System and method for controlling a surgical system

Abstract

Systems and methods for controlling a surgical system are provided. Accordingly, a first output signal is received from the force sensor unit in response to a first commanded movement of the distal portion of the medical device within the cannula. A force sensor bias value is determined based on a difference between a portion of the first output signal of the force sensor and a baseline output signal. A validity of the force sensor bias value is determined based on a magnitude of a deviation between the second output signal corrected by the force sensor bias value and the baseline output signal. Under the condition that the force sensor bias value is valid, haptic feedback is provided to a user control unit based on a load indication from the force sensor unit modified by the force sensor bias value.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority and filing date benefit of U.S. Provisional Patent Application No. 63 / 415,491, filed on October 12, 2022, entitled “Systems and Methods for Control of a Surgical System,” the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] Embodiments described herein relate to surgical systems, and more particularly, to teleoperated surgical systems. More particularly, embodiments described herein relate to systems and methods for determining a force sensor bias value to be applied to a force sensor output in order to control a surgical system that includes force feedback that can be provided to a system operator. Background Art

[0004] Known minimally invasive surgical (MIS) techniques employ instruments that can be controlled manually or via a handheld or mechanically grounded teleoperated medical system that operates at least in part with computer assistance ("telesurgical systems"). Many known MIS instruments include a therapeutic or diagnostic end effector (e.g., forceps, cutting tools, or cauterizing tools) mounted on an optional wrist mechanism at the distal end of a shaft. In a MIS procedure, the end effector, wrist mechanism, and distal end of the shaft are generally inserted through a cannula into a small incision or natural orifice in a patient to position the end effector at a working site in the patient's body. The optional wrist mechanism can be used to change the position and orientation of the end effector about the axis to perform a desired procedure at the working site. In known instruments, the overall motion of the instrument provides the mechanical degrees of freedom (DOF) for the motion of the end effector, and the wrist mechanism generally provides the desired DOF for the motion of the end effector about the instrument axis. For example, for forceps or other grasping tools, known wrist mechanisms can change the pitch and yaw of the end effector reference axis. The wrist may optionally provide a roll DOF for the end effector, or the roll DOF may be achieved by rolling the axis. The end effector may optionally have additional mechanical DOF, such as clamping or blade motion. In some cases, the wrist and end effector mechanical DOF may be combined. For example, U.S. Pat. No. 5,792,135 (filed May 16, 1997) discloses a mechanism that combines the wrist and end effector clamping DOF.

[0005] Force sensing surgical instruments are known and, together with associated telesurgery systems, can transmit tactile feedback to the surgeon performing the procedure during an MIS procedure. Tactile feedback can increase the immersion, realism, and intuitiveness of the procedure. For effective tactile rendering and accuracy, a force sensor can be placed on the medical device and interact as close to the anatomical tissue as possible. One approach is to include a force sensor unit having an electrical sensor element (e.g., a strain sensor or strain gauge) at the distal end of the medical device shaft to measure the strain applied to the medical device. The measured strain can be used to determine the force applied to the medical device and as an input based on which the desired tactile feedback can be generated.

[0006] Generally, the force sensor unit is calibrated when the device is manufactured. This calibration establishes a zero offset for the force sensing function of the medical device, that is, a force sensor unit output that provides an indication that no force is applied to the device. However, during the life cycle of the medical device, the zero offset can shift, so that when no force is applied to the device, the force sensing unit will incorrectly indicate that a force is applied. For example, the medical device is to undergo a reprocessing procedure after use, and this reprocessing procedure can include exposing the medical device or a portion thereof to a relatively high temperature. This exposure can affect the force sensor unit, causing the zero offset of the medical device to shift. The shift of the zero offset can in turn affect the accuracy of the measured strain, which is used to determine the force applied to the medical device and as an input, based on which the desired tactile feedback can be generated. Therefore, it is desirable to determine the correct zero offset of the medical device immediately before using the medical device in a surgical procedure so as to provide accurate tactile feedback based on an accurate measurement of the strain applied to the medical device.

[0007] In view of the foregoing, there is a continuing search in the art for new and improved systems and methods for controlling surgical systems based on accurate measurement of strain applied to a medical device. Summary of the invention

[0008] This summary introduces certain aspects of the various embodiments described herein to provide a basic understanding. This summary is not an extensive overview of the inventive subject matter and is not intended to identify key or critical elements or to delineate the scope of the inventive subject matter.

[0009] The systems and methods described herein facilitate accommodation of deviations of the force sensor unit from a calibration point (e.g., zero offset) established during manufacture. With the accommodation in place, the output of the force sensor unit can be used to generate accurate force feedback and / or can support other functions of the surgical system.

[0010] On the one hand, the present invention relates to a surgical system, which includes a medical device having a distal portion. The medical device is supported by a manipulator unit that moves the device and its distal portion. A force sensor unit is coupled to the medical device to provide an indication of the force applied to the device at the distal portion. A user control unit including an input device is operatively coupled to the medical device and the manipulator unit to allow an operator to move the medical device during a medical procedure. A controller is operatively coupled to the manipulator unit, the input device, and the force sensor unit to provide a control relationship among these components. The controller includes at least one processor and a haptic feedback module, which provides haptic feedback to the input device based on an output from the force sensor unit during a medical procedure. The controller is configured to perform a set of operations. The set of operations includes, in response to a first commanded movement of the distal portion of the medical device within a cannula, receiving a first output signal from the force sensor unit. Determining a force sensor bias value based on a difference between a portion of the first output signal of the force sensor and a baseline output signal. Initiating a second commanded movement and receiving a second output signal from the force sensor unit. The second output signal is corrected by the force sensor bias value. Determining the validity of the force sensor bias value based on a difference magnitude between the second output signal and the baseline output signal. The force sensor bias value is valid under the condition that the deviation magnitude is within a predefined tolerance range. In addition, under the condition that the force sensor bias value is determined to be valid, haptic feedback is provided to the input device via the haptic feedback module of the controller. The haptic feedback is based on a load indication from the force sensor unit corrected by the force sensor bias value.

[0011] In some embodiments, an error signal is generated under the condition that the force sensor bias value is invalid.

[0012] In some embodiments, the first commanded movement includes a roll movement of the distal portion about a longitudinal instrument axis from a first roll limit, through a neutral roll orientation, to a second roll limit, and back to the neutral roll orientation. The distal portion of the medical device is held within the cannula throughout the roll movement. Similarly, in some embodiments, the first commanded movement includes a linear movement along the longitudinal instrument axis. Throughout the linear movement, the distal portion of the medical device is held within the cannula.

[0013] In some embodiments, the manipulator unit includes an instrument carrier on which the medical device is mounted, and the instrument carrier includes a set of drive outputs (e.g., disks). Each individual drive output is coupled to a corresponding individual motor in a set of motors. The medical device includes a set of instrument drive inputs (e.g., disks). Each individual instrument drive input is configured to engage the corresponding individual drive output. The drive input of the instrument is configured to receive motion from the drive output of the manipulator to move the distal portion. Accordingly, the operation includes detecting the mounting of the medical device on the instrument carrier of the manipulator unit. In response to detecting the mounting, automatically initiating the engagement process of the medical device. For example, at least one drive output (e.g., the drive output disk) is moved via its corresponding motor until the drive output engages its corresponding instrument drive input (e.g., the drive input disk). Optionally, positive engagement is established by moving the instrument drive input against a mechanical stop. It should be understood that in some embodiments, the motor can be included as a component of the instrument.

[0014] In some embodiments, the set of drive outputs includes a roll drive output that is configured to produce a rolling motion of the distal end of the medical device about the longitudinal axis of the instrument axis. Accordingly, the operation includes holding the roll drive output at a first roll limit while rotating at least one non-roll drive output to a neutral orientation, and performing the first commanded motion by producing the rolling motion of the distal portion of the instrument through a range of roll motion to a second roll limit.

[0015] In some embodiments, the longitudinal orientation of the distal portion of the medical device within the cannula is a first longitudinal orientation. The instrument carrier is configured to move the distal portion of the medical device within the cannula in a proximal direction and in a distal direction. Accordingly, the operation includes moving the distal portion of the medical device within the cannula to a second longitudinal orientation parallel to the longitudinal axis of the instrument axis, and then returning the distal portion of the medical device within the cannula to the first longitudinal orientation.

[0016] In some embodiments, the operation includes determining the difference between the determined magnitude of a force sensor bias value and a defined maximum force sensor bias value. Under the condition that the magnitude of the determined force sensor bias value exceeds the maximum force sensor bias value, providing an error indication to the operator of the surgical system. In some embodiments, the error indication includes an instruction to disassemble the medical device from the manipulator unit and optionally reinstall the medical device.

[0017] In some embodiments, the commanded movement includes establishing the distal portion of the medical device in a first pose, transitioning the distal portion out of the first pose, and returning the distal portion to the first pose. Accordingly, the operation includes determining the variability of the output from the force sensor unit among each of the cases when the distal portion is in the first pose. Under the condition that the variability exceeds a maximum variability value, an error indication is provided to the operator of the surgical system.

[0018] In some embodiments, under the condition that the variability exceeds the maximum variability value, the commanded movement of the distal portion of the medical device within the cannula is repeated to generate an alternative output from the force sensor unit, and the force sensor offset value is determined at least in part based on the alternative output from the force sensor unit.

[0019] In some embodiments, the difference in magnitude between the determined force sensor offset value and a historical force sensor offset value associated with the medical device is determined. Under the condition that the difference between these offset values exceeds a deviation threshold, an error indication indicating a failure of the force sensor unit is provided to the operator of the surgical system.

[0020] In some embodiments, the coordinate system of the force sensor unit of the medical device is defined to have a first axis, a second axis, and a third axis that are orthogonal to each other. The force sensor offset value is a first force sensor offset value parallel to the first axis. Accordingly, the operation includes resolving the output of the force sensor unit in the coordinate system to determine a first axis component, a second axis component, and a third axis component. The operation further includes determining a second force sensor offset value parallel to the second axis based on the difference between a portion of the second axis component and a baseline second axis component, and determining a third force sensor offset value parallel to the third axis based on the difference between a portion of the third axis component and a baseline third axis component.

[0021] In some embodiments, the controller is configured to perform the set of operations upon receipt of a human command.

[0022] In some embodiments, the portion of the first output signal for which the force sensor offset value is determined is a portion of the output signal associated with the medical device in a specified sampling pose. In some embodiments, the specified sampling pose includes a roll orientation of the distal portion of the medical device corresponding to a defined zero orientation.

