Detection of disengagement in cable-driven tools

Abstract

The disclosed embodiments relate to systems and methods for surgical tools or surgical robotic systems. One example system for detecting disengagement of a surgical tool includes an end effector connected to and driven by cables of a tool driver, a sensor configured to detect a force associated with the cables, and one or more processors. The one or more processors identify a cable tension derived from the force detected by the sensor, compare the tension to a threshold tension value, calculate a velocity norm value based on a vector comprising the velocity value of each of the cables, compare the velocity norm value to a statistical velocity threshold, and identify disengagement of at least one of the plurality of cables based on the first comparison and the second comparison.

Description

Technical Field

[0001] This disclosure relates to the detection of detachment, breakage or other malfunctions in cables used to drive surgical tools. Background Technology

[0002] Minimally invasive surgery (MIS), such as laparoscopic surgery, involves techniques designed to minimize tissue damage during surgical procedures. For example, laparoscopic surgery typically involves making multiple small incisions inside the patient (e.g., in the abdomen) and introducing one or more surgical instruments (e.g., end effectors or endoscopes) through these incisions. The introduced surgical instruments can then be used to perform the surgical procedure, with visualization aids provided by the endoscope.

[0003] Generally speaking, surgical instruments (MIS) offer multiple beneficial effects, such as reducing patient scarring, alleviating patient pain, shortening patient recovery time, and reducing medical costs associated with patient recovery. Recent technological advancements have allowed for the use of robotic systems to perform more MIS. These robotic systems include one or more robotic arms used to manipulate surgical instruments based on commands from a remote operator. The robotic arms can support various devices at their distal ends, such as surgical end effectors, imaging equipment, and cannulas for providing access to patient cavities and organs. In robotic MIS systems, it may be desirable to establish and maintain a high degree of positioning accuracy for surgical instruments supported by the robotic arms.

[0004] In surgical robotic systems, surgical tools can be attached to the surgical robotic arm. These tools can be used to access, view, or manipulate the patient's internal anatomy. The surgical tools are cable-driven for movement. Cable malfunctions can occur. For example, one or more cables may detach from the surgical tool or the drive system. One or more cables may break under high tension. Detection of these events prevents potential hazards from uncontrolled movement of the tools. Summary of the Invention

[0005] This paper discloses a robot-assisted surgical electromechanical system designed for surgeons to perform minimally invasive surgical procedures. A set of compatible tools can be attached to / detached from instrument actuators mounted to the distal end of a robotic arm, enabling surgeons to perform a variety of surgical tasks. The instrument actuators provide intra-body access to the surgical site, mechanical actuation of the compatible tools via sterile interfaces, and communication with the compatible tools via sterile interfaces and user contact points. The system detects obstacles or hard stops encountered by the tools.

[0006] The disclosed embodiments relate to systems and methods for surgical instruments or surgical robot systems. An exemplary system for detecting disengagement of a surgical instrument includes an end effector connected to and driven by a cable of an instrument driver, a sensor configured to detect forces associated with the cable, and one or more processors. The one or more processors identify cable tension derived from the force detected by the sensor, compare the tension to a threshold tension value, calculate a velocity norm based on a vector including the velocity values ​​of each cable in the cable, compare the velocity norm to a statistical velocity threshold, and identify disengagement of at least one of the plurality of cables based on the first comparison and the second comparison. Attached Figure Description

[0007] Figure 1 An exemplary operating room environment including a surgical robot system is shown.

[0008] Figure 2 An exemplary surgical robotic system is shown, comprising a robotic arm, tool actuators, and a cannula loaded with surgical tools.

[0009] Figure 3A An exemplary tool driver with loaded surgical tools is shown.

[0010] Figure 3B An exemplary tool driver without loaded surgical tools is shown.

[0011] Figure 4A and Figure 4B An exemplary gripper end effector is shown, which has a robot wrist, a pair of opposing jaws, and a pulley and cable system for coupling the robot wrist and the pair of jaws to an actuator of a tool driver.

[0012] Figure 5 A controller for a robot wrist, tool actuator, and / or surgical tool is shown.

[0013] Figure 6 This illustrates the mapping from tool drivers to surgical tools.

[0014] Figure 7 A cable drive system for a surgical tool is shown.

[0015] Figure 8 A more detailed view of the cable drive system is shown.

[0016] Figure 9 A detailed implementation of the sensor array and controller is shown.

[0017] Figure 10 An exemplary cable detachment detection algorithm for cable drive systems and surgical tools is shown.

[0018] Figure 11 An exemplary flowchart of exemplary operation of the controller is shown. Detailed Implementation

[0019] The following implementation relates to cable-driven surgical tools. An algorithm for detecting wrist cable detachment during normal wrist manipulation is described. The wrist cable is driven by a motor or actuator. The cable detachment detection algorithm uses measured tension and actuator speed to determine when cable detachment may have occurred. In cable-driven tools, the cable can detach from the drive motor during normal tool operation. Unintended wrist movement can lead to damage without remedial measures. The cable detachment detection algorithm ensures that the motor is disabled in a controlled and timely manner.

[0020] Figure 1 This is a diagram illustrating an exemplary operating room environment with a surgical robot system 100.

[0021] like Figure 1 As shown, the surgical robot system 100 includes a user console 110, a control tower 130, and a surgical robot 120 having one or more surgical robotic arms 122 mounted on a surgical platform 124 (e.g., a table or bed). Surgical tools with end effectors are attached to the distal ends of the robotic arms 122 for performing surgical procedures. The robotic arms 122 are shown as tabletop mounted, but in other configurations, the robotic arms may be mounted on a trolley, ceiling, sidewall, or other suitable support surface.

[0022] Generally, a user (such as a surgeon or other operator) can sit at user console 110 to remotely manipulate the robotic arm 122 and / or surgical instruments (e.g., remote operation). User console 110 may be located in the same operating room as the robotic system 100, such as... Figure 1 As shown. In other environments, the user console 110 may be located in an adjacent or nearby room, or operated remotely from a remote location in a different building, city, or country. The user console 110 may include a seat 112, a pedal 114, one or more handheld user interface devices (UIDs) 116, and an open display 118 configured to display a view, for example, of a surgical site inside a patient's body. As illustrated by the exemplary user console 110, a surgeon seated in the seat 112 and viewing the open display 118 can manipulate the pedal 114 and / or the handheld user interface device 116 to remotely control the robotic arm 122 and / or surgical instruments mounted to the distal end of the arm 122.

[0023] In some variations, the user can also operate the surgical robotic system 100 in an "OTB" (on-bed) mode, where the user is positioned to one side of the patient and simultaneously manipulates both the robot-driven tools / end effectors attached to it (e.g., holding a handheld user interface device 116 with one hand) and manual laparoscopic tools. For example, the user's left hand can manipulate the handheld user interface device 116 to control the robotic surgical components, while the user's right hand can manipulate the manual laparoscopic tools. Thus, in these variations, the user can perform both robot-assisted minimally invasive surgery (MIS) and manual laparoscopic surgery on the patient.

[0024] End effectors can be configured to perform surgical procedures such as cutting, grasping, puncturing, or energy emission. Surgical tools can be manually manipulated, robotically manipulated, or both during surgery. For example, a surgical tool can be an instrument for accessing, viewing, or manipulating a patient's internal anatomy. In one embodiment, a surgical tool is a gripper capable of grasping a patient's tissues. Surgical tools can be directly and manually controlled by a bedside operator's hand, or can be actuated by a robot via electronic commands.

[0025] During exemplary procedures or surgical procedures, the patient is aseptically prepared and covered for anesthesia. Initial approach to the surgical site can be manually performed using the robotic system 100 in a retracted or collapsed configuration to facilitate access. Once approach is complete, initial positioning and / or preparation of the robotic system can be performed. During the procedure, the surgeon at the user console 110 can use pedals 114 and / or user interface devices 116 to manipulate various end effectors and / or imaging systems to perform surgical procedures. Manual assistance can also be provided at the operating table by a person wearing sterile gowns, whose tasks include, but are not limited to, retracting tissue, or performing manual repositioning or tool changes involving one or more robotic arms 122. Non-sterile personnel may also be present to assist the surgeon at the user console 110. When the procedure or surgery is completed, the robotic system 100 and / or user console 110 may be configured or set to a state that facilitates one or more postoperative procedures, including but not limited to cleaning and / or sterilizing the robotic system 100, and / or medical record input or printout, whether electronic or paper, via the user console 110.

