Surgical robot and method of controlling, system of controlling the same

Abstract

The application provides a surgical robot and a control method and system thereof. The surgical robot comprises an operating device, a display device and a control device. The control device is coupled with the display device and the driving mechanism and / or the micro-control mechanism. When an identifiable error occurs in the driving mechanism and / or the micro-control mechanism during operation, the control device identifies the faulty driving mechanism and / or the faulty micro-control mechanism associated with the identifiable error, generates a model image of the operating device, and highlights the area of the model image associated with the faulty driving mechanism and / or the faulty micro-control mechanism in the display device. The surgical robot and the control method and system thereof can highlight the area of the model image associated with the identifiable error of the area of the faulty driving mechanism and / or the faulty micro-control mechanism, greatly facilitating error troubleshooting.

Description

Technical Field

[0001] This application relates to the field of medical devices, and in particular to a surgical robot, a control method for the surgical robot, and a control system for the surgical robot. Background Technology

[0002] Minimally invasive surgery refers to a surgical procedure performed inside the human body using modern medical instruments and equipment such as laparoscopes and thoracoscopes. Compared to traditional surgical methods, minimally invasive surgery has advantages such as less trauma, less pain, and faster recovery.

[0003] With the advancement of technology, minimally invasive surgical robot technology has gradually matured and is widely used. A minimally invasive surgical robot typically includes a master control panel and slave operating devices. The master control panel sends control commands to the slave operating devices based on the surgeon's instructions, thereby controlling the slave operating devices. The slave operating devices respond to the control commands sent by the master control panel and perform the corresponding surgical procedures.

[0004] During routine use, surgical robots inevitably encounter errors in their control systems, including operational and motion errors. Therefore, how to indicate these errors to improve the system's availability and reliability has become an urgent problem to be solved. Summary of the Invention

[0005] Based on this, in order to solve the above-mentioned surgical problems, this application provides a surgical robot and its control method and control system.

[0006] A first aspect of this application provides a surgical robot, comprising:

[0007] Operating device, including drive mechanism and / or microcontroller mechanism;

[0008] Display device; and

[0009] A control device, coupled to the display device and to the drive mechanism and / or the microcontroller, is configured to perform:

[0010] When an identifiable error is detected in the drive mechanism and / or the microcontroller during operation, the faulty drive mechanism and / or the faulty microcontroller associated with the identifiable error is identified.

[0011] Obtain a model image of the operating device;

[0012] The area in the model image associated with the fault drive mechanism and / or fault microcontroller mechanism is prominently displayed in the display device.

[0013] In one specific embodiment, the operating device includes a main operating console, which includes the drive mechanism and / or the microcontroller mechanism.

[0014] In one specific embodiment, the operating device includes a slave operating device, which includes the drive mechanism and / or the microcontroller mechanism.

[0015] In one specific embodiment, the operating device includes an operating table, which includes the drive mechanism and / or the microcontroller mechanism.

[0016] In one specific embodiment, the identifiable error includes motion errors of the drive mechanism.

[0017] In one specific embodiment, the identifiable error includes operational errors of the microcontroller.

[0018] In one specific embodiment, the control device is configured to perform:

[0019] Determine the error type of the identifiable error;

[0020] The error types include at least one of the following: follower error error, current overload error, microcontroller error, digital control axis error, encoder error, and driver error.

[0021] In one specific embodiment, the control device is configured to perform:

[0022] The error level is determined based on the identifiable error type.

[0023] Among them, the error levels of encoder errors and driver errors are higher than those of microcontroller errors and the following error errors. The error levels of microcontroller errors and the following error errors are higher than those of current overload errors and digital control axis errors.

[0024] In one specific embodiment, the step of monitoring the drive mechanism and / or microcontroller for identifiable errors during operation includes:

[0025] Monitor whether the current following error of the drive mechanism exceeds the set following error threshold;

[0026] When the current following error of the drive mechanism exceeds the following error threshold, the surgical robot is configured to perform:

[0027] Stop the operation of the drive mechanism;

[0028] Clear the aforementioned follow-up error;

[0029] If the number of clearing attempts exceeds the preset clearing attempt threshold and the follow error clearing is still unsuccessful, the operation of the module unit to which the drive mechanism belongs is stopped, and the error level of the follow error is set to the highest error level.

[0030] In one specific embodiment, the step of monitoring the drive mechanism and / or microcontroller for identifiable errors during operation includes:

[0031] Monitor whether the average current of the drive mechanism within a preset time period exceeds a set current threshold.

[0032] When the average current of the drive mechanism exceeds the current threshold within a preset time period, the surgical robot is configured to perform:

[0033] Detect whether the drive mechanism associated with the module unit to which the faulty drive mechanism belongs is in motion;

[0034] When the drive mechanism of the module unit to which the faulty drive mechanism belongs is detected to be in motion, the drive mechanism is braked.

[0035] In one specific embodiment, the step of monitoring the drive mechanism and / or microcontroller for identifiable errors during operation includes:

[0036] Monitor whether the microcontroller is running;

[0037] When the faulty microcontroller is identified, it is detected whether the drive mechanism associated with the module unit to which the faulty microcontroller belongs is in motion.

