Instrument drive for a surgical robot and surgical robot

Abstract

The application discloses an instrument driver for a surgical robot and the surgical robot. The instrument driver comprises a motor, a reduction gearbox, a reduction gearbox output stage and a driving disc assembly. The motor drives the rotation of the gear of the reduction gearbox, and the reduction gearbox drives the rotation of the driving disc assembly. The instrument driver further comprises an output stage magnetic ring and an output stage encoder. The output stage magnetic ring is coaxially arranged with the reduction gearbox output stage and synchronously rotates with the latter. The output stage encoder is fixedly arranged in the radial direction of the reduction gearbox output stage and is used for detecting the rotation of the output stage magnetic ring. The application enables the detection of the rotary position of the driving disc in an axial height of less than 4.5 mm and a space of 7.5 mm in the radial direction of the central axis of the reduction gearbox. This simplifies the structure inside the instrument driver, can eliminate errors such as gaps or deformations caused by complex structures, can directly measure the rotation angle of the output stage, and is more accurate in the measurement of the rotation angle of the output stage and higher in the control precision of the end instrument.

Description

Technical Field

[0001] This invention relates generally to the field of surgical robots, and more specifically to an instrument actuator for a surgical robot and a surgical robot. Background Technology

[0002] Surgical robots possess advantages such as accurate positioning, stable operation, high dexterity, large working range, and immunity to radiation and infection, making them widely used in various surgeries. The use of surgical robots helps improve the precision of surgical procedures, addressing issues like hand tremors, fatigue, and muscle nerve feedback, allowing surgeons to perform operations in the most comfortable state. This is of great value in improving surgical success rates and reducing patient suffering, and in recent years, its research has become a new field of medical device application.

[0003] Surgical robots typically have surgical instrument drive units at the end of one or more of their robotic arms to accommodate the need to change and adapt multiple surgical instruments to perform various actions during different types of surgery and throughout the procedure.

[0004] To achieve accurate, safe, and highly responsive control of the end effector of surgical instruments, the power unit needs to be sensor-detected to confirm the position of the motor rotor and the end of the drive output device, thus enabling closed-loop control.

[0005] Existing technology requires machining tooth profiles on the outer side of the last stage output disc of the gearbox and opening a notch on the outer wall of the gearbox when measuring the position of the rotating pair at the end of the drive device. Additionally, it requires arranging a meshing external gear and a linkage shaft system for the Hall sensor unit at a position parallel to the drive disc's axis. This causes the following problems:

[0006] 1. It has many parts and is relatively complex to install;

[0007] 2. For a pair of meshing gears, there will inevitably be a situation where transmission backlash cannot be completely eliminated, which introduces an error term to the accurate position measurement of the end output device;

[0008] 3. The measuring unit is far from the actual drive disk unit that needs to be tested. The stiffness deformation between the drive disk and the last stage output component of the gearbox cannot be included in the measurement, which leads to a further reduction in measurement accuracy.

[0009] Therefore, there is a need for an instrument actuator for surgical robots to at least partially solve the above problems. Summary of the Invention

[0010] The summary section introduces a series of simplified concepts, which will be further explained in detail in the detailed description section. The summary section of this invention is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.

[0011] To at least partially address the aforementioned problems, a first aspect of the present invention provides an instrument actuator for a surgical robot, the instrument actuator comprising a plurality of motors, a gearbox, a gearbox output stage, and a drive disk assembly, wherein the motors drive the gearbox to rotate the gearbox output stage, and the gearbox in turn drives the drive disk assembly to rotate; the instrument actuator further comprises:

[0012] The output stage magnetic ring is arranged coaxially with the output stage of the gearbox and rotates synchronously with the output stage of the gearbox.

[0013] An output stage encoder is fixedly arranged in the radial direction of the output stage of the gearbox and is used to detect the rotation of the output stage magnetic ring.

