Configuring a surgical robotic system

Abstract

A control system for a surgical robot system, the surgical robot system including a first robotic arm and a second robotic arm, each of the first and second robotic arms including a series of joints, the configuration of the robotic arm being changeable by the series of joints extending from a base at a proximal end of the robotic arm to an attachment for a surgical instrument at a distal end of the robotic arm, the control system being configured to reconfigure the surgical robot system by: controlling the first robotic arm to operate in a surgical mode in which a first surgical instrument attached to the first robotic arm is inside a patient's body; and while the first robotic arm is operating in the surgical mode: (i) controlling the second robotic arm to allow a second surgical instrument attached to the second robotic arm to be inserted into a port in the patient's body; (ii) determining a pivot point around which the second surgical instrument pivots when the configuration of the second robotic arm is changed while the second surgical instrument is inside the port; and (iii) controlling the second robotic arm to operate in a surgical mode in which the configuration of the second robotic arm and the second surgical instrument is controlled in response to input received at a remote surgeon's console, while maintaining the intersection between the second surgical instrument and the determined pivot point.

Description

Background Technology

[0001] This invention relates to a method for reconfiguring a surgical robot system.

[0002] Surgical robotic systems can be used to perform invasive medical procedures. Figure 1 A typical surgical robot system is illustrated. A surgical robot system 100 is shown performing invasive medical procedures on a patient 102 located on an operating table 103. The surgical robot system 100 includes three arms 101a, 101b, and 101c. The three arms 101a, 101b, and 101c are attached to a common unit 110. Each arm 101a, 101b, and 101c may carry surgical instruments 106, such as tools for performing cutting or grasping, or imaging devices, such as endoscopes. Each arm 101a, 101b, and 101c may manipulate its carried surgical instruments to perform various aspects of the invasive procedure. The surgical robot system is supported by a base 109 placed on the floor of the operating room.

[0003] In the event that one or more of arms 101a, 101b, or 101c fail or become unavailable for any other reason, a decision must typically be made regarding whether the invasive procedure can be performed using only the remaining arms of the surgical robotic system, or whether the invasive procedure should be converted to a manual procedure (e.g., in which the surgeon manipulates surgical instruments to complete the procedure, rather than the robotic surgical system). Both scenarios are undesirable—both increase the difficulty of completing the invasive procedure, and the conversion to a manual procedure generally results in a longer recovery time for the patient.

[0004] Therefore, it would be desirable if there were improved methods for reconfiguring surgical robot systems that could solve the above problems. Summary of the Invention

[0005] According to a first aspect of the invention, a method for reconfiguring a surgical robot system is provided, the surgical robot system including a first robotic arm and a second robotic arm, each of the first and second robotic arms including a series of joints, the configuration of the robotic arm being changeable by the series of joints extending from a base at a proximal end of the robotic arm to an attachment for a surgical instrument at a distal end of the robotic arm, the method comprising: operating the first robotic arm in a surgical mode, in which a first surgical instrument attached to the first robotic arm is inside a patient's body; and when operating the first robotic arm in the surgical mode: (i) inserting a second surgical instrument attached to the second robotic arm into a port in the patient's body; (ii) determining a pivot point around which the second surgical instrument pivots when the configuration of the second robotic arm is changed while the second surgical instrument is inside the port; and (iii) operating the second robotic arm in a surgical mode, in which the configuration of the second robotic arm and the second surgical instrument is controlled by a remote surgeon's console while maintaining an intersection between the second surgical instrument and the determined pivot point.

[0006] The fulcrum can be determined by: enabling the configuration of the second robotic arm to change in response to an external force; applying an external force to the second robotic arm, causing its configuration to change, when the second surgical instrument is inside the port; and determining the fulcrum, which is the point around which the surgical instrument of the second robotic arm pivots when it is inside the port.

[0007] The second robotic arm may further include: one or more force sensors configured to sense forces at one or more joints of a series of joints of the second robotic arm; and one or more motors configured to drive one or more joints of the series of joints of the second robotic arm, and the method may further include: sensing external forces at one or more joints of the series of joints of the second robotic arm using the one or more force sensors; and driving one or more joints of the series of joints of the second robotic arm using the one or more motors according to the sensed external forces, so as to change the configuration of the second robotic arm.

[0008] The second robotic arm may further include one or more position sensors configured to sense the position of one or more joints of a series of joints of the second robotic arm, and the method may further include: recording the position of one or more joints of the series of joints of the second robotic arm under various conditions using the at least one position sensor while the configuration of the second robotic arm is being changed; determining the position of the distal end of the second robotic arm for each condition based on the corresponding recorded one or more joint positions; determining the vector of the second surgical instrument from the determined distal end position of the second robotic arm for each condition based on the corresponding recorded one or more joint positions; and determining the intersection point of the determined vector of the second surgical instrument to determine the fulcrum.

[0009] The fulcrum can be the natural rotation center of the port.

[0010] The method may further include: determining the fulcrum when the second robotic arm is operating in a calibration mode; and switching the second robotic arm from operating in the calibration mode to operating in the surgical mode.

[0011] The second robotic arm may also include a more distal interface and a less distal interface, and the method may further include: using the more distal interface to switch the second robotic arm from operation in the calibration mode to operation in the surgical mode.

[0012] The method may further include: inserting the second surgical instrument into the port by operating the second robotic arm in a compatibility mode, wherein the configuration of the second robotic arm can be changed in response to an external force; and switching the operation of the second robotic arm from the compatibility mode to the calibration mode.

[0013] The method may further include: using the more distal interface to switch the second robotic arm from operating in the compatibility mode to operating in the calibration mode.

[0014] The method may further include: after determining the fulcrum, operating the second robotic arm in an instrument adjustment mode, in which the configuration of the second robotic arm can be changed in response to an external force, but is constrained to maintain an intersection between the second surgical instrument and the determined fulcrum; and while maintaining the intersection between the second surgical instrument and the determined fulcrum, applying an external force to the second robotic arm to change its configuration.

[0015] The method may further include: switching the second robotic arm from operation in the calibration mode to operation in the instrument adjustment mode; and switching the second robotic arm from operation in the instrument adjustment mode to operation in the surgical mode.

[0016] The method may further include: using the more distal interface to switch the second robotic arm from operation in the calibration mode to operation in the instrument adjustment mode; and using the more distal interface to switch the second robotic arm from operation in the instrument adjustment mode to operation in the surgical mode.

[0017] The method may further include: switching the second robotic arm from operating in the surgical mode to operating in the instrument adjustment mode.

[0018] The method may further include: using the less distal interface to switch the second robotic arm from operating in the surgical mode to operating in the instrument adjustment mode.

[0019] The second robotic arm may be supported by a movable arm support structure, and the method may further include: moving the arm support structure to a position adjacent to the patient while the first robotic arm is operating in the surgical mode and before inserting the second surgical instrument into the port.

[0020] Each of the first and second robotic arms may further include an orientation interface, and the method may further include: after moving the movable arm support structure supporting the second robotic arm to a position adjacent to the patient, identifying a common orientation by using the orientation interface of the first robotic arm to indicate an orientation and by using the orientation interface of the second robotic arm to indicate a corresponding orientation.

[0021] In the surgical mode, the second robotic arm can be remotely controlled by: receiving inputs related to the second robotic arm into the remote control console; converting the inputs into control signals for the second robotic arm based on a determined fulcrum and an identified common direction; and controlling one or more joints of a series of joints of the second robotic arm according to the control signals in order to control the configuration of the second robotic arm.

[0022] The surgical robot system may include a third robotic arm comprising a series of joints, the configuration of which can be altered by the series of joints extending from a base at the proximal end of the robotic arm to an attachment for a surgical instrument at the distal end of the robotic arm, and the method may further include: retracting a third surgical instrument attached to the third robotic arm from the patient's body while the first robotic arm is operating in the surgical mode and before inserting a second surgical instrument into the port.

[0023] The method may further include retracting the third surgical instrument from the patient's body by: enabling the configuration of the third robotic arm to change in response to an external force, restricting the degrees of freedom of the third robotic arm such that the third surgical instrument can only move linearly away from the patient's body in a direction coaxial with the longitudinal axis of the third surgical instrument; and applying an external force to the third robotic arm to change its configuration in order to retract the third surgical instrument from the patient's body.

