Test unit for testing a surgical robot system

Abstract

A surgical robot test unit for testing a surgical robot system, the surgical robot system comprising: a first subsystem configured to generate a first signal having a first characteristic behavior; and a second subsystem configured to receive the first signal and to respond to the received first signal, the test unit configured to: emulate the first subsystem by: generating an emulated signal representative of the first signal of the first subsystem, the emulated signal having an emulated behavior that exceeds a boundary of the first characteristic behavior of the first signal, such that the test unit is operable to test the second subsystem beyond the capabilities of the first subsystem; transmitting the generated emulated signal for receipt at the second subsystem; and receiving a response signal from the second subsystem, the response signal indicative of a response of the second subsystem to the emulated signal; analyzing the received response signal; and determining a state of the second subsystem based on the analysis.

Description

Technical Field

[0001] This invention relates to a test unit for testing at least a portion of a surgical robot system. Specifically, this invention relates to a test unit for connecting to one or more subsystems of a surgical robot system for testing those subsystems. Background Technology

[0002] The use of robots to assist and perform surgery is known. Figure 1 A typical surgical robot 100 is shown, comprising a base 108 and an arm 102. An instrument 105 is attached to the arm. The base supports the robot and is rigidly attached itself to, for example, an operating room floor, operating room ceiling, or trolley. The arm extends between the base and the instrument. The arm is hinged by means of a plurality of flexible joints 103 along its length, which are used to position the surgical instrument relative to the patient in a desired location. The surgical instrument is attached to the distal end 104 of the robotic arm. The surgical instrument penetrates the body of the patient 101 at a port 107 to access the surgical site. As shown, the instrument includes an end effector 106 at its distal end for performing medical procedures. The term "instrument" includes endoscopes for imaging the surgical site and includes electrosurgical instruments.

[0003] Surgical robot 100 is operated by an operator (e.g., a surgeon) via... Figure 2 The operator console 200 shown is remotely controlled. The operator console 200 can be located in the same room (e.g., an operating room) as the surgical robot 100 or remotely from the surgical robot. The operator console 200 includes input devices 202, 204 for controlling the state of the arm 102 and / or the instruments 105 attached thereto. The input devices 202, 204 can be handles or manual controllers mounted on a parallelogram linkage. The control system converts movement of the manual controller into control signals to move the arm, joints, and / or instrument end effectors of the surgical robot. The operator can select when to activate the electrosurgical instrument (power it on). The control system can determine when the electrosurgical instrument will be powered on and can generate another control signal accordingly.

[0004] The operator console 200 also includes a display 206. The display 206 is arranged to be visible to the user of the operating input devices 202, 204. The display is used to display a video stream (e.g., endoscopic video) of the surgical site.

[0005] Some surgical procedures may require several surgical robots, each carrying instruments or other equipment that are used simultaneously with other equipment at the surgical site. Figure 3A surgical robot system 300 is illustrated, comprising multiple robots 302, 304, and 306 operating in a shared workspace on a patient 308. Surgical robots are commonly used for endoscopic procedures (e.g., laparoscopic surgery), which may also be referred to as minimally invasive surgery. As known to those skilled in the art, during an endoscopic procedure, a surgeon inserts an endoscope through a small incision or natural opening in the body (e.g., but not limited to the mouth or nostril). The endoscope is a rigid or flexible tube with a camera attached thereto, which transmits real-time images to a video monitor (e.g., display 206), which the surgeon uses to help guide his tools through the same incision / opening or through different incisions / openings. Endoscopy allows surgeons to view relevant areas of the body in detail without having to cut and expose those areas. This technology allows surgeons to see inside the patient's body and operate through incisions much smaller than those required for conventional open surgery. Therefore, in a typical robotic endoscopic surgery, there is an endoscope attached to one robotic arm and one or more other surgical instruments, such as a pair of forceps and / or scissors, attached to one or more other robotic arms.

[0006] The endoscope can be docked to the robotic arm to which it is mounted, or to another part of the robotic system, to provide power and data connectivity to the endoscope. The power connection can supply power to the endoscope's hinges and / or its lights. The data connection can provide control signals for controlling the endoscope. The endoscope can capture still and / or moving images (video). The data connection appropriately allows for the transmission of images from the endoscope, for example, to an operator console for display and / or storage.

[0007] In addition to endoscopic video, data including telemetry data can be transferred between the robotic arm (and the instruments attached to it) and the operator's console. This data may include control signals used to manipulate the robotic arm and instruments, as well as sensing data generated by sensors located on the arm and / or instruments. Therefore, the data can be correlated with the state of the robotic system. Being able to determine the state of the robotic system in a more flexible manner would be useful. Summary of the Invention

[0008] This summary is provided to introduce the choice of concepts further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter.

[0009] According to one aspect of the present invention, a surgical robot test unit is provided for testing a surgical robot system, the surgical robot system comprising: a first subsystem configured to generate a first signal having a first characteristic behavior; and a second subsystem configured to receive and respond to the first signal, the test unit being configured to:

[0010] The first subsystem is mimicked by the following operations:

[0011] A simulated signal representing a first signal of the first subsystem is generated, the simulated signal having simulated behavior exceeding the boundary of a first characteristic behavior of the first signal, such that the test unit is operable to test the second subsystem beyond the capabilities of the first subsystem;

[0012] Transmit the generated analog signal for reception at the second subsystem; and

[0013] Receive a response signal from the second subsystem, the response signal indicating the response of the second subsystem to the simulated signal;

[0014] Analyze the received response signal; and

[0015] The state of the second subsystem is determined based on the analysis.

