Robotic arm for a radiation treatment system

• US 8,655,429 B2
• Filed: 06/29/2007
• Issued: 02/18/2014
• Est. Priority Date: 06/29/2007
• Status: Active Grant

• Current Assignee: Accuray Incorporated
• Original Assignee: Accuray Incorporated
• Inventors: Kuduvalli, Gopinath R., Sayeh, Sohail
• Primary Examiner(s): SMYTH, ANDREW P
• Application Number:
  US11/824,080
• Publication Number:
  US 20090003975A1
• Time in Patent Office: 2,426 Days
• Field of Search: None
• US Class Current: 600/407
• CPC Class Codes: A61B 6/4458 the source unit or the detector unit being attached to robotic arms
• CPC Class Codes: A61B 6/4464 the source unit or the detector unit being mounted to ceiling
• CPC Class Codes: A61N 2005/1062 using virtual X-ray images, e.g. digitally reconstructed radiographs [DRR]
• CPC Class Codes: A61N 2005/1074 Details of the control system, e.g. user interfaces
• CPC Class Codes: A61N 5/1049 for verifying the position of the patient with respect to the radiation beam
• CPC Class Codes: A61N 5/1067 in real time, i.e. during treatment
• CPC Class Codes: B25J 15/0019 End effectors other than grippers
• CPC Class Codes: B25J 9/0084 comprising a plurality of manipulators
• CPC Class Codes: B25J 9/042 comprising an articulated arm
• CPC Class Codes: B25J 9/1682 Dual arm manipulator; Coordination of several manipulators
• CPC Class Codes: G16H 20/40 relating to mechanical, radiation or invasive therapies, e.g. surgery, laser therapy, dialysis or acupuncture
• CPC Class Codes: G16H 40/63 for local operation
• CPC Class Codes: G16H 40/67 for remote operation
• CPC Class Codes: H05H 7/00 Details of devices of the types covered by groups H05H9/00, H05H11/00, H05H13/00
• CPC Class Codes: H05H 9/00 Linear accelerators

Abstract

A robotic treatment delivery system including a linear accelerator (LINAC), and a robotic arm coupled to the LINAC. The robotic arm is configured to move the LINAC along at least four rotational degrees of freedom and one substantially linear degree of freedom.

Claims

1. An apparatus, comprising:

a linear accelerator (LINAC); and

a robotic arm coupled to the LINAC, the robotic arm configured to move the LINAC along five degrees of freedom (DOF), wherein the five DOF comprise four rotational DOF and one substantially linear DOF, wherein the substantially linear DOF is a substantially vertical, linear DOF having a substantially linear axis for translational movements of the LINAC along a substantially vertical line in the z-axis substantially perpendicular to the mutually orthogonal horizontal coordinate x- and y-axes, and wherein the robotic arm comprises;

a wrist assembly rotatably mounted to a mounting plate;

an elbow assembly coupled to the wrist assembly, the elbow assembly comprising one or more elbow gearboxes;

a shoulder assembly coupled to the elbow assembly, the shoulder assembly comprising one or more shoulder gearboxes; and

a track and a track mount assembly coupled to the shoulder assembly to provide the substantially linear axis and configured to support a load of the LINAC up to 500 lbs while enabling movement of the robotic arm using smaller gearboxes than capable without the track and track mount assembly.

2. The apparatus of claim 1, wherein the four rotational DOF comprise:

one rotational axes for translational movement of the LINAC along mutually orthogonal horizontal coordinate x- and y-axes; and

three rotational axes for roll-, pitch-, and yaw- rotational movements about an x-axis, a y-axis, and a z-axis, respectively.

3. The apparatus of claim 1, wherein the substantially linear DOF is a first DOF of the five DOF, and wherein the first DOF is configured to move the other four rotational DOF of the robotic arm.

4. The apparatus of claim 3, wherein the first DOF is the DOF closest to the base end of the robotic arm.

5. The apparatus of claim 3, wherein the first DOF is configured to move the LINAC along the substantially linear axis throughout substantially an entire range of motion of the LINAC without movement of the LINAC along the four rotational DOF.

6. The apparatus of claim 1, wherein the robotic arm is configured to move the LINAC along six DOF, and wherein the six DOF comprise:

five rotational DOF; and

one substantially linear DOF.

7. The apparatus of claim 6, wherein the five rotational DOF comprise:

two rotational axes for translational movements of the LINAC along mutually orthogonal horizontal coordinate x- and y-axes; and

three rotational axes for roll-, pitch-, and yaw- rotational movements about the x-axis, the y-axis, and a z-axis, respectively.

8. The apparatus of claim 6, wherein the substantially linear DOF is a first DOF of the six DOF, and wherein the first DOF is configured to move the other five rotational DOF of the robotic arm.

