Autonomous tool exchange system for automated and semi-automated intraocular surgical procedures

Abstract

Devices, methods, and systems are provided for autonomous tool exchange systems for automated and semi-automated intraocular surgical procedures. According to various embodiments of the present invention, for example, there is a tool exchange system for an autonomous intraocular surgical robot. The system includes a removable, rotatable tool carousel configured to be releasably engaged with a rotating base, the tool carousel having a plurality of tool assembly docks each disposed about the tool carousel, each tool assembly dock adapted for kinematic coupling to a kinematic coupling of a surgical tool holder assembly, and each surgical tool holder assembly including an end effector kinematic coupling adapted and configured to couple with a corresponding kinematic coupling of a robot end effector while the surgical tool assembly is engaged with the tool assembly dock. Other embodiments are described herein.

Description

[Technical Field]

[0001] Priority claims

[0001] This application claims priority to U.S. Provisional Application No. 63 / 478,581, entitled "AUTONOMOUS TOOL EXCHANGE SYSTEM FOR AUTOMATED AND SEMI-AUTOMATED INTRAOCULAR SURGICAL PROCEDURES," filed January 5, 2023, the contents of which are incorporated herein by reference in their entirety. Incorporation by Reference

[0002] All publications and patent applications mentioned in this specification are herein incorporated by reference in their entirety to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

[0002]

[0003] The present invention relates to an automated tool changer, and more particularly to an automated tool changer for use in automated intraocular robotic surgery. [Background technology]

[0003]

[0004] Automated tool changes have been widely developed in manufacturing applications such as CNC machine tools and automated assembly lines. While some advances have been made in medical robotics, improvements are still needed, especially in surgical procedures where multiple tool changes are required, minimizing the time required for the tool change itself, as well as the process of coordination between two or more robotic end-effectors.

[0004]

[0005] During standard intraocular surgery, surgeons frequently switch between many surgical tools depending on the subtask being performed. This is typically accomplished by rapid handover between the surgeon and assistant in the operating room or by the surgeon reaching for tools on a tray prepared next to or above the patient's body. Reusing the same tool within a single surgical procedure is common, and the order in which tools are used throughout the procedure may vary from patient to patient and by type of surgical procedure.

[0005]

[0006] Many challenges remain to meet the requirements of robot-assisted, partially automated, or fully automated intraocular robotic surgery, including further advances in the speed and reliability of the tool exchange process, along with high-precision position control according to surgical steps, subsets, or the entire surgical workflow. Summary of the Invention [Means for solving the problem]

[0006]

[0007] According to various embodiments of the present invention, for example, there is a tool exchange system for an autonomous intraocular surgical robot, the system having a removable rotatable tool carousel configured to be releasably engaged with a rotating base, the tool carousel having a plurality of tool assembly docks each disposed about the tool carousel, each tool assembly dock adapted for kinematic coupling to a kinematic coupling of a surgical tool holder assembly, and each surgical tool holder assembly further including an end effector kinematic coupling adapted and configured to couple with a corresponding kinematic coupling of a robot end effector while the surgical tool assembly is engaged with the tool assembly dock.

[0007]

[0008] According to one example of this embodiment, the kinematic coupling of the surgical tool holder assembly adapted for coupling with the tool assembly dock is a bidirectional kinematic coupling configured to repeatedly extract and replace each of the surgical tool assemblies from the rotating tool carousel.

[0008]

[0009] According to one example of this embodiment, a first coupling orientation is used by the robotic end effector during removal or replacement of the surgical tool assembly, and a second coupling orientation is used by the rotating tool carousel to hold the surgical tool assembly.

[0009]

[0010] According to one example of this embodiment, the first and second coupling directions are oriented such that coordinated relative movement between the end effector and the rotatable tool carousel exchanges the surgical tool assembly from coupling with the tool assembly dock or from coupling with the robotic end effector.

[0010]

[0011] According to one example of this embodiment, the coordinated relative movement is biphasic, with the end effector first moving along a first articulated direction and then moving along a second, different articulated direction.

[0011]

[0012] According to one example of this embodiment, the kinematic coupling includes one or more of a mechanical slot and pin, or a magnet or magnetic coupling.

[0013] According to one example of this embodiment, the surgical tool assembly includes a memory chip configured to provide computer or machine readable, tool-specific information regarding the surgical tool or specific information of the surgical tool assembly coupled to the robotic end effector.

