the motorized arm 2705 of FIGS. 21-23 includes the first link 2211 and the second link 2212 extending between the shoulder 2709 and the arm support 2707. As will be described in more detail below, the second link 2212 can be configured to rotate relative to the first link 2211 to provide an additional rotational degree of freedom for the motorized arm 2705. This additional degree of freedom can allow for increased clinical workspace and reach above the table 2701, thereby providing greater flexibility for positioning the arm supports 2707 and the attached robotic arms. Further, in some embodiments, with the additional rotational degree of freedom between the first link 2711 and the second link 2712, the motorized arm 2705 may be less likely to contact the side of the table 2701.

In the illustrated embodiment, the two motorized arms 2705 are positioned on opposite sides of the column 2702 that supports the table 2701 above the base 2703. In some embodiments, each motorized arm 2705 can be independently controllable and positionable, such that arm supports 2707 can be positioned at different positions on each side of the table 2701. While the two motorized arms 2705 can be independently controllable and positionable, they may comprise similar features. Thus, this discussion will focus on one of the motorized arms 2705 with the understanding that the other motorized arm 2705 can be similar. In some embodiments, the robotic system 2700 includes only one motorized arm 2705. In some embodiments, the robotic system 2700 includes more than one motorized arm 2705. For example, the robotic system 2700 can include two motorized arms 2705 (as illustrated), three motorized arms 2705, four motorized arms 2705, etc. Further, each motorized arm 2705 and arm support 2707 can support two or three robotic arms. Other numbers of robotic arms may be used in other embodiments.

FIG. 21 further illustrates that, similar to the systems discussed above, the motorized arms 2705 of the robotic medical system 2700 can be configured to be stored in a compact space below the table 2701. For example, the motorized arms 2705 can be configured to move the arm supports 2707 to a position in or proximal to the base 2703 as shown. As will be discussed more fully below, the motorized arms 2705 can be configured to move from this stowed configuration (as shown, for example, in FIG. 21) to a range of deployed positions that enable the robotic arms to be employed during robotic surgical or medical procedures.

FIGS. 22A and 22B illustrate an embodiment of the motorized arm 2705 alone. FIG. 22A illustrates the motorized arm 2705 in an example deployed position, and FIG. 22B illustrates the motorized arm 2705 in an example stowed position. As shown in FIGS. 22A and 28B, the motorized arm 2705 comprises the shoulder 2709, the first link 2711, and the second link 2712. Although not illustrated in FIGS. 22A and 22B, the second link 2712 is further configured to connect to the arm support 2707, as shown in FIG. 21 and as will be described in more detail below with reference to FIG. 32. The shoulder 2709 may be similar to the shoulder 2209 described previously with reference to FIGS. 17-20. For example, the shoulder 2709 may be coupled to the column 2702 with a joint that allows the shoulder 2709 to translate along the column 2702, for example, in a z-lift motion as described above.

The first link 2711 extends between a proximal end 2713 and a distal end 2715. As illustrated in FIGS. 22A and 22B, the proximal end 2713 can be connected to the shoulder 2709 by a rotational joint. The rotational joint between the proximal end 2713 of the first link 2711 and the shoulder 2709 can be configured to permit the first link 2711 to rotate relative to the shoulder 2709 with a first rotational degree of freedom 2717. In some embodiments, the first rotational degree of freedom 2717 allows for 180 degrees of rotation for the first link 2711, although this need not be the case in all embodiments. For example, in some embodiments, the first rotational degree of freedom 2717 allows for greater than or less than 180 degrees of rotation for the first link 2711. In some embodiments, the first rotational degree of freedom 2717 allows the first link 2711 to move relative to the shoulder 2709 in a bicep curl or sweeping motion.

As illustrated in FIGS. 22A and 22B, the first link 2711 may comprise a first lateral side 2723 and a second lateral side 2725. As shown, the first lateral side 2723 may be separated from the second lateral side 2725 to create a space therebetween. The shoulder 2709 can be positioned between the first lateral side 2723 and the second lateral side 2725 of the first link 2711. That is, the first lateral side 2723 can be connected to a first lateral side of the shoulder 2709 and the second lateral side 2725 can be connected to a second lateral side of the shoulder 2709. This configuration can advantageously allow the first link 2711 to rotate relative to the shoulder 2709 over a large range of motion (e.g., 180 degrees) without the first link 2711 coming into contact with the shoulder 2709.

The second link 2712 also extends between a proximal end 2714 and a distal end 2716. As illustrated in FIGS. 22A and 22B, the proximal end 2714 of the second link 2712 can be connected to the distal end 2715 of the first link 2711 by a rotational joint. The rotational joint between the proximal end 2714 of the second link 2712 and the distal end 2715 of the first link 2711 can be configured to permit the second link 2712 to rotate relative to the first link 2711 with a second rotational degree of freedom 2718. In some embodiments, the second rotational degree of freedom 2718 allows for 150 degrees of rotation for the second link 2712 relative to the first link 2711, although this need not be the case in all embodiments. For example, in some embodiments, the second rotational degree of freedom 2718 allows for greater than or less than 150 degrees of rotation for the second link 2712 relative to the first link 2711. In some embodiments, the second rotational degree of freedom 2718 allows the second link 2712 to move relative to the first link 2711 in a bicep curl or sweeping motion.

Similar to the first link 2711, the second link 2712 may also comprise a first lateral side 2724 and a second lateral side 2726. As shown, the first lateral side 2724 may be separated from the second lateral side 2726 to create a space therebetween. The first link 2711 can be positioned between the first lateral side 2724 and the second lateral side 2726 of the second link 2712. That is, the first lateral side 2724 of the second link 2712 can be connected to a first lateral side 2723 of the first link 2711 and the second lateral side 2726 of the second link 2712 can be connected to the second lateral side 2725 of the first link 2711. This configuration can advantageously allow the second link 2712 to rotate relative to the first link 2711 over a large range of motion (e.g., 150 degrees) without the second link 2712 coming into contact with the first link 2711. This configuration can also allow the motorized arm 2705 to fold to a small, compact size in the stowed configuration, as shown, for example, in FIGS. 21 and 22B.

The distal end 2716 of the second link 2712 can be configured to connect to an arm support 2707 (not illustrated in FIGS. 22A and 22B) configured as a rail or bar for supporting one or more robotic arms. Features of the distal end 2716 of the second link 2712 will be described in more detail below with reference to FIG. 32.

Because the motorized arm 2705 includes two links 2711, 2712 that are each configured to rotate with their own rotational degree of freedom 2717, 2718, the motorized arm 2705 is capable of moving an attached arm support to an even wider range of positions to facilitate robotic medical procedures. In some embodiments, for example, inclusion of the second link 2712 and additional rotational degree of freedom 2718 enables the motorized arm 2705 to reach around the table 2701 and next to the patient.

3. Robot Arms Associated with Adjustable Arm Supports

The adjustable arm supports described above can be configured to mount to the table, the column, or the base, and are adjustable (moveable in various degrees of freedom) to support robotic arms positioned on the adjustable arm supports. As the adjustable arm supports can be configured to mount below the surface of the table in accordance with some embodiments, it can be advantageous to employ certain types of robotic arms with the adjustable arm supports. In particular, robotic arms that have increased movement and flexibility may be desirable, as the robotic arms may have to “work up” from a lower position and avoid collisions (e.g., with the table). This section outlines certain features of robotic arms configured for use with adjustable arm supports.

For example, in some embodiments, robotic arms configured for use with the adjustable arm supports differ from parallelogram remote center robotic arms. In one example, a robotic arm configured for use with the adjustable arm supports can comprise a shoulder with at least two degrees of freedom, an elbow with at least one degree of freedom, and a wrist with at least two degrees of freedom. The kinematics associated with such an arm allow the arm base to be positioned arbitrarily relative to the workspace, allowing for setups that would be challenging for a parallelogram remote center robot mounted alongside a bed.

Further, in some embodiments, a robotic arm configured for use with the adjustable arm supports may include a semi-spherical or spherical wrist configured with at least three degrees of freedom. Such a wrist can allow the robotic arm to roll its wrist joint such that an instrument drive mechanism positioned at the distal end of the robotic arm can be below the arm wrist. This can enable procedures where target workspaces are far above ports.

Some surgical robotic arms include a mechanically constrained remote center with no redundant degrees of freedom (e.g., parallelogram robotic arms). That is, for any remote center position, the distance to the base is mechanically constrained. Robotic arms coming from below the bed, as is the case with robotic arm mounted on the adjustable arm supports described above, can be limited by their mount structures and cannot reach the optimal configurations to make parallelogram robot arms excel. To address this issue, robotic arms configured for use with the adjustable arm supports described above can include one or more redundant degrees of freedom. The redundant degrees of freedom can allow the arms to be jogged within their null space without moving the tool tip, allowing for intraoperative collision avoidance that is not possible previously known surgical robotic arms.

FIG. 24 illustrates an example of a robotic arm 1700 usable with the systems and components depicted in FIGS. 1-23. The robotic arm 1700 comprises an RRRPP serial chain manipulator, with “R” referring to a revolute joint and “P” referring to a prismatic joint, with such joint labeling beginning at the proximal-most joint 1705A and moving serially along the robotic arm towards the distal-most joint 1705E. The robotic arm 1700 can be configured for use as a low-inertia remote center laparoscopy system or as a virtual rail endoscopic system.

The robotic arm 1700 includes a number of motorized joints 1705A-1705E connected in serial fashion by linkages 1710A-1710D. The first linkage 1710A connects the first motorized joint 1705A and the third motorized joint 1705B, the second linkage 1710B connects the third motorized joint 1705B to the fourth motorized joint 1705C, the third linkage 1710C connects the fourth motorized joint 1705C to the fifth motorized joint 1705D, and the fourth linkage 1710D connects the fifth motorized joint 1705D to the second motorized joint 1705E.

