ELECTRO-MECHANCIAL STRAP STACK IN ROBOTIC ARMS

• US 20080021440A1
• Filed: 12/15/2006
• Published: 01/24/2008
• Est. Priority Date: 09/30/2004
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Solomon, Todd
• Granted Patent: US 10,646,292 B2
• Time in Patent Office: Days
• US Class Current: 606/1
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2034/715 Cable tensioning mechanisms for removing slack
• CPC Class Codes: A61B 34/30 Surgical robots
• 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: A61B 90/361 Image-producing devices, e.g. surgical cameras
• CPC Class Codes: B25J 9/1045 comprising tensioning means

Abstract

In one embodiment of the invention, a strap drive-train for use in a robotic arm to enable movement of a linkage assembly of the robotic arm is provided. The linkage assembly includes a plurality of links pivotally coupled in series together at a plurality of joints, respectively, for movement of the robotic arm about a pitch axis. The strap drive-train includes a first driver pulley rigidly coupled to a link of the plurality of links and a second driver pulley rigidly coupled to another link of the plurality of links. The electro-mechanical strap stack includes at least one of a ground strap and an electrical cable strap in a stacked configuration with a drive strap, wherein the electro-mechanical strap stack is connected between the first driver pulley and the second driver pulley through a middle link.

Claims

1. A robotic arm comprising:

a first driver pulley rigidly coupled to a first link of a plurality of links pivotally coupled in series together at a plurality of joints to form a linkage assembly to pitch the robotic arm;

a second driver pulley rigidly coupled to a second link of the plurality of links; and

an electro-mechanical strap stack routed between the first driver pulley and the second driver pulley and over an idler pulley in a third link, the electro-mechanical strap stack to improve electrical conduction in the third link between the first link and the second link.

2. The robotic arm of claim 1, wherein

the electro-mechanical strap stack includes a drive strap in a stacked configuration with a ground strap to improve chassis grounding.

3. The robotic arm of claim 1, wherein

the electro-mechanical strap stack includes a drive strap in a stacked configuration with an electrical cable strap to improve signal routing.

4. The robotic arm of claim 1, wherein

the electro-mechanical strap stack includes a drive strap in a stacked configuration with a ground strap and an electrical cable strap to both improve chassis grounding and signal routing.

5. The robotic arm of claim 2, wherein

the ground strap includes a conductive material and is stacked onto the drive strap in parallel relation.

6. The robotic arm of claim 5, wherein

the ground strap includes one or more layers of beryllium copper (BeCu).

7. The robotic arm of claim 2, wherein

the ground strap of the electro-mechanical strap stack is coupled to the first driver pulley and the second driver pulley;

and the robotic arm further comprises

a ground cable including a conductive material, the ground cable having a first end coupled to the first link, the ground cable extending through the first link and having a second end coupled to a chassis ground such that the plurality of links are coupled to the chassis ground by the ground cable and the ground strap.

8. The robotic arm of claim 4, wherein

the ground strap of the electro-mechanical strap stack is coupled to the first driver pulley and the second driver pulley;

and the robotic arm further comprises

a ground cable including a conductive material, the ground cable having a first end coupled to the first link, the ground cable extending through the first link and having a second end coupled to a chassis ground such that the plurality of links are coupled to the chassis ground by the ground cable and the ground strap.

9. The robotic arm of claim 3, wherein

the electrical cable strap includes one or more flexible electrical cable straps, and

each flexible electrical cable strap includes one or more flexible electrical signal lines.

10. The robotic arm of claim 9, wherein

the one or more flexible electrical cable straps and the flexible electrical signal lines are flat.

11. The robotic arm of claim 4, wherein

the electrical cable strap includes one or more flexible electrical cable straps, and

each flexible electrical cable strap includes one or more flexible electrical signal lines.

12. The robotic arm of claim 11, wherein

the one or more flexible electrical cable straps and the flexible electrical signal lines are flat.

13. The robotic arm of claim 9, further comprising:

a first printed circuit board in the first link coupled to a first end of the flexible electrical cable straps of the electro-mechanical strap stack, and

a second printed circuit board in the second link coupled to a second end of the flexible electrical cable straps of the electro-mechanical strap stack.

14. The robotic arm of claim 1, wherein

the third link is bent and includes the idler pulley pivotally coupled to the third link near a bend to direct the electro-mechanical strap stack around the bend in the third link.

15. The robotic arm of claim 14, further comprising:

a stacked strap guide system located proximate the idler pulley, the stacked strap guide system including a plurality of pulleys through which the electro-mechanical strap stack extends to laterally constrain the electro-mechanical strap stack moving over the idler pulley.

16. The robotic arm of claim 15, wherein

the stacked strap guide system further comprises one of an anti-friction pad or a roller to longitudinally constrain the electro-mechanical strap stack moving over the idler pulley.