[0023] In some embodiments, determining the force sensor bias value includes identifying a free space portion of an output from the force sensor that corresponds to a free space condition of a distal portion of the medical device within a cannula. The force sensor bias value corresponds to a difference between an average magnitude of the free space portion of the output of the force sensor and the baseline output. In some embodiments, the free space portion of the output corresponds to a portion of the output that is a fitted line having a slope less than a defined slope threshold over a specified minimum time interval.

[0024] In some embodiments, the operations include determining a confidence score for the free space portion of the force sensor output. The confidence score indicates a correlation between the free space portion and a state of the medical device in which the commanded movement of the medical device is not affected by contact with another object (e.g., the cannula). A commanded action is performed based at least in part on the confidence score.

[0025] In some embodiments, under the condition that the confidence score is less than a confidence score threshold, performing the commanded action includes repeating the commanded movement of the distal portion of the medical device within the cannula to generate an alternative first output signal, identifying an alternative free space portion of the first output signal, and determining the force sensor bias value based at least in part on the alternative free space portion.

[0026] In some embodiments, under the condition that the confidence score is less than a confidence score threshold, performing the command action includes providing an error indication to the input device.

[0027] In some embodiments, performing the command action includes applying a gain value to the tactile feedback provided to the input device. The gain value is determined at least in part based on the confidence score. A higher gain value is associated with a higher confidence score, while a lower gain value is associated with a lower confidence score.

[0028] In some embodiments, under the condition that the confidence score is less than a confidence score threshold, performing the commanded action includes generating a maintenance alarm indicating a failed or malfunctioning force sensor unit.

[0029] With respect to the validity of the force sensor bias value, in some embodiments, under the condition that the difference between the second output signal and the baseline output signal falls outside the tolerance range, an error signal is generated, and a command action is performed based at least in part on the error signal. In some embodiments, performing the command action includes transmitting an instruction to remove the medical device from the manipulator unit and reinstall the medical device. In some embodiments, performing the command action includes transmitting an instruction to an operator of the surgical system to remove and disable the medical device due to a fault condition of the force sensor unit.

[0030] In some embodiments, performing the commanded action includes repeating the first commanded movement of the distal portion of the medical device within the cannula to generate a substitute first output signal, determining a substitute force sensor bias value based on a difference between a portion of the substitute first output signal and a baseline output signal of the force sensor, and providing tactile feedback to the input device based on the load indication from the force sensor unit corrected by the substitute force sensor bias value.

[0031] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 is a plan view of a minimally invasive teleoperated medical system for performing a medical procedure, such as surgery, according to one embodiment.

[0033] Figure 2 yes Figure 1 A perspective view of a user console for a minimally invasive teleoperated surgical system is shown.

[0034] Figure 3 yes Figure 1 A perspective view of an optional auxiliary unit of a minimally invasive teleoperated surgical system is shown.

[0035] Figure 4 yes Figure 1 A front view of a manipulator unit including multiple instruments of a minimally invasive teleoperated surgical system is shown.

[0036] Figure 5 According to an embodiment Figure 1 Illustration of a portion of a teleoperation system showing an instrument carrier of a manipulator unit.

[0037] Figure 6 is a perspective view of a medical device according to one embodiment.

[0038] Figure 7 yes Figure 6A side view of a portion of a medical device with the outer shaft removed.

[0039] Figure 8 yes Figure 1 A perspective view of a cannula of a minimally invasive teleoperated surgical system is shown.

[0040] Fig. 9 yes Figure 8 A cross-sectional side view of a portion of a sleeve having a Figure 6 The distal portion of the medical device is in an unloaded state.

[0041] Fig.10 yes Figure 8 A cross-sectional side view of a portion of a sleeve having a Figure 6 The distal portion of the medical device comes into contact with an obstruction.

[0042] Fig.11 A flow chart of a set of operations or controls for a surgical system.

[0043] Fig.12 is a graph showing the force sensor unit responding to Figure 6 A graph of the output of a commanded motion of a distal portion of a medical device.

[0044] Fig.13 is a schematic diagram of a controller for a minimally invasive teleoperated surgical system according to one embodiment.

[0045] Fig.14 is a flow chart of a method for controlling a surgical system according to one embodiment. DETAILED DESCRIPTION

[0046] Reference will now be made in detail to various embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. Each example is provided by way of illustration of the present invention, rather than by way of limitation. In fact, it will be apparent to those skilled in the art that various modifications and changes can be made to the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as part of one embodiment can be used together with another embodiment to produce yet another embodiment. Therefore, the present invention is intended to encompass these modifications and changes within the scope of the appended claims and their equivalents.

[0047] The embodiments described herein can be advantageously used for various grasping, cutting and manipulation operations associated with minimally invasive surgery. The medical device or apparatus of the present application can move with three or more degrees of freedom (DOF). For example, in some embodiments, the end effector of the medical device can move relative to the body of the instrument in three mechanical DOFs, for example, pitch, yaw and roll (axial roll). The end effector itself can also have one or more mechanical DOFs, for example, two jaws, each rotating about a U-shaped clip (clevis) (2 DOFs), and the distal U-shaped clip can rotate relative to the proximal U-shaped clip (one DOF). Therefore, in some embodiments, the medical device or apparatus of the present application can achieve six DOFs of movement. The embodiments described herein can also be used to transmit tactile feedback to the system operator based on a load indication corrected by a force sensor bias value from a force sensor unit.

[0048] In general, the present disclosure relates to systems and methods for controlling surgical systems (systems), such as minimally invasive teleoperated surgical systems. Specifically, the present disclosure includes a system and method that can facilitate accurate sensing (e.g., measurement) of loads affecting a medical device and the transmission of tactile feedback based on the sensed loads. Thus, the systems and methods described herein facilitate the adjustment of deviations of a force sensor unit from a calibration point (e.g., zero offset) established at the time of manufacture.

[0049] As described herein, a medical device is coupled to a manipulator unit of a surgical system, and a distal portion of the medical device is positioned within a cannula. When the distal portion of the medical device is within the cannula, the distal portion performs a first command motion. A controller of the system receives a first output signal from a force sensor unit of the medical device in response to the first command motion. When the distal portion is within the cannula, the medical device is in an unloaded state while performing the first command motion. In a nominal (e.g., designed) unloaded state, the distal portion is affected by gravity without generating an action or reaction force in contact with another object. In other words, in an unloaded state, an initial zero offset (e.g., bias) will generate a force sensor output to indicate that the load magnitude is "zero" in the absence of drift or other deviations in the zero offset - only negligible deviations - with negligible deviations.

[0050] Upon receiving the first output signal, the controller determines a difference between a portion of the first output signal of the force sensor and the baseline output signal. This difference can correspond to a force sensor bias value (e.g., a correction value) required to compensate for deviations (e.g., drift) of the force sensor unit from an initial calibration point. In other words, the difference can be used to establish a new zero offset for the current installation of the medical device (e.g., to recalibrate the force sensor unit). Thus, each time the medical device is coupled to the manipulator unit, the force sensor bias value can be recalculated to ensure an accurate representation of the load applied to or by the medical device.

[0051] In order to determine the validity of the force sensor bias value, the controller performs a second command movement of the distal portion within the sleeve. Similar to the first command movement, the second command movement also corresponds to a no-load state. In response to the second command movement, a second output signal is received from the force sensor unit. However, the second output signal is corrected by the force sensor bias value. The controller then determines the validity of the force sensor bias value based on the deviation between the second output signal and the baseline output signal. If the deviation is within a predefined tolerance range, the force sensor bias value is valid. For example, if the second output signal indicates a load magnitude of "zero" (only negligible deviation) when corrected by the force sensor bias value, the force sensor bias value is valid. If the force sensor bias value is valid, the force sensor bias value can be applied to the load indication from the force sensor unit during system operation. When corrected by the force sensor bias value, the load indication from the force sensor unit can be used to provide tactile feedback to the input device of the system. However, if the force sensor bias value is invalid, the controller generates an error signal and the operation of the system is corrected. For example, in response to the error signal, the medical device can be detached and recoupled to the manipulator unit, the cannula can be inspected for obstructions, the medical device can be replaced, the magnitude of the tactile feedback can be limited, and / or other suitable modifications can be performed.

[0052] As used herein, the term "about" when used in conjunction with a referenced numerical indication means the referenced numerical indication plus or minus 10% of the referenced numerical indication. For example, the term "about 50" encompasses a range of 45 to 55. Similarly, the term "about 5" encompasses a range of 4.5 to 5.5.

[0053] As used in this specification and the appended claims, the word "distal" refers to a direction toward a working site, while the word "proximal" refers to a direction away from a working site. Thus, for example, the end of a tool closest to the target tissue would be the distal end of the tool, while the end opposite the distal end (i.e., the end manipulated by the user or coupled to the actuation shaft) would be the proximal end of the tool.

[0054] Furthermore, the specific words chosen to describe one or more embodiments and optional elements or features are not intended to limit the invention. For example, spatial relative terms—such as "below", "beneath", "under", "above", "over", "proximal", "distal", and / or the like—may be used to describe the relationship of one element or feature to another as shown in the figures. These spatial relative terms are intended to cover different orientations (i.e., translational placement) and orientations (i.e., rotational placement) of the device during use or operation in addition to the orientation and orientation shown in the figures. For example, if the device in the figure is flipped, an element described as "below" or "beneath" other elements or features will be "above" or "over" other elements or features. Thus, the term "below" can cover both upper and lower orientations and orientations. The device can be oriented in other ways (e.g., rotated 90 degrees or in other orientations), and the spatial relative descriptors used herein are to be interpreted accordingly. Similarly, descriptions of movement along (translation) and around (rotation) various axes include various spatial device orientations and orientations. The combination of the orientation and orientation of the body defines the posture of the body (e.g., kinematic posture).

[0055] Similarly, geometric terms, such as "parallel", "perpendicular", "circular", or "square", are not intended to require absolute mathematical precision unless the context indicates otherwise. Instead, such geometric terms allow for variations due to manufacturing or equivalent functionality. For example, if an element is described as "circular" or "substantially circular", components that are not precisely circular (e.g., slightly oval or polygonal components) are still covered by this description.

[0056] In addition, the singular forms "a", "an", and "the" are also intended to include the plural forms unless the context indicates otherwise. The terms "comprising", "including", "having", and / or the like specify the presence of the stated features, steps, operations, elements, components, etc., but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, or groups.