[0026] In some respects, communication between the surgical robot 120 and the user console 110 can be achieved via a control tower 130, which can translate user input from the user console 110 into robot control commands and transmit those commands to the surgical robot 120. The control tower 130 can also transmit status and feedback from the robot 120 back to the user console 110. The connection between the surgical robot 120, the user console 110, and the control tower 130 can be a wired and / or wireless connection, and can be proprietary and / or implemented using any of a variety of data communication protocols. Any wired connection can optionally be integrated into the floor and / or walls or ceiling of the operating room. The surgical robot system 100 can provide video output to one or more displays, including displays within the operating room and remote displays accessed via the Internet or other networks. Video output or feeds can also be encrypted to ensure privacy, and all or part of the video output can be stored on a server or electronic healthcare record system.

[0027] Before initiating surgery using a surgical robotic system, the surgical team can perform preoperative setup. During preoperative setup, the main components of the surgical robotic system (platform 124 and robotic arm 122, control tower 130, and user console 110) are positioned, connected, and powered in the operating room. The surgical platform 124 and robotic arm 122 can be in a fully retracted configuration, with the arm 122 positioned below the surgical platform 124 for storage and / or transport purposes. The surgical team can extend the arm from its retracted position for sterile draping.

[0028] After draping, arm 122 can be partially retracted until needed again. Several routine laparoscopic procedures can be performed, including cannula placement and installation. For example, each cannula can be inserted into a small incision and through the body wall using a tampon. The cannulas and tampon allow light to enter, enabling visualization of tissue layers during insertion and minimizing the risk of injury during placement. Typically, an endoscope is first placed to provide visualization for a handheld camera for the placement of other cannulas.

[0029] After insufflation, manual instruments can be inserted through the cannula if needed to perform any laparoscopic steps manually. Next, the surgical team can position the robotic arms 122 above the patient and attach each arm 122 to its corresponding cannula. The surgical robotic system 100 is capable of immediately and uniquely identifying each tool (endoscope and surgical instrument) once attached and displaying the tool type and arm position on an open or immersive display 118 at the user console 110 and a touchscreen display on the control tower 130. The corresponding tool function is enabled and activated using the master UID 116 and foot switch 114. The patient-side assistant can attach and detach tools as needed throughout the procedure. The surgeon, seated at the user console 110, can begin surgery using tools controlled by two master UIDs 116 and foot switch 114. The system translates the surgeon's hand, wrist, and finger movements into precise, real-time movements of the surgical instruments via the master UID 116. Therefore, the system continuously monitors each surgical procedure performed by the surgeon, and pauses instrument movement if the system cannot accurately reflect the surgeon's hand movements. During surgery, if the endoscope moves from one arm to the other, the system can adjust the master UID 116 for instrument calibration and continue controlling the instrument's movement. The foot switch 114 can be used to activate various system modes, such as endoscope control and various instrument functions, including monopolar and bipolar ablation, without requiring the surgeon's hand to be removed from the master UID 116.

[0030] The surgical platform 124 can be repositioned intraoperatively. For safety reasons, all instruments should be within the surgeon's field of vision and under their active control at the user console 110. Instruments not under the surgeon's active control are removed, and the table legs are locked. During table movement, the integrated robotic arm 122 can passively follow the table's movement. Audio and visual cues are available to guide the surgical team during table movement. Audio cues may include tone and voice prompts. Visual messages on displays at the user console 110 and control tower 130 inform the surgical team of the table movement status.

[0031] Figure 2 This is a schematic diagram illustrating an exemplary design of a robotic arm, tool actuators, and a cannula loaded with robotic surgical tools. Figure 2 As shown, the exemplary robotic arm 200 may include a plurality of connectors (e.g., connector 202) and a plurality of engagement modules (e.g., engagement 204) for actuating the plurality of connectors relative to each other. The engagement modules may include various engagement types, such as pitch engagements or roll engagements, which can substantially constrain the movement of adjacent connectors about certain axes relative to other axes. Figure 2The exemplary design also illustrates a tool actuator 230 attached to the distal end of the robotic arm 200. The tool actuator 230 may include a cannula 214 coupled to its end for receiving and guiding surgical instruments (e.g., endoscopes, sutures, etc.). The surgical instrument 220 (or “tool”) may include an end effector 222 located at the distal end of the tool 220. A plurality of actuated joint modules of the robotic arm 200 are used to position and orient the tool actuator 230, which actuates the tool 220 to perform robotic surgery.

[0032] Figure 3A and Figure 3B This is a schematic diagram illustrating exemplary tool drivers according to various aspects of the art, which have and do not have adjacent loaded tools. For example... Figure 3A and Figure 3B As shown, in one variant, the tool actuator 230 may include an elongated base (or “tower”) 310 having a longitudinal track 313 and a tool holder 320 slidably engaged with the longitudinal track 313. The tower 310 may be configured to couple to the distal end of a robotic arm such that joint movements of the robotic arm position and / or orient the tool actuator 230 in space. Additionally, the tool holder 320 may be configured to receive a tool base 352 that may also include a tool shaft 354 extending from the tool base 352 and through a cannula 214, with an end effector 222 positioned at the distal end.

[0033] Additionally, the tool holder 320 can actuate a set of joint movements of the end effector, such as via a cable system or line manipulated and controlled by an actuated drive mechanism. The tool holder 320 may include different configurations with actuated drive mechanisms. For example, a rotary shaft drive mechanism may include a motor with a hollow rotor and a planetary gear transmission at least partially disposed within the hollow rotor. Multiple rotary shaft drives may be arranged in any suitable manner. For example, the tool holder 320 may include six rotary drives 322A-322F arranged in two rows extending longitudinally along the base, slightly staggered to reduce the width of the holder and increase the compact nature of the tool actuator. Figure 3B As shown, rotary drive units 322A, 322B and 322C can typically be arranged in the first row, while rotary drive units 322D, 322E and 322F can typically be arranged in the second row, which is slightly longitudinally offset from the first row.

[0034] Figure 4A and Figure 4BThis is a schematic diagram illustrating an end effector of an exemplary tool, having a robotic wrist, a pair of opposing jaws, and a pulley and cable system for coupling the robotic wrist and the pair of jaws to an actuator of a tool driver. It should be noted that although the tool model and controller design described below are with reference to an exemplary surgical robotic gripper, the proposed control system for position and gripping force control is adaptable to any tool including an end effector coupled to a tool axis via a robotic wrist that allows for multi-axis movement (e.g., pitch and yaw) of the end effector. Similar tools include, but are not limited to, needle drivers, monopole scissors, monopole hooks, bipole forceps, and other instruments. A needle driver or needle holder includes opposing grippers for holding the needle and operating in a manner similar to the grippers described in detail herein (e.g., opening / closing, yaw, and pitch). A set of monopole scissors is a double-action scissor with a curved plane that also operates in a manner similar to the gripper (e.g., opening / closing, yaw, and pitch). A set of bipolar forceps includes two tips designed to grasp, manipulate, and coagulate selected tissue and also to operate in a manner similar to that of a gripper (e.g., opening / closing, deflecting, and pitching).

[0035] like Figure 4A As shown, a pair of opposing jaws 401A and 401B are movably coupled to a first yoke 402 of the robot wrist via an extension shaft 412 along a first axis 410. The first yoke 402 is movably coupled to a second yoke 403 of the robot wrist via a second extension shaft 422 along a second axis 420. The pair of jaws 401A and 401B can each be coupled to or integrally formed with pulleys 415A and 415B via the extension shaft 412, such that both jaws can rotate about axis 410. Pulleys 425A, 425B, 425C, and 425D are coupled to the extension shaft 422 and rotate about axis 420. Pulleys 425A, 425B, 425C, and 425D are arranged as a first set of pulleys 425B and 425C on one side of the yoke 402 and a second set of pulleys 425A and 425D on the other side of the yoke 402. Pulleys 425A and 42C are outer pulleys, and pulleys 425B and 425D are inner pulleys. Similarly, the third set of pulleys 435A, 435B, 435C, and 435D are coupled to the third extension shaft 432 and rotate about the axis 430 which is parallel to the axis 420.