17. A robotic arm comprising:

a linkage assembly including a plurality of links pivotally coupled in series together at a plurality of joints, respectively, to provide an insertion axis for the robotic arm; and

a strap drive-train coupled to the linkage assembly, the strap drive train to enable movement of the linkage assembly about a pitch axis;

wherein the strap drive-train includes an electro-mechanical strap stack having a drive strap coupled between a drive link and an instrument holder link of the plurality of links.

18. The robotic arm of claim 17, wherein

the electro-mechanical strap stack includes a ground strap in a stacked configuration with the drive strap.

19. The robotic arm of claim 17, wherein

the electro-mechanical strap stack includes an electrical cable strap in a stacked configuration with the drive strap.

20. The robotic arm of claim 17, wherein

the electro-mechanical strap stack includes a ground strap and an electrical cable strap in a stacked configuration with the drive strap.

21. The robotic arm of claim 18, wherein

the ground strap includes a conductive material and is stacked onto the drive strap in parallel relation.

22. The robotic arm of claim 21, wherein

the ground strap includes one or more layers of beryllium copper (BeCu).

23. The robotic arm of claim 21, further comprising:

the ground strap electrically couples to a ground cable including a conductive material, the ground cable extending through other links of the plurality of links to a chassis ground such that the plurality of links are coupled to the chassis ground.

24. The robotic arm of claim 22, wherein

the electrical cable includes one or more flexible electrical cable straps, and wherein each flexible electrical cable strap includes one or more flexible electrical signal lines.

25. The robotic arm of claim 24, wherein

the flexible electrical cable straps and flexible electrical signal lines are flat.

26. The robotic arm of claim 25, wherein

one end of the flexible electrical cable straps of the electro-mechanical strap stack couples to a printed circuit board,

and the robotic arm further comprises

an electrical cable having a first end coupled to the printed circuit board and a second end extending through the first link of the plurality of links to an electrical signal interface of the robotic arm.

27. The robotic arm of claim 17, wherein

the electro-mechanical strap stack is routed between the drive link and the instrument holder link through a middle link of the plurality of links, and

the strap drive-train further comprises

a first driver pulley rigidly coupled to the drive link;

and

a second driver pulley rigidly coupled to the instrument holder link;

wherein the drive strap of the electro-mechanical strap stack is coupled between the first driver pulley and the second driver pulley and routed through the middle link.

28. The robotic arm of claim 27, wherein:

the middle link is bent and includes an idler pulley pivotally coupled to the bent link near the bend to direct the electro-mechanical strap stack around the bend in the bent link.

29. The robotic arm of claim 28, further comprising:

a stacked strap guide system located proximate the idler pulley, the stacked strap guide system including a plurality of pulleys through which the electro-mechanical strap stack extends to laterally constrain its movement over the idler pulley.

30. The robotic arm of claim 29, wherein

the stacked strap guide system further comprises one of an anti-friction pad or a roller to longitudinally constrain the electro-mechanical strap stack moving over the idler pulley.

31. A method for a robotic arm, the method comprising:

pitching a linkage assembly having a plurality of links coupled in series together to constrain movement of a tool along an insertion axis; and

enabling movement of the linkage assembly about a pitch axis with a strap drive-train coupled thereto using an electro-mechanical strap stack routed between a first link and a second link;

wherein the electro-mechanical strap stack includes a drive strap coupled to the linkage, the drive strap to move the linkage assembly.

32. The method of claim 31, wherein

the electro-mechanical strap stack further includes a ground strap in a stacked configuration with the drive strap to improve chassis grounding.

33. The method of claim 31, wherein

the electro-mechanical strap stack further includes an electrical cable in a stacked configuration with the drive strap to improve signal routing.

34. The method of claim 31, wherein

the electro-mechanical strap stack further includes a ground strap and an electrical cable in a stacked configuration with the drive strap to both improve chassis grounding and signal routing.

35. The method of claim 32, wherein

the ground strap includes a conductive material and the ground strap is stacked onto the drive strap in parallel relation.

36. The method of claim 35, wherein

the ground strap includes one or more layers of beryllium copper (BeCu).

37. The method of claim 35, further comprising:

coupling a ground cable having a conductive material to the ground strap of the electro-mechanical strap stack, the ground cable extending through other links of the plurality of links to a chassis ground such that the plurality of links are coupled to the chassis ground.

38. The method of claim 33, wherein

the electrical cable includes one or more flexible electrical cables, and

each flexible electrical cable includes one or more flexible electrical signal lines.

39. The method of claim 38, wherein

the flexible electrical cable and flexible electrical signal lines are flat.

40. The method of claim 39, further comprising:

coupling a first end of the flat electrical cable of the electro-mechanical strap stack to a printed circuit board; and

coupling a first end of an electrical cable extending through at least one other link of the plurality of links to the printed circuit board and a second end of the electrical cable to an electrical signal interface of the robotic arm.