[0057] Unless otherwise indicated, the terms device, medical device, instrument, and their variants can be used interchangeably.

[0058] Aspects of the invention are described with reference to a robotic surgical system. An example architecture of such a robotic surgical system is the da Vinci Surgical System commercialized by Intuitive Surgical, Inc. of Sunnyvale, California. Surgical system. However, those skilled in the art will appreciate that the various aspects of the invention disclosed herein may be embodied and implemented in a variety of ways, including computer-assisted, non-computer-assisted, and hybrid combinations of manual and computer-assisted embodiments and implementations. The implementations are presented only as examples, and they should not be considered to limit the scope of the various aspects of the invention disclosed herein. If applicable, the various aspects of the invention may be embodied and implemented in relatively small handheld manually operated devices as well as relatively larger systems with additional mechanical support.

[0059] Figure 1 1 is a plan view of a remotely operated surgical system ("system") 1000 ("telesurgical system") that operates at least in part with computer assistance. The telesurgical system 1000 and its components are considered medical devices. The telesurgical system 1000 is a minimally invasive robotic surgery (MIRS) system for performing minimally invasive diagnostic or surgical procedures on a patient P lying on an operating table 1010. The system can have any number of components, such as a user control unit 1100 used in the procedure by an operator of the system (such as a surgeon or other skilled clinician S). The MIRS system 1000 can also include a manipulator unit 1200 (generally referred to as a surgical robot) and an optional auxiliary equipment unit 1150. The manipulator unit 1200 can include an arm assembly 1300 and a surgical instrument tool assembly removably coupled to the arm assembly. The manipulator unit 1200 can manipulate at least one detachably coupled medical device (instrument) 1400 through a minimally invasive incision or a natural opening in the body of the patient P while the surgeon S views the surgical site and controls the movement of the instrument 1400 through the control unit 1100. The image of the surgical site is obtained by an endoscope (not shown), such as a stereo endoscope, which can be manipulated by the manipulator unit 1200 to orient the endoscope. The auxiliary device unit 1150 can be used to process the image of the surgical site for subsequent display to the surgeon S through the user control unit 1100. The number of instruments 1400 used at one time will generally depend on factors such as the diagnostic or surgical procedure and the space limitations in the operating room. If it is necessary to replace one or more of the instruments 1400 being used during the procedure, the assistant removes the instrument 1400 from the manipulator unit 1200 and replaces it with another instrument 1400 on the tray 1020 in the operating room. Although shown as being used with the instrument 1400, any instrument described herein can be used with the system 1000.

[0060] Figure 211 is a perspective view of the control unit 1100. The user control unit 1100 includes a left-eye display 1112 and a right-eye display 1114 for presenting a coordinated stereoscopic view of the surgical site to the surgeon S that enables depth perception. The user control unit 1100 also includes one or more input control devices 1116 (input devices), which in turn enable the manipulator unit 1200 ( Figure 1 The input devices 1116 provide at least the same degrees of freedom as the instruments 1400 to which they are associated to provide telepresence to the surgeon S, or provide a sense that the input devices 1116 are integral to (or directly connected to) the instruments 1400. In this manner, the user control unit 1100 provides the surgeon S with a strong sense of directly controlling the instruments 1400. To this end, position, force, strain, or tactile feedback sensors (not shown) or any combination of such senses are returned from the instruments 1400 to one or both hands of the surgeon via one or more input devices 1116.

[0061] The user control unit 1100 Figure 1 1100 is shown in the same room as the patient, enabling the surgeon S to directly monitor the procedure (in person if necessary) and speak directly to the assistant, rather than over the phone or other communication medium. However, in other embodiments, the user control unit 1100 and the surgeon S can be in different rooms, completely different buildings, or other locations remote from the patient, thereby achieving a remote surgical procedure.

[0062] Figure 3 11 is a perspective view of the auxiliary equipment unit 1150. The auxiliary equipment unit 1150 can be coupled to an endoscope (not shown) and can include one or more processors to process captured images for subsequent display, such as display via the user control unit 1100, or display on another suitable display located locally (e.g., displayed on the unit 1150 itself, displayed on a wall-mounted display) and / or remotely. For example, in the case of using a stereoscopic endoscope, the auxiliary equipment unit 1150 can process the captured images to present a coordinated stereoscopic image of the surgical site to the surgeon S via the left eye display 1112 and the right eye display 1114. Such coordination can include alignment between relative images and can include adjusting the stereo working distance of the stereoscopic endoscope. As another example, image processing can include using previously determined camera calibration parameters to compensate for imaging errors of the image capture device, such as optical aberrations.

[0063] Figure 4A front perspective view of the manipulator unit 1200 is shown. The manipulator unit 1200 includes components (e.g., arms, linkages, motors, sensors, etc.) for manipulating the instrument 1400 and an imaging device (not shown), such as a stereo endoscope, for capturing images of the site of the procedure. Specifically, the instrument 1400 and the imaging device can be manipulated by a remote operating mechanism having one or more mechanical joints. In addition, the instrument 1400 and the imaging device are positioned and manipulated through an incision or natural orifice in the patient P, so that the center of motion, which is away from the manipulator and generally located at a certain position along the instrument axis, is maintained at the incision or orifice by kinematic mechanical constraints or software constraints. In this way, the size of the incision can be minimized.

[0064] Figure 5 13 is a perspective view of a portion of an arm assembly 1300 and an instrument bracket 1330 to which an instrument 1400 can be removably coupled. The instrument bracket 1330 includes a remotely operated actuator (e.g., a motor 1340 with a coupled drive disk 1320) to provide controller motion to the instrument 1400, which in turn is converted into a distal portion 1402 ( Figure 6 ) at one or more tools at the patient's site. Arm assembly 1300 includes a connection portion 1324 in which an instrument bracket 1330 can be coupled. Instrument bracket 1330 can translate relative to arm assembly 1300 (e.g., along an insertion axis extending between a proximal end and a distal end of arm assembly 1300) for inserting and removing instruments from a patient. Translation of instrument bracket 1330 can translate relative to distal portion 1402 ( Figure 6 )'s longitudinal axis A L (e.g., in the distal or proximal direction) to produce a corresponding linear motion LM (see Fig. 9 ). In addition, the arm assembly 1300 can also provide additional degrees of freedom to orient and position the instrument bracket 1330 and the instrument 1400 in a desired position. When the instrument 1400 is coupled to the instrument bracket 1330, the input provided by the surgeon S to the user control unit 1100 (the "master" command) is converted into a corresponding action of the instrument 1400 (the "slave" response) via the drive disk 1320 of the instrument bracket 1330, which is operably coupled to the instrument disk on the instrument 1400 ( Figure 6 ).

[0065] The instrument bracket 1330 includes a bracket interface including a drive disk 1320 configured to be operably coupled to the instrument disc 1474 at a drive member interface. In embodiments utilizing a sterile adapter or other similar structure, the drive disk 1320 can be matingly coupled to a coupler of the instrument sterile adapter. The instrument bracket 1330 also includes a notch or cutout area 1310 that allows the instrument shaft (axle) 1410 ( Figure 6 ) can extend in the notch or cutout area. In some embodiments, the drive disk 1320 of the carriage 1330 can be directly coupled to the input end of the instrument disk 1474 of the instrument 1400 without the need for an intermediate sterile adapter.

[0066] In some embodiments, the instrument holder 1330 can include a roll drive disk 1350. The roll drive disk 1350 is configured to be operably coupled to a roll drive instrument disk 1476 to generate a rotation of the distal end portion 1402 of the instrument 1400 about a longitudinal (eg, shaft) axis A of the instrument 1400. L Rolling motion RM( Fig. 9 ). The roll motion RM has a roll motion range defined between a first roll limit and a second roll limit. For example, the roll motion range can include a roll of up to 360 degrees (e.g., 350 degrees) in a clockwise direction from a neutral roll orientation (e.g., a zero degree orientation) to the first roll limit, and a roll of up to 360 degrees (e.g., 350 degrees) in a counterclockwise direction from a neutral roll orientation to the second roll limit. Thus, the roll motion range can include a roll of 720 degrees (e.g., 700 degrees) from the first roll limit through an intermediate roll orientation to the second roll limit.

[0067] Reference now Figure 6 and Figure 7 , Figure 6 A perspective view of the device 1400 is depicted in FIG. Figure 7 1400 with a portion of the outer shaft portion removed. In some embodiments, the instrument 1400 or any component thereof is optionally part of a surgical system for performing a surgical procedure, and can include a manipulator unit, a series of kinematic linkages, a set of cannulas, or the like. The instrument 1400 (and any instrument described herein) can be used in any suitable surgical system, such as the MIRS system 1000 shown and described above. Figure 6As shown, the instrument 1400 is defined to include a proximal mechanical structure 1470, an axis 1410, a distal portion 1402, and a set of cables (not shown). The cables act as tension elements that couple the proximal mechanical structure 1470 to the distal portion 1402. In some embodiments, the distal portion 1402 includes a distal wrist assembly 1500 and a distal end effector 1460. The instrument 1400 is configured so that movement of one or more of the cables produces movement of the end effector 1460 about an axis of the beam coordinate system BCS (e.g., pitch, yaw, or clamp).

[0068] In addition, although the proximal mechanical structure 1470 is shown as including a capstan 1472, in other embodiments, the mechanical structure can include one or more linear actuators that produce a portion of the cable translation (linear motion). Such a proximal mechanical structure can include, for example, a universal joint, a lever, or any other suitable mechanism to directly pull (or release) the end of any cable. For example, in some embodiments, the proximal mechanical structure 1470 can include any proximal mechanical structure or component described in U.S. Patent Application Publication No. US2015 / 0047454 A1 (filed on August 15, 2014) entitled "Lever Actuated Gimbal Plate" or U.S. Patent No. US 6,817,974 B2 (filed on June 28, 2001) entitled "Surgical Tool Having Positively Positionable Tendon Actuated Multi Disc Wrist Joint", each of which is incorporated herein by reference in its entirety.