[0038] When the drive mechanism of the module unit to which the faulty microcontroller belongs is detected to be in motion, the drive mechanism is braked.

[0039] In one specific embodiment, the step of determining the error type of the identifiable error is performed when the error type is a digital control axis error:

[0040] Reset the digital control axis status;

[0041] If the number of reset attempts exceeds the preset reset threshold and the digital control axis status still fails to be reset, the operation of the drive mechanism corresponding to the digital control axis is stopped, and the error level of the digital control axis error is increased by one level.

[0042] Repeat the above two steps until the error level of the digital control axis rises to the highest level or the digital control axis status is successfully reset.

[0043] In one specific embodiment, the step of determining the error type of the identifiable error is performed when the error type is an encoder error or a driver error:

[0044] Stop the operation of the drive mechanism corresponding to the encoder error or the driver error;

[0045] Stop the movement of other drive mechanisms in the module unit to which the drive mechanism belongs, and lock the braking mechanism of the drive mechanism.

[0046] In one specific embodiment, in the step of highlighting the area of ​​the model image associated with the fault drive mechanism and / or fault microcontroller mechanism in the display device, different highlighting methods are used to display identifiable errors of different error types and / or error levels according to the different error types and / or error levels of the identifiable errors. The different highlighting methods include one or more of the following: color, pattern, brightness, flashing, and marking.

[0047] In one specific embodiment, in the step of highlighting the area in the model image associated with the fault drive mechanism and / or fault microcontroller mechanism in the display device, the display device displays the code corresponding to the error type and / or error level of the identifiable error and / or the location number of the fault drive mechanism and / or fault microcontroller mechanism of the identifiable error.

[0048] A second aspect of this application provides a surgical robot control method, the surgical robot comprising: an operating device including a drive mechanism and / or a microcontroller mechanism; a display device; and a control device coupled to the display device and coupled to the drive mechanism and / or the microcontroller mechanism; characterized in that the surgical robot control method comprises the following steps:

[0049] When an identifiable error is detected in the drive mechanism and / or microcontroller during operation, the faulty drive mechanism and / or faulty microcontroller associated with the identifiable error are identified.

[0050] Generate a model image of the operating device;

[0051] The area in the model image associated with the fault drive mechanism and / or fault microcontroller mechanism is prominently displayed in the display device.

[0052] A third aspect of this application provides a surgical robot control system, comprising:

[0053] Memory, used to store computer programs;

[0054] and a controller for loading and executing the computer program;

[0055] The computer program is configured to be loaded by the controller and executed to implement the steps of the surgical robot control method as described above.

[0056] Another aspect of this application provides a computer-readable storage medium, characterized in that: the computer-readable storage medium is suitable for a surgical robot, the surgical robot comprising: an operating device including a drive mechanism and / or a microcontroller mechanism; a display device; and a control device coupled to the display device and coupled to the drive mechanism and / or the microcontroller mechanism;

[0057] The surgical robot control method includes the following steps:

[0058] When an identifiable error is detected in the drive mechanism and / or microcontroller during operation, the faulty drive mechanism and / or faulty microcontroller associated with the identifiable error are identified.

[0059] Generate a model image of the operating device;

[0060] The area in the model image associated with the fault drive mechanism and / or fault microcontroller mechanism is prominently displayed in the display device.

[0061] The surgical robot and its control method and control system of this application have at least the following beneficial effects: If the drive mechanism or the microcontroller mechanism of this application has a motion error, the area associated with the faulty drive mechanism and / or the faulty microcontroller mechanism can be highlighted on the model image generated on the display device, which greatly facilitates error troubleshooting. Attached Figure Description

[0062] Figure 1 This is a schematic diagram of the circuit structure of the main control console of a surgical robot according to an embodiment of this application;

[0063] Figure 2 This is a schematic diagram of the main control console of a surgical robot according to an embodiment of this application;

[0064] Figure 3 This is a schematic diagram of the main wrist of the operating unit of the main operating console according to one embodiment of the application;

[0065] Figure 4 This is a schematic diagram of the operating device of a surgical robot according to an embodiment of this application;

[0066] Figure 5 This is a schematic diagram of the operating device of a surgical robot according to another embodiment of this application;

[0067] Figure 6 This is a schematic diagram of the structure of a surgical robot control system according to an embodiment of this application;

[0068] Figure 7 This is a flowchart of a surgical robot control method according to an embodiment of this application;

[0069] Figure 8 This is a flowchart illustrating the follow-up error monitoring process of a surgical robot control method according to an embodiment of this application.

[0070] Figure 9 This is a flowchart illustrating the following error handling process of a surgical robot control method according to an embodiment of this application.

[0071] Figure 10 This is a flowchart of a current overload error monitoring method for a surgical robot control method according to an embodiment of this application;

[0072] Figure 11 This is a flowchart illustrating the current overload error handling process of a surgical robot control method according to an embodiment of this application.

[0073] Figure 12 This is a flowchart of a microcontroller error monitoring method for a surgical robot control method according to an embodiment of this application;

[0074] Figure 13 This is a flowchart of the microcontroller error handling process of a surgical robot control method according to an embodiment of this application;

[0075] Figure 14 This is a flowchart illustrating the NC axis error handling process of a surgical robot control method according to an embodiment of this application.