[0012]

[0014] According to one example of this embodiment, the memory chip uses wireless communication including radio frequency identification (RFID) or low power wireless or near field communication protocols, and the tool specific information includes tool identification, and the tool specific information includes manufacturing information such as calibration data and mechanical properties.

[0013]

[0015] According to one example of this embodiment, the rotating tool carousel includes alignment and mounting hardware for releasable coupling and detachment to a fixed portion of a tool changer of a tool changing system.

[0014]

[0016] According to one example of this embodiment, the fixed part is a fixed cylindrical body of the tool changer.

[0017] According to another embodiment of the present invention, there is an autonomous tool exchange system for managing the exchange of tool assemblies, for example, the system includes a tool carousel having a plurality of surgical tool assemblies, a controller configured to relay information regarding a requested surgical tool assembly from the plurality of surgical tool assemblies loaded on the tool carousel, and an actuation system configured to rotate the tool carousel to present the requested tool assembly from the plurality of tool assemblies in position for access by a robotic end effector.

[0015]

[0018] According to one example of this embodiment, the actuation system is in a fixed part of the tool carousel.

[0019] According to another embodiment of the present invention, for example, there is a method for tool exchange that includes verifying a surgical tool assembly via contactless communication between an end effector of a surgical robot and a memory of the surgical tool assembly, and removing or replacing the surgical tool assembly from a tool carousel via a bidirectional kinematic coupling.

[0016]

[0020] According to one example of this method, the step of removing or replacing the surgical tool assembly is performed by an end effector of a surgical robot.

[0021] According to one example of this embodiment, the step of removing or replacing the surgical tool assembly is performed manually.

[0017]

[0022] According to another embodiment of the present invention, for example, there is a method for tool exchange, the method including the steps of requesting a tool assembly for a robot end effector, moving an empty robot end effector to a tool exchange position adjacent a rotatable tool carousel, rotating the rotatable tool carousel to place the requested tool assembly in the tool exchange position adjacent the empty robot end effector, moving the empty robot end effector according to an engagement motion to couple the requested tool assembly with the robot end effector, moving the robot end effector according to a disengagement motion to discouple the requested tool assembly from the rotatable tool carousel, and performing steps of a surgical procedure by manipulating the robot end effector and manipulating the tool assembly. performing a surgical procedure; moving the robot end effector to a tool change position adjacent to the rotatable tool carousel in accordance with the steps of performing the surgical procedure; rotating the rotatable tool carousel to position an empty tool assembly dock at the tool change position; moving the robot end effector according to an engagement movement to couple a requested tool assembly with the rotatable tool carousel at the empty tool assembly dock; moving the robot end effector according to a disengagement movement to decouple the tool assembly from the robot end effector; and moving the robot end effector according to a disengagement movement to decouple the tool assembly from the robot end effector. [Brief explanation of the drawings]

[0018] [Figure 1A]

[0023] 1 is a cross-sectional view of a rotary tool carousel having eight tool assembly docks 1-8 to which eight surgical tool holder assemblies are coupled. The robot end effector is shown empty and in an exchange position relative to the rotary tool carousel. [Figure 1B]

[0024] 1B is a cross-sectional view of the rotating tool carousel of FIG. 1A illustrating rotation of the rotating tool carousel to position the requested surgical tool holder assembly adjacent to the exchange location and the robot end effector. FIG. [Figure 1C]

[0025] FIG. 1C is a cross-sectional view of the rotating tool carousel of FIG. 1B, showing the end effector moving through the exchange space and moving to interrogate or couple with the surgical tool holder assembly. [Figure 1D]

[0026] 1D is a cross-sectional view of the rotatable tool carousel of FIG. 1C after the end effector has made a movement to uncouple the surgical tool holder assembly from a tool assembly dock on the rotatable tool carousel. [Figure 2]

[0027] FIG. 1 is a perspective view of a removable rotating tool carousel. [Figure 3]

[0028] FIG. 3 is a cross-sectional view of the removable rotatable tool carousel of FIG. 2. [Figure 4]

[0029] 4A is a side view of a removable tool carousel showing the magnetic coupling location of the tool assembly dock. Adjacent to the tool assembly dock is a surgical tool holder assembly. Also visible in this view are kinematic features of the surgical tool holder assembly adapted to couple with the end effector. Also visible in this view are kinematic features adapted to couple with the tool assembly dock.