[0069] The shaft 1410 can be any suitable elongated shaft coupled to the wrist assembly 1500 and the proximal mechanical structure 1470. Specifically, the shaft 1410 includes a proximal end 1411 coupled to the proximal mechanical structure 1470 and a distal portion 1412 coupled to the wrist assembly 1500 (e.g., a proximal link of the wrist assembly 1500). The shaft 1410 defines a channel or a series of channels through which cables and other components (e.g., wires, ground wires, or similar cables) can be routed from the proximal mechanical structure 1470 to the wrist assembly 1500. In some embodiments, the shaft 1410 can be at least partially formed of, for example, a conductive material (e.g., stainless steel). In such embodiments, the shaft can include either an inner insulating cover or an outer insulating cover. Thus, the shaft 1410 can be a shaft assembly including a plurality of different components. For example, shaft 1410 can include (or be coupled to) spacers that provide desired fluid seals, electrical insulation features, and any other desired components for coupling wrist assembly 1500 to shaft 1410. Similarly stated, while wrist assembly 1500 (and other wrist assemblies or linkages described herein) are described as being coupled to shaft 1410, it should be understood that any wrist assembly or linkage described herein can be coupled to a shaft via any suitable intermediate structure (e.g., spacers and cable guides) or the like.

[0070] like Figure 7 As shown, instrument 1400 (e.g., a surgical or medical instrument) includes a force sensor unit 1850, which includes a beam 1852 with one or more strain sensors 1860. Strain sensor 1860 can include a set of strain gauges (e.g., (one or more) tensile strain gauge resistors or (one or more) compressive strain gauge resistors) arranged in at least one bridge circuit (e.g., a Wheatstone bridge) mounted on a surface along beam 1852. In some embodiments, end effector 1460 can be coupled to distal portion 1854 of beam 1852 (e.g., coupled to distal portion 1402 of surgical instrument 1400) via wrist assembly 1500. Shaft 1410 includes distal portion 1412 coupled to proximal portion 1856 of beam 1852. In some embodiments, the distal portion 1412 of the shaft 1410 is coupled to the proximal portion 1856 of the beam 1852 via another coupling component (such as an anchor or coupler, not shown). In some embodiments, the force sensor unit 1850 can include any structure or component described in U.S. Patent Application Publication No. US2020 / 0278265A1, entitled “Split Bridge Circuit Force Sensor” (filed on May 13, 2005), which is incorporated herein by reference in its entirety.

[0071] In some embodiments, the end effector 1460 can include at least one tool member 1462, which has a contact portion configured to engage or manipulate the target tissue in a surgical procedure. For example, in some embodiments, the contact portion can include an engagement surface that acts as a clamp, a cutter, a tissue manipulator, or a similar instrument. In other embodiments, the contact portion can be an energized tool member for a cautery or electrosurgical procedure. The end effector 1460 can be operably coupled to a proximal mechanical structure 1470 so that the tool member 1462 rotates relative to the shaft 1410. In this way, the contact portion of the tool member 1462 can be actuated to engage or manipulate the target tissue in a surgical procedure. The tool member 1462 (or any tool member described herein) can be any suitable medical tool member. In addition, although only one tool member 1462 is identified, as shown, the instrument 1400 can include two tool members that cooperate to perform a clamping or shearing function. In other embodiments, the end effector can include more than two tool members.

[0072] Figure 8 A cross-sectional view of a cannula 1600 for use in the system 1000 is depicted. As shown, the cannula 1600 can be configured to surround at least a portion of the instrument 1400 to facilitate access to the surgical site by the end effector 1460. Thus, the cannula 1600 can have a proximal end 1610 and a distal end 1620. A central channel 1640 extends between the proximal end 1610 and the distal end 1620. Thus, the cannula 1600 forms a channel or passage through which the instrument 1400 can be inserted to access the surgical site. As shown, the cannula 1600 can be a straight cannula. However, in additional embodiments, the cannula 1600 can be, for example, a curved cannula having a combination of linear and nonlinear segments, a cannula having a plurality of non-parallel linear segments, a cannula having a plurality of curved segments with different characteristics, and / or a cannula having other combinations of linear and nonlinear segments. In some embodiments, the distal end 1620 of the cannula 1600 is inserted into the patient's body cavity through an incision. The proximal end 1610 of the cannula 1600 remains outside the patient's body wall and is coupled to the arm assembly 1300 of the system 1000.

[0073] Fig. 9 16 is a cross-sectional side view of a portion of the cannula 1600 with the distal portion 1402 of the instrument 1400 positioned therein in an unloaded state. As shown, the distal portion 1402 is positioned in a first longitudinal orientation LP within the central passage 1640 of the cannula 1600. 1When positioned in the cannula, the distal portion 1402 is separated from the patient's body. Therefore, the distal portion 1402 does not generate any action or reaction force in contact with the patient's body, and the instrument 1400 is in a nominally unloaded state. In addition, in the unloaded state, the distal portion 1402 is separated from the central channel 1640 and from any other obstacles (e.g., debris such as biological tissue or surgical materials) in the central channel 1640. Therefore, in the unloaded state, the movement of the distal portion 1402 in the central channel 1640 is not affected by contact with the patient's body, the cannula 1600, and any obstacles in the central channel 1640. Therefore, any output from the force sensor unit 1850 is independent of any external force (except gravity) applied to the distal portion 1402. Therefore, in the unloaded state, the movement of the distal portion 1402 in the central channel can be used to confirm or re-establish the zero offset of the force sensor unit 1850 or the instantaneous installation of the instrument 1400 on the arm assembly 1300. Confirmation or re-establishment of the zero offset each time the instrument 1400 is installed can facilitate accurate measurement of the loads affecting the instrument 1400 and provide tactile feedback to the operator based on the measurement.

[0074] Fig.10 14 is a cross-sectional side view of a portion of the cannula 1600 in which the distal portion 1402 of the instrument 1400 is positioned and in contact with the object OB during at least a portion of the movement. The object OB can include a portion of the cannula 1600 (e.g., a wall of the central channel 1640 contacted by the end effector 1460) or debris, such as biological tissue or surgical material within the central channel 1640. In some embodiments, a portion of the movement of the distal portion 1402 within the central channel 1640 can be affected by the contact with the object OB. The contact with the object OB during the portion of the movement within the central channel 1640 can be sensed (e.g., measured) by the force sensor unit 1850 as a load affecting the instrument 1400. Therefore, the contact between the distal portion 1402 and the object OB can affect the confirmation or re-establishment of the bias of the force sensor unit 1850. Even when the portion of the movement of the distal portion 1402 is affected by the contact with the object OB, the use of the systems and methods described herein can facilitate the confirmation or re-establishment of the zero offset of the force sensor unit 1850. Thus, utilizing the systems and methods described herein can facilitate accurate measurement of the loads affecting the instrument 1400 and providing tactile feedback to the operator based on the measurement.

[0075] In some embodiments, the system 1000 includes a force sensor unit 1850 coupled to an instrument 1400 supported by a manipulator unit 1200. As previously described, the input device 1116 is operably coupled to the instrument 1400 and the manipulator unit 1200. The system 1000 includes a controller 1800 operably coupled to the manipulator unit 1200, the input device 1116, and the force sensor unit 1850. As further described below, the controller 1800 includes at least one processor 1802 and a tactile feedback module 1820. The controller 1800 is configured to perform a set of operations 1700, such as Fig.11 shown.

[0076] In some embodiments, the controller 1800 is configured to perform the set of operations 1700 upon receiving a human command (e.g., user input). For example, during a procedure, an operator of the system 1000 can input a recalibration command, thereby triggering the performance of the set of operations 1700 or any of the operations described herein. In additional embodiments, the controller 1800 is configured to detect the installation of the instrument 1400 on the instrument bracket 1330 of the manipulator unit 1200 and perform the set of operations 1700 (or any of the operations described herein) in response to the installation. In further embodiments, the controller 1800 is configured to perform the set of operations 1700 (or any of the operations described herein) based on parameters of a signal received from the force sensor unit 1850 indicating an abnormality of the force sensor unit 1850.

[0077] like Fig.11 As shown at 1702, in some embodiments, the set of operations 1700 includes positioning the distal portion 1402 of the instrument 1400 within the sleeve 1600, such as with reference to Fig. 9 and Fig.10 With the distal portion 1402 positioned within the sleeve 1600 (eg, positioned within the central channel 1640), at 1704, the controller 1800 initiates a first commanded motion. The first commanded motion of the distal portion 1402 can include moving the distal portion 1402 about the shaft axis A. L (e.g., longitudinal axis) Fig. 9 ), along the axis A L Linear motion LM( Fig. 9 ), rotation of the end effector 1460 relative to the beam coordinate system BCS, clamping of the end effector 1460, or any combination of these movements.

[0078] At 1708, the controller 1800 receives a first output signal 1706 from the force sensor unit 1850. The first output signal 1706 is responsive to a first commanded movement of the distal portion 1402 of the instrument 1400 within the cannula 1600. The first output signal 1706 corresponds to the force (e.g., load) sensed by the force sensor unit 1850 that affects the distal portion 1402 within the cannula 1600. In a nominal no-load state within the central channel 1640, an initial zero offset will produce the first output signal 1706, in the absence of drift or other biases in the offset, to indicate - with only negligible deviation - a load magnitude of "zero".

[0079] At 1710, the controller 1800 determines the difference between a portion of the first output signal 1706 of the force sensor unit 1850 and a baseline output signal 1712. The baseline output signal 1712 corresponds to the output signal of the force sensor unit 1850 corrected for the initial zero offset. For example, in a nominal no-load state within the central channel 1640, the baseline output signal 1712 has a load magnitude within a specified self-zeroing deviation. For example, the baseline output signal 1712 can indicate a force magnitude between 0.2 N and -0.2 N (e.g., 0.1 N to -0.1 N). The baseline output signal 1712 can be specific to the particular instrument 1400 coupled to the manipulator unit 1200.

[0080] As shown at 1714, the controller 1800 determines a force sensor bias value 1716 based on the difference between this portion of the first output signal 1706 and the baseline output signal 1712. The force sensor bias value 1716, in combination with the initial zero offset, can have a magnitude such that when applied to the output from the force sensor unit 1850 in a no-load state, it produces an output signal indicating - with only negligible deviation - a load magnitude of zero.