[0024] The third robotic arm may further include one or more force sensors configured to sense forces at one or more joints of a series of joints of the third robotic arm; and one or more motors configured to drive one or more joints of the series of joints of the third robotic arm, and the method may further include: sensing external forces at one or more joints of the series of joints of the third robotic arm using the one or more force sensors; decomposing the sensed external forces to determine a component of the force parallel to the longitudinal axis of the third surgical instrument and away from the patient's body; and driving one or more joints of the series of joints of the third robotic arm using the one or more motors according to the component of the force parallel to the longitudinal axis of the third surgical instrument, so as to change the configuration of the third robotic arm.

[0025] The method may further include: retracting the second surgical instrument from the patient's body while the first robotic arm is operating in the surgical mode and before inserting the second surgical instrument into the port; and performing maintenance tasks on the second robotic arm before inserting the second surgical instrument into the patient's body.

[0026] The method may further include retracting the second surgical instrument from the patient's body by: enabling the configuration of the second robotic arm to change in response to an external force, restricting the degrees of freedom of the second robotic arm such that the second surgical instrument can only move linearly in a direction parallel to the longitudinal axis of the second surgical instrument; and applying an external force to the second robotic arm to change its configuration in order to retract the second surgical instrument from the patient's body.

[0027] The second robotic arm may further include one or more force sensors configured to sense forces at one or more joints of a series of joints of the second robotic arm; and one or more motors configured to drive one or more joints of the series of joints of the second robotic arm, and the method may further include: sensing external forces at one or more joints of the series of joints of the second robotic arm using the one or more force sensors; decomposing the sensed external forces to determine a component of the force parallel to the longitudinal axis of the second surgical instrument; and driving one or more joints of the series of joints of the second robotic arm using the one or more motors according to the component of the force parallel to the longitudinal axis of the second surgical instrument, so as to change the configuration of the second robotic arm.

[0028] The surgical mode in which the first robotic arm is operating may be an adjoint surgical mode, in which a remote surgeon's console controls the configuration of the first robotic arm and the first surgical instrument.

[0029] The surgical mode in which the first robotic arm is operating can be a discontinued surgical mode, in which the configuration of the first robotic arm and the first surgical instruments can be controlled by a remote surgeon's console.

[0030] According to a second aspect of the invention, a control system for a surgical robot system is provided, the surgical robot system including a first robotic arm and a second robotic arm, each of the first and second robotic arms including a series of joints, the configuration of the robotic arm being changeable by the series of joints extending from a base at a proximal end of the robotic arm to an attachment for a surgical instrument at a distal end of the robotic arm, the control system being configured to reconfigure the surgical robot system by: controlling the first robotic arm to operate in a surgical mode, in which a first surgical instrument attached to the first robotic arm is inside a patient's body; and when the first robotic arm operates in the surgical mode: (i) controlling the second robotic arm to allow a second surgical instrument attached to the second robotic arm to be inserted into a port in the patient's body; (ii) determining a pivot point around which the second surgical instrument pivots when the configuration of the second robotic arm is changed while the second surgical instrument is inside the port; and (iii) controlling the second robotic arm to operate in a surgical mode, in which the configuration of the second robotic arm and the second surgical instrument is controlled in response to input received at a remote surgeon's console, while maintaining the intersection between the second surgical instrument and the determined pivot point.

[0031] The fulcrum can be determined by: controlling the second robotic arm to change its configuration in response to external forces when the second surgical instrument is inside the port; and determining the fulcrum as the point around which the surgical instrument of the second robotic arm pivots inside the port.

[0032] The second robotic arm may further include: one or more force sensors configured to sense external forces at one or more joints of a series of joints of the second robotic arm; and one or more motors configured to drive one or more joints of a series of joints of the second robotic arm, and the control system may further be configured to: control the one or more motors to drive one or more joints of a series of joints of the second robotic arm based on the external forces sensed by the one or more force sensors, so as to change the configuration of the second robotic arm.

[0033] The second robotic arm may further include one or more position sensors configured to sense the position of one or more joints of a series of joints of the second robotic arm, and to record the position of one or more joints of the series of joints of the second robotic arm under various conditions when the configuration of the second robotic arm is being changed, and the control system may further be configured to: determine the position of the distal end of the second robotic arm for each condition based on the corresponding recorded one or more joint positions; determine the vector of the second surgical instrument from the determined distal end position of the second robotic arm for each condition based on the corresponding recorded one or more joint positions; and determine the intersection point of the determined vector of the second surgical instrument in order to determine the fulcrum.

[0034] The control system can also be configured to: determine the fulcrum when controlling the second robotic arm to operate in calibration mode; and control the second robotic arm to switch from operating in calibration mode to operating in surgical mode.

[0035] The second robotic arm may also include a more distal interface and a less distal interface, and the control system may also be configured to control the second robotic arm to switch from operating in the calibration mode to operating in the surgical mode in response to an interaction between the operator and the more distal interface.

[0036] The control system can also be configured to: control the second robotic arm to operate in a compatibility mode, control the second robotic arm to allow the second surgical instrument to be inserted into the port, in which the configuration of the second robotic arm can be changed in response to an external force; and control the second robotic arm to switch from operating in the compatibility mode to operating in the calibration mode.

[0037] The control system can also be configured to control the second robotic arm to switch from operating in the compatibility mode to operating in the calibration mode in response to user interaction with the more remote interface.

[0038] The control system can also be configured to: after determining the fulcrum, control the second robotic arm to operate in an instrument adjustment mode, in which the configuration of the second robotic arm can be changed in response to external forces, but is constrained to maintain an intersection between the second surgical instrument and the determined fulcrum.

[0039] The control system may also be configured to: control the second robotic arm to switch from operating in the calibration mode to operating in the instrument adjustment mode; and control the second robotic arm to switch from operating in the instrument adjustment mode to operating in the surgical mode; and optionally, control the second robotic arm to switch from operating in the surgical mode to operating in the instrument adjustment mode.

[0040] Each of the first and second robotic arms may further include an orientation interface, and the control system may further be configured to receive input identifying a common direction in response to an operator indicating a direction using the orientation interface of the first robotic arm and indicating a corresponding direction using the orientation interface of the second robotic arm.

[0041] In the surgical mode, the second robotic arm can be remotely controlled by the control system configured to: receive inputs related to the second robotic arm from the remote console; convert the inputs into control signals for the second robotic arm based on a determined fulcrum and an identified common direction; and control one or more joints of a series of joints of the second robotic arm according to the control signals in order to control the configuration of the second robotic arm.

[0042] The surgical robot system may include a third robotic arm comprising a series of joints, the configuration of which can be altered by the series of joints extending from a base at the proximal end of the robotic arm to an attachment for a surgical instrument at the distal end of the robotic arm, and the control system may also be configured to control the third robotic arm while controlling the first robotic arm to operate in the surgical mode and before allowing the second surgical instrument to be inserted into the port, so as to allow the third surgical instrument attached to the third robotic arm to retract from the patient's body.

[0043] The control system may also be configured to allow the third surgical instrument to retract from the patient's body by: enabling the configuration of the third robotic arm to change in response to external forces, and restricting the degrees of freedom of the third robotic arm such that the third surgical instrument can only move linearly away from the patient's body in a direction coaxial with the longitudinal axis of the third surgical instrument.

[0044] The third robotic arm may further include: one or more force sensors configured to sense external forces at one or more joints of a series of joints of the third robotic arm; and one or more motors configured to drive one or more joints of the series of joints of the third robotic arm. The control system may also be configured to: decompose the external forces sensed by the one or more force sensors to determine a component of the force parallel to the longitudinal axis of the third surgical instrument and away from the patient's body; and control the one or more motors according to the component of the force parallel to the longitudinal axis of the third surgical instrument to drive one or more joints of the series of joints of the third robotic arm to change the configuration of the third robotic arm.

[0045] The control system may also be configured to: control the second robotic arm to allow the second surgical instrument to retract from the patient's body while the first robotic arm is operating in the surgical mode and before allowing the second surgical instrument to be inserted into the port; and control the second robotic arm to allow the second surgical instrument to be inserted into the patient's body after a maintenance task has been performed on the second robotic arm.