[0030] FIG. 4B is a view of the top connection plate along the top surface of the tool assembly housing that covers the tool assembly components shown in FIG. 4A. [Figure 5A]

[0031] FIG. 10 is a side view of a robotic end effector moving across an exchange zone adjacent to an engagement plate of a surgical tool holder assembly. [Figure 5B]

[0032] FIG. 5B is a side view of the end effector and surgical tool holder assembly of FIG. 5A, with the end effector contacting the tool assembly engagement plate. [Figure 5C]

[0033] FIG. 5C is a side view of the end effector and surgical tool holder assembly of FIG. 5B illustrating movement of the end effector to couple with the surgical tool holder assembly. [Figure 5D]

[0034] FIG. 5D is a side view of the end effector-tool assembly of FIG. 5C completing the movement to decouple the surgical tool holder assembly from the tool assembly dock of the rotating tool carousel. [Figure 6]

[0035] 10 is an exemplary method for verifying a surgical tool holder assembly selected for coupling with a tool carousel. [Figure 7]

[0036] 1 illustrates an exemplary method of coupling a selected surgical tool holder assembly with a robotic end effector. DETAILED DESCRIPTION OF THE INVENTION

[0019]

[0037] The embodiments of the automated tool changer described herein have a variety of capabilities intended to meet the requirements of robot-assisted, partially automated, or fully automated intraocular robotic surgery. As described in detail below, the automated tool changer provides the speed and reliability necessary for complex tool exchange process sequences, including precise position control according to surgical steps, subsets, or the entire surgical workflow. The automated tool changer can quickly hand over various surgical tools to the surgical robot as needed. Additionally, the automated tool changer can receive used tools and track the location of all tools during the surgical procedure. Furthermore, the reliability and precision of the tool exchange procedure ensures that the held surgical tool is always in its intended position.

[0020]

[0038] As a result, embodiments of the automatic tool changer meet the requirements of automated tool exchange for automated intraocular robotic surgery with an electromechanical system and control framework for managing the exchange of surgical tools.

[0021]

[0039] For example, there is a tool exchange system for an autonomous intraocular surgical robot that includes a robot end effector and a removable, rotating tool carousel (tool changer) configured to hold a plurality of tool assemblies, the plurality of surgical tool assemblies including a plurality of surgical tools, and a mechanical interface on at least one of the plurality of surgical tool assemblies configured to provide kinematic calibration between the end effector of the surgical robot and the plurality of surgical tools.

[0022]

[0040] According to certain embodiments, each of the plurality of surgical tool assemblies has a bidirectional kinematic coupling configured to repeatedly extract and replace each of the plurality of tool assemblies from the rotary tool carousel.

[0023]

[0041] According to certain embodiments, a first coupling orientation is used by the end effector during removal or replacement of the multiple surgical tool assemblies, and a second coupling orientation is used to hold the multiple surgical tool assemblies by the rotatable tool carousel.

[0024]

[0042] According to certain embodiments, the first and second coupling directions are oriented such that coordinated relative movement between the end effector and the rotatable tool carousel successfully exchanges multiple surgical tool assemblies.

[0025]

[0043] According to certain embodiments, this coordinated relative movement is biphasic, with the end effector first moving along a first articulated direction and then moving along a second articulated direction.

[0026]

[0044] According to certain embodiments, the kinematic coupling includes one or more of a mechanical slot and pin and a magnetic coupling.

[0045] According to certain embodiments, each of the plurality of surgical tool assemblies includes a memory chip configured to provide tool-specific information regarding one or more of the plurality of surgical tools held by the end effector.

[0027]

[0046] According to a specific embodiment, the memory chip uses wireless communication, including radio frequency identification (RFID), and the tool specific information includes tool identification, manufacturing information such as calibration data and mechanical properties.

[0028]

[0047] According to certain embodiments, the rotating tool carousel includes alignment and mounting hardware for releasable coupling and detachment to a fixed portion of a tool changer of a tool changing system.

[0029]

[0048] According to a particular embodiment, the fixed part is a fixed cylindrical body of the tool changer.

[0049] According to another embodiment of the present invention, there is an autonomous tool exchange system for managing the exchange of tool assemblies, the system including a robotic end effector, a tool carousel having a plurality of tool assemblies, a controller configured to relay information regarding a requested tool assembly of the plurality of tool assemblies, and an actuation system configured to rotate the tool carousel to present the requested tool assembly of the plurality of tool assemblies to the end effector.