[0036] The end effector 222 (gripper) can be actuated to move one or both of jaws 401A and 401B about axis 410 in various ways. For example, jaws 401A and 401B can open and close relative to each other. Jaws 401A and 401B can also be actuated to rotate together as a pair to provide deflection motion of the end effector 222 (gripper). Furthermore, the first yoke 402, pulleys 415A and 415B, and jaws 401A and 401B can rotate about axis 420 to provide pitch motion of the end effector 222 (gripper). These movements of the jaws of the robot wrist and / or tool can be achieved by controlling four independent cables 405A-405D. Figure 4A As shown, cable 405A may begin (or terminate) on one side of pulley 415A and be routed along pulleys 425A and 435A, and cable 405B is configured to terminate on the other side of pulley 415A and be routed through pulleys 425B and 435B. Similarly, another pair of cables 405C and 405D may be coupled to jaw 401B. For example, cable 405C extends from one side of pulley 415B to pulleys 425C and 435C; and cable 405D is routed through pulleys 425D and 435D and terminates on the other side of pulley 415B. A third set of pulleys 435A, 435B, 435C, and 435D is arranged in such a way that cables 405A-405D remain attached to the second set of pulleys 425A-425D and slip or slide relative to pulleys 425A-425D.

[0037] Controlling the movement of the end effector 222 (gripper) via four independent cables offers several advantages. One advantage is the reduction in the number of cables extending from the tool base 352 to the robot wrist compared to typical market designs using six cables (or three cable loops with six cable ends). Fewer cables reduce tool size and wrist assembly complexity, which can be advantageous for minimally invasive surgical procedures or non-surgical applications. Furthermore, instead of two or three cable loops, the arrangement of four independent cables not only allows for independent control of the tension on each cable without the need for pre-tensioning, but also enables variable compliance and increased sensitivity to external loads in the wrist joint. Additionally, the tension on each cable can be independently readjusted, which further enhances tool performance.

[0038] like Figure 4A and Figure 4BAs shown, the end effector 222 (gripper) can be actuated to move the jaws 401A and 401B in various ways, such as by imparting motion to one or more of the pulleys 425A, 415B, 415A, 425B, 425C, and 425D to thereby impart motion to the first yoke 402 and / or one or both of the jaws 401A and 401B, to perform gripping (e.g., the jaws rotate independently about axis 410), deflection (e.g., the jaws rotate together about axis 410), and pitching (e.g., the jaws rotate about axis 420). The cables 405A-405D can be divided into two opposing pairs, such that when one cable in the opposing pair is actuated or tensioned while the other cable is released, the jaws will rotate in one direction. When only the other cable is tensioned, the jaws will rotate in the opposite direction.

[0039] For example, cables 405A and 405B are a first pair of opposing forces for moving jaws 401A, and cables 405C and 405D are a second pair of opposing forces for controlling jaws 401B. When cable 405A is tensioned (e.g., by at least one of the rotary drive devices 322A-322F) and cable 405B is released, jaws 401A close (moving toward the opposing jaws 401B). On the other hand, when cable 405B is tensioned and cable 405A is released, jaws 401A open (moving away from the opposing jaws 401B). Similarly, when tensioned, cable 405C closes jaws 401B (moving toward the opposing jaws 401A), and cable 405D opens jaws 401B (moving away from the opposing jaws 401A), while the other cable is released. As another example, the clamping force between jaws 401A and 401B can be achieved by continuing to tension cables 405A and 405C after the jaws are closed (in contact with each other) while simultaneously releasing cables 405B and 405D.

[0040] When two opposing cables are simultaneously tensioned while two cables of another pair are released, pulley 415A or pulley 415B does not rotate. Instead, the first yoke 402, together with jaws 401A and 401B, is given pitch about axis 420 by pulleys 415A and 415B. For example, when a pair of cables 405A and 405B are simultaneously tensioned while a pair of cables 405C and 405D are released, the jaws (together with the yoke 402) pitch out of the paper plane. However, when two cables 405C and 405D are simultaneously tensioned and a pair of cables 405A and 405B remain released, the jaws pitch in the paper plane.

[0041] Figure 4BThis is a schematic diagram illustrating exemplary angle definitions for various movements of the end effector 221 (gripper). The angles are defined with reference to axes 410 and 420, and to axis 452 of the first yoke 402 and axis 453 of the second yoke 403. For example, as... Figure 4B As shown, the angle (θ1) between axes 452 and 453 can represent the rotation angle of yoke 402 about axis 420. This rotation angle can also be defined as the pitch angle (θ) of end effector 222 (gripper). 俯仰 (while) Figure 4A In this configuration, the axis 452 of the yoke 402 is superimposed on the axis 453 of the yoke 403 because the jaws remain in the reference position (i.e., without pitch motion). Furthermore, angles (θ2) and (θ3) can represent the angles between each of the jaws 401A and 401B and the axis 452 of the yoke 402 (as the origin), respectively. To distinguish the sides of the axis 452, angles (θ2) and (θ3) can take different signs. For example, as... Figure 4B As shown, angle (θ2) is negative and angle (θ3) is positive.

[0042] To perform control tasks, it is often beneficial to define a consistent coordinate system for the joint angles. For example, the jaw angle (θ) 钳口 The angle (θ) can be defined as the angle between the two jaws 401A and 401B, and the deflection angle (θ) 偏转 Angles can be defined as the angle between the axis 45° and the line bisecting the jaw angle. These angles can be defined according to equations 1 to 3: θ 俯仰 = θ1 Equation 1 θ 偏转 = 1 / 2(θ² + θ³) Equation 2 θ 钳口 = θ2 - θ3 Equation 3 exist Figure 4B The conversion between the angle in equation 4 and the defined angle is described as follows: Equation 4 Figure 4A and Figure 4B The pulleys of the pulley and cable system can be described using the following nomenclature, which is based on the pulley geometry: a) r11 is the radius of the outer pulleys 425A and 425C on which cables 405A and 405C are located, respectively; b) r12 is the radius of the inner pulleys 425B and 425D on which cables 405B and 405D are located respectively (r11 may be equal to or not equal to r12). c) r21 is the radius of the pulley 415A on the side where cable 405A is located (see the center of pulley 415A and shaft 412, as shown). Figure 4A (as shown) d) r22 is the radius of the pulley 415A on the side where cable 405B is located (see the center of pulley 415A and shaft 412, as shown). Figure 4A (as shown) e) r31 is the radius of the pulley 415B on the side where cable 405C is located; and f) r32 is the radius of pulley 415B on the side where cable 405D is located.

[0043] Although in the above exemplary symmetrical design, r31=r21, r32=r22 and r21 (as... Figure 4A (as shown), but in some other designs r31=r21=r32=r22, and r11=r12.

[0044] The fundamental equation relating cable tension (ξ[4×1]) or force in the cable (F[4×1]) to joint torque (τ[3×1]) is expressed by equations 5a and 5b: τ[3×1]=B[3×4]·ξ[4×1] Equation 5a The matrix (B) has the form given by equation 5b: Equation 5b The torque at the joint may include the pitch joint τ. 俯仰 τ deflection joint 偏转 , its in Figure 4A and Figure 4B In the example, it could be τ 偏转 = τ 钳口1 + τ 钳口2 Furthermore, the cable tension can be the force in the cable (F[4×1]), as shown in Equation 6. Equation 6

[0045] The kinematic relationship between the ideal cable displacement (assuming the cable is inelastic) and the jaw angle is described in Equation 7: Equation 7 Here, q = [q1q2q3q4] T This is the cable displacement under the ideal condition that the cable is rigid. Therefore, the relationship in extended form is described by Equation 8: Where θ1 is the pitch joint angle, and θ2 and θ3 are the joint angles of jaws A and B, respectively (see Figure 3). In practice, the cable can be somewhat elastic, and the cable force and elongation follow Hooke's Law, as shown in Equation 9: Where k is the cable elasticity (assuming four cables are similar), and x is the actuator displacement. The actuator displacement can then be related to the joint angle of the end effector 222 in two different coordinate systems.

[0046] If the cable cannot be assumed to be elastic, the above equations can be replaced by nonlinear equations related to cable elongation and force.

[0047] The angular position and clamping force of the distal end effector of a robotic surgical instrument. The end effector may include a robotic wrist and a pair of opposing components (e.g., jaws or claws), each movable between an open and closed position, actuated by two opposing cables. A total of four cables may be driven by independent actuators or motors. The control system may include a feedback loop involving position and velocity feedback from the actuators and force feedback measured on the four cables to achieve the desired position and clamping force. In some implementations, the actuator controller may operate in a position plus feedforward current mode. For example, the position controller may drive the distal end effector to a desired angular position in space based on position feedback, while the clamping force controller provides additional feedforward current based on the clamping force measured by force sensors on the four cables to achieve the desired clamping force between the opposing components.