[0014] According to the instrument actuator for surgical robots of the present invention, an output stage magnetic ring is arranged coaxially with the output stage of the gearbox, and an output stage encoder is arranged radially thereon. This allows the rotational position detection of the drive disk to be achieved within a space of less than 4.5 mm axial height and 7.5 mm radial distance from the central axis of the gearbox. This simplifies the internal structure of the instrument actuator and greatly saves internal space, resulting in a smaller overall size of the instrument actuator and a more optimized structure for the surgical robot. Furthermore, the present invention can eliminate errors such as gaps or deformations caused by structural complexity, and can directly measure the rotation angle of the output stage, resulting in more accurate measurement of the output stage rotation angle and higher control precision for the end effector.

[0015] Optionally, the instrument driver further includes an output sensor plate disposed between the bearing of the gearbox output stage and the drive disk assembly. The output sensor plate has a through hole for the gearbox output stage to pass through.

[0016] The output stage encoder is mounted to the output sensor board.

[0017] According to the instrument driver for surgical robots of the present invention, the output stage encoder is mounted between the drive disk assembly and the bearing of the gearbox output stage.

[0018] Optionally, the output stage magnetic ring is mounted to the drive disk assembly, and the output stage encoder is mounted to the side of the output sensor board facing the drive disk assembly.

[0019] According to the instrument driver for surgical robots of the present invention, the output stage encoder can be located below the output stage magnetic ring.

[0020] Optionally, the drive disk assembly includes a drive disk guide and a drive disk, the drive disk guide is coupled to the shaft of the gearbox output stage, the drive disk is slidably engaged with the drive disk guide, and the output stage magnetic ring is coupled to the drive disk guide.

[0021] According to the instrument driver for surgical robots of the present invention, the output stage magnetic ring is directly mounted to the output disk guide, which simplifies the internal structure of the instrument driver.

[0022] Optionally, the drive disk and the drive disk guide are made of non-magnetic or weakly magnetic materials.

[0023] According to the instrument driver for surgical robots of the present invention, the materials near the output stage magnetic ring are all non-magnetic or weakly magnetic materials, which avoids these materials from being magnetized and thus affecting the measurement accuracy and precision of the encoder, and greatly improves the measurement accuracy and precision.

[0024] Optionally, the output stage magnetic ring is mounted to the output stage of the gearbox and close to the bearing of the gearbox output stage, and the output stage encoder is mounted to the side of the output sensor plate facing the bearing of the gearbox output stage.

[0025] According to the instrument driver for surgical robots of the present invention, the output stage encoder can be located above the output stage magnetic ring.

[0026] Optionally, the bearing of the gearbox output stage includes an outer bearing and an inner bearing, with the output stage magnetic ring located near the outer bearing.

[0027] According to the instrument driver for surgical robots of the present invention, the gearbox shaft system adopts a dual-bearing design, which can reduce the influence of the axial movement of the output stage shaft itself on the sensor measurement and reduce the sensor measurement error caused by the up-and-down movement of the magnetic ring.

[0028] Optionally, the outer bearing and the inner bearing are spaced apart, or the outer bearing and the inner bearing are arranged adjacent to each other.

[0029] According to the instrument actuator for surgical robots of the present invention, the distance between the two bearings in the gearbox shaft system can be adjusted according to the actual space size inside the instrument actuator.

[0030] Optionally, the outer bearing is made of a non-magnetic or weakly magnetic material.

[0031] According to the instrument driver for surgical robots of the present invention, the materials near the output stage magnetic ring are all non-magnetic or weakly magnetic materials, which avoids these materials from being magnetized and thus affecting the measurement accuracy and precision of the encoder, and greatly improves the measurement accuracy and precision.

[0032] Optionally, the output stage encoder is located outside the convex polygon formed by the line connecting the centers of the multiple gearbox output stages.

[0033] The instrument actuator for surgical robots according to the present invention minimizes the mutual interference between individual encoder units.

[0034] Optionally, the gearbox includes a top cover made of a non-magnetic or weakly magnetic material.

[0035] Optionally, the output stage of the gearbox is made of non-magnetic or weakly magnetic material.

[0036] According to the instrument driver for surgical robots of the present invention, the materials near the output stage magnetic ring are all non-magnetic or weakly magnetic materials, which avoids these materials from being magnetized and thus affecting the measurement accuracy and precision of the encoder, and greatly improves the measurement accuracy and precision.