[0030]

[0050] According to a particular embodiment, the actuation system is in a fixed part of the tool carousel (tool changer).

[0051] Each of the major elements of the automated tool changer will now be described in turn.

[0031] Rotating Tool Carousel (Figures 2 and 3)

[0052] FIG. 2 is a perspective view of a removable rotatable tool carousel 200 coupled to a fixed base portion 201B. The rotatable tool carousel 200 is a mechanical assembly that holds several tool subassemblies 202 configured to hold surgical tools 204. Each tool subassembly 202 can be removed from and reattached to the carousel 200 during the course of a surgical procedure, such as via a carousel mounting bracket 206, which may include a coupler. According to certain embodiments, the rotatable tool carousel 200 can be positioned on or outside the barrel, rotating table, or other socket of a surgical robot. Also shown are the carousel actuation system 201B, tool assembly dock 201A, and tool assembly interface 202A to the robot end effector (see FIGS. 4A-4B). Also shown are the fixed portion base 201B, electronics mounting plate 201E, carrying handle 201D, and carousel side plate 201C.

[0032]

[0053] Figure 3 is a cross-sectional view 300 of the removable rotatable tool carousel 200 of Figure 2. The carousel 200 itself can be loaded into place before a surgical procedure and unloaded afterward. In the operating room workflow, sterile nurses can load and unload the tool changer as needed according to clinical needs and the surgical plan. A collection of new tool holders is coupled to the tool carousel. Tool assemblies 302 are manually loaded while the carousel 200 is attached to the cart, or tool assemblies 302 are attached to the carousel 200 before the carousel 200 is attached to the cart. Advantageously, a particular tool carousel may be pre-loaded with surgical tools preferred by a particular surgeon or required to perform a particular procedure. Additionally or optionally, surgical tool holder assemblies can be loaded onto the carousel to increase the efficiency of the rotation / exchange operation (see Figures 1A-1D). According to certain embodiments, the carousel actuation system 301B may be pre-loaded with surgical tools and configured so that the identities and proper orientations of the surgical tools are recognized and / or indexed by the surgical robot and ready to use for a particular surgical procedure. According to yet other embodiments, there is a fixed portion 310 of the tool changer to which the rotatable carousel 200 may be attached via a carousel mounting bracket 306 that also couples the carousel 200 to the carousel actuation system 310B. According to other embodiments, the carousel actuation system 301B may couple to the surgical robot and the rotatable tool carousel 300 via a carousel alignment bracket 307 and a carousel mounting bracket 306, such as a coupler. In such embodiments, information regarding the loaded surgical tools and other data may be transmitted to the surgical robot pursuant to such coupling. Actuator 301G, brake / encoder 301F, carousel bottom plate 301G, carousel side plate 301H, fixed portion base 301B, mounting bracket handle 306A, and carousel rotation shaft 308 are also shown.

[0033]

[0054] The fixed part of the tool changer 310 is rigidly mounted to the robot frame, e.g., the robot end effector. The tool assemblies 302 are attached to the carousel 300 via a kinematic linkage. The carousel 300, with all tool assemblies 302 attached, slides on the fixed part 310 and aligns with the carousel rotation shaft 308 through a carousel alignment fixture 307, which radially constrains the rotating tool carousel 300. When the robot needs to grasp a tool, the rotation shaft 308, and therefore the entire carousel 300, rotates to orient the tool assemblies 302 in the correct position. The robot end effector 102 (from FIGS. 1A-1D) then picks up or drops off the selected tool 204. During this process, the robot end effector 102 interacts only with the tool assemblies 302 and does not directly interact with the carousel 300.

[0034]

[0055] The cylindrical shape of the tool carousel ensures that all tool assemblies 302 are mounted at a fixed distance from the axis of rotation. Because each of the tool assembly docks has a similar form factor, each surgical tool holder assembly 302 is mounted in a similar location on the tool assembly dock, regardless of the surgical tool holder assembly's function. This standardization of the tool assembly docks and the fixed rotational indexing provided by the carousel's rotational movement allow each surgical tool holder assembly 302 to be moved to a consistent, known configuration relative to the surgical end effector. These aspects of the rotary tool carousel improve the reliability and accuracy of the tool change system. Advantageously, the rotary carousel is precisely driven by only one motor. Repeatable positioning of the tool subassemblies 302 allows for repeatable, predefined end effector movement during tool changes.