[0048] Figure 5 This is an illustration of a subsystem or part of a surgical robot system 100, used to detect engagement between a surgical tool 240 and a tool actuator 230 (tool actuator) of a surgical robot arm 122. The surgical robot arm 122 may be relative to... Figure 1 The surgical robotic arm of the surgical robotic system 100 shown and discussed is one of the surgical robotic arms. The control unit 210 may be, for example... Figure 1 Part of the control tower. As discussed in more detail herein, engagement can be detected by control unit 210 based on one or more rotary motor operating parameters of one or more actuators (e.g., actuator 238-j) in tool driver 230.

[0049] Different surgical tools (e.g., surgical tool 240, and other detachable surgical tools for rotation of an endoscope camera, pivoting of a gripper jaw, or translation of a needle) are selectively attached (one at a time) to a tool actuator 230. This can be accomplished by, for example, a human user holding the housing of surgical tool 240 in her hand and moving the housing in the direction of the indicated arrow 280 until the outer surface of surgical tool 240, in which one or more tool disks (e.g., tool disk 244-i) are present, contacts the outer surface of tool actuator 230, in which one or more drive disks (e.g., drive disk 234-j) are present. The one or more tool disks and / or the one or more drive disks may be implemented as discs, which may be formed of plastic or another durable material. In the example shown, tool actuator 230 is a segment of surgical robotic arm 122 at the distal end portion of surgical robotic arm 122. The proximal end portion of the arm is attached to the surgical robotic platform, as described above. Figure 1 The operating table shown.

[0050] Control unit 210 is configured to control the movement of various motorized joints in the surgical robot arm 122 (including drive disk 234), thereby enabling the operation of end effector 222 (its position and orientation, and its surgical functions such as opening, closing, cutting, pressurizing, etc.), which simulates the operation of user-input devices. The aforementioned operations are achieved via mechanical transmissions in surgical tool 240 when surgical tool 240 has been engaged to transmit force or torque (e.g., torsional force) from tool driver 230. Control unit 210 can be implemented as a programmable processor, for example as... Figure 1 This is part of the control tower 130. It can respond to one or more user commands received via local or remote user input (e.g., joystick, touch control, wearable device, or other user input device communicating via the console computer system). Alternatively, the control unit 210 can respond to one or more autonomous commands or controls (e.g., received from a trained surgical machine learning model executed by the control unit 210 or the console computer system) or a combination thereof. These commands instruct movement of the robotic arm 122 and operation of its attached end effector 222.

[0051] End effector 222 can be any surgical instrument, such as jaws (e.g., as shown in the image). Figure 4A and Figure 4B(As shown), cutting tools, endoscopes, unfolders, implantation tools, etc. Different surgical tools, each with different end effectors, can be selectively attached (one at a time) to the robotic arm 122 for use during surgical or other medical procedures. The end effector 222 may be a jaw located at the distal end of the surgical tool 240, and the jaw may retract into or extend from the shown cannula (e.g., a thin tube that can be inserted into a patient undergoing a surgical procedure).

[0052] The robotic arm 122 includes a tool actuator 230, in which one or more actuators, such as actuators 238-j, are present. Each actuator may be a linear or rotary actuator having one or more corresponding electric motors (e.g., brushless permanent magnet motors), whose drive shafts may be coupled to a corresponding drive disk 234-j via a transmission mechanism (e.g., a gear train to achieve a given gear reduction ratio). The tool actuator 230 includes one or more drive disks 234, which may be arranged on a planar or flat surface of the tool actuator 230, wherein the figure illustrates several such drive disks arranged on the same plane of a flat surface. Each drive disk (e.g., drive disk 234-j) is exposed on an outer surface of the tool actuator 230 and is designed to mechanically engage (e.g., securely hold via snap, friction, or other mating features) a mating tool disk 244-j of the surgical tool 240 to achieve direct torque transmission between the two. This can occur, for example, when the planar or flat surface of the surgical tool 240 and the corresponding or mating planar or flat surface of the tool actuator 230 come into contact with each other.

[0053] Furthermore, a motor driver circuit (e.g., mounted elsewhere in tool driver 230 or surgical robot arm 122) is electrically coupled to the input drive terminal of one or more actuators in actuator 238 that constitute the motor. The motor driver circuit manipulates the electrical power drawn from the motor according to a motor driver circuit input, in order to regulate, for example, the speed of the motor or its torque, which can be set or controlled by control unit 210, thereby causing powered rotation of the associated drive disk (e.g., drive disk 234-j).

[0054] When the drive disc 234-j is mechanically engaged with the corresponding tool disc 244-j, the power rotation of the drive disc 234-j causes the tool disc 244-j to rotate. For example, the two discs can rotate as a single unit, thereby imparting motion to a linkage, gear, cable, chain, or other transmission device within the surgical tool 240, for controlling the movement and operation of the end effector 222, which can be mechanically coupled to the transmission device.

[0055] Different surgical tools may have different numbers of tool discs based on the type of movement and the number of degrees of freedom of movement (such as rotation, joint movement, opening, closing, extension, retraction, compression, etc.) performed by their end effectors.

[0056] Furthermore, within the surgical tool 240, more than one tool disk 244 can facilitate a single movement of the end effector 222 to achieve objectives such as load sharing by two or more motors, each driven by a mating drive disk 234. On the other hand, within the tool driver 230, two or more motors may be present, their drive shafts coupled (via a transmission) to rotate the same output shaft (or drive disk 234) to share a load.

[0057] On another front, within the surgical instrument 240, there is a transmission mechanism that converts the torque from two drive discs 234 (via corresponding tool discs 244) for performing complementary actions with the same degree of freedom. For example, the first drive disc 234-j rotates a roller within the housing of the surgical instrument 240 to receive one end of a rod, and the second drive disc 234-i rotates another roller within the housing of the surgical instrument 240 to receive the other end of the rod. Alternatively, two tool discs 234-i, 234-j can be used to extend and retract the end effector along a single axis, one tool disc for extension and the other for retraction. This contrasts with actuators that also move with one degree of freedom (e.g., extending and retracting longitudinally along a single axis of movement) but require only a single tool disc to control their entire range of motion. Furthermore, actuators that move with multiple degrees of freedom (such as wrist movement, movement along multiple axes, energy emitter activation in addition to end effector movement, etc.) may require several tool discs (each engaged with a corresponding drive disc). In another type of surgical tool 240, a single tool disk 244 is sufficient to perform both extension and retraction movements via direct input (e.g., gears). Alternatively, as discussed in more detail herein, in the case where the end effector 222 is a jaw, two or more tool disks 244 can collaboratively control the movement of the jaw for load sharing.

[0058] On another front, within the surgical instrument 240, there is a transmission mechanism that converts the torque from two drive discs 234 (via corresponding tool discs 244) for performing complementary actions with the same degree of freedom. For example, the first drive disc 234-i rotates a roller within the housing of the surgical instrument 240 to receive one end of a cable, and the second drive disc 234-j rotates another roller within the housing of the surgical instrument 240 to receive the other end of the cable. Alternatively, two tool discs 234-i, 234-j can be used to extend and retract the end effector along a single axis, one tool disc for extension and the other for retraction (e.g., via different cables). This contrasts with actuators that also move with one degree of freedom (e.g., extending and retracting longitudinally along a single axis of movement) but require only a single tool disc to control their entire range of motion. Furthermore, actuators that move with multiple degrees of freedom (such as wrist movement, movement along multiple axes, energy emitter activation in addition to end effector movement, etc.) may require several tool discs (each engaged with a corresponding drive disc). In another type of surgical tool 240, a single tool disk 244 is sufficient to perform both extension and retraction movements via direct input (e.g., gears). Alternatively, as discussed in more detail herein, in the case where the end effector 246 is a jaw, two or more tool disks 244 can collaboratively control the movement of the jaw for load sharing.

