Methods, systems, and devices for controlling a motor of a robotic surgical system

• US 9,968,412 B2
• Filed: 08/16/2016
• Issued: 05/15/2018
• Est. Priority Date: 08/16/2016
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery LLC (Johnson & Johnson)
• Inventors: Overmyer, Mark D., Yates, David C., Shelton, IV, Frederick E., Harris, Jason L., Swayze, Jeffrey S.
• Primary Examiner(s): Masih, Karen
• Application Number:
  US15/237,657
• Publication Number:
  US 20180049814A1
• Time in Patent Office: 637 Days
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/302 specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2090/064 for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 2090/066 for measuring torque
• 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 46/10 specially adapted for instruments, e.g. microscopes

Abstract

Various exemplary methods, systems, and devices for controlling a motor of a robotic surgical system are provided.

Claims

1. A surgical system, comprising:

a surgical tool having a housing configured to removably and replaceably couple to a robotic surgical system, an elongate shaft extending distally from the housing, an end effector at a distal end of the shaft configured to perform a function in a body of a patient, the surgical tool being configured to receive a torque from the robotic surgical system when removably and replaceably coupled to the robotic surgical system, the surgical tool being configured to limit a maximum torque delivered from the robotic surgical system to the surgical tool by sensing at least a current applied by the robotic surgical system to the surgical tool, and the surgical tool is configured to limit the maximum torque in response to the sensed current exceeding a predetermined threshold current.

2. The system of claim 1, further comprising a motor of the robotic surgical system, the motor being configured to drive the torque, the sensed current applied by the robotic surgical system to the surgical tool exceeding the predetermined threshold causing the motor to slow down and thereby limit the maximum torque.

3. The system of claim 1, further comprising a motor of the robotic surgical system, the motor being configured to drive the torque, the motor including first and second wire windings around first and second magnets that contribute to generation of an electromagnetic field, the sensed current applied by the robotic surgical system to the surgical tool exceeding the predetermined threshold causing one of the first and second wire windings to no longer contribute to the generation of the electromagnetic field and thereby limit the maximum torque.

4. The system of claim 1, wherein the surgical tool is configured to generate a current in response to receipt of the torque from the robotic surgical system, and the surgical tool is configured to deliver the generated current to the robotic surgical system to limit the maximum torque.

5. The system of claim 4, wherein the shaft has a wire wound therearound that is configured to generate the current in response to the shaft rotating.

6. The system of claim 4, further comprising a motor of the robotic surgical system, the motor being configured to drive the torque, and the generated current delivered to the robotic surgical system is configured to cause the motor to provide less torque to the surgical tool.

7. The system of claim 6, further comprising a switch of the robotic surgical system that is operatively coupled to the motor, and the generated current delivered to the robotic surgical system exceeding the predetermined threshold current is configured to actuate the switch and thereby cause the motor to provide less torque to the surgical tool.

8. The system of claim 6, wherein the motor has first and second wire windings around first and second magnets that contribute to generation of an electromagnetic field, and the generated current delivered to the robotic surgical system exceeding the predetermined threshold current is configured to cause one of the first and second wire windings to no longer contribute to the generation of the electromagnetic field and thereby limit the maximum applicable torque.

9. A surgical system, comprising:

a surgical tool having a housing configured to removably and replaceably couple to a robotic surgical system, an elongate shaft extending distally from the housing, an end effector at a distal end of the shaft configured to perform a function in a body of a patient, the surgical tool being coupled to the robotic surgical system, the surgical tool being configured to limit a maximum torque delivered from the robotic surgical system to the surgical tool by sensing at least a speed of rotation of the shaft, and the surgical tool is configured to limit the maximum torque in response to the sensed speed of rotation exceeding a predetermined threshold speed of rotation.

10. The system of claim 9, further comprising a motor of the robotic surgical system, the motor being configured to drive the torque, the sensed speed of rotation of the shaft exceeding the predetermined threshold causing the motor to slow down and thereby limit the maximum torque.

11. The system of claim 9, further comprising a motor of the robotic surgical system, the motor being configured to drive the torque, the motor including first and second wire windings around first and second magnets that contribute to generation of an electromagnetic field, the sensed speed of rotation of the shaft exceeding the predetermined threshold causing one of the first and second wire windings to no longer contribute to the generation of the electromagnetic field and thereby limit the maximum torque.

