Robotic surgical system and methods for articulation calibration

• US 10,327,854 B2
• Filed: 02/02/2017
• Issued: 06/25/2019
• Est. Priority Date: 02/02/2017
• Status: Active Grant

• Current Assignee: Ethicon, LLC (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Overmyer, Mark D., Swayze, Jeffrey S., Koch, Robert L.
• Primary Examiner(s): Bendidi, Rachid
• Application Number:
  US15/422,767
• Publication Number:
  US 20180214219A1
• Time in Patent Office: 873 Days
• CPC Class Codes: A61B 17/00234 for minimally invasive surgery A61B17/0218, A61B17/0469, A61B17/12013, A61B17/1285, A61B17/29, A61B17/320016 take precedence
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• 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 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: B25J 9/1692 Calibration of manipulator

Abstract

Systems and methods for articulation calibration of a surgical tool configured to be coupled to a robotic surgical system are provided. The tool including a tool shaft with an end effector has at least one linkage member extending along the shaft and operably coupled to the end effector such that force selectively applied to the linkage member is able to cause articulation of the end effector. The tool can also include a homing mechanism. To perform articulation calibration of the end effector, it can be constrained, force can be applied to the linkage member to attempt articulation of the end effector until a resistance against further articulation exceeds a threshold, and a home position of the end effector can be determined based on a force at which the resistance has exceeded the threshold.

Claims

1. A surgical method, comprising:

actuating a homing mechanism to constrain an end effector coupled to a distal end of a shaft of a surgical tool coupled to a robotic surgical system to thereby substantially limit articulation of the end effector relative to the shaft, the homing mechanism having a fork member and a push rod that moves distally into the fork member to cause the fork member to lockingly engage at least one linkage member operably coupled to the end effector;

applying, by at least one motor, a first force to the at least one linkage member to attempt articulation of the constrained end effector in a first direction until a resistance against further articulation exceeds a first threshold, and storing a first value of a force at which the resistance has exceeded the first threshold;

applying, by the at least one motor, a second force to the at least one linkage member to attempt articulation of the constrained end effector in a second direction that is opposite the first direction until a resistance against further articulation exceeds a second threshold, and storing a second value of a force at which the resistance has exceeded the second threshold;

determining, by a processor, first and second articulation angles based on the first and second values; and

averaging, by the processor, the first and second articulation angles to obtain a home position of the constrained end effector.

2. The surgical method of claim 1, wherein:

the at least one linkage member comprises a first linkage member and a second linkage member;

the first force is applied to the first linkage member; and

the second force is applied to the second linkage member.

3. The surgical method of claim 1, wherein the at least one linkage member comprises a plurality of flexible cables.

4. The surgical method of claim 1, wherein determining the first and second articulation angles comprises correlating the first and second values with stored values of a force that can be applied to the at least one linkage member, each of the stored values being stored in association with a respective value of an articulation angle.

5. The surgical method of claim 1, wherein storing the first and second values comprises storing the first and second values in a memory associated with the robotic surgical system.

6. The surgical method of claim 1, further comprising applying a force to the at least one linkage member to cause at least a portion of the end effector to pivot relative to the shaft with reference to the home position of the end effector.

7. The surgical method of claim 1, wherein the home position of the end effector indicates a position of the end effector at which an articulation angle of the end effector with respect to the shaft is considered to be zero.

8. The surgical method of claim 1, wherein the first and second thresholds are predetermined thresholds known to the robotic surgical system.

9. A surgical tool configured to be coupled to a robotic surgical system, comprising:

a tool shaft having an end effector coupled to a distal end thereof;

a wrist disposed between the tool shaft and the end effector;

at least one linkage member associated with the tool shaft and operably coupled to the end effector such that force selectively applied to the at least one linkage member is able to cause at least one of a pitch and a yaw motion of the end effector; and

a homing mechanism configured to be actuated to angularly adjust a presumed zero position of the end effector relative to the tool shaft to an adjusted zero position of the end effector, wherein the homing mechanism includes a fork member and a push rod configured to move distally into the fork member to cause the fork member to lockingly engage the at least one linkage member.

10. The surgical tool of claim 9, wherein the end effector is configured to be moved with respect to the wrist with reference to the adjusted zero position.

11. The surgical tool of claim 9, wherein when the end effector is in the adjusted zero position relative to the tool shaft, the at least one linkage member is configured to have force applied thereto to attempt articulation of the end effector in at least one direction until a resistance against further articulation exceeds a threshold.

12. The surgical tool of claim 9, wherein the at least one linkage member comprises a plurality of flexible cables.

13. The surgical tool of claim 9, further comprising a memory configured to store a plurality of values of a force that can be applied to the at least one linkage member, each of the stored values being stored in association with a respective value of an articulation angle.

14. The surgical tool of claim 9, wherein the fork member comprises a plurality of teeth configured to engage a plurality of teeth formed on the at least one linkage member.

15. The surgical tool of claim 14, wherein the homing mechanism is configured to angularly adjust the presumed zero position of the end effector by causing the teeth of the fork member to engage the teeth formed on the at least one linkage member such that the at least one linkage member is disposed at one of a plurality of predetermined positions with respect to the homing mechanism.