9. The apparatus of claim 8, wherein the first DOF is configured to move the LINAC along the substantially linear axis throughout substantially an entire range of motion of the LINAC without movement of the LINAC along the five rotational DOF.

10. The apparatus of claim 1, wherein the track is vertically oriented.

11. The apparatus of claim 10, wherein the track is coupled to a vertical side of a column.

12. The apparatus of claim 11, wherein the column is mounted to at least one of a floor and a ceiling.

13. The apparatus of claim 10, wherein the track is coupled to a wall.

14. The apparatus of claim 1, wherein the track is horizontally oriented.

15. The apparatus of claim 14, wherein the track is mounted to at least one of a floor and a ceiling.

16. The apparatus of claim 1, wherein the wrist assembly comprises:

a tool-yaw joint coupled to the mounting plate;

a tool-pitch joint coupled to the tool-yaw joint; and

a tool-roll joint coupled to the tool-pitch joint.

17. The apparatus of claim 16, wherein the tool-yaw joint is coupled to rotate the LINAC along a z-axis, wherein the tool-pitch joint is coupled to rotate the LINAC along a y-axis, and wherein the tool-roll joint is coupled to rotate the LINAC along a x-axis.

18. The apparatus of claim 17, wherein the elbow assembly comprises:

a first drive shaft coupled to the tool-yaw joint;

a first motor coupled to the first drive shaft, the first motor configured to drive rotational movement of the tool-yaw joint of the robotic arm in a first rotational axis of the six DOF of the robotic arm;

a second drive shaft coupled to the tool-pitch joint;

a second motor coupled to the second drive shaft, the second motor configured to drive rotational movement of the tool-pitch joint of the robotic arm in a second rotational axis of the six DOF of the robotic arm;

a third drive shaft coupled to the tool-roll joint; and

a third motor coupled to the third drive shaft, the third motor configured to drive rotational movement of the tool-roll joint of the robotic arm in a third rotational axis of the six DOF of the robotic arm.

19. The apparatus of claim 18, further comprising:

an elbow joint coupled to the elbow assembly and the shoulder assembly, wherein the elbow joint comprises the elbow gearbox configured to drive rotational movement of elbow assembly of the robotic arm in a fourth rotational axis of the six DOF of the robotic arm; and

a shoulder joint coupled to the shoulder assembly and the track mount assembly, wherein the shoulder joint comprises a the shoulder gearbox configured to drive rotational movement of the robotic arm in a fifth rotational axis of the six DOF of the robotic arm.

20. The apparatus of claim 19, wherein the elbow and shoulder gearboxes are configured to move the LINAC in a two-dimensional horizontal plane.

21. The apparatus of claim 20, wherein the track and track assembly are configured to move the LINAC in a substantially linear translational movement either in the two-dimensional horizontal plane or perpendicular to the two-dimensional horizontal plane.

22. The apparatus of claim 18, wherein the robotic arm is configured to move the LINAC along seven DOF, and wherein the seven DOF comprise:

six rotational DOF; and

one substantially linear DOF.

23. The apparatus of claim 22, wherein the six rotational DOF comprise:

three rotational axes for translations along mutually orthogonal x-, y-, and z-coordinate axes; and

three rotational axes for roll-, pitch-, and yaw- rotations about x-, y-, and z- axes, respectively, and wherein the one substantially linear DOF is a substantially linear DOF that includes a substantially linear axis for translational movement of the LINAC along either a substantially vertical line in the z-axis substantially perpendicular to the mutually orthogonal horizontal coordinate x- and y-axes or a substantially horizontal line in the mutually orthogonal horizontal coordinate x- and y-axes substantially perpendicular to the z-axis.

24. The apparatus of claim 23, further comprising:

a plate member rotatably mounted on the track mount assembly and the shoulder assembly;

a first shoulder joint coupled to the shoulder assembly and the plate member, wherein the first shoulder joint comprises a first shoulder gearbox configured to drive a fifth rotational axis of the six DOF of the robotic arm; and

a second shoulder joint coupled to the plate member and the track mount assembly, wherein the second shoulder joint comprises a second shoulder gearbox configured to drive an sixth rotation axis of the six DOF of the robotic arm.

25. The apparatus of claim 1, further comprising:

a mounting plate coupled to the LINAC;

a wrist assembly of the robotic arm coupled to the mounting plate, the mounting plate coupled to the LINAC; and

a track mount assembly coupled to a track, wherein the track mount assembly including a track mount collar.

26. The apparatus of claim 1, further comprising a controller coupled to the robotic arm, wherein the controller is configured to move the robotic arm and the LINAC in the five DOF.

27. The apparatus of claim 26, further comprising a user interface unit coupled to the controller, wherein the user interface unit is configured to manually move the robotic arm and the LINAC in the five DOF.