[0016] The test unit can be configured to analyze the received response signal by comparing the received response signal with an expected signal. The boundary of the first characteristic behavior may include a maximum signal value, and the test unit can be configured to generate a simulated signal having a value greater than the maximum signal value.

[0017] The boundary of the first characteristic behavior may include a minimum signal value, and the test unit may be configured to generate a simulated signal having a value smaller than the minimum signal value.

[0018] The test unit can be configured to generate a simulated signal that exceeds a value range that includes a first value range of the first signal.

[0019] The boundary of the first characteristic behavior may include a repeatability indication of the first signal, and the test unit may be configured to generate a simulated signal with repeatability greater than the indicated repeatability. The repeatability indication may include a standard deviation, and the test unit may be configured to generate a simulated signal with a standard deviation smaller than the standard deviation of the repeatability indication.

[0020] The boundary of the first characteristic behavior may include the rate of change of the value of the first signal, and the test unit may be configured to generate a simulated signal having a rate of change that is larger and / or smaller than the boundary rate of change.

[0021] The test unit can be configured to generate one or more analog signals from a set of analog signals, each analog signal representing a signal that can be generated by the first subsystem.

[0022] The test unit can be configured to:

[0023] The second subsystem is simulated through the following operations:

[0024] A second signal representing the second subsystem is generated for use with another emulated signal received at the first subsystem. The second signal has a second characteristic behavior, and the other emulated signal has an emulated behavior that exceeds another boundary of the second characteristic behavior of the second signal, such that the test unit is operable to test the first subsystem beyond the capabilities of the second subsystem.

[0025] Transmit another analog signal generated for reception at the first subsystem; and

[0026] Receive another response signal from the first subsystem, the other response signal indicating the response of the first subsystem to the other emulated signal;

[0027] Analyze the received response signal and the expected signal; and

[0028] The state of the first subsystem is determined based on the comparison.

[0029] The test unit can be configured to analyze another received response signal by comparing it with another expected signal. The first subsystem may include one of a console and a bedside unit, and the second subsystem may include the other of the console and the bedside unit.

[0030] The test unit can be configured to mimic multiple console and / or bedside units. The mimicked signals can represent arm control signals. The mimicked signals may include one or more desired joint torques and / or speeds. The mimicked signals can represent instrument control signals. The mimicked signals may include electrosurgical signals.

[0031] The simulated signal includes the desired range of motion of the arm and / or the device.

[0032] According to another aspect of the present invention, a surgical system is provided, comprising:

[0033] Surgical robot system, the surgical robot system having

[0034] A first subsystem, configured to generate a first signal having a first characteristic behavior, and

[0035] A second subsystem, configured to receive the first signal and respond to the received first signal; and

[0036] Surgical robot testing unit, the surgical robot testing unit being configured to:

[0037] The first subsystem is mimicked by the following operations:

[0038] A simulated signal representing a first signal of the first subsystem is generated, the simulated signal having simulated behavior exceeding the boundary of a first characteristic behavior of the first signal, such that the test unit is operable to test the second subsystem beyond the capabilities of the first subsystem;

[0039] Transmit the generated analog signal for reception at the second subsystem; and

[0040] Receive a response signal from the second subsystem, the response signal indicating the response of the second subsystem to the simulated signal;

[0041] Analyze the received response signal; and

[0042] The state of the second subsystem is determined based on the analysis.

[0043] According to another aspect of the present invention, a method for testing a surgical robot system is provided, the surgical robot system comprising: a first subsystem configured to generate a first signal having a first characteristic behavior; and a second subsystem configured to receive the first signal and respond to the received first signal, the method comprising:

[0044] Generate an imitation signal representing a first signal of the first subsystem, the imitation signal having imitation behavior exceeding the boundary of a first characteristic behavior of the first signal;

[0045] The generated analog signal is transmitted for reception at the second subsystem;

[0046] Receive a response signal from the second subsystem, the response signal indicating the response of the second subsystem to the simulated signal;

[0047] Analyze the received response signal; and

[0048] Based on the analysis, the state of the second subsystem is determined, thereby exceeding the capabilities of the first subsystem to test the second subsystem.

[0049] According to another aspect of the invention, a test unit configured to perform the methods described herein is provided.

[0050] According to another aspect of the invention, a surgical robot system is provided, the surgical robot system comprising: a robot having a base and an arm extending from the base to an attachment for an instrument; and a test unit configured to perform the methods described herein.

[0051] According to another aspect of the invention, a non-transitory computer-readable storage medium is provided, having stored thereon computer-readable instructions that, when executed at a computer system, cause the computer system to perform the methods described herein.

[0052] Any feature of any of the above aspects may be combined with any one or more other features of any of the above aspects. Any method feature may be written as a device feature, and vice versa. Attached Figure Description

[0053] The invention will now be described by way of example with reference to the accompanying drawings.

[0054] In the attached diagram:

[0055] Figure 1 An example surgical robot is schematically shown performing an example surgical procedure;

[0056] Figure 2 An example operator console is shown schematically;

[0057] Figure 3 An example surgical robot system with multiple surgical robots is illustrated schematically;

[0058] Figure 4 A typical setup of a surgical robot system is illustrated schematically;

[0059] Figure 5a A surgical robot system with a test unit is schematically shown;

[0060] Figure 5b Another surgical robot system with a test unit is schematically shown;

[0061] Figure 6 The connection arrangement between the test unit and the subsystems of the surgical robot system is schematically shown;

[0062] Figure 7An example of an operator console is shown schematically;

[0063] Figure 8 An example of a bedside unit is shown schematically;

[0064] Figure 9 An example of a test unit is illustrated schematically; and

[0065] Figure 10 The method for operating the test unit is shown. Detailed Implementation

[0066] The following description is presented by way of example to enable those skilled in the art to make and use the invention. The invention is not limited to the embodiments described herein, and various modifications to the disclosed embodiments will be apparent to those skilled in the art. The embodiments are described by way of example only.