[0081] Still referring to Fig.11In some embodiments, the set of operations 1700 includes, at 1718, initiating a second command motion. In response to the second command motion, the controller 1800 receives a second output signal 1720 from the force sensor unit 1850. At 1722, the second output signal 1720 is modified by the force sensor offset value 1716. For example, the force sensor offset value 1716 is added to the second output signal 1720 generated by the force sensor unit 1850 in response to the second command motion. At 1724, the controller 1800 determines a magnitude of a deviation between the second output signal 1720 and the baseline output signal 1712. Based on the magnitude of the deviation, the controller 1800 determines, at 1726, whether the force sensor offset value 1716 is valid. The force sensor offset value 1716 is valid if the magnitude of the deviation is within a predefined tolerance range 1728. In other words, applying a valid force sensor bias value 1716 to the second output signal 1720 in a no-load state produces an output signal having a magnitude deviation from zero that falls within a predefined tolerance range 1728. For example, the predefined tolerance range 1728 may require that the output of the force sensor unit 1850 be within 0.2 N (e.g., 0.1 N or less) of zero in a no-load state. In some embodiments, the controller can simulate the second command motion and utilize previously recorded data to determine whether the force sensor bias value 1716 is valid.

[0082] Under the condition that the force sensor bias value 1716 is effective, this set of operations 1700 includes, at 1730, providing tactile feedback to the user control unit 1100 (e.g., input device 1116) via the tactile feedback module 1820 of the controller 1800. The tactile feedback provided to the user control unit 1100 by the tactile feedback module 1820 is based on the load indication from the force sensor unit 1850 corrected by the force sensor bias value 1716. In other words, the output from the force sensor unit 1850 is corrected by the force sensor bias value 1716 to provide an accurate indication of the load affecting the instrument 1400 under the loading condition. The controller 1800 then uses the corrected indication of the load to provide accurate tactile feedback to the operator of the system 1000.

[0083] Under the condition that the force sensor bias value 1716 is invalid, the set of operations 1700 includes - at 1732 - generating an error signal (e.g., an error notification). The force sensor bias value 1716 is invalid when the magnitude of the deviation between the second output signal 1720 corrected by the force sensor bias value 1716 and the baseline output signal 1712 is greater than the tolerance range. For example, in some embodiments, if the magnitude of the deviation is greater than 0.2N, the force sensor bias value 1716 is invalid. In other words, if the magnitude of the force sensor bias value 1716 is insufficient to correct any displacement or drift of the force sensor unit 1850 from the initial zero offset, the force sensor bias value 1716 is invalid. In some embodiments, the error signal can include a visual indication, an audible indication, a tactile indication, or a combination thereof configured to alert an operator to the error condition. In some embodiments, a command action is performed in response to the error condition. For example, in response to the error signal, the operator can remove the instrument 1400 from the manipulator unit 1200 and reinstall the instrument 1400. In some embodiments, in response to the error signal, the operator can withdraw the instrument 1400 from the cannula 1600 and clear the obstruction (eg, object OB) from the cannula 1600. In some embodiments, the error signal can indicate that there is a malfunction in the force sensor unit 1850 necessitating the removal of the instrument 1400 from service.

[0084] In some embodiments, under the condition that the difference between the second output signal 1720 and the baseline output signal 1712 falls outside the tolerance range 1728, the controller 1800 generates an error signal to the operator of the system 1000 and performs a command action based at least in part on the error signal. In some embodiments, performing the command action includes transmitting an instruction to remove and reinstall the instrument 1400 from the manipulator unit 1200 (e.g., the arm assembly 1300). In additional embodiments, performing the command action can include repeating the first command movement of the distal portion 1402 within the sleeve 1600 to generate an alternative first output signal. The controller 1800 can then determine an alternative force sensor bias value based on the difference between a portion of the alternative first output signal and the baseline output signal 1712. Based on the load indication from the force sensor unit 1850 corrected by the alternative force sensor bias value, tactile feedback is provided to the user control unit 1100. Furthermore, in some embodiments, executing the command action includes transmitting an instruction to an operator of the system 1000 to disassemble and deactivate the instrument 1400 due to a fault condition of the force sensor unit 1850 .

[0085] Still for reference Fig.11 In some embodiments, at 1704, initiating the first command motion includes - at 1734 - generating a rolling motion RM of the distal portion 1402 (see, e.g., Fig. 9 and Fig.10). The rolling motion RM is around the axis A of the shaft 1410 L The rolling motion RM can be a rotational motion about the longitudinal axis (e.g., a longitudinal axis). The rolling motion RM can be from a first rolling limit, through a neutral orientation, to a second rolling limit, and then back to the neutral rolling orientation. For example, the first rolling limit can be achieved after rolling up to 360 degrees (e.g., 350 degrees) in a clockwise direction from a neutral rolling orientation (e.g., a zero degree orientation), and the second rolling limit can be achieved after rolling up to 360 degrees (e.g., 350 degrees) in a counterclockwise direction from the neutral rolling orientation. Thus, the rolling motion RM can include rolling about the shaft axis A. L The controller 1800 is configured to maintain the distal end portion 1402 of the instrument 1400 within the cannula 1600 throughout the rolling motion RM. For example, the controller 1800 is configured to maintain the distal end portion 1402 in the first longitudinal orientation LP throughout the rolling motion RM. 1 Place.

[0086] In some embodiments, at 1704, initiating the first commanded motion includes, at 1736, generating a linear motion LM of the distal portion 1402 (see, e.g., Fig. 9 and Fig.10 ). The linear motion LM is parallel to the shaft axis A of the shaft 1410 L The controller 1800 is configured to maintain the distal portion 1402 of the instrument 1400 within the cannula 1600 throughout the linear motion LM. For example, the controller 1800 is configured to move the distal portion 1402 from a first longitudinal orientation LP within the central passage 1640 of the cannula 1600. 1 Move to a second longitudinal orientation.

[0087] As referenced in this article Figure 5 and Figure 6As described, the manipulator unit 1200 includes an instrument bracket 1330. The instrument bracket 1330 includes a set of drive disks 1320. Each independent drive disk 1320 is coupled to an independent motor 1340. The instrument 1400 includes a set of instrument disks 1474. Each independent instrument disk 1474 is configured to engage a corresponding drive disk 1320. The instrument disk 1474 is configured to receive movement from the drive disk 1320 to move the distal portion 1402. Therefore, this set of operations 1700 includes detecting the installation of the instrument 1400 on the instrument bracket 1330. Once the installation is detected, the controller 1800 initiates the engagement process of the instrument 1400. The engagement process includes rotating at least one of the drive disks 1320 via the motor 1340 until (one or more) drive disks 1320 engage the corresponding instrument disk 1474. (One or more) drive disks 1320 continue to rotate until (one or more) drive disks 1320 reach a stop condition.

[0088] The set of drive disks 1320 can include a rolling drive disk 1350. For example, Figure 5 and Figure 6 As shown, the system 1000 can include a rolling drive disk 1350, a rolling drive instrument disk 1476, four non-rolling drive disks, and four non-rolling instrument disks. The rolling drive disk 1350 is configured to be operably coupled to the rolling drive instrument disk 1476 to generate a rotation of the distal portion 1402 around the shaft axis A. L The non-rolling drive disks 1474 are each configured to be operably coupled to the corresponding drive disk 1320 so that the rotation of the non-rolling drive disk produces the end effector 1460 rotating around the beam coordinate system BCS (see Figure 6 ) axis (e.g., pitch, yaw, or clamp). In some embodiments, the engagement process includes maintaining roll drive disk 1350 at a first roll limit while rotating at least one non-roll drive disk in the set of drive disks 1320 to a neutral orientation (e.g., wrist 1500 is at a zero pitch angle and yaw angle). With the non-roll drive disk in the neutral orientation, the first command motion is performed by generating a roll motion RM of distal portion 1402 from the first roll limit, through the roll motion range, to the second roll limit. In some embodiments, performing the first command motion may include further rolling distal portion 1402 from the second roll limit to the neutral orientation.

[0089] In some embodiments, the instrument holder 1330 is configured to retain the distal portion 1402 of the instrument 1400 within the sleeve 1600 while moving the distal portion 1402 in the proximal direction and in the distal direction. Thus, in some embodiments, the engagement process includes moving the distal portion 1402 parallel to the shaft axis A within the sleeve 1600. L The distal portion 1402 is moved from the first longitudinal orientation LP1 In some embodiments, the distal portion 1402 is then returned to the first longitudinal position LP. 1 This longitudinal movement of the distal portion 1402 can facilitate measurement of the force exerted by the cannula seal (not shown) on the instrument shaft 1410. Under conditions where the force exerted by the cannula seal exceeds a predetermined threshold, an error signal can be generated.

[0090] Refer to Fig.11 In some embodiments, the controller 1800 is configured to determine, at 1738, a difference between the magnitude of the force sensor bias value 1716 and a defined maximum force sensor bias value 1740. The maximum force sensor bias value 1740 corresponds to a maximum cumulative bias magnitude that can be applied to the output of the force sensor unit 1850 without affecting the accuracy of the representation of the forces affecting the instrument 1400. Based on the difference, the controller 1800 determines, at 1742, whether the magnitude of the force sensor bias value 1716 exceeds the maximum force sensor bias value 1740. When the magnitude of the force sensor bias value 1716 exceeds the maximum force sensor bias value 1740, the controller 1800 generates, at 1744, an error signal to an operator of the system 1000. The error signal can, for example, include instructions to the operator to remove the instrument 1400 from the manipulator unit 1200 and reinstall the instrument 1400. Alternatively, the error signal can instruct the operator to remove the instrument 1400 from use. As a further alternative, in response to the error signal, the operator can at least partially disable the tactile feedback and perform an operation using the instrument 1400 .

[0091] refer to Fig.11 And also refer to Fig.12 In some embodiments, at 1704, initiating the first commanded motion includes establishing that the distal portion 1402 is in a first posture P 1 (eg, a first kinematic posture). For example, it is established that the distal portion 1402 is in a first posture P 1 The method can include positioning the distal portion 1402 in the first longitudinal orientation LP at a specified roll degree (e.g., 30 degrees, 40 degrees, 50 degrees, etc.) from a neutral roll orientation. 1 Establish the first posture P 1 The first commanded motion also includes moving the distal end portion 1402 from the first posture P 1 Transition to any additional pose P n and returning the distal end portion 1402 to the first posture P 1 ,like Fig.12At 1746, the controller 1800 determines that the distal portion 1402 is in the first posture P 1 The variability V of the first output signal 1706 between each case OS At 1748, the controller 1800 determines the variability V OS Whether the maximum variability value 1750 (eg, the maximum variability threshold) is exceeded. OS In the event that the maximum variability value 1750 is exceeded, the controller 1800 transmits an error signal at 1752 to an operator of the system 1000. In some embodiments, in the event that the variability V OS Upon exceeding the maximum variability value 1750 , at 1754 , the first commanded motion is repeated to generate an alternate first output signal 1756 , and a force sensor bias value 1716 is determined (as described herein) based at least in part on the alternate first output signal 1756 .