[0059] Figure 6 An example of a surgical tool 240 (TD 6 is not shown in this example) including rotary device allocation or mapping for tool discs TD1-5 is illustrated. In this example, tool disc TD5 is mapped to the rolling axis 258 of an end effector, shown as jaws 251, and may include a first opposing jaw 401A and a second opposing jaw 401B. Tool disc TD5 may be coupled to one or more gears that drive the wrist to rotate about the rolling axis. Each opposing jaw is allocated two tool discs. For example, the first opposing jaw 401A may be allocated to tool disc TD1 for opening the jaws (i.e., increasing the angle between the first opposing jaw 401A and the second opposing jaw 401B) and tool disc TD3 for closing the jaws (i.e., decreasing the angle between the first opposing jaw 401A and the second opposing jaw 401B). Tool disc TD1 may be coupled to a cable that rotates pulley 415A in a first direction, and tool disc TD3 may be coupled to a cable that rotates pulley 415A in a second direction.

[0060] Similarly, the second relative jaws 401B can be assigned to a tool disc TD2 for opening the jaws (i.e., increasing the angle between the first relative jaws 401A and the second relative jaws 401B) and a tool disc TD4 for closing the jaws (i.e., decreasing the angle between the first relative jaws 401A and the second relative jaws 401B). The tool disc TD2 can be coupled to a cable that rotates the pulley 415B in a first direction, and the tool disc TD4 can be coupled to a cable that rotates the pulley 415B in a second direction.

[0061] In some implementations, when the surgical tool 240 is first attached to or mounted on the tool driver 230 in order to bring the tool disk to substantially coplanar and coaxial alignment with the corresponding drive disk (although the tool disk and drive disk may not have been successfully engaged yet), the control unit 210 initially detects the type of the surgical tool 240. In one embodiment, the surgical tool 240 has an information storage unit 242, such as solid-state memory, radio frequency identification (RFID) tags, barcodes (including two-dimensional barcodes or matrix barcodes), etc., which identifies tool or end effector information of the surgical tool, such as one or more of the following: tool type or end effector type identification information, unique tool ID or end effector ID, number of tool disks used, positions of those tool disks used (e.g., from a total of six possible tool disks 244-e, 244-f, 244-g, 244-h, 244-i, 244-j), type of drive mechanism of the tool disk (e.g., direct drive, cable drive, etc.), what kind of movement or actuation the tool disk assigns to the end effector, one or more tool calibration values ​​(e.g., the rotational position of the tool disk determined during tool coefficient testing / assembly), whether the movement of the end effector is constrained by maximum or minimum movement, and other tool attributes. In one embodiment, the information storage unit 242 identifies minimal information, such as the tool ID, and its control unit 210 can be used to perform lookups of various tool attributes.

[0062] The tool driver 230 may include a communication interface 232 (e.g., a memory writer, near-field communication, NFC, transceiver, RFID scanner, barcode reader, etc.) to read information from the information storage unit 242 and transmit the information to the control unit 210. Furthermore, in some embodiments, the surgical tool 240 may contain more than one information storage unit, such as one information storage unit associated with each tool disk 244. In this embodiment, the tool driver 230 may also include corresponding sensors for each possible information storage unit present in a given tool.

[0063] After the surgical tool 240 is attached to the tool driver 230 such that the tool disk is brought to be aligned with and superimposed on the corresponding drive disk (although not necessarily mechanically engaged), and after obtaining tool disk information, for example, read by the control unit 210, the control unit 210 performs an engagement process to detect when all tool disks intended to be attached to the corresponding drive disks are mechanically engaged with their respective drive disks (e.g., their mechanical engagement has been achieved, or the tool driver 230 is now considered to be engaged with the tool). That is, attaching the surgical tool 240 to the tool driver 230 does not necessarily ensure the correct fit required for the mechanical engagement of the tool disks with the corresponding drive disks (e.g., due to misalignment of the fitting features). The engagement process may include activating one or more motors that drive the actuator (e.g., actuator 238-j) of the corresponding drive disk 234-j. Then, based on one or more monitored motor operating parameters of the actuator 238-j, the mechanical engagement of the tool disk 244-i with the drive disk 234-j can be detected when the actuator is driving the drive disk 234-j. This process can be repeated for each drive disk 234 in the tool driver 230 that is expected to be currently attached (e.g., determined based on tool disk information obtained from the specific surgical tool 240 currently attached).

[0064] When a particular type of surgical tool 240 is detected to be attached to the tool driver 230, the control unit 210 activates one or more actuators (e.g., motors) of the tool driver 230 that were previously associated with that type of surgical tool 240. In some embodiments, each actuator associated with the corresponding drive disk 234 of the surgical tool 240 may be activated simultaneously, sequentially, or in a combination of simultaneous and sequential activation.

[0065] Figure 7 A cable-driven system for a surgical tool 240 is shown. As described in other embodiments herein, four cables 405A-D are driven by a tool actuator 230 to provide the tool with a desired position or movement, the tool including a wrist 223 and an end effector 222. Cables 405A-D are connected to the wrist 223 at a cable interface 224. The wrist 223 is connected to or includes the end effector 222. A shaft 239 contains and protects the cables 405A-D. The cables are connected to the distal end of a robotic arm 200 at a tool attachment interface 205. A control unit 210 provides data to one or more components of the surgical tool 240 and receives feedback data from the surgical tool 240, as described in more detail below.

[0066] Figure 8 A more detailed view of the cable drive system is shown. Motor 231 operates cable 405. Motor 231 can be directly connected to a shaft for winding cable 405 in a specific sequence to move wrist 223. Figure 8 In the example shown, motor 231 drives gear train 235 to rotate a cable around its wound drive wheel 237. Various sensors may be included in the cable drive system. Position encoder 233 may be a rotary position encoder that monitors the motor shaft position and, for example, encodes the current motor shaft position as a value representing an angular position. Sensor 236 may include a tension sensor coupled to the corresponding cable, or a torque sensor that measures the torque of the corresponding motor coupled to the cable. The measured torque (rotational force) may be converted into tension (linear force). Each cable may have an initial tension (pretension) at the tool's initial "relaxed" position. In some embodiments, the pretension is 10 N. In some embodiments, the pretension value may be set to 0 or other low values ​​where the tool does not require cable pretension.

[0067] Figure 9 An example of a surgical tool 240 is shown, which utilizes five tool discs, such as tool discs 244-e, 244-f, 244-g, 244-i, and 244-j, arranged coplanarly on the mating surfaces of its housing. Each tool disc contributes to at least a portion of the movement and / or activation of the end effector 222. Upon detection that the surgical tool 240 is attached to the tool driver 230 (e.g., connection of the mating surfaces of the corresponding housings), the control unit 210 (or its processor 312, while executing instructions stored in the memory 314) performs a process to determine that only the corresponding five drive discs (such as drive discs 234-e, 234-f, 234-g, 234-i, and 234-j) will be rotated (the corresponding actuators 238 are activated) to perform the engagement process.

[0068] In some implementations, motor operating parameters monitored by control unit 210 (via sensor 236) are interpreted as indicating successful mechanical engagement of the tool disk and drive disk. Control unit 210 is connected to and receives sensor data from sensor 236 in an exemplary sensor array, which includes any combination of presence sensor 341, torque sensor 342, position sensor 343, electrical sensor 345, optical sensor 347, and force sensor 348. The sensor array may include individual sensors for different degrees of freedom of the surgical tool (e.g., closure joints, rolling joints, or other operations of the surgical tool). That is, the sensor array or one or more sensors thereof may be repeated for multiple tool disks 244 in the tool driver 230.

[0069] The measurement results may include a measurement of the torque (e.g., torsional force) applied by the actuator 238-j, measured by the torque sensor 342 or the force sensor 348; a measurement of the current supplied to the motor 231 of the actuator 238-j when attempting to drive the actuator at a specific rate (e.g., where the sensor 236-j may include a current-sensing resistor connected in series with the motor input drive terminal), measured by the electrical sensor 345; a measurement of the impedance seen at the input drive terminal of the motor 231 of the actuator 238 when attempting to drive the motor at a specific rate (e.g., where the sensor 236-j may also include a voltage-sensing circuit to measure the voltage at the motor input drive terminal), measured by the electrical sensor 345; the speed of the actuator 238-j (e.g., where the optical sensor 347 may include a position encoder on the output shaft of the actuator 238-j or on the drive shaft of the motor 231); and other parameters referred to herein as motor operating parameters. Measurement results may include presence data from presence sensor 341, implicit in any sensor in sensor array 236, or determined from the interaction between information storage unit 242 and communication interface 232. Position sensor 343 is shown separately, but it can be implemented using a combination of presence sensor 341, torque sensor 342, electrical sensor 345, optical sensor 347, and force sensor 348. In one example, additional sensors of the same type may be used for position sensor 343.

