Methods and apparatus for stacked electro-mechancial straps in robotic arms

• US 10,595,948 B2
• Filed: 05/26/2015
• Issued: 03/24/2020
• Est. Priority Date: 09/30/2004
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Solomon, Todd R., Cooper, Thomas G.
• Primary Examiner(s): Downey, John R
• Application Number:
  US14/722,101
• Publication Number:
  US 20150250549A1
• Time in Patent Office: 1,764 Days
• Field of Search: 606 1, 606130
• 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 2034/715 Cable tensioning mechanisms for removing slack
• 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 90/361 Image-producing devices, e.g. surgical cameras
• CPC Class Codes: B25J 9/1045 comprising tensioning means

Abstract

In one embodiment, a method is disclosed for a robotic arm. The method includes pitching a linkage assembly having a plurality of links coupled in series together to constrain movement of a tool along an insertion axis; and enabling movement of the linkage assembly about a pitch axis with a strap drive-train coupled thereto using an electro-mechanical strap stack routed between a first link and a second link. The electro-mechanical strap stack includes a drive strap coupled to the linkage. The drive strap moves the linkage assembly.

Claims

1. A method for a robotic arm, the method comprising:

pitching a linkage assembly having a plurality of links coupled in series together to constrain movement of a surgical tool along an insertion axis; and

enabling movement of the linkage assembly about a pitch axis with a strap drive-train coupled thereto using an electro-mechanical strap stack routed between a first link and a second link of the linkage assembly, a first driver pulley rigidly coupled to the first link, a second driver pulley rigidly coupled to the second link, and an idler pulley rotatably coupled to a bent third link between the first and second links;

wherein the electro-mechanical strap stack includes

a drive strap coupled to the linkage, the drive strap routed between the first driver pulley and the second driver pulley and over the idler pulley in the third link to move the linkage assembly and

an electrical cable coupled to the drive strap, and routed over the drive strap in a stacked configuration with the drive strap, the electrical cable configured to carry electrical signals along the robotic arm;

further wherein, the electrical cable strap is not bonded to the drive strap but is mechanically held in a stacked position on top of the drive strap by cable clamps proximate the first and second ends of the electrical cable strap.

2. The method of claim 1, wherein

the electro-mechanical strap stack further includes a ground strap in a stacked configuration with the drive strap to improve chassis grounding.

3. The method of claim 2, wherein

the ground strap includes a conductive material and the ground strap is stacked onto the drive strap in parallel relation.

4. The method of claim 3, wherein

the ground strap includes one or more layers of beryllium copper (BeCu).

5. The method of claim 3, further comprising:

coupling a ground cable having a conductive material to the ground strap of the electro-mechanical strap stack, the ground cable extending through other links of the plurality of links to a chassis ground such that the plurality of links are coupled to the chassis ground.

6. The method of claim 1, wherein

the electrical cable includes one or more flexible electrical cables, and

each flexible electrical cable includes one or more flexible electrical signal lines.

7. The method of claim 6, wherein

the flexible electrical cable and flexible electrical signal lines are flat.

8. The method of claim 7, further comprising:

coupling a first end of the flat electrical cable of the electro-mechanical strap stack to a printed circuit board; and

coupling a first end of an electrical cable extending through at least one other link of the plurality of links to the printed circuit board and a second end of the electrical cable to an electrical signal interface of the robotic arm.

9. The method of claim 1, further comprising:

coupling the electro-mechanical strap stack between the first link and the second link through a third link of the plurality of links, by;

clamping the electro-mechanical strap stack to a first driver pulley rigidly coupled to the first link; and

clamping the electro-mechanical strap stack to a second driver pulley rigidly coupled to the second link;

wherein the electro-mechanical strap stack extends through the third link between the first and second links.

10. The method of claim 1, wherein

the idler pulley is rotatably coupled to the third link near the bend and is configured to direct the electro-mechanical strap stack around the bend in the third link.

11. The method of claim 10, further comprising:

laterally constraining movement of the electro-mechanical strap stack to track the electro-mechanical strap stack over the idler pulley and avoid wandering off the idler pulley.

12. The method of claim 10, further comprising:

longitudinally constraining movement of the electro-mechanical strap stack to track the electro-mechanical strap stack over the idler pulley and avoid puffing of the electro-mechanical strap stack.

22. The method of claim 1, wherein

the electrical signals include providing, power to, and communicating electrical data signals with a surgical tool at the distal end of the robotic arm.

13. An electro-mechanical strap stack routed between a first link and a second link of the linkage assembly, a first driver pulley rigidly coupled to the first link, a second driver pulley rigidly coupled to a second link, and an idler pulley rotatably coupled to a bent third link between the first and second links, the electro-mechanical strap stack comprising:

a flat metal drive strap coupled to the first driver pulley and the second driver pulley and routed over the idler pulley,

one or more flat flexible signal cables coupled to the flat metal drive strap and in a stacked configuration with the flat metal drive strap, the one or more flat flexible signal cables configured to carry electrical signals along the robotic arm; and

wherein the electro-mechanical strap stack is configured to pitch the robotic arm

about a pitch axis;

further wherein, the one or more flat flexible signal cables are not bonded to the drive strap but are mechanically held in a stacked position on top of the drive strap by cable clamps proximate the first and second ends of the one or more flat flexible signal cables.

14. The electro-mechanical strap stack of claim 13, wherein

the flat metal drive strap is a multi-ply metal drive strap including a plurality of flat metal layers stacked upon each other and coupled together at each end.

15. The electro-mechanical strap stack of claim 14, wherein

each flat metal layer is steel.

16. The electro-mechanical strap stack of claim 14, wherein

the plurality of flat metal layers are coupled together at a first end by a tab and at a second end by a tensioning block.

17. The electro-mechanical strap stack of claim 14, wherein

the plurality of flat metal layers are coupled together at each end by a tab.

18. The electro-mechanical strap stack of claim 15, wherein

the flat metallic ground strapping includes a plurality of flat beryllium copper (BeCu) layers.

19. The electro-mechanical strap stack of claim 13, further comprising

a flat metallic ground strapping stacked on and in parallel to the metal drive strap, the flat metallic ground strapping including a plurality of conductive material layers coupled to the first driver pulley and the second driver pulley.

20. The electro-mechanical strap stack of claim 13, wherein

each of the one or more flat flexible signal cables having a plurality of flat flexible electrical signal lines surrounded by an insulating material.

21. The electro-mechanical strap stack of claim 19, wherein

the one or more flat flexible signal cables are pinched against the ground strapping at the first driver pulley by a first clamp near a first end and pinched against the ground strapping at the second driver pulley by a second clamp near a second end.