[0067] Surgical robotic systems typically comprise many different subsystems. For example, the operator console and one or more bedside units interact with each other to enable the robotic system to function as a whole. The operator console can operatively control the robotic arm and instruments coupled to the bedside units and can receive responses from the bedside units. Various subsystems of the robotic system can be connected and operated together to determine the status of individual subsystems or the entire system by monitoring data transmitted between them.

[0068] In the improved method, the surgical robot test unit can be coupled to one or more subsystems of the robot system. The test unit can mimic another subsystem, for example, by generating signals and transmitting them to the subsystem under test. The test unit can monitor the response of the subsystem under test and thereby determine its state. For example, the test unit can be coupled to a bedside unit with an arm mounted thereon. The test unit can generate drive signals to drive the arm joints in a specific manner. The test unit can monitor sensor signals, such as signals from torque and / or acceleration sensors on the arm, to determine how the arm responds to the drive signals. If the arm moves in an unexpected manner, the test unit can determine that a fault has occurred in the arm. Therefore, the test unit can be used to diagnose faults in one or more subsystems. The test unit can also be used for maintenance testing by analyzing the response to one or more of a predetermined series of test signals.

[0069] The advantage of the test unit described in this paper lies in its ability to generate signals beyond the capabilities of the subsystem it is mimicking. For example, it can generate signals outside the signal range of the mimicked subsystem. The test unit can appropriately generate signals that change at a rate faster or slower than that possible from the mimicked subsystem. The test unit can appropriately generate signals with higher repeatability than that possible from the mimicked subsystem. This allows for higher accuracy in testing the subsystem.

[0070] Enabling the test unit to test the corresponding subsystem using signals with characteristics exceeding those of the boundary signals from different subsystems means that the test unit can "stress-test" the corresponding subsystem. In other words, the test unit can test the corresponding subsystem under more extreme conditions than those experienced during standard operation of the surgical robot system. This testing method allows for greater reliability of the subsystem's response during standard operation.

[0071] A surgical robot test unit is used to test a surgical robot system. Suitably, the surgical robot system includes a first subsystem. The first subsystem may be an operator console or a bedside unit. The first subsystem is configured to generate a first signal having a first characteristic behavior. The robot system includes a second subsystem, such as a bedside unit or operator console, configured to receive and respond to the first signal. The test unit is configured to mimic the first subsystem. The test unit suitably mimics the first subsystem by generating a mimic signal. The mimic signal represents the first signal of the first subsystem. The mimic signal has mimicked behavior. The mimicked behavior exceeds the boundaries of the first characteristic behavior of the first signal, enabling the test unit to operate beyond the capabilities of the first subsystem to test the second subsystem.

[0072] The test unit can further mimic the first subsystem by transmitting a generated simulating signal for reception at the second subsystem. The test unit is also configured to receive a response signal from the second subsystem indicating the second subsystem's response to the simulating signal.

[0073] The test unit is configured to compare the received response signal with the expected signal and determine the state of the second subsystem based on the comparison.

[0074] Therefore, the test unit can perform maintenance or diagnostic tests on the second subsystem by transmitting the required signals to the second subsystem and monitoring the second subsystem's response to the transmitted signals.

[0075] Generally, the operator console can be considered a subsystem of a surgical robotic system. A bedside unit can be considered another subsystem. These subsystems can be viewed at a higher level of generalization. For example, multiple bedside units can be connected together and considered as a whole as a subsystem. These subsystems can also be viewed at a lower level of generalization. For example, instruments or endoscopes attached to an arm can be considered subsystems. A robotic arm attached to a bedside unit can be considered a subsystem. The processing or control modules within the operator console can be considered subsystems. However, precisely defining which are considered subsystems of the surgical robotic system is not important.

[0076] This technology applies to situations where a portion of a surgical robot system can receive input and generate output in response to that input. This allows the portion to be "queried" by a test unit. The portion's response to the test unit's query can then be used in routine maintenance and / or troubleshooting procedures.

[0077] In the following discussion, the bedside unit will be considered a subsystem of the surgical robotic system. The bedside unit may have a robotic arm attached to it. For the purposes of this discussion, the robotic arm may also be considered part of the subsystem when attached to the bedside unit. The robotic arm may have instruments or endoscopes attached to it. For the purposes of this discussion, the instruments or endoscopes may also be considered part of the subsystem when attached to the arm. It should be understood that the robotic arm and instruments do not need to be part of the bedside unit subsystem.

[0078] Figure 4 The image shows a typical setup of a surgical robot system 400. Figure 4 An operator console 402 is shown connected to three bedside units: bedside unit A 404, bedside unit B 406, and bedside unit C 408. In the illustrated arrangement, bedside unit C 408 is located on one side of the patient table 410, and bedside units A 404 and B 406 are located on the other side of the patient table 410. Each bedside unit is directly connected to the operator console 402. In other arrangements, the bedside units may be connected in series, and the operator console is connected to the first bedside unit.

[0079] Figure 5a As shown Figure 4 The surgical robot system 500 is included, but a test unit 502 is added. The test unit can be provided for direct connection to any one or more of the operator console and / or bedside units. Figure 5aIn this exemplary arrangement, test units 502 are coupled to the bedside unit while remaining coupled to the operator console. In this arrangement, test units 502 can be operated to test one or more of the operator console and the bedside unit without disconnecting the console or bedside unit from the rest of the system. This approach allows test units to be conveniently coupled to the robot system without requiring the reconfiguration of the robot system itself.