[0037] Optionally, the bearings of the motor include an input bearing and an output bearing.

[0038] According to the instrument driver for surgical robots of the present invention, a dual-bearing design is adopted in the motor shaft system, which can reduce the influence of the axial movement of the motor shaft itself on the sensor measurement and reduce the sensor measurement error caused by the up-and-down movement of the magnetic ring.

[0039] Optionally, the input end bearing is made of a non-magnetic or weakly magnetic material.

[0040] According to the instrument actuator for surgical robots of the present invention, the materials near the input stage magnetic ring are all non-magnetic or weakly magnetic materials, which avoids these materials from being magnetized and thus affecting the measurement accuracy and precision of the encoder, and greatly improves the measurement accuracy and precision.

[0041] Optionally, the instrument driver further includes:

[0042] An input stage magnetic ring is arranged coaxially with the input stage of the motor and rotates synchronously with the input stage of the motor.

[0043] An input-level encoder is fixedly arranged in the instrument driver and is used to detect the rotation of the input-level magnetic ring.

[0044] According to the instrument driver for surgical robots of the present invention, a compact rotation detection scheme with a motor input end and a gearbox output end is realized. The detection value of the output-level coding detection unit can be compared with the detection value of the input-level coding detection unit, and then the error that may be generated in the output stage can be compensated by software control, thus the control accuracy of the instrument driver is higher.

[0045] Optionally, the input-stage magnetic ring is arranged coaxially with the sensing unit of the input-stage encoder.

[0046] According to the instrument driver for surgical robots of the present invention, the accuracy of detecting the rotation angle of the motor input end can be improved by arranging the input-level magnetic ring and the sensitive unit of the input-level encoder coaxially.

[0047] Optionally, the motor includes a bottom cover made of a non-magnetic or weakly magnetic material; and / or

[0048] The motor includes a base made of a non-magnetic or weakly magnetic material; and / or

[0049] The motor includes a housing made of a non-magnetic or weakly magnetic material.

[0050] According to the instrument actuator for surgical robots of the present invention, the materials near the input stage magnetic ring are all non-magnetic or weakly magnetic materials, which avoids these materials from being magnetized and thus affecting the measurement accuracy and precision of the encoder, and greatly improves the measurement accuracy and precision.

[0051] A second aspect of the invention provides a surgical robot comprising the instrument actuator described above for a surgical robot.

[0052] According to the surgical robot of the present invention, an output stage magnetic ring is arranged coaxially with the output stage of the gearbox of the instrument actuator, and an output stage encoder is arranged radially thereon. This allows the rotational position detection of the drive disk to be achieved within a space of less than 4.5 mm axial height and 7.5 mm radial distance from the central axis of the gearbox. This simplifies the internal structure of the instrument actuator and greatly saves internal space, resulting in a smaller overall size of the instrument actuator and a more optimized structure for the surgical robot. Furthermore, the present invention can eliminate errors such as gaps or deformations caused by structural complexity, and can directly measure the rotation angle of the output stage, resulting in more accurate measurement of the output stage rotation angle and higher control precision for the end effector. Attached Figure Description

[0053] The following drawings, which are incorporated herein by reference as part of this invention, are provided for understanding the invention. The drawings illustrate embodiments of the invention and their descriptions, serving to explain the principles of the invention.

[0054] In the attached image:

[0055] Figure 1 An exploded perspective view of the drive assembly of a surgical robot according to a preferred embodiment of the present invention;

[0056] Figure 2 This is a side sectional view of a device actuator according to a specific embodiment of the present invention;

[0057] Figure 3 A front sectional view of a device actuator according to a specific embodiment of the present invention.

[0058] Figure 4 This is a perspective view of an instrument actuator according to a specific embodiment of the present invention, wherein part of the outer casing of the instrument actuator is omitted;

[0059] Figure 5 For along Figure 4 Example of a partial sectional view of line AA in the middle;

[0060] Figure 6 This is a perspective view of an instrument actuator according to a specific embodiment of the present invention, wherein part of the outer casing of the instrument actuator is omitted.

[0061] Figure 7 For along Figure 4 Another example of a partial sectional view of line AA in the middle.