[0076] Figure 15 This is a flowchart illustrating the encoder / driver error handling process of a surgical robot control method according to an embodiment of this application.

[0077] Figure 16 A highlighted schematic diagram of a display device for a surgical robot control method according to an embodiment of this application;

[0078] Figure 17 This is another highlighted schematic diagram of a display device for a surgical robot control method according to an embodiment of this application.

[0079] The component labels in the diagram are as follows:

[0080] Main control console 100 (including main arm 110 and main wrist 120; the main wrist 120 includes a first lever 121, a second lever 122, a third lever 123, a clamp 124, a first rotary joint 125, a second rotary joint 126, a third rotary joint 127, a fourth rotary joint 128, and a push button 129);

[0081] From the operating device 200 (including robotic arm 210, actuator 220, puncture device 230, adjusting arm 240, and manipulator 250);

[0082] Control system 300 (including memory 301, controller 302, encoder 303, and driver 304). Detailed Implementation

[0083] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings. Preferred embodiments of this application are shown in the drawings. However, this application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this application.

[0084] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intervening element. When an element is considered to be "coupled" to another element, it can be directly coupled to the other element or there may be an intervening element. The term "joint" as used herein refers to a connection in which two elements have power transmission. The terms "vertical," "horizontal," "left," "right," "above," "below," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementations. It should be understood that these spatially related terms are intended to cover different orientations of the device in use or operation, in addition to those depicted in the drawings. For example, if the device is flipped in the drawings, an element or feature described as "below" or "under" other elements or features will be oriented "above" other elements or features. Therefore, the example term "below" can include both above and below orientations.

[0085] The terms "distal" and "proximal" used in this article are directional terms commonly used in the field of interventional medical devices. "Distal" refers to the end furthest from the operator during the procedure, while "proximal" refers to the end closest to the operator. The term "coupling" as used in this article can be broadly understood as two or more objects being connected to any event in a manner that allows absolutely coupled objects to operate together such that there is no relative movement between the objects in at least one direction. For example, the coupling of a protrusion and a groove, where they can move radially relative to each other but not axially.

[0086] The term "instrument" is used herein to describe a medical device for insertion into a patient's body and for performing surgical or diagnostic procedures. This instrument includes an end effector, which can be a surgical tool used to perform surgical procedures, such as an electrocautery device, clamp, stapler, scissor, imaging device (e.g., an endoscope or ultrasound probe), and the like. Some instruments used in embodiments of this application further include an articulated component (e.g., a joint assembly) for the end effector, allowing the position and orientation of the end effector to be manipulated with one or more mechanical degrees of freedom relative to an instrument axis. Further, the end effector includes functional mechanical degrees of freedom, such as opening and closing clamps. The instrument may also include stored information that can be updated by a surgical system, whereby the storage system can provide one-way or two-way communication between the instrument and one or more system components.

[0087] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The terms “and / or” and “and / or” as used herein include any and all combinations of one or more of the associated listed items.

[0088] One embodiment of the surgical robot of this application includes an operating device, a display device, and a control device. The operating device includes a main operating console, a slave operating device, and an operating table. The main operating console, the slave operating device, and the operating table each include a drive mechanism and / or a microcontroller mechanism. The control device is coupled to the display device and is also coupled to the drive mechanism and / or the microcontroller mechanism. The circuit structure diagram is shown below. Figure 1 As shown in the image.

[0089] Specifically, one embodiment of the surgical robot in this application includes, as follows: Figure 2 The main control panel 100 shown and as Figure 4The slave operating device 200 shown allows doctors to control it from the main operating console 100. The slave operating device 200 performs surgery on the human body based on input commands from the main operating console 100. The main operating console 100 and the slave operating device 200 can be placed in the same operating room, in different rooms, or even far apart, for example, in different cities. Data transmission between the main operating console 100 and the slave operating device 200 can be wired or wireless. For example, if they are in the same operating room, they can transmit data via wired connection; if they are in different cities, they can transmit data over long distances via 5G wireless signals.

[0090] by Figure 2 Taking the main operation console 100 shown as an example, the drive mechanism is used to drive the movement of related structures, including motors, drivers, and / or sensors (such as encoders). Figure 2 The diagram shows a main control panel 100 including an operating unit comprising a main arm 110 and a main wrist 120. The user controls the movement of the slave operating device 200 by operating the main arm 110 and the main wrist 120. The control signal processing system of the main control panel 100 processes the input signals from the main arm 110 and the main wrist 120 and sends control commands to the slave operating device 200. The slave operating device 200 responds to the control commands sent by the main control panel and performs corresponding operations. Specifically, a positional mapping control is established between the main arm 110 and the main wrist 120 and the robotic arm and instrument of the slave operating device. This mapping can be a positional correspondence, such as a proportional distance or a distance trend correspondence. Alternatively, this mapping can be a motion correspondence, such as a motion posture correspondence or a motion trend correspondence. Thus, the user can control the instrument to perform corresponding actions (e.g., pitch, yaw, roll, gripping, etc.) by operating the main arm 110 and the main wrist 120. Motors with encoders are installed in multiple joints of the main arm 110 and the main wrist 120, which can realize automatic alignment and other corresponding control functions.