[0035]

[0056] In view of the above, various embodiments of an improved tool exchange system for an autonomous intraocular surgical robot are provided, including a removable rotary tool carousel 200 that holds multiple tool assemblies 202. Each individual tool assembly includes a mechanical interface that provides a repeatable kinematic interface between the surgical robot end effector and a respective surgical tool holder assembly disposed on the rotary tool carousel. Furthermore, each surgical tool holder assembly carries a surgical tool. Each surgical tool holder assembly has a bidirectional kinematic coupling 400A, thereby allowing the surgical tool holder assembly to be repeatedly withdrawn from and returned to a position on the rotary tool carousel. A common set of motions is also provided between the robot end effector, a selected surgical tool holder assembly, and the rotary tool carousel. A first coupling orientation is used during removal or replacement of the surgical tool holder assembly by the robot end effector. A second coupling orientation is used by the rotary tool carousel to hold the surgical tool holder assembly. In use, the coupling direction is oriented such that coordinated relative motion between the surgical end effector and the rotatable tool carousel successfully exchanges the surgical tool holder assembly (a) from coupled with the rotatable tool carousel's dock assembly to coupled with the robotic end effector, and (b) from coupled with the robotic end effector to coupled with the rotatable tool carousel's dock assembly. This coordinated relative motion is biphasic, with the end effector first moving along a first coupling direction, followed by movement along a second coupling direction. In one embodiment, the kinematic coupling includes mechanical slots and pins 406 alone or in combination with a kinematic coupling implementation including a specifically aligned magnetic coupling 404A.

[0036]

[0057] In yet another alternative embodiment, each surgical tool holder assembly includes a memory chip. The memory chip may include computer-readable code containing tool-specific information about the surgical tool 204 held therein. In one aspect, the memory chip may use wireless communication, such as RFID, low-power wireless communication, or other near-field communication (NFC) protocols, depending on the procedure and capabilities of the operating room. In another aspect, the tool-specific information includes tool identification, usage information, and unique characteristics, as well as user-specific preferences from previous use or intended use in surgical planning, such as designation of a particular instrument. Additionally or optionally, the tool-specific information may include manufacturing information, such as calibration data and mechanical properties.

[0037]

[0058] In yet another embodiment, the rotatable tool carousel 300 includes alignment fittings 307 and mounting fittings 306. The use of alignment fittings 307 and mounting fittings 306 includes highly accurate and reliable installation and removal of the tool carousel 300 from a fixed portion of the tool changer 310. Thus, there is a fixed cylindrical body of the tool changer 310 to which the rotatable tool carousel 300 is removably mounted using alignment fittings 307 and mounting fittings 306.

[0038]

[0059] In one embodiment, there is an autonomous system that manages the exchange of tool assemblies between an end effector and a rotating tool carousel. The autonomous exchange system includes a controller that relays information regarding a requested surgical tool holder assembly and an actuation system that rotates the tool carousel to present the requested surgical tool holder assembly to the end effector. In one aspect, the actuation system is in a fixed portion of the tool changer. Methods are also provided for exchange procedures in which the surgical tool holder assembly is verified by contactless communication between the surgical end effector and a memory of the surgical tool holder assembly. Additionally, some exchange procedures use a bidirectional kinematic coupling to remove and replace the surgical tool holder assembly from and onto the tool carousel. In one aspect, the exchange procedure is performed autonomously by the surgical robot end effector. Additionally or optionally, the exchange procedure may be performed manually.

[0039] Bidirectional Kinematic Linkage (Figures 4A-4B and 5A-5D)

[0060] According to various embodiments, there are various cases where kinematic coupling can occur, including (1) kinematic coupling: end effector (coupling between end effector and tool holder assembly), and (2) kinematic coupling: rotating tool carousel (coupling between rotating tool carousel and surgical tool assembly). Both kinematic couplings can occur using mechanical holes / slots and pins, as well as magnetic couplings.

[0040] Kinematic linkage: end effector.

[0061] The surgical tool assembly can be coupled to a rotatable tool carousel via magnets, and its orientation is constrained using pins on the carousel and holes in the surgical tool assembly.

[0041] Kinematic linkage: Rotating tool carousel.

[0062] When the surgical robot picks up a tool, it aligns and engages slots on the surgical robot with a second set of pins on the surgical tool assembly, and the magnets on both assemblies align with each other. The robot then disengages the tool holder assembly from the set of pins and magnets on the carousel and removes the surgical tool assembly from the carousel. To replace the tool, the procedure is reversed.