[0092] like Fig.11 As shown, in some embodiments, the controller 1800 is configured to determine a difference in the magnitude of the force sensor offset value 1716 relative to a historical force sensor offset value 1758. The historical force sensor offset value 1758 can include force sensor offset values ​​recorded during previous installations of the particular instrument 1400. The force sensor offset value 1716 used for the current instrument 1400 installation—which deviates significantly from the force sensor offset value that has been previously used for the particular instrument 1400—can indicate a failed or malfunctioning component of the instrument 1400, such as the force sensor unit 1850. Thus, under conditions where the difference exceeds a difference threshold, the controller 1800 transmits an error signal to an operator of the system 1000. In some embodiments, the error signal indicates a malfunction of the force sensor unit 1850.

[0093] In some embodiments, the historical force sensor bias value 1758 can be the effective force sensor bias value 1716 recorded during the installation of the particular instrument 1400 at the start of the current surgical procedure. In other words, since the instrument 1400 can be processed (e.g., sterilized) before each surgical procedure is started, the historical force sensor bias value 1758 can be the most recent effective force sensor bias value 1716 recorded after the instrument 1400 was last processed. Under conditions where the instrument 1400 has not been exposed to relatively high reprocessing heat during the current surgical procedure, in some embodiments, the effective force sensor bias value 1716 recorded during the installation of the particular instrument 1400 at the start of the current surgical procedure can be used to correct the output from the force sensor unit 1850. For example, during a single surgical procedure, the particular instrument 1400 can be installed and the effective force sensor bias value 1716 can be recorded during the first portion of the procedure. This effective force sensor bias value 1716 can be considered the historical force sensor bias value 1758. The instrument 1400 can then be disassembled from the manipulator unit 1200 while other portions of the procedure are performed. During a subsequent portion of the procedure, the instrument 1400 can be reinstalled and an invalid force sensor bias value can be calculated (e.g., the corrected output signal has a magnitude deviation from zero that falls outside of a tolerance range). When this occurs, the controller 1800 can generate a notification to an operator of the system 1000 and apply the historical force sensor bias value 1758 to the output from the force sensor unit 1850. Thus, the output from the force sensor unit 1850 is corrected by the historical force sensor bias value 1758 to provide an accurate indication of the load affecting the instrument 1400 under the loading condition. The controller 1800 then provides accurate tactile feedback to the operator of the system 1000 using the corrected indication of the load.

[0094] like Figure 6As shown, the apparatus 1400 includes a beam coordinate system BCS. The beam coordinate system BCS includes a first axis, a second axis, and a third axis that are orthogonal to each other. Thus, in some embodiments, the force sensor bias value 1716 is a first force sensor bias value parallel to the first axis. Therefore, this set of operations 1700 includes parsing the first output signal 1706 in the beam coordinate system BCS to determine the first axis component, the second axis component, and the third axis component of the first output signal 1706. The controller 1800 is then configured to determine a second force sensor bias value parallel to the second axis based on the difference between a portion of the second axis component and the baseline second axis component. The controller 1800 can also be configured to determine a third force sensor bias value parallel to the third axis component and the baseline third axis component. In other words, this set of operations 1700 can include determining a force sensor bias value 1716 in each orthogonal axis of the beam coordinate system BCS. Each of the first force sensor bias value, the second force sensor bias value, and the third force sensor bias value can have a magnitude different from at least one other force sensor bias value. For example, a first force sensor bias value can have a first magnitude, a second force sensor bias value can have a second magnitude, and a third force sensor bias value can have a third magnitude, each magnitude being different.

[0095] As previously described, the controller 1800 determines the force sensor bias value 1716 based on the difference between a portion of the first output signal 1706 and the baseline output signal 1712. In some embodiments, this portion of the first output signal 1706 is associated with the instrument 1400 (e.g., the distal portion 1402) in a specific sampling posture. In some embodiments, the specific sampling posture includes a specified roll orientation of the distal portion 1402. The specified roll orientation can correspond to a defined zero orientation (e.g., a neutral roll orientation). For example, in some embodiments, after the instrument 1400 is installed, each non-roll drive disk is rotated to a neutral orientation to place the wrist assembly 1500 and the end effector 1460 in a neutral orientation and aligned with the shaft axis A. L Alignment. In other words, the non-rolling drive disk is rotated so that the pitch angle is zero, the jaws are closed, and the yaw angle is zero. The distal portion 1402 is then rolled through at least a portion of the rolling motion range to achieve a defined zero orientation. The defined zero orientation can include an arc extending on either side of the zero degree point (e.g., 5 degrees or less). The arc on either side of the zero degree point can be 5 degrees or less (e.g., 2 degrees). The arc can be used for signal-to-noise ratio adjustment. In some embodiments, this portion of the first output signal 1706 can be received only when the distal portion 1402 is oriented at the zero degree point. In other embodiments, this portion of the first output signal 1706 can be associated with a specified time interval after installation or other suitable startup event of the instrument 1400.

[0096] like Fig.11 As shown at 1760 in FIG. 1 , in some embodiments, determining the force sensor bias value 1716 includes identifying a free space portion FSP of the first output signal 1706. In some embodiments, the free space portion FSP corresponds to a portion of the first output signal 1706 having a fitted line having a slope less than a defined slope threshold within a specified minimum time interval, such as Fig.12 In other words, Fig.12 As illustrated, the free space portion FSP can correspond to the flattest and / or most horizontal region of the first output signal 1706. The free space portion FSP can be identified (eg, selected or defined) via any suitable means, such as graphically, algorithmically, and / or manually.

[0097] The free space portion FSP of the first output signal 1706 corresponds to the free space state of the distal portion 1402 of the instrument 1400. Fig. 9 As shown, the free space state of the distal portion 1402 indicated by the free space portion FSP is the following state of the instrument 1400: in this state, the first command motion of the instrument 1400 (e.g., the distal portion 1402) is not subject to the other object OB (see, for example, Fig.10 ) contact. Thus, the free space portion FSP can correspond to a no-load state. Thus, at 1762, the controller 1800 can determine an average size of the free space portion FSP. At 1764, the controller 1800 determines a difference between the average size of the free space portion FSP of the first output signal 1706 of the force sensor 1850 and the baseline output signal 1712. In some embodiments, the force sensor offset value 1716 corresponds to the difference between the average size of the free space portion FSP of the first output signal 1706 and the baseline output signal 1712.

[0098] Still for reference Fig.11 In some embodiments, the controller 1800 - at 1766 - is configured to determine a confidence score for the free space portion FSP of the first output signal 1706. The confidence score indicates a correlation between the free space portion FSP and a state in which the first command motion of the instrument 1400 is not affected by contact with another object OB. For example, a free space portion FSP having a minimum deviation from a zero slope within a time interval exceeding a minimum time interval can be assigned a confidence score close to 1. A confidence score close to 1 indicates a relatively high likelihood that the first command motion is not affected by contact with another object OB. However, a free space portion FSP having a greater deviation from a zero slope can be assigned a lower confidence score, indicating a lower likelihood of a free space state.

[0099] In some embodiments, the controller 1800 - at 1768 - performs a command action based at least in part on the confidence score. For example, under the condition that the confidence score is less than the confidence score threshold, the command action can include repeating the first commanded movement of the distal portion 1402 within the cannula 1600 to generate an alternative first output signal. The controller 1800 can then identify an alternative free space portion FSP that replaces the first output signal and determine the force sensor bias value based at least in part on the alternative free space portion FSP. In additional embodiments, under the condition that the confidence score is less than the confidence score threshold, performing the command action can include transmitting an error signal to the user control unit 1100. In further embodiments, under the condition that the confidence score is less than the confidence score threshold, the command action can include generating a maintenance alarm indicating a failed or malfunctioning force sensor unit 1850.

[0100] In some embodiments, performing the command action can include applying a gain value to the tactile feedback provided to the input device 1116. The gain value can be determined based at least in part on the confidence score. For example, under conditions where the confidence score is close to 1, a nominal (e.g., designed) tactile feedback of the force affecting the device 1400 can be transmitted to the input device 1116. However, under conditions where the confidence score is less than 1, for the same force, a gain value can be applied to reduce the tactile feedback transmitted to the input device 1116.

[0101] Especially Fig.13 , a schematic diagram of one embodiment of suitable components that may be included in controller 1800 is shown. In some embodiments, controller 1800 is located within a component of surgical system 1000, such as user control unit 1100 and / or optional auxiliary device unit 1150. However, controller 1800 may also include a distributed computing system, wherein at least one aspect of controller 1800 is located at a different location from the rest of the components of surgical system 1000, for example, at least a portion of controller 1800 may be an online controller.

[0102] As shown, the controller 1800 includes one or more processors 1802 and an associated memory device 1804, which is configured to perform various computer-implemented functions (e.g., perform methods, steps, calculations, etc., and store related data as disclosed herein). Additionally, in some embodiments, the controller 1800 includes a communication module 1806 to facilitate communication between the controller 1800 and various components of the surgical system 1000.

[0103] As used herein, the term "processor" refers not only to what is known in the art as an integrated circuit included in a computer, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application specific integrated circuits, and other programmable circuits. In addition, (one or more) memory devices 1804 may also generally include (one or more) memory elements, including but not limited to computer-readable media (e.g., random access memory (RAM)), computer-readable non-volatile media (e.g., flash memory), floppy disks, compact disk read-only memories (CD ROMs), magneto-optical disks (MODs), digital versatile disks (DVDs), and / or other suitable memory elements. Such (one or more) memory devices 1804 may generally be configured to store suitable computer-readable instructions that, when executed by (one or more) processors 1802, configure the controller 1800 to perform various functions.

[0104] In some embodiments, the controller 1800 includes a tactile feedback module 1820. The tactile feedback module 1820 can be configured to deliver tactile feedback to the operator based on input received from the force sensor unit 1850 of the instrument 1400. In some embodiments, the tactile feedback module 1820 can be a separate module of the controller 1800. However, in some embodiments, the tactile feedback module 1820 can be included in the memory device(s) 1804.

[0105] The communication module 1806 may include a control input module 1808 configured to receive control inputs from an operator / surgeon S, such as via an input device 1116 of the user control unit 1100. The communication module may also include an indicator module 1812 configured to generate various indications to alert the operator.