[0091] Figure 3This is a schematic diagram of the main wrist of the operating unit of the main control console according to an embodiment of this application. The main wrist 120 has multiple degrees of freedom, generally including at least three. The main wrist 120 includes a first lever 121, a second lever 122, a third lever 123, a clamp 124, a first rotary joint 125, a second rotary joint 126, a third rotary joint 127, a fourth rotary joint 128, and push buttons 129. The clamp 124 is mounted to one end of the first lever 121 via the first rotary joint 125. Two symmetrical push buttons 129 are also provided on the clamp 124. The other end of the first lever 121 is mounted to one end of the second lever 122 via the second rotary joint 126; the other end of the second lever 122 is mounted to one end of the third lever 123 via the third rotary joint 127; and the other end of the third lever 123 is mounted to the main arm 110 via the fourth rotary joint 128.

[0092] The clamp 124 is rotatably connected to the first rod 121 via the first rotary joint 125, so that the clamp 124 can rotate around the first rotation axis J1 of the first rotary joint 125. The first rod 121 is rotatably connected to the second rod 122 via the second rotary joint 126, so that the first rod 121 can rotate around the second rotation axis J2 of the second rotary joint 126. The second rod 122 is rotatably connected to the third rod 123 via the third rotary joint 127, so that the second rod 122 can rotate around the third rotation axis J3 of the third rotary joint 127. The third rod 123 is rotatably connected to the main arm 110 via the fourth rotary joint 128, so that the third rod 123 can rotate around the rotation axis of the fourth rotary joint 128.

[0093] In the illustrated embodiment, the rotation axes of the first rotational joint 125, the second rotational joint 126, and the third rotational joint 127—the first rotation axis J1, the second rotation axis J2, and the third rotation axis J3—intersect at a single point. The master wrist 120 adopts a multi-axis intersection design, which relatively decouples the posture and position of the entire master hand, facilitating kinematic calculations.

[0094] In the illustrated embodiment, the first rod 121, the second rod 122, and the third rod 123 are L-shaped rods, each rod has two ends that are perpendicularly connected to each other, and the two ends of each rod are connected to a rotating joint.

[0095] In the illustrated embodiment, the clamp 124 can perform multiple degrees of freedom of movement through multiple rods (first rod 121, second rod 122, third rod 123) and multiple rotary joints (first rotary joint 125, second rotary joint 126, third rotary joint 127, fourth rotary joint 128); in other embodiments, the number of rods and rotary joints can be set according to the actual degrees of freedom of movement required by the clamp 124.

[0096] The main arm 110 has a mounting end and a connecting end. The mounting end can be fixedly connected to the support base of the main operating table 100. The main arm 110 has at least one degree of freedom of movement. The main wrist 120 is movably mounted on the connecting end of the main arm 110 via a fourth rotary joint 128. The main wrist 120 allows the user to perform corresponding operations, such as rotation or clamping. The clamp 124 has an opening and closing degree of freedom. After the opening and closing degree of freedom of the clamp 124 is mapped to the instrument, it can control the opening and closing action of the end effector (such as clamping or shearing). After the rotational degree of freedom of the clamp 124 around the first rotation axis J1 of the first rotary joint 125 is mapped to the instrument, it can control the rolling motion of the end effector of the instrument.

[0097] like Figure 4 As shown, the single-port robot's slave operating device 200 includes a robotic arm 210 and an actuator 220 disposed at the distal end of the robotic arm 210. Surgical instruments (not shown) for performing surgery are connected to the actuator 220, which drives the surgical instruments through multiple actuators within it. Multiple surgical instruments can be connected to one actuator 220. A detachable trocar 230 is mounted at the distal end of the actuator 220 for connection with the human body to achieve an airtight seal. The surgical instruments mounted on the actuator 220 pass through the trocar 230 and are inserted into the patient's body.

[0098] Figure 5 This is a schematic diagram of another slave operating device 200 in an embodiment of this application, illustrating a slave operating device of a multi-hole surgical robot, and... Figure 4 The main difference between the single-port surgical robots shown is the difference in their operating devices. Figure 5 The illustrated multi-hole surgical robot's drive arm, from the operating device 200, comprises a robotic arm 210, an adjusting arm 240, and a manipulator 250 connected in sequence. The number of adjusting arms 240 and manipulators 250 is the same, and there are two or more of each. A detachable trocar is mounted on the manipulator 250 for connection to the human body to achieve an airtight seal. Surgical instruments are mounted on the manipulator 250 and pass through the trocar to be inserted into the human body.

[0099] Doctors can input position and posture commands, including position and posture commands, through the operating section of the main control console 100 to control the movement of surgical instruments mounted on the operating device 200.

[0100] In the aforementioned surgical robot, the main control console 100, the slave control device 200, and the operating table each have one or more drive mechanisms. These drive mechanisms are used to drive the movement of related structures and include motors, drivers, and / or sensors (such as encoders). The master arm 110 and master wrist 120 of the main control console 100 have multiple drive mechanisms according to their designed degrees of freedom; similarly, the robotic arm 210, adjusting arm 240, and manipulator 250 of the slave control device 200 also have multiple drive mechanisms.

