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

• US 8,624,537 B2
• Filed: 07/01/2011
• Issued: 01/07/2014
• 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:
  US13/175,498
• Publication Number:
  US 20110276059A1
• Time in Patent Office: 921 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 tele-surgical system comprising:

a first manipulator assembly comprising a first surgical instrument supported by a first manipulator, wherein the first surgical instrument includes a proximal end, a distal end effector suitable for insertion into a patient, and an intermediate portion between the proximal end and the distal end effector, wherein the

first manipulator is configured to support the proximal end of the first surgical instrument so as to move the first surgical instrument from outside the patient wherein the first manipulator assembly includes a plurality of driven joints, the plurality of driven joints providing sufficient degrees of freedom to allow a range of joint states for a position of the end effector while the intermediate portion passes through an access site, and wherein a range of configurations for the first manipulator assembly includes a first pre-determined configuration;

an input for receiving a movement command to effect a desired movement of the end effector of the first surgical instrument within a surgical workspace;

a second manipulator assembly comprising a second surgical instrument supported by a second manipulator, wherein a range of configurations for the second manipulator assembly includes a second pre-determined configuration that is different from the first pre-determined configuration such that when the first manipulator assembly having the first configuration is disposed adjacent the second manipulator assembly in the second configuration, overall configurations of the system in which first and second manipulators collide are reduced; and

a processor coupling the input to the first manipulator assembly,

wherein the processor is configured to determine movements of the plurality of driven joints in response to the movement command so that the intermediate portion of the first surgical instrument is within the access site during the desired movement of the end effector, wherein the processor is configured to move the second manipulator assembly in response to commands of the processor, and

wherein the processor is configured to calculate movements of the plurality of driven joints in response to signals associated with movement of the second manipulator assembly so that the first manipulator assembly driven to the first pre-determined configuration is disposed adjacent the second manipulator assembly driven to the second pre-determined configuration so as to inhibit collisions between the first manipulator and the second manipulator.

2. The tele-surgical system of claim 1, wherein the processor is configured to calculate movements of the plurality of driven joints of the first manipulator assembly so as to drive the first manipulator assembly toward the first configuration concurrent with the second manipulator assembly being disposed in the second configuration so as to inhibit manipulator collisions.

3. The tele-surgical system of claim 1, wherein the processor is configured to calculate the desired end effector movement by driving the first manipulator assembly to a primary solution, the primary solution being underconstrained;

and

wherein the processor comprises a configuration-dependent filter for a secondary control task, the processor driving the first manipulator assembly toward desired combinations of joint states that achieve the primary solution and the secondary control task using the configuration-dependent filter.

4. The tele-surgical system of claim 1, wherein the processor embodies instructions for:

a) effecting master-slave movement of the end effector in response to movement of the input;

b) constraining motion of the intermediate portion so as to inhibit injury to tissues adjacent the access site; and

c) urging the first manipulator assembly toward a pre-determined collision-inhibiting pose;

wherein the instructions for a)-c) over-constrain the joints.

5. The tele-surgical system of claim 4, wherein the processor defines a task priority, wherein the processor is configured to drive the plurality of driven joints to states complying with at least a selected higher priority one of a)-c) per the priority.

6. The tele-surgical system of claim 5, the processor compromising at least a lower-priority one of a)-c) per the priority.

7. The tele-surgical system of claim 1, wherein a position of the access site is at least in part determined from movement of the first surgical instrument.

8. The tele-surgical system of claim 1, wherein the processor has a port stiffness factor, and wherein the processor is configured to calculate movements of the plurality of driven joints of the first manipulator assembly so as to inhibit movement of a pivotal center of the intermediate portion in response to the port stiffness factor.

9. The tele-surgical system of claim 1, further comprising a sensor system transmitting a signal to the processor, the signal indicating at least one of:

a position of the access site, and

a reactive force between the intermediate portion of the first surgical instrument and a minimally invasive aperture.

10. The tele-surgical system of claim 9, wherein the sensor system comprises a cannula force sensor or at least one manipulator joint torque sensor of the first manipulator assembly.

11. The tele-surgical system of claim 10, wherein the processor comprises a hybrid force/position controller, and wherein the processor is configured to compensate for movement of the access site using the reactive force.

