Calibration of a robotic surgical tool

• US 10,376,276 B2
• Filed: 02/02/2017
• Issued: 08/13/2019
• 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., Beckman, Andrew
• Primary Examiner(s): Bendidi, Rachid
• Application Number:
  US15/422,963
• Publication Number:
  US 20180214167A1
• Time in Patent Office: 922 Days
• CPC Class Codes: A61B 17/29 Forceps for use in minimally invasive surgery
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61B 18/1402 Probes for open surgery
• CPC Class Codes: A61B 2017/00725 Calibration or performance testing
• CPC Class Codes: A61B 2017/2901 Details of shaft
• CPC Class Codes: A61B 2018/00202 rotating
• CPC Class Codes: A61B 2018/00988 Means for storing information, e.g. calibration constants, or for preventing excessive use, e.g. usage, service life counter
• CPC Class Codes: A61B 2034/2059 Mechanical position encoders
• CPC Class Codes: A61B 2034/302 specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2090/067 for measuring angles
• CPC Class Codes: A61B 34/30 Surgical robots

Abstract

Systems and methods for calibration of a shaft of a surgical tool are provided. The tool includes an elongate shaft configured to be coupled to an electromechanical arm of a robotic surgical system and having an end effector coupled to a distal end thereof, the shaft being rotatable about its longitudinal axis. The tool also includes at least one target associated with the shaft and configured to be non-independently movable with respect to the shaft, wherein a position of the target is detected using at least one sensor disposed such that the shaft is able to move independently of the sensor. The detected position is used to determine a rotational angle of the shaft. This can involve accessing a memory on the tool or the system storing values related to a target position in association with corresponding values of a shaft rotation angle.

Claims

1. A surgical tool, comprising:

an elongate shaft configured to be coupled to an electromechanical arm of a robotic surgical system and having an end effector coupled to a distal end thereof, the elongate shaft being rotatable about a longitudinal axis of the elongate shaft; and

at least one target associated with the elongate shaft and configured to be non-independently movable with respect to the elongate shaft, wherein a position of the target is detected using at least one sensor disposed on the electromechanical arm of the robotic surgical system such that the elongate shaft is able to move independently of the sensor, and wherein the detected position is used to determine a rotational angle of the elongate shaft.

2. The surgical tool of claim 1, wherein the sensor is at a position so as to be remote from the elongate shaft.

3. The surgical tool of claim 1, wherein the at least one target is coupled to the elongate shaft.

4. The surgical tool of claim 1, wherein the at least one target comprises a portion of the elongate shaft having properties distinct from a remainder of the elongate shaft.

5. The surgical tool of claim 1, wherein the at least one target is associated with the elongate shaft such that a position of the target, when detected, is used to determine a zero rotational angle position of the elongate shaft.

6. The tool of claim 1, wherein the target comprises at least one substantially circular magnetic feature disposed in the elongate shaft coaxially therewith, and the at least one sensor comprises first and second sensors.

7. The surgical tool of claim 1, wherein the at least one target comprises at least one portion of the elongate shaft that is magnetized and disposed at least partially along a circumference of the elongate shaft, and the at least one sensor comprises first and second sensors.

8. The surgical tool of claim 1, wherein the at least one target comprises at least one portion of the elongate shaft that is disposed at least partially along a circumference of the elongate shaft, the at least one portion having at least one light absorption property that is different from at least one light absorption property of a remainder of the elongate shaft, and wherein the at least one sensor comprises a transmitter and a receiver.

9. The surgical tool of claim 1, wherein the at least one target comprises an elongate magnetic element having first and second ends and disposed substantially helically around the elongate shaft, and the at least one sensor is disposed adjacent to one of the first and second ends.

10. The surgical tool of claim 1, wherein the at least one target comprises at least one magnet disposed at a predetermined position along the elongate shaft and offset from a central longitudinal axis of the elongate shaft.

11. The surgical tool of claim 1, wherein the at least one target comprises at least one substantially circular conductive feature disposed around a circumference of the elongate shaft, and the at least one sensor comprises an inductive sensor.

12. The surgical tool of claim 1, further comprising:

a memory configured to store a plurality of first values representing positions of the target with respect to the sensor, and a plurality of second values representing rotational angles of the elongate shaft each corresponding to respective one of the first values.

13. The surgical tool of claim 12, wherein the tool is further configured to receive a user-initiated input requesting rotational movement of the elongate shaft with reference to the stored values.

14. The surgical tool of claim 12, further comprising a controller configured to receive a user-initiated input requesting rotational movement of the elongate shaft with reference to the stored values.

15. A method of operating a surgical tool, comprising:

detecting a connection between an elongate shaft and an electromechanical arm of a robotic surgical system, the elongate shaft having an end effector coupled to a distal end thereof and being rotatable about a longitudinal axis thereof, and having at least one target associated therewith that is configured to be movable together with the elongate shaft;

acquiring, by a sensor disposed on the electromechanical arm of the robotic surgical system, at least one value corresponding to a position of the target with respect to the sensor; and

determining, by a processor in operable communication with the sensor, a rotational angle of the elongate shaft based on the acquired value.

16. The method of claim 15, further comprising:

receiving a user-initiated input requesting rotational movement of the elongate shaft to position the elongate shaft such that the sensor is able to acquire the at least one value indicating the position of the target with respect to the sensor.

17. The method of claim 15, further comprising:

accessing a storage storing a plurality of first values representing positions of the target with respect to the sensor, and a plurality of second values representing rotational angles of the elongate shaft each corresponding to respective one of the first value;

comparing the acquired value to the plurality of first values to identify a matching first value; and

determining the rotational angle of the elongate shaft based on a second value of the plurality of second values that corresponds to the matching first value.

18. The method of claim 15, wherein the at least one value is a voltage value.

19. A robotic surgical system, comprising:

a surgical tool having

an elongate shaft configured to be coupled to an electromechanical arm of the robotic surgical system and having an end effector coupled to a distal end thereof, the elongate shaft being rotatable about a longitudinal axis thereof; and

at least one target associated with the elongate shaft and configured to be non-independently movable with respect to the elongate shaft;

at least one sensor disposed on the electromechanical arm and configured to detect a position of the target, wherein the detected position is used to determine a rotational angle of the elongate shaft;

a memory configured to store a plurality of first values representing positions of the target with respect to the sensor, and a plurality of second values representing rotational angles of the elongate shaft each corresponding to respective one of the first values; and

a controller configured to access the memory to determine the rotational angle of the elongate shaft based on a comparison of the detected position of the target with the plurality of first values.