[0101] Please see Figure 6 The surgical robot control system 300 mainly includes a controller 302, an encoder 303, and a driver 304. The controller 302 executes the program stored in the memory 301 and sends instructions to the driver 304 for execution. The driver 304 drives the motor to move, and the encoder 303 obtains the current motor motion data and feeds it back to the controller 302. The controller 302 adjusts the instructions based on the data fed back from the encoder 303, thereby achieving precise control. The controller 302 may include PLCs, FPGAs, CPUs, or other similar controllers.

[0102] During daily operation, surgical robots may malfunction or fail to operate normally due to various reasons, such as hardware damage or mismatch between different module programs. In order to ensure the availability and robustness of the control system 300, this application provides a surgical robot control method.

[0103] Please see Figure 7 The surgical robot control method of one embodiment of this application includes the following steps:

[0104] Step S10: Monitor whether any identifiable errors occur during the operation of the operating device.

[0105] When an identifiable error is detected in the drive mechanism and / or microcontroller of the operating device during operation, the faulty drive mechanism and / or faulty microcontroller associated with the identifiable error is identified.

[0106] Step S20: If an identifiable error occurs, an error signal is generated based on the identifiable error. Step S30: The error type and error level of the identifiable error are determined based on the error signal.

[0107] Step S40: Divide the surgical robot into several modular units according to its physical structure, display a model image of the surgical robot (operating device) on the display device, and highlight the areas in the model image of the surgical robot associated with the fault drive mechanism and / or fault micro-control mechanism.

[0108] Specifically, the control device acquires a model image of the operating device; and the area in the model image associated with the fault drive mechanism and / or the fault microcontroller mechanism is prominently displayed on the display device.

[0109] The control device can directly call existing model images of the operating device or generate model images of the operating device in real time.

[0110] Step S50: Process the identifiable errors in descending order of error level.

[0111] To address errors in the control system, including motion errors in the drive mechanism and operational errors in the microcontroller, identifiable errors need to be categorized. The error types in step S30 include follow-up error, current overload error, microcontroller error, CNC axis error, encoder error, and driver error.

[0112] The following error is an error caused by the controller 302 issuing commands. The following error refers to the difference between the commanded position and the actual position at a certain moment. It is a positional problem that occurs during motor execution and is obtained through the driver and encoder. For example, the driver sends a command associated with position A to the motor. If the encoder detects that the position has reached B after the motor starts working, and if the difference between position A and position B exceeds a set threshold within a certain time period, then the problem is identified. When the motor moves at a constant speed, there will be a small following error. When the motor is accelerating or decelerating, the following error value will increase. However, an excessively large following error indicates that the difference between the commanded position and the actual position is too large, usually indicating a problem with the motor's movement. Therefore, to ensure operational safety, taking the slave operating device 200 of a multi-surgery robot as an example, in the control system 300, the CNC axes corresponding to the guide rails, columns, upper arm, forearm, turntable, and chassis motors of the robotic arm 210, and the NC axes corresponding to the horizontal arm, vertical arm, and cyclone joint motors of the adjusting arm 240 are set with following error thresholds. When these motors are in motion, if the detected following error exceeds the corresponding following error threshold, the motor will automatically stop moving and generate a following error signal. The NC module program in the automation control software uses an abstract subroutine "NC axis" (numerical control axis) to correspond to and control a physical motor. An NC axis error refers to an error that occurs when the NC module calls methods within the NC axis to control the motor's movement. NC axis errors can be caused by various reasons, such as problems with NC axis configuration parameters or inappropriate commands issued by the controller 302, leading to controller errors.

[0113] The data fed back by encoder 303 reflects the current actual position of the motor. An encoder error refers to the encoder data exceeding the valid range. The valid range is set differently for encoders corresponding to different motors based on actual conditions. For the same position, the absolute encoder detects the first position value in the first cycle, and if the second position value detected in the second cycle is inconsistent with the first position value, an encoder error is considered to exist. An encoder error is reported to controller 302. Driver errors are errors occurring within the driver program, including overvoltage, overcurrent, undervoltage, and undercurrent issues within the driver itself. These are manufacturer-defined issues related to the driver itself. Driver errors are reported to controller 302 when they occur.

[0114] A current overload error is a current problem that occurs during motor operation, detected by the driver. The motor driver parameters include a rated current. When the average current value consistently exceeds a certain threshold during motor operation, it indicates that the motor's movement is being obstructed by external forces. In practical terms, a current overload error might occur during master-slave operation, where the operated robotic arm 210 collides with something else. Continuous monitoring of the motor current value will trigger a current overload error when the average current value exceeds a certain threshold over a period of time.

[0115] Microcontroller errors occur when a microcontroller, such as an STM32 board, processes hardware signals on the robotic arm 210, such as button operation signals, adapter board and tool / instrument position signals. If an error occurs within the STM32 board, the detected signals may not match the actual situation, causing misprocessing by the PLC controller. Therefore, a response to microcontroller errors needs to be implemented in the PLC program. As an EtherCAT slave, the STM32 board needs to be synchronized with the EtherCAT master to send and receive data. If the STM32 is not in OP (operational) state (running state), an STM32 error, i.e., a microcontroller error, is generated.