12. The tele-surgical system of claim 10, wherein the processor comprises a hybrid force/position controller, and wherein the processor is configured to assist in retracting a cannula by applying the reactive force perpendicular to an axis of the cannula.

13. The tele-surgical system of claim 1, wherein the processor is configured to calculate movements of the plurality of driven joints of the first manipulator assembly in response to signals from at least one other manipulator assembly so as to inhibit collisions between the manipulators during movement of the manipulator assemblies.

14. The tele-surgical system of claim 13, wherein the processor is configured to individually calculate movements of a respective manipulator assembly towards the first or second configurations in response to signals from at least one adjacent manipulator assembly so as to inhibit collisions between the first and second manipulators during movement of the manipulator assemblies.

15. The tele-surgical system of claim 14, wherein the processor is configured to simultaneously calculate joint movements of the first and second manipulator assemblies towards the respective configurations in response to signals associated with movement of the first and second manipulator assemblies so as to inhibit collisions.

16. The tele-surgical system of claim 15, wherein the processor is configured to calculate a pose of each of the first and second manipulator assemblies in response to signals from each other manipulator assembly so as to globally configure the manipulator assemblies.

17. The tele-surgical system of claim 13, wherein the first and second configuration each comprise a substantially planar configuration with a plurality of links of the respective manipulator extending along a plane, wherein the first and second configurations comprise a first and second planar configuration having a lateral and/or an angular offset therebetween, and wherein the processor is configured to drive the first and second manipulator assemblies toward the first and second planar configurations, respectively, with the lateral and/or angular offset maintained so as to inhibit collisions between the manipulators.

18. The tele-surgical system of claim 1, wherein a position of the access site is at least in part input to the processor by actuating a button and manually articulating the manipulator so that the first manipulator assembly is aligned with the access site.

19. The tele-surgical system of claim 1, wherein each of the first and second configurations comprise a substantially planar profile, and wherein the planar profile associated with the first configuration comprises a lateral and/or angular offset from the planar profile of the second configuration such that overall configurations of the system in which first and second manipulators collide are reduced.

20. The tele-surgical system of claim 1, wherein a joint of the plurality of driven joints of the first manipulator assembly in the first configuration defines an apex generally oriented in a first direction, and wherein a joint of the second manipulator assembly in the second configuration defines an apex generally oriented in a second direction opposing the first direction such that overall configurations of the system in which first and second manipulators collide are reduced.

21. The tele-surgical system of claim 20, wherein the first direction is generally upwards and the second direction is generally downwards.

22. A tele-surgical system comprising:

a first manipulator assembly comprising a first surgical instrument supported by a first manipulator, wherein the first surgical instrument includes a proximal end, a distal end effector suitable for insertion into a patient, and an intermediate portion between the proximal end and the distal end effector, wherein the first manipulator is configured to support the proximal end of the first surgical instrument so as to move the first surgical instrument from outside the patient, wherein the first manipulator assembly includes a plurality of driven joints, the plurality of driven joints providing sufficient degrees of freedom to allow a range of joint states for a position of the distal end effector while the intermediate portion passes through an access site;

an input for receiving a movement command to effect a desired movement of the distal end effector of the first surgical instrument within a surgical workspace;

a processor coupling the input to the first manipulator assembly, the processor configured to determine movements of the plurality of driven joints in response to the movement command so that the intermediate portion of the first surgical instrument is within the access site during the desired movement of the end effector; and

a second manipulator assembly comprising a second surgical instrument supported by a second manipulator, the second manipulator moving the second surgical instrument in response to 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 signals associated with movement of the second manipulator assembly so as to inhibit collisions between the first and second manipulators during movement of the first and second manipulator assemblies,

wherein the range of configurations for each of the first and second manipulator assemblies includes a first configuration and a second configuration, a joint of the respective manipulator assembly in the first configuration defining a generally upwardly oriented apex, the joint in the second configuration defining a generally downwardly oriented apex, wherein the processor is configured to drive the first and second manipulator assemblies so that the first manipulator assembly in the first configuration is disposed adjacent the second first manipulator assembly in the second configuration.