[0046] The control system may also be configured to allow the second surgical instrument to retract from the patient's body by: enabling the configuration of the second robotic arm to change in response to an external force, and restricting the degrees of freedom of the second robotic arm such that the second surgical instrument can only move linearly in a direction parallel to the longitudinal axis of the second surgical instrument.

[0047] The second robotic arm may further include one or more force sensors configured to sense external forces at one or more joints of a series of joints of the second robotic arm; and one or more motors configured to drive one or more joints of the series of joints of the second robotic arm. The control system may also be configured to: decompose the external forces sensed by the one or more force sensors to determine a component of the force parallel to the longitudinal axis of the second surgical instrument; and control the one or more motors according to the component of the force parallel to the longitudinal axis of the second surgical instrument to drive one or more joints of the series of joints of the second robotic arm to change the configuration of the second robotic arm.

[0048] The surgical mode in which the control system controls the operation of the first robotic arm can be: an engaged surgical mode, in which the configuration of the first robotic arm and the first surgical instrument is controlled in response to input received at the remote surgeon's console; or a disengaged surgical mode, in which the configuration of the first robotic arm and the first surgical instrument can be controlled in response to input received at the remote surgeon's console. Attached Figure Description

[0049] The invention will now be described by way of example with reference to the accompanying drawings. In the drawings:

[0050] Figure 1 A typical surgical robot system is shown.

[0051] Figure 2 A surgical robot system is shown.

[0052] Figure 3 The surgical robot arm of the surgical robot system is shown.

[0053] Figure 4 The pattern startup sequence for a surgical robotic arm is shown.

[0054] Figure 5 This is a flowchart illustrating the steps used to calibrate a surgical robot arm.

[0055] Figure 6 A floor plan of the surgical robot system is shown.

[0056] Figure 7 A flowchart is shown illustrating the reconfiguration of a surgical robot system based on the principles described herein. Detailed Implementation

[0057] The following description is presented to enable those skilled in the art to make and use the invention, and is provided in the context of a particular application. Various modifications to the disclosed embodiments will be apparent to those skilled in the art.

[0058] The general principles defined herein can be applied to other embodiments and applications without departing from the spirit and scope of the invention. Therefore, the invention is not intended to be limited to the embodiments shown, but rather to be given the broadest scope based on the principles and features disclosed herein.

[0059] Figure 2 A surgical robot system is shown. Figure 2 A surgical robot system 200 is shown performing an invasive medical procedure on a patient 202. The patient 202 is positioned on an operating table 203. The surgical robot system 100 includes a first robotic arm 201a and a second robotic arm 201b. Although Figure 2Two robotic arms 201a and 201b are shown, but it should be understood that a surgical robot system constructed according to the principles described herein may include any number of robotic arms. Each robotic arm 201a and 201b extends from the base 209 at its proximal end. Each robotic arm 201a and 201b includes a plurality of joints 204 by which the configuration of the robotic arm can be changed.

[0060] Each robotic arm 201a, 201b includes an attachment at its distal end for a surgical instrument 206. The surgical instrument may have an elongated shaft with an end effector at its distal end for performing invasive procedures. The surgical instrument may be, for example, a cutting or grasping device or an imaging device (e.g., an endoscope). Each surgical instrument 206 may be inserted into the patient's body 202. Each surgical instrument 206 may be inserted into the patient's body 202 via a port. Each surgical instrument 206 may be inserted into the patient 202 through a different port.

[0061] The base 209 of each robotic arm 201a, 201b is supported by a support structure 209a. The support structure 209a may be movable. This support structure may be a trolley or a handcart. For example, each support structure may include one or more wheels (not shown) on which the support structure can move. In other instances, the movable support structure may be mounted on one or more of the following: rails, slides, or bearings, or any other element on which the support structure can move. In instances not shown, the base 209a may be supported by a wall- or top-mounted arm support structure (e.g., by fixing it to the structure). The wall- or top-mounted arm support structure may be mounted on one or more rails, or any other suitable element, such that the wall- or top-mounted arm support structure can be moved. The arm support structure may be movably mounted on any other suitable surface (e.g., operating table 203). The movable support structure may be equipped with brakes (not shown) so that the support structure can be kept stationary when needed (e.g., when the robotic arm it supports is involved in an invasive medical procedure).

[0062] The configuration of each robotic arm 201a, 201b can be remotely controlled in response to input received at the remote surgeon's console 220. The surgeon can provide input to the remote console 220. The remote surgeon's console includes one or more surgeon input devices 223. These may take the form of manual controllers and / or foot pedals. The surgeon's console also includes a display 221.

[0063] The control system 224 connects the surgeon's console 220 to each surgical robot 201a, 201b. The control system receives input from the surgeon's input device and converts this input into control signals to move the joints of the robotic arm 104 and the surgical instruments 206. The control system 224 sends these control signals to the robots, where the corresponding joints are driven accordingly. The control system 224 can be decoupled from the remote surgeon's console 220 and the robotic arms 201a, 201b. The control system 224 can be co-located with the remote surgeon's console 220. The control system 224 can be co-located with one of the robotic arms 201a, 201b. The control system 224 can be distributed between the remote surgeon's console 220 and the robotic arms 201a, 201b.

[0064] The configuration of each robotic arm 201a, 201b can be controlled in response to external forces applied directly to that robotic arm. For example, a member of the bedside team (e.g., an operating room nurse) can apply forces directly to the robotic arm (e.g., by pushing the joints of the robotic arm). This behavior will be described in more detail herein.

[0065] Figure 3 An example of a robotic arm 301 is shown. Figure 2 The robotic arms 201a and 201b shown can have the same characteristics as... Figure 3 The robot arm 301 shown has the same features.

[0066] The robotic arm includes a base 309. The robotic arm has a series of rigid arm components. Each arm component in this series is engaged to the preceding arm component by a corresponding joint 304a-g. Joints 304a-e and 304g are rotary joints. Joint 304f consists of two rotary joints with axes orthogonal to each other, as in a Hooke's universal joint or a gimbal joint. Joint 304f may be referred to as a "wrist joint". The robotic arm can be coupled with… Figure 3 The arms engage differently. For example, joints 304d and / or 304f may be omitted, allowing rotation about a single axis. The robotic arm may include one or more joints that allow movement in addition to rotation between corresponding sides of the joint, such as prism joints, through which the instrument attachment can slide linearly relative to a more proximal portion of the robotic arm.

[0067] The joints are configured such that the configuration of the robotic arm can be changed, thereby allowing the distal end 330 of the robotic arm to move to any point within the three-dimensional working volume, shown generally as 335. One way to achieve this is to make the joints have... Figure 3 The arrangement is shown in the diagram. Other combinations and configurations of the joints can achieve a similar range of motion, at least within region 335. The arm components can be more or fewer.

[0068] The distal end of the robotic arm 330 has an attachment 316 to which the surgical instrument 306 can be releasably attached. The surgical instrument has a linear rigid axis 361 and an end effector 362 located at the distal end of this axis. The end effector 362 comprises means for engaging procedures (e.g., cutting, grasping, or imaging devices). As described herein, the end joint 304g can be a rotary joint. The surgical instrument 306 and / or the attachment 316 can be configured such that the instrument extends linearly parallel to the axis of rotation of the end joint 304g of the robotic arm. In this example, the instrument extends along an axis coinciding with the axis of rotation of the joint 304g.

[0069] Joints 304e and 304f of the robotic arm are configured such that the surgical instrument 306 can be guided in any direction within the cone when the distal end of the robotic arm 330 is held at any position within the working volume 335. This cone is generally shown at 336. One implementation is that the distal portion of the arm includes a pair of joints 304e and 304f, whose axes are arranged relative to each other as described above. Other mechanisms can achieve similar results. For example, if the instrument extends in a direction not parallel to the axis of joint 304g, joint 304g can influence the posture of the instrument.