A first motorized joint 1705A at the proximal end of the robotic arm (e.g., closest to setup joints or a base of the robotic system to which the robotic arm 1700 is attached) is a revolute joint that causes rotational motion of medical instrument 1725 around yaw axis 1735A. A second motorized joint 1705E at the distal end of the robotic arm (e.g., closest to the medical instrument 1725) is a prismatic joint that moves linearly along distal face 1715B of the fourth linkage 1710D. Additional motorized joints 1705B, 1705C, 1705D are positioned serially between the first and second motorized joints.

The fifth motorized 1705D joint is a prismatic joint that moves linearly along the proximal face 1715A of the fourth linkage 1710D. The axes of prismatic joints 1705D and 1705E are depicted as being parallel to each other due to the shape of the fourth linkage 1710D, however in other embodiments the axes may not be parallel and the shape of the fourth linkage 1710D may vary accordingly.

The third motorized joint 1705B and fourth motorized joint 1705C are revolute joints that each rotate in a plane positioned orthogonally to the plane of rotation of the first motorized joint 1705A. Actuation of the third motorized joint 1705B and fourth motorized joint 1705C can cause the medical instrument 1725 to rotate about pitch axis 1735C.

Each motorized joint 1705A-1705E can comprise a motor, a position sensor, and a gearbox. In some embodiments, the motor can be an interior permanent magnet motor including a stator, a rotor rotatable within the stator, and a plurality of windings wound through the stator and configured to carry one or more phases of electrical current. The rotor can comprise a magnetically permeable material and at least one permanent magnet embedded within the magnetically permeable material. One example of the position sensor is an optical encoder positioned with a field of view encompassing the rotor such that the optical encoder can capture image data representative of the rotor, the image data usable to determine a position of the rotor. Other examples of suitable position sensors include closed loop position control systems that monitor the current in one or more of the windings of a motor (for example via a Hall sensor or other current sensor), as well as angular joint sensors that generate data usable to determine the angle between adjacent linkages (for example one or more of accelerometers, gyroscopes, magnetometers, conductive fibers, etc.). Output from the position sensors of each of the motorized joints 1705A-1705E can be used by the controller 206 to control actuation of the robotic arm 1700 in the operational modes described herein. The gearbox can include a number of gears to achieve a desired gear ratio for each joint. One example joint can have a 100:1 to 150:1 gear ratio in order to achieve the desired stiffness for operation during endoscopic medical procedures. The gearbox can be a harmonic gearbox using strain wave gearing and thus provides advantages over traditional gear-based gearboxes due to having low or no backlash, high compactness, and light weight.

An instrument driver 1720 can be coupled to the second motorized joint 1705E to secure and/or manipulate medical instrument 1725. The instrument driver 1720 can be the instrument driver described with respect to FIG. 12 in some embodiments. Movement of the second motorized joint 1705E along the distal face 1715B of the fourth linkage 1710D and/or movement of the fifth motorized joint 1705D along the proximal face 1715A of the fourth linkage 1710D can translate into linear motion of the medical instrument 1725 along the insertion axis 1725B. Actuation of the motorized joints 1705A-1705C together with one or more setup joints can also move the medical instrument 1725 along the insertion axis 1725B. The instrument driver 1720 can move the medical instrument 1725 in other degrees of freedom, for example roll of the medical instrument 1725 around the insertion axis 1725B, deflection of the tip of a steerable medical instrument, and the like. The medical instrument 1725 can be any endoscopic or laparoscopic tool, for example a bronchoscope, gastroscope, ureteroscope, colonoscope, steerable catheter, a laparoscope, a tool positioned within the working channel of such a scope (e.g., needles, forceps, cytology brushes, augers, etc.), electrosurgical shears, and other medical instruments used in the disclosed procedures.

In some medical procedures, the instrument 1725 can extend into a cannula 1730 positioned for example in an incision forming an opening into the body of a patient. In other medical procedures the instrument 1725 can extend directly into a natural orifice forming an opening into a luminal network of a patient and thus the cannula 1730 can be omitted. Some embodiments of the robotic arm 1700 can further include a dock (not illustrated, see for example dock 1840 of FIG. 25) that can couple the fourth linkage 1710D to the cannula 1730. The cannula 1730 may snap into the dock, and the dock can be removable from the fourth linkage 1710D. Not fixedly holding onto the cannula can provide advantages when looking to adapt from an endoscopic procedure to a laparoscopic procedure arm, however the proximity between the fourth linkage 1710D and the portion of the insertion axis that passes through the cannula makes it possible to provide a dock to hold the cannula. Such a dock can help resolve medical instrument forces and keep the cannula aligned with the medical instrument axis for medical instrument exchange. This dock can be removable for when the robotic arm 1700 is to be configured for an endoscopic procedure, and the fourth linkage 1710D can include a coupling for attaching to the dock, an additional instrument driver, or another type of attachment, like a patient introducer.

The specific depicted locations of the axes 1735A, 1735B, 1735C can be varied depending upon the positioning of the robotic arm 1700, with the yaw axis 1735A extending through the center of the first motorized joint 1705A and the insertion axis 1735B extending through the instrument driver 1720 coupled to the second motorized joint 1705E. It will be appreciated that simultaneous actuation of multiple joints 1705A-1705E can move the instrument 1725 along or about multiple axes simultaneously. The yaw axis 1735A can be considered as the axis of rotation of revolute joint 1705A and the co-axial axis of rotation of the motion translated to the medical instrument 1725. The present disclosure also refers to the yaw axis 1735A as a “first axis,” the insertion axis 1735B as a “second axis,” and the pitch axis 1725C as a “third axis.”

Actuation of the motorized joints 1705A-1705E of robotic arm 1700 can be controlled programmatically by the controller 206 (automatically or in response to user guidance at console 200) based on different sets of motion constrains corresponding to different medical procedures. For example, in a laparoscopic configuration, configuring the robotic arm 1700 into a low-inertia remote center laparoscopic system is achieved by identifying a remote center 1745 location (corresponding to a point on a cannula and/or a location of an incision in the patient's body), orienting the revolute first axis 1735A to pass through the remote center 1745, constraining actuation of the three intermediate RRP joints (motorized joints 1705B, 1705C, and 1705D) based on software instructions to form remote pitch axis 1735C fixed in space and passing through the remote center 1745, and orienting the distal prismatic axis (along the linear distal face 1715B of the fourth linkage 1710D) parallel to the insertion axis 1735B such that the medical instrument 1725 is inserted through the remote center 1745. Thus, in this first mode of operation, the structures of the robotic arm 1700 that create the first axis 1735A and second axis 1735C are oriented such that these axes pass through the location of the remote center 1745, while the remote pitch axis 1735C is defined by the software constraints and fixed in space to pass through the remote center 1745. During use in the first mode, actuation of the motorized joints 1705A-1705E is controlled to maintain these three axes 1735A, 1735B, 1735C passing through the remote center 1745. Thus, in the first mode the robotic arm 1700 can be considered as a RRRPP serial chain manipulator with a first R axis 1735A configured to point towards the remote center 1745, a last P axis configured to be parallel to the insertion axis 1735B, and a software-constrained remote pitch axis 1735C formed by the intermediate RRP joints, where the robotic arm 1700 is controlled such that the axes 1735A, 1735B, 1735C intersect with one another at a pre-identified a remote center location. The remote center geometry (e.g., its distance along the yaw axis 1735A from the first motorized joint 1705A) can be adjusted during use, as described in more detail below with respect to FIGS. 31A and 31B.

In an endoscopic configuration, the software constraint relating to the remote center is removed, and the motorized joints 1705A-1705E are instead operated with respect to a virtual rail. A virtual rail can be considered as a linear axis in space that is aligned with an opening of a patient, for example a natural orifice leading to an interior luminal network of the patient. In some examples, an additional instrument driver 1720 can be affixed to one end of the fourth linkage 1710D in endoscopic mode. In some examples, motorized joints 1705A-1705E can be used to position a series of robotic arms 1700 next to each other with their insertion axes aligned along the virtual rail. The insertion axes of the various instrument drivers and/or arms need to be coincident, however the instrument drivers can be spaced apart along the virtual rail to provide a maximum workspace and/or to avoid collisions.

In some embodiments, the instrument driver 1720 can rotate relative to the second motorized joint 1705E as, for some endoscopic procedures, it is desirable to have a top-loading medical instrument. This can be achieved by adding a rotary degree of freedom between the instrument driver 1720 and second motorized joint 1705E. This degree of freedom can either be active or a passive setup joint. A passive setup joint can include detent positions or an integer number of positions where it can be latched, for example in order to facilitate rotating the instrument driver 1720 in 90-degree increments.

The robotic arm 1700 can be delivered by an active or passive setup joint. If the setup joint is active, the setup joint can re-position the workspace of the robotic arm 1700 intraoperatively while maintaining intersection of the axes 1735A, 1735B, 1735C with the remote center. The setup joint can also reposition the first motorized joint 1705A such that the first axis 1735A passes through the remote center. One advantage of using such a setup joint is that this puts a set of fast axes (e.g., axes with performance suitable for performing laparoscopic procedures with a limited workspace) on set of slow axes (e.g., axes that are not suitable for performing laparoscopic procedures alone but have a large workspace). As such, it is possible to perform null-space movements to keep the medical instrument 1725 centered on the fast axes, thus enabling the robotic arm 1700 to have a fast performance over a large workspace. This design reflects a trade-off for the robotic arm 1700 between range of motion of the robotic arm 1700 and minimizing size while still satisfying the requirements of laparoscopic procedures.

