Software center and highly configurable robotic systems for surgery and other uses

• US 8,541,970 B2
• Filed: 07/01/2011
• Issued: 09/24/2013
• Est. Priority Date: 05/19/2005
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Nowlin, William C., Mohr, Paul W., Schena, Bruce M., Larkin, David Q., Guthart, Gary S.
• Primary Examiner(s): Chan, Kawing
• Application Number:
  US13/175,572
• Publication Number:
  US 20110264111A1
• Time in Patent Office: 816 Days
• Field of Search: 318/560, 318/567, 318/568.1, 318/568.11, 318/568.2, 318/568.21
• US Class Current: 318/568.21
• CPC Class Codes: A61B 2034/301 for introducing or steering flexible instruments inserted into the body, e.g. catheters or endoscopes
• CPC Class Codes: A61B 2034/302 specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2090/065 for measuring contact or contact pressure
• 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: A61B 34/77 Manipulators with motion or force scaling
• CPC Class Codes: A61B 90/361 Image-producing devices, e.g. surgical cameras
• CPC Class Codes: A61B 90/37 Surgical systems with images on a monitor during operation
• 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 9/1682 Dual arm manipulator; Coordination of several manipulators
• CPC Class Codes: B25J 9/1689 Teleoperation
• CPC Class Codes: G05B 2219/39135 For multiple manipulators operating at same time, avoid collision
• CPC Class Codes: G05B 2219/39212 Select between autonomous or teleoperation control
• CPC Class Codes: G05B 2219/39322 Force and position control
• CPC Class Codes: G05B 2219/40184 Compliant teleoperation, operator controls motion, system controls contact, force
• CPC Class Codes: G05B 2219/45117 Medical, radio surgery manipulator

Abstract

Telerobotic, telesurgical, and/or surgical robotic devices, systems, and methods employ surgical robotic linkages that may have more degrees of freedom than an associated surgical end effector n space. A processor can calculate a tool motion that includes pivoting of the tool about an aperture site. Linkages movable along a range of configurations for a given end effector position may be driven toward configurations which inhibit collisions. Refined robotic linkages and method for their use are also provided.

Claims

1. A surgical robotic system comprising:

a surgical instrument having a proximal end, a distal end effector suitable for insertion into a patient, and an intermediate portion between the proximal end and the end effector;

a first manipulator configured to support the proximal end of the instrument so as to move the instrument from outside the patient;

the first manipulator and instrument together comprising a first manipulator assembly having a plurality of driven joints, the plurality of driven joints being configured to provide sufficient degrees of freedom to allow a range of joint states for a position of the end effector while the intermediate portion is within an access site;

an input configured to receive a movement command to effect a desired movement of the end effector within a surgical workspace;

a second manipulator configured to support a second instrument, the second instrument having a distal end effector, the second manipulator and the second instrument together comprising a second manipulator assembly having a plurality of driven joints; and

a processor coupling the input to the first manipulator assembly, the processor being configured to determine movements of the plurality of driven joints of the first manipulator assembly in response to the received movement command so as to effect the desired movement of the end effector of the first instrument and so that the intermediate portion of the first instrument is within the access site during the desired movement of the end effector of the first instrument, the processor being further configured to calculate movements of the plurality of driven joints of the first manipulator assembly so as to drive the first manipulator assembly towards a manipulator collision inhibiting configuration prior to any determination of contact or near contact between the first and second manipulators.

2. The robotic system of claim 1,

wherein the plurality of driven joints of the second manipulator assembly are configured to provide sufficient degrees of freedom to allow a range of joint states for a position of the end effector of the second instrument;

wherein the first manipulator assembly is configured to move in response to a first signal from the processor and the second manipulator assembly is configured to move in response to a second signal from the processor; and

wherein during simultaneous movement of the first and second manipulator assemblies, the processor is configured to inhibit collisions between the first and second manipulators by, prior to any determination of contact or near contact between the first manipulator and the second manipulator, calculating the first signal for the first manipulator assembly at least in part in response to a joint configuration of the second manipulator assembly and calculating the second signal for the second manipulator assembly at least in part in response to a joint configuration of the first manipulator assembly.

3. The system of claim 2, wherein the processor is configured to inhibit collisions during movement of the first and second manipulators by individually calculating a desired pose of the first manipulator in response to the second signal and a desired pose of the second manipulator in response to the first signal, wherein the pose of the first manipulator in relation to the pose of the second manipulator comprises the collision inhibiting configuration.

4. The system of claim 3, further comprising:

a third manipulator assembly configured to move in response to a third signal from the processor,

wherein the processor is configured to globally configure the first, second and third manipulator assemblies by calculating a desired pose of each of the first, second and third manipulator assemblies in response to the respective signal associated with each other manipulator of the first, second and third manipulator assemblies, wherein the pose of the first manipulator relative the pose of each of the second and third manipulators comprises the collision inhibiting configuration.

5. The system of claim 1, further comprising a collision sensor system along the first manipulator, wherein the processor is further configured to drive the first manipulator in response to a signal from the collision sensing system.

6. The system of claim 5, wherein the collision sensor system comprises at least one sensor selected from a group consisting of tape switches, flexible sensing arrays, individual force sensing resistors or arrays, and active or passive capacitive sensing systems.

7. The robotic surgical system of claim 5, wherein the collision sensor system comprises a collision sensor at one or more locations on the first manipulator, wherein the sensor comprises either a contact sensor or a proximity sensor or both.

8. The robotic surgical system of claim 7, wherein the processor is configured to drive the first manipulator to a different pose in response to contact sensed by the contact sensor or in response to near contact sensed by the proximity sensor.

