Methods, systems, and devices relating to force control surgical systems

• US 9,888,966 B2
• Filed: 03/14/2014
• Issued: 02/13/2018
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Board of Regents of the University of Nebraska
• Original Assignee: Board of Regents of the University of Nebraska
• Inventors: Farritor, Shane, Frederick, Thomas, Lackas, Kearney, Bartels, Joe, Greenburg, Jacob
• Primary Examiner(s): Stransky, Katrina
• Application Number:
  US14/210,934
• Publication Number:
  US 20140371762A1
• Time in Patent Office: 1,432 Days
• Field of Search: 606130
• 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 34/76 Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: B25J 9/1602 characterised by the control system, structure, architecture
• CPC Class Codes: B25J 9/1633 compliant, force, torque control, e.g. combined with position control
• CPC Class Codes: G05B 2219/36432 By putting some constraints on some DOF, move within limited volumes, areas, planes, limits motion in x, y or z planes, virtual reality constraints
• CPC Class Codes: G05B 2219/39181 Compensation of coulomb friction in joint
• CPC Class Codes: G05B 2219/39194 Compensation gravity
• CPC Class Codes: G05B 2219/39321 Force control as function of position of tool
• CPC Class Codes: G05B 2219/40619 Haptic, combination of tactile and proprioceptive sensing
• CPC Class Codes: G05B 2219/45117 Medical, radio surgery manipulator
• CPC Class Codes: Y10S 901/27 Arm part
• CPC Class Codes: Y10S 901/46 Sensing device

Abstract

The various embodiments herein relate to robotic surgical systems and devices that use force and/or torque sensors to measure forces applied at various components of the system or device. Certain implementations include robotic surgical devices having one or more force/torque sensors that detect or measure one or more forces applied at or on one or more arms. Other embodiments relate to systems having a robotic surgical device that has one or more sensors and an external controller that has one or more motors such that the sensors transmit information that is used at the controller to actuate the motors to provide haptic feedback to a user.

Claims

1. A robotic surgical system comprising:

(a) a robotic surgical device configured to be positioned into a cavity of a patient through an incision, the device comprising;

(i) a device body;

(ii) at least one arm operably coupled to the body, wherein the at least one arm is configured to be positioned entirely within the cavity of the patient; and

(iii) at least one sensor operably coupled to the device;

(b) a processor operably coupled to the at least one sensor; and

(c) a user controller operably coupled to the processor, the user controller comprising;

(i) a base;

(ii) an upper arm component operably coupled to the base at a shoulder joint, wherein the shoulder joint comprises a first actuator operably coupled to the processor;

(iii) a forearm component operably coupled to the upper arm component at an elbow joint, wherein the elbow joint comprises a second actuator operably coupled to the processor; and

(iv) a grasper operably coupled to the forearm component at a wrist joint, wherein the wrist joint comprises a third actuator operably coupled to the processor,

wherein the at least one sensor is configured to sense force or torque at the robotic surgical device and transmit force or torque information to the processor,

wherein the processor is configured to calculate the force or torque being applied at the robotic surgical device and transmit instructions to actuate at least one of the first, second, or third actuator based on the force or torque, thereby providing haptic feedback at the controller.

2. The robotic surgical system of claim 1, wherein the at least one sensor is a force sensor operably coupled to the at least one arm.

3. The robotic surgical system of claim 1, wherein the at least one sensor is a torque sensor operably coupled to a joint of the at least one arm.

4. The robotic surgical system of claim 1, wherein the at least one sensor is a force sensor positioned between the device body and the at least one arm.

5. The robotic surgical system of claim 1, wherein the at least one sensor is a force sensor disposed within the device body.

