Main controller assembly and robotic surgery system

Abstract

The present disclosure relates to a master controller assembly for a robotic surgical system and a robotic surgical system including the master controller assembly. The master controller assembly includes a master input tool and a sensing assembly. The master input tool includes at least one manipulation surface designed to be held by a surgeon's finger, and the master input tool is mechanically unconstrained by the slave robotic assembly such that the master input tool can be naturally moved, rotated, and revolved by the surgeon. The sensing assembly at least detects the relative positions of a first elongate body member and a second elongate body member of the master input tool such that a clamping pressure applied by the surgeon's finger on the master input tool to move the first elongate body member and the second elongate body member closer to each other determines a paired clamping motion of a surgical clamping device.

Description

Technical Field

[0001] The object of the present invention is a master controller assembly for a robotic surgical system.

[0002] Furthermore, the present invention relates to a robotic surgical system.

[0003] In particular, the robotic surgical system is suitable for microsurgery. Background Art

[0004] Robotic surgical assemblies including a master interface and slave surgical tools are generally known in the art. Specifically, known types of robotic surgical assemblies include a master control station capable of controlling the movement of a slave surgical end effector, as shown, for example, in document US-5876325. This document discloses a non-portable robotic hanging articulated attachment that is suspended from a beam fixedly constrained to the master control station, the attachment including a master tool for controlling a slave surgical end effector operating on a patient's anatomy.

[0005] Similar non-portable robotic held master tool solutions are shown, for example, in documents US-6063095, US-6424885, and US-6594552, where the attachment of the master control station acting as a master tool for controlling a slave surgical end effector includes an attachment body rigidly constrained to the master control station. The transmission of movement to the slave end effector is based on the detection of mechanical stresses caused by advancing the attachment body of the master control station in different spatial directions. Such an attachment body may be associated with a pair of opposing fins, each of which is constrained at one of its ends to the attachment body, such that a cantilevered fin is formed suitable for receiving manual commands for activating the grip degrees of freedom of the slave end effector.

[0006] However, non-portable robotic hanging or robotic held master tool solutions of the above type exhibit some drawbacks. Providing such a control attachment mechanically constrained to the master control station of a robotic surgical assembly strongly limits the natural degrees of freedom of movement of the surgeon during surgery and forces the surgeon to operate from a predetermined position from which the master control station, and in particular the control attachment attached to the master control station, can be easily reached. The discomfort of the surgeon is still enhanced because the position of such an attachment cannot be adjusted in real time during surgery, for example, in terms of the height above the ground. This causes the surgeon to become prematurely fatigued during surgery and lose concentration earlier.

[0007] Often, surgeons undergo years of training to properly handle surgical tools adapted to operate directly on a patient's anatomy. Surgical tools are typically portable tools and include a tool handle adapted to be held and manipulated by a surgeon, the handle being mechanically directly connected to a tool tip adapted to operate on a patient's anatomy. Some examples of surgical tools for traditional ophthalmic surgery are shown in documents US-5634918 and WO-2012-064361. Such traditional surgical tools allow a surgeon to definitely know when the tool tip is not in contact with the patient's anatomy, which allows the surgeon to safely roll the tool handle (i.e., without transmitting movement to the patient's anatomy) between the fingers around the longitudinal axis of the tool handle - a need for reducing gesture stress quite common among surgeons, useful for example for relaxing hand muscles and preventing muscle cramps during surgery.

[0008] Robotic microsurgery, instead, forces the surgeon to use a master tool to control the movement of an associated slave end effector operating on the patient's anatomy, and generally the master tool limits the surgeon's comfort during surgery and often forces the surgeon to undergo an additional training period to properly use the master tool to control the slave end effector. If the shape and function of the master tool differ from those of traditional surgical tools, the additional training period may even be longer.

[0009] Wearable master tools have been provided, as disclosed for example in document US-8996173, where a pair of rings are designed to fit on a surgeon's fingers and are wired to a robotic slave assembly. A coded set of gestures of the surgeon's fingers triggers predefined slave end effector actions on the patient's anatomy. Clearly, this solution requires very long training of the surgeon to properly manage such wearable master rings so as to avoid transmitting unexpected commands to the slave end effector. For patient safety reasons, transmitting unexpected commands to the slave should be avoided. Additionally, documents DE-102014006264 and DE-102010009065 show a wearable master tool.

[0010] In order to overcome the deficiencies of the above-known solutions and to provide a handheld manipulandum (i.e., from Latin: "thing to be manipulated") master tool having a shape familiar to most surgeons, documents WO-2017-064303 and WO-2017-064306 in the name of the same applicant show a master tool device that substantially replicates the appearance of traditional surgical forceps. Such a master tool device includes a pair of flexible metal strips that are welded together at one of their ends to form a forceps-like master input device. Appropriately positioned sensors assist a magnetic pad in tracking the movement of the forceps and detecting when the forceps close to mimic object grasping and transmit the detected movement to a slave surgical end effector.

[0011] Although this solution can satisfactorily improve the comfort of surgeons during surgery, it is prone to drawbacks. In particular, such flexible metal strips forming the forceps-like device force the sensors placed on the free ends of the strips to undergo non-linear movements, and thus, detecting manually induced forceps closing movements for mimicking the grasping of a certain object often results in measurement uncertainties and low sensing resolution. Mechanical vibrations occurring during the elastic bending of each metal strip generate noise detected by the tracking pad. This can lead to an unsatisfactory movement response of the slave end effector, and such an unsatisfactory movement response of the slave end effector may even result in serious complications to the patient's body after surgery. In addition, the tracking pad is adapted to generate a tracking magnetic field only from one side of the pad, forcing the surgeon not to move the handheld master tool behind the pad, where the movement cannot be tracked and thus command signals cannot be transmitted to the end effector.

[0012] Furthermore, documents US-2013-0035697, WO-2014-151621, and US-2015-038981 disclose a portable handheld master input tool that can be manipulated while the surgeon moves at different positions in the operating site. This solution utilizes a video camera that tracks a properly designed ball that cantileveredly protrudes from the portable handheld master tool body. In other words, a set of three asymmetric balls mounted on the master tool can be tracked by a camera device on the robot to determine the position and orientation of the master input tool, with the aim of transmitting command signals to a slave surgical end effector.

