Control arm for robotic surgical systems

• US 11,446,099 B2
• Filed: 06/02/2017
• Issued: 09/20/2022
• Est. Priority Date: 06/03/2016
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Cecil, Cameron
• Primary Examiner(s): Labranche, Brooke Nicole
• Application Number:
  US16/306,827
• Publication Number:
  US 20190321112A1
• Time in Patent Office: 1,936 Days
• CPC Class Codes: A61B 34/00 Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
• 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 34/74 Manipulators with manual electric input means
• CPC Class Codes: A61B 34/76 Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: A61B 90/37 Surgical systems with images on a monitor during operation
• CPC Class Codes: B25J 13/02 Hand grip control means handles or pedals for crane control B66C13/56; for measuring the force applied to control members G01L5/22; hand-held casings for switching devices, e.g. joy-sticks H01H9/0214
• CPC Class Codes: B25J 9/046 Revolute coordinate type
• CPC Class Codes: B25J 9/06 characterised by multi-articulated arms

Abstract

A control arm for a robotic surgical system includes a base, a swivel member, a vertical member, a horizontal member, and a drive mechanism. The swivel member is rotatably supported on the base about a first axis of rotation. The vertical member is pivotally supported on the swivel member about a second axis of rotation. The horizontal member is pivotally supported by the vertical member about a third axis of rotation. The drive mechanism is disposed on the base and is configured to independently rotate the swivel member about the first axis of rotation, to pivot the vertical member about the second axis of rotation, and to pivot the horizontal member about the third axis of rotation.

Claims

1. A control arm for a robotic surgical system, the control arm comprising:

a base;

a swivel member rotatably supported on the base about a first axis of rotation;

a vertical member pivotally supported on the swivel member about a second axis of rotation;

a horizontal member pivotally supported by the vertical member about a third axis of rotation; and

a drive mechanism disposed on the base to independently rotate the swivel member about the first axis of rotation, pivot the vertical member about the second axis of rotation, and pivot the horizontal member about the third axis of rotation, wherein the drive mechanism includes;

a first lower pulley disposed about the first axis of rotation operably coupled to a second drive motor by a first pair drive cables; and

a first upper pulley disposed about the first axis of rotation and rotatably fixed to the first lower pulley, the first upper pulley operably coupled to the vertical member to pivot the vertical member about the second axis of rotation.

2. The control arm according to claim 1, wherein the drive mechanism includes a first drive motor to affect rotation of the swivel member about the first axis of rotation, the second drive motor to affect pivoting of the vertical member about the second axis of rotation, and a third drive motor to affect pivoting of the horizontal member about the third axis of rotation.

3. The control arm according to claim 1, wherein the drive mechanism includes:

a first drive motor;

a rotation shaft disposed about the first axis of rotation and rotatably fixed to the swivel member; and

a rotation flange including a cylindrical member disposed about the first axis of rotation and rotatably fixed to the rotation shaft, the cylindrical member operably coupled to the first drive motor to affect rotation of the swivel member about the first axis of rotation.

4. The control arm according to claim 3, wherein the rotation flange includes a web that extends to an arced wall, the arced wall forming an arc about the first axis of rotation.

5. The control arm according to claim 4, wherein the drive mechanism includes a first rotation cable and a second rotation cable that operably couple the first drive motor to the rotation flange.

6. The control arm according to claim 5, wherein the first rotation cable extends from the first drive motor in a first direction to a first end of the arced wall and the second rotation cable extends from the first drive motor in a second direction to a second end of the arced wall.

7. The control arm according to claim 1, wherein the drive mechanism includes a first idler and a second idler and the vertical member defines a first vertical member groove and a second vertical member groove, the drive mechanism further including a first pivot cable and a second pivot cable, the first pivot cable disposed about the first upper pulley, around the first idler, and within the first vertical member groove and the second pivot cable disposed about the first upper pulley, around the second idler, and within the second vertical member groove to operably couple the first upper pulley to the vertical member.

8. The control arm according to claim 1, wherein the drive mechanism includes a first pulley shaft that rotatably fixes the first lower pulley to the first upper pulley, a second lower pulley and a second upper pulley that are rotatably fixed to one another by a second pulley shaft that is disposed about the first pulley shaft.

9. A control arm for a robotic surgical system, the control arm comprising:

a base;

a swivel member rotatably supported on the base about a first axis of rotation;

a vertical member pivotally supported on the swivel member about a second axis of rotation;

a horizontal member pivotally supported by the vertical member about a third axis of rotation;

a support member and a support arm, the support arm pivotally supported by the swivel member about the second axis of rotation, the support member pivotally coupled to the support arm and the horizontal member to pivot the horizontal member about the third axis of rotation in response to pivoting of the support arm about the second axis of rotation; and

a drive mechanism disposed on the base to independently rotate the swivel member about the first axis of rotation, pivot the vertical member about the second axis of rotation, and pivot the horizontal member about the third axis of rotation, wherein the drive mechanism includes;

a drive motor;

a lower pulley disposed about the first axis of rotation operably coupled to the drive motor by a pair drive cables; and

an upper pulley disposed about the first axis of rotation and rotatably fixed to the lower pulley, the upper pulley operably coupled to the support arm to pivot the support arm about the second axis of rotation.

10. The control arm according to claim 9, wherein the drive mechanism includes a first idler and a second idler and the support arm defines a first support groove and a second support groove, the drive mechanism further including a first pivot cable and a second pivot cable, the first pivot cable disposed about the upper pulley, around the first idler, and within the first support groove and the second pivot cable disposed about the upper pulley, around the second idler, and within the second support groove to operably couple the upper pulley to the support arm.

11. A method of manipulating a control arm including a base, a swivel member rotatable relative to the base about a first axis of rotation, a vertical member pivotally supported by the swivel member about a second axis of rotation, and a horizontal member pivotally supported by the vertical member about a third axis of rotation, the method comprising:

activating a first drive motor to rotate the swivel member about the first axis of rotation;

activating a second drive motor to pivot the vertical member about the second axis of rotation, wherein activating the second drive motor to pivot the vertical member about the second axis of rotation includes rotating a first lower pulley about the first axis of rotation which affects rotation of a first upper pulley about the first axis of rotation which affects rotation of the vertical member about the second axis of rotation; and

activating a third drive motor to pivot the horizontal member about the third axis of rotation.

12. The method according to claim 11, wherein activating the first drive motor to rotate the swivel member about the first axis of rotation includes rotating a flange rotatably disposed on a lower side of the base about the first axis of rotation to rotate the swivel member.

13. The method according to claim 12, wherein rotating the flange includes wrapping a first drive cable around a drive shaft of the first drive motor and unwrapping a second drive cable from around the drive shaft of the first drive motor, wherein the first and second drive cables are disposed about an arced wall of the flange.

14. The method according to claim 11, wherein rotating the first lower pulley about the first axis of rotation includes wrapping a first drive cable about a drive shaft of the second drive motor and unwrapping a second drive cable about the drive shaft of the second drive motor.

15. The method according to claim 11, wherein activating the third drive motor to pivot the horizontal member about the third axis of rotation includes rotating a second lower pulley about the first axis of rotation which affects rotation of a second upper pulley about the first axis of rotation which affects rotation of the horizontal member about the third axis of rotation.

16. The method according to claim 15, wherein rotating the second lower pulley about the first axis of rotation includes wrapping a first drive cable about a drive shaft of the third drive motor and unwrapping a second drive cable about the drive shaft of the third drive motor.