Characterising robot environments

• US 9,943,964 B2
• Filed: 05/27/2016
• Issued: 04/17/2018
• Est. Priority Date: 05/29/2015
• Status: Active Grant

• Current Assignee: CMR Surgical Ltd.
• Original Assignee: CMR Surgical Ltd.
• Inventors: Hares, Luke David Ronald
• Primary Examiner(s): Sample, Jonathan L
• Application Number:
  US15/166,449
• Publication Number:
  US 20160346930A1
• Time in Patent Office: 690 Days
• Field of Search: 700245-264, 318567-56825, 901 6, 901 46, 901 50
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/32 operating autonomously
• CPC Class Codes: B25J 9/1679 characterised by the tasks executed
• CPC Class Codes: B25J 9/1682 Dual arm manipulator; Coordination of several manipulators
• CPC Class Codes: B25J 9/1692 Calibration of manipulator
• CPC Class Codes: G05B 2219/39021 With probe, touch reference positions
• CPC Class Codes: G05B 2219/39024 Calibration of manipulator
• CPC Class Codes: G05B 2219/39026 Calibration of manipulator while tool is mounted
• CPC Class Codes: G05B 2219/39047 Calibration plate mounted on robot, plate comprises sensors for measuring target
• CPC Class Codes: G05B 2219/39051 Calibration cooperating manipulators, closed kinematic chain by alignment
• CPC Class Codes: G05B 2219/39135 For multiple manipulators operating at same time, avoid collision
• CPC Class Codes: G05B 2219/39399 Convert position of old, teach to new, changed, actual tool by transform matrix
• CPC Class Codes: Y10S 901/09 Closed loop, sensor feedback controls arm movement
• CPC Class Codes: Y10S 901/15 Jointed arm
• CPC Class Codes: Y10S 901/46 Sensing device

Abstract

A method for characterizing the environment of a robot, the robot having a flexible arm having a plurality of joints, a datum carried by the arm, a plurality of drivers arranged to drive the joints to move and a plurality of position sensors for sensing the position of each of the joints, the method comprising: contacting the datum carried by the arm with a first datum on a second robot in the environment of the first robot, wherein the second robot has a flexible arm having a plurality of joints, and a plurality of drivers arranged to drive those joints to move; calculating in dependence on the outputs of the position sensors a distance between a reference location defined in a frame of reference local to the robot and the first datum; and controlling the drivers to reconfigure the first arm in dependence on at least the calculated distance.

Claims

1. A method of characterising the environment of a first robot, the first robot having a base, a flexible arm extending from the base and having a plurality of joints whereby the configuration of the arm can be altered, a first datum carried by the arm, a plurality of drivers arranged to drive the joints to move and a plurality of position sensors configured to sense the position of each of the joints, the method comprising:

mating the first datum carried by the arm of the first robot with a second datum on a second robot in the environment of the first robot, wherein the second robot has a base, a flexible arm extending from the base and having a plurality of joints whereby the configuration of the arm can be altered, and a plurality of drivers arranged to drive those joints to move, and the datum carried by the arm of the first robot and the datum on the second robot are mutually configured so that the configuration of the first robot arm is dependent on the orientation of the second datum when the datums are mated;

calculating in dependence on the outputs of the position sensors when the first and second datums are mated a distance between a reference location defined in a frame of reference local to the first robot and the second robot and an orientation of the first robot relative to the second robot; and

controlling the drivers to reconfigure the first arm in dependence on at least the calculated distance and orientation.

2. A method as claimed in claim 1, wherein the second datum is on an object on the second robot, and the step of calculating the orientation of the first robot relative to the second robot comprises calculating in dependence on the outputs of the position sensors when the first datum and the second datum are mated an orientation of the second datum relative to a reference direction defined in a frame of reference local to the first robot.

3. A method as claimed in claim 1, wherein the step of calculating is performed in dependence on stored information defining the lengths of the parts of the first robot arm separated by the joints.

4. A method as claimed in claim 1, wherein the step of controlling is performed in dependence on stored information defining the shape of the object.

5. A method as claimed in claim 1, wherein the first and second robots are surgical robots.

6. A method as claimed in claim 1, wherein the step of controlling the drivers to reconfigure the first robot arms in dependence on the calculated distance and/or orientation comprises controlling the drivers so as to inhibit collision between each arm in dependence on the calculated distance and orientation.

7. A method as claimed in claim 1, comprising the step of moving the first datum into contact with the second datum by manipulating the first robot arm through the application of external force directly to that arm.