[0013] Although this solution is satisfactory in some respects, it is prone to drawbacks. Since a vision-based tracking system allows the surgeon to operate while moving at different positions in the operating site, while forcing the robot to have a powerful control system and may cause unwanted delays in the transmission of movement to the slave end effector, it causes discomfort to the surgeon.

[0014] There is a need to provide a master tool solution for robotic surgery that can overcome the drawbacks listed with reference to the prior art.

[0015] There is a need to provide a master tool for robotic surgery that is suitable for improving the comfort of the surgeon and at the same time can provide high sensing accuracy.

[0016] There is a need to provide a master tool for robotic surgery that can minimize the training time of the surgeon.

[0017] There is a need to provide a master tool for robotic surgery that is suitable for avoiding transmitting unwanted command signals to the slave end effector.

[0018] There is a need to provide a master tool for robotic surgery that has no mechanical constraints on the master control station or on the slave robot. Summary of the Invention

[0019] The scope of the present invention is to overcome the drawbacks mentioned with reference to the prior art.

[0020] These and other scopes are achieved by the master controller assembly and the robotic surgery system according to the present application.

[0021] According to one aspect of the present invention, the master controller assembly includes at least one master input tool and at least one sensing component. Wherein, the master input tool includes at least one manipulation surface, which is designed to be held by the fingers of the surgeon and is not mechanically constrained by the slave robot component, so that the master input tool can be naturally moved, rotated and revolved by the surgeon. The at least one manipulation surface is a convex surface, so that the master input tool (106) can roll between the fingers of the surgeon around the longitudinal axis of the tool. Thus, the comfort of the surgeon during the operation is maintained. The master input tool includes: a first elongated element having a first element elongated body, wherein the first element elongated body is a rigid body; and a second elongated element having a second element elongated body, wherein the second element elongated body is a rigid body; and a tool joint that connects and hinges the first element elongated body and the second element elongated body, providing a single degree of freedom of movement between the first element elongated body and the second element elongated body.

[0022] The at least one sensing component at least detects the relative positions of the first element elongated body and the second element elongated body, so that the clamping pressure applied by the fingers of the surgeon on the master input tool to move the first element elongated body and the second element elongated body closer to each other determines the paired clamping movement of the surgical clamping device.

[0023] The sensing assembly may include a pair of sensors received in respective slots of the main input tool body. Each slot may be mechanically shaped to be compatible with only one of the sensors.

[0024] Each sensor in the sensing assembly may be encapsulated by a sterile barrier such as a plastic bag or a plastic box to allow for reuse of the sensor. The main input tool body may be disposable. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The following preferred embodiments with reference to the accompanying drawings, which are given by way of example and not meant to be limiting, other features and advantages of the main controller assembly and the robotic surgical system according to the present invention will be apparent, in the drawings:

[0026] - Figure 1 and Sub of Figure 1 FIG. is a perspective view showing a robotic surgical system according to some embodiments;

[0027] - Figures 2 to 5 is a perspective view showing a main controller assembly held by a surgeon according to some embodiments;

[0028] - Figure 6 is a perspective view showing a main controller assembly according to an embodiment;

[0029] - Figure 7 and Figure 8 is a perspective view of the main controller assembly according to some embodiments, showing the sensing assembly and the main input tool as separate components;

[0030] - Figure 9 is an exploded perspective view of the main input tool according to an embodiment;

[0031] - Figure 10 is a longitudinal cross-section of the main input tool taken along the Figure 8 cutting plane indicated by X-X-X-X in

[0032] - Figure 11 is a perspective view of the main controller assembly according to an embodiment;

[0033] - Figure 12 and Figure 13 is a longitudinal cross-section of the main input tool in the closed position according to an embodiment;

[0034] - Figure 14 is a longitudinal cross-section of the trigger of the main input tool according to an embodiment;

[0035] - Figure 15is a longitudinal cross-section of a tool joint of a master input tool according to an embodiment;

[0036] - Figure 16 is a perspective view of a master controller assembly according to an embodiment, wherein the sensing assembly is shown as a separate component relative to the master input tool;

[0037] - Figure 17 is a perspective view of a master controller assembly according to an embodiment;

[0038] - Figure 18 is a perspective view of a master controller assembly held by a surgeon according to an embodiment;

[0039] - Figure 19 is a sketch showing, in perspective, a robotic surgical system according to an embodiment including a paired master controller assembly and a slave surgical grasping device;

[0040] - Figure 20 is a perspective view showing a master controller assembly according to an embodiment;

[0041] - Figure 21 is a perspective view of a robotic surgical system according to an embodiment;

[0042] - Figure 22 and Figure 23 is a block diagram showing a robotic surgical assembly according to some embodiments. Detailed Description

[0043] According to a general embodiment, a robotic surgical system 101 includes: at least one master controller assembly 102 adapted to detect a manual command 161; and at least one slave robotic assembly 103 including a slave surgical instrument 104 designed to operate on a patient's anatomical structure.

[0044] The slave surgical instrument 104 includes at least one surgical grasping device 117 that provides movement with a grasping degree of freedom for the slave surgical instrument 104.

[0045] According to an embodiment, the surgical grasping device 117 includes a first elongate element 142 of the surgical grasping device and a second elongate element 143 of the surgical grasping device. The first elongate element 142 of the surgical grasping device and the second elongate element 143 of the surgical grasping device are hinged relative to each other to form a surgical grasping joint 144, preferably the surgical grasping joint 144 is a pin joint. Preferably, each of the first elongate element 142 of the surgical grasping device and the second elongate element 143 of the surgical grasping device includes: a joint portion 145 of the surgical grasping device that forms at least a part of the surgical grasping joint 144; and a cantilevered free end portion 146 of the surgical grasping device.

[0046] According to a preferred embodiment, the robotic surgery system 101 includes a control unit 105 that is adapted to receive a first command signal 162 containing information about the manual command 161 and to transmit a second command signal 163 containing information about the manual command 161 to the slave robotic assembly 103 to actuate the slave surgical instrument 104.

[0047] According to a preferred embodiment, the master controller assembly 102 is paired with the slave surgical instrument 104 in a master-slave pair. According to a preferred embodiment, the master controller assembly 102 and the slave surgical instrument 104 form a master-slave pair through the control unit 105.