[0080] Therefore, the test unit 502 can be operatively connected to the robot system 500 in a quick and easy manner. When testing is performed without a surgical procedure, the ability to connect the test unit 502 to the robot system with minimal disruption reduces downtime when the robot system cannot perform a surgical procedure. Thus, maintenance checks or fault diagnosis procedures can be performed efficiently. If replacement is needed, for example due to a faulty instrument connected to the robot system, this can be done before the system is used for another procedure. If a fault is detected and replacement is only performed at the start of another procedure, harmful interruptions can be reduced. If replacement is not required, the test unit 502 can be detached from the surgical system, allowing the surgical system to be ready for another procedure without reconnection.

[0081] Another approach is to connect test unit 502 to the subsystem when it is separated from the rest of the surgical robot system. This method... Figure 5b The diagram shows a test unit 502 connected to bedside unit C 408. Bedside unit C is not connected to operator console 402. This approach allows test unit 502 to test bedside unit C 408 without potential interference from signals transmitted from operator console 402. Therefore, this alternative approach allows operator console to continue communicating with other bedside units 404, 406, for example, for repositioning the arms and / or instruments of those units. Thus, while testing is performed on another part of the system, the rest of the surgical robot system can be prepared for another surgical procedure. This arrangement also allows operator console 402 to operatively control bedside units A 404 and B 406 during a surgical procedure while bedside unit C 408 is being tested by test unit 502. In this arrangement, bedside unit C 408 does not need to be held or located near patient table 410.

[0082] Appropriately, test unit 502 is configured to connect to a maximum of three bedside units at a time, such as Figure 6As shown, however, in other configurations, test unit 502 can be connected to more or fewer bedside units. Test unit 502 is connected to bedside units A404, B406, and C408. In this configuration, the test unit is appropriately configured to mimic an operator's console when connected to a bedside unit. Therefore, the test unit can generate appropriate signals, such as drive signals for the actuator arm and / or the instruments of the bedside unit.

[0083] Test unit 502 can also be appropriately connected to operator console 402 (e.g., Figure 6 (Indicated by the dashed line in the diagram). This connection can occur simultaneously with the connection between test unit 502 and the bedside unit, but is not required. In one method, test unit 502 is configured to be connected to operator console 402 when test unit 502 is not connected to a bedside unit. In a configuration where test unit 502 is connected to operator console 402 (whether or not it is also connected to one or more bedside units), the test unit is appropriately configured to mimic one or more bedside units (optionally including corresponding arms, potentially including surgical instruments and / or endoscopes). In this way, the test unit can interact with the operator console such that the operator console appears to be connected to one or more actual bedside units. The behavior of the operator console in response to signals mimicking bedside unit signals can therefore be tested by test unit 502.

[0084] Now refer to Figures 7 to 9 Further descriptions of the operator console, bedside unit, and test unit are provided. An illustrative example of the operator console is provided in [link to example]. Figure 7As shown in the diagram. The operator console 402 includes one or more input controllers 702, a kinematic controller 704 with a signal generator 706, a memory 708, and a transceiver 710. Typically, two input controllers are provided for manipulation by the hands of an operator, such as a surgeon. Other examples of input controllers include foot pedals, eye-tracking sensors, gesture sensors, touch-sensitive interfaces, audio sensors, such as voice-activated interfaces, etc. The input controller 702 is coupled to the kinematic controller 704. The kinematic controller processes signals received from the input controllers and generates appropriate signals, such as drive signals for driving the robotic arm and instruments. The kinematic controller 704 appropriately responds to sensor signals from sensors at the bedside unit (e.g., on the arm and / or instrument). The kinematic controller may include a signal generator unit 706 for generating signals to be transmitted to the bedside unit. In some embodiments, it is not necessary to provide the signal generator as a separate module. In some embodiments, the signal generator may be provided as a separate module. The kinematic controller is coupled to memory 708, for example, to access stored sensor readings and / or previously generated signals related to the bedside unit, such as drive signals from which the current drive signal is to be generated. Input controller 702 may also be directly coupled to memory 708, for example, to store input controller signals. The kinematic controller is coupled to transceiver 710, which facilitates the transmission of signals generated by the operator's console to another subsystem. The transceiver also facilitates the reception of signals from such other subsystems. The received signals can be processed at the operator's console, for example, at the kinematic controller.

[0085] It should be understood that, for the purpose of understanding this technology, the above description of the operator console has focused on selected elements of the operator console. This description is not necessarily considered a complete description of an actual implementation of such an operator console.

[0086] Figure 8 An example of a bedside unit 800 is shown. The bedside unit includes sensors 802, including an arm sensor 804 and an instrument (and / or endoscope) sensor 806. The bedside unit also includes actuators 808, including an arm actuator 810 and an instrument (and / or endoscope) actuator 812. As shown, the bedside unit also includes an electrosurgical generator 814. It should be understood that the electrosurgical generator is only required when electrosurgical instruments are coupled to a robotic arm. The bedside unit also includes a processor 816, a memory 820, and a transceiver 822.

[0087] Figure 8The sensor 802, schematically shown, is typically mounted on or part of a robotic arm or instrument. Arm sensor 804 is mounted on or part of a surgical robotic arm. Instrument sensor 806 is mounted on or part of a surgical instrument. Instrument sensors can be replaced by endoscopic sensors, where an endoscope is provided instead of a surgical instrument. In other embodiments, instrument sensors may be located on or part of a surgical robotic arm. Where multiple sensors, such as instrument sensor 806, are provided, subsets of the multiple sensors may be mounted on or part of the surgical robotic arm, and different subsets of the multiple sensors may be mounted on or part of a surgical instrument.