FIG. 25 illustrates another example of a robotic arm 1800 usable with the systems and components depicted in FIGS. 1-23. The robotic arm 1800 comprises an RRRRP serial chain manipulator, with such joint labeling beginning at the proximal-most joint 1805A and moving serially along the robotic arm towards the distal-most joint 1805E.

The robotic arm 1800 includes a number of motorized joints 1805A-1805E connected in serial fashion by linkages 1810A-1810D. The first linkage 1810A connects the first motorized joint 1805A and the third motorized joint 1805B, the second linkage 1810B connects the third motorized joint 1805B to the fourth motorized joint 1805C, the third linkage 1810C connects the fourth motorized joint 1805C to the fifth motorized joint 1805D, and the fourth linkage 1810D connects the fifth motorized joint 1805D to the second motorized joint 1805E. In the embodiment of FIG. 25, the second linkage 1810B is shorter than the first linkage 1810A such that the fourth motorized joint 1805C can rotated by actuation of the third motorized joint 1805B in a full circle. For example, the fourth motorized joint 1805C can be rotated from its illustrated position on a first side of the first linkage 1810A past the first motorized joint 1805A to a second side of the first linkage 1810A due to the shorter length of the second linkage 1810B. During such a movement, the fourth joint 1805C can be actuated to prevent collision between the first motorized joint 1805A and the structures positioned distally from the fourth motorized joint 1805C (e.g., third linkage 1810C, fifth motorized joint 1805D, fourth linkage 1810D, second motorized joint 1805E, instrument driver 1810, and medical instrument 1825).

A first motorized joint 1805A at the proximal end of the robotic arm (e.g., closest to setup joints or a base of the robotic system to which the robotic arm 1800 is attached) is a revolute joint that causes rotational motion of medical instrument 1825 around yaw axis 1835A. A second motorized joint 1805E at the distal end of the robotic arm (e.g., closest to the medical instrument 1825) is a prismatic joint that moves linearly along distal face 1815B of the fourth linkage 1810D. Additional motorized joints 1805B, 1805C, 1805D are positioned serially between the first and second motorized joints, and are revolute joints that each rotate in a plane positioned orthogonally to the plane of rotation of the first motorized joint 1805A. Actuation of the additional motorized joints 1805B, 1805C, 1805D can cause the medical instrument 1825 to rotate about pitch axis 1835C. Each motorized joint 1805A-1805E can comprise a motor, a position sensor, and a gearbox, as described above with respect to the robotic arm 1700. Output from the position sensors of each of the motorized joints 1805A-1805E can be used to control actuation of the robotic arm 1800 in the operational modes described herein.

An instrument driver 1820 can be coupled to the second motorized joint 1805E to secure and/or manipulate medical instrument 1825. The instrument driver 1820 can be the instrument driver described with respect to FIG. 12 in some embodiments. Movement of the second motorized joint 1805E along the distal face 1815B of the fourth linkage 1810D and/or coordinate movement of the additional motorized joints 1805A-1805E, alone or together with one or more setup joints, can translate into linear motion of the medical instrument 1825 along the insertion axis 1825B. The instrument driver 1820 can move the medical instrument 1825 in other degrees of freedom, for example roll of the medical instrument 1825 around the insertion axis 1825B, deflection of the tip of a steerable medical instrument, and the like. The medical instrument 1825 can be any endoscopic or laparoscopic tool, for example a bronchoscope, gastroscope, ureteroscope, colonoscope, steerable catheter, a laparoscope, a tool positioned within the working channel of such a scope (e.g., needles, forceps, cytology brushes, augers, etc.), electrosurgical shears, and other medical instruments used in the disclosed procedures.

In some medical procedures, the instrument 1825 can extend into a cannula 1830 positioned for example in an incision forming an opening into the body of a patient. The robotic arm 1800 can further include a dock 1840 that can couple the fourth linkage 1810D to the cannula 1830. The cannula 1830 may snap into the dock, and the dock can be removable from the fourth linkage 1810D. Not fixedly coupling the robotic arm 1800 to the cannula 1830 can provide advantages when looking to adapt from an endoscopic procedure to a laparoscopic procedure arm, however the proximity between the fourth linkage 1810D and the portion of the insertion axis that passes through the cannula 1830 makes it possible to provide dock 1840 to hold the cannula. Dock 1840 can help resolve medical instrument forces and keep the cannula aligned with the medical instrument axis for medical instrument exchange. Dock 1840 can be removable for when the robotic arm 1800 is to be configured for an endoscopic procedure, and the fourth linkage 1810D can include a coupling for attaching to the dock 1840, an additional instrument driver, or another type of attachment, like a patient introducer. In some medical procedures the instrument 1825 can extend directly into a natural orifice forming an opening into a luminal network of a patient and thus the cannula 1830 can be omitted.

The specific depicted locations of the axes 1835A, 1835B, 1835C can be varied depending upon the positioning of the robotic arm 1800, with the yaw axis 1835A extending through the center of the first motorized joint 1805A and the insertion axis 1835B extending through the instrument driver 1820 coupled to the second motorized joint 1805E. It will be appreciated that simultaneous actuation of multiple joints 1805A-1805E can move the instrument 1825 along or about multiple axes simultaneously. The yaw axis 1835A can be considered as the axis of rotation of revolute joint 1805A and the co-axial axis of rotation of the motion translated to the medical instrument 1825. The present disclosure also refers to the yaw axis 1835A as a “first axis,” the insertion axis 1835B as a “second axis,” and the pitch axis 1825C as a “third axis.”

Actuation of the motorized joints 1805A-1805E of robotic arm 1800 can be controlled programmatically by the controller 206 (automatically or in response to user guidance at console 200) based on different sets of motion constrains corresponding to different medical procedures. In a first mode suitable for laparoscopic procedures, as described above with respect to the robotic arm 1700, the robotic arm 1800 can be controlled via a software-constrained remote center architecture such that the first R axis 1835A points through the remote center 1845, the software-defined remote pitch axis 1835C passes through the remote center 1845, and the insertion axis 1835B points through the remote center 1845. This remote center constraint can be removed to operate the robotic arm 1800 in a second mode suitable for an endoscopic procedure, where in the second mode the robotic arm 1800 is controlled with respect to a virtual rail, such that the insertion axis 1835B is maintained co-axial with the virtual rail.

It will be appreciated with respect to FIGS. 24 and 25 that the illustrated shapes and sizes of the linkages can be varied. For example, the linkages may be curved rather than straight in variations of the illustrated embodiments, and certain linkages may be lengthened or shortened.

4. Overview of Example Operational Modes

FIG. 26A depicts the robotic arm 1700 of FIG. 24 begin actuated in a first mode of operation 1900. The first mode of operation 1900 can be suitable for laparoscopic procedures. The robotic arm 1800 of FIG. 25 can be operated in a similar manner in the first mode of operation. For clarity in the drawing, certain reference numbers shown for the robotic arm 1700 in FIG. 24 that are not specifically referenced in the discussion of FIG. 26A are omitted from FIG. 26A, and the reference numbers relating to the structures of the robotic arm 1700 are provided on only the first position 1905A of the five illustrated positions 1905A-1905E.

In the first mode of operation 1900, the movement of the robotic arm 1700 is controlled such that the first axis 1705A points through the remote center 1910 and the second axis 1735B also points through the remote center 1910. In the illustrated example, the software-defined remote pitch axis (the third axis) extends through the page of FIG. 26A at the location of the remote center 1910.

During use in the first mode of operation 1900, the robotic arm 1700 can be positioned in a number of different positions 1905A-1905E (as well as other in positions intermediately located between the illustrated positions) that span a range of possible positions between the first position 1905A and the last position 1905E. In each position, the motorized joint 1705A is oriented so that the first axis 1705A points through the remote center 1910. Further, in each position the actuations of motorized joints 1705B-1705D are cooperatively controlled such that the third axis intersects with the remote center 1910. Further, in each position the instrument driver 1720 is positioned such that the second axis 1735B points through the remote center 1910. The movement between the illustrated positions 1905A-1905E is effected by controlling the third, fourth, and fifth motorized joints 1705B-1705D to rotate the medical instrument 1725 around the remote pitch axis and the remote center 1910. Other movements are also possible while controlling the robotic arm 1700 under the constraints of the first mode of operation 1900.

As illustrated, the position and orientation of the first linkage 1710A may remain stationary, or the orientation may rotate around the first axis 1735A while its position remains stationary. In some embodiments the position of the first linkage 1710A can be varied by setup joints while maintaining intersection of the first axis 1735A with the remote center 1910. The positions and orientations of the second, third, and fourth linkages 1710B-1710D can vary relative to the position of the first motorized joint 1705A and relative to one another as the robotic arm 1700 is rotated around the remote pitch axis through the range of positions 1905A-1905E under control of the first operating mode 1900. Although the instrument driver 1720 as depicted in FIG. 26B is maintained a fixed distance from the cannula 1730, in other embodiments distance between the instrument driver 1720 and the cannula 1730 can be varied to adjust the insertion depth of the medical instrument 1725 within the body of the patient.

FIG. 26B depicts a table-based robotic system 1955 including a number of robotic arms as depicted in FIG. 24 in a first configuration 1950 suitable for operating in the first mode 1900 for a laparoscopic procedure. As illustrated, four robotic arms 1700A-1700D each control a medical instrument to rotate about a remote center located at (or near) an incision 1945 in the abdomen of a patient 1940. For clarity in the drawing, certain reference numbers shown for the robotic arm 1700 in FIG. 24 that are not specifically referenced in the discussion of FIG. 26A are omitted from FIG. 26A, and only one incision 1945 is labeled though each robotic arm 1700A-1700D is controlled with respect to a different remote center located at (or near) a different incision. The robotic arm 1800 can alternatively be used in place of one, some, or all of the robotic arms 1700 in other embodiments, and table-based robotic system 1950 can include greater or fewer than four robotic arms.