[0048] The master controller assembly 102 includes at least one portable hand-held master input tool body 106 (or master input tool 106) that is adapted to be held and manipulated by a surgeon at different positions in the operating site during surgery. In this way, the master controller assembly 102 is portable within the operating site, for example, during surgery. Preferably, the portable hand-held master input tool 106 is held and manipulated by a surgeon at different positions in the operating site during surgery. Preferably, the master input tool 106 receives the manual command.

[0049] According to a preferred embodiment, the term "portable" in relation to the master input tool means that the master input tool can be held or moved by a surgeon, for example, during surgery.

[0050] According to a preferred embodiment, the term "hand-held" in relation to the master input tool means that the master input tool is designed to be operated when held in the hand, for example, in the hand of a surgeon.

[0051] According to a preferred embodiment, the term "operating site" refers to a part of the space that at least partially surrounds the patient's anatomical structure. Preferably, different positions other than the patient's anatomical structure are included within the operating site.

[0052] According to a preferred embodiment, the term "manipulate" in relation to the master input tool means that the master input tool can be handled or operated by hand or as if by hand.

[0053] According to a preferred embodiment, the master input tool 106 is paired with the slave surgical instrument 104 in a master-slave pair. According to a preferred embodiment, the master input tool 106 and the slave surgical instrument 104 form a master-slave pair through the control unit 105.

[0054] The master controller assembly 102 is operably connected to the slave robot assembly 103. According to an embodiment, the master controller assembly 102 is connected to the slave robot assembly 103 by electromagnetic communication.

[0055] The master input tool 106 includes at least one manipulation surface 109, 110, which is designed to be held by the fingers 111, 112 of a surgeon. In this way, the portability of the master input tool 106 is enhanced.

[0056] The master input tool 106 is not mechanically constrained by the slave robot assembly 103, such that the master input tool 106 can be preferably moved, rotated and swiveled naturally by the surgeon.

[0057] The master input tool 106 is not mechanically grounded.

[0058] According to an embodiment, the master input tool is not adapted to provide force feedback.

[0059] The at least one manipulation surface 109, 110 is a convex surface, such that the master input tool 106 can roll between the fingers 111, 112 of the surgeon about the tool longitudinal axis X-X.

[0060] According to a preferred embodiment, the master input tool 106 includes a first elongate element 113 having a first element elongate body 114, wherein the first element elongate body 114 is a rigid body. According to a preferred embodiment, the term "rigid body" means that such a body lacks or is devoid of flexibility. According to an embodiment, the term "rigid body" means that such a body is not capable of providing an elastically bendable deformation under operating conditions.

[0061] According to an embodiment, the first element elongate body 114 defines a first element direction X1-X1 that is substantially coincident with the axis of longitudinal development of the first element elongate body 114.

[0062] According to a preferred embodiment, the master input tool 106 includes a second elongate element 115 having a second element elongate body 116, wherein the second element elongate body 116 is a rigid body.

[0063] According to an embodiment, the second element elongate body 116 defines a second element direction X2-X2 that is substantially coincident with the axis of longitudinal development of the second element elongate body 116.

[0064] According to a preferred embodiment, the master input tool 106 includes a tool joint 118 that connects and articulates the first element elongated body 114 and the second element elongated body 116, and the tool joint provides a single degree of freedom of movement between the first element elongated body 114 and the second element elongated body 116.

[0065] According to an embodiment, the single degree of freedom of movement between the first element elongated body 114 and the second element elongated body 116 lies in a predetermined plane.

[0066] According to a preferred embodiment, the master controller assembly 102 includes at least one sensing assembly 119 that at least detects the relative positions of the first element elongated body 114 and the second element elongated body 116, and preferably detects the relative positions and orientations. In this way, the clamping pressure action 147 exerted by the surgeon's fingers 111, 112 on the master input tool 106 to move the first element elongated body 114 and the second element elongated body 116 closer to each other determines the paired driven clamping movement 148 of the surgical clamping device 117.

[0067] Due to the fact that both the first element elongated body 114 and the second element elongated body 116 are rigid bodies, the sensing resolution of the sensing assembly 119 is improved relative to known solutions.

[0068] According to an embodiment, the manual command 161 includes the clamping pressure action 147.

[0069] According to an embodiment, the paired driven clamping movement 148 moves the first elongated element 142 of the surgical clamping device and the second elongated element 143 of the surgical clamping device closer to each other.

[0070] According to an embodiment, the clamping pressure action 147 is exerted by the surgeon's fingers 111, 112 on at least one of the manipulation surfaces 109, 110 of the master input tool 106.

[0071] According to an embodiment, the sensing assembly 119 includes at least one capacitive incremental position sensor, such as a capacitive encoder.

[0072] According to an embodiment, the robotic surgical system 201, preferably the master controller assembly 102, includes at least one field generator 107 that generates a predefined field volume. According to a preferred embodiment, the at least one field generator 107 generates a magnetic field.

[0073] According to an embodiment, the at least one sensing assembly 119 detects at least the position of the primary input tool 106 within the predefined field volume, preferably the position and orientation.

[0074] According to an embodiment, the field generator 107 defines a reference zero point X0, Y0, Z0 integral with the field generator 107, and wherein the at least one sensing assembly 119 detects the generated field local vectors X1, Y1, Z1; X2, Y2, Z2 and at least determines the position of the sensing assembly 119. In this way, the sensing assembly 119 at least determines the position of the primary tool assembly 106 integral with the sensing assembly 119 within the predefined field volume.

[0075] According to an embodiment, the master controller assembly 102 is operatively connected to the slave robotic assembly 103 by a wired electrical connection.

[0076] According to an embodiment, the master controller assembly 102 is operatively connected to the slave robotic assembly 103 by a wireless connection.

[0077] According to an embodiment, the primary input tool 106 is mechanically unconstrained by both the field generator 107 and the slave robotic assembly 103 such that the primary input tool 106 can be naturally moved, rotated, and revolved by a surgeon within the predefined field volume.

[0078] According to an embodiment, at least one of the first element elongated body 114 and the second element elongated body 116 includes the at least one manipulation surface 109, 110.

[0079] According to a preferred embodiment, each of the first element elongated body 114 and the second element elongated body 116 includes the at least one manipulation surface 109, 110. In this way, the first element elongated body 114 includes a first manipulation surface 109, and the second element elongated body 116 includes a second manipulation surface 110.