[0106] The communication module 1806 may also include a sensor interface 1810 (e.g., one or more analog-to-digital converters) to allow signals transmitted from one or more sensors (e.g., strain sensors of the force sensor unit 1850) to be converted into signals that can be understood and processed by the processor 1802. The sensors can be communicatively coupled to the communication module 1806 using any suitable means. For example, the sensors can be coupled to the communication module 1806 via a wired connection and / or via a wireless connection, such as by using any suitable wireless communication protocol known in the art. Additionally, in some embodiments, the communication module 1806 includes a device control module 1814 that is configured to modify the operating state of the instrument 1400 (and / or any instrument described herein). Thus, the communication module is communicatively coupled to the manipulator unit 1200 and / or the instrument 1400. For example, the communication module 1806 can transmit to the manipulator unit 1200 and / or the instrument 1400 an excitation voltage for (one or more) strain sensors, a handshake and / or an excitation voltage for an orientation sensor (e.g., for detecting the orientation of a specified portion relative to a cannula), a burn control, an orientation set point, and / or an end effector operation set point (e.g., a clamping, cutting, and / or other similar operation performed by the end effector).

[0107] Fig.14 60 is a flow chart of a method 60 for controlling a surgical system according to one embodiment. In one embodiment, the method 60 may be performed via a remote operating system (such as reference Figure 1-Figure 13 The method 60 may be performed by the system 1000 described herein. However, it should be understood that in various embodiments, aspects of the method 60 may be performed via additional embodiments of the system 1000 or its components as described herein. Thus, the method 60 may be performed on any suitable device as described herein. Therefore, the method 60 is described below with reference to the instrument 1400 and controller 1800 of the system 1000 as previously described, but it should be understood that the method 60 can be used with any medical device / instrument and controller described herein.

[0108] As shown at 61, method 60 includes, via a controller, receiving a first output signal from a force sensor unit in response to a first commanded movement of a distal portion of a medical device within a cannula. As shown at 62, method 60 includes, via the controller, determining a force sensor bias value based on a difference between a portion of the first output signal and a baseline output signal of the force sensor unit. As shown at 63, method 60 includes, via the controller, receiving a second output signal from the force sensor unit in response to a second commanded movement. The second output signal is corrected by the force sensor bias value. As shown at 64, method 60 includes, via the controller, determining whether the force sensor bias value is valid based on a magnitude of a deviation between the second output signal and the baseline output signal. Under the condition that the magnitude of the deviation is within a predefined tolerance range, the force sensor bias value is valid. Under the condition that the force sensor bias value is valid, method 60 - as shown at 65 - includes, via a tactile feedback module of the controller, providing tactile feedback to a user control unit based on a load indication from the force sensor unit corrected by the force sensor bias value.

[0109] Although various embodiments have been described above, it should be understood that they are presented by way of example only and not limitation. Where the above methods and / or schematics indicate certain events and / or flow patterns occurring in a certain order, the ordering of certain events and / or operations may be modified. Although these embodiments have been specifically shown and described, it should be understood that various changes in form and detail may be made.

[0110] For example, any instrument described herein (and parts thereof) is optionally a part of a surgical assembly for performing minimally invasive surgery, and such surgical assembly may include a manipulator unit, a series of kinematic linkages, a set of sleeves or similar devices. Therefore, any instrument described herein can be used in any suitable surgical system (as shown and described above MIRS system 1000). In addition, any instrument shown and described herein can be used to manipulate target tissue in a surgical procedure. This target tissue can be cancer cells, tumor cells, lesions, vascular occlusions, thrombosis, stones, uterine fibroids, bone metastases, adenomyosis or any other body tissue. The examples of target tissues given are not exhaustive enumerations. In addition, the target structure can also include artificial substances (or non-tissues) associated with the body or with the body, such as, for example, a part of a stent, an artificial tube, a fastener or similar substances in the body.

[0111] For example, any part of the surgical instrument described herein can be constructed of any material, such as medical grade stainless steel, nickel alloy, titanium alloy or similar material. In addition, any of the connecting rods, tool members, beams, shafts, cables or other parts described herein can be constructed by multiple pieces connected together at a later stage. For example, in some embodiments, the connecting rod can be constructed by connecting independently constructed parts together. However, in other embodiments, any of the connecting rods, tool members, beams, shafts, cables or parts described herein can be constructed as a whole.

[0112] Although various embodiments have been described as having specific features and / or combinations of components, other embodiments are possible having any combination of features and / or components from any of the embodiments discussed above. Aspects have been described in the general context of medical devices, and more specifically surgical instruments, but aspects of the invention are not necessarily limited to use in medical devices.

Claims

1. A surgical system, include: a medical device comprising a distal portion, the medical device being supported by a manipulator unit; a force sensor unit coupled to the medical device; a user control unit operably coupled to the medical device and the manipulator unit; and a controller operably coupled to the manipulator unit, the user control unit, and the force sensor unit, the controller comprising at least one processor and a tactile feedback module, the controller being configured to perform a plurality of operations, the plurality of operations comprising: receiving a first output signal from the force sensor unit in response to a first commanded movement of the distal portion of the medical device within the cannula, determining a force sensor bias value based on a difference between a portion of the first output signal of the force sensor unit and a baseline output signal, receiving a second output signal from the force sensor unit in response to a second commanded motion, the second output signal being modified by the force sensor offset value, determining whether the force sensor bias value is valid based on a deviation between the second output signal and the baseline output signal, the force sensor bias value being valid under the condition that the deviation is within a predefined tolerance range, and Under the condition that the force sensor bias value is valid, tactile feedback is provided to the user control unit via the tactile feedback module based on the load indication from the force sensor unit corrected by the force sensor bias value.

2. The system according to claim 1, in: The multiple operations include: In the event that the force sensor bias value is invalid, an error signal is provided to an operator of the surgical system.

3. The system according to claim 1, in: The first commanded motion comprises a roll motion of the distal portion about the longitudinal axis from a first roll limit, through a neutral roll orientation, to a second roll limit, and back to the neutral roll orientation; and The controller is configured to maintain the distal portion of the medical device within the cannula throughout the rolling movement.

4. The system according to claim 1, in: The first commanded motion comprises linear motion of the distal portion parallel to the longitudinal shaft axis; and The controller is configured to maintain the distal portion of the medical device within the cannula throughout the linear movement.

5. The system according to any one of claims 1 to 4, in: The manipulator unit includes a plurality of motors and a plurality of drive discs; Each independent drive disk of the plurality of drive disks is coupled to a corresponding independent motor of the plurality of motors; The medical device includes a plurality of instrument discs configured to receive motion from the plurality of drive discs to move the distal portion; Each individual instrument disk of the plurality of instrument disks is configured to engage a corresponding individual drive disk of the plurality of drive disks; and The multiple operations include: detecting the mounting of the medical device on the manipulator unit, In response to detecting the installation, initiating an engagement process of the medical device, and At least one of the plurality of drive disks is rotated via the plurality of motors until the drive disk engages a corresponding instrument disk and the drive disk comes to a stop.

6. The system according to claim 5, in: The plurality of drive disks include a roll drive disk configured to generate a roll motion of the distal portion of the medical device about a longitudinal axis; and The multiple operations include: maintaining the roll drive plate at a first roll limit, rotating at least one non-rolling drive disk of the plurality of drive disks to a neutral orientation, and The first command motion is performed by generating the roll motion of the distal end portion through a roll motion range to a second roll limit.

7. The system according to claim 5, in: The distal portion of the medical device within the cannula is in a first longitudinal orientation; The manipulator is configured to move the distal portion of the medical device in a proximal direction and in a distal direction within the cannula; and The multiple operations include: moving the distal portion of the medical device parallel to the longitudinal axis to a second longitudinal orientation within the cannula, and Returning the distal portion of the medical device from the second longitudinal orientation to the first longitudinal orientation.

8. The system according to any one of claims 1 to 4, in: The multiple operations include: determining a difference between the magnitude of the force sensor offset value and a defined maximum force sensor offset value, and Under the condition that the magnitude of the force sensor offset value exceeds the maximum force sensor offset value, an error signal is provided to an operator of the surgical system.

9. The system according to claim 8, in: Providing the error signal comprises providing instructions to remove the medical device from the manipulator unit and to reinstall the medical device.

10. The system according to any one of claims 1 to 4, in: The first commanded motion includes establishing the distal portion of the medical device in a first posture, transitioning the distal portion away from the first posture, and returning the distal portion to the first posture; and The multiple operations include: determining a variability of the first output signal between each instance when the distal portion is in the first posture; and Under the condition that the variability exceeds a maximum variability value, an error signal is provided to an operator of the surgical system.

11. The system according to claim 10, in: The multiple operations include: Under the condition that the variability exceeds the maximum variability value, repeating the first commanded movement of the distal portion of the medical device within the cannula to generate an alternative first output signal, and determining the force sensor bias value based at least in part on the alternative first output signal.

12. The system according to any one of claims 1 to 4, in: The multiple operations include: determining a difference in magnitude of the force sensor bias value relative to historical force sensor bias values ​​associated with the medical device; and Under the condition that the difference exceeds a difference threshold, an error signal indicating a malfunction of the force sensor unit is transmitted to an operator of the surgical system.

13. The system according to any one of claims 1 to 4, in: The medical device includes a beam coordinate system having a first axis, a second axis, and a third axis that are orthogonal to each other; The force sensor bias value is a first force sensor bias value parallel to the first axis; and The multiple operations include: Resolving the first output signal in the beam coordinate system to determine a first axis component, a second axis component, and a third axis component of the first output signal, determining a second force sensor bias value parallel to the second axis based on a difference between a portion of the second axis component and a baseline second axis component, and A third force sensor bias value parallel to the third axis is determined based on a difference between a portion of the third axis component and a baseline third axis component.

14. The system according to any one of claims 1 to 4, in: The controller is configured to perform the plurality of operations upon receiving a human command.

15. The system according to any one of claims 1 to 4, in: The portion of the first output signal is associated with the medical device being in a specified sampling posture.

16. The system according to claim 15, in: The specified sampling pose includes a roll orientation of the distal portion of the medical device corresponding to a defined zero orientation.

17. The system according to any one of claims 1 to 4, in: determining the force sensor bias value includes identifying a free space portion of the first output signal corresponding to a free space state of the distal portion of the medical device; and The force sensor bias value corresponds to a difference between an average magnitude of the free space portion of the first output signal of the force sensor unit and the baseline output signal.