[0088] The electrosurgical generator 814 is configured to supply power to an electrosurgical instrument, such as a cauterizer. A specific power distribution can be provided by the electrosurgical generator 814 in response to a control signal sent by the processor 816. The power supplied by the electrosurgical generator can be coupled to an electrosurgical instrument (not shown).

[0089] Processor 816 is configured to receive sensor input from sensor 802 and provide drive signals to actuator 808. The processor is configured to process signals according to the control system to achieve appropriate control of various parts of the bedside unit 800. The processor can operate in response to signals received from another subsystem, such as an operator console. The processor can transmit signals to another subsystem, such as an operator console.

[0090] One or more of the sensor 802, actuator 808, electrosurgical generator 814, and processor 816 are suitably coupled to memory 820. This allows signals and / or other data to be saved to and read from memory.

[0091] Processor 816 is coupled to transceiver 822, which facilitates the transmission of signals generated by bedside unit 800 to another subsystem. The transceiver also facilitates the reception of signals from such other subsystems. The received signals can be processed at the bedside unit, for example, at processor 816.

[0092] It should be understood that, for the purpose of understanding this technology, the above description of the bedside unit 800 has focused on selected elements of the bedside unit (where the robotic arm and the instruments attached to the robotic arm are considered part of the bedside unit). This description is not necessarily a complete description of an actual implementation of such a bedside unit.

[0093] Example of test unit 502 in Figure 9As shown in the diagram, the test unit includes a processor 900, a memory 902, a database 904, and a transceiver 906. The processor includes a kinematic controller emulator 908 for simulating the kinematic controller 704 of the operator console 402. The kinematic controller emulator may include a signal generator module 910 for simulating the signal generator 706 of the operator console. The kinematic controller emulator 908 enables the test unit 502 to mimic the behavior of the operator console when generating signals (e.g., drive signals) for transmission to the bedside unit. Therefore, the test unit 502 can mimic the operator console, for example, when coupled to one or more bedside units.

[0094] The processor 900 is also suitably configured to process signals received from the operator console and, in response, generate appropriate signals, such as response signals characterizing the response of the bedside unit (optionally including analog sensor signals and / or actuator signals, and / or electrosurgical signals). Thus, the test unit 502 is capable of simulating one or more bedside units, for example, when coupled to the operator console.

[0095] Processor 900 is coupled to memory 902, database 904, and transceiver 906. Memory 902 allows the processor to store signals and data related to the subsystem emulated by unit under test 502. The processor can access the data stored in memory 902. Database 904 includes test routines 912. The test routines appropriately relate to predetermined methods for testing subsystems of the surgical robot system, as described in more detail elsewhere herein.

[0096] Transceiver 906 facilitates the transmission of signals generated by test unit 502 to the subsystem under test. Transceiver 906 also facilitates the reception of signals from such subsystems. The received signals can be processed at the test unit, for example, at processor 900.

[0097] It should be understood that, for the purposes of understanding this technology, the above description of test unit 502 focuses on selected elements of the test unit. This description is not necessarily considered a complete description of an actual implementation of such a test unit.

[0098] Test unit 502 is useful when testing one or more subsystems of a surgical robot system. The test unit can be coupled to an operator console to enable testing of outputs generated by the operator console and / or the operator console's response to simulated signals generated based on the operator console's output signals. Examples of ways in which such testing may be advantageous are provided here, but it should be understood that these are merely examples of many different ways in which test units such as those described herein can be used.

[0099] Operator consoles are typically used to drive the movement of surgical robotic arms and instruments that form part of the bedside unit described herein. Troubleshooting or testing of new drive algorithms may be necessary, or identification of faults in existing drive algorithms may be required. The use of test unit 502 allows the operator console to be tested without requiring a larger-capacity bedside unit during testing. Therefore, the bedside unit can be used in conjunction with different operator consoles to perform surgical procedures, thereby improving the overall operational efficiency of the system. Furthermore, a single test unit can replace multiple bedside units used with the operator console. This reduces the space requirements for testing, not only reducing the space requirements for the size of the bedside unit itself, but also reducing the space requirements for ensuring arm clearance when the robotic arm and instruments move in response to control signals output from the operator console.

[0100] Using a test unit can be particularly effective when testing for collision avoidance. Using a bedside unit with an operator console carries the risk of arm collisions, which can damage the arm, requiring maintenance or potentially replacement. When a test unit is used in place of the bedside unit with the operator console, it can determine whether an arm collision has occurred. Therefore, using a test unit can improve efficiency and help reduce the potential costs of the testing procedure.

[0101] Test units can be used, for example, to effectively restore a system after a failure, such as a collision, during surgical procedures. Such failure recovery can be achieved, for example, by using a test unit to simulate data (such as telemetry data from a part of the system that may have experienced a failure). This simulated data can then be analyzed, for example, compared with data from the part of the system that may have experienced the failure. The comparison of the simulated data (which may be expected data in the absence of a failure) with data from the potentially failed part of the system can help reveal whether the failure has caused any damage and / or whether it is safe to continue using the overall system or, in particular, that part of the system. The comparison may include characteristic values ​​of the compared data. The comparison may include comparison signal profiles.

