Ribbed force sensor

• US 9,952,107 B2
• Filed: 12/09/2013
• Issued: 04/24/2018
• 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., Hasser, Christopher J.
• Primary Examiner(s): Jackson, Gary
• Assistant Examiner(s): Nganga, Boniface N
• Application Number:
  US14/100,924
• Publication Number:
  US 20140137667A1
• Time in Patent Office: 1,597 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: A61B 90/06 Measuring instruments not otherwise provided for
• CPC Class Codes: G01L 1/246 using integrated gratings, e.g. Bragg gratings

Abstract

In one embodiment, a force sensor apparatus is provided including a tube portion having a plurality of radial ribs and a strain gauge positioned over each of the plurality of radial ribs, a proximal end of the tube portion that operably couples to a shaft of a surgical instrument that operably couples to a manipulator arm of a robotic surgical system, and a distal end of the tube portion that proximally couples to a wrist joint coupled to an end effector.

Claims

1. A force sensor apparatus comprising:

a tube portion including an outer surface and a lengthwise axis, the tube portion being a shaft of a surgical instrument, and the outer surface extending in a direction of the lengthwise axis, the shaft of the surgical instrument extending between a housing of the surgical instrument and a joint of the surgical instrument;

a plurality of radial ribs, the plurality of radial ribs being inside the tube portion, each radial rib of the plurality of radial ribs extending lengthwise in the direction of the lengthwise axis, and each radial rib of the plurality of radial ribs extending radially along a radius of the tube portion to the tube portion, a first surface of a first radial rib in the plurality of radial ribs, a second surface of a second radial rib in the plurality of radial ribs, and a portion of inner surface of the tube portion bounding a through-passage within the tube portion;

a plurality of strain gauges, each strain gauge in the plurality of strain gauges being at the outer surface, each strain gauge in the plurality of strain gauges being positioned and aligned lengthwise with a corresponding radial rib of the plurality of radial ribs; and

a cable extending from the housing through the through-passage to the joint.

2. The apparatus of claim 1, wherein the plurality of radial ribs are comprised of a material selected from a group consisting of metal alloys, treated metals, and plated metals.

3. The apparatus of claim 1, wherein the plurality of radial ribs includes one plurality selected from the group consisting of four ribs spaced apart by about 90 degrees about the lengthwise axis of the tube portion and three ribs spaced apart by about 120 degrees about the lengthwise axis of the tube portion.

4. The apparatus of claim 1, wherein the plurality of radial ribs includes two ribs spaced apart by 110 degrees about the lengthwise axis of the tube portion and two ribs spaced apart by 70 degrees about the lengthwise axis of the tube portion.

5. The apparatus of claim 1, wherein each strain gauge of the plurality of strain gauges is aligned with one other strain gauge of the plurality of strain gauges along an axis parallel to the lengthwise axis of the tube portion.

6. The apparatus of claim 1, wherein a primary strain sensing direction of each of the plurality of strain gauges is oriented parallel to the lengthwise axis of the tube portion.

7. The apparatus of claim 1, wherein the plurality of strain gauges is selected from the group consisting of a Fabry-Perot strain gauge and a fiber Bragg grating strain gauge.

8. The apparatus of claim 1, wherein the plurality of strain gauges are positioned in a plurality of grooves in the outer surface.

9. The apparatus of claim 1, further comprising at least one aperture on the outer surface of the tube portion, wherein the aperture is spaced between individual stain gauges in the plurality of strain gauges, and wherein the aperture exposes at least one of the plurality of radial ribs.

10. The apparatus of claim 1, further comprising a thermal shunt shell over the outer surface of the tube portion, and a fluid filled gap between an inner surface of the thermal shunt shell and the outer surface of the tube portion.

11. The apparatus of claim 10, further comprising an insulating material over the thermal shunt shell.

12. The apparatus of claim 10, further comprising a light reflective coating over the thermal shunt shell.

13. The apparatus of claim 1, further comprising a central through passage along a lengthwise axis of the tube portion.

14. A force sensor apparatus comprising:

a first tube portion including an outer surface and a lengthwise axis, the first tube portion being a shaft of a surgical instrument, and the outer surface extending in a direction of the lengthwise axis, the shaft of the surgical instrument extending between a housing of the surgical instrument and a joint of the surgical instrument;

a second tube portion, the second tube portion being positioned inside the first tube portion;

a plurality of ribs, the plurality of ribs being inside the first tube portion and outside the second tube portion, each of the plurality of ribs extending radially along a radius of the first tube portion and extending from the second tube portion to the first tube portion, and each rib of the plurality of ribs extending lengthwise in the direction of the lengthwise axis, a first surface of a first radial rib in the plurality of ribs, a second surface of a second radial rib in the plurality of ribs, a portion of inner surface of the first tube portion, and a portion of an outer surface of the second tube portion bounding a through-passage within the first tube portion;

a plurality of strain gauges, each strain gauge in the plurality of strain gauges being at the outer surface of the first tube portion, each strain gauge in the plurality of strain gauges being positioned and aligned lengthwise with a corresponding rib of the plurality of ribs; and

a cable extending from the housing through the through-passage to the joint.

15. The apparatus of claim 14, wherein the plurality of ribs are comprised of a material selected from a group consisting of metal alloys, treated metals, and plated metals.

16. The force sensor apparatus of claim 14, wherein the plurality of ribs includes two ribs spaced apart by 110 degrees about the lengthwise axis of the first tube portion and two ribs spaced apart by 70 degrees about the lengthwise axis of the first tube portion.

17. The apparatus of claim 14, wherein each strain gauge of the plurality of strain gauges is aligned with one other strain gauge of the plurality of strain gauges along an axis parallel to the lengthwise axis of the first tube portion.

18. The apparatus of claim 14, further comprising a shell positioned over the outer surface of the first tube portion to form a gap between an inner surface of the shell and the outer surface of the first tube portion.

19. The apparatus of claim 14, further comprising at least one aperture on the outer surface of the first tube portion, wherein the aperture is spaced between individual stain gauges in the plurality of strain gauges, and wherein the aperture exposes at least one of the plurality of ribs.