[0116] In step S30, different identifiable errors will have different error levels, and the corresponding processing methods will also be different. The specific correspondence table between error types and error levels is as follows:

[0117] CNC axis error Level 1 Encoder error Level 3 drive error Level 3 Current overload error Level 1 Follow-up error Level 2 Microcontroller error Level 2

[0118] When several identifiable errors of different levels occur simultaneously, they are processed sequentially from the highest level (level 3) to the lowest level (level 1). The lower level errors are processed only after the higher level errors have been processed. If an unrecoverable error occurs (such as encoder error or driver error in the table above), the lower level error will be ignored.

[0119] In step S50, when the above-mentioned identifiable error is detected, the motor movement associated with the identifiable error must first be stopped to ensure a safe state before the identifiable error is cleared and the machine is restored to a normal state so that it can be used.

[0120] Specifically, when the identifiable error is a follow-up error, such as Figure 8 As shown, monitor for follow-up error errors during operation by following these steps:

[0121] Step S111: Set a following error threshold for each drive mechanism;

[0122] Step S112: Monitor whether the current following error of each drive mechanism exceeds the following error threshold.

[0123] The tracking error monitoring function is enabled for the motor shafts of the main control console 100, slave control devices 200, and motion mechanisms in the operating table of the surgical robot, and a tracking error threshold is set. When the surgical robot performs operations, the tracking error of the motors is constantly monitored during normal program operation. If the tracking error exceeds the set tracking error threshold, adjustments are made according to... Figure 9 Steps S511 to S517 shown in the diagram handle errors; otherwise, normal operation continues.

[0124] like Figure 9 As shown, follow these steps to handle follow-up error errors:

[0125] Step S511: Stop the operation of the drive mechanism;

[0126] Step S512: Obtain the error clearing command;

[0127] Step S513: Clear the following error error according to the error clearing instruction;

[0128] Step S514: Check if the clearing was successful;

[0129] Step S515: Count the number of times the clearing is performed;

[0130] Step S516: Determine whether the number of clearing attempts exceeds the preset threshold number of clearing attempts;

[0131] Step S517: If the number of clearing attempts exceeds the preset clearing attempt threshold, stop the operation of the module unit to which the drive mechanism belongs, and raise the error level of the following error to the highest error level.

[0132] When a tracking error occurs, the motor automatically stops. Based on the physical module unit to which the motor belongs, the user interface (UI) of the display device displays the faulty component and provides reference information. For example, if a tracking error occurs on the chassis roller motor shaft while pushing the cart, the display will show: "Please check if there are any obstacles blocking the cart rollers" and "Please manually clear the error on the touchscreen." After troubleshooting the error, the operator needs to manually clear it on the touchscreen. In addition to displaying the error on the display device, the system can also provide voice prompts via speaker to indicate the fault and provide instructions on how to handle it.

[0133] Specifically, when the identifiable error is a current overload error, such as Figure 10 As shown, monitor for current overload errors during operation by following these steps:

[0134] Step S121: Set the current threshold of the drive mechanism;

[0135] Step S122: Monitor whether the average current of the drive mechanism within a preset time period exceeds the current threshold.

[0136] like Figure 11 As shown, the current overload error should be handled according to the following steps:

[0137] Step S521: Traverse all drive mechanisms on the module unit where the drive mechanism is located;

[0138] Step S522: Stop the operation of the drive mechanism until all the drive mechanisms on the module unit are stopped.

[0139] The current overload error is a custom error defined by the controller 302 at the software function level. When handling the current overload error, the robotic arm (e.g., the upper arm and the lower arm) is treated as a module unit. By monitoring the motor current value of the robotic arm during its movement in real time, the current overload error is triggered when the average current over a period of time exceeds the set current threshold.

[0140] Specifically, when the error is a microcontroller error, such as Figure 12 As shown, monitor for microcontroller errors during operation by following these steps:

[0141] Step S131: Monitor whether the microcontroller is running.

[0142] like Figure 13 As shown, follow these steps to handle microcontroller errors:

[0143] Step S531: When the faulty microcontroller is identified, detect whether the drive mechanism associated with the module unit to which the faulty microcontroller belongs is in motion.

[0144] Step S532: When it is detected that the drive mechanism of the module unit to which the faulty microcontroller belongs is in motion, the drive mechanism is braked.

[0145] Please see Figure 14 To handle NC axis errors, follow these steps:

[0146] Step S541, reset NC axis status;

[0147] Step S542: Check if the reset was successful;

[0148] Step S543: Count the number of resets;

[0149] Step S544: Determine if the number of resets exceeds the preset reset count threshold;

[0150] Step S545: If the number of resets exceeds the preset reset number threshold, stop the operation of the drive mechanism corresponding to the NC axis and raise the error level of the NC axis error by one level.

[0151] Step S546: Determine whether the error level is the highest error level;

[0152] If the error level is not the highest error level, repeat steps S541 to S546 until the error level of the NC axis error rises to the highest level or the NC axis state is successfully reset.

[0153] NC axis errors are errors generated by the NC module, including errors generated when the controller 302 issues commands, errors generated during data interaction with the underlying driver 304 and encoder 303, or errors generated during its own internal operation. NC axis errors belong to the first-level error category.