[0102] The test unit can be configured to simulate data based on faults that have occurred in the system portion being simulated. In this case, the test unit can generate multiple data streams. Each data stream can be generated based on different faults or different sets of fault conditions being simulated. For example, the first fault condition to be simulated may include a first type of collision (e.g., a collision between an arm and a table). The second fault condition to be simulated may include a second type of collision (e.g., a collision between two arms). The third fault condition to be simulated may include the arm actuator becoming faulty. It should be understood that many other faults, etc., can be simulated similarly, including combinations: for example, the fourth fault condition to be simulated may include the first type of collision and the arm actuator becoming faulty.

[0103] A simulated data stream can be compared with data obtained from a portion of the system under test. This comparison can help identify faults or sets of fault conditions that have occurred. For example, a simulated data stream that most closely matches the acquired data can be identified (e.g., based on known comparison metrics, such as a general signal profile, predefined characteristics of the comparison signal, etc.), and fault conditions or sets of fault conditions associated with that simulated data stream can be identified as fault conditions or sets of fault conditions that have occurred or are most likely to have occurred. As mentioned above, the comparison may include characteristic values ​​of the comparison data stream. The comparison may include a comparison signal profile.

[0104] Failure conditions may not always be correctly identified in this way. However, identifying the most likely failure conditions can help save time in subsequent analysis and repair tasks, so the test unit can still provide benefits.

[0105] The example will now be discussed in the context of a collision between the arm and another object. A test unit may be attached to the arm under discussion. The test unit may analyze data from the arm, for example, by comparing telemetry data from the arm with a predicted signal, such as a signal generated at the test unit itself or accessible to the test unit, to see if the collision caused any mechanical damage to the arm, or whether continued use of the arm and / or the overall system is safe. For example, the comparison may be performed by comparing the impact force of the collision (as determined from the arm's telemetry data) with a threshold (generated at the test unit or accessible to the test unit). The analysis may be performed by running tests on the arm (e.g., driving tests using the test unit) and analyzing the signals received from the actuators to ensure they are functioning correctly.

[0106] This method of using test units can improve efficiency by eliminating the need to replace bedside units that are undamaged, still functioning, and safe to use.

[0107] Test cells can be used for design verification and / or specification testing. Test cells are appropriately capable of testing subsystems, such as operator consoles and bedside units, to ensure that those subsystems operate as designed. For example, to ensure that the response to a given simulated signal conforms to the subsystem's design specifications. Using test cells allows for accurate auditing of the responses these subsystems will make without the need for careful control and / or manipulation of the robotic arm by a human operator, such as through the input controllers of an operator console.

[0108] The test unit will now be described in more detail.

[0109] The subsystem to which the test unit is configured to couple (which may be an operator console or a bedside unit) is capable of generating a first signal having a first characteristic behavior, as discussed elsewhere. The boundary of the characteristic behavior suitably includes a maximum signal value. The test unit is configured to generate a mimic signal, the value of which is greater than the maximum signal value.

[0110] The boundary of the characteristic behavior may include a minimum signal value. The test unit is configured to generate a mimic signal having a value smaller than the minimum signal value. Suitably, the test unit is configured to generate a mimic signal that exceeds the value range encompassing the first value range of the first signal. For example, where the subsystem under test is capable of generating a signal with a value range of [x,y], the test unit can suitably generate a mimic signal with a value range of [p,q], where (i) p<x; and / or (ii) q>y.

[0111] The boundary of the first characteristic behavior may include a repeatability indicator of the first signal. The repeatability indicator is an indication of the degree to which the signal value is repeatable. The repeatability indicator may include a standard deviation. The test unit is configured to generate a mimic signal having a repeatability greater than the indicated repeatability. That is, the mimic signal value may be more stable than the first signal value. The improved signal stability facilitates a more accurate test procedure.

[0112] The boundary of the first characteristic behavior may include the rate of change of the value of the first signal. The test unit is suitably configured to generate a mimic signal having a rate of change greater than the boundary rate of change. This can enable the subsystem to be "stress tested" by applying a greater rate of change than that applied during standard operation of the surgical robotic system. This can enable the test unit to verify that the subsystem under test can respond appropriately at a faster processing speed than is required during such standard operations.

[0113] The test unit is suitably configured to generate a mimic signal having a rate of change smaller than the boundary rate of change. Thus, the test unit can verify that the subsystem under test can respond appropriately to a slower time-varying signal. For example, this may be used to test the response to signal drift over time.

[0114] The test unit is suitably configured to generate one or more simulated signals from a set of simulated signals, each of which represents a signal that can be generated by a first subsystem. The first subsystem is suitably configured to operate in one of a set of modes. For example, an operation control mode may exist, in which an operator console is operatively coupled to drive the surgical robot arm and operate surgical robotic instruments. A clutch mode may also exist, in which the operator console is configured such that operator input does not drive at least one instrument. Many other modes are possible. This set of simulated signals may correspond to the set of modes of the surgical robot system. For example, one simulated signal in this set of simulated signals may correspond to the operation control mode. Another simulated signal in this set of simulated signals may correspond to the clutch mode. Therefore, selecting a simulated signal from this set of simulated signals can be used to simulate various possible control modes that can be selectively enabled and / or disabled in the surgical robot system.