28. A method, comprising:

providing a linear accelerator (LINAC) coupled to a robotic arm; and

moving the LINAC along five degrees of freedom (DOF), wherein the five DOF comprise four rotational DOF and one substantially linear DOF, wherein the substantially linear DOF is a substantially vertical, linear DOF having a substantially linear axis for translational movements of the LINAC along a substantially vertical line in the z-axis substantially perpendicular to the mutually orthogonal horizontal coordinate x- and y-axes, and wherein the robotic arm comprises;

a wrist assembly rotatably mounted to a mounting plate;

an elbow assembly coupled to the wrist assembly, the elbow assembly comprising one or more elbow gearboxes;

a shoulder assembly coupled to the elbow assembly, the shoulder assembly comprising one or more shoulder gearboxes; and

a track and a track mount assembly coupled to the shoulder assembly to provide the substantially linear axis and configured to support a load of the LINAC up to 500 lbs while enabling movement of the robotic arm using smaller gearboxes than capable without the track and track mount assembly.

29. The method of claim 28, wherein moving the LINAC along the four rotational DOF comprises:

moving the LINAC in one rotational axis for translational movement of the LINAC along mutually orthogonal horizontal coordinate x- and y-axes; and

moving the LINAC in three rotational axes for roll-, pitch-, and yaw-rotational movements about an x-axis, a y-axis, and a z-axis, respectively.

30. The method of claim 28, further comprising moving the LINAC along the substantially linear axis throughout substantially an entire range of motion of the LINAC without moving the LINAC along the four rotational DOF.

31. The method of claim 28, wherein moving the LINAC along five DOF comprises:

rotating the LINAC along the z-axis using a tool-yaw joint of the robotic arm;

rotating the LINAC along the y-axis using a tool-pitch joint of the robotic arm;

rotating the LINAC along the x-axis using a tool-roll joint of the robotic arm;

rotating the LINAC along the one horizontal rotational axis using a elbow joint of the robotic arm; and

translating the LINAC along a substantially linear axis using a track and track mount assembly either in one horizontal rotational axis or perpendicular to the one horizontal rotational axis.

32. The method of claim 28, further comprising moving the LINAC along a sixth DOF, wherein the sixth DOF comprises an additional rotational DOF.

33. The method of claim 32, wherein moving the LINAC along the six DOF comprises:

moving the LINAC in two rotational axes for translational movement of the LINAC along mutually orthogonal horizontal coordinate x- and y-axes; and

moving the LINAC in three rotational axes for roll-, pitch-, and yaw-rotational movements about an x-axis, a y-axis, and a z-axis, respectively.

34. The method of claim 33, wherein moving the LINAC along the one substantially linear DOF comprises moving the LINAC along a substantially horizontal, linear DOF having a substantially linear axis for translational movements of the LINAC along a horizontal line in the mutually orthogonal horizontal coordinate x- and y-axes that is perpendicular to the z-axis.

35. The method of claim 32, further comprising moving the LINAC along the substantially linear axis throughout substantially an entire range of motion of the LINAC without moving the LINAC along the five rotational DOF.

36. The method of claim 32, wherein moving the LINAC further comprises:

rotating the LINAC along the z-axis using a tool-yaw joint of the robotic arm;

rotating the LINAC along the y-axis using a tool-pitch joint of the robotic arm;

rotating the LINAC along the x-axis using a tool-roll joint of the robotic arm;

rotating the LINAC along the two horizontal rotational axes using a elbow joint and a shoulder joint of the robotic arm; and

translating the LINAC along a substantially linear axis using a track and track mount assembly perpendicular to the two horizontal rotational axes.

37. The method of claim 28, further comprising rotating the LINAC along an additional translational axis using an additional shoulder joint.

38. A system, comprising:

a linear accelerator (LINAC);

a first robotic arm coupled to the LINAC, the robotic arm configured to move the LINAC along five degrees of freedom (DOF), wherein the five DOF comprise four rotational DOF and one substantially linear DOF;

a treatment couch; and

a second robotic arm coupled to the treatment couch, the second robotic arm is configured to move the treatment couch along five degrees of freedom (DOF), wherein the five DOF comprise four rotational DOF and one substantially linear DOF, wherein the substantially linear DOF is a substantially vertical, linear DOF having a substantially linear axis for translational movements of the LINAC along a substantially vertical line in the z-axis substantially perpendicular to the mutually orthogonal horizontal coordinate x- and y-axes, and wherein the first robotic arm comprises;

a wrist assembly rotatably mounted to a mounting plate;

an elbow assembly coupled to the wrist assembly, the elbow assembly comprising one or more elbow gearboxes;

a shoulder assembly coupled to the elbow assembly, the shoulder assembly comprising one or more shoulder gearboxes; and

a track and a track mount assembly coupled to the shoulder assembly to provide the substantially linear axis and configured to support a load of the LINAC up to 500 lbs while enabling movement of the first robotic arm using smaller gearboxes than capable without the track and track mount assembly.