[0070] When monitoring the operating parameters of one or more motors in a specific actuator, the detection of such a situation, when one or more of these parameters meet (e.g., conform to or reach) a predetermined condition or threshold, can be interpreted by the control unit 210 as a mechanical engagement event. It should be noted that meeting the predetermined condition can, for example, mean that, according to the threshold, the monitored operating parameter exhibits a specific change relative to the operating parameter of another motor that is simultaneously controlled by the control unit 210 during the engagement detection process and is part of either the same actuator 238-j or another actuator 238-i.

[0071] In some implementations, during operation of actuator 238-j, specific motor operating parameters, such as one or more of the following: i) torque that meets (e.g., rises and reaches) a torque threshold, ii) motor current that meets (e.g., rises and reaches) a current threshold, iii) impedance that decreases below an impedance threshold, iv) motor speed that decreases below a motor rate threshold, or a combination thereof, are detected. Control unit 210 uses these motor operating parameters to determine that mechanical engagement between tool disk 244-j and drive disk 234-j has occurred. Some examples of such processes are given below.

[0072] The control unit 210, including its programming processor 312, can be integrated into the surgical robot system 100. Figure 1 In, for example, as a shared microprocessor and program memory within control tower 130. Alternatively, it can be in a remote computer (such as...) Figure 1 The control unit 210 is implemented in a room different from the operating room or in a building different from the surgical site, as shown. Furthermore, the control unit 210 may also include (though not shown) user interface hardware (e.g., keyboard, touchscreen, microphone, speaker) that enables manual control of the robotic arm and its attached surgical tools 240, power supply (e.g., battery), and other components typically associated with electronics for controlling the surgical robotic system.

[0073] Memory 314 is coupled to one or more processors 312 (generally referred to herein as processors for simplicity) to store instructions for execution by processor 312. In some embodiments, the memory is non-transitory and may store one or more program modules, including tension assessment control 316 and velocity assessment control 315, whose instructions configure processor 312 to perform the calibration process and calibration assessment process described herein. In other words, processor 312 may operate under the control of the execution of programs, routines, or instructions stored in memory 314 as part of tension assessment control 316 and velocity assessment control 315 to perform methods or processes according to the aspects and features described herein.

[0074] The memory 314 may include one or more settings, coefficient values, thresholds, tolerance values, and calibration values ​​for the surgical tool 240 and / or tool driver 230. The memory 314 may include specific values ​​of the threshold tension values ​​and / or speed thresholds described below. These values ​​may be stored in the memory 314 as a configuration file, table, or matrix. Some values ​​in the configuration file may be provided by the user, some values ​​may be accessed or retrieved based on the identifier of the surgical tool 240 or tool driver 230, and other values ​​may be set by the control unit 210.

[0075] Figure 10 A block diagram of a procedure or technique that can be performed by any system described herein (e.g., a controller such as control unit 210) is shown. Each action or block may refer to a separate process that may have many steps. The illustrated sequence is merely an example and the steps may be performed in any order. Additional, different, or fewer blocks may be included.

[0076] As described above, each or more of the actuators 238 or motors 231 may be associated with a sensor such as torque sensor 342. The corresponding torque sensor 342 measures the torque on the actuator 238. The tension in the cable coupled to the actuator 238 is determined based on the measured torque. The torque on the actuator 238 measured by torque sensor 342 can be multiplied by the radius of the actuator 238 to equal the tension in the corresponding coupled cable. Control unit 210 can calculate a set of cable tensions 501A-D, including tension values ​​from the torque on the corresponding actuator and / or the transmission system between the actuator and the cable.

[0077] Control unit 210 can calculate the tension of at least one cable based on the inverse kinematics model of surgical tool 240. For example, user input from input device 317 can request a specific position or direction of movement in the joint space. Control unit 210 converts the command position according to the inverse kinematics model including the aforementioned B matrix to convert the command position in the actuator space or directly to the cable space. The inverse kinematics model includes the relationship between the torque detected at a corresponding motor among a plurality of motors and the tension of at least one cable among a plurality of cables, based on the inverse kinematics matrix.

[0078] Alternatively, control unit 210 may receive the tension of at least one cable from a tension sensor coupled to the respective cable. In all these examples, control unit 210 identifies the tension of at least one of a plurality of cables derived from at least one of the forces detected by the sensor.

[0079] Control unit 210 performs tension threshold comparison 503 (e.g., included in tension assessment control 316) to compare the tension of at least one cable with a threshold tension value. The output of threshold comparison 503 may be a binary value corresponding to a first value (e.g., a high value or 1) when the tension is less than the threshold tension value and a second value (e.g., a low value or 0) when the tension is greater than the threshold tension value.

[0080] The control unit 210 can also determine a set of cable speeds 502A-D based on sensor data corresponding to the actuator 238. In one example, the position encoder 233 provides sensor data regarding the position of the actuator 238. Changes in the rotational position of the actuator 238 are converted into the linear velocity of the cable. Alternatively, the set of cable speeds 502A-D is based on sensor data of motor torque, for example, motor torque.

[0081] Another example of calculating a set of cable speeds 502A-D considers the drive pulley 237 and / or gear train. A set of cable speeds 502A-D can be determined based on the actuator position and the radius of the drive pulley 237. The drive pulley radius is the radius around which the corresponding cable is fixed and wound when the drive pulley 237 rotates. The rotation of the drive pulley can be achieved by one or more gears that convert the rotational motion of the motor 231 into the rotational motion of the drive pulley 237. As the drive pulley rotates, the cable position and cable tension change accordingly, depending on the amount and direction of rotation.

[0082] In some implementations, the position (c) of the measuring cable is determined by the product of the actuator position (x) and the radius (r), as shown in Equation 10. The radius (r) can be the radius of the actuator or the radius of the drive wheel, which can be adjusted by the gear ratio of the gear train. Equation 10

[0083] The change in cable position (C) is the cable velocity (V), as shown in Equation 11. The derivative of the cable position with respect to time is the cable velocity. Similarly, the derivative of the actuator position with respect to time multiplied by the radius is the cable velocity. Equation 11

[0084] Control unit 210 generates a velocity vector 504 based on a set of cable velocities 502A-D (e.g., using a velocity evaluation control 315). Control unit 210 can identify the velocity value of at least one of a plurality of cables calculated according to any of the techniques described above. Velocity vector 504 includes an item for each cable in the cable drive system. Velocity vector 504 can be arranged such that pairs of cables are at predetermined positions within velocity vector 504. For example, the velocity values ​​of pairs of cables can be adjacent in velocity vector 504.

[0085] The control unit 210 can calculate the measured velocity norm 506 based on the velocity vector 504. The sum of squares of the terms in the velocity vector 504 is taken, and the square root of the result is the velocity norm 506, as shown in Equation 12. The magnitude of the velocity vector 504 is the measured velocity norm 506. Therefore, the measured velocity norm (V...) 测量 ) represents the measured speed (MV1, MV2,... MV) of all cables in a cable drive system. n A single value. Equation 12

[0086] The measured speed range 506 can be compared with the command speed. The command speed is the expected speed of the cable based on the command sent to actuator 238. When the command speed differs from the measured speed, unexpected behavior has already occurred. The engagement between the actuator and the sterile adapter may have disengaged or otherwise damaged. When this happens, the energy stored as tension in one or more cables can move the wrist in unexpected ways.

[0087] The control unit 210 can calculate the command speed norm based on the command speed value of the cable input by the user. The command speed values ​​are summed by squares, and the square root of the result is the command speed norm (V). 命令 As shown in Equation 13, the command speed norm represents the command speed (CV1, CV2,... CV) of all cables in the cable drive system. n A single value. Equation 13

[0088] Control unit 210 performs a speed threshold comparison 510 (e.g., using speed evaluation control 315) to compare a speed norm value with a statistical speed threshold. The statistical speed threshold can be set equal to the command speed norm value so that the comparison is a direct comparison. The output of threshold comparison 503 can be a binary value corresponding to a first value (e.g., a high value or 1) when the speed is greater than the statistical speed threshold and a second value (e.g., a low value or 0) when the tension is less than the statistical speed threshold.