The table-based robotic system 1950 includes four setup arms 1960 each including a number of setup joints 1920 serially coupled by linkages 1915. The setup joints 1920 of a setup arm 1960 can be passive, active, or a mix. The configuration of a setup arm 1960 can be varied depending upon the intended usage of the table-based robotic system 1950. Each setup arm 1960 is attached to one of the robotic arms 1700A-1700D and thus positions the corresponding robotic arm in the space surrounding the patient 1940.

In the illustrated embodiment, the setup arms 1960 are attached to carriages 1925 that are secured around a column 1930 positioned under a bed such that setup arms 1960 emerge from below patient table 1935. The column 1930 is illustrated with three carriages 1925 and four robotic arms 1700A-1700D, where two arms are attached to the same carriage and one of the carriages may have no arms and may be omitted. In other embodiments the third carriage can have an additional arm or two arms, and the specific configuration of carriages and robotic arms can be modified based on the requirements of the system 1950. Further, the disclosed robotic arms are not limited to a table-based system as illustrated, and in other embodiments can be mounted to a movable cart or ceiling-mounted base. Regardless of how they are mounted, a robotic system 1950 including multiple arms 1700A-1700D retains the advantage of being able to perform both laparoscopic procedures and endoscopic procedures with the same system 1950.

During operation in the first mode, a single controller 206 or a group of controllers in communication with one another may be used to control motion of each of the robotic arms 1700A-1700D and setup arms 1960 so that the various physical structures do not collide or interfere with one another. Each controller 206 can include one or more processors and an associated memory configured with computer-executable instructions for controlling joint actuation in various operation modes based on user guidance via input controls, data from joint position encoders, stored mode-specific operational constraints, and stored size parameters of the structures of the robotic arms 1700A-1700D. Accordingly, the controller 206 may limit the range of motion or workspace of a particular arm or arms in order to prevent collisions. Such a limitation can be set at the beginning of a procedure or can be varied dynamically during the procedure based upon the positions of other arms. Though not illustrated, in some embodiments the table-based robotic system 1950 can include one or more image sensing devices positioned around the table 1935 and in communication with the controller 206 in order to identify positions of medical personnel around the patient and to control the robotic arms 1700A-1700D to avoid the positions of the medical personnel. The controller 206 can be located within the table 1935, column 1930, or a control system (for example console base 201) or distributed among these structures.

FIG. 27A depicts three of the robotic arms 1700A-1700C of FIG. 24 configured in a second mode of operation 2000. The second mode of operation 2000 can be suitable for endoscopic procedures. The robotic arm 1800 of FIG. 25 can be operated in a similar manner in the second mode of operation 2000. For clarity in the drawing, certain reference numbers shown for the robotic arm 1700 in FIG. 24 that are not specifically referenced in the discussion of FIG. 27A are omitted from FIG. 27A, and the reference numbers relating to the structures of the robotic arm 1700 are provided only on the first robotic arm 1700A.

In the second mode of operation 2000, robotic arms 1700A-1700C are positioned such that the insertion axes (not labeled) that pass through the instrument driver 1720 of each robotic arm 1700A-1700C are aligned to be co-axial with virtual rail 2005. The robotic arms 1700A-1700C are further positioned such that none of the linkages 1710A-1710D, joints 1705A-1705E, or instrument driver 1720 of a particular robotic arm interferes with the required ranges of motion of the instrument drivers of the other robotic arms. Thus, the robotic arms 1700A-1700C can each be used to position and actuate (via the instrument driver) one of a number of coaxial medical instruments during an endoscopic procedure. For example, robotic arm 1700A may position and actuate a bronchoscope having a working channel, robotic arm 1700B may position and actuate a catheter (steerable or non-steerable) extending into and potentially beyond the working channel of the bronchoscope, and robotic arm 1700C may position a conduit that extends into the catheter and is coupled at its distal end to a needle or other medical tool. For example, robotic arm 1700C can extend and retract the needle relative to the catheter by actuating the second motorized joint 1705E, fifth motorized joint 1705D, and/or a combination of the motorized joints 1705B-1705E (with or without setup joint movement).

FIG. 27B depicts a second configuration 2050 of the table-based robotic system 1955 of FIG. 26B including robotic arms 1700A-1700C configured as shown in FIG. 27A for operating in the second mode 2000 suitable for an endoscopic procedure. The fourth arm 1700D is folded into a compact storage configuration (one example of which is illustrated in FIG. 33 with respect to arm 1800) and is not visible in the view of FIG. 27B. The robotic arms 1700A-1700C position concentric endoluminal medical instruments 1725A, 1725B, 1725C along the virtual rail 2005 that is shown as being co-axial with the insertion axis 1725B of each robotic arm 1700A-1700C. The virtual rail 2005 is aligned with the natural orifice 2045 (mouth) of patient 1940.

In some medical procedures, it may be desirable to have one or a subset of the robotic arms 1700A-1700D of the table-based robotic system 1955 operating in the first mode 1900 and another or another subset of the robotic arms 1700A-1700D operating in the second mode 2000. For example, some uteroscopic procedures involve a first medical instrument that enters the kidney through an incision, which could be controlled by a robotic arm in the first mode 1900, as well as a second medical instrument passed endoluminally to the kidney through the ureter, which could be controlled by a robotic arm in the second mode 2000.

FIGS. 28A and 28B depict a range Rext of position options for the instrument driver 1720 mounted to the robotic arm of FIG. 24 given a fixed location of the fourth motorized joint 1705C. For example, the location of the fourth motorized joint 1705C may be fixed in the second mode of operation 2000 in order to maintain a coaxial insertion axis and software-constrained virtual rail location. The range Rext is provided by a “double insertion axis” resulting from the linear movement of the second motorized joint 1705E along the distal face 1715B of the fourth linkage 1710D and the linear movement of the fifth motorized joint 1705D along the proximal face 1715A of the fourth linkage 1710D. FIGS. 28A and 28B are illustrated with the first motorized joint 1705A aligned along axis 2105 in order to accurately depict the range Rext.

In FIG. 28A, the robotic arm 1700 is positioned in a first configuration 2100A with the second motorized joint 1705E and instrument driver 1720 positioned at a first end of the fourth linkage 1710D and the fifth motorized joint 1705D positioned at a second end of the fourth linkage 1710D, the second end opposing the first end with the proximal and distal faces 1715A, 1715B extending therebetween. In FIG. 28B, the robotic arm 1700 is positioned in a second configuration 2100B with the second motorized joint 1705E and instrument driver 1720 positioned at the second end of the fourth linkage 1710D and the fifth motorized joint 1705D positioned at the first end of the fourth linkage 1710D. As illustrated, this provides a range Rext of possible locations to which the instrument driver 1720 may be moved using just the fifth and second motorized joints 1705D, 1705E, for example during operation of the robotic arm 1700 in the second mode of operation 2000. Though the instrument driver 1720 is depicted as facing the same direction in FIGS. 28A and 28B, the instrument driver 1720 may be rotated 180 degrees to cover the entire depicted range Rext. The double insertion axis thus provides advantages for endoscopic procedures, because it gives an insertion range of motion of that is double the length of the range of motion that would be provided using a single prismatic joint at the distal end of the robotic arm (for example, as in the embodiment of FIG. 25). This greater range of motion gives the robotic arm 1700 greater flexibility with endoscopic procedures.

FIGS. 29A-29D depict a series of example steps of a setup process 2200 for setting up the robotic arm of FIG. 25 to operate in the first mode 1900 depicted in FIG. 26A. Similar setup processes can be implemented using the robotic arm 1700 and other disclosed variations.

Block 2205 shown in FIG. 29A depicts the robotic arm 1800 with the dock 1840 uncoupled from cannula 1830. Though depicted as floating in space, in use the cannula 1830 may be positioned within an opening into the body of a patient.

At block 2210 shown in FIG. 29B, the dock 1840 of the robotic arm 1800 is coupled to the cannula. For example, the motorized joints 1705A-1705E can be operated in a passive mode such that a user can manually move the robotic arm 1800 to connect the dock 1840 and the cannula 1830. The controller 206 of the robotic arm 1800 can identify when the cannula 1830 is docked, for example by a sensor or mechanical button in the dock 1840 or based on user input at a control system. Once docked, the controller 206 can identify the location of the remote center 2225 as a point along or within the cannula 1830. The location may be identified based on a pre-defined spatial relationship between the docked portion of the cannula 1830 and the remote center, based on user input designated a depth of insertion of the cannula into the opening, or identified automatically and then adjusted by user input. At block 2210, the yaw axis 1835A (the axis of revolution of first motorized joint 1705A) does not yet intersect with the remote center 2225, but the insertion axis (not illustrated) passes through the remote center 2225 due to the docking of the cannula 1930 and the geometry of the dock 1840.

At block 2215 shown in FIG. 29C, the controller 206 can actuate setup joints (such as setup joints 1920 or a variation thereof) to position the first axis 1835A to intersect with the identified location of the remote center 2225. At the same time, the controller 206 can actuate some or all of the motorized joints 1705A-1705E to maintain a fixed position and orientation of the cannula 1830. As such, the actuation of robotic arm 1800 and any setup joints at block 2215 can be considered as a null-space movement that maintains the orientation of the insertion axis and the location of the remote center 2225.

At block 2220 shown in FIG. 29D, the instrument driver 1820 is actuated along the distal surface 1815B of the fourth linkage 1810D in order to insert the medical instrument 1825 through the cannula 1830. Block 2220 can further involve actuation of the robotic arm 1800 in the first mode 1900 described herein.