[0070] Surgical instrument 306 can be inserted into the patient's body through port 317. Port 317 may include a hollow tube 317a. Hollow tube 317a can pass through the patient's external tissue 302 to limit damage to these tissues during insertion and removal of the surgical instrument and during manipulation of the instrument within the patient's body. Port 317 may include a collar 317b. Collar 317b can prevent port 317 from being inserted too far through the patient's external tissue 302. In other instances (not shown), surgical instruments may be inserted directly into the patient's body, for example, through a natural orifice such as the throat. The natural orifice through which surgical instruments are inserted into the patient's body is also referred to herein as a "port".

[0071] The robotic arm 301 includes a series of motors 310a-h. In addition to the compound joint 304f provided by two motors, each motor is arranged to drive rotation about a corresponding joint of the robotic arm. The motors are controlled by a control system (e.g., Figure 2 The control system 224 shown herein controls the motors. The control unit includes a processor and a memory. The memory stores software code that can be executed by the processor in a non-transitory manner to enable the processor to control the motors 310a-h in the manner described herein.

[0072] The robotic arm 301 may include a series of sensors 307a-h and 308a-h. For each joint, these sensors may include a position sensor 307a-h for sensing the rotational position of the joint, and a force sensor 308a-h for sensing the force (e.g., torque) applied about the rotational axis of the joint. The complex joint 304f may have two pairs of sensors. One or both of the position sensor and the force sensor for the joint may be integrated with a motor for that joint. The outputs of the sensors are transmitted to the control system, where they form inputs to the processor.

[0073] The robotic arm 301 may also include an orientation interface 350. The orientation interface 350 may be an accessible button or set of buttons, for example, by a member of the bedside team (e.g., an operating room nurse). The orientation interface 350 can be used to identify the surgical robotic system (e.g., Figure 2 The common orientation of the robotic arms of the surgical robot system 200 shown is indicated. The output of the orientation sensor can be transmitted to the control system, where it forms an input to the processor. The orientation interface 350 will be described in more detail below.

[0074] The robotic arm 301 may also include one or more interfaces 370, 371. Interfaces 370, 371 may be buttons or a set of buttons accessible to, for example, bedside team members (e.g., operating room nurses). Interfaces 370, 371 can be used to select between operating modes of the robotic arm. Interfaces 370, 371 will be described in more detail below.

[0075] Configure robotic arm

[0076] To configure the robotic arm so that it can be used as part of a surgical robotic system, a pattern-initiated sequence can be used. Figure 4 The pattern activation sequence for the surgical robot arm is shown. It should be understood that the control system of the surgical robot system (e.g., Figure 2 The control system 224 shown controls the operation of each robotic arm in the surgical robot system, that is, according to reference... Figure 4 The various operating modes are described. It should be understood that the control system controls the operation and behavior of each robotic arm in each operating mode, and controls the transition of each robotic arm between operating modes as described herein.

[0077] like Figure 4 As shown, the robotic arm can operate in sleep mode 401, followed by locked mode 402, then compatible mode 403, then calibration mode 404, then adjustment mode 405, and finally surgical mode 406. That is, in order to be configured so that the robotic arm can operate in surgical mode 406, it is not necessary to... Figure 4The robotic arm operates in all the modes shown. For example, the robotic arm can operate in calibration mode 404, followed immediately by surgical mode 406. The robotic arm can perform... Figure 4 The arrows in the diagram indicate any possible sequence pattern transitions. Figure 4 The robotic arm operates sequentially in any combination of the modes shown. For example, the robotic arm may operate in calibration mode 404, followed by surgical mode 406, then instrument adjustment mode 405, and then back to surgical mode 406.

[0078] The robotic arm can operate in sleep mode 401. In sleep mode 401, the robotic arm can be configured for storing or transporting the robotic arm. This configuration can be a compact one. For example, in such a configuration, the proximal arm components can be substantially parallel to each other, but other compact configurations are also suitable. When the surgical instrument 306 is operating in sleep mode 401, the surgical instrument may not be attached to the robotic arm.

[0079] In sleep mode 401, the robotic arm can resist external forces to maintain its configuration. Braking can be applied at one or more of the joints 304a-g of the robotic arm, allowing it to resist external forces and maintain its configuration. The brakes can be of any suitable type, such as electronic, magnetic, or mechanical brakes. In sleep mode 401, the robotic arm responds to a remote surgical console (e.g., Figure 2 The input at the remote surgeon console 220 shown in the figure does not change its configuration.

[0080] The robotic arm can operate in locked mode 402. In locked mode, the robotic arm can adopt a "horseshoe" configuration (e.g., Figure 2 and Figure 3 (As shown in the diagram). In locked mode 402, a "horseshoe" configuration is preferred because the orientation of the robot arm's joints is away from its joint limitations and singular configuration. That is, the "horseshoe" configuration allows for a greater range of movement of the robot arm. In the "horseshoe" configuration, the robot arm can be positioned near the port in a configuration similar to the final / optimal configuration used during surgery, giving the surgeon a good understanding of how the surgical setup will look. When transitioning from sleep mode 401 to locked mode 402, the robot arm configuration can be changed from a compact configuration to a "horseshoe" configuration. This change can be driven by one or more of a series of motors 310a-h.

[0081] When the surgical instrument 306 is operated in locked mode 402, it can be attached to the robotic arm. In locked mode 402, the robotic arm can resist external forces to maintain its configuration. Braking can be applied at one or more of the joints 304a-g of the robotic arm, allowing the robotic arm to resist external forces to maintain its configuration. The brakes can be of any suitable type, such as electronic, magnetic, or mechanical brakes. In locked mode 402, the robotic arm responds to a remote surgical console (e.g., Figure 2 The input at the remote surgeon console 220 shown in the figure does not change its configuration.

[0082] When the surgical instrument 306 is operating in locked mode 402, it can be attached to the robotic arm. When the robotic arm is operating in locked mode 402, a cover sheet (not shown) can be applied to the robotic arm.

[0083] The operating mode of the robotic arm can also be changed from locked mode 402 to sleep mode 401, for example, when the robotic arm is preparing to store data after the program is completed.

[0084] The robotic arm can operate in compatibility mode 403. For example... Figure 4 As shown, the operating mode of the robotic arm can be changed from locked mode 402 to compatible mode 403. The operating mode of the robotic arm can also be changed directly from sleep mode 401 to compatible mode 403. When changing from sleep mode 401 to compatible mode 403, the configuration of the robotic arm can be changed from a compact configuration to a "horseshoe" configuration.

[0085] In compatibility mode 403, the configuration of the robotic arm can be changed in response to external forces directly applied to the robotic arm. For example, a member of the bedside team (e.g., an operating room nurse) can directly apply forces to the robotic arm (e.g., by pushing the joints of the robotic arm). In compatibility mode 403, the control system (e.g. Figure 2 The control system 224 shown controls the robot arm to maintain the position of the robot arm by external forces applied directly to it.

[0086] To achieve this, the control system receives input from position sensors 307a-h and force sensors 308a-h. From the position sensors, the control system can determine the current configuration of the robotic arm. The control system stores for each component and surgical instrument of the robotic arm its mass, the distance of its center of mass from the previous joint of the robotic arm, and the relationship between the center of mass and the position output of the position sensor used for the previous joint. The current configuration of the robotic arm can be inferred by other means. For example, a camera-based positioning system can be used to track points in space, such as reference markers attached to the robotic arm. This technique can be used to determine joint angles. Other techniques include using current sensors to infer joint positions. For example, the position of a joint can be inferred from the amount of current passing through a motor and assuming that a given relationship is constant.

[0087] Using this information, the control system simulates the effect of gravity on the components of the robotic arm for its current configuration and estimates the force (e.g., torque) resulting from gravity at each joint of the robotic arm. The processor then drives the motors 310a-h of each joint to apply a force (e.g., torque) that will be exactly opposite to the calculated gravity. Using this control strategy, an operator (e.g., an operating room nurse) can push or pull any part of the robotic arm to a desired position, and that part will remain in that position despite the effects of gravity on the robotic arm and on any part thereof. Forces on the arm can cause torque around multiple joints. The control system can be programmed to prioritize certain joints to neutralize the torque. In this example, some joints may be locked in place while others can move compatibly; the position of a given link or point in space may be prioritized, rather than a group of joints.

