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

• US 8,786,241 B2
• Filed: 07/01/2011
• Issued: 07/22/2014
• 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:
  US13/175,458
• Publication Number:
  US 20110264108A1
• Time in Patent Office: 1,117 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 robotic system comprising:

a manipulator assembly configured to robotically move a distal end effector relative to a proximal base, the manipulator assembly having a linkage extending distally between the base and the end effector, the linkage having a plurality of joints, the plurality of joints being configured to provide sufficient degrees of freedom to allow a range of joint states for a position of the end effector;

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

a force sensor system configured to sense an external articulation of at least one joint of the plurality of joints, the external articulation comprising a force applied against the manipulator assembly by a tissue adjacent a minimally invasive access site in a patient; and

a processor coupling the input to the manipulator assembly and coupled to the force sensing system, the processor being configured to determine movements of the plurality of joints in response to the command so as to move the end effector with the desired movement, the processor being further configured to drive at least one other joint of the plurality of joints in response to the external articulation sensed by the force sensor system such that the commanded desired movement of the end effector is maintained.

2. The system of claim 1, wherein the processor comprises a master-slave controller that comprises a hybrid velocity/force master-slave controller configured to effect the desired movement by calculating joint velocity commands in response to the command, joint states of the plurality of joints, and a sensed force between the manipulator assembly and the tissue.

3. The system of claim 1, further comprising:

a cannula configured to be disposed within a minimally invasive aperture at the minimally invasive access site, the cannula being further configured to receive a shaft of the manipulator assembly therethrough, the shaft being configured to support the end effector; and

wherein the force sensor system comprises a cannula force sensor.

4. The robotic surgical system of claim 3, wherein the processor is configured to move the minimally invasive access site in response to a force sensed by the cannula force sensor.

5. The system of claim 1, wherein the force sensor system comprises joint state sensors.

6. The system of claim 1, wherein the processor is configured to compensate for movement of the minimally invasive aperture by using the sensed external articulation, the movement of the minimally invasive access site being induced by at least one of patient breathing, patient movement, and movement of a surgical table supporting the patient.

7. The system of claim 1, wherein the processor is configured to move the minimally invasive access site in response to a force sensed by the force sensing system at the minimally invasive access site.

8. The system of claim 7,

wherein the manipulator assembly comprises a shaft that pivots about a pivotal center adjacent a minimally invasive aperture at the access site, and

wherein the force sensing system is configured to track changes in a location of the pivotal center, from which changes the processor is configured to identify and compensate for movement of the patient.

9. The system of claim 8, wherein the movement of the patient comprises one or more cyclical physiological movements, the cyclical physiological movements including breathing or a heartbeat of the patient.

10. The system of claim 8, wherein the processor is configured to calculate and store on a memory of the processor a location of the pivotal center and to regularly update the stored calculated location of the pivotal center.

11. The system of claim 7, wherein moving the minimally invasive access site comprises moving a surgical table that supports the patient.

12. The system of claim 8, wherein the processor comprises a master-slave controller that is configured to compensate for the movement of the patient due to one or more cyclical physiological movements.

13. The system of claim 7, wherein moving the minimally invasive access site comprises repositioning the patient on a surgical table.

14. The system of claim 8, wherein the processor comprises a master-slave controller that is configured to compensate for the movement of the patient via moving the surgical table that supports the patient or repositioning of the patient on a surgical table.

15. The robotic system of claim 1, wherein the desired movement of the end effector comprises a commanded position of the end effector.

16. The robotic system of claim 1, wherein the desired movement of the end effector comprises a commanded movement of the end effector.

17. A robotic system comprising:

a manipulator assembly configured to robotically move a distal end effector relative to a proximal base, the manipulator assembly having a linkage extending distally between the base and the distal end effector, the linkage having a plurality of joints;

an input configured to receive commands to effect desired movements of the end effector;

a force sensor system coupled to the manipulator assembly, the force sensor system being configured to sense an external articulation of the manipulator assembly; and

a processor coupling the input to the manipulator assembly and to the force sensor system, the processor being configured to determine movements of the joints in response to the command so as to move the end effector with the desired movements, the processor being further configured to conform with the external articulation of the manipulator assembly when the sensed external articulation exceeds a threshold so that at least some of the movements of the plurality of joints are determined in part in response to the threshold-exceeding external articulation, wherein the processor is configured to conform with the sensed external articulation of the manipulator assembly by driving at least one joint of the plurality of joints in response to the threshold-exceeding external articulation of another joint of the plurality of joints such that the commanded desired movements of the end effector are maintained.

18. The robotic system of claim 17:

wherein the plurality of joints is configured to provide sufficient degrees of freedom to allow a range of joint states for a position of the end effector;

wherein the threshold comprises a threshold force; and

wherein the external articulation effects at least one of;

alignment of a manipulator shaft with an aperture pivotal center,

configuration of the manipulator assembly in a desired pose, or

repositioning of the end effector relative to the base.

19. The robotic system of claim 17, wherein the force sensor system is configured to determine a force applied to a shaft of the manipulator assembly by a side of an aperture along the shaft such that the threshold-exceeding external articulation comprises a sensed force between a patient and the shaft.

20. A robotic method comprising:

receiving a command from an input to effect a desired movement of a distal end effector of a manipulator assembly relative to a proximal base, the manipulator assembly comprising a linkage extending between the base and the distal end effector;

sensing an external articulation of the manipulator assembly that exceeds an articulation force threshold; and

moving the distal end effector relative to the proximal base of the manipulator assembly by robotically articulating a plurality of joints of the linkage of the manipulator assembly;

wherein robotically articulating the plurality of joints comprises determining movements of the plurality of joints in response to the received command so as to move the end effector with the desired movement, and determining movements of the plurality of joints in response to the external articulation that results from exceeding the articulation force threshold by driving at least one joint of the plurality of joints in response to the threshold-exceeding external articulation of another joint of the plurality of joints such that the desired movement of the end effector according to the input command is maintained.

21. A robotic method comprising:

receiving a command from an input to effect a desired state of a distal end effector of a manipulator assembly, the manipulator assembly comprising a linkage extending between a proximal base and the distal end effector, the manipulator assembly being configured to effect the desired state of the end effector according to the received input command, the desired state being a position or motion state of the end effector relative to the base;

sensing an external articulation of a joint of a plurality of joints of the linkage of the manipulator assembly;

determining movements of the plurality of joints in response to the external articulation if the sensed external articulation exceeds an articulation force threshold; and

driving at least one of the joints of the plurality of joints in response to the threshold-exceeding external articulation such that the commanded desired state of the end effector is maintained.

22. The method of claim 21:

wherein the manipulator assembly comprises a surgical instrument shaft;

wherein a pivotal center is defined along the instrument shaft; and

wherein driving at least one of the joints of the plurality of joints further comprises keeping the pivotal center stationary.