18. The system according to claim 17, in: The free space portion of the first output signal corresponds to a portion of the first output signal having a fitted line having a slope less than a defined slope threshold within a specified minimum time interval.

19. The system according to claim 17, in: The multiple operations include: determining a confidence score for the free space portion, and performing a command action based at least in part on the confidence score; and The confidence score indicates a correlation between the free space portion and a state of the medical device in which the first commanded motion of the medical device is not affected by contact with another object.

20. The system according to claim 19, in: Under the condition that the confidence score is less than the confidence score threshold, executing the command action includes: repeating the first commanded movement of the distal portion of the medical device within the cannula to generate a substitute first output signal, identifying a replacement free space portion of the replacement first output signal, and The force sensor bias value is determined based at least in part on the substitute free space portion of the substitute first output signal.

21. The system according to claim 19, in: Under the condition that the confidence score is less than a confidence score threshold, executing the command action includes providing an error signal to the user control unit.

22. The system according to claim 19, in: performing the command action includes applying a gain value to the tactile feedback provided to the user control unit; and The gain value is determined based at least in part on the confidence score.

23. The system according to claim 19, in: Under the condition that the confidence score is less than a confidence score threshold, performing the commanded action includes generating a maintenance alarm indicating a failed or malfunctioning force sensor unit.

24. The system according to any one of claims 1 to 4, wherein the plurality of operations include: providing an error signal to an operator of the surgical system under the condition that a difference between the second output signal and the baseline output signal falls outside of the tolerance range; as well as A command action is performed based at least in part on the error signal.

25. The system according to claim 24, in: Executing the command action includes providing instructions to detach the medical device from the manipulator unit and to reinstall the medical device.

26. The system according to claim 24, in: The execution of the command action includes: repeating the first commanded movement of the distal portion of the medical device within the cannula to generate a substitute first output signal, determining a substitute force sensor bias value based on a difference between a portion of the substitute first output signal of the force sensor unit and the baseline output signal, and The tactile feedback is provided to the user control unit based on the load indication from the force sensor unit modified by the substitute force sensor bias value.

27. The system according to claim 24, in: Executing the command action includes providing instructions to an operator of the surgical system to disassemble and disable the medical device due to a fault condition of the force sensor unit.

28. A method of controlling a surgical system, the surgical system comprising a manipulator unit, a controller, a user control unit and a medical instrument, the medical instrument being supported by the manipulator unit and operably coupled to be controlled by the user control unit via the controller, the medical instrument comprising a force sensor unit, the method include: receiving, via the controller, a first output signal from the force sensor unit in response to a first commanded movement of a distal portion of the medical device within a cannula; determining, via the controller, a force sensor bias value based on a difference between a portion of the first output signal of the force sensor unit and a baseline output signal; receiving, via the controller, a second output signal from the force sensor unit in response to a second commanded motion, the second output signal being modified by the force sensor offset value; Based on the deviation between the second output signal and the baseline output signal, determining via the controller whether the force sensor bias value is valid, the force sensor bias value being valid under the condition that the deviation is within a predefined tolerance range; as well as Under the condition that the force sensor bias value is valid, tactile feedback is provided to the user control unit via a tactile feedback module of the controller based on a load indication from the force sensor unit corrected by the force sensor bias value.

29. The method according to claim 28, in: The method comprises: In the event that the force sensor bias value is invalid, an error signal is provided to an operator of the surgical system via the controller.

30. The method according to claim 28, in: The first commanded motion comprises a roll motion of the distal end portion about the longitudinal axis from a first roll limit, through a neutral roll orientation, to a second roll limit, and back to the neutral roll orientation; and The controller maintains the distal portion of the medical device within the cannula throughout the rolling motion.

31. The method according to claim 28, in: The first commanded motion comprises linear motion of the distal portion parallel to the longitudinal shaft axis; and The controller maintains the distal portion of the medical device within the cannula throughout the linear movement.

32. The method according to any one of claims 28 to 31, in: The manipulator unit includes a plurality of motors and a plurality of drive discs; Each independent drive disk of the plurality of drive disks is coupled to a corresponding independent motor of the plurality of motors; The medical device includes a plurality of instrument discs configured to receive motion from the plurality of drive discs to move the distal portion; Each individual instrument disk of the plurality of instrument disks is configured to engage a corresponding individual drive disk of the plurality of drive disks; and The multiple operations include: detecting, via the controller, the mounting of the medical device on the manipulator unit, In response to detecting the installation, initiating, via the controller, an engagement process of the medical device, and rotating, via the controller, at least one of the plurality of drive disks via the plurality of motors until the drive disk engages the corresponding instrument disk and the drive disk reaches a stop state.

33. The method according to claim 32, in: The plurality of drive disks include a roll drive disk configured to generate a roll motion of the distal portion of the medical device about a longitudinal axis; and The method comprises: maintaining the roll drive plate at a first roll limit, rotating at least one non-rolling drive disk of the plurality of drive disks to a neutral orientation, and The first command motion is performed by generating the roll motion of the distal end portion through a roll motion range to a second roll limit.

34. The method according to claim 32, in: The distal portion of the medical device within the cannula is in a first longitudinal orientation; The manipulator is configured to move the distal portion of the medical device in a proximal direction and in a distal direction within the cannula; and The method comprises: moving the distal portion of the medical device parallel to the longitudinal axis to a second longitudinal orientation within the cannula, and Returning the distal portion of the medical device from the second longitudinal orientation to the first longitudinal orientation.

35. The method according to any one of claims 28 to 31, in: The method comprises: determining, via the controller, a difference between the magnitude of the force sensor offset value and a defined maximum force sensor offset value, and Under the condition that the magnitude of the force sensor offset value exceeds the maximum force sensor offset value, an error signal is provided to an operator of the surgical system via the controller.

36. The method according to claim 35, in: Transmitting the error signal includes transmitting instructions to detach the medical device from the manipulator unit and to reinstall the medical device.

37. The method according to any one of claims 28 to 31, in: The first commanded motion includes establishing the distal portion of the medical device in a first posture, transitioning the distal portion away from the first posture, and returning the distal portion to the first posture; and The method comprises: determining, via the controller, a variability of the first output signal between each instance when the distal portion is in the first posture; as well as Under the condition that the variability exceeds a maximum variability value, an error signal is provided to an operator of the surgical system via the controller.

38. The method according to claim 37, in: The method comprises: repeating the first commanded movement of the distal portion of the medical device within the cannula to generate a substitute first output signal under the condition that the variability exceeds the maximum variability value, and The force sensor bias value is determined via the controller based at least in part on the alternative first output signal.

39. The method according to any one of claims 28 to 31, in: The method comprises: determining, via the controller, a difference in magnitude of the force sensor bias value relative to historical force sensor bias values ​​associated with the medical device; and Under the condition that the difference exceeds a difference threshold, an error signal indicating a malfunction of the force sensor unit is transmitted to an operator of the surgical system via the controller.

40. The method according to any one of claims 28 to 31, in: The medical device includes a beam coordinate system having a first axis, a second axis, and a third axis that are orthogonal to each other; The force sensor bias value is a first force sensor bias value parallel to the first axis; and The method comprises: Resolving, via the controller, the first output signal in the beam coordinate system to determine a first axis component, a second axis component, and a third axis component of the first output signal, determining, via the controller, a second force sensor bias value parallel to the second axis based on a difference between a portion of the second axis component and a baseline second axis component, and A third force sensor bias value parallel to the third axis is determined via the controller based on a difference between a portion of the third axis component and a baseline third axis component.

41. The method according to any one of claims 28 to 31, in: The controller executes the method upon receiving a human command.

42. The method according to any one of claims 28 to 31, in: The portion of the first output signal is associated with the medical device being in a specified sampling posture.

43. The method according to claim 42, in: The specified sampling pose includes a roll orientation of the distal portion of the medical device corresponding to a defined zero orientation.

44. The method according to any one of claims 28 to 31, in: determining the force sensor bias value includes identifying a free space portion of the first output signal corresponding to a free space state of the distal portion of the medical device; and The force sensor bias value corresponds to a difference between an average magnitude of the free space portion of the first output signal of the force sensor unit and the baseline output signal.

45. The method according to claim 44, in: The free space portion of the first output signal corresponds to a portion of the first output signal having a fitted line having a slope less than a defined slope threshold within a specified minimum time interval.

46. ​​The method according to claim 44, in: The method comprises: determining, via the controller, a confidence score for the free space portion, and performing, via the controller, a command action based at least in part on the confidence score; and The confidence score indicates a correlation between the free space portion and a state of the medical device in which the first commanded motion of the medical device is not affected by contact with another object.

47. The method according to claim 46, in: Under the condition that the confidence score is less than the confidence score threshold, executing the command action includes: repeating the first commanded movement of the distal portion of the medical device within the cannula to generate a substitute first output signal, identifying a replacement free space portion of the first output signal, and The force sensor bias value is determined based at least in part on the substitute free space portion.

48. The method according to claim 46, in: Under the condition that the confidence score is less than a confidence score threshold, performing the command action includes providing an error signal to the user control unit via the controller.

49. The method according to claim 46, in: performing the command action comprises applying, via the controller, a gain value to the tactile feedback provided to the user control unit; and The gain value is determined based at least in part on the confidence score.

50. The method according to claim 46, in: Under the condition that the confidence score is less than a confidence score threshold, performing the commanded action includes generating, via the controller, a maintenance alarm indicating a failed or malfunctioning force sensor unit.

51. The method according to any one of claims 28 to 31, wherein the method include: providing an error signal to an operator of the surgical system via the controller under the condition that the difference between the second output signal and the baseline output signal falls outside of the tolerance range; as well as A command action is performed based at least in part on the error signal.

52. The method according to claim 51, in: Executing the command action includes providing instructions via the controller to detach the medical device from the manipulator unit and to reinstall the medical device.

53. The method according to claim 51, in: The execution of the command action includes: repeating the first commanded movement of the distal portion of the medical device within the cannula to generate a substitute first output signal, determining, via the controller, a substitute force sensor bias value based on a difference between a portion of the substitute first output signal of the force sensor unit and the baseline output signal, and The tactile feedback is provided to the user control unit via the controller based on the load indication from the force sensor unit modified by the substitute force sensor bias value.

54. The method according to claim 51, in: Executing the command action includes providing instructions to an operator of the surgical system via the controller to disassemble and disable the medical device due to a fault condition of the force sensor unit.

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