12. A surgical system, comprising:

a surgical tool configured to removably and replaceably couple to a robotic surgical system, the surgical tool being configured to receive a torque from the robotic surgical system when removably and replaceably coupled thereto to drive a function of the surgical tool, the surgical tool being configured to transmit an electrical signal to the robotic surgical system removably and replaceably coupled thereto, the electrical signal being configured to prevent the robotic surgical system from providing an amount of the torque to the surgical tool that exceeds a first predetermined threshold amount of torque, and the surgical tool is configured to generate a current in response to the received torque, and the electrical signal is configured to reflect the generated current exceeding a predetermined threshold amount of current.

13. The system of claim 12, further comprising a second surgical tool configured to removably and replaceably couple to the robotic surgical system, the second surgical tool being configured to receive a second torque from the robotic surgical system when removably and replaceably coupled thereto to drive a function of the second surgical tool, the second surgical tool being configured to transmit a second electrical signal to the robotic surgical system removably and replaceably coupled thereto, the second electrical signal being configured to prevent the robotic surgical system from providing an amount of torque to the second surgical tool that exceeds a second predetermined threshold amount of torque that is different from the first predetermined threshold amount of torque.

14. A surgical system, comprising:

a surgical tool configured to removably and replaceably couple to a robotic surgical system, the surgical tool being configured to receive a torque from the robotic surgical system when removably and replaceably coupled thereto to drive a function of the surgical tool, the surgical tool being configured to transmit an electrical signal to the robotic surgical system removably and replaceably coupled thereto, the electrical signal being configured to prevent the robotic surgical system from providing an amount of the torque to the surgical tool that exceeds a predetermined threshold amount of torque; and

a motor of the robotic surgical system, the motor being configured to drive the torque, and the electrical signal being configured to reduce a speed of the motor and thereby prevent the robotic surgical system from providing the amount of torque to the surgical tool that exceeds the predetermined threshold amount of torque.

15. A surgical method, comprising:

receiving at a surgical tool a torque from a robotic surgical system to drive a function of the surgical tool, the surgical tool being removably and replaceably coupled to the robotic surgical system;

generating a current at the surgical tool in response to the receipt of the torque; and

transmitting the generated current from the surgical tool to the robotic surgical system and thereby prevent the torque received at the surgical tool from exceeding a predetermined maximum amount of torque,

wherein the torque received at the surgical tool causes an elongate shaft of the surgical tool to rotate, and a speed of the rotation of the shaft defines an amount of the generated current.

16. The method of claim 15, further comprising receiving at a second surgical tool a second torque from the robotic surgical system to drive a function of the second surgical tool, the second surgical tool being removably and replaceably coupled to the robotic surgical system;

generating a second current at the second surgical tool in response to the receipt of the second torque; and

transmitting the generated second current from the second surgical tool to the robotic surgical system and thereby prevent the second torque received at the second surgical tool from exceeding a second predetermined maximum amount of torque that is different from the predetermined maximum amount of torque,

wherein the robotic surgical system includes a motor that drives the second torque, and the transmission of the generated second current causes the motor to provide less torque to the second surgical tool.

17. A surgical method, comprising:

receiving at a surgical tool a torque from a robotic surgical system to drive a function of the surgical tool, the surgical tool being removably and replaceably coupled to the robotic surgical system;

generating a current at the surgical tool in response to the receipt of the torque; and

transmitting the generated current from the surgical tool to the robotic surgical system and thereby prevent the torque received at the surgical tool from exceeding a predetermined maximum amount of torque,

wherein the robotic surgical system includes a motor, and the generated current exceeding a predetermined threshold amount of current causes the motor to slow down and thereby prevent the torque received at the surgical tool from exceeding the predetermined maximum amount of torque.

18. The method of claim 17, further comprising receiving at a second surgical tool a second torque from the robotic surgical system to drive a function of the second surgical tool, the second surgical tool being removably and replaceably coupled to the robotic surgical system;

generating a second current at the second surgical tool in response to the receipt of the second torque; and

transmitting the generated second current from the second surgical tool to the robotic surgical system and thereby prevent the second torque received at the second surgical tool from exceeding a second predetermined maximum amount of torque that is different from the predetermined maximum amount of torque,

wherein the robotic surgical system includes a motor that drives the second torque, and the transmission of the generated second current causes the motor to provide less torque to the second surgical tool.

19. A surgical method, comprising:

receiving at a surgical tool a torque from a robotic surgical system to drive a function of the surgical tool, the surgical tool being removably and replaceably coupled to the robotic surgical system;

generating a current at the surgical tool in response to the receipt of the torque; and

transmitting the generated current front the surgical tool to the robotic surgical system and thereby prevent the torque received at the surgical tool from exceeding a predetermined maximum amount of torque,

wherein the robotic surgical system includes a motor, and the generated current causes a change in a strength of an electromagnetic field generated by the motor and thereby prevent the torque received at the surgical tool from exceeding the predetermined maximum amount of torque.