[0115] The test unit need not be connected to only one subsystem of the surgical robot system. In some embodiments, the test unit can be connected to more than one subsystem. The different subsystems to which the test unit is connected do not necessarily have to be of the same type. For example, the test unit can be connected to an operator console and a bedside unit. Suitably, the test unit is configured to mimic the second subsystem by generating a second signal representing the second subsystem to another mimic signal received at the first subsystem, the second signal having a second characteristic behavior. This other mimic signal suitably has a mimic behavior that exceeds another boundary of the second characteristic behavior of the second signal, such that the test unit can operate to test the first subsystem beyond the capabilities of the second subsystem. Suitably, the test unit is configured to mimic the second subsystem by transmitting the generated other mimic signal for reception at the first subsystem. The test unit can also be configured to mimic the second subsystem by receiving from the first subsystem another response signal indicating the first subsystem's response to the other mimic signal. The test unit is suitably configured to compare the received other response signal with another expected signal and determine the state of the first subsystem based on the comparison.

[0116] Analog signals can represent arm control signals, such as signals that command the robot arm to move. Analog signals may include, for example, one or more desired joint torques and / or speeds of one or more joints of the robot arm.

[0117] Analog signals can represent instrument control signals, such as signals commanding the instrument to move. The instrument is properly coupled to a surgical robotic arm, and the instrument control signals can be transmitted to the instrument via the robotic arm. Analog signals may include, for example, one or more desired joint torques and / or speeds of one or more joints of the instrument. Analog signals may include desired instrument states, such as the opening angle between a pair of jaws of a gripper tool. Analog signals may include electrosurgical signals, such as the electrical activation level of an electrosurgical tool. The electrical activation level may include the voltage applied to the tool, or the power level used for the tool.

[0118] The simulated signal may include the desired range of motion of the arm and / or the instrument.

[0119] The test unit described herein can be provided as part of a surgical system. The surgical system may include a surgical robot system having a first subsystem (e.g., an operator console or bedside unit) and a second subsystem (e.g., a bedside unit or operator console), the first subsystem being configured to generate a first signal having a first characteristic behavior, and the second subsystem being configured to receive and respond to the received first signal. The surgical system may also include a surgical robot test unit.

[0120] Now refer to Figure 10 A method for operating the test unit is described. The test unit is operable to generate a simulated signal 1002 representing a first signal of a first subsystem. This simulated signal has simulated behavior that exceeds the boundary of a first characteristic behavior of the first signal. The test unit transmits the generated simulated signal for reception 1004 at a second subsystem.

[0121] The test unit receives a response signal 1006 from the second subsystem, indicating the second subsystem's response to the simulated signal. The test unit analyzes the received response signal 1008, for example, by comparing it to an expected signal, and determines the state 1010 of the second subsystem based on the analysis, such as the comparison. Therefore, the test unit is operable to test the second subsystem beyond the capabilities of the first subsystem.

[0122] A test unit may include independent modules. Therefore, a test unit may be equipped with necessary processors, transceivers, etc., for communicating with subsystems. A test unit may include multiple modules that are physically or conceptually separate. For example, a processing module may be coupled to a data storage and transmission module. In some examples, a test unit includes a computing device, such as a laptop or tablet. The functionality of the test unit described herein may be provided across any one or more, or two or more, combinations of such modules.

[0123] Any processor or kinematic controller described herein may be a microprocessor, controller, or any other suitable type of processor for processing computer-executable instructions. In some examples, such as when using a system-on-a-chip architecture, the processor and / or kinematic controller may include one or more fixed-function blocks (also referred to as accelerators) that implement a portion of the methods described herein in hardware (rather than software or firmware). Platform software, including an operating system or any other suitable platform software, may be provided to enable implementations such as... Figure 10 The software application software can be executed using this method.

[0124] Computer-executable instructions can be provided using any computer-readable medium accessible by a computing-based device. Computer-readable media can include, for example, computer storage media, such as memory and communication media. Computer storage media (i.e., non-transitory machine-readable media), such as memory, include volatile and non-volatile, removable and non-removable media implemented in any method or technology to store information, such as computer-readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, RAM, ROM, EPROM, EEPROM, flash memory or other storage technologies, CD-ROM, digital versatile disk (DVD) or other optical storage devices, magnetic tape cassettes, magnetic tape, disk storage devices or other magnetic storage devices, or any other non-transfer medium that can be used to store information for access by a computing-based device. In contrast, communication media can contain computer-readable instructions, data structures, program modules, or other data in modulated data signals such as carrier waves or other transmission mechanisms. As defined herein, computer storage media does not include communication media. Although computer storage media (i.e., non-transitory machine-readable media, such as memory) may be located within a computing-based device, it should be understood that storage may be remotely distributed or located and accessed via a network or other communication link (e.g., using a communication interface).

[0125] In the above description, for ease of explanation, the actions taken by the system are divided into functional blocks or modules. In practice, two or more of these blocks can be combined architecturally. These functions can also be divided into different functional blocks.

[0126] The techniques of the present invention have been described in the context of surgical robot systems, but at least some of the features described are not limited to such systems, but can be applied more generally to robot systems that include various subsystems that communicate with each other.

[0127] Robotic systems can include manufacturing systems, such as vehicle manufacturing systems, parts handling systems, laboratory systems, and manipulators, such as manipulators for hazardous materials or surgical manipulators.

[0128] The applicant hereby independently discloses each individual feature described herein, as well as any combination of two or more such features, provided that such features or combinations can be implemented based on this specification as a whole according to common general knowledge of those skilled in the art, regardless of whether such features or combinations of features solve any problem disclosed herein, and without limiting the scope of the claims. The applicant notes that aspects of the invention can consist of any such individual feature or combination of features. In view of the foregoing description, it will be apparent to those skilled in the art that various modifications can be made within the scope of the invention.