9. The robotic surgical system of claim 1, further comprising

at least one other manipulator assembly, the or each other manipulator assembly having a manipulator supporting a corresponding surgical instrument having a proximal end, a distal end effector suitable for insertion into a patient, and an intermediate portion between the proximal end and the end effector, the or each other manipulator being configured to move the end effector of the corresponding surgical instrument in the surgical workspace in accordance with commands of the processor;

wherein the processor is configured to calculate movements of the plurality of driven joints of the first manipulator assembly in response to at least one signal from the processor associated with the or each other manipulator so as to inhibit collisions between the first manipulator and the or each other manipulator during simultaneous movement of the first manipulator assembly and the or each other manipulator assemblies.

10. The robotic surgical system of claim 9,

the or each other manipulator assembly having a plurality of driven joints, the plurality of driven joints of the or each other manipulator assembly being configured to provide sufficient degrees of freedom to allow a range of joint states for a position of the end effector of the corresponding instrument of the or each other manipulator assembly while the intermediate portion of the associated surgical instrument is within an associated access site;

wherein the range of joint states for the first manipulator assembly and the or each other manipulator assembly includes a first configuration and a second configuration, a joint of the first manipulator assembly in the first configuration defining a generally upwardly oriented apex, and a joint of the or each other manipulator assembly in the second configuration defining a generally downwardly oriented apex; and

wherein the processor is configured to drive the first manipulator and the or each other manipulator so that the first manipulator having the first configuration is disposed adjacent at least one of the or each other manipulator having the second configuration, wherein the first configuration relative the second configuration comprises the collision inhibiting configuration.

11. The robotic surgical system of claim 9,

wherein each of the first manipulator and the or each other manipulator comprises a plurality of interconnected links;

wherein the range of joint states for each of the first manipulator and the or each other manipulator comprise a state in which each plurality of interconnected links extends along an associated plane; and

wherein the processor is configured to inhibit collisions between the first manipulator and the or each other manipulator by driving each of the first manipulator and the or each other manipulator such that the associated planes are offset, wherein the plane of the first manipulator relative the plane of the or each other manipulator comprises the collision inhibiting configuration.

12. The robotic surgical system of claim 1,

wherein the system comprises a plurality of manipulators, the first manipulator being one of the plurality of manipulators;

and

wherein the collision inhibiting configuration comprises a joint axis of a first joint in the first manipulator being co-planar with a joint axis of a second joint of the first manipulator to maintain a substantially planar configuration so as to avoid potential collisions between the first manipulator and an adjacent manipulator of the plurality of manipulators.

13. The system of claim 1,

wherein the processor comprises a first module and a second module;

wherein the first module is configured to determine the movement of the plurality of driven joints so as to effect the desired movement of the end effector, and

wherein the second module is configured to drive the first manipulator assembly so as to enhance a range of available joint states for a movement of the first manipulator by avoiding a singularity of the first manipulator.

14. A master-slave robotic system comprising:

a first manipulator assembly having a first end effector movable within a workspace, the first manipulator assembly having a plurality of joints, the plurality of joints being configured with a plurality of alternative joint states for a position of the first end effector in the workspace;

a second manipulator assembly having a second end effector movable within the workspace, the second manipulator assembly having a plurality of joints and being configured to transmit a state signal indicating movement of the second manipulator assembly;

an input device configured to receive an input for a first desired movement of the first end effector within the workspace; and

a processor coupled to the input device, the first manipulator assembly, and the second manipulator assembly, the processor being configured to determine a movement of the first manipulator assembly in response to the input for the first desired movement and in response to the or each state signal from the second manipulator assembly so as to drive the first manipulator assembly toward a collision inhibiting configuration prior to any determination of contact or near contact between the first and second manipulators to inhibit collisions between the first and second manipulator assemblies, the processor controlling movement of the first end effector in effecting the first desired movement.

15. The robotic system of claim 14, wherein the processor is configured to drive the first manipulator assembly toward the collision inhibiting configuration simultaneously with controlling the movement of the first end effector.

16. The robotic system of claim 14,

wherein each of the first and second manipulators includes a range of movement of the respective plurality of joints, and

wherein the collision inhibiting configuration of the first manipulator comprises a range of alternative configurations within the respective range of movement of the first manipulator, the range of alternative configurations having reduced interference with a given configuration of the second manipulator as compared to the entire range of movement of the first manipulator.

17. The robotic system of claim 14,

wherein each of the first and second manipulators has an associated joint space, and

wherein the collision inhibiting configuration is a subset of the joint space of the first manipulator having reduced interference with a subset of the joint space of the second manipulator as compared to interference between the entire respective joint spaces of the first and second manipulators.

18. The robotic system of claim 17,

wherein each of the first and second manipulators has an associated joint apex, and wherein the subset of the first manipulator comprises a range joint configurations having an upward oriented apex and the subset of the second manipulator comprises a range of joint configurations having a downwardly oriented apex.

19. The robotic system of claim 17,

wherein each subset comprises a range of planar joint configurations in which the respective joints extend substantially along a plane, and wherein the collision-inhibiting configuration comprises the associated planes being offset.

20. A robotic method comprising:

robotically moving a first end effector of a first manipulator assembly, the first manipulator assembly having sufficient degrees of freedom to allow a range of alternative joint states for a position of the first end effector in a workspace;

robotically moving a second end effector of a second manipulator assembly;

generating a signal indicating movement of the second manipulator assembly;

receiving an input for a desired movement of the first end effector within the workspace; and

calculating a movement of the first manipulator assembly in response to the received input for the first desired movement and the signal so that the first end effector effects the first desired movement and so that the first manipulator moves toward a collision inhibiting configuration to inhibit a collisions between the first and second manipulator assemblies prior to any determination of contact or near contact between the first and second manipulators.