[0088] Each motor 310a-h can be controlled in response to a force (e.g., torque) measured around the corresponding joint. When the force measured at the joint is adjusted for gravity, any remaining sensed force represents a force applied by an external force (e.g., due to pushing or pulling the robotic arm). In response to this force, the control system can control the corresponding motor 310a-h to change the configuration of the robotic arm. For example, this can be achieved by controlling the motor 310a-h to move its corresponding joint 304a-g in a certain direction to reduce the measured force and at a rate depending on the magnitude of the measured force. Thus, the bedside worker may perceive the robotic arm as moving freely in response to the forces it applies—in reality, this movement is driven by the motors of the robotic arm.

[0089] Compatibility mode 403 can be used to insert surgical instruments into a port in the patient's body. That is, compatibility mode 403 can be used to insert the end effector 362 of a surgical instrument into a port 317 located within the patient's body. In compatibility mode 403, the surgical instrument can be positioned at the entrance of port 317 such that the end effector 362 is concentric with the entrance of port 317. The entrance of the port may protrude slightly from the patient's body. Of course, in compatibility mode 403, the end effector 362 of the surgical instrument can be further inserted into port 317. As described herein, this port can alternatively be a natural orifice within the patient's body, such as the throat.

[0090] Refer again Figure 3 When the robotic arm is in compatibility mode 403, an operator (e.g., an operating room nurse) can grasp one or both of the robotic arm 301 and the surgical instrument 306. The operator can then apply an external force to change the configuration of the robotic arm 301 such that the elongated axis of the instrument's shaft 361 is substantially aligned with the channel through the hollow tube 317a of the port 317. The operator can then apply an external force (e.g., a thrust) to the robotic arm and / or the instrument, causing the instrument to move substantially parallel to its elongated axis and into the channel in the port 317.

[0091] The operating mode of the robotic arm can also be switched from compatible mode 403 to locked mode 402 or hibernation mode 401, for example when the robotic arm is preparing to store data after the program has been completed.

[0092] The robotic arm can operate in calibration mode 404. For example... Figure 4 As shown, this changes the robot arm's operating mode from compatibility mode 403 to calibration mode 404.

[0093] As described herein, surgical instrument 306 can be inserted into the patient's body, for example, through port 317. This can be performed in either compatibility mode 403 or calibration mode 404. This is because the robotic arm can respond to external forces in calibration mode 404 in the same manner as in compatibility mode 403.

[0094] In calibration mode 404, the position of port 317 relative to robotic arm 301 is estimated. For example, the position of port 317 can be estimated relative to wrist joint 304e-g. Specifically, a fulcrum can be determined, which is the point around which the surgical instrument 306 pivots when it is inside the patient's body. The fulcrum can be the natural center of rotation of port 317.

[0095] The control system of the robotic arm 301 (e.g., Figure 2 The control system 224 shown is able to determine the fulcrum through a calibration process performed when the surgical instrument 306 is inside the port 317. Figure 5 This is a flowchart illustrating the steps of this calibration process.

[0096] When the surgical instrument is inside port 317, the configuration of the robotic arm is altered 501. This alteration is achieved by directly applying an external force to the robotic arm 301. The robotic arm can move substantially laterally to the axis 361 of the instrument 306. This causes port 317 to apply a lateral force on the instrument axis 316. This force is modulated by movement about joint 304f. As the configuration of the robotic arm is altered, position sensors 307a-h record the position of each joint of the robotic arm. Position sensors 307a-h record the position of each joint of the robotic arm 502 under various conditions. That is, position sensors 307a-h record the position of each joint of the robotic arm at multiple points in time. The position information can be recorded irregularly or at predetermined intervals, such as every 0.5 seconds. The position sensors provide the recorded position information to the control system. The control system uses this received information to determine: (a) the position of the distal end of the robotic arm relative to the base and (b) the vector of the instrument axis 361 relative to the distal end of the robotic arm. The position (a) and vector (b) may be referred to as a data pair. The control system can determine data pairs for each case where the position sensors record position information. That is, for each case, the control system determines the position of the distal end of the robotic arm 503 based on the recorded one or more joint positions. Additionally, for each case, the control system determines the vector of the surgical instrument from the determined distal end position of the second robotic arm 504 based on the recorded joint positions. Since the axis of the instrument axis 361 passes through the channel of port 317, the channel of the port lies on this vector. When the distal end of the robotic arm is moved, the control system calculates multiple pairs of distal end positions and instrument axis vectors. These vectors converge from their respective distal end positions at the natural rotation center of the channel of port 317. By collecting a series of these data pairs and then solving for the average position of the converged instrument axis vectors, the control system estimates the position of the port relative to the robotic arm. That is, the control system determines the intersection point of the determined vectors of the surgical instrument 505 to determine the pivot point. The control system then stores the determined pivot point in a non-transient form in memory for later use.

[0097] During step 501, the configuration of the robotic arm can be changed such that the distal end of the robotic arm moves in two dimensions: for example, having (i) a component parallel to a direction transverse to the instrument axis 361, and also having (ii) a component orthogonal to that direction but transverse to the instrument axis 361. For this purpose, an operator (e.g., a member of the bedside team) can rotate the distal end of the robotic arm about a point generally aligned with the natural axis of the hollow tube 317a of the port.

[0098] The number of data pairs determined in step 502 and used in steps 503 to 505 to determine the fulcrum with acceptable accuracy depends on various factors, such as the accuracy of the robot arm position sensors and the extent to which the operator moves the arm laterally during calibration. Once enough coherent measurements have been collected such that the difference between the fulcrum estimates derived using consecutive measurements has been reduced to below a predefined level, the control system can determine that the fulcrum has been adequately estimated.

[0099] After the fulcrum is determined, the robotic arm can operate in machine adjustment mode 405. For example... Figure 4 As shown, the operating mode of the robotic arm can be switched from calibration mode 404 to instrument adjustment mode 405. The operating mode of the robotic arm can also be switched from surgical mode 406 to instrument adjustment mode 405.

[0100] In instrument adjustment mode 405, the configuration of the robotic arm can be changed in response to external forces in the same manner as in compatibility mode 403, except that the configuration of the robotic arm is constrained to maintain intersection between the instrument axis 361 and a defined fulcrum. Instrument adjustment mode 405 can be used to adjust the position of the instrument within the patient's body. For example, instrument adjustment mode 405 can be used to position the instrument in an optimal position to begin a procedure. For example, as described herein, in compatibility mode 403, the surgical instrument can be positioned at the entrance of port 317 such that the end effector 362 is concentric with the entrance of port 317. Instrument adjustment mode 405 can be used to assist in further insertion of the instrument into the patient's body (e.g., toward the intended surgical site). In this example, the control system (e.g., Figure 2 The control system 224 uses a defined fulcrum position to control the arm to adopt a configuration in which the instrument is generally aligned with the port channel. An operator (e.g., a member of the bedside team, such as an operating room nurse) can then further insert the instrument through the port by applying an external force to the robotic arm. As the instrument is further inserted through the port, the control system controls the robotic arm such that the axis of the instrument intersects the fulcrum. That is, the intersection between the instrument and the fulcrum is maintained.

[0101] After the fulcrum is determined, the robotic arm can operate in surgical mode 406. For example... Figure 4 As shown, the operating mode of the robotic arm can be directly switched from calibration mode 404 to surgical mode 406, or from instrument adjustment mode 405 to surgical mode 406.

[0102] In surgical mode 406, it can respond to the remote surgeon's console (e.g., Figure 2The configuration of the robotic arm is remotely controlled by input received at the remote surgeon's console 220 (shown in the diagram). The surgeon can provide input to the remote console 220. The remote surgeon's console includes one or more surgeon input devices 223. These may take the form of manual controllers and / or foot pedals.

[0103] In surgical mode 406, the operator (e.g., a surgeon) uses a remote surgical console to signal the desired position of the end effector 362. The control system (e.g.) Figure 2 The control system 224 shown determines the configuration of the joints of the robotic arm that will place the end effector 362 in the desired position. The robotic arm may have multiple configurations that will place the end effector 362 in the desired position. The control system may select between these configurations based on an algorithm that seeks to avoid collisions between the robotic arm and other objects known to be close to the robotic arm, or an algorithm that seeks to minimize the amount of joint movement to achieve the new configuration. Once the control system has selected a new configuration, it signals the joints 304a-g to adopt the desired state for bringing the arm into that configuration. In this way, in surgical mode 406, the operator (e.g., a surgeon) can signal the end effector 362 to move to the desired position.