[0089] A statistical speed threshold can be the statistically significant difference between a measured speed norm and a commanded speed norm. For example, the measured speed norm and / or commanded speed norm can be monitored by the control unit 210 over time to determine how much change in the measured speed norm and / or commanded speed norm indicates that one or more cables have experienced energy release due to disconnection or breakage, and not just insignificant changes in the data.

[0090] Statistical velocity thresholds can be calculated in part based on Bayesian filters. For example, Bayesian filters can analyze time series data based on measured velocity norms, commanded velocity norms, or the difference between measured and commanded velocity norms. Bayesian filters can promptly determine the joint probability distribution of any of these variables to identify statistically significant changes in the variables and filter out changes that are merely noise.

[0091] A statistical velocity threshold can be determined using statistical hypothesis testing (e.g., a chi-square test). The statistical hypothesis determines whether there is a statistically significant difference between the measured velocity norm and the expected value derived from the commanded velocity norm.

[0092] The statistical velocity threshold is calculated in part based on the average of the velocity norms at the first and second time points. For example, it can also be calculated in part based on the standard deviation of the time series of data that includes the velocity norms at the first and second time points.

[0093] The AND gate 505, included only for graphical representation, represents the logical operation of the outputs of tension threshold comparison 503 and speed comparison threshold 510. There may be no component corresponding to gate 505; it may only be a graphical representation. When the output of speed threshold comparison 510 indicates that the speed is greater than a statistical speed threshold and tension threshold comparison 503 indicates that the measured tension is less than a threshold tension value, the output of AND gate 505 may be high, causing control unit 210 to generate one or more messages. Control unit 210 is configured to identify the disconnection of at least one of a plurality of cables or an associated motor based on a first comparison and a second comparison.

[0094] The message may indicate the disconnection of a cable or the detachment of a motor from a sterile adapter, resulting in a disconnected cable. Control unit 210 may generate a message in response to the disconnection of at least one of the cables. The message may specify the cable. For example, the cable may be identified based on the torque on the corresponding actuator 238 or according to the inverse kinematics model of the surgical tool 240, using a set of minimum tension values ​​of cable tensions 501A-D.

[0095] Messages can be warnings to the user (e.g., 507). For example, a message can state that an error has occurred. Messages can provide instructions for the user to handle the error, such as reconnecting a loose cable or a detached motor. Messages can instruct the user to remove a tool. Messages can instruct the user to replace a tool with a new one.

[0096] The message may be an internal message instructing control unit 210 to disable surgical tool 240. Therefore, surgical tool 240 is disabled when disengagement is detected. Upon detection of disengagement, control unit 210 may generate an error command to disable surgical tool 240 in response to the message. Re-enabling the tool may require inputting a code to surgical tool 240 or providing a factor reset command to surgical tool 240.

[0097] The message can be an external message sent to an external device. For example, the message may be sent to the manufacturer or another entity that dispatches services for the surgical tool. The external device or control unit 210 can track the occurrence of messages or warnings at the surgical tool 240, and when a set number of messages have occurred, a fatal error can be assigned to the surgical tool 240 and the surgical tool 240 can be permanently disabled. Messages may be recorded by the external device along with other surgical tools to identify trends in the deployment of a specific model of the surgical tool.

[0098] Figure 11A process for detecting cable faults is described. This process can be executed by a programmable processor (also referred to herein as a processor or controller), configured according to instructions stored in memory (e.g., Figure 8 The processor 312 and memory 314 are configured according to instructions from the tension evaluation control 316 and the speed evaluation control 315. It can perform operations more... Figure 11 The actions in the text are more, different, or fewer.

[0099] At action S101, processor 312 identifies the tension in the cables of the surgical instrument. Processor 312 can calculate the tension value or receive that value directly or indirectly from a sensor. The tension value can be received or calculated repeatedly at predetermined time intervals. The tension value can be identified at sampling rates such as every 1 second, every 100 milliseconds, or every 10 milliseconds. The tension values ​​of any number or all of the cables in the surgical instrument can be received.

[0100] In one example, tension is measured or received only at specific times. For instance, processor 312 may determine that the cable is tensioned based on the movement of the end effector. In some examples, the cable or a subset of the cable may not be tensioned when a degree of freedom (e.g., roll, pitch, yaw, or jaw) changes direction. A degree of freedom changes direction when the corresponding angle changes from an increasing value to a decreasing value or from a decreasing value to an increasing value.

[0101] At action S103, processor 312 performs a comparison of the tension of at least one cable with a threshold tension value retrieved from memory 314. The threshold tension value can be set by the user or manufacturer. Alternatively, the threshold tension value can vary over time. The threshold tension can be based on the average of past tension values, such as twice the average of past tension values ​​within a time window. The threshold tension value can be different for different cables. The threshold tension value can be different for different cable pairs. In one example, for each pair of opposing cables, only one of the opposing pairs is compared at a time. In another example, a threshold tension value is assigned to a pair of opposing cables, and the comparison is the sum of the tension values ​​for that pair of opposing cables.

[0102] At action S105, processor 312 identifies the speed of each cable of the surgical instrument or at least multiple cables of the surgical instrument. Processor 312 may calculate the speed value or receive the value directly or indirectly from a sensor. The speed value may be received or calculated repeatedly at predetermined time intervals. The speed value may be identified at sampling rates such as every 1 second, every 100 milliseconds, or every 10 milliseconds.

[0103] At action S107, processor 312 calculates the velocity norm or representative value of all cables or multiple cables of a surgical tool. The velocity norm can be the sum of the velocity values. The velocity norm can include the sum of squares of the velocity values. The sum of velocities can be the square root of the sum of squares of the velocity values. Other examples of the relative velocities of the cables of a combined surgical tool are possible.

[0104] At action S109, processor 312 compares the velocity norm with a velocity threshold. The velocity threshold can be set by the user or the manufacturer. Alternatively, the velocity threshold can vary over time. The velocity threshold can be set based on past values ​​(such as twice the average velocity norm over a time window).

[0105] At action S111, processor 312 detects a malfunction of the surgical instrument. The malfunction is based on a comparison of tension and speed. When the tension is below a tension threshold and the speed is above a threshold, processor 312 identifies a malfunction related to the cables. The malfunction may indicate a disconnection between the sterile adapter and the surgical instrument. The malfunction may be the disconnection of at least one cable.

[0106] Processor 312 may generate commands for remedial actions in response to determining a malfunction in the surgical tool. The remedial action may disable the surgical tool. The surgical tool may be disabled for a predetermined time until user intervention (e.g., resetting a switch) occurs, or until the surgical tool is reconfigured. Reconfiguration of the surgical tool may include homing and / or calibration. Reconfiguration of the surgical tool may include replacing one or more cables.

[0107] In this document, the phrase "coupled with" is defined as meaning a direct connection or an indirect connection via one or more intermediate components. Such intermediate components may include hardware-based and software-based components. Furthermore, for the purpose of clarifying its use in the pending claims and to provide notice to the public, the applicant defines the phrase "coupled with" in the broadest sense. 、 ,…and <n> at least one of them or< / n> 、 、… <n>"at least one or a combination thereof" replaces any other implied definition above or below. Unless the applicant expressly interprets otherwise, these phrases mean one or more elements selected from the group consisting of A, B, ... and N, that is, any combination of one or more elements of elements A, B, ... or N, including any one element alone or possibly in combination with other elements not listed.

[0108] The disclosed mechanism can be implemented at any logical component and / or physical point or combination thereof, where relevant information / data (e.g., its messaging traffic and responses) can be monitored or flowed or otherwise accessible or measurable, including one or more gateway devices, modems, one or more market participants’ computers or terminals, such as client computers, etc.

[0109] Those skilled in the art will understand that one or more modules described herein can be implemented using a tangible computer-readable medium, including computer-executable instructions (e.g., executable software code). Alternatively, modules can be implemented as software code, firmware code, specifically configured hardware or processor, and / or a combination of the foregoing.

[0110] < / n> Figures 1 to 2 The operation of the computer apparatus and system shown in 5 can be controlled by computer-executable instructions stored on a non-transitory computer-readable medium. For example, the exemplary computer apparatus or control unit 210 may store computer-executable instructions, generate electronic messages, extract information from electronic messages, perform actions related to electronic messages, and / or calculate values ​​from electronic messages to facilitate any algorithms or actions described herein. Numerous additional servers, computers, handheld devices, personal digital assistants, telephones, and other devices may also be connected to control unit 210.

