Robotic surgery system including position sensors using fiber bragg gratings

• US 9,066,739 B2
• Filed: 03/16/2011
• Issued: 06/30/2015
• Est. Priority Date: 12/30/2005
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Larkin, David Q., Shafer, David C.
• Primary Examiner(s): Nguyen, John Q
• Assistant Examiner(s): KIM, KYUNG J
• Application Number:
  US13/049,012
• Publication Number:
  US 20110224825A1
• Time in Patent Office: 1,567 Days
• Field of Search: 700/245, 700/254
• US Class Current: 1/1
• CPC Class Codes: A61B 1/009 with bending or curvature detection of the insertion part
• CPC Class Codes: A61B 2017/00057 Light
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/0477 with pre-tied sutures
• CPC Class Codes: A61B 2017/2906 Multiple forceps
• CPC Class Codes: A61B 2034/2048 using an accelerometer or inertia sensor
• CPC Class Codes: A61B 2034/2059 Mechanical position encoders
• CPC Class Codes: A61B 2034/2061 using shape-sensors, e.g. fiber shape sensors with Bragg gratings
• CPC Class Codes: A61B 2034/2065 Tracking using image or pattern recognition
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2090/3614 using optical fibre
• CPC Class Codes: A61B 34/20 Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis
• 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 90/30 Devices for illuminating a surgical field, the devices having an interrelation with other surgical devices or with a surgical procedure
• CPC Class Codes: A61B 90/361 Image-producing devices, e.g. surgical cameras
• CPC Class Codes: B25J 18/06 flexible
• CPC Class Codes: B25J 19/025 including optical fibres
• CPC Class Codes: B25J 9/1635 flexible-arm control
• CPC Class Codes: Y10S 901/09 : Closed loop, sensor feedback controls arm movement
• CPC Class Codes: Y10S 901/28 : Joint
• CPC Class Codes: Y10S 901/46 : Sensing device
• CPC Class Codes: Y10S 901/47 : Optical
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 74/20305 : Robotic arm

Abstract

A surgical instrument is provided, including: at least one articulatable arm having a distal end, a proximal end, and at least one joint region disposed between the distal and proximal ends; an optical fiber bend sensor provided in the at least one joint region of the at least one articulatable arm; a detection system coupled to the optical fiber bend sensor, said detection system comprising a light source and a light detector for detecting light reflected by or transmitted through the optical fiber bend sensor to determine a position of at least one joint region of the at least one articulatable arm based on the detected light reflected by or transmitted through the optical fiber bend sensor; and a control system comprising a servo controller for effectuating movement of the arm.

Claims

1. A calibration method for a surgical instrument mounted on a robotic manipulator comprising:

positioning the surgical instrument using a control system in a minimally invasive surgical system, wherein the surgical instrument comprises;

an elongate arm having a joint region, and

an optical fiber bend sensor positioned in a sensor region that is at least in part within the joint region, wherein the optical fiber bend sensor translates axially relative to the joint region in response to bending of the joint region, and wherein a length of the sensor region exceeds a length of the joint region;

determining a measured location of the surgical instrument based on information from the optical fiber bend sensor;

determining an expected location of the surgical instrument based on the positioning; and

generating a kinematic error map of the elongate arm using the measured location and the expected location.

2. The calibration method of claim 1, further comprising:

performing the positioning, the determinings, and the generating prior to use of the surgical instrument.

3. The calibration method of claim 1, further comprising:

performing the positioning, the determinings, and the generating in the manufacturing process following assembly of the surgical instrument.

4. The calibration method of claim 1, further comprising:

storing the kinematic error map in a non-volatile memory.

5. The calibration method of claim 1, wherein the optical fiber bend sensor comprises a plurality of optical fiber cores in an optical fiber, and each optical fiber core comprises a Fiber Bragg Grating region.