[0080] According to an embodiment, the at least one manipulation surface 109, 110 includes a friction enhancing portion 121 adapted to improve the gripping of the surgeon's fingers 111, 112 thereon.

[0081] According to an embodiment, the at least one manipulation surface 109, 110 is part of a cylindrical surface. In this way, the rollability of the primary input tool 106 about the tool longitudinal axis X-X is enhanced.

[0082] According to an embodiment, the first control surface 109 and the second control surface 110 cooperate to form at least a part of a cylindrical surface. In this way, the rollability of the main input tool 106 about the tool longitudinal axis X-X is enhanced.

[0083] According to an embodiment, the tool joint 118 is a hinge that provides a rotational movement with a single degree of freedom between the first element elongated body 114 and the second element elongated body 116. In this way, the first element elongated body 114 and the second element elongated body 116 are movable relative to each other with respect to angular movement.

[0084] According to an embodiment, the main clamping angle α+γ is defined as the angle between the first element elongated body 114 and the second element elongated body 116. According to an embodiment, the angle between the first element elongated body 114 and the second element elongated body 116 defines the main clamping angle α+γ.

[0085] According to an embodiment, the first element elongated body 114 and the second element elongated body 116 are movable relative to each other with respect to angular movement between at least one open position and at least one closed position, in which the main clamping angle α+γ is greater than a predefined clamping threshold angle γ in the open position and the main clamping angle α+γ is less than the predefined clamping threshold angle γ in the closed position.

[0086] According to a preferred embodiment, when the first element elongated body 114 and the second element elongated body 116 are in the open position, the main clamping angle α+γ is equal to or less than 60 degrees. Preferably, when the first element elongated body 114 and the second element elongated body 116 are in the open position, the main clamping angle α+γ is equal to or less than 45 degrees. When the first element elongated body 114 and the second element elongated body 116 are in the open position, the main clamping angle α+γ is equal to or less than 35 degrees.

[0087] According to an embodiment, the tool joint 118 is a pin joint that provides a rotational movement with a single degree of freedom, preferably a rotational angular movement with a single degree of freedom, between the first element elongated body 114 and the second element elongated body 116.

[0088] According to an embodiment, the tool longitudinal axis X-X is defined to coincide with the bisector of the main clamping angle α+γ.

[0089] According to an embodiment, the tool longitudinal axis X-X is defined as the set of points equidistant from the first element direction X1-X1 and the second element direction X2-X2.

[0090] According to an embodiment, when the first element elongated body 114 and the second element elongated body 116 are in the closed position, the tool longitudinal axis X-X is defined as the longitudinally developed axis of the main input tool 106.

[0091] According to an embodiment, the first element elongated body 114 includes: a first element joint portion 132 that forms a part of the tool joint 118; and a first element cantilever portion 122 that is positioned opposite to the first element joint portion 132 along the first element direction X1-X1.

[0092] According to an embodiment, the second element elongated body 116 includes: a second element joint portion 133 that forms a part of the tool joint portion 118; and a second element cantilever portion 123 that is positioned opposite to the second element joint portion 132 along the second element direction X2-X2.

[0093] Preferably, the first element cantilever portion 122 forms a free end, and the second element cantilever portion 123 forms a free end.

[0094] According to an embodiment, the relative spatial positions of the first element cantilever portion 122 and the second element cantilever portion 123 are rigidly determined by the main clamping angle α+γ width. In this way, the sensing resolution of the sensing assembly 119 is enhanced.

[0095] According to a preferred embodiment, the first element joint portion 132 and the second element joint portion 133 cooperate to form the tool joint 118.

[0096] According to a preferred embodiment, the first element joint portion 132 and the second element joint portion 133 are constrained to each other by a tool joint pin 124 to form the tool joint 118.

[0097] According to an embodiment, the first element cantilever portion 122 and the second element cantilever portion 123 are respectively located at a predetermined distance from the tool joint 118 along the first element elongated body 114 and the second element elongated body 116.

[0098] According to an embodiment, the sensing assembly 119 includes at least one joint sensor, preferably an encoder, located within the tool joint 118.

[0099] According to an embodiment, the sensing assembly 119 includes at least one proximity sensor 166 and at least one target object 167, and the proximity sensor 166 cooperates with the target object 167 to at least detect the relative positions of the first elongated element and the second elongated element, preferably the relative positions and relative orientations. Preferably, one of the first element elongated body and the second element elongated body includes the proximity sensor, and the other includes the target object.

[0100] According to an embodiment, the main input tool 106 includes at least one joint spring 120 that biases at least the first element cantilever portion 122 of the first element elongated body 114 away from the second element cantilever portion 123 of the second element elongated body 116 along the single degree of freedom of the movement.

[0101] According to an embodiment, the joint spring 120 angularly biases the first element elongated body 114 and the second element elongated body 116 towards the at least one open position.

[0102] According to an embodiment, the joint spring 120 is disposed between the first element elongated body 114 and the second element elongated body 116.

[0103] According to an embodiment, the joint spring 120 is disposed between the first element joint portion 122 and the second element joint portion 123.

[0104] According to an embodiment, the joint spring 120 is a torsion spring.

[0105] According to an embodiment, the joint spring 120 is an axial spring.

[0106] According to an embodiment, the joint spring 120 is positioned around the tool joint 118. According to an embodiment, the joint spring 120 is positioned around the tool joint pin 124 of the tool joint 118.

[0107] According to an embodiment, the joint spring 120 exerts an elastic biasing action that is directed to increase the main clamping angle α + γ.

[0108] According to an embodiment, each of the first element elongated body 114 and the second element elongated body 116 is made as a single piece.

[0109] According to an embodiment, each of the first element elongated body 114 and the second element elongated body 116 is made of a polymeric material.

[0110] According to an embodiment, each of the first element elongated body 114 and the second element elongated body 116 is made by molding, preferably by injection molding. In this way, the number of components assembled together to form the main input tool 106 is reduced.

[0111] According to an embodiment, the angle between the first elongated element 142 and the second elongated element 143 of the surgical clamping device is equal to the master clamping angle α + γ along the master-slave pair.