[0111] As shown in Figure 3, a computer system may include a processor 312 implemented by a central processing unit (CPU), a graphics processing unit (GPU), or both. The processor 312 can be a component in a variety of systems. For example, the processor 312 may be part of a standard personal computer or workstation. The processor 312 may be one or more general-purpose processors, digital signal processors, specifically configured processors, application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), servers, networks, digital circuits, analog circuits, combinations thereof, or other means now known or later developed for analyzing and processing data. The processor 312 may implement software programs, such as manually generated (i.e., programmed) code.

[0112] The computer system includes a memory 314 that can communicate via a bus. The memory 314 may be main memory, static memory, or dynamic memory. The memory 314 may include, but is not limited to, computer-readable storage media, such as various types of volatile and non-volatile storage media, including but not limited to random access memory, read-only memory, programmable read-only memory, electrically programmable read-only memory, electrically erasable read-only memory, flash memory, magnetic tape or disk, optical media, etc. In one embodiment, the memory 314 includes a cache or random access memory of the processor 312. In another embodiment, the memory 314 is separate from the processor 312, such as the processor's cache memory, system memory, or other memory. The memory 314 may be an external storage device or database for storing data. Examples include hard disk drives, compact discs ("CDs"), digital video discs ("DVDs"), memory cards, memory sticks, floppy disks, universal serial bus ("USB") storage devices, or any other device operable to store data. The memory 314 is operable to store instructions executable by the processor 312. The functions, actions, or tasks illustrated in the accompanying drawings or described herein can be executed by a programmed processor 312 that executes instructions stored in memory 314. These functions, actions, or tasks are independent of a specific type of instruction set, storage medium, processor, or processing strategy, and can be executed by software, hardware, integrated circuits, firmware, microcode, etc., operating individually or in combination. Similarly, processing strategies can include multi-processing, multi-tasking, parallel processing, etc.

[0113] The computer system may further include a display unit 319, such as a liquid crystal display (LCD), an organic light-emitting diode (OLED), a flat panel display, a solid-state display, a cathode ray tube (CRT), a projector, a printer, or other display devices now known or developed later for outputting specific information. The display 319 may serve as an interface for a user to view the functions of the processor 312, or specifically as an interface to instructions stored in memory 314 or elsewhere in the control unit 210.

[0114] Additionally, the computer system may include an input device 317 configured to allow a user to interact with any component of the system. The input device 317 may be a numeric keypad, keyboard, or cursor control device, such as a mouse or joystick, touchscreen display, remote control, or any other device operable to interact with the control unit 210.

[0115] This disclosure envisions a computer-readable medium that includes instructions or receives and executes instructions in response to signals, enabling devices connected to a network to transmit voice, video, audio, images, or any other data over the network. Furthermore, instructions can be transmitted or received over the network via a communication interface 318. The communication interface 318 may be part of a processor 312 or may be a separate component. The communication interface 318 may be a physical connection in hardware. The communication interface 318 is configured to connect to a network, external media, a display unit 319, or any other component or combination thereof in the system. The connection to the network may be a physical connection such as a wired Ethernet connection, or a wireless connection may be established. Similarly, additional connections to other components of the system may be physical connections or additional connections may be established wirelessly.

[0116] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The illustrations are not intended as a complete description of all elements and features of devices and systems utilizing the structures or methods described herein. Many other embodiments may become apparent to those skilled in the art upon viewing this disclosure. Other embodiments can be utilized and derived from this disclosure, allowing structural and logical substitutions and changes to be made without departing from the scope of this disclosure. Furthermore, the illustrations are merely representative and may not be drawn to scale. Some scales within the illustrations may be enlarged, while others may be minimized. Therefore, this disclosure and the accompanying drawings should be considered illustrative rather than restrictive.

[0117] While this specification contains numerous details, these details should not be construed as limiting the scope of the invention or the content protected by the claims, but rather as descriptions of features specific to particular embodiments of the invention. Certain features described in this specification in the context of individual embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, while features may be described as functioning in certain combinations and even initially so protected by the claims, one or more features from a claimed combination may be removed from that combination in some cases, and a claimed combination may involve sub-combinations or variations thereof.

[0118] Similarly, although the operations are depicted in the accompanying drawings and described herein in a specific order, this should not be construed as requiring such operations to be performed in the specific order shown or sequentially, or requiring the execution of all illustrated operations to achieve the desired result. In some cases, multitasking and parallel processing may be advantageous. Furthermore, the separation of various system components in the described embodiments should not be construed as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or encapsulated in multiple software products.

Claims

1. A device for detecting the dislodgement of a surgical instrument, the device comprising: An end effector, which is connected to and driven by multiple cables of a tool driver; Multiple sensors are configured to detect forces associated with the multiple cables; and One or more processors, said one or more processors being configured to: Identify the tension of at least one of the plurality of cables derived from at least one of the forces detected by the plurality of sensors; Perform a first comparison between the tension of at least one of the plurality of cables and a threshold tension value; Identify the speed value of each of the multiple cables; The velocity norm is calculated based on a vector comprising the velocity values ​​of each of the plurality of cables. Perform a second comparison between the stated velocity norm and the statistical velocity threshold; as well as The disconnection of at least one of the plurality of cables or associated components is identified based on the first comparison and the second comparison.

2. The apparatus of claim 1, wherein the velocity norm is a magnitude of the vector comprising the velocity value of each of the plurality of cables.

3. The apparatus of claim 2, wherein one or more processors are configured to: The statistical speed threshold is calculated in part based on the command speed.

4. The apparatus of claim 3, wherein the statistical velocity threshold is calculated in part based on a Bayesian filter.

5. The apparatus of claim 3, wherein the statistical velocity threshold is calculated in part based on the average of the velocity norm at a first time point and the velocity norm at a second time point.

6. The apparatus of claim 5, wherein the statistical velocity threshold is calculated in part based on the standard deviation of a time series of data including the velocity norm at the first time point and the velocity norm at the second time point.

7. The apparatus of claim 6, wherein one or more processors are configured to: Calculate the chi-square value of the time series of the data.

8. The apparatus according to claim 1, further comprising: Multiple motors are coupled to multiple cables, wherein multiple sensors detect torque at a corresponding motor among the multiple motors.

9. The apparatus of claim 8, wherein one or more processors are configured to: The tension of at least one of the plurality of cables is calculated based on the inverse kinematics model of the surgical instrument.

10. The apparatus of claim 9, wherein the inverse kinematics model comprises the relationship between the torque detected at a respective motor among the plurality of motors and the tension of at least one of the plurality of cables, according to an inverse kinematics matrix.

11. The apparatus of claim 1, wherein one or more processors are configured to: The velocity value of each of the multiple cables is calculated based on the inverse kinematics model.

12. The apparatus of claim 1, wherein one or more processors are configured to: A message is generated in response to the detachment of at least one of the plurality of cables or associated components.

13. The apparatus of claim 12, wherein the message is a user warning having instructions for the user of the surgical instrument.

14. The apparatus of claim 12, wherein the message is a surgical tool dispatch service.

15. The apparatus of claim 12, wherein the message is an erroneous command to disable the surgical tool.

16. A method for detecting the detachment of a surgical instrument, the surgical instrument being connected to and driven by a plurality of cables, the method comprising: Identify the tension of at least one of the plurality of cables derived from at least one force detected by multiple sensors; Perform a first comparison between the tension of at least one of the plurality of cables and a threshold tension value; Identify the speed value of each of the multiple cables; The velocity norm is calculated based on a vector comprising the velocity values ​​of each of the plurality of cables. Perform a second comparison between the stated velocity norm and the statistical velocity threshold; as well as Detachment is identified based on the first comparison and the second comparison.

17. The method of claim 16, wherein the velocity norm is a magnitude of the vector comprising the velocity values ​​of each of the plurality of cables.

18. The method of claim 16, wherein the statistical speed threshold is at least partially based on the command speed.

19. The method of claim 16, wherein the statistical velocity threshold is based at least in part on the velocity norm at a first time and the velocity norm at a second time.

20. An apparatus comprising: A memory configured to store threshold tension values ​​and statistical velocity thresholds; and A controller configured to perform a first comparison of the tension of at least one of a plurality of cables connected to an end effector of a surgical tool with a threshold tension value and a second comparison of a velocity norm with a statistical velocity threshold, wherein at least one of the plurality of cables is disengaged based on the first comparison and the second comparison, wherein the velocity norm is based on a vector for the plurality of cables.

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