Force sensor temperature compensation

• US 9,855,102 B2
• Filed: 09/20/2013
• Issued: 01/02/2018
• Est. Priority Date: 12/18/2007
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Blumenkranz, Stephen J.
• Primary Examiner(s): Jackson, Gary
• Assistant Examiner(s): Nganga, Boniface N
• Application Number:
  US14/032,491
• Publication Number:
  US 20140088614A1
• Time in Patent Office: 1,565 Days
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2090/064 for measuring force, pressure or mechanical tension
• 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: G01L 1/00 Measuring force or stress, in general measuring force due to impact G01L5/00

Abstract

A force sensor apparatus includes a tube portion having a plurality of radial ribs and at least one fiber optic strain gauge positioned over each of the plurality of radial ribs. The strain gauges comprise a negative thermo-optic coefficient optical fiber material. A proximal end of the tube portion is operably couplable to a shaft of a surgical instrument and a distal end of the tube portion is proximally couplable to a wrist joint. Optionally, a thermal shunt shell is over an outer surface of the tube portion. Adjacent fiber optic strain gauges with differing thermal responses are used to solve simultaneous equations in strain and temperature to derive strain while rejecting thermal effects.

Claims

1. A surgical instrument, comprising:

a housing portion that interfaces with a manipulator arm of a robotic surgical system;

a wrist joint;

a tubular shaft comprising a proximal end, a distal end, a lengthwise axis, a lengthwise outer surface extending from the proximal end to the distal end, and a distal portion of the tubular shaft including the distal end, the lengthwise axis extending from the proximal end to the distal end, the proximal end of the tubular shaft being operably coupled to the housing portion, the distal end of the tubular shaft being operably coupled to the wrist joint, the distal portion including a plurality of radial ribs, each of the plurality of radial ribs extending along the lengthwise axis of the tubular shaft, the plurality of radial ribs forming through-passages within the tubular shaft;

a plurality of strain gauges, each strain gauge of the plurality of strain gauges being mounted on the lengthwise outer surface of the distal portion of the tubular shaft and each of the plurality of strain gauges being positioned over a different one of the plurality of radial ribs;

one or more cables extending from the housing portion through at least one of the through-passages to the wrist joint; and

an end effector operably coupled to the wrist joint.

2. The instrument of claim 1, wherein the distal portion of the tubular shaft is a tube made of a material selected from a group consisting of a copper alloy, an aluminum alloy, and a silver alloy.

3. The instrument of claim 1, wherein each of the plurality of strain gauges is comprised of a negative thermo-optic coefficient optical fiber material.

4. The instrument of claim 1, wherein the housing portion interfaces with a sterile adaptor that interfaces with the manipulator arm.

5. The instrument of claim 1, further comprising a thermal shunt shell over the lengthwise outer surface of the distal portion of the tubular shaft.

6. The instrument of claim 5, wherein the thermal shunt shell is comprised of a material selected from a group consisting of an aluminum alloy, a copper alloy, and a silver alloy.

7. The instrument of claim 5, further comprising one of a fluid-filled gap and an evacuated gap between an inner surface of the thermal shunt shell and the outer lengthwise surface of the distal portion of the tubular shaft.

8. The instrument of claim 5, further comprising a compliant elastomer ring between an inner surface of the thermal shunt shell and the outer lengthwise surface of the distal portion of the tubular shaft.

9. The instrument of claim 5, further comprising an annular ring comprised of a metal material that thermally connects the thermal shunt shell to the distal tube portion at a point midway between a pair of axially-separated strain gauges.

10. The instrument of claim 5, wherein ends of the thermal shunt shell are thermally isolated from the distal portion of the tubular shaft.

11. The instrument of claim 5, further comprising one of an insulating material and a light reflective surface or coating over the thermal shunt shell.

12. The instrument of claim 1, further comprising at least one aperture in the outer surface of the distal portion of the tubular shaft, wherein the aperture is spaced between a first strain gauge of the plurality of strain gauges positioned over a first radial rib of the plurality of radial ribs and a second strain gauge of the plurality strain gauges positioned over a second radial rib of the plurality of radial ribs, and wherein the aperture exposes at least one of the first radial rib and the second radial rib of the plurality of radial ribs.

13. The instrument of claim 1, further comprising a second plurality of strain gauges, a different strain gauge of the second plurality of strain gauges being positioned over each of the plurality of radial ribs, the second plurality of strain gauges being displaced from the plurality of strain gauges along the lengthwise axis of the tubular shaft.