[0154] Please see Figure 15 To handle encoder errors, follow these steps:

[0155] Step S551: Stop the operation of the drive mechanism corresponding to the encoder error;

[0156] Step S552: Stop the movement of other drive mechanisms in the module unit to which the drive mechanism belongs, and lock the braking mechanism of the drive mechanism.

[0157] Similarly, execute the following when the error type is driver error:

[0158] Stop the operation of the drive mechanism corresponding to the driver error;

[0159] Stop the movement of other drive mechanisms in the module unit to which the drive mechanism belongs, and lock the braking mechanism of the drive mechanism.

[0160] Encoder errors and driver errors both belong to error level three, which are unrecoverable errors. This means that when an encoder or driver error occurs, the module will enter an unusable state. For example, in the robotic arms of a multi-port surgical robot's hand-operated device, each robotic arm 210 has multiple motors, as well as corresponding drivers and encoders. When the driver or encoder of a certain motor malfunctions, the robotic arm 210, as a module unit, will enter an inoperable state, disengaging the motor brake and stopping the moving motor, thus not responding to external operation signals.

[0161] In step S40, the surgical robot is divided into several modular units according to its physical structure. The main control panel, slave control devices, and operating table of the surgical robot system are divided into several large modules. Taking the slave control device in a multi-hole surgical robot as an example, it can be divided into several modular units, including the chassis, the upper arm, the adjusting arm, the manipulator arm (RCM arm), and the surgical instruments. The control device generates a model image of the control device and displays the model image of the surgical robot's control device on the UI of the display device. When a recognizable error is detected in the corresponding modular unit, the corresponding modular unit is highlighted on the model image (e.g., highlighted, flashing, etc.) to facilitate the doctor or maintenance personnel in troubleshooting the error.

[0162] Furthermore, a corresponding code can be configured for each error type, and a position number can be configured for each drive mechanism in each module unit. When the module unit is highlighted on the user interface of the display device, the code and / or position number corresponding to the identifiable error are displayed simultaneously, thereby further associating the specific location and error type of the identifiable error. Highlighting the corresponding module unit on the model image, combined with the error code, can help maintenance personnel identify the specific location where the problem occurred in that module unit.

[0163] Taking the chassis of the multi-hole robot's operating device 200 as an example, it typically includes support legs driven by multiple first motors for fixed support, and sliding wheels driven by multiple second motors for movement. When a chassis malfunctions, the display device can respond according to the following... Figure 16 The chassis on the model image is highlighted in the manner shown, or, in a display device, it can be displayed as follows: Figure 17 The method shown illustrates how the chassis on the model image is labeled and highlighted.

[0164] Furthermore, the corresponding module units on the surgical robot model screen can be highlighted using various methods, including color, pattern, brightness, flashing, and marking. Additionally, different highlighting methods can be used to display different error types and / or error levels depending on the determined error type and / or error severity. For example, if no fault occurs, the model image is green; as the error type and / or error severity increases, the color gradually deepens, reaching a deep red. The colors mentioned here are merely examples of different colors corresponding to different error types and / or error levels, and are not limitations on specific colors or different highlighting methods.

[0165] This application provides a computer-readable storage medium suitable for a surgical robot, the surgical robot comprising: an operating device including a drive mechanism and / or a microcontroller mechanism; a display device; and a control device coupled to the display device and coupled to the drive mechanism and / or the microcontroller mechanism. The surgical robot control method includes the following steps: when an identifiable error is detected in the drive mechanism and / or the microcontroller mechanism during operation, identifying the faulty drive mechanism and / or the faulty microcontroller mechanism associated with the identifiable error; generating a model image of the operating device; and prominently displaying the area in the model image associated with the faulty drive mechanism and / or the faulty microcontroller mechanism in the display device.

[0166] In summary, the surgical robot and its control method and control system of this application can handle motion errors of the drive mechanism and operational errors of the microcontroller. If the drive mechanism stalls or experiences hardware failure, or if the microcontroller malfunctions, the area associated with the identifiable error is highlighted on the model image generated on the display device, and the drive mechanism can be automatically stopped, thereby preventing the motor of the drive mechanism from burning out or going out of control due to stalling and causing damage.

[0167] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0168] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A surgical robot, characterized in that, include: Operating device, including drive mechanism and / or microcontroller mechanism; Display device; as well as A control device, coupled to the display device and to the drive mechanism and / or the microcontroller, is configured to perform: When an identifiable error is detected in the drive mechanism and / or the microcontroller during operation, the faulty drive mechanism and / or the faulty microcontroller associated with the identifiable error is identified. Obtain a model image of the operating device; The area in the model image associated with the fault drive mechanism and / or the fault microcontroller mechanism is prominently displayed in the display device; The control device is configured to perform: determining the error type of the identifiable error, determining the error level based on the error type of the identifiable error, and processing the identifiable errors in descending order of error level, wherein the error type includes a follow-up error, and in the step of monitoring the occurrence of identifiable errors in the drive mechanism and / or microcontroller during operation, the following is performed: Monitor whether the current following error of the drive mechanism exceeds the set following error threshold; When the current following error of the drive mechanism exceeds the following error threshold, the control device is configured to execute: Stop the operation of the drive mechanism; Clear the aforementioned follow-up error; If the number of clearing attempts exceeds the preset clearing attempt threshold and the follow error clearing is still unsuccessful, the operation of the module unit to which the drive mechanism belongs is stopped, and the error level of the follow error is set to the highest error level.