[0062] Explanation of reference numerals in the attached figures:

[0063] 10: Sterile adapter

[0064] 10A: Top surface of the sterile adapter

[0065] 10C: Sterile adapter notch

[0066] 20: Surgical instrument box

[0067] 28: Slender tube

[0068] 30: Instrument driver

[0069] 30A: Upper surface of the instrument actuator

[0070] 30C: Instrument actuator notch

[0071] 31: Base

[0072] 32: Outer shell

[0073] 33: Cooling System

[0074] 34: Output sensor board

[0075] 50: Driver Components

[0076] 60: Transmission components

[0077] 70: Electric motor

[0078] 71: Motor shaft

[0079] 72: Motor bearings

[0080] 72A: Motor input bearing

[0081] 72B: Motor output bearing

[0082] 73: Motor stator

[0083] 74: Motor rotor

[0084] 75: Input stage magnetic ring

[0085] 76: Input level encoder

[0086] 80: Gearbox

[0087] 81 / 81A / 81B / 81C / 81D / 81E: Gearbox Output Stage

[0088] 82: Output stage bearing

[0089] 82A: Output stage outer bearing

[0090] 82B: Output stage internal bearing

[0091] 85: Output stage magnetic ring

[0092] 86 / 86A / 86B / 86C / 86D / 86E: Output stage encoder

[0093] 90: Drive disk assembly

[0094] 91: Drive disk

[0095] 92: Drive disk guide section Detailed Implementation

[0096] In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to those skilled in the art that embodiments of the invention may be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described in order to avoid confusion with embodiments of the invention.

[0097] To fully understand the embodiments of the present invention, detailed structures will be presented in the following description. Obviously, the implementation of the embodiments of the present invention is not limited to the specific details familiar to those skilled in the art.

[0098] This invention provides an instrument actuator for a surgical robot and a surgical robot including the instrument actuator. Preferred embodiments of the invention are described below with reference to the accompanying drawings.

[0099] like Figure 1 As shown, in a preferred embodiment, the surgical robot according to the present invention includes a drive assembly 50, which is mounted to a sliding arm. The drive assembly 50 includes an instrument driver 30, a sterile adapter 10, and a surgical instrument cartridge 20. The instrument driver 30 is connected to the sliding arm of the surgical robot and is controllably movable on the sliding arm. The sterile adapter 10 is coupled to the instrument driver 30. The surgical instrument cartridge 20 is connected to the sterile adapter 10. Specifically, the sterile adapter 10 is mounted to the upper surface 30A of the instrument driver 30, and the surgical instrument cartridge 20 is mounted to the upper surface 10A of the sterile adapter 10. The sterile adapter 10 is sandwiched between the instrument driver 30 and the surgical instrument cartridge 20, detachably connecting sterile surgical instruments (e.g., forceps, scissors, clamps, etc.) to the non-sterile instrument driver 30. When mounted to the sliding arm, the instrument driver 30, the sterile adapter 10, and the surgical instrument cartridge 20 are all located on the same side of the sliding arm, allowing them to move as a whole on the sliding arm.

[0100] The surgical instruments are connected to the surgical instrument cartridge 20. The instrument actuator 30 provides driving force to the rear-end actuator of the surgical instruments in the surgical instrument cartridge 20 via a sterile adapter 10, achieving pitch, yaw, and gripping movements. Specifically, the surgeon controls the instruments on the surgical-side actuator from the console side to control the internal mechanism of the instrument actuator 30. The instrument actuator 30 is connected to the sterile adapter 10, which is connected to the rear end of the surgical instruments via the surgical instrument cartridge 20. After connection, the drive disc 91 of the instrument actuator 30 drives the connector of the sterile adapter 10, which in turn drives the driven disc of the surgical instrument cartridge 20, which in turn drives the wire that pulls the surgical instruments. One end of the wire is connected to the surgical instruments, thereby controlling the surgical instruments to perform pitch, yaw, and gripping movements. The wire for the surgical instruments is housed in an elongated tube 28 of the surgical instrument cartridge 20. The elongated tube 28 is typically located at the end of the surgical instrument cartridge 20 away from the sliding arm. Preferably, the extension direction of the elongated tube 28 is parallel to the extension direction of the sliding arm. The sterile adapter 10 is provided with a sterile adapter 10 recess 10C, and the instrument driver 30 is provided with an instrument driver 30 recess 30C for accommodating the slender tube 28.