The setup process 2200 provides advantages compared to setup with existing systems having mechanical remote centers that maintain a parallelogram (or virtual parallelogram) configuration of the robotic arm linkages. In such existing systems, a user needs to move the whole arm around to connect it to the cannula, which is accomplished with passive setup joints. A few challenges with this existing process are that either the user has to work hard to make the movements fluid during docking or the user efforts can be minimized at the cost of forcing other engineering and design tradeoffs, and the high inertia of the arm makes small adjustments difficult. With the ability to break the “parallelogram” of the arm by implementing a software-based remote center constraint, the disclosed robotic arms have additional degrees of freedom relative to the described existing systems, and these additional degrees of freedom allow a user to easily dock to the cannula 1830. The controller 206 can then actuate the motorized joints 1805A-1805E in order to reconstruct the remote center constraint (and create a parallelogram if desired, as described in more detail below), as described above with respect to block 2215. This is achieved by having the yaw axis point above the remote center, and then having the arm in an admittance mode. Then the setup person has 3 DOF of positioning control for the cannula attachment and can dock it.

FIGS. 30A-30C depict different sub-modes for operating the robotic arm of FIG. 25 in the first mode 1900 depicted in FIG. 26A. Because the open kinematic chain of the robotic arm 1800 is not mechanically constrained to maintain a parallelogram, the controller 206 can vary the distance of the third motorized joint 1810B from the remote center 2225 along the yaw axis 1835A and can compute the kinematics needed to actuate the motorized joints 1805A-1805E to achieve the needed movement of the medical instrument 1825 while operating under the remote center architecture described for the first mode 1900. This achieves an additional setup degree of freedom, which can beneficially simplify the setup joint system. The tradeoffs of this additional degree of freedom are a relatively more limited range of motion around the pitch axis and non-linear joint velocities for the pitch motion, which in turn impart a requirement of faster joints in the design of the robotic arm 1800 in order to get an equivalent pitch velocity. These nonlinearities can be minimized through design optimization and further workspace limiting.

FIG. 30A depicts a parallelogram setup 2300A in which the configuration of the robotic arm 1800 forms a parallelogram 2340A. As implied by the geometric terminology, the parallelogram 2340A has a first set of parallel sides 2325, 2305A of equal length to one another and a second set of parallel sides 2315, 2335A of equal length to one another. Side 2325 is defined along the third linkage 1810C between a center 2330 of the fifth motorized joint 1805D and a center 2320 of the fourth motorized joint 1805C. Side 2315 is defined along the second linkage 1810B between a center 2330 of the fourth motorized joint 1805C and a center 2310 of the third motorized joint 1805B. Side 2335A is defined between a center 2330 of the fifth motorized joint 1805D and the remote center 2225. Side 2305A, also referred to as a “virtual link,” is defined between the remote center 2225 and the center 2310 of the third motorized joint 1805B. In some embodiments, the controller 206 can configure the robotic arm 1800 in the parallelogram setup 2300A at block 2215 of FIG. 29C.

FIG. 30B depicts a broken parallelogram setup 2300B having a longer virtual link 2305B than the virtual link 2305A in parallelogram setup 2300A. Such a configuration is achievable due the open kinematic chain and software-constrained remote center architecture of the arm 1800. In the broken parallelogram setup 2300B, the virtual link 2305B is still parallel to the side 2325, however the length of the virtual link 2305B is greater than the length of side 2325. As a result, the sides 2335B and 2315 are not parallel and may have unequal lengths. Accordingly, a “broken” parallelogram 2340B is formed having a longer virtual link 2305B than side 2325. In some embodiments, the controller 206 can configure the robotic arm 1800 in the broken parallelogram setup 2300B at block 2215 of FIG. 29C. In some embodiments, the controller 206 can transition the robotic arm 1800 between the parallelogram setup 2300A and the broken parallelogram setup 2300B intraoperatively by actuating at least some of the motorized joints 1805A-1805E together with powered setup joints. During such a transition, the location of the remote center 2225 remains unchanged.

FIG. 30C depicts a broken parallelogram setup 2300C having a shorter virtual link 2305C than the virtual link 2305A in parallelogram setup 2300A. Such a configuration is achievable due the open kinematic chain and software-constrained remote center architecture of the arm 1800. In the broken parallelogram setup 2300C, the virtual link 2305C is still parallel to the side 2325, however the length of the virtual link 2305C is shorter than the length of side 2325. As a result, the sides 2335C and 2315 are not parallel and may have unequal lengths. Accordingly, a “broken” parallelogram 2340C is formed having a shorter virtual link 2305C than side 2325. In some embodiments, the controller 206 can configure the robotic arm 1800 in the broken parallelogram setup 2300C at block 2215 of FIG. 29C. In some embodiments, the controller 206 can transition the robotic arm 1800 between the parallelogram setup 2300A or broken parallelogram setup 2300B to the broken parallelogram setup 2300C intraoperatively by actuating at least some of the motorized joints 1805A-1805E together with powered setup joints. During such a transition, the location of the remote center 2225 remains unchanged.

FIGS. 31A and 31B depict different sub-modes for operating the robotic arm 1700 of FIG. 24 in the first mode 1900 depicted in FIG. 26A. The controller 206 can configure the robotic arm 1700 in one of the sub-modes 2400A, 2400B (or a similar sub-mode having a fixed distance between the first motorized joint 1705A and the remote center) at the beginning of operating in the first mode 1900, or can transition the robotic arm 1700 between the sub-modes 2400A, 2400B intraoperatively using powered setup joints. The particular distances between the first motorized joint 1705A and the remote center are provided for example only, and the first motorized joint 1705A and the remote center can be positioned any mechanically possible distance apart along the first axis 1735A in use. Another null-space reconfiguring made possible by the open kinematic chain of the robotic arm 1700 thus is to intraoperatively adjust the distance between the first motorized joint 1705A and the remote center. By doing this, the robotic system can trade off the range of the workspace of the robotic arm 1700 with the capability to work at shallower pitch angles. This can be helpful when there is limited room in which the robotic arm 1700 can operate, for example in order to avoid interfering or colliding with other robotic arms, medical equipment, or medical personnel.

FIGS. 31A and 31B illustrate the impact on range of motion and minimum arm angle due to increasing the distance between the first motorized joint 1705A and the remote center. FIG. 31A depicts a first configuration 2400A of the robotic arm 1700 with the remote center 2405 located a first distance D1 from the first motorized joint 1705A along the yaw axis 1735A. In the first configuration 2400A, the robotic arm 1700 has a 40-degree minimum angle α1 between the insertion axis 1735B and the yaw axis 1735A with a 100-degree range of motion ROM1. FIG. 31B depicts a second configuration 2400B of the robotic arm 1700 with the remote center 2405 located a second distance D2 from the first motorized joint 1705A along the yaw axis 1735A, with the second distance D2 being greater than the first distance D1. In the second configuration 2400B, the robotic arm 1700 has a 25-degree minimum angle α2 between the insertion axis 1735B and the yaw axis 1735A with a 73-degree range of motion ROM2. This can help the robotic arm 1700 work closer to obstacles, for example other robotic arms, the patient bed, etc., without colliding with the obstacles. Though distances D1 and D2 are shown as being measured between the remote center 2405 and the cap of motorized joint 1705A, the distances can alternatively be measured between the remote center 2405 and any structure of the arm 1700 positioned along the first axis 1735A, for example the center of rotary joint 1705B.

FIGS. 32A and 32B depict addition of a second instrument driver 2510 to the robotic arm 1800 of FIG. 25 during operation in the second mode 2000 depicted in FIG. 27A. As illustrated, the second instrument driver 2510 includes an attachment portion 2525 that secures to a docking port of the fourth linkage 1810D in place of the dock 1840. Addition of the second instrument driver 2510 allows the robotic arm 1800 to control first and second coaxial medical instruments 2505, 2515. System insertion of the medical instruments 2505, 2515 can be controlled with respect to a virtual rail defined along the axis of the first medical instrument 2505, for example.

As shown in FIG. 32A, the robotic arm 1800 can be positioned in a first configuration 2500A with the instrument driver 1820 positioned by the second motorized joint 1805E as far as possible from the second instrument driver 2510. As shown in FIG. 32B, the second motorized joint 1805E can be actuated along the distal surface 1815B of the fourth linkage 1810D to move the instrument driver 1820 towards the second instrument driver 2510. In the second configuration 2400B, this actuation advances the first medical instrument 2505 through the second medical instrument 2515 and farther beyond the end 2520 of the second medical instrument 2515 than in the configuration 2500A. The second motorized joint 1805E can continue to be actuated until the instrument driver 1820 is adjacent to the second instrument driver 2510, if desired to effect relative motion of the first and second medical instruments 2505, 2515.

FIG. 33 depicts the robotic arm 1800 of FIG. 25 in a storage configuration 2500C. In the storage configuration 2500C, the first, second, and third linkages 1810A-1810C are positioned in a stack in a substantially parallel fashion with the second linkage 1810B positioned between the first linkage 1810A and third linkage 1810C. The fourth linkage 1810D rests on the third linkage 1810C and is also substantially parallel to the other linkages 1810A-1810C. Substantially parallel refers to collapsing the arm as compact as possible with the proximal face of the fourth linkage 1810D resting against the third linkage 1810C and with the first, second, and third linkages 1810A-1810C positioned in the illustrated compact stack. The deviation from true parallel positioning depends upon the specific shapes of the linkages, which can be varied in some embodiments from the illustrated shapes. The storage configuration 2500C is possible due to the open kinematic chain of the robotic arm 1800, which allows breaking of the virtual link used during the first operational mode to provide for compact storage. This can be advantageous for a multi-arm system as shown in FIG. 27B, where some arms are not used in a particular procedure and can be stowed out of the way of the remaining arms and medical personnel, freeing up limited operating room space.