[0104] When the robotic arm operates in surgical mode 406, the control system uses a determined fulcrum to assist in controlling the configuration of the robotic arm. The control system is configured, for example by means of software stored in memory, to select an arm configuration for which (i) the end effector 362 is in a desired position, and (ii) the axis 361 of the instrument 306 passes through the determined fulcrum, moving the arm to that configuration. In this way, the end effector 362 can be provided at the desired position with relatively little damage to the patient's external tissues.

[0105] Surgical mode 406 may include an engaged surgical mode and a disengaged surgical mode. In the engaged surgical mode, the configuration of the robotic arm and surgical instruments is controlled by a remote surgeon's console as described herein. In the disengaged surgical mode, the configuration of the robotic arm and surgical instruments can be controlled by the remote surgeon's console. That is, in the disengaged surgical mode, the pivot point around which the surgical instruments pivot is known when the configuration of the robotic arm changes—and therefore the configuration of the robotic arm and surgical instruments can be controlled by the remote surgeon's console. However, in the disengaged surgical mode, the configuration of the surgical instruments can be temporarily locked or maintained. For example, the surgeon may choose to place the robotic arm in the disengaged surgical mode for rest, or to allow them to focus their attention on the control of the different robotic arms (e.g., during particularly difficult parts of the procedure). The surgeon can control the transition between the engaged and disengaged surgical modes—for example, via an interface on the remote surgeon's console, or by instructing a member of the operating room staff to interact with an interface on the robotic arm itself.

[0106] When operating in surgical mode 406, certain parts of the robotic arm can exhibit similar compatible behavior. For example, the configuration of the elbow joint 304d may be able to change in response to external forces in the manner described herein, provided that the configuration of the instrument 306 is not affected. Achieving this similar compatible behavior while the robotic arm is operating in surgical mode allows an operator of, for example, a robotic surgical system to move the elbow of the robotic arm (e.g., so that they can approach the patient during the procedure). To implement this similar compatible behavior, the control system can define a permissible area or volume of one or more parts of the robot (e.g., a set of wrist joints 304e-g) such that movement of these parts in response to externally applied forces is limited within said permissible area or volume. The permissible area or volume is defined such that movement within that area or volume in response to externally applied forces does not affect the configuration of the instrument 306.

[0107] In instances where the robotic arm includes an orientation interface, the control system can also use the identified common orientation to convert inputs at the remote surgeon's console into appropriate control signals to control the configuration of the robotic arm operating in surgical mode 406.

[0108] The robotic arm can also operate in the retracted mode 406. For example... Figure 4 As shown, the operating mode of the robotic arm can be switched from surgical mode 406 to instrument retraction mode 407.

[0109] The instrument retraction mode 407 is engaged to remove the instrument 306 from the patient's body (e.g., at the end of the procedure). In instrument retraction mode 407, the control system controls motors 310a-h to reconfigure the robotic arm so that the instrument 306 retracts from the port along the longitudinal axis of the instrument. The longitudinal axis of the instrument may be coaxial with the instrument axis 361. The control system can achieve this by controlling motors 310a-h to allow the robotic arm to be reconfigured by the action of an external force applied to the robotic arm, similar to compatible mode 403. That is, in instrument retraction mode 407, the control system enables the configuration of the robotic arm to be changed in response to an external force, but restricts the degrees of freedom of the robotic arm so that the surgical instrument can only move linearly away from the patient's body in a direction parallel and / or coaxial with its longitudinal axis. In other words, an external force applied to the robotic arm in a direction away from the patient's body, parallel to the axis 361 of the instrument 306, causes the instrument to be removed from the patient's body. Upon detecting an external force applied in this direction, the control system responds by signaling motors 310a-h at the appropriate joints to drive the joints to move in the direction in which the external force is applied. The force of gravity on each joint is opposite to that described above regarding compatibility mode 403. Thus, an operator (e.g., a member of the bedside team, such as an operating room nurse) can manually push or pull the robotic arm in a direction away from the patient's body, and the robotic arm will respond by moving in that direction. Therefore, the robotic arm provides the operator with a sense of freedom of movement under its push or pull to remove instruments from the patient's body.

[0110] The control system detects external forces applied to the robotic arm using force sensors 307a-h. The control system uses this sensor input to determine whether the applied external force acts along and / or parallel to the longitudinal axis of the instrument and away from the patient's body. In an example where the instrument extends along an axis coinciding with the rotational axis of joint 304g, the control system can use the sensor input to determine whether the applied external force coincides with (and is therefore inherently parallel to) the longitudinal axis of the instrument and is away from the patient's body. In an example where the instrument extends linearly parallel to (but not necessarily coaxial with) the rotational axis of the end joint 304g of the robotic arm, the control system can use the sensor input to determine whether the applied external force is parallel to the longitudinal axis of the instrument and away from the patient's body.

[0111] To make this determination, the control system decomposes the detected applied force and signals motors 310a-h to drive the robotic arm based only on the component of the force parallel to the longitudinal axis of the instrument. In instrument retraction mode 407, the component of the external force applied in the direction transverse to the longitudinal axis of the instrument has no effect. This counteracts external forces applied in these directions. Furthermore, the component of the applied external force acting along the longitudinal axis of the instrument toward the patient's body has no effect. This counteracts external forces applied in this direction.

[0112] The operating mode of the robotic arm can be switched from instrument retraction mode 407 to any one of compatibility mode 403, calibration mode 404, or instrument adjustment mode 405.

[0113] As referenced in this article Figure 3 The robotic arm 301 may include one or more interfaces 370, 371. Interfaces 370, 371 may be, for example, buttons or a set of buttons accessible to bedside team members (e.g., operating room nurses). Interfaces 370, 371 may be actuated to [reference / function]. Figure 4 The description describes the switching between different operating modes.

[0114] Refer again Figure 3 Interface 370 can be positioned more distally than interface 371. That is, interface 370 can be positioned closer to surgical instrument 306 than interface 371. For example, interface 370 can be positioned on or near wrist joint 304e-g, while interface 371 is positioned on or near elbow joint 304d. Robotic arm 301 can be configured such that interaction between the operator and the more distal interface 370 causes the robotic arm's operating mode to shift "towards" surgical mode 406. Figure 4 In this context, the operating mode considered to be transitioning "towards" surgical mode 406 is labeled 370. For example, transitioning "towards" surgical mode 406 includes: transitioning from sleep mode 401 to locked mode 401 or compatible mode 403; transitioning from locked mode 402 to compatible mode 403; transitioning from compatible mode 403 to calibration mode 404; and transitioning from calibration mode 404 to instrument adjustment mode 405 or surgical mode 406. The robotic arm 301 can be configured such that interaction between the operator and a not-too-far side interface 371 causes the robotic arm's operating mode to transition "away" from surgical mode 406. Figure 4In this context, the operation mode transition considered "away from" surgical mode 406 is labeled 371. For example, transitions from "away from" surgical mode 406 include: transitioning from surgical mode 406 to instrument adjustment mode 405; transitioning from instrument retraction mode 407 to any one of compatibility mode 403, calibration mode 404, or instrument adjustment mode 405; transitioning from compatibility mode 403 to locked mode 402 or sleep mode 401; and transitioning from locked mode 402 to sleep mode 401. For example, if the robotic arm is operating in compatibility mode 403, interaction with (i) the more distant interface 370 can transition the operation mode to calibration mode 404, and interaction with (ii) the less distant interface 371 can transition the operation mode to locked mode 402. This allows the operator to more intuitively select the next operation mode.

[0115] One or more conditions may be associated with each operating mode. These conditions determine whether the mode can be accessed. For example, a surgical mode may require that the fulcrum has been determined and the instruments have been inserted into the patient's body at least a predetermined distance (e.g., to ensure that the surgeon can see the instruments through the endoscope inside the patient's body). In certain situations (e.g., during a safety alarm), some modes may not be available.