Claims

1. A surgical robot test unit for testing a surgical robot system, the surgical robot system comprising: A first subsystem, configured to generate a first signal having a first characteristic behavior; The second subsystem is configured to receive and respond to the first signal, and the surgical robot test unit is configured to: The first subsystem is mimicked by the following operations: A simulated signal representing a first signal of the first subsystem is generated, the simulated signal having simulated behavior exceeding the boundary of a first characteristic behavior of the first signal, such that the surgical robot testing unit is operable to test the second subsystem beyond the capabilities of the first subsystem; The generated analog signal is transmitted for reception at the second subsystem; as well as Receive a response signal from the second subsystem, the response signal indicating the response of the second subsystem to the simulated signal; Analyze the received response signal; as well as The state of the second subsystem is determined based on the analysis.

2. The surgical robot testing unit of claim 1, wherein the surgical robot testing unit is configured to analyze the received response signal by comparing the received response signal with an expected signal.

3. The surgical robot testing unit according to claim 1 or claim 2, wherein the boundary of the first characteristic behavior includes a maximum signal value, and the surgical robot testing unit is configured to generate a simulated signal having a value greater than the maximum signal value.

4. The surgical robot testing unit according to claim 1 or claim 2, wherein the boundary of the first characteristic behavior includes a minimum signal value, and the surgical robot testing unit is configured to generate a simulated signal having a value smaller than the minimum signal value.

5. The surgical robot testing unit according to claim 1 or claim 2, wherein the surgical robot testing unit is configured to generate a simulated signal exceeding a value range that includes a first value range of the first signal.

6. The surgical robot testing unit according to claim 1 or claim 2, wherein the boundary of the first characteristic behavior includes a repeatability indication of the first signal, and the surgical robot testing unit is configured to generate a mimic signal having a repeatability greater than the indicated repeatability.

7. The surgical robot testing unit of claim 6, wherein the repeatability indication includes a standard deviation, and the surgical robot testing unit is configured to generate a simulated signal having a standard deviation smaller than the standard deviation of the repeatability indication.

8. The surgical robot testing unit according to claim 1 or claim 2, wherein the boundary of the first characteristic behavior includes the boundary rate of change of the value of the first signal, and the surgical robot testing unit is configured to generate a simulated signal having a rate of change greater than and / or smaller than the boundary rate of change.

9. The surgical robot testing unit according to claim 1 or claim 2, wherein the surgical robot testing unit is configured to generate one or more simulated signals from a set of simulated signals, each of the set of simulated signals representing a signal that can be generated by the first subsystem.

10. The surgical robot testing unit of claim 9, wherein the first subsystem is configured to operate in one of a set of modes, and the set of simulated signals corresponds to the set of modes.

11. The surgical robot testing unit according to claim 1 or claim 2, wherein the surgical robot testing unit is configured to: The second subsystem is simulated through the following operations: A second signal representing the second subsystem is generated for use with another mimic signal received at the first subsystem. The second signal has a second characteristic behavior, and the other mimic signal has a mimic behavior that exceeds another boundary of the second characteristic behavior of the second signal, such that the surgical robot test unit is operable to test the first subsystem beyond the capabilities of the second subsystem. Transmit another analog signal generated for reception at the first subsystem; as well as Receive another response signal from the first subsystem, the other response signal indicating the response of the first subsystem to the other emulated signal; Analyze the other response signal received; as well as The state of the first subsystem is determined based on the analysis.

12. The surgical robot testing unit according to claim 1 or claim 2, wherein the first subsystem comprises one of a console and a bedside unit, and the second subsystem comprises the other of the console and the bedside unit.

13. The surgical robot test unit according to claim 1 or claim 2, wherein the surgical robot test unit is configured to mimic a plurality of consoles and / or bedside units.

14. The surgical robot test unit according to claim 1 or claim 2, wherein the simulated signal represents an arm control signal.

15. The surgical robot testing unit according to claim 1 or claim 2, wherein the simulated signal includes one or more desired joint torques and / or speeds.

16. The surgical robot testing unit according to claim 1 or claim 2, wherein the simulated signal represents an instrument control signal.

17. The surgical robot testing unit according to claim 1 or claim 2, wherein the simulated signal includes an electrosurgical signal.

18. The surgical robot testing unit according to claim 1 or claim 2, wherein the simulated signal includes the desired range of motion of the arm and / or instrument.

19. A surgical system comprising: Surgical robot system, the surgical robot system having A first subsystem, configured to generate a first signal having a first characteristic behavior, and A second subsystem, configured to receive the first signal and respond to the received first signal; and Surgical robot testing unit, the surgical robot testing unit being configured to: The first subsystem is mimicked by the following operations: A simulated signal representing a first signal of the first subsystem is generated, the simulated signal having simulated behavior exceeding the boundary of a first characteristic behavior of the first signal, such that the surgical robot testing unit is operable to test the second subsystem beyond the capabilities of the first subsystem; The generated analog signal is transmitted for reception at the second subsystem; as well as Receive a response signal from the second subsystem, the response signal indicating the response of the second subsystem to the simulated signal; Analyze the received response signal; as well as The state of the second subsystem is determined based on the analysis.

20. A method for testing a surgical robot system, the surgical robot system comprising: A first subsystem, configured to generate a first signal having a first characteristic behavior; A second subsystem, configured to receive the first signal and respond to the received first signal, the method comprising: Generate an imitation signal representing a first signal of the first subsystem, the imitation signal having imitation behavior exceeding the boundary of a first characteristic behavior of the first signal; The generated analog signal is transmitted for reception at the second subsystem; Receive a response signal from the second subsystem, the response signal indicating the response of the second subsystem to the simulated signal; Analyze the received response signal; and Based on the analysis, the state of the second subsystem is determined, thereby exceeding the capabilities of the first subsystem to test the second subsystem.

Images