[0112] According to an embodiment, the first elongated element 142 and the second elongated element 143 of the surgical clamping device define a slave clamping angle β therebetween. Preferably, the first elongated element 142 and the second elongated element 143 of the surgical clamping device of the slave surgical clamping device 117 are movable relative to each other between at least one open position where the slave clamping angle β is greater than a predefined slave clamping threshold and at least one closed position where the slave clamping angle β is less than the predefined slave clamping threshold, preferably substantially equal to zero. Preferably, when the first elongated element 142 and the second elongated element 143 of the surgical clamping device are in the closed position, the first elongated element 142 and the second elongated element 143 of the surgical clamping device are aligned, preferably along the longitudinal axis Y-Y of the slave clamping device.

[0113] According to an embodiment, when the first element elongated body 114 and the second element elongated body 116 are in the closed position, the paired slave surgical clamping device 117 is in the closed position.

[0114] According to a preferred embodiment, the main input tool 106 includes a clamping force detector device 125 that detects a clamping pressure action 147 applied by the surgeon's fingers 111, 112 to move the first element elongated body 114 and the second element elongated body 116 closer to each other to be below the predefined clamping threshold angle γ.

[0115] According to a preferred embodiment, the clamping force detector device 125 of the main input tool 106 detects the clamping pressure action 147 when the master clamping angle is below the clamping threshold angle γ.

[0116] According to an embodiment, when the clamping pressure action 147 applied by the surgeon's fingers 111, 112 causes the first element elongated body 114 and the second element elongated body 116 to move closer to each other to be below the predefined clamping threshold angle γ, it is determined that the paired clamping force applied by the surgical clamping device 117 increases. In this way, it is allowed for the surgeon to be aware, through mechanical force feedback, of when the slave surgical clamping device 117 is cutting at least a part of the patient's anatomical structure.

[0117] According to an embodiment, the clamping force detector device 125 includes at least one trigger 126 that is rotatably connected to the first element elongated body 114, thereby forming a trigger joint 127.

[0118] According to an embodiment, the trigger joint 127 is a pin joint that includes a trigger pin 164. According to an embodiment, the trigger joint 127 is a hinge.

[0119] According to an embodiment, the trigger 126 includes a trigger root 128 that forms a part of the trigger joint 127 and a trigger free end 129 that extends cantilevered relative to the trigger joint 127.

[0120] According to an embodiment, the clamping force detector device 125 includes at least one clamping spring 130 that biases the trigger free end 129 away from the first element elongated body 114 such that the trigger 126 extends cantilevered facing the second element elongated body 116.

[0121] According to an embodiment, when the trigger free end 129 is pushed towards the first element elongated body 114 by the clamping pressure action applied by the surgeon's fingers 111, 112, the clamping spring 130 exerts an elastic return action that is directed in contrast to the clamping pressure action applied by the surgeon's fingers 111, 112, such that the surgeon is aware, through mechanical force feedback, of the increase in the paired clamping force applied by the slave clamping device 117.

[0122] According to an embodiment, the second element elongated body 116 includes a trigger abutment portion 140 that forms an abutment wall for the trigger free end 129 when the clamping pressure action applied by the surgeon's fingers 111, 112 causes the first element elongated body 114 and the second element elongated body 116 to move closer to each other below a predetermined clamping threshold γ.

[0123] According to an embodiment, when the main input tool 106 is in the closed position, the trigger abutment portion 140 defines a trigger seat 149 for receiving at least a portion of the trigger 126.

[0124] According to an embodiment, when the clamping pressure applied by the surgeon's fingers 111, 112 causes the first element elongated body 114 and the second element elongated body 116 to move closer to each other below a predefined clamping threshold γ, the trigger abutment portion 140 defines a trigger seat 149 adapted to receive at least the free end portion 129 of the trigger.

[0125] According to an embodiment, the clamping force detector device 125 includes at least one force sensor.

[0126] According to an embodiment, the sensing assembly 119 includes at least one first sensor 134. Preferably, the first sensor 134 is integral with the first elongated element 113, preferably integral with the first element elongated body 114.

[0127] According to an embodiment, the first element elongated body 114 defines at least one first notch 138 for receiving at least a portion of the sensing assembly 119. According to an embodiment, the at least one first notch 138 receives at least a portion of the sensing assembly 119 in a separable manner such that the main input tool 106 with or without the sensing assembly 119 is disposable.

[0128] According to an embodiment, the sensing assembly 119 includes at least one sterile sensor container 165, such as a plastic bag or a plastic box and / or the like, which encloses at least one of the first sensor 134 or the second sensor 135. In this way, the sterility of the sensor assembly 119 can be achieved, avoiding the need to replace the sensors 134, 135 after a single surgery. Thus, the main input tool body 106 can be made disposable, and the sensors 134, 135 can be reused multiple times as their sterility is maintained. Preferably, the wired connections 136, 137 to the sensors 134, 135 are also enclosed by the sterile box 165 or its accessories.

[0129] According to an embodiment, the first notch 138 receives the first sensor 134.

[0130] According to an embodiment, the first sensor 134 is operably connected to the field generator 107 via a first sensor connection 136. According to an embodiment, the first sensor connection 136 is a wired connection. According to an embodiment, the first sensor connection 136 is a wireless connection.

[0131] According to a preferred embodiment, the sensing assembly 119 includes at least one second sensor 135. Preferably, the second sensor 135 is integral with the second elongate element 115.

[0132] According to an embodiment, the second element elongate body 116 defines at least one second notch 139 that receives at least a portion of the sensing assembly 119. According to an embodiment, the second notch 139 receives at least a portion of the sensing assembly 119 in a separable manner such that the main input tool 106 with or without the sensing assembly 119 is disposable.

[0133] According to an embodiment, the second notch 139 receives the second sensor 135.

[0134] According to an embodiment, the second sensor 135 is operably connected to the field generator 107 via a second sensor connection 137. According to an embodiment, the second sensor connection 137 is a wired connection. According to an embodiment, the second sensor connection 137 is a wireless connection.

[0135] According to an embodiment, the first notch 138 faces in a direction opposite to the second notch 139, thereby allowing a unique arrangement of the sensing assembly 119. In this way, the chance of misplacing the sensing assembly 119 is significantly reduced.

[0136] According to an embodiment, the notches 138, 139 include at least one marking element, such as a notch and / or the like, to signal whether the sensors 134, 135 are operably received in the respective notches 138, 139.

[0137] According to an embodiment, the notches 138, 139 have marking elements that are different from each other such that the sensors 134, 135 can be operably connected to only one of the notches 138, 139.