6. The calibration method of claim 1, wherein upon the axial translation of the optical fiber bend sensor, the determining the measured location includes:

sensing light from a first portion of a length of the optical fiber bend sensor, wherein the first portion is strained by the bending of the joint region; and

sensing light from a second portion of the length of the optical fiber bend sensor wherein the second portion is axially outside of the joint region and so is unstrained by the bending of the joint region.

7. The calibration method of claim 6, wherein the determining a measured location of the surgical instrument further comprises:

detecting a reflectance spectrum from the optical fiber bend sensor, wherein the reflectance spectrum includes first reflected light from the first portion of the optical fiber bend sensor and second reflected light from the second portion of the optical fiber bend sensor, and the first reflected light and the second reflected light add coherently to form the reflectance spectrum.

8. The calibration method of claim 7:

wherein the first reflected light is shifted in wavelength, and the second reflected light is not shifted in wavelength, and

wherein the determining a measured location of the surgical instrument further comprises analyzing a shape of the reflectance spectrum.

9. The calibration method of claim 1:

wherein the optical bend sensor is positioned in a channel;

wherein a length of the optical fiber bend sensor along an axis of the channel is longer than a length of the joint region along the axis of the channel, and wherein upon the translation of the optical fiber bend sensor, the determining the measured location includes;

sensing light from a first portion of the length of the optical fiber bend sensor, wherein the first portion is within the entire length of the joint region and is strained by the bending of the joint region; and

sensing light from a second portion of the length of the optical fiber bend sensor, wherein the second portion is axially outside the length of the joint region and so is unstrained by the bending of the joint region.

10. The calibration method of claim 1:

wherein an optic fiber including the optical fiber bend sensor is positioned in a channel of the elongate arm; and

wherein a longitudinal axis of the channel is a neutral axis of the elongate arm.

11. An apparatus comprising:

a robotic manipulator; and

a surgical instrument mounted on the robotic manipulator,

the surgical instrument comprising;

an elongate arm having a joint region;

an optical fiber bend sensor positioned in a sensor region that is at least in part within the joint region, wherein the optical fiber bend sensor translates axially relative to the joint region in response to bending of the joint region, and wherein a length of the sensor region exceeds a length of the joint region; and

a memory having stored therein a kinematic error map of the elongate arm, wherein the kinematic error map is created by;

positioning the surgical instrument using a control system in a minimally invasive surgical system;

determining a measured location of the surgical instrument based on information from the optical fiber bend sensor;

determining an expected location of the surgical instrument based on the positioning; and

generating the kinematic error map of the elongate arm using the measured location and the expected location.

12. The apparatus of claim 11, wherein the surgical instrument is configured such that upon the axial translation of the optical fiber bend sensor, a first portion of a length of the optical fiber bend sensor is strained by the bending of the joint region;

and a second portion of the length of the optical fiber bend sensor translates axially outside of the joint region and is unstrained by the bending of the joint region.

13. The apparatus of claim 11:

wherein a length of the optical fiber bend sensor along an axis of a channel in the elongate arm is longer than a length of the joint region along the axis of the channel; and

wherein the surgical instrument is configured such that upon the translation of the optical fiber bend sensor, a first portion of the length of the optical fiber bend sensor is within the entire length of the joint region and is strained by the bending of the joint region; and

a second portion of the length of the optical fiber bend sensor is outside the length of the joint region and is unstrained by the bending of the joint region.

14. A method for a surgical instrument mounted on a robotic manipulator comprising:

generating a kinematic error map of a elongate arm of the surgical instrument using location data and expected location data,

wherein the location data is determined based on information from an optical fiber bend sensor positioned in a sensor region that is at least in part within a joint region of the elongate arm, wherein the optical fiber bend sensor translates axially relative to the joint region in response to bending of the joint region, and wherein a length of the sensor region exceeds a length of the joint region;

wherein the expected location information is determined based on a position of the elongate arm; and

storing the kinematic error map in a memory of the surgical instrument.