[0101] like Figure 2 and Figure 3As shown, to achieve control of the end-effector, the instrument driver 30 typically includes a base 31, a housing 32, a cooling system 33 (e.g., a fan and exhaust vents), and multiple transmission components 60. Each transmission component 60 includes a motor 70, a gearbox 80, a gearbox output stage 81, and a drive disk assembly 90. Each transmission component 60 is used to control the movement of the end-effector in a specific dimension. In the transmission component 60, the motor 70, gearbox 80, gearbox output stage 81, and drive disk assembly 90 are configured in combination. The motor 70 drives the central gear of the gearbox 80 to rotate, and this central gear is directly connected to the gearbox output stage 81. The gearbox 80 then drives the drive disk assembly 90 (including the drive disk 91) to rotate, thereby allowing the drive disk 91 to drive the driven disk in the surgical instrument housing 20. Since the end effector of the surgical instrument needs to perform operations such as gripping, deflection, and pitching, three to five power sources are required to provide power. That is, the instrument driver 30 needs to have three to five transmission components 60.

[0102] In the instrument driver 30 according to the present invention, the motor 70 is the power source, and the reduction gearbox 80 serves to adjust the torque and reduce the speed. In order to accurately control the motor 70, a high-precision sensor unit is provided at each motor input end. In order to accurately monitor the position and orientation of the drive disk 91, a high-precision sensor is also provided on the side near the drive disk 91.

[0103] Specifically, the motor 70 includes a motor shaft 71, a motor bearing 72, a motor stator 73, and a motor rotor 74. In a preferred embodiment of the invention, the instrument driver 30 is provided with an input-level encoding detection unit at the motor input end, such as an input-level magnetic ring 75 and an input-level encoder 76, for detecting the rotation angle of the motor 70. The input-level magnetic ring 75 is coaxially arranged with the input stage of the motor 70 and moves synchronously with the input stage of the motor 70 (e.g., the motor shaft 71). The input-level encoder 76 is fixedly arranged in the instrument driver 30 for detecting the rotation of the input-level magnetic ring 75. The input-level magnetic ring 75 is coaxially arranged with the sensing element of the input-level encoder 76. When the input-level magnetic ring 75 rotates with the motor shaft 71, the input-level encoder 76 senses the rotation of the magnetic ring, thereby monitoring the rotation at the input end. To reduce the influence of the axial movement of the motor shaft 71 itself on the sensor measurement, a dual-bearing design is adopted in the motor shaft system, including a motor input end bearing 72A and a motor output end bearing 72B. This allows the axial movement of the motor shaft 71 to be controlled within the range of a few micrometers (below 0.1mm), greatly reducing sensor measurement errors caused by the vertical movement of the magnetic ring. Meanwhile, the motor input bearing 72A, motor base cover, base 31, and housing 32 are made of non-magnetic or weakly magnetic materials (e.g., non-magnetic steel with a permeability μ ≤ 1.319 × 10⁻⁶). -6 H / m; Stainless steel, permeability μ≤1.339×10-6 H / m) was fabricated to reduce the impact on the measurement accuracy and precision of the input stage encoder 76.

[0104] It is understood that the aforementioned non-magnetic or weakly magnetic materials are not limited to non-magnetic steel and stainless steel, but can also be other materials with equivalent magnetic permeability. Furthermore, in this invention, as described above, the purpose of using non-magnetic or weakly magnetic materials is to reduce the impact on the measurement accuracy and precision of the input encoder 76. Therefore, the selected non-magnetic or weakly magnetic materials are chosen to ensure that they do not affect the measurement accuracy and precision of the input encoder 76, or that the impact is within the allowable error range.