[0138] According to an embodiment, the arrangement of the notches 138, 139 is asymmetric. According to an embodiment, the arrangement of the sensors 134, 135 is asymmetric.

[0139] According to an embodiment, the first notch 138 is opposite the second notch 139 with respect to the tool longitudinal axis X-X.

[0140] According to an embodiment, the notches 138, 139 have substantially the same shape and size.

[0141] According to an embodiment, the notches 138, 139 have a substantially parallelepiped shape.

[0142] According to an embodiment, the notches 138, 139 are provided near the free end portions of each elongated body 114, 116 so as to have a maximum linear displacement with a constant angular displacement, and the sensors 134, 135 are received in the respective notches 138, 139.

[0143] According to an embodiment, the notches 138, 139 are provided at a maximum distance from the tool joint 118 so as to have a maximum linear displacement with a constant angular displacement, and the sensors 134, 135 are received in the respective notches 138, 139.

[0144] For example, when the tool joint 118 is near or at the proximal end of each elongated body 114, 116, the notches 138, 139 and the sensors 134, 135 are provided near or at the distal end of each elongated body.

[0145] According to an embodiment, the first element cantilever portion 122 and the second element cantilever portion 123 of the main input tool 106 define a first longitudinal side 150, and wherein a second longitudinal side 151 is defined as being opposite to the first longitudinal side 150 with respect to the tool joint 118.

[0146] According to an embodiment, both the first sensor connection 136 and the second sensor connection 137 are wired connections, and wherein the wiring of the first sensor connection 136 and the wiring of the second sensor connection 137 are both gathered on the same longitudinal sides 150; 151 of the main input tool 106. In this way, the interference of the sensor connections is reduced.

[0147] According to an embodiment, the main input tool 106 includes at least one dorsal hand rest portion 131, which is designed to contact at least a part of the dorsal hand 141 of the surgeon when in an operating state.

[0148] According to an embodiment, the positions of the manipulation surfaces 109, 110 along the tool longitudinal axis X-X are between the first tool longitudinal side 150 and the sensing assembly 119. According to an embodiment, the positions of the manipulation surfaces 109, 110 along the tool longitudinal axis X-X are between the first tool longitudinal side 150 and the force detector device 125.

[0149] According to an embodiment, the elongated body 114 of the first element includes at least one manipulation surface 109, 110, which are located between the cantilevered portion 122 of the first element and the trigger joint 127 along the first elongated element direction X1-X1. According to an embodiment, the elongated body 114 of the first element includes at least one manipulation surface 109, 110, which are located between the joint portion 132 of the first element and the trigger joint 127 along the first elongated element direction X1-X1.

[0150] According to an embodiment, the manipulation surfaces 109, 110 are positioned along the tool longitudinal axis X-X between the second tool longitudinal side 151 and the sensing assembly 119. According to an embodiment, the manipulation surfaces 109, 110 are positioned along the tool longitudinal axis X-X between the second tool longitudinal side 151 and the force detector device 125. According to an embodiment, the slave robot assembly 103 further includes at least one surgical arm 152 for manipulating the slave surgical instrument 104. According to an embodiment, the slave robot assembly 103 includes at least one micromanipulator 153 for manipulating the slave surgical instrument 104. Preferably, the at least one micromanipulator 153 is directly connected in series to the surgical arm 152, forming a kinematic chain with the surgical arm 152, and the micromanipulator 153 manipulates the slave surgical instrument 104. According to an embodiment, at least two micromanipulators 153 are directly connected in series to the surgical arm 152, forming a kinematic chain with at least two branches with the surgical arm 153.

[0151] According to an embodiment, the robotic surgical system 101 includes at least one robotic cart 154, which includes at least one cart ground contact unit 155 and a cart handle 156, and the cart handle 156 is adapted to move at least a part of the robotic surgical system 101, preferably the slave robot assembly 103, at least within the operating site. Preferably, the robotic cart 154 forms a mechanical and structural support for the slave robot assembly 103, preferably a movable mechanical and structural support.

[0152] According to an embodiment, the robotic cart 154 is connected to a power supply cable 157.

[0153] According to an embodiment, the robotic cart 154 includes the control unit 105. Preferably, the control unit 105 is positioned integrally with the robotic cart 154.

[0154] According to an embodiment, the robotic cart 154 includes the field generator 107.

[0155] According to an embodiment, the master controller assembly 102 further includes at least one operating chair 158, which includes at least one seating surface 159 for a surgeon to sit on during a surgery.

[0156] According to an embodiment, the operating chair 158 is mechanically unconstrained by the slave robot assembly 103, thereby preventing vibratory motion from propagating from the operating chair 158 to the slave robot assembly 103 through mechanical contact. In this way, the risk of unwanted commands being transmitted to the slave surgical robot 103, and in particular to the slave surgical instrument 104, is reduced.

[0157] According to an embodiment, the operating chair 158 includes the field generator 107 such that the field volume is integral with at least a portion of the operating chair 158.

[0158] According to an embodiment, the master input tool 106 is operably connected to the operating chair 158 through a chair operation connection 160. According to an embodiment, the chair operation connection 160 is a wired connection. According to an embodiment, the chair operation connection 160 is a wireless connection.

[0159] According to a general embodiment, there is provided a master controller assembly 102 for a robotic surgery system 101, the robotic surgery system 101 further including a slave robot assembly 103, the slave robot assembly including a slave surgical instrument 104 having a surgical clamping device 117 that provides motion with a clamping degree of freedom for the slave surgical instrument 104.

[0160] According to any of the above embodiments, the master controller assembly 102 includes a master input tool body 106 and a sensing assembly 119.

[0161] According to a preferred embodiment, the master input tool 106 is adapted to be held and manipulated by a surgeon at different positions in an operating site during a surgery, and the master input tool 106 is adapted to receive manual commands.

[0162] According to a preferred embodiment, the master input tool 106 includes at least one manipulation surface 109, 110, which is designed to be held by the fingers 111, 112 of a surgeon.

[0163] According to a preferred embodiment, the master input tool 106 is mechanically unconstrained by the slave robot assembly 103 such that the master input tool 106 can be naturally moved, rotated, and turned by a surgeon.