[0042]

[0063] 4A is a side view of a removable tool carousel 400 showing the magnetic coupling location of the tool assembly dock. Adjacent to the tool assembly dock is shown a surgical tool holder assembly 402. Also visible in this view are end effectors 402A (not shown) and kinematic features of the surgical tool holder assembly 402 adapted to couple with the rotatable tool carousel 400A. Also visible in this view are kinematic features adapted to couple with the tool assembly dock.

[0043]

[0064] Tool subassembly 402 includes two sets of mounting hardware for kinematic linkage 400A / 402A. Figure 4B is a view of the top link plate along the top surface of tool assembly housing 450, which covers the components of tool assembly 402 shown in Figure 4A.

[0044]

[0065] 4B, in certain embodiments, a first set of mounting hardware may include alignment cutouts 404B and are used to kinematically couple or attach the tool subassembly to the rotatable tool carousel 400A. In certain embodiments, a second set of mounting hardware may include pins and slots 406 and are used by a surgical robot end effector (not shown) to remove and replace the tool subassembly 402 via the kinematic coupling between the tool subassembly and the robot end effector 402A.

[0045]

[0066] Figure 4B is a view of the top link plate along the top surface of the tool assembly housing, which covers the tool assembly components shown in Figure 4A. The top link plate includes three alignment cutouts 404B and three magnets 404A. One alignment cutout 404B is located in the center portion of the left side of the assembly. The other two alignment cutouts 404B are located in the right front corner and the right left corner. One magnet 404A is located in the center portion of the right side. Two magnets 404A are located in the left front corner and the left rear corner.

[0046]

[0067] According to a specific example, the tool holder housing has a bottom coupling plate (not shown) with a configuration similar to that described above. A pair of pins 406 are located along the sides of the base adjacent the front and rear corners. Additionally, a magnet 404M is located in the center portion of each of the left and right sides. In one exemplary embodiment, the pins 406 can slide vertically into appropriately sized cutouts located in the end effector plate to kinematically constrain movement via the kinematic coupling 402A. It should be appreciated that the interface between the tool holder assembly housing and the end effector plate incorporates multiple differently sized and positioned clearances and chamfers to facilitate easy alignment. Additionally, one or a series of magnets 404M / 404A can be installed on the holder housing and plate to provide unique coupling configurations as well as repeatable and highly accurate alignment of the holder relative to the plate. In one exemplary coupling operation, magnets 404M / 404A are positioned to push / pull tool holder assembly 402 to one side of the end effector plate, pulling tool holder assembly 402 to the back of the plate, where pin 406 described above is secured in a cutout in the plate.

[0047]

[0068] Considering the top and bottom linkage plates together, it should be understood that the upper surface of the surgical tool holder includes a series of magnets 404A, pins / extrusions 406, and / or cutouts / holes 404B that correspond to corresponding ones on various surfaces of an appropriately configured tool changer or rotary tool carousel 400. When placed near the tool changer 402, the magnets 404A act to pull the tool holder toward the changer 402 and insert dowel pins 406 into the dowel holes in each section. Advantageously, these pins / holes 406 and the upper linkage plate linkage movements 402A are positioned to kinematically prevent the movements achieved by the lower linkage plate linkage action used to connect / disconnect the robot end effector (at the plate) with the tool holder (at the holder housing). Thus, embodiments of the surgical tool assembly can use one set of linkage movements for the upper linkage plate and a different, compatible set of linkage movements for the lower linkage plate. In this manner, various surgical tool holder assembly embodiments provide the surgeon with a wide variety of different tools and functions, all with a common set of coupling exchanges unique to each tool changer 402 and robot end effector.

[0048]

[0069] Additionally, or optionally, depending on the number and configuration of surgical tool holder assemblies for a given robotic surgical procedure, the bidirectional kinematic linkage features of the tool assemblies may be adapted for a top-to-bottom linkage (as shown in FIGS. 5A-5D ) or a left-to-right or “side linkage” as shown and further described in FIGS. 1A, 1B, and 2 of U.S. Provisional Patent Application No. 63 / 478,770, entitled “SURGICAL TOOL HOLDER FOR INTRAOCULAR ROBOTIC SURGICAL SYSTEMS,” filed January 6, 2023, and Patent Cooperation Treaty Application No. PCT / US2024 / XXXXX (Attorney Docket No. 14843-701.600), entitled “SURGICAL TOOL HOLDER FOR INTRAOCULAR ROBOTIC SURGICAL SYSTEMS,” filed January 5, 2024. Each of these applications is incorporated herein by reference in its entirety.