[0105] The drive disk assembly 90 includes a drive disk 91 and a drive disk guide 92. The drive disk guide 92 is coupled to the shaft of the gearbox output stage 81, and the drive disk 91 is slidably engaged with the drive disk guide 92. The drive disk 91 can move up and down along the axis of the motor and the gearbox 80 to achieve a flexible connection with the sterile adapter 10. To monitor the rotation of the drive disk 91, the instrument driver 30 provides an output stage encoding detection unit, such as an output stage magnetic ring 85 and an output stage encoder 86, on the gearbox output stage 81. The output stage magnetic ring 85 is coaxially arranged with the gearbox output stage 81 and rotates synchronously with it. The output stage encoder 86 is fixedly arranged in the radial direction of the gearbox output stage 81 to detect the rotation of the output stage magnetic ring 85, that is, to detect the rotation of the gearbox output stage 81 and the rotation of the drive disk 91.

[0106] In this invention, rotational encoding detection units are set at both the input and output stages of the instrument driver. This allows for comparison of the detection values ​​of the output stage encoding detection units with the detection values ​​of the output stage encoding detection units. Then, software control can be used to compensate for possible errors in the output stage, resulting in higher control accuracy of the instrument driver.

[0107] Specifically, the instrument driver 30 includes an output sensing plate 34 disposed between the output stage bearing 82 of the gearbox 80 and the drive disk assembly 90. The output sensing plate 34 is provided with a through hole for the gearbox output stage 81 (specifically, the shaft of the gearbox output stage 81) to pass through axially. An output stage encoder 86 is fixedly mounted to the output sensing plate 34.

[0108] like Figure 2As shown, in one embodiment, the output stage magnetic ring 85 is coupled to the drive disk guide 92 and can rotate synchronously with the gearbox output stage 81 (or drive disk guide 92). The output stage encoder 86 is mounted adjacent to the output stage magnetic ring 85 on the side of the output sensing plate 34 facing the drive disk assembly 9090. The output stage sensing unit is arranged as close as possible to the terminal output component drive disk 91, thus reducing measurement errors caused by the stiffness torsion of the entire output connection link and the meshing of parallel axis gears (with inherent backlash). At the same time, the output stage magnetic ring 85 is directly mounted to the drive disk guide 92, and the output stage measurement unit components are used in combination, which greatly reduces the complexity of production assembly, improves production efficiency, and reduces product costs.

[0109] like Figure 3 As shown, in another embodiment, the output stage magnetic ring 85 is mounted to the output stage 81 of the gearbox and close to the output stage bearing 82 of the gearbox 80. The output stage encoder 86 is mounted to the side of the output sensor plate 34 facing the output stage bearing 82 of the gearbox 80. Similar to the motor input stage, to reduce the influence of the axial movement of the output stage shaft itself on the sensor measurement, a dual-bearing design is adopted in the shaft system of the gearbox 80, including an output stage outer bearing 82A and an output stage inner bearing 82B, and a preload clearance elimination technology is adopted. The output stage outer bearing 82A and the output stage inner bearing 82B are arranged along the length direction (axial direction) of the gearbox output stage 81, and they can be spaced apart or placed close together. This dual-bearing design can control the axial movement of the output stage shaft to the level of a few microns (less than 0.1 mm), greatly reducing the sensor measurement error caused by the up-and-down movement of the magnetic ring. Preferably, the output stage magnetic ring 85 is close to the output stage outer bearing 82A and located between the output stage outer bearing 82A and the output sensor plate 34.

[0110] This invention arranges an output stage magnetic ring 85 along the coaxial direction of the output stage 81 of the gearbox, and an output stage encoder 86 is arranged radially thereon. This allows for the detection of the rotational position of the drive disk 91 within an axial height of less than 4.5 mm and a radial space of 7.5 mm between the central axis of the gearbox 80 and the output stage. This overcomes the shortcomings of existing solutions that employ complex designs involving gears, sensor transmission shafts, and other components arranged parallel to the output axis of the gearbox 80.

