Ratcheting for master alignment of a teleoperated minimally invasive surgical instrument

• US 9,814,537 B2
• Filed: 01/05/2017
• Issued: 11/14/2017
• Est. Priority Date: 06/30/2009
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Itkowitz, Brandon D., DiMaio, Simon P., Nowlin, William C., Niemeyer, Gunter D., Mintz, David S.
• Primary Examiner(s): Sample, Jonathan L
• Application Number:
  US15/399,600
• Publication Number:
  US 20170112582A1
• Time in Patent Office: 313 Days
• CPC Class Codes: A61B 2017/00725 Calibration or performance testing
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 34/25 User interfaces for surgical systems
• 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 34/77 Manipulators with motion or force scaling
• CPC Class Codes: A61B 90/10 for stereotaxic surgery, e.g. frame-based stereotaxis
• 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 9/1669 characterised by special application, e.g. multi-arm co-operation, assembly, grasping
• CPC Class Codes: B25J 9/1689 Teleoperation
• CPC Class Codes: G05B 2219/45117 Medical, radio surgery manipulator
• CPC Class Codes: Y10S 901/27 Arm part
• CPC Class Codes: Y10S 901/41 Tool

Abstract

A minimally-invasive surgical system includes a slave surgical instrument having a slave surgical instrument tip and a master grip. The slave surgical instrument tip has an alignment in a common frame of reference and the master grip, which is coupled to the slave surgical instrument, has an alignment in the common frame of reference. An alignment error, in the common frame of reference, is a difference in alignment between the alignment of the slave surgical instrument tip and the alignment of the master grip. A ratcheting system (i) coupled to the master grip to receive the alignment of the master grip and (ii) coupled to the slave surgical instrument, to control motion of the slave by continuously reducing the alignment error, as the master grip moves, without autonomous motion of the slave surgical instrument tip and without autonomous motion of the master grip.

Claims

1. A teleoperated system comprising:

a master grip; and

a ratcheting system coupled to the master grip and configured to be coupled to a slave surgical instrument having a slave surgical instrument tip, the ratcheting system being configured to align the master grip with the slave surgical instrument tip,

the ratcheting system comprising;

an introduce control system error controller configured to introduce a control system error between a slave surgical instrument tip alignment and a master grip alignment to speed up convergence of alignment between the slave surgical instrument tip and the master grip relative to convergence of alignment between the slave surgical instrument tip and the master grip without introduction of the control system error.

2. The teleoperated system of claim 1, the ratcheting system being configured to use a new alignment error to control motion of the slave surgical instrument tip only if the new alignment error is smaller than a current alignment error.

3. The teleoperated system of claim 2, wherein the introduce control system error controller configured to introduce a control system error comprises:

the introduce control system error controller being configured to artificially adjust a commanded angular velocity of the slave surgical instrument tip.

4. The teleoperated system of claim 3, the ratcheting system being configured to characterize a rotation angle error between an alignment of the master grip and an alignment of the slave surgical instrument tip.

5. The teleoperated system of claim 4, wherein the introduce control system error controller being configured to artificially adjust the commanded angular velocity of the slave surgical instrument tip comprises:

the introduce control system error controller being configured to adjust the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error.

6. The teleoperated system of claim 5, wherein the introduce control system error controller being configured to adjust the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error comprises:

the introduce control system error controller being configured to penalize the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error and an angular velocity scale factor.

7. The teleoperated system of claim 6, wherein the introduce control system error controller being configured to penalize the commanded angular velocity comprises:

the introduce control system error controller being configured to select the angular velocity scale factor based on the rotation angle error, wherein the angular velocity scale factor increases as the rotation angle error decreases so that the commanded angular velocity increases as the rotation angle error decreases.

8. The teleoperated system of claim 6, wherein the introduce control system error controller being configured to penalize the commanded angular velocity comprises:

the introduce control system error controller being configured to select the angular velocity scale factor from a continuous and monotonic angular velocity penalty profile.

9. The teleoperated system of claim 5, wherein the introduce control system error controller being configured to adjust the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error comprises:

the introduce control system error controller being configured to penalize the commanded angular velocity of the slave surgical instrument tip using an angular velocity penalty profile.

10. The teleoperated system of claim 9, wherein the angular velocity penalty profile comprises a continuous and monotonic angular velocity penalty profile.

11. The teleoperated system of claim 9, wherein the angular velocity penalty profile is the same for all users of the teleoperated system.

12. The teleoperated system of claim 4:

wherein the rotation angle error is expressed as;

θ

_e=cos<sup>−

1</sup>[0.5*(R<sub>Δ

11</sub>+R<sub>Δ

22</sub>+R<sub>Δ

33</sub>−

1)], and

wherein R<sub>Δ

11</sub>, R<sub>Δ

22</sub>, R<sub>Δ

33</sub> are diagonal elements of a relative rotation matrix R_Δ

.

13. The teleoperated system of claim 4, wherein the rotation angle error is one Euler angle in a set of Euler angles.

14. The teleoperated system of claim 1, the master grip comprising an unpowered master grip.

15. The teleoperated system of claim 1, the master grip comprising a powered master grip.

16. The teleoperated system of claim 2, the ratcheting system being configured to determine and use the new alignment error while the master grip is used to control the slave surgical instrument tip.

17. A method comprising:

aligning, by a controller, a master grip of a teleoperated system with a slave surgical instrument tip of a slave surgical instrument of the teleoperated system by introducing a control system error between a slave surgical instrument tip alignment and a master grip alignment to speed up convergence of alignment between the slave surgical instrument tip and the master grip relative to convergence of alignment between the slave surgical instrument tip and the master grip using without introducing the control system error.

18. The method of claim 17, wherein the introducing a control system error comprises:

adjusting artificially a commanded angular velocity of the slave surgical instrument tip.

19. The method of claim 18, wherein the adjusting artificially the commanded angular velocity of the slave surgical instrument tip comprises:

adjusting the commanded angular velocity of the slave surgical instrument tip based on a rotation angle error between a first alignment of the master grip and a first alignment of the slave surgical instrument tip.

20. The method of claim 19, wherein the adjusting the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error comprises:

penalizing the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error and an angular velocity scale factor.

21. The method of claim 19, wherein the adjusting the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error comprises:

penalizing the commanded angular velocity of the slave surgical instrument tip using an angular velocity penalty profile.

22. A non-transitory computer program product having embedded therein executable instructions for a method comprising:

aligning a master grip of a teleoperated system with a slave surgical instrument tip of a slave surgical instrument of the teleoperated system by introducing a control system error between a slave surgical instrument tip alignment and a master grip alignment to speed up convergence of alignment between the slave surgical instrument tip and the master grip relative to convergence of alignment between the slave surgical instrument tip and the master grip using without introducing the control system error.

23. The non-transitory computer program product of claim 22, wherein the introducing a control system error comprises:

adjusting artificially a commanded angular velocity of the slave surgical instrument tip.

24. The non-transitory computer program product of claim 23, wherein the adjusting artificially the commanded angular velocity of the slave surgical instrument tip comprises:

adjusting the commanded angular velocity of the slave surgical instrument tip based on a rotation angle error between a first alignment of the master grip and a first alignment of the slave surgical instrument tip.

25. The non-transitory computer program product of claim 24, wherein the adjusting the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error comprises:

penalizing the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error and an angular velocity scale factor.

26. The non-transitory computer program product of claim 24, wherein the adjusting the commanded angular velocity of the slave surgical instrument tip based on the rotation angle error comprises:

penalizing the commanded angular velocity of the slave surgical instrument tip using an angular velocity penalty profile.