In addition to the embodiments noted herein, some embodiments can implement robotic arm kinematic layouts for performing laparoscopic surgery on a bed-based surgical robotics platform. For example, in accordance with some embodiments disclosed herein is the realization that current robotic systems continue to face certain limitations and challenges including the available reach of the robotic arms, potential access and maneuverability of the robotic arms, stiffness of the robotic arms and support architecture, and performance of the system, among other things. Moreover, in accordance with some embodiments disclosed herein is the realization and recognition of the increased complexity of robotic systems that utilize a software-constrained remote center of motion. Indeed, these and other challenges can be particularly acute in robotic systems that use six robotic arms. Accordingly, some embodiments disclosed herein can be configured to address these and other considerations to provide a robotic system that utilizes a common mounting platform for the robotic arms, a robotic setup joint, and a distal manipulator linkage that uses a hardware-constrained remote center of motion. These and other optional features can be implemented in a robotic system to provide improved rigidity, reduce collisions, and increase the maneuverability and positioning of the robotic arms of the system. Further, some embodiments can optionally implement a hardware-constrained center of motion for one or more robotic arms of the system in order to reduce the complexity, increase the reliability, and streamline operation of the system.

Referring now to FIGS. 34-37, so embodiments disclosed herein can implement a unique combination of features in order to provide a robotic system that overcomes several of the aforementioned challenges. For example, FIG. 34 illustrates a surgical robotic system 2600 having a table-based robotic system 2602 that includes six robotic arms 2604 coupled to a table base 2606 (having a table 2607) via a mount platform 2608, suitable for a laparoscopic procedure. As illustrated, the robotic arms 2604 can be supported on a shared mount platform 2610, illustrated as a bar or rail on which one or more of the robotic arms 2604 can be mounted. In other embodiments, the robotic arms 2604 can be coupled via an attachment portion directly to the table on which the patient resides. In the illustrated example, the bar or rail 2610 can be coupled to a column 2612 of the table base 2606 by a bar or rail connector and a carriage, such as that described above with reference to FIGS. 17-23. One of the advantages of such a system is that the shared mount platform 2610 allows multiple arms 2604 to be supported and for the structure to be much larger and more rigid than would otherwise be possible if each of the arms 2604 was supported or coupled individually to the table base 2606. As a result, such embodiments can provide significantly improved rigidity, precision, and dynamic performance. The direct mounting of the mount platform 2610 to the column 2612 can provide structural benefits over alternative configurations in which the mount platform 2610 is coupled directly to the table 2607, which otherwise requires the stiffness path to pass through joints of the table 2607 that may experience other forces (such as those static and dynamic forces created by supporting the patient on the table 2607). Moreover, the shared mount platform 2610 can provide an architecture that allows tremendous setup flexibility, such as by enabling the robotic arms 2604 to be mounted high and low and otherwise allow significant longitudinal translation and arm positioning at locations spaced far from the column 2612.

Referring now to FIG. 35, the system 2600 can be configured such that one or more of the robotic arms 2604 comprises a hardware-constrained remote center of motion. A hardware-constrained remote center of motion can include any mechanism that is able to isolate a degree of freedom (DoF) of laparoscopic tool motion to motion of a single joint or set of joints that only perform that motion.

For example, the robotic arm 2604 shown in FIG. 35 can be configured to isolate angulation of a tool shaft 2620 about a yaw axis 2620A and a remote center of motion 2622 to at least one joint or joint set. Yaw motion of the tool shaft 2620 about the yaw axis 2620A and the remote center of motion 2622 is provided by the distal yaw joint 2620B of the tool 2624, whose yaw axis 2620A points directly at the remote center of motion 2622. The yaw axis 2620A represents the axis along which the tool 2624 can roll (revolute) and/or the tool 2624 can translate (instrument insertion axis, via prismatic motion). Because the yaw axis 2620A points straight at the remote center of motion 2622, motion of the tool 2624 about the yaw axis 2620A does not affect the position of the remote center of motion 2622, and thus, motion of the tool 2624 is isolated.

In the kinematics shown in FIG. 35, pitch motion of the tool shaft 2620 about the remote center of motion 2622 is provided by a distal manipulator linkage 2626. The distal manipulator linkage can comprise a parallelogram linkage 2628 which is able to articulate about the remote center of motion 2622. The parallelogram linkage 2628 can comprise a plurality of joints. For example, the parallelogram linkage 2628 can comprise a powered joint and/or a passive joint. Further, in some embodiments, the parallelogram linkage can comprise a single powered joint and two passive joints. A “passive joint” can be a joint whose rotations are mechanically constrained with bands, belts, chains, links, and/or other means.

In some embodiments, the distal manipulator linkage can comprise a setup linkage. The setup linkage can be adjusted to manipulate a pose of the distal manipulator linkage and a location of the remote center of motion.

For example, in the embodiment illustrated in FIG. 35, the distal manipulator linkage 2626 can comprise a yaw link 2630 that can be coupled to a distal end portion of a setup linkage 2631. The distal manipulator linkage 2626 can also comprise a pitch base link 2632, a first pitch link 2634, a second pitch link 2636, and a stage link 2638. The yaw link 2630 can be rotatably coupled to the setup linkage 2631 at a first joint 2639 and to the pitch base link 2632 at a second joint 2640. The yaw link 2630 can define a second yaw axis 2630A that can intersect with the remote center of motion 2622 and the first yaw axis 2620A. The yaw link 2630 can also be rotatably coupled to the pitch base link 2632 at a base yaw joint 2630B. Advantageously, the setup linkages/joints and the distal manipulator linkages/joints can re-orient and/or re-position the base yaw joint 2630B independently and in conjunction while maintaining a remote center of motion. This capability is available regardless of whether the RCM is fixed in space or moved in a particular active motion. The pitch base link 2632 can be rotatably coupled to the first pitch link 2634 at a first pitch joint 2642. Further, the first pitch link 2634 can be coupled to the second pitch link 2636 at a second pitch joint 2644. Finally, the second pitch link 2636 can be coupled to the stage link 2638 at a third pitch joint 2646. The first, second, and third pitch joints 2642, 2644, and 2646 can allow the parallelogram linkage 2628 to change a pitch of the tool shaft 2620 while maintaining the first yaw axis 2620A and the second yaw axis 2620B in alignment with and intersecting at the remote center of motion 2622.

Optionally, in some embodiments, the distal manipulator linkage 2626 can thereby provide a hardware-constrained remote center of motion. Additionally, an advantage of some embodiments is that the parallelogram linkage 2628 can advantageously provide a comparatively slim profile (relative to alternative architectures) that allows the distal manipulator linkage 2626 to operate within a narrower patient-side operating volume, thereby reducing collision potential. In accordance with some embodiments is the realization that a gimbal used on some haptic input devices can provide motion about a remote center by pointing all of their axes inwards towards a central remote center of motion; however, the gimbal may also have a relatively larger swept motion for a given workspace and operate in a larger patient-side operating volume, thus having more collision potential than the relatively slim parallelogram-type linkage.

Additionally, the embodiment of the robotic arm 2604 illustrated in FIG. 35 illustrates that the setup linkage 2631 can comprise a first setup link 2650 and a second setup link 2652. The first setup link 2650 can be rotatably coupled to the second setup link 2652 at a first setup joint 2654. Further, the second setup link 2652 can comprise a roll joint 2656 that permits an end portion of the second setup link 2652 to rotate about a longitudinal axis of the second setup link 2652 (i.e., the roll joint 2656 can provide yaw motion about the longitudinal axis of the setup link 2652).

FIG. 36 illustrates an additional embodiment in which a robotic arm 2660. The robotic arm 2660 can comprise all of the features and components discussed above with respect to the robotic arm 2604 illustrated in FIG. 35. For example, the robotic arm 2660 can comprise a setup linkage 2662. However, in contrast to the robotic arm 2604 shown in FIG. 35, the robotic arm 2660 can omit the roll joint of the setup linkage.

Further, FIG. 36 also illustrates that the robotic arm 2660 (or other such embodiments of the robotic arm, such as that illustrated in FIG. 35) can be coupled to a mount platform, such as the bar 2664 at a prismatic joint 2666.

FIGS. 35 and 36 illustrated that in accordance with some embodiments, the robotic arms of the system can also comprise a robotic setup linkage or joint. The robotic setup linkage can be adjusted to manipulate a pose of the distal manipulator linkage and a location of the remote center of motion. In such embodiments, the term “robotic” can refer to having one or more of the joints be motorized and controlled with closed-loop control. A robotic joint can allow for advantages over having passive braked joints, such as the ability to dynamically provide gravity counterbalance to the user, the ability to have the robotic arm provide scripted motions (e.g., such as stow/unstow), and the ability to use extra or redundant joints in the set-up linkage to perform repositioning motions (e.g., where the base of the distal manipulator linkage can be moved while maintaining alignment with the remote center of motion), which can thereby improve access and/or reduce collisions.

Referring now to FIG. 37, optional modifications to the robotic arm of the system can be implemented to achieve additional benefits and advantages. For example, in addition to the features discussed above with respect to FIGS. 34-36, the robotic arm(s) of the system can be configured to omit contact-sensing shells and/or a force/torque sensor (e.g., a 6-DoF torque sensor), while including a force sensor in A0 joint. Optionally, all the six or more joints in the robotic arm 2604, 2660 can be back-drivable and can be put under various impedance control, as needed.