[0111] In the instrument driver 30, preferably, the materials of the drive disk 91, drive disk guide 92, gearbox output stage outer bearing 82A, gearbox output stage 81, and gearbox top cover (not shown) near the output stage magnetic ring 85 are all non-magnetic or weakly magnetic materials (e.g., non-magnetic steel with a permeability μ≤1.319×10⁻⁶). -6 H / m; Stainless steel, permeability μ≤1.339×10 -6(H / m) This avoids magnetizing these materials themselves, thus preventing them from affecting the measurement accuracy and precision of the encoder 86, and greatly improves the measurement accuracy and precision. Similarly, the non-magnetic or weakly magnetic materials defined in this invention are all materials whose impact on the measurement accuracy and precision of the output stage encoder 86 is within the error allowable range of the technical solution of this invention. Whether a material is suitable for the technical solution of this invention can be determined by those skilled in the art through experiments.

[0112] like Figure 4 and Figure 5 As shown, the output stage encoder 86 is arranged radially on the gearbox output stage 81. When the instrument driver 30 includes multiple transmission components 60, the line connecting the centers of the multiple gearbox output stages 81 (e.g., 81A, 81B, 81C, 81D) forms a convex polygon (e.g., a quadrilateral), and the output stage encoders 86 (e.g., 86A, 86B, 86C, 86D) are all located on the outside of this convex polygon to minimize the mutual interference between the encoder units. Moreover, experimental verification shows that this arrangement method reduces the mutual interference of encoders to such an extent that it is unnecessary to place magnetic shielding material near each sensor unit, greatly reducing the complexity of installation and commissioning.

[0113] like Figure 6 and Figure 7 As shown, when the number of transmission components 60 increases, the output stage encoders 86 are arranged radially in the gearbox output stage 81. The line connecting the centers of the multiple gearbox output stages 81 located on the outer sides (e.g., 81A, 81B, 81C, 81D) forms a convex polygon (e.g., a quadrilateral). The outer output stage encoders 86 (e.g., 86A, 86B, 86C, 86D) are all located on the outer side of this convex polygon to minimize the mutual interference between the encoder units. The encoder (86E) of the inner gearbox output stage 81 (e.g., 81E) is arranged symmetrically with respect to the outer encoders, so that the inner encoder can be positioned where the influence of the outer encoders can cancel each other out.

[0114] To provide the surgical robot's end effector with the largest possible workspace, the end effector actuator needs to be made as compact as possible, including in terms of dimensions in the height, width, and length directions. In this invention, the sensor layout scheme realizes a compact rotation detection solution between the motor input and the gearbox output.

[0115] In this invention, the detection value of the output-level encoding detection unit can first be compared with the detection value of the output-level encoding detection unit, and then the error that may be generated by the output stage can be compensated by software control, thus the control accuracy of the instrument driver is higher.

[0116] According to the instrument actuator for a surgical robot and the surgical robot including the instrument actuator of the present invention, an output stage magnetic ring is arranged coaxially with the output stage of the gearbox, and an output stage encoder is arranged radially thereon. This allows the rotational position detection of the drive disc to be achieved within a space of less than 4.5 mm axial height and 7.5 mm radial distance from the central axis of the gearbox. This eliminates the need for complex designs such as gears and sensor transmission shafts arranged parallel to the output axis of the gearbox in existing solutions, greatly saving internal space of the instrument actuator, resulting in a smaller overall size of the instrument actuator and a more optimized structure for the surgical robot. Furthermore, the present invention eliminates errors such as gaps or deformations caused by structural complexity, and can directly measure the rotation angle of the output stage, resulting in more accurate measurement of the output stage rotation angle and higher control precision for the end effector.

[0117] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used herein is for descriptive purposes only and is not intended to limit the invention. Terms such as “set” appearing herein can refer to either a component being directly attached to another component or a component being attached to another component via an intermediary. A feature described in one embodiment herein may be applied, alone or in combination with other features, to another embodiment, unless that feature is not applicable in that other embodiment or is otherwise stated.

[0118] The present invention has been described through the above embodiments; however, it should be understood that the above embodiments are for illustrative purposes only and are not intended to limit the present invention to the described embodiments. Those skilled in the art will understand that many variations and modifications can be made based on the teachings of the present invention, and all such variations and modifications fall within the scope of protection claimed by the present invention.