6. A robotic surgical system comprising:

(a) a robotic surgical device comprising;

(i) a device body configured to be positioned through an incision into a cavity of a patient;

(ii) a first shoulder component operably coupled to the device body;

(iii) a first arm operably coupled to the first shoulder component, wherein the first arm is configured to be positioned entirely within the cavity of the patient; and

(iv) a sensor operably coupled to the device,

wherein the device body is configured to be disposed in the incision when the first arm is positioned within the cavity;

(b) a processor operably coupled to the sensor; and

(c) a user controller operably coupled to the processor, the user controller comprising;

(i) a base;

(ii) a controller upper arm component operably coupled to the base at a shoulder joint, wherein the shoulder joint comprises a first actuator operably coupled to the processor;

(iii) a controller forearm component operably coupled to the controller upper arm component at an elbow joint, wherein the elbow joint comprises a second actuator operably coupled to the processor; and

(iv) a grasper operably coupled to the controller forearm component at a wrist joint, wherein the wrist joint comprises a third actuator operably coupled to the processor,

wherein the sensor is configured to sense force or torque at the robotic surgical device and transmit force or torque information to the processor, and

wherein the processor is configured to calculate the force or torque being applied at the robotic surgical device and transmit instructions to actuate at least one of the first, second, or third actuator based on the force or torque, thereby providing haptic feedback at the controller.

7. The robotic surgical system of claim 6, wherein the sensor is disposed between the device body and the first shoulder component.

8. The robotic surgical system of claim 6, wherein the sensor is disposed on the first arm.

9. The robotic surgical system of claim 8, wherein the first arm comprises a first arm upper arm component and a first arm forearm component, wherein the sensor is disposed on the first arm forearm component.

10. The robotic surgical system of claim 6, wherein the first arm comprises a first arm upper arm component and a first arm forearm component, wherein the first arm forearm component is operably coupled to the first arm upper arm component at an elbow joint, wherein the first arm forearm component comprises a link operably coupled at a distal end to the force sensor and operably coupled at a proximal end to the elbow joint.

11. The robotic surgical system of claim 10, further comprising an interface plate disposed between the force sensor and the link.

12. The robotic surgical system of claim 6, wherein the sensor is positioned to measure the amount of force applied at a distal-most point on the first arm.

13. A robotic surgical system comprising:

(a) a robotic surgical device comprising;

(i) a device body configured to be positioned through an incision into a cavity of a patient;

(ii) a first arm operably coupled to the device body, the first arm comprising an arm actuator disposed within the first arm, wherein the first arm is configured to be positioned entirely within the cavity of the patient;

(iii) a sensor operably coupled to the arm actuator; and

(iv) an end effector operably coupled to the arm actuator, the end effector positioned at a distal end of the first arm;

(b) a processor operably coupled to the sensor; and

(c) a user controller operably coupled to the processor, the user controller comprising;

(i) a base;

(ii) a controller upper arm component operably coupled to the base at a shoulder joint, wherein the shoulder joint comprises a first actuator operably coupled to the processor;

(iii) a controller forearm component operably coupled to the forearm upper arm component at an elbow joint, wherein the elbow joint comprises a second actuator operably coupled to the processor; and

(iv) a controller grasper operably coupled to the controller forearm component at a wrist joint, wherein the wrist joint comprises a third actuator operably coupled to the processor,

wherein the sensor is configured to sense force or torque at the robotic surgical device and transmit force or torque information to the processor,

wherein the processor is configured to calculate the force or torque being applied at the robotic surgical device and transmit instructions to actuate at least one of the first, second, or third actuator based on the force or torque, thereby providing haptic feedback at the controller.

14. The robotic surgical system of claim 13, further comprising a push/pull rod comprising a distal portion and a proximal portion, wherein the push/pull rod is operably coupled to the arm actuator at the proximal portion and further wherein the push/pull rod is operably coupled to the end effector at the distal portion.

15. The robotic surgical system of claim 14, wherein the sensor is disposed proximal to the arm actuator and is operably coupled to the proximal portion of the push/pull rod.

16. The robotic surgical system of claim 14, wherein the end effector is a device grasper, wherein the device grasper comprises an open configuration when the push/pull rod is urged to a distal position, and further wherein the device grasper comprises a closed configuration when the push/pull rod is urged to a proximal position.

17. The robotic surgical system of claim 14, wherein the sensor is operably coupled to the push/pull rod such that the sensor is positioned along the length of the push/pull rod.

18. The robotic surgical system of claim 13, wherein the end effector is a device grasper.

19. The robotic surgical system of claim 13, further comprising a shaft operably coupled to the end effector and a first gear operably coupled to the shaft, wherein the arm actuator comprises a second gear operably coupled to the first gear.

20. The robotic surgical system of claim 19, wherein actuation of the arm actuator causes the shaft to rotate, thereby causing the end effector to rotate.