Ratcheting for master alignment of a teleoperated minimally invasive surgical instrument

• US 10,278,783 B2
• Filed: 09/18/2017
• Issued: 05/07/2019
• Est. Priority Date: 06/30/2009
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Itkowitz, Brandon D., DiMaio, Simon P., Nowlin, William C., Niemeyer, Gunter D., Mintz, David S.
• Primary Examiner(s): Sample, Jonathan L
• Application Number:
  US15/706,883
• Publication Number:
  US 20180028270A1
• Time in Patent Office: 596 Days
• Field of Search: 700245-264, 31856811-56822, 318572, 606 1, 606130, 901 2, 901 14, 901 41
• CPC Class Codes: A61B 2017/00725 Calibration or performance testing
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 34/25 User interfaces for surgical systems
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/35 for telesurgery
• CPC Class Codes: A61B 34/37 Master-slave robots A61B34/35 takes precedence
• CPC Class Codes: A61B 34/77 Manipulators with motion or force scaling
• CPC Class Codes: A61B 90/10 for stereotaxic surgery, e.g. frame-based stereotaxis
• CPC Class Codes: B25J 3/00 Manipulators of master-slave type, i.e. both controlling unit and controlled unit perform corresponding spatial movements
• CPC Class Codes: B25J 9/1669 characterised by special application, e.g. multi-arm co-operation, assembly, grasping
• CPC Class Codes: B25J 9/1689 Teleoperation
• CPC Class Codes: G05B 2219/45117 Medical, radio surgery manipulator
• CPC Class Codes: Y10S 901/27 Arm part
• CPC Class Codes: Y10S 901/41 Tool

Abstract

A minimally-invasive surgical system includes a slave surgical instrument having a slave surgical instrument tip and a master grip. The slave surgical instrument tip has an alignment in a common frame of reference and the master grip, which is coupled to the slave surgical instrument, has an alignment in the common frame of reference. An alignment error, in the common frame of reference, is a difference in alignment between the alignment of the slave surgical instrument tip and the alignment of the master grip. A ratcheting system (i) coupled to the master grip to receive the alignment of the master grip and (ii) coupled to the slave surgical instrument, to control motion of the slave by continuously reducing the alignment error, as the master grip moves, without autonomous motion of the slave surgical instrument tip and without autonomous motion of the master grip.

Claims

1. A teleoperated system comprising:

a master grip; and

a controller configured to be coupled to a teleoperated slave instrument, the controller being configured to;

align the master grip with the slave instrument, wherein the controller being configured to align the master grip with the slave instrument comprises;

the controller being configured to introduce a control system error between a slave instrument alignment and a master grip alignment to speed up convergence of alignment between the slave instrument and the master grip relative to convergence of alignment between the slave instrument and the master grip without introduction of the control system error.

2. The teleoperated system of claim 1, wherein the controller being configured to align the master grip with the slave instrument further comprises:

the controller being configured to use a new alignment error to control motion of the slave instrument only if the new alignment error is smaller than a current alignment error.

3. The teleoperated system of claim 1, wherein the controller being configured to introduce a control system error comprises:

the controller being configured to artificially adjust a commanded movement of the slave instrument.

4. The teleoperated system of claim 1:

wherein the controller being configured to align the master grip with the slave instrument further comprises;

the controller being configured to characterize a rotation angle error between an alignment of the master grip and an alignment of the slave instrument; and

wherein the controller being configured to introduce a control system error comprises;

the controller being configured to adjust a commanded movement of the slave instrument based on the rotation angle error.

5. The teleoperated system of claim 4, wherein the controller being configured to adjust a commanded movement of the slave instrument based on the rotation angle error comprises:

the controller being configured to penalize the commanded movement of the slave instrument based on the rotation angle error and a penalty profile.

6. The teleoperated system of claim 5, wherein the controller being configured to adjust a commanded movement of the slave instrument based on the rotation angle error comprises:

the controller being configured to select a scale factor based on the rotation angle error, wherein the scale factor is used to adjust the commanded movement of the slave instrument.

7. The teleoperated system of claim 5, wherein the penalty profile comprises a continuous and monotonic penalty profile.

8. The teleoperated system of claim 5, wherein the penalty profile comprises a first region for values of the rotation angle error less than a first value, a third region for values of the rotation angle error greater than a second value, and a second region for values of the rotation angle error between the first value and the second value.

9. The teleoperated system of claim 1, wherein the master grip is selected from a group consisting of:

a master grip without powered alignment and a master grip with powered alignment.

10. A teleoperated system comprising:

a master grip; and

a controller coupled to the master grip and configured to be coupled to a teleoperated slave instrument, the controller being configured to align the master grip with the teleoperated slave instrument, wherein the controller being configured to align the master grip with the teleoperated slave instrument comprises the controller being configured to;

characterize a rotation angle error between an alignment of the master grip and an alignment of the slave instrument; and

generate a commanded movement for the slave instrument based on an output taken from a penalty profile, wherein the output taken from the penalty profile is selected using the rotation angle error.

11. The teleoperated system of claim 10, wherein the alignment of the teleoperated slave instrument is an alignment of a tip of the teleoperated slave instrument.

12. The teleoperated system of claim 10, wherein the penalty profile comprises a first region for values of the rotation angle error less than a first value, a third region for values of the rotation angle error greater than a second value, and a second region for values of the rotation angle error between the first value and the second value.

13. The teleoperated system of claim 12, wherein the penalty profile comprises a curve, wherein the first value is at a first inflection point of the curve, and wherein the second value is at a second inflection point of the curve.

14. The teleoperated system of claim 10, wherein the output is a scale factor.

15. The teleoperated system of claim 10, the controller further being configured to impose a joint limit on the commanded movement.

16. The teleoperated system of claim 10, wherein the rotation angle error is one Euler angle in a set of Euler angles.

17. The teleoperated system of claim 10, wherein the penalty profile comprises a continuous and monotonic penalty profile.

18. The teleoperated system of claim 10, wherein the penalty profile is the same for all users of the teleoperated system.

19. The teleoperated system of claim 10, wherein the master grip is selected from a group consisting of:

a master grip without powered alignment and a master grip with powered alignment.

20. A method of operating a teleoperated system, the teleoperated system comprising a master grip and a robot arm configured to move a slave instrument, the method comprising:

characterizing a rotation angle error between an alignment of the master grip and an alignment of the slave instrument; and

generating a commanded movement for the slave instrument based on an output taken from a penalty profile, wherein the output taken from the penalty profile is selected using the rotation angle error.

21. The method of claim 20, wherein the penalty profile comprises a first region for values of the rotation angle error less than a first value, a third region for values of the rotation angle error greater than a second value, and a second region for values of the rotation angle error between the first value and the second value.

22. The method of claim 20, wherein the alignment of the slave instrument is an alignment of a tip of the slave instrument.

23. The method of claim 20, wherein the penalty profile comprises a continuous and monotonic penalty profile.