2. The surgical robot according to claim 1, characterized in that, The operating device includes a main operating console, which includes the drive mechanism and / or the microcontroller mechanism; and / or... The operating device includes a slave operating device, which includes the drive mechanism and / or the microcontroller mechanism; and / or... The operating device includes an operating table, which includes the drive mechanism and / or the microcontroller mechanism.

3. The surgical robot according to claim 1, characterized in that, The identifiable errors include motion errors in the drive mechanism; and / or, The identifiable errors include operational errors of the microcontroller mechanism.

4. The surgical robot according to claim 3, characterized in that, The error types also include at least one of the following: current overload error, microcontroller error, digital control axis error, encoder error, and driver error.

5. The surgical robot according to claim 4, characterized in that, in, The error levels of the encoder error and the driver error are higher than those of the microcontroller error and the follower error. The error levels of the microcontroller error and the follower error error are higher than those of the current overload error and the digital control axis error.

6. The surgical robot according to claim 4, characterized in that, In the step of monitoring for identifiable errors in the drive mechanism and / or microcontroller mechanism during operation, the following is performed: Monitor whether the average current of the drive mechanism within a preset time period exceeds a set current threshold. When the average current of the drive mechanism exceeds the current threshold within a preset time period. Detect whether the drive mechanism associated with the module unit to which the faulty drive mechanism belongs is in motion; When the drive mechanism of the module unit to which the faulty drive mechanism belongs is detected to be in motion, the drive mechanism is braked.

7. The surgical robot according to claim 4, characterized in that, In the step of monitoring for identifiable errors in the drive mechanism and / or the microcontroller during operation, the following is performed: Monitor whether the microcontroller is running; When the faulty microcontroller is identified, it is detected whether the drive mechanism associated with the module unit to which the faulty microcontroller belongs is in motion. When the drive mechanism of the module unit to which the faulty microcontroller belongs is detected to be in motion, the drive mechanism is braked.

8. The surgical robot according to claim 4, characterized in that, In the step of determining the error type of the identifiable error, the following is executed when the error type is a digital control axis error: Reset the state of the digital control axis; If the number of reset attempts exceeds the preset reset threshold and the digital control axis status still fails to be reset, the operation of the drive mechanism corresponding to the digital control axis is stopped, and the error level of the digital control axis error is increased by one level. Repeat the above two steps until the error level of the digital control axis rises to the highest level or the digital control axis status is successfully reset.

9. The surgical robot according to claim 4, characterized in that, In the step of determining the error type of the identifiable error, the following is performed when the error type is encoder error or driver error: Stop the operation of the drive mechanism corresponding to the encoder error or the driver error; Stop the movement of other drive mechanisms in the module unit to which the drive mechanism belongs, and lock the braking mechanism of the drive mechanism.

10. The surgical robot according to claim 1, characterized in that, In the step of highlighting the area model image associated with the fault drive mechanism and / or fault microcontroller mechanism in the model image on the display device, different highlighting methods are used to display identifiable errors of different error types and / or error levels according to the different error types and / or error levels of the identifiable errors. The different highlighting methods include one or more of the following: color, pattern, brightness, flashing, and marking.

11. The surgical robot according to claim 1, characterized in that, In the step of highlighting the area in the model image associated with the fault drive mechanism and / or fault microcontroller in the display device, the display device displays the code corresponding to the error type and / or error level of the identifiable error and / or the location number of the fault drive mechanism and / or fault microcontroller of the identifiable error.

12. A surgical robot control method, characterized in that, The surgical robot includes: an operating device, including a drive mechanism and / or a microcontroller; a display device; and a control device coupled to the display device and coupled to the drive mechanism and / or the microcontroller; the surgical robot control method includes the following steps: When an identifiable error is detected in the drive mechanism and / or microcontroller during operation, the faulty drive mechanism and / or faulty microcontroller associated with the identifiable error are identified. Generate a model image of the operating device; The area in the model image associated with the fault drive mechanism and / or fault microcontroller mechanism is prominently displayed in the display device; The control device is configured to perform: determining the error type of the identifiable error, determining the error level based on the error type of the identifiable error, and processing the identifiable errors in descending order of error level, wherein the error type includes a follow-up error, and in the step of monitoring the occurrence of identifiable errors in the drive mechanism and / or microcontroller during operation, the following is performed: Monitor whether the current following error of the drive mechanism exceeds the set following error threshold; When the current following error of the drive mechanism exceeds the following error threshold, the control device is configured to execute: Stop the operation of the drive mechanism; Clear the aforementioned follow-up error; If the number of clearing attempts exceeds the preset clearing attempt threshold and the follow error clearing is still unsuccessful, the operation of the module unit to which the drive mechanism belongs is stopped, and the error level of the follow error is set to the highest error level.

13. A surgical robot control system, characterized in that, include: Memory, used to store computer programs; and a controller for loading and executing the computer program; The computer program is configured to be loaded by the controller and executed to implement the steps of the surgical robot control method as described in claim 12.

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