SURGICAL ROBOTIC SYSTEM

• US 20100130986A1
• Filed: 11/11/2009
• Published: 05/27/2010
• Est. Priority Date: 11/11/2008
• Status: Active Grant

• Current Assignee: Omnilife Science, Inc. (OrthoUnited, Inc.)
• Original Assignee: Perception Raisonnement Action en Medecine
• Inventors: Mailloux, Pierre, Plaskos, Christopher
• Granted Patent: US 9,033,958 B2
• Time in Patent Office: Days
• US Class Current: 606/130
• CPC Class Codes: A61B 2090/0813 Accessories designed for easy sterilising, i.e. re-usable
• CPC Class Codes: A61B 34/30 Surgical robots

Abstract

In one embodiment, a surgical robotic system includes a main controller and a motor unit assembly that is associated with a robot and is in communication with the main controller. The motor unit assembly has a non-sterile motor unit and a sterile enclosure that surrounds and contains the motor unit. The motor unit includes at least one motor and a motor controller that is operatively connected to the motor unit, wherein the motor unit and the enclosure are configured to permit attachment between the motor unit and the controller.

Claims

1. A surgical robotic system comprising:

a main controller; and

a motor unit assembly that is associated with a robot and is in communication with the main controller, the motor unit assembly having a non-sterile motor unit and a sterile enclosure that surrounds and contains the motor unit, wherein the motor unit includes at least one motor and a motor controller that is operatively connected to the motor unit, wherein the motor unit and the enclosure are configured to permit attachment between the motor unit and the controller.

2. The surgical robotic system of claim 1, wherein the enclosure is formed of two parts that are detachable from one another in which each part includes a sterile outer surface, while an inner surface of each part is non-sterile due to the presence of the non-sterile motor unit.

3. The surgical robotic system of claim 2, wherein the first part is a hollow enclosure base that receives the motor unit and include a first seal member at one end thereof, the second part being an enclosure cover that mates with the enclosure base for capturing the motor unit therebetween, the enclosure cover having a second seal member that mates with the first seal member for providing a seal.

4. The surgical robotic system of claim 1, wherein the motor unit includes a pair of motors each of which has a drive shaft and the enclosure includes a pair of output shafts that are coupled to the drive shaft of the motors when the motor unit is in a fully assembled position within the enclosure.

5. The surgical robotic system of claim 4, wherein the enclosure includes an interface for coupling the motor units to the output shafts of the enclosure, the interface permitting engagement of the respective drive shafts of the motors regardless of an angular position of the drive shafts.

6. The surgical robotic system of claim 5, wherein the interface comprises a plurality of teeth arranged radially from the center and allowing engagement of the respective motor shafts at any angle.

7. The surgical robotic system of claim 3, wherein the motor unit includes a first connector and the enclosure cover includes a second connector that mates with the first connector for operatively connecting the motor unit to the controller via a cable that is connected to the main controller.

8. The surgical robotic system of claim 1, wherein the motor unit includes hall sensors for communication encoders for position measurement, the motor controller being connected to the motor.

9. The surgical robotic system of claim 3, wherein the motor unit, enclosure base and enclosure cover have an asymmetrical feature that allows the motor unit to be inserted into the enclosure base in only one unique direction and the enclosure cover to be assembled on the enclosure base in only one unique direction.

10. The surgical robotic system of claim 1, wherein a connection between each motor and the respective motor controller is fully contained within the enclosure and is remote from the main controller.

11. The surgical robotic system of claim 1, wherein the surgical robotic system comprises a computer assisted surgical system that includes a computer that is configured to send a positioning command from the computer to the main controller via a first cable and according to a first communication protocol, wherein the first communication protocol is converted into a first signal using a converter, the first signal being delivered to the motor controller that is located in the motor unit via a second cable.

12. The surgical robotic system of claim 11, wherein the motor controller in the motor unit converts the signal to a low level second signal that commands the motor to move to a desired position.

13. The surgical robotic system of claim 12, wherein the first cable comprises a USB cable, the first communication protocol comprises USB protocol, the first signal comprises CAN bus signal, the converter comprises a USB-to-CAN converter, and the second signal comprises low level hall sensor communication pulses and motor phase signals.

14. The surgical robotic system of claim 1, wherein the motor unit contains gears and shafts contained within the motor unit and that interface with the enclosure and are supported by bearings, thereby providing smooth and accurate positioning qualities.

15. The surgical robotic system of claim 14, wherein the motor unit contains at least one accurately supported position output shaft that is coupled with at least one floating enclosure output shaft, whereby after coupling the enclosure output shaft rotates about the rotational axes of the accurately supported motor unit output shaft.

16. A process for assembling a motor unit assembly that is associated with a surgical robotic system in an aseptic transfer process comprising the steps of:

sterilizing an insertion guide, an enclosure base and an enclosure cover that is complementary to the enclosure base, wherein the motor unit is in a non-sterile condition, the enclosure base having an opening that forms an entrance into a hollow interior space;

coupling the insertion guide to the enclosure base while maintaining the insertion guide and enclosure base in a sterile condition, the insertion guide having an opening that is axially aligned with the opening of the enclosure base;

inserting the motor unit into the hollow interior space by passing it through the opening of the insertion guide;

removing the insertion guide off of the enclosure base and from the sterile field that includes the enclosure base and cover; and

coupling the enclosure cover to the enclosure base with the motor unit being sealingly contained therebetween;

wherein the motor unit includes at least one motor and a motor controller that is operatively connected to the motor unit and fully contained within the sealed enclosure surrounding the motor unit, wherein the motor unit and the enclosure are configured to permit attachment between the motor unit and a main controller.

17. The process of claim 16, wherein the insertion guide has flared or outward extending sides to increase the coverage over the external surface of the sterile enclosure body when it is axially aligned with the opening of the enclosure base.

18. A robotic assisted surgical system comprising:

a computer;

a robot;

a main controller in communication with the computer and the robot; and

a motor unit assembly that is associated with a robot and is in communication with the main controller, the motor unit assembly having a non-sterile motor unit and a sterile enclosure that surrounds and contains the non-sterile motor unit, wherein the motor unit includes at least one motor and a motor controller that is operatively connected to the motor unit, wherein the motor unit and the enclosure are configured to permit attachment between the motor unit and the controller.

19. The system of claim 18, wherein the motor unit includes a pair of motors each of which has a drive shaft and the enclosure includes a pair of output shafts that are coupled to the drive shaft of the motors when the motor unit is in a fully assembled position within the enclosure.

20. The system of claim 19, wherein the enclosure includes an interface for coupling the motor units to the output shafts of the enclosure, the interface permitting engagement of the respective drive shafts of the motors regardless of an angular position of the drive shafts.