[0116] Reconfigure the surgical robot system

[0117] Now refer to Figure 6 Describe the reconfiguration of the surgical robot system. Figure 6 A plan view of the surgical robot system is shown. The surgical robot system 600 includes robotic arms 601a, 601b, 601c, and 601d. For simplicity, Figure 6 The links and joints of each of the robot arms 601a-d are not shown in the diagram. Each robot arm 601a-d may include references... Figure 3 Equivalent features of the described robotic arm 301. Although Figure 6 Four robotic arms 601a-d are shown in the illustration, but it should be understood that surgical robotic systems configured according to the principles described herein may include any number of robotic arms.

[0118] The robotic arms 601a-d are positioned around the operating table 603. For simplicity, Figure 6 No patients were shown in the data. Figure 6 The robotic arms 601a-d are shown positioned at each corner of the operating table 603, but it should be understood that the robotic arms 601a-d can be positioned in any other arrangement.

[0119] Figure 6 The remote surgeon console 620 is also shown. Figure 6The control system 624 is not shown – however, it can be located in any of the locations previously described herein. It should be understood that the control system of the surgical robot system is configured to control the operation of each robotic arm in the surgical robot system, i.e., according to reference… Figure 4 Various operating modes are described to reconfigure the surgical robot system. Robotic arms 601a-d can be connected to console 620 via wired or wireless connections. These connections can provide control signals from console 620 to each robotic arm 601a-d, and optionally provide power. One or more of the robotic arms 601a-d can be directly connected to a power source (i.e., not connected to a power source via console) and / or powered by a local power source such as a battery. These connections can also provide feedback from the robotic arms 601a-d to console 620. A suitable wired connection for transmitting control signals is an Ethernet fieldbus.

[0120] like Figure 6 As shown, robotic arms 601b and 601d are connected to console 620 via direct connections. Robotic arm 601a is also connected to console 620 via a direct connection. Robotic arm 601c is not connected to console 620 via a wired connection, but rather to robotic arm 601a, which is itself connected to console 620 via a direct connection. Robotic arms 601a, 601c, and 601d can be considered part of a “daisy chain.” All robotic arms in a surgical robot system can be connected to the console via direct connections, or all robotic arms can be part of a “daisy chain,” or any combination of direct connections and “daisy chain” connections can be used (e.g., as shown in the diagram). Figure 6 (as shown in the image).

[0121] At any time, each robotic arm 601a-d in the surgical robot system 600 can be Figure 5 The different modes shown are for operation. At any given time, each robotic arm in the surgical robot system can operate in the same mode.

[0122] Figure 7 A flowchart illustrating the reconfiguration of a surgical robot system according to the principles described herein is shown. A robotic arm can be added to the surgical robot system, while an existing robotic arm operates in surgical mode 406. For example, refer to... Figure 6The procedure can be performed using only the first robotic arm 601a. ​​That is, the surgical instruments of robotic arms 601b-d may not initially be inserted into the patient's body. The first robotic arm 601a can operate in surgical mode 406. While the first robotic arm 601a is operating in surgical mode 406, the second robotic arm 601b can be added to the surgical robot system 600. Adding the second robotic arm 601b to the surgical robot system involves inserting its carried surgical instruments (“second surgical instruments”) 702 into a port within the patient's body and configuring the robotic arm so that it can operate in surgical mode 406. That is, determining 703 (as described herein with reference to calibration mode 404) the pivot point around which the second surgical instruments pivot when inside the port. The second robotic arm 601b can then operate in surgical mode 704, wherein the configuration of the second robotic arm and the second surgical instruments is controlled by a remote surgeon's console 620 while maintaining the intersection between the second surgical instruments and the determined pivot point (as described herein with reference to surgical mode 406). The first robotic arm 601a can operate continuously in surgical mode when the second robotic arm 601b is added to the surgical robot system 600. That is, the second robotic arm 601b can be added to the surgical robot system 600 without interrupting the operation of the first robotic arm 601a in surgical mode 406. In other words, the operations 701 of the first robotic arm 601a in surgical mode 406 and the additions 702, 703, and 704 of the second robotic arm 601b to the surgical robot system 600 can be performed simultaneously. When the second robotic arm 601b is added 702, 703, and 704 to the surgical robot system 600, the first robotic arm 601a can operate 701 in an engaged or disengaged surgical mode, or sequentially in engaged and disengaged surgical modes as described herein. Adding the second robotic arm 601b to the surgical robot system may involve, prior to operating the second robotic arm 601b in surgical mode 406, [further details are needed]. Figure 4 The second robotic arm 601b is operated in any one or more of the following modes: sleep mode 401, lock mode 402, compatibility mode 403, calibration mode 404, and instrument adjustment mode 405.

[0123] As described herein, the robotic arm may be supported by a movable support structure. Before being added to the surgical robot system, the robotic arm can be moved to a location adjacent to the patient. The robotic arm can be moved from a location distant from the patient to a location adjacent to the patient. For example, a spare robotic arm may be positioned in or outside the operating room for use when needed (e.g., for any of the reasons given earlier herein). Alternatively, the robotic arm may be moved from a location adjacent to the patient to a different location adjacent to the patient (e.g., for any of the reasons given in the preceding paragraph). After the robotic arm has been moved to a location adjacent to the patient, it can be added to the surgical robot system. The robotic arm can be moved to a location adjacent to the patient in any of the following modes: sleep mode 401, locked mode 402, or compatible mode 403.

[0124] As referenced in this article Figure 3 Each of the robotic arms 601a-d may include an orientation interface 650a-d. The orientation interface 650a-d of each robotic arm 601a-d may be, for example, an accessible button or a set of buttons for bedside team members (e.g., operating room nurses). Although Figure 6 The orientation interfaces 601a-d shown are intended to indicate four directions, but it should be understood that any number of directions can be indicated.

[0125] The orientation interfaces 650a-d of each robotic arm 601a-d can be used to identify the common orientation of the robotic arms 601a-d of the surgical robot system 600. In an example, each orientation interface 650a-d can be used to select an orientation such that all selected orientations point in the same direction. For example, refer to... Figure 6 You can select direction A for robot arms 601a and 601b, and direction C for robot arms 601c and 601d.

[0126] When one or more of the robotic arms 601a-d are operating in surgical mode 406, the robotic surgical system 600 can use a common direction to translate input from the remote console 620 into appropriate control signals for those robotic arms. The common direction can be identified in any of the following modes: sleep mode 401, locked mode 402, or compatible mode 403.

[0127] Robotic arms may not have an orientation interface. For example, in some surgical robot systems, the robotic arms are positioned at predetermined locations and orientations. For instance, grippers can be provided in the operating room that allow each robotic arm to be accurately positioned at a predetermined location and orientation. Camera-based tracking systems can be provided to detect the relative position and orientation of the robotic arms, or positioning devices can be used within the robotic arms to detect their relative position and orientation.

[0128] The robotic arm may not need to move before being added to the surgical robotic system. That is, the robotic arm may already be located near the patient. For example, see reference... Figure 6 Robotic arms 601a-c can be part of a surgical robot system. Robotic arm 601d can be located in... Figure 6 The position shown is for use with robotic arm 601, but it may not be used as part of the surgical robot system. That is, robotic arm 601d can be a redundant robotic arm. When one or more of robotic arms 601a-c are operating in surgical mode 406, robotic arm 601d can be added to the surgical robot system if needed during the procedure.

[0129] In one instance, a new robotic arm can be added to a surgical robot system to increase its capabilities. For example, a user of the surgical robot system (e.g., a surgeon) may require additional surgical instruments to assist in the procedure, so a new robotic arm carrying those instruments can be added to the surgical robot system.

[0130] In other instances, a new robotic arm can be added to a surgical robot system in exchange for an existing robotic arm that is already part of the system. For example, such an exchange can be performed if an existing robotic arm malfunctions. That is, an existing robotic arm can be removed before a new one is added, or a new robotic arm can be added before the old one is removed. To remove a faulty robotic arm from the system, the instrument retraction mode described herein can be used. In other words, a robotic arm of a surgical robot system can be replaced by a different robotic arm. Examples of faults that can lead to a replacement robotic arm include mechanical failures (e.g., drive cable failure under mechanical stress), software failures (e.g., the introduction of software errors), console power failures, loss of communication with the console, loss of communication with the instruments, the robotic arm housing exceeding a predetermined temperature (e.g., caused by overheating of the robotic arm's motors), other problems such as insufficient local battery power, motor tracking errors (e.g., motor slippage), problems with the movable support structure (e.g., broken wheels or brake failure) or the housing of a track-mounted arm, mechanical problems with the track-mounted arm attachment, or any other fault.