Claims

1. A surgical robot, characterized in that, The surgical robot includes a sliding arm, an instrument driver, a sterile adapter, and surgical instruments. The instrument driver is connected to the sliding arm and is movable along a first direction on the sliding arm. The surgical instruments include an instrument box and a slender tube. The instrument driver connects to the instrument box. The sterile adapter connects between the instrument driver and the instrument box. The slender tube connects to the instrument box and extends along the first direction. The sterile adapter and the instrument driver each have a notch for accommodating the slender tube. The instrument driver includes several motors, several gearboxes, several gearbox output stages, and several drive disk assemblies. Corresponding motors, gearboxes, gearbox output stages, and drive disks are arranged along the first direction. The motors drive the gearboxes to rotate the gearbox output stages, which in turn drive the drive disk assemblies to rotate. The drive disk assemblies drive the driven disks of the surgical instrument box. The instrument driver also includes: Several output stage magnetic rings are arranged coaxially with each gearbox output stage and rotate synchronously with the gearbox output stage. The axis of the gearbox output stage is parallel to the first direction. A plurality of output stage encoders are fixedly arranged in the radial direction of each of the gearbox output stages and are used to detect the rotation of the output stage magnetic ring; An output sensing board is disposed between the bearing of the gearbox output stage and the drive disk assembly. The output sensing board has a through hole, and the gearbox output stage extends along the first direction through the through hole to connect to the drive disk assembly. Each of the output stage encoders is mounted to the output sensing board and is located between the output sensing board and the output stage magnetic ring along the axial direction of the gearbox output stage. The drive disk assembly includes a drive disk guide and a drive disk. The drive disk guide is coupled to the shaft of the gearbox output stage. The drive disk and the drive disk guide are slidably engaged to achieve a flexible connection with the sterile adapter. The output stage magnetic ring is coupled to the drive disk guide.

2. The surgical robot according to claim 1, characterized in that, The output stage magnetic ring is mounted to the drive disk assembly, and the output stage encoder is mounted to the side of the output sensor board facing the drive disk assembly.

3. The surgical robot according to claim 2, characterized in that, The drive disk and the drive disk guide are made of non-magnetic or weakly magnetic materials.

4. The surgical robot according to claim 1, characterized in that, The output stage magnetic ring is mounted to the output stage of the gearbox and close to the bearing of the gearbox output stage, and the output stage encoder is mounted to the side of the output sensor plate facing the bearing of the gearbox output stage.

5. The surgical robot according to claim 4, characterized in that, The output stage bearing of the gearbox includes an outer bearing and an inner bearing, and the output stage magnetic ring is located near the outer bearing.

6. The surgical robot according to claim 5, characterized in that, The outer bearing and the inner bearing are spaced apart, or the outer bearing and the inner bearing are arranged adjacent to each other.

7. The surgical robot according to claim 5, characterized in that, The outer bearing is made of non-magnetic or weakly magnetic material.

8. The surgical robot according to any one of claims 1-7, characterized in that, The output stage encoder is located on the outside of the convex polygon formed by the line connecting the centers of the multiple gearbox output stages.

9. The surgical robot according to any one of claims 1-7, characterized in that, The gearbox includes a top cover, which is made of a non-magnetic or weakly magnetic material.

10. The surgical robot according to any one of claims 1-7, characterized in that, The output stage of the gearbox is made of non-magnetic or weakly magnetic materials.

11. The surgical robot according to any one of claims 1-7, characterized in that, The motor's bearings include an input bearing and an output bearing.

12. The surgical robot according to claim 11, characterized in that, The input end bearing is made of non-magnetic or weakly magnetic material.

13. The surgical robot according to any one of claims 1-7, characterized in that, The surgical robot also includes: An input stage magnetic ring is arranged coaxially with the input stage of the motor and rotates synchronously with the input stage of the motor. An input-level encoder is fixedly arranged in the surgical robot and is used to detect the rotation of the input-level magnetic ring.

14. The surgical robot according to claim 13, characterized in that, The input-level magnetic ring is arranged coaxially with the sensitive unit of the input-level encoder.

15. The surgical robot according to any one of claims 1-7, characterized in that, The motor includes a base cover, which is made of a non-magnetic or weakly magnetic material; and / or The motor includes a base made of a non-magnetic or weakly magnetic material; and / or The motor includes a housing made of a non-magnetic or weakly magnetic material.

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