8. A method as claimed in claim 7, comprising, during the said moving step, automatically controlling the drivers so as to counteract the action of gravity on the first robot arm.

9. A robotic system comprising:

a first and second robot, each comprising;

a base;

a flexible arm extending from the base and having a plurality of joints whereby the configuration of the arm can be altered;

a plurality of drivers arranged to drive the joints to move; and

a plurality of position sensors configured to sense the position of each of the joints;

wherein the first robot further comprises a first datum carried by its arm and the second robot comprises a second datum, the first and second datums being mutually configured so that the configuration of the first robot arm is dependent on the orientation of the second datum when the datums are mated; and

wherein the first robot further comprises a control unit configured to;

(i) calculate, in dependence on the outputs of the position sensors when the first datum carried by the arm of the first robot is mated with the second datum on the second robot, a distance between a reference location defined in a frame of reference local to the first robot and the second robot and an orientation of the first robot relative to the second robot; and

(ii) subsequently control the drivers to reconfigure the first arm in dependence on at least the calculated distance and orientation.

10. A method of characterising the environment of a first and second robot, each of the robots having a base, a flexible arm extending from the base and having a plurality of joints whereby the configuration of the arm can be altered, a plurality of drivers arranged to drive the joints to move and a plurality of sensors configured to sense the positions of each of the joints, wherein the arm of the first robot comprises an interface carrying a first datum, the method comprising:

mating the first datum carried by the interface of the first robot with an interface in the shape of a proximal instrument or endoscope end of a second datum in the environment of the first and second robots, the first datum of the first robot and the second datum being mutually configured so that when the first datum and the second datum are mated the orientation of the first datum is fixed with respect to the orientation of the second datum and the second datum has a known relationship to the second robot arm;

calculating, in dependence on the outputs of the position sensors of the first robot arm when the first datum and the second datum are mated, an orientation and position of the second robot relative to the first robot; and

controlling the drivers to reconfigure at least one of the first and second robot arms in dependence on at least the calculated orientation and/or position.

11. A method as claimed in claim 10, wherein the orientation and distance between the first robot and second robot is calculated in dependence on the outputs of the position sensors of the first robot arm when the first datum and the second datum are mated and the known relationship of the second datum to the second robot arm.

12. A method as claimed in claim 10, wherein the second datum is located on the second robot.

13. A method as claimed in claim 10, wherein the arm of the second robot carries a third datum and the second datum comprises first and second interfaces configured to mate with the first and third datums, the first interface having a known relationship to the second interface, the method further comprising:

mating the first datum with the first interface of the second datum;

mating the third datum with the second interface of the second datum when the second datum is in the same position and orientation as when the first interface was mated with the first datum; and

calculating, in dependence on;

i) the outputs of the position sensors of the first robot arm when the first datum and first interface are mated; and

ii) the outputs of the position sensors of the second robot arm when the third datum and second interface are mated, an orientation and distance between the first and second robot.

14. A method as claimed in claim 10, wherein the second datum has a fixed position and orientation in the environment.

15. A method as claimed in claim 13, wherein the second datum is a mobile block and the first and third datums are mated to the respective first and second interfaces concurrently.

16. A method as claimed in claim 10, wherein the second datum is in the form of a mating surface configured to engage a complementary surface integral with the first robot arm.

17. A method as claimed in claim 10, wherein the method further comprises characterising the environment of a third robot, the third robot comprising a base, a flexible arm extending from the base and having a plurality of joints whereby the configuration of the arm can be altered, a plurality of drivers arranged to drive the joints to move and a plurality of sensors configured to sense the positions of each of the joints, wherein the arm of the third robot carries a fourth datum;

the method further comprising;

mating the fourth datum with an object datum in the environment of the first robot, the fourth datum and the object datum in the environment of the first robot being mutually configured so that when the fourth datum and the object datum in the environment of the first robot are mated the configuration of the third robot arm is dependent on the orientation of said object datum and said object datum has a known relationship to the first robot arm;

calculating, in dependence on the outputs of the position sensors of the third robot arm when the fourth datum and the object datum in the environment of the first robot are mated, an orientation and distance between the first robot and the third robot; and

controlling the drivers to reconfigure at least one of the first and third robot arms in dependence on at least the calculated orientation and/or distance.

18. A method as claimed in claim 17, wherein the method further comprises calculating an orientation and distance between the third robot and second robot in dependence on the calculated orientations and distances between the first and second robots and the third and first robots.

19. A method as claimed in claim 17, wherein the object in the environment of the first robot is located on the first robot.