[0164] According to a preferred embodiment, the at least one manipulation surface 109, 110 is a convex surface such that the primary input tool 106 can roll between the surgeon's fingers 111, 112 about the tool longitudinal axis X-X.

[0165] According to a preferred embodiment, the primary input tool 106 includes a first elongate element 113 having a first element elongate body 114, wherein the first element elongate body 114 is a rigid body, and wherein the primary input tool 106 includes a second elongate element 115 having a second element elongate body 116, wherein the second element elongate body 116 is a rigid body.

[0166] According to a preferred embodiment, the primary input tool 106 includes a tool joint 118 that connects and hinges the first element elongate body 114 and the second element elongate body 116, the tool joint providing a single degree of freedom of movement between the first element elongate body 114 and the second element elongate body 116.

[0167] According to a preferred embodiment, the primary controller assembly 102 includes at least one sensing assembly 119 that at least detects the relative positions of the first element elongate body 114 and the second element elongate body 116 such that the clamping pressure exerted by the surgeon's fingers 111, 112 on the primary input tool 106 to move the first element elongate body 114 and the second element elongate body 116 closer to each other determines the paired clamping movement of the surgical clamping device 117.

[0168] By virtue of the above features provided singly or in combination as applicable in a particular embodiment, the sometimes contrasting requirements disclosed above can be met and the above advantages obtained, and in particular:

[0169] - A handheld non-grounded primary controller assembly is provided that is simple to manufacture and at the same time capable of accurate and reliable sensing;

[0170] - A primary controller assembly is provided in which no structural constraints on the robot are required and the connection to the robot can be wired for data transfer purposes;

[0171] - Improved degrees of freedom of movement are provided to the surgeon and at the same time a familiar tool for performing robotic surgery is provided;

[0172] - A primary controller assembly is provided that is particularly suitable for robotic microsurgery;

[0173] - The mechanical features of the sensing assembly and the mechanical features of the notch of the receiving sensor allow for a unique arrangement of the sensor, thereby avoiding misplacement, improving safety compared to known solutions, and at the same time without incurring high manufacturing costs;

[0174] - The main input tool body can be made disposable, and the sensing assembly can be not made disposable.

[0175] Those skilled in the art can make many changes and adjustments to the above embodiments, or can replace elements with other functionally equivalent elements to meet the requirements that are met or may occur without departing from the scope of the appended claims.

[0176] List of reference numerals

[0177] 101 Robotic surgery system

[0178] 102 Main controller assembly

[0179] 103 Slave robotic assembly

[0180] 104 Slave surgical instrument, or surgical instrument

[0181] 105 Control unit

[0182] 106 Main input tool body, or main input tool

[0183] 107 Field generator

[0184] 109 First manipulation surface

[0185] 110 Second manipulation surface

[0186] 111 Surgeon's finger

[0187] 112 Another surgeon's finger

[0188] 113 First elongated element

[0189] 114 First element elongated body, or first elongated element body

[0190] 115 Second elongated element

[0191] 116 Second element elongated body, or second elongated element body

[0192] 117 Surgical clamping device, or slave surgical clamping device

[0193] 118 Tool joint

[0194] 119 Sensing assembly

[0195] 120 Joint spring

[0196] 121 Friction enhancement part

[0197] 122 First element cantilever part

[0198] 123 Second element cantilever part

[0199] 124 Tool joint pin

[0200] 125 Clamping force detector device

[0201] 126 Trigger

[0202] 127 Trigger joint

[0203] 128 Trigger root

[0204] 129 Trigger free end

[0205] 130 Trigger spring

[0206] 131 Back of hand rest part

[0207] 132 First element joint part

[0208] 133 Second element joint part

[0209] 134 First sensor

[0210] 135 Second sensor

[0211] 136 First sensor connection

[0212] 137 Second sensor connection

[0213] 138 First notch

[0214] 139 Second notch

[0215] 140 Trigger abutment part

[0216] 141 Surgeon's back of hand

[0217] 142 First elongated element of surgical clamping device

[0218] 143 Second elongated element of surgical clamping device

[0219] 144 Surgical clamping joint

[0220] 145 Joint part of surgical clamping device

[0221] 146 Free end of surgical clamping device

[0222] 147 Clamping pressure action

[0223] 148 Paired driven clamping movement

[0224] 149 Trigger seat

[0225] 150 First longitudinal side

[0226] 151 Second longitudinal side

[0227] 152 Surgical arm, or driven surgical arm

[0228] 153 Micromanipulator

[0229] 154 Robot cart

[0230] 155 Cart ground contact unit

[0231] 156 Cart handle

[0232] 157 Power supply cable

[0233] 158 Operating chair

[0234] 159 Seating surface

[0235] 160 Chair operation connection

[0236] 161 Manual command

[0237] 162 First command signal

[0238] 163 Second command signal

[0239] 164 Trigger pin

[0240] 165 Sterile sensor container

[0241] 166 Proximity sensor

[0242] 167 Target object

[0243] X-X Tool longitudinal axis

[0244] X1-X1 First element direction

[0245] X2-X2 Second element direction

[0246] Y-Y Driven clamping device longitudinal axis

[0247] α+γ Main clamping angle

[0248] β Driven clamping angle

[0249] γ Clamping threshold angle.