[0131] In another instance, the robotic arm can be removed from the surgical robot system and then added back to the same system. In these instances, the robotic arm can be removed before being added back to the system to allow for maintenance tasks (e.g., troubleshooting and / or resetting alarms), or it can be removed before being added back to the surgical robot system so that it can be moved to a different position relative to the operating table (e.g., for better access to the surgical site or to avoid collisions with other robotic arms).

[0132] The robotic arm described in this article can be used for purposes other than surgery. For example, the port could be an inspection port in a manufactured item such as a car engine, and the robot could control observation tools to examine the inside of the engine.

[0133] 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 control system for a surgical robot system, the surgical robot system including a first robotic arm and a second robotic arm, each of the first and second robotic arms including a series of joints, the configuration of the robotic arm being changeable via the series of joints extending from a base at a proximal end of the robotic arm to an attachment for surgical instruments at a distal end of the robotic arm, the control system being configured to reconfigure the surgical robot system in such a way that: Control the first robotic arm to operate in a surgical mode in which a first surgical instrument attached to the first robotic arm is inside the patient’s body, and control the configuration of the first robotic arm and the first surgical instrument in response to input received at a remote surgeon’s console; as well as When the first robotic arm operates in the surgical mode: (i) Controlling the second robotic arm to allow a second surgical instrument attached to the second robotic arm to be inserted into a port in the patient's body; (ii) When the second surgical instrument is inside the port, determine the fulcrum around which the second surgical instrument pivots when the configuration of the second robotic arm changes; as well as (iii) Controlling the operation of the second robotic arm in the surgical mode in which the second surgical instrument attached to the second robotic arm is inside the patient’s body, and controlling the configuration of the second robotic arm and the second surgical instrument in response to input received at the remote surgeon’s console, while maintaining the intersection between the second surgical instrument and the determined fulcrum.

2. The control system according to claim 1, wherein the fulcrum is determined by the following: When the second surgical instrument is inside the port, the second robotic arm is controlled to change its configuration in response to external forces; and The fulcrum is defined as the point around which the surgical instruments of the second robotic arm pivot within the port.

3. The control system according to claim 2, wherein the second robotic arm further comprises: One or more force sensors, the one or more force sensors being configured to sense external forces at one or more joints of a series of joints of the second robotic arm; and one or more motors configured to drive one or more joints of a series of joints of the second robotic arm, and the control system is further configured to: Based on the external force sensed by the one or more force sensors, the one or more motors are controlled to drive one or more joints of a series of joints of the second robotic arm in order to change the configuration of the second robotic arm.

4. The control system according to any one of claims 1 to 3, wherein the second robotic arm further comprises one or more position sensors configured to sense the position of one or more joints of a series of joints of the second robotic arm, and to record the position of one or more joints of the series of joints of the second robotic arm under various conditions when the configuration of the second robotic arm is being changed, and the control system is further configured to: Based on one or more joint positions recorded accordingly, determine the position of the distal end of the second robotic arm for each case; Based on one or more recorded joint positions, for each case, the vector of the second surgical instrument is determined from the determined position of the distal end of the second robotic arm; and The intersection point of the vectors of the determined second surgical instrument is determined in order to determine the fulcrum.

5. The control system according to any one of claims 1 to 3, further configured to: The fulcrum is determined when the second robotic arm is controlled to operate in calibration mode; and Control the second robotic arm to switch from operating in the calibration mode to operating in the surgical mode.

6. The control system of claim 5, wherein the second robotic arm further comprises a first interface and a second interface, the first interface being located closer to the surgical instrument than the second interface, and the control system is further configured to: In response to the operator's interaction with the first interface, the second robotic arm is controlled to switch from operating in the calibration mode to operating in the surgical mode.

7. The control system according to claim 6, further configured to: By controlling the second robotic arm to operate in a compatibility mode, the second robotic arm is controlled to allow the second surgical instrument to be inserted into the port, in which the configuration of the second robotic arm can be changed in response to external forces; and Control the second robotic arm to switch from operating in the compatibility mode to operating in the calibration mode.

8. The control system according to claim 7, further configured to: In response to user interaction with the first interface, the second robotic arm is controlled to switch from operating in the compatibility mode to operating in the calibration mode.

9. The control system according to claim 5, further configured to: After the fulcrum is determined, the second robotic arm is controlled to operate in an instrument adjustment mode, in which the configuration of the second robotic arm can be changed in response to external forces, but is constrained to maintain an intersection between the second surgical instrument and the determined fulcrum.

10. The control system according to claim 9, further configured to: Control the second robotic arm to switch from operating in the calibration mode to operating in the instrument adjustment mode; Control the second robotic arm to switch from operating in the instrument adjustment mode to operating in the surgical mode.

11. The control system of claim 10, further configured to control the second robotic arm to switch from operating in the surgical mode to operating in the instrument adjustment mode.

12. The control system according to any one of claims 1 to 3, wherein each of the first robotic arm and the second robotic arm further includes an orientation interface, and the control system is further configured to: In response to the operator indicating a direction using the orientation interface of the first robot arm and indicating a corresponding direction using the orientation interface of the second robot arm, input identifying a common direction is received.

13. The control system of claim 12, wherein in the surgical mode, the second robotic arm is remotely controlled by the control system, the control system being configured to: Inputs related to the second robotic arm are received at the remote control console; The input is converted into control signals for the second robotic arm based on the determined fulcrum and the identified common direction; and The control signal controls one or more joints of a series of joints of the second robotic arm in order to control the configuration of the second robotic arm.

14. The control system according to any one of claims 1 to 3, wherein the surgical robot system includes a third robotic arm, the third robotic arm including a series of joints, the configuration of the robotic arm being changeable by the series of joints extending from a base at the proximal end of the robotic arm to an attachment for surgical instruments at the distal end of the robotic arm, and the control system is further configured to: While controlling the first robotic arm to operate in the surgical mode and before allowing the second surgical instrument to be inserted into the port, the third robotic arm is controlled to allow the third surgical instrument attached to the third robotic arm to retract from the patient's body.

15. The control system of claim 14, further configured to allow the third surgical instrument to retract from the patient's body in the following manner: The configuration of the third robotic arm is made to change in response to external forces, and the degrees of freedom of the third robotic arm are restricted, so that the third surgical instrument can only move linearly away from the patient's body in a direction coaxial with the longitudinal axis of the third surgical instrument.

16. The control system of claim 15, wherein the third robotic arm further comprises: One or more force sensors, the one or more force sensors being configured to sense external forces at one or more joints of a series of joints of the third robotic arm; and one or more motors configured to drive one or more joints of a series of joints of the third robotic arm, and the control system is further configured to: Decompose the external forces sensed by the one or more force sensors to determine the force components that are parallel to the longitudinal axis of the third surgical instrument and away from the patient's body; as well as The one or more motors are controlled according to the force component parallel to the longitudinal axis of the third surgical instrument to drive one or more joints of a series of joints of the third robotic arm in order to change the configuration of the third robotic arm.

17. The control system of claim 16, further configured to allow the second surgical instrument to retract from the patient's body in such a manner as: The configuration of the second robotic arm is made to change in response to external forces, and the degrees of freedom of the second robotic arm are restricted, so that the second surgical instrument can only move linearly in a direction parallel to the longitudinal axis of the second surgical instrument.

18. The control system of claim 17, wherein the second robotic arm further comprises: One or more force sensors, the one or more force sensors being configured to sense external forces at one or more joints of a series of joints of the second robotic arm; and one or more motors configured to drive one or more joints of a series of joints of the second robotic arm, and the control system is further configured to: Decompose the external force sensed by the one or more force sensors in order to determine the force component parallel to the longitudinal axis of the second surgical instrument; as well as The one or more motors are controlled according to the force component parallel to the longitudinal axis of the second surgical instrument to drive one or more joints of a series of joints of the second robotic arm in order to change the configuration of the second robotic arm.

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