In accordance with some embodiments, the robotic arm 2604, 2660 of the system can be configured to omit a joint proximal to the distal parallelogram (such as one of the joints 2639, 2630B or 2640 in FIG. 35). This can result in a robotic arm that has a five-joint count between A0 and the ADM (as labeled in FIG. 37), which can reduce the total kinematic chain DoF count of the arm from eight down to seven. Further, such embodiments may also constrain the setup of parallelogram by one DoF, but still preserve one DoF of nullspace redundancy in the entire kinematic chain.

Accordingly, some embodiments can incorporate the features discussed in FIGS. 34-37 to realize certain advantages over various predicate devices. For example, in accordance with some embodiments, the distal manipulator linkage can provide a hardware-constrained remote center of motion that limits the amount of motion during teleoperated laparoscopic driving to the joints of the manipulator, which has the potential of reducing collisions and providing more predictable motion to the user (the proximal part of the robotic arm need not move during teleoperated motion). The positioning of the system can also provide an extremely stable and flexible arm support for high setup flexibility and dynamic performance. The robotic setup joint can also provide capability not enabled by a manual braked setup joint (such as constrained repositioning and scripted motions to aid in workflow).

5. Additional Example Flexible Kinematic Chains

FIG. 38 depicts a table 2700 showing various examples of robotic arms and their kinematic chains that can be operated in the various modes (e.g., 1900 and 2000) and sub-modes (e.g., 2200, 3200A-2300C, 2400A-2400B) or positioned in the various configurations (e.g., 2500A-2500C) of the present disclosure. The various illustrated arms are also depicted with setup arms that can be suitable for use with such arms, for example in a table-based, cart-based, or ceiling-based robotic system. As illustrated by the table, robotic arm 2705 is an embodiment of an RRRRP kinematic chain, robotic arm 2710 is another embodiment of an RRRRP kinematic chain, robotic arm 2715 is an embodiment of an RRRPP kinematic chain, robotic arm 2720 is another embodiment of an RRRPP kinematic chain, robotic arm 2725 is another embodiment of an RRRPP kinematic chain, robotic arm 2730 is an embodiment of an RRPRP kinematic chain, and robotic arm 2735 is an embodiment of an RPRPP kinematic chain. Each of these robotic arms is suitable for use in both the first operation mode 1900 and the second operating mode 2000 described herein.

Other configurations of the kinematic chain are also possible within the scope of the present disclosure. For example, if the design starts with a revolute joint at the proximal end of the robotic arm having a revolution axis capable of being pointed through a remote center and ends with a prismatic joint at the distal end of the robotic arm having a linear movement axis that is parallel to the tool insertion axis, the design provides a flexible R (XXX) P kinematic chain where the X's can be populated with either R or Ps to put together a series of joints that can perform a software constrained remote center as described herein. There are 8 categories of robotic arms that can satisfy the flexible R (XXX) P kinematic chain. Of these, R (PPP) P is not suitable for the first operating mode because at least one revolute is needed to create a remote pitch axis as described herein. There are various ways that each of the axes can be arranged and still have the same designation. For example, with respect to the R (RRP) P robotic arms 2715, 2720, and 2725, the last two prismatic axes are parallel to one another. However, in other embodiments these axes could also be configured to be at an angle to each other.

6. Overview of Operating Techniques

FIG. 39 depicts a flowchart of an example process 2800 for operating the robotic arms 1700, 1800, 2705-2735 of FIGS. 24, 25, and 33. The process 2800 can be implemented wholly or partly by the controller 206 based on computer-executable instructions that control actuation of the motorized joints of the robotic arm, or may involve some motion imparted by human operators, as described below.

At block 2805, the controller 206 can initiate the robotic arm 1700, 1800, 2705-2735, for example by bringing it out of a storage configuration 2500C and/or by activating powered setup joints to position the robotic arm 1700, 1800, 2705-2735 near a patient or patient table.

At block 2810, the controller 206 can receive a command to operate the robotic arm 1700, 1800, 2705-2735 in either a first operating mode 1900 or a second operating mode 2000. At decision block 2815, the controller 206 can recognize the command and retrieve the appropriate operating instructions from a memory.

If the command is to operate the robotic arm 1700, 1800, 2705-2735 in the first operating mode 1900, the process 2800 transitions to block 2820 to execute a setup procedure. As shown in FIGS. 29A-29D, the setup procedure can involve (i) fixing a location of a remote center such that the second axis is aligned with an opening of a patient and passes through the remote center, and (ii) constraining the motion of the plurality of motorized joints when actuated in the first operating mode such that the second axis passes through the remote center. Fixing the location of the remote center can be accomplished based on docking the robotic arm 1700, 1800, 2705-2735 to a cannula and identifying the location as a point along or within the cannula. Block 2820 can involve one or more null space movements to align a yaw axis defined by the axis of revolution of a proximal revolute joint of the robotic arm 1700, 1800, 2705-2735 with the remote center, and creating a remote pitch axis that passes through the remote center.

At decision block 2825, the controller 206 can determine whether or not to maintain a parallelogram (or virtual parallelogram) in the configuration of the robotic arm 1700, 1800, 2705-2735 in the first operating mode 1900, as described with respect to FIGS. 30A-30B.

If so, the process 2800 transitions to block 2830 in which the controller 206 configures the robotic arm 1800, 2705 via null-space movements to form a parallelogram 2340A with a virtual link 2305A passing through the remote center 2225 and constrains actuation of the joints to maintain the parallelogram 2340A.

If not, the process 2800 transitions to block 2835 in which the controller 206 configures the robotic arm 1800, 2705 to form a broken parallelogram 2340B, 2340C and optionally to transition between a number of different broken parallelogram shapes while maintaining the position of the remote center 2225. The process 2800 may loop back to block 2825 intraoperatively after either of blocks 2830 and 2835 if the workspace or range of motion requirements for the robotic arm 1800, 2705 change.

For disclosed robotic arms such as robotic arm 1700 that may not be capable of forming a parallelogram (or virtual parallelogram), blocks 2825-2835 can instead involve the controller 206 determining a distance along the yaw axis 1735A between the remote center and the first motorized joint 1705A, as described with respect to FIGS. 31A and 31B.

If the command is to operate the robotic arm 1700, 1800, 2705-2735 in the second operating mode 2000, the process 2800 transitions to block 2840 to identify a positioning of a virtual rail based on positioning of the second axis when aligned with the opening of the patient. The second axis can be aligned with the patient opening by a user manually moving the robotic arm 1700, 1800, 2705-2735, by user control via command console 200, or by the controller 206.

At block 2850, the controller 206 controls movement of the medical instrument along the virtual rail. As described with respect to FIG. 27B, this can involve controlling movement of multiple medical instruments 1725A-1725C by multiple robotic arms 1700A-1700C along the virtual rail 2005. As described with respect to FIGS. 32A and 32B, this can involve controlling movement of multiple medical instruments 2505, 2515 by a single robotic arm 1800. In some embodiments, the robotic arms 1700A-1700C of FIG. 27B can be configured with additional instrument drivers as shown in FIGS. 32A and 32B. In some embodiments, the process 2800 can return to block 2840, for example if patient movement requires repositioning the virtual rail.

Blocks 2825-2835 for the first mode 1900 or block 2850 for the second mode 2000 can continue for the duration of a medical procedure. At block 2855, the controller 206 receives a storage command for some or all robotic arms of a robotic system. Accordingly, at block 2860 the controller 206 (or a user) can position the robotic arm 1800 in the storage configuration 2500C with the linkages positioned substantially parallel to one another. The other disclosed robotic arms 1700, 2705-2735 can have similar compact storage configurations and can be controlled to be positioned in such configurations manually or by the controller 206.

7. Illustration of Subject Technology as Clauses

Various examples of aspects of the disclosure are described as numbered clauses (1, 2, 3, etc.) for convenience. These are provided as examples, and do not limit the subject technology. Identifications of the figures and reference numbers are provided below merely as examples and for illustrative purposes, and the clauses are not limited by those identifications.

Clause 1. A surgical robotics system comprising: a column-based mount platform having a table supported on a column; and a robotic arm coupled to the table, the robotic arm comprising a setup joint and a distal manipulator linkage that collectively define a remote center of motion, the setup joint being adjustable to manipulate a pose of the distal manipulator linkage and a location of the remote center of motion, the distal manipulator linkage being configured to isolate a degree of freedom of motion of a tool coupled thereto to articulate the tool about the remote center of motion.

Clause 2. The surgical robotics system of Clause 1, wherein the column-based mount platform further comprises a base and a column extending therefrom.

Clause 3. The surgical robotics system of any one of the preceding clauses, wherein the column-based mount platform further comprises a shoulder coupled to the column, a first link coupled to the shoulder by a first rotary joint, and a second link coupled to the first link by a second rotary joint.

Clause 4. The surgical robotics system of Clause 3, wherein the column-based mount platform further comprises an adjustable arm support coupled to the second link, the adjustable arm support being configured to support the robotic arm thereon.

Clause 5. The surgical robotics system of Clause 4, wherein the adjustable arm support comprises a bar.

Clause 6. The surgical robotics system of any one of the preceding clauses, wherein the distal manipulator linkage constrains the motion of the tool in a single joint.

Clause 7. The surgical robotics system of any one of the preceding clauses, wherein the distal manipulator linkage constrains the motion of the tool in a set of joints.

Clause 8. The surgical robotics system of any one of the preceding clauses, wherein the robotic arm comprises a base yaw joint coupling the setup joint to the distal manipulator linkage, the base yaw joint having a rotational axis that extends through the remote center of motion.

Clause 9. The surgical robotics system of any one of the preceding clauses, wherein the robotic arm can reposition the distal manipulator linkage while maintaining the remote center of motion.

Clause 10. The surgical robotics system of any one of the preceding clauses, wherein the distal manipulator linkage of the robotic arm comprises a parallelogram linkage.

Clause 11. The surgical robotics system of Clause 10, wherein the parallelogram linkage is configured to articulate about the remote center of motion.