Claims

1. A master controller assembly (102) for a robotic surgical system (101), the robotic surgical system (101) further comprising a slave robotic assembly (103), the slave robotic assembly including a slave surgical instrument (104), the slave surgical instrument having a surgical clamping device (117) that provides movement with a clamping degree of freedom for the slave surgical instrument (104), the master controller assembly comprising: - At least one master input tool (106), at least one of the master input tools being adapted to be held and manipulated by a surgeon at different positions in the operating site during surgery, and - At least one sensing assembly (119); Wherein: - The master input tool (106) is adapted to receive manual commands; - The master input tool (106) includes at least one manipulation surface (109, 110) designed to be held by the surgeon's fingers (111, 112); - The master input tool (106) is not mechanically constrained by the slave robotic assembly (103), such that the master input tool (106) can be naturally moved, rotated, and spun by the surgeon; - The at least one manipulation surface (109, 110) is a convex surface, such that the master input tool (106) can roll between the surgeon's fingers (111, 112) about the tool longitudinal axis (X-X); And wherein: - The master input tool (106) includes a first elongate element (113) having a first element elongate body (114), wherein the first element elongate body (114) is a rigid body; - The master input tool (106) includes a second elongate element (115) having a second element elongate body (116), wherein the second element elongate body (116) is a rigid body; - The master input tool (106) includes a tool joint (118) that connects and hinges the first element elongate body (114) and the second element elongate body (116), providing a single degree of freedom of movement between the first element elongate body (114) and the second element elongate body (116); - At least one of the sensing assemblies (119) at least detects the relative positions of the first element elongate body (114) and the second element elongate body (116), such that the clamping pressure applied by the surgeon's fingers (111, 112) on the master input tool (106) to move the first element elongate body (114) and the second element elongate body (116) closer to each other determines the paired clamping movement of the surgical clamping device (117); and Wherein, The first element elongate body (114) defines at least one first notch (138), at least a portion of the sensing assembly (119) being received in at least one of the first notches; The sensing assembly (119) includes at least one first sensor (134); and the first notch (138) receives the first sensor (134) such that the first sensor (134) is integral with the first elongated element (113); and wherein, The second element elongated body (116) defines at least one second notch (139), and at least one of the second notches receives at least a portion of the sensing assembly (119); The sensing assembly (119) includes at least one second sensor (135); and the second notch (139) receives the second sensor (135) such that the second sensor (135) is integral with the second elongated element (115).

2. The main controller assembly (102) according to claim 1, wherein, The first notch (138) receives the first sensor (134) in a separable manner such that the main input tool (106) with or without the sensing assembly (119) is disposable.

3. The main controller assembly (102) according to claim 1 or 2, wherein, The first sensor (134) is operably connected to the field generator (107) of the main controller assembly (102) through a first sensor connection (136), and wherein the first sensor connection (136) is a wired connection or a wireless connection.

4. The main controller assembly (102) according to claim 1 or 2, wherein, - The second sensor (135) is integral with the second elongated element (115); - In a separable manner such that the main input tool (106) with or without the sensing assembly (119) is disposable.

5. The main controller assembly (102) according to claim 3, wherein, The second sensor (135) is operably connected to the field generator (107) through a second sensor connection (137), and wherein the second sensor connection (137) is a wired connection or a wireless connection.

6. The main controller assembly (102) according to claim 1 or 2, wherein, The first notch (138) faces in the opposite direction with respect to the second notch (139) such that a unique arrangement of the sensing assembly (119) is allowed.

7. The main controller assembly (102) according to claim 1 or 2, wherein, The first notch (138) and the second notch (139) are opposite with respect to the tool longitudinal axis (X-X).

8. The main controller assembly (102) according to claim 1 or 2, wherein, The first notch (138) is provided near the free end portion of the first element elongated body (114), and the second notch (139) is provided near the free end portion of the second element elongated body (116), so as to have the maximum linear displacement with the angular displacement remaining constant, and the first sensor (134) is received in the first notch (138), and the second sensor (135) is received in the second notch (139).

9. The main controller assembly (102) according to claim 8, wherein, When the tool joint (118) is near or at the proximal end of each of the first element elongated body (114) and the second element elongated body (116), the first notch (138) and the first sensor (134) are arranged to be near or at the distal end of the first element elongated body (114), and the second notch (139) and the second sensor (135) are arranged to be near or at the distal end of the second element elongated body (116).

10. The main controller assembly (102) according to claim 1 or 2, wherein, The sensing assembly (119) includes at least one sterile sensor container (165) that encloses at least one of the first sensor (134) or the second sensor (135), thereby maintaining the sterility of the sensing assembly (119).

11. The main controller assembly (102) according to claim 5, wherein, Both the first sensor connection (136) and the second sensor connection (137) are wired connections, and wherein the wiring of the first sensor connection (136) and the wiring of the second sensor connection (137) are both gathered on the same longitudinal side of the main input tool (106).

12. The main controller assembly (102) according to claim 1 or 2, wherein, The main input tool (106) includes at least one dorsal hand resting portion (131) that is designed to contact at least a portion of the surgeon's dorsal hand (141) when in an operating condition.

13. The main controller assembly (102) according to claim 1 or 2, wherein: - Each of the first element elongated body (114) and the second element elongated body (116) is made as a single piece.

14. The main controller assembly (102) according to claim 1 or 2, wherein: - Each of the first element elongated body (114) and the second element elongated body (116) includes the at least one manipulation surface (109, 110); and wherein The at least one manipulation surface (109, 110) is a part of a cylindrical surface.

15. The main controller assembly (102) according to claim 1 or 2, wherein, The tool joint (118) is a hinge that provides a single degree of rotational movement between the first element elongated body (114) and the second element elongated body (116), such that the first element elongated body (114) and the second element elongated body (116) can move relative to each other with respect to angular movement.

16. The main controller assembly (102) according to claim 15, wherein, - The first element elongated body (114) includes: a first element joint portion (132) that forms a part of the tool joint (118); and a first element cantilever portion (122) that is positioned along the tool longitudinal axis (X-X) opposite to the first element joint portion (132); and wherein - The second element elongated body (116) includes: a second element joint portion (133) that forms part of the tool joint (118); and a second element cantilever portion (123) that is positioned opposite the second element joint portion (133) along the tool longitudinal axis (X-X); and wherein - The first element joint portion (132) and the second element joint portion (133) cooperate to form the tool joint (118); and wherein - The main input tool (106) includes at least one joint spring (120) that biases at least the first element cantilever portion (122) of the first element elongated body (114) away from the second element cantilever portion (123) of the second element elongated body (116) along the single degree of freedom of movement.

17. The main controller assembly (102) according to claim 1 or 2, wherein, The main controller assembly (102) includes at least one field generator (107) that generates a predefined field volume; and wherein, - The sensing assembly (119) at least detects the position of the main input tool (106) within the predefined field volume.

18. A robotic surgical system (101), comprising: - The main controller assembly (102) according to any one of at least one of claims 1 to 17; - At least one slave robotic assembly (103), at least one of the slave robotic assemblies including a slave surgical instrument (104) designed to operate on a patient's anatomical structure, the slave surgical instrument (104) including at least one surgical clamping device (117) that provides movement with a clamping degree of freedom for the slave surgical instrument (104); - A control unit (105) that is adapted to receive a first command signal containing information about the manual command and transmit a second command signal containing information about the manual command to the slave robotic assembly (103) to actuate the slave surgical instrument (104).

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