System and method for breakaway clutching in an articulated arm

• US 10,034,717 B2
• Filed: 03/17/2015
• Issued: 07/31/2018
• Est. Priority Date: 03/17/2014
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Miller, Daniel, Swarup, Nitish, Turner, Michael, Hourtash, Arjang M., Griffiths, Paul G., Mohr, Paul W.
• Primary Examiner(s): Figueroa, Jamie
• Application Number:
  US15/126,996
• Publication Number:
  US 20170172671A1
• Time in Patent Office: 1,232 Days
• Field of Search: 700245, 700258
• CPC Class Codes: A61B 2018/00666 using a threshold value
• CPC Class Codes: A61B 2018/00672 lower
• CPC Class Codes: A61B 2018/00678 upper
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2090/035 preventing further rotation
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: B25J 13/085 Force or torque sensors B25J13/082, B25J13/084 take precedence
• CPC Class Codes: B25J 13/088 with position, velocity or acceleration sensors
• CPC Class Codes: B25J 9/1689 Teleoperation
• CPC Class Codes: B25J 9/1694 characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion

Abstract

A system and method of breakaway clutching in a computer-assisted medical device includes an articulated arm having one or more first joints and a control unit coupled to the articulated arm and having one or more processors. The control unit operates each of the first joints in multiple states. The multiple states include a locked state, wherein movement of respective first joints is restricted, and a float state, wherein movement of the respective first joints is permitted. The control unit further switches one or more second joints selected from the first joints from the locked state to the float state when a stimulus on the second joints exceeds one or more unlock thresholds and switches the second joints from the float state to the locked state when a velocity of each of the second joints is below one or more lock thresholds.

Claims

1. A computer-assisted medical device, the device comprising:

an articulated arm comprising a first joint; and

a control unit coupled to the articulated arm and comprising one or more processors;

wherein the control unit;

operates the first joint in a locked state, in which movement is restricted, and a float state, in which movement is permitted;

switches the first joint from the locked state to the float state when a stimulus on the first joint exceeds a first unlock threshold;

switches the first joint from the float state to the locked state when a velocity of the first joint is below a first lock threshold; and

on the condition that the first joint is in the float state, commands the first joint to move to a commanded position based on a current actual position of the first joint, or to a commanded velocity based on a current actual velocity of the first joint.

2. The device of claim 1, wherein the control unit determines the stimulus based on readings from one or more sensors associated with the first joint.

3. The device of claim 1, wherein the control unit determines the velocity of the first joint based on readings from one or more sensors associated with the first joint.

4. The device of claim 1, wherein the first unlock threshold is different from one or more second unlock thresholds for other joints of the articulated arm, the first lock threshold is different from one or more second lock thresholds for the other joints of the articulated arm, or both the first unlock threshold is different from the one or more second unlock thresholds for the other joints of the articulated arm and the first lock threshold is different from the one or more second lock thresholds for the other joints of the articulated arm.

5. The device of claim 1, wherein the first unlock threshold is based on a current pose, position, or orientation of the articulated arm, the first lock threshold is based on the current pose, position, or orientation of the articulated arm, or both the first unlock threshold and the first lock threshold are based on the current pose, position, or orientation of the articulated arm.

6. The device of claim 1, wherein the control unit switches the first joint from the locked state to the float state when a stimulus on a second joint of the articulated arm exceeds a second unlock threshold for the second joint.

7. The device of claim 1, wherein the control unit switches the first joint from the float state to the locked state when the velocity of the first joint is below the first lock threshold continuously for a predetermined period of time.

8. The device of claim 1, wherein the control unit releases one or more brakes on the first joint when the first joint is a non-actuated joint and the first joint is in the float state.

9. The device of claim 1, wherein the commanded position is the current actual position.

10. The device of claim 1, wherein the commanded position is between the current actual position and a previous commanded position.

11. The device of claim 1, wherein the commanded velocity is lower than the current actual velocity.

12. The device of claim 1, wherein the control unit prevents switching of the first joint to the float state when an operating mode of the device corresponds to a transport mode, a teleoperation mode, a commanded motion mode, or a docked to a patient mode.

13. A method of controlling motion in a medical device, the method comprising:

operating a first joint of an articulated arm of the medical device in a locked state, in which movement of the first joint is restricted, and a float state, in which movement of the first joint is permitted;

determining a stimulus on the first joint;

switching the first joint from the locked state to the float state when the stimulus exceeds a first unlock threshold;

determining a velocity of the first joint;

switching the first joint from the float state to the locked state when the velocity of the first joint is below a first lock threshold; and

on condition that the first joint is in the float state, commanding the first joint to move to a commanded position based on a current actual position of the first joint, or to a commanded velocity based on a current actual velocity of the first joint.

14. The method of claim 13, wherein determining the stimulus comprises reading one or more sensors associated with the first joint.

15. The method of claim 13, wherein determining the velocity of the first joint comprises reading one or more sensors associated with the first joint.

16. The method of claim 13, wherein the first unlock threshold is different from one or more second unlock thresholds for other joints of the articulated arm, the first lock threshold is different from one or more second lock thresholds for the other joints of the articulated arm, or both the first unlock threshold is different from the one or more second unlock thresholds for the other joints of the articulated arm and the first lock threshold is different from the one or more second lock thresholds for the other joints of the articulated arm.

17. The method of claim 13, wherein the first unlock threshold is based on a current pose, position, or orientation of the articulated arm, the first lock threshold is based on the current pose, position, or orientation of the articulated arm, or both the first unlock threshold and the first lock threshold are based on the current pose, position, or orientation of the articulated arm.

18. The method of claim 13, further comprising switching the first joint from the locked state to the float state when a stimulus on a second joint of the articulated arm exceeds a second unlock threshold for the second joint.

19. The method of claim 13, further comprising switching the first joint from the float state to the locked state when the velocity of the first joint is below the first lock threshold continuously for a predetermined period of time.

20. The method of claim 13, further comprising releasing one or more brakes on the first joint when the first joint is a non-actuated joint and the first joint is in the float state.

21. The method of claim 13, wherein the commanded position is the current actual position.

22. The method of claim 13, further comprising preventing switching of the first joint to the float state when the articulated arm is in a transport mode, a teleoperation mode, a commanded motion mode, or a docked to a patient mode.

23. The method of claim 13, further comprising switching the first joint from the locked state to the float state when a second joint of the articulated arm is beyond a soft stop position.