41. The method of claim 31, further comprising:

coupling the electro-mechanical strap stack between the first link and the second link through a third link of the plurality of links, by;

clamping the electro-mechanical strap stack to a first driver pulley rigidly coupled to the first link; and

clamping the electro-mechanical strap stack to a second driver pulley rigidly coupled to the second link;

wherein the electro-mechanical strap stack extends through the third link between the first and second links.

42. The method of claim 41, wherein

the third link is bent and includes an idler pulley pivotally coupled to the third link near the bend to direct the electro-mechanical strap stack around the bend in the third link.

43. The method of claim 42, further comprising:

laterally constraining movement of the electro-mechanical strap stack to track the electro-mechanical strap stack over the idler pulley and avoid wandering off the idler pulley.

44. The method of claim 42, further comprising:

longitudinally constraining movement of the electro-mechanical strap stack to track the electro-mechanical strap stack over the idler pulley and avoid puffing of the electro-mechanical strap stack.

45. A strap drive-train for use in a robotic arm to enable movement of a linkage assembly having a plurality of links pivotally coupled in series together at a plurality of joints, respectively, for movement of the robotic arm about a pitch axis, the strap drive-train comprising:

a first driver pulley rigidly coupled to a first link of the plurality of links;

a second driver pulley rigidly coupled to a second link of the plurality of links; and

an electro-mechanical strap stack routed between the first driver pulley and the second driver pulley through a third link located between the first link and the second link, the electro-mechanical strap stack including

a drive strap coupled to the first driver pulley and the second driver pulley,

a ground strap having a conductive material,

a flexible electrical cable strap having one or more flexible electrical signal lines, and

wherein the ground strap and the flexible electrical cable strap being in a stacked and parallel configuration with the drive strap.

46. The strap drive-train of claim 45, wherein

the ground strap includes one or more layers of beryllium copper (BeCu).

47. The strap drive-train of claim 45, further comprising:

a ground cable including a conductive material coupled to the ground strap of the electro-mechanical strap stack, the ground cable extending through other links of the plurality of links to a chassis ground such that the plurality of links are coupled to the chassis ground.

48. The strap drive-train of claim 45, wherein

the flexible electrical cable strap and flexible electrical signal lines are flat.

49. The strap drive-train of claim 48, further comprising:

an electrical cable coupled to the flat electrical cable straps of the electro-mechanical strap stack, the electrical cable extending through at least one other link of the plurality of links to an electrical signal interface of the robotic arm.

50. The strap drive-train of claim 45, wherein

the third link is bent and includes an idler pulley pivotally coupled to the third link near the bend to direct the electro-mechanical strap stack around the bend in the third link.

51. The strap drive-train of claim 50, further comprising:

a stacked strap guide system located proximate the idler pulley, the stacked strap guide system including a plurality of pulleys through which the electro-mechanical strap stack extends to laterally constrain the electro-mechanical strap stack moving over the idler pulley.

52. The strap drive-train of claim 51, wherein

the stacked strap guide system further comprises one of an anti-friction pad or a roller to longitudinally constrain the electro-mechanical strap stack moving over the idler pulley.

53. An electro-mechanical strap stack routed over an idler pulley in a link of a robotic arm between a first driver pulley and a second driver pulley, the electro-mechanical strap stack comprising:

a flat metal drive strap coupled to the first driver pulley and the second driver pulley,

flat metallic ground strapping stacked on and in parallel to the metal drive strap, the flat metallic ground strapping including a plurality of conductive material layers coupled to the first driver pulley and the second driver pulley,

one or more flat flexible signal cables stacked on the flat metallic ground strapping in parallel with the flat metal drive strap, each of the one or more flat flexible signal cables having a plurality of flat flexible electrical signal lines surrounded by an insulating material.

54. The electro-mechanical strap stack of claim 53, wherein

the flat metal drive strap is a multi-ply metal drive strap including a plurality of flat metal layers stacked upon each other and coupled together at each end.

55. The electro-mechanical strap stack of claim 54, wherein

each flat metal layer is steel.

56. The electro-mechanical strap stack of claim 54, wherein

the plurality of flat metal layers are coupled together at a first end by a tab and at a second end by a tensioning block.

57. The electro-mechanical strap stack of claim 54, wherein

the plurality of flat metal layers are coupled together at each end by a tab.

58. The electro-mechanical strap stack of claim 55, wherein

the flat metallic ground strapping includes a plurality of flat beryllium copper (BeCu) layers.

59. The electro-mechanical strap stack of claim 53, wherein

the one or more flat flexible signal cables are pinched against the ground strapping at the first driver pulley by a first clamp near a first end and pinched against the ground strapping at the second driver pulley by a second clamp near a second end.