39. The system of claim 38, further comprising a controller coupled to the first and second robotic arms, wherein the controller is configured to control movement of the LINAC, the treatment couch, or both the LINAC and the treatment couch to align a radiation source of the LINAC with a treatment target within a patient disposed on the treatment couch.

40. The system of claim 39, wherein the orientation and position of the treatment couch and the LINAC are dynamically coordinated by the controller.

41. The system of claim 39, further comprising an imaging system coupled to the controller to generate a plurality of images of the patient.

42. The system of claim 39, wherein the controller is configured to positioning the treatment couch and the LINAC to access a treatment target in a previously obstructed location caused by a positioning restriction within a mechanical range of motion of the first robotic arm and the LINAC.

43. The system of claim 42, wherein the positioning restriction comprises at least one of obstructions of a possible collision between at least two of the first robotic arm, the second robotic arm, the LINAC, and the treatment couch.

44. The system of claim 42, wherein positioning restriction comprises obstructions of a radiation beam of the LINAC with at least one of the treatment couch, the first robotic arm, or the second robotic arm.

45. The system of claim 38, wherein the first robotic arm and the second robotic arm are substantially identical.

46. A method comprising:

providing a LINAC coupled to a first robotic arm;

providing a treatment couch coupled to a second robotic arm;

moving the LINAC along five degrees of freedom (DOF) using the first robotic arm, wherein the five DOF of the first robotic arm comprise four rotational DOF and one substantially linear DOF, wherein the substantially linear DOF is a substantially vertical, linear DOF having a substantially linear axis for translational movements of the LINAC along a substantially vertical line in the z-axis substantially perpendicular to the mutually orthogonal horizontal coordinate x- and y-axes, and wherein the robotic arm comprises;

a wrist assembly rotatably mounted to a mounting plate;

an elbow assembly coupled to the wrist assembly, the elbow assembly comprising one or more elbow gearboxes;

a shoulder assembly coupled to the elbow assembly, the shoulder assembly comprising one or more shoulder gearboxes; and

a track and a track mount assembly coupled to the shoulder assembly to provide the substantially linear axis and configured to support a load of the LINAC up to 500 lbs while enabling movement of the first robotic arm using smaller gearboxes than capable without the track and track mount assembly; and

moving the treatment couch along five DOF using the second robotic arm, wherein the five DOF of the second robotic arm comprise four rotational DOF and one substantially linear DOF.

47. The method of claim 46, wherein moving the LINAC along five DOF comprises:

rotating the LINAC along the z-axis using a tool-yaw joint of the first robotic arm;

rotating the LINAC along the y-axis using a tool-pitch joint of the first robotic arm;

rotating the LINAC along the x-axis using a tool-roll joint of the first robotic arm;

rotating the LINAC along the one horizontal rotational axis using a elbow joint of the first robotic arm; and

translating the LINAC along a substantially linear axis using a first track and a first track mount assembly in the vertical linear axis perpendicular to the horizontal linear axis, and wherein moving the treatment couch along five DOF comprises;

rotating the treatment couch along the z-axis using a tool-yaw joint of the second robotic arm;

rotating the treatment couch along the y-axis using a tool-pitch joint of the second robotic arm;

rotating the treatment couch along the x-axis using a tool-roll joint of the second robotic arm;

rotating the treatment couch along the one horizontal rotational axis using a elbow joint of the second robotic arm; and

translating the treatment couch along a substantially linear axis using a second track and a second track mount assembly either in a horizontal axis or a vertical axis.

48. The method of claim 46, further comprising:

moving the LINAC along a sixth DOF using the first robotic arm, wherein the sixth DOF of the first robotic arm comprises an additional rotational DOF; and

moving the treatment couch along a sixth DOF using the second robotic arm, wherein the sixth DOF of the second robotic arm comprises an additional rotational DOF.

49. The method of claim 46, further comprising dynamically coordinating orientations and positions of the LINAC and the treatment couch.

50. The method of claim 49, wherein dynamically coordinating the orientations and positions of the LINAC and the treatment couch comprise aligning a radiation source of the LINAC with a treatment target within a patient disposed on the treatment couch.

51. The method of claim 49, wherein dynamically coordinating the orientations and positions of the L1NAC and the treatment couch comprise positioning the LINAC and the treatment couch to access a treatment target in a previously obstructed location caused by a positioning restriction within a mechanical range of motion of the first robotic arm and the LINAC.

52. The method of claim 50, wherein the positioning restriction comprise obstructions of a radiation source of the LINAC due to at least one of an x-ray imaging source and detector, the first robotic arm, the second robotic arm, or the treatment couch.

53. The method of claim 46, further comprising:

providing an imaging system having an imaging field of view; and

maintaining the LINAC substantially outside of the imaging field of view for all supported treatment positions.