Clause 12. The surgical robotics system of any one of Clauses 10 or 11, wherein the parallelogram linkage comprises one powered joint and two passive joints.

Clause 13. The surgical robotics system of Clause 12, wherein rotation of the passive joints is mechanically constrained by a limiter mechanism.

Clause 14. The surgical robotics system of Clause 13, wherein the limiter mechanism comprises a band, belt, chain, or link.

Clause 15. The surgical robotics system of any one of Clauses 10-14, wherein the parallelogram linkage comprises four links that are rotatably coupled to each other at three rotary joints, the three rotary joints being configured to rotate in a 1:1:1 ratio.

Clause 16. The surgical robotics system of Clause 15, wherein the four links comprise a pitch base link, a first pitch link, a second pitch link, and a stage link, the pitch base link and coupled to the first pitch link via a first pitch joint, the first pitch link being coupled to the second pitch link via a second pitch joint, and the second pitch link being coupled to the stage link via a third pitch joint.

Clause 17. The surgical robotics system of Clause 16, wherein the stage link supports a tool driver, the tool driver being configured to support a tool thereby for articulation about the remote center of motion.

Clause 18. The surgical robotics system of any one of the preceding clauses, wherein the setup joint comprises a prismatic joint coupled to the mount platform.

Clause 19. The surgical robotics system of any one of the preceding clauses, wherein the setup joint comprises a plurality of links that are rotatably coupled together.

Clause 20. The surgical robotics system of any one of the preceding clauses, wherein the setup joint comprises a roll joint.

Clause 21. The surgical robotics system of any one of the preceding clauses, wherein the setup joint is a robotic setup joint.

Clause 22. The surgical robotics system of Clause 21, wherein the setup joint is motorized.

Clause 23. The surgical robotics system of any one of the preceding clauses, wherein the remote center of motion is hardware constrained.

Clause 24. The surgical robotics system of any one of the preceding clauses, wherein the remote center of motion is software constrained.

Clause 25. A robotic arm coupleable to a table of a surgical robotics system, the robotic arm comprising: a robotic setup joint being adjustable to manipulate a pose of the distal manipulator linkage and a location of the remote center of motion relative to the table; and a distal manipulator linkage coupled to the robotic setup joint to collectively define a remote center of motion, the distal manipulator linkage being configured to isolate a degree of freedom of motion of a tool coupled thereto to articulate the tool about the remote center of motion.

Clause 26. The robotic arm of Clause 25, wherein the distal manipulator linkage constrains the motion of the tool in a single joint.

Clause 27. The robotic arm of Clause 25, wherein the distal manipulator linkage constrains the motion of the tool in a set of joints.

Clause 28. The robotic arm of any one of Clauses 25-27, wherein the robotic arm comprises a base yaw joint coupling the setup joint to the distal manipulator linkage, the base yaw joint having a rotational axis that extends through the remote center of motion.

Clause 29. The robotic arm of any one of Clauses 25-28, wherein the distal manipulator linkage of the robotic arm comprises a parallelogram linkage.

Clause 30. The robotic arm of Clause 29, wherein the parallelogram linkage is configured to articulate about the remote center of motion.

Clause 31. The robotic arm of Clause 29, wherein the parallelogram linkage comprises one powered joint and two passive joints.

Clause 32. The robotic arm of Clause 31, wherein rotation of the passive joints is mechanically constrained by a limiter mechanism.

Clause 33. The robotic arm of Clause 32, wherein the limiter mechanism comprises a band, belt, chain, or link.

Clause 34. The robotic arm of any one of Clauses 29-33, wherein the parallelogram linkage comprises four links that are rotatably coupled to each other at three rotary joints, the three rotary joints being configured to rotate in a 1:1:1 ratio.

Clause 35. The robotic arm of Clause 34, wherein the four links comprise a pitch base link, a first pitch link, a second pitch link, and a stage link, the pitch base link and coupled to the first pitch link via a first pitch joint, the first pitch link being coupled to the second pitch link via a second pitch joint, and the second pitch link being coupled to the stage link via a third pitch joint.

Clause 36. The robotic arm of Clause 35, wherein the stage link supports a tool driver, the tool driver being configured to support a tool thereby for articulation about the remote center of motion.

Clause 37. The robotic arm of any one of Clauses 25-36, wherein the setup joint comprises a plurality of links that are rotatably coupled together.

Clause 38. The robotic arm of any one of Clauses 25-37, wherein the setup joint comprises a roll joint.

Clause 39. The robotic arm of any one of Clauses 25-38, wherein the setup joint is motorized.

Clause 40. The robotic arm of any one of Clauses 25-39, wherein the remote center of motion is hardware constrained.

Clause 41. The robotic arm of any one of Clauses 25-40, wherein the remote center of motion is software constrained.

Clause 42. A surgical method comprising: receiving a setup command to position a setup joint of a robotic arm in a setup position, wherein the robotic arm is coupled to a table; in response to the setup command, driving one or more motorized joints of the setup joint of the robotic arm to position the setup joint in the setup position; receiving an adjustment command to position a distal manipulator linkage about a remote center of motion; and in response to the adjustment command, driving a distal manipulator linkage of the robotic arm to an adjusted position wherein the distal manipulator linkage constrains a degree of freedom of motion of a tool coupled thereto and articulates the tool about the remote center of motion.

Clause 43. The method of Clause 42, wherein in response to the setup command, the method further comprises driving a column-based mount platform to move the robotic arm toward the setup position.

Clause 44. The method of any one of Clauses 42 or 43, wherein the driving the distal manipulator linkage comprises constraining the articulation of the tool in a single joint.

Clause 45. The method of any one of Clauses 42-44, wherein the driving the distal manipulator linkage comprises constraining the articulation the tool in a set of joints.

Clause 46. The method of any one of Clauses 42-45, wherein the driving the distal manipulator linkage comprises articulating a parallelogram linkage.

Clause 47. The method of Clause 46, wherein the driving the distal manipulator linkage comprises articulating a parallelogram linkage having four links that are rotatably coupled to each other at three rotary joints, wherein the three rotary joints are driven in a 1:1:1 ratio.

Clause 48. The method of Clause 47, further comprising articulating a tool driver to control an operation of the tool.

Clause 49. The method of any one of Clauses 42-48, further comprising constraining the remote center of motion via hardware.

Clause 50. The method of any one of Clauses 42-49, further comprising constraining the remote center of motion via software.

8. Further Considerations

In some embodiments, any of the clauses herein may depend from any one of the independent clauses or any one of the dependent clauses. In one aspect, any of the clauses (e.g., dependent or independent clauses) may be combined with any other one or more clauses (e.g., dependent or independent clauses). In one aspect, a claim may include some or all of the words (e.g., steps, operations, means or components) recited in a clause, a sentence, a phrase or a paragraph. In one aspect, a claim may include some or all of the words recited in one or more clauses, sentences, phrases or paragraphs. In one aspect, some of the words in each of the clauses, sentences, phrases or paragraphs may be removed. In one aspect, additional words or elements may be added to a clause, a sentence, a phrase or a paragraph. In one aspect, the subject technology may be implemented without utilizing some of the components, elements, functions or operations described herein. In one aspect, the subject technology may be implemented utilizing additional components, elements, functions or operations.

Implementations disclosed herein provide systems, methods and apparatus for convertible medical robotic systems that leverage a versatile, open kinematic chain together with a set of medical-procedure-specific software-controlled actuation constraints in order to perform a variety of medical procedures.

It should be noted that the terms “couple,” “coupling,” “coupled” or other variations of the word couple as used herein may indicate either an indirect connection or a direct connection. For example, if a first component is “coupled” to a second component, the first component may be either indirectly connected to the second component via another component or directly connected to the second component.

The various functions for controlling actuation of the robotic arms described herein according to the disclosed operational modes may be stored as one or more instructions on a processor-readable or computer-readable medium. The term “computer-readable medium” refers to any available medium that can be accessed by a computer or processor. By way of example, and not limitation, such a medium may comprise RAM, ROM, EEPROM, flash memory, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. It should be noted that a computer-readable medium may be tangible and non-transitory. As used herein, the term “code” may refer to software, instructions, code or data that is/are executable by a computing device or processor.

The methods disclosed herein comprise one or more steps or actions for achieving the described method. The method steps and/or actions may be interchanged with one another without departing from the scope of the claims. In other words, unless a specific order of steps or actions is required for proper operation of the method that is being described, the order and/or use of specific steps and/or actions may be modified without departing from the scope of the claims.

As used herein, the term “plurality” denotes two or more. For example, a plurality of components indicates two or more components. The term “determining” encompasses a wide variety of actions and, therefore, “determining” can include calculating, computing, processing, deriving, investigating, looking up (e.g., looking up in a table, a database or another data structure), ascertaining and the like. Also, “determining” can include receiving (e.g., receiving information), accessing (e.g., accessing data in a memory) and the like. Also, “determining” can include resolving, selecting, choosing, establishing and the like.

The phrase “based on” does not mean “based only on,” unless expressly specified otherwise. In other words, the phrase “based on” describes both “based only on” and “based at least on.”

The previous description of the disclosed implementations is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these implementations will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the scope of the invention. For example, it will be appreciated that one of ordinary skill in the art will be able to employ a number corresponding alternative and equivalent structural details, such as equivalent ways of fastening, mounting, coupling, or engaging tool components, equivalent mechanisms for producing particular actuation motions, and equivalent mechanisms for delivering electrical energy. Thus, the present invention is not intended to be limited to the implementations shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

	Number	Date	Country
Parent	PCT/IB2022/062545	Dec 2022	WO
Child	18750542		US

SURGICAL PLATFORM WITH MOTORIZED ARMS

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