[0049]

[0070] The two fitting sets are designed so that only coordinated movement by the surgical robot end effector / carousel actuation system 501B can successfully exchange the tool subassembly 502 between the carousel 500 and the end effector / carousel actuation system 501B. This coordinated movement is summarized in Figures 5A-5D.

[0050]

[0071] 5A is a side view of a robot end effector / carousel actuation system 501B moving across an exchange zone adjacent to an engagement plate of a surgical tool holder assembly 502 on a removable rotatable tool carousel 500, with pins and slots 506 in the robot end effector / carousel actuation system 501B and the surgical tool holder assembly 502 aligning. In some embodiments, the robot end effector / carousel actuation system 501B may be directly above the surgical tool holder assembly 502.

[0051]

[0072] 5B is a side view of the end effector / carousel actuation system 501B and surgical tool holder assembly 502 of FIG. 5A, with the end effector / carousel actuation system 501B contacting the tool assembly engagement plate. In some examples, the end effector / carousel actuation system 501B moves downward (510) and contacts the surgical tool assembly 502.

[0052]

[0073] 5C is a side view of the end effector / carousel actuation system 501B and surgical tool holder assembly 502 of FIG. 5B illustrating movement of the end effector / carousel actuation system to couple 512 with the surgical tool holder assembly 502. In some embodiments, the end effector / carousel actuation system 501B slides 512 forward on the surgical tool holder assembly 502, causing engagement between pins and slots 506 on the end effector / carousel actuation system 501B and the surgical tool holder assembly 502.

[0053]

[0074] 5D is a side view of the end effector / carousel actuation system 501B-tool assembly 502 of FIG. 5C completing the movement to decouple (514) the surgical tool holder assembly 502 from the tool assembly dock of the rotatable tool carousel 500. In some embodiments, decoupling (514) is achieved by disengagement of pins and slots 506 in the end effector / carousel actuation system 501B and the surgical tool holder assembly 502.

[0054]

[0075] Figures 5A and 5B together illustrate this coordinated movement, in which the surgical end effector / carousel actuation system 501B moves in a direction that aligns with the second set of mounting hardware on the surgical tool holder assembly 502, while the first set of mounting hardware connecting the surgical tool holder assembly 502 to the tool assembly dock remains fixed. This results in a secure retention of the surgical tool holder assembly 502 by both the surgical end effector / carousel actuation system 501B and the rotatable tool carousel 500, as shown in Figure 5C. Figure 5D illustrates a second step of coordinated movement, in which the surgical end effector / carousel actuation system 501B moves in a direction that aligns with the first set of mounting hardware. This second step releases the surgical tool holder assembly 502 from the tool assembly dock of the rotatable tool carousel 500 (514). The surgical end effector / carousel actuation system 508 is now free to return to the surgical site and position the coupled surgical tool holder assembly 502 according to the step of the surgical procedure to use the selected surgical tool.

[0055]

[0076] The transfer of the surgical tool holder assembly 502 onto the rotating tool carousel 500 by the surgical end effector / carousel actuation system 501B uses the same movements as those described in Figures 5A-5D, but in reverse order. Starting in Figure 5D, the end effector / carousel actuation system 501B is positioned over an empty tool assembly dock designated by the control system to receive the surgical tool holder assembly 502 currently coupled to the end effector / carousel actuation system 501B. The end effector / carousel actuation system 501B is then moved toward the tool assembly dock, causing the surgical tool holder assembly 502 to become coupled to the tool assembly dock while remaining coupled to the end effector / carousel actuation system 501B (Figure 5C). The movement of the end effector / carousel actuation system 501B is reversed from that shown in FIG. 5C to first disengage the pin and slot 506, and then, once cleared as in FIG. 5B, the end effector / carousel actuation system 501B can be moved away from the surgical tool holder assembly 502 as in FIG. 5A.

[0056] Methods for Automated Exchange (Figures 1, 5, 6, and 7A-7B)

[0077] A rotatable tool carousel 104 (from FIG. 1) is positioned near the surgical site, within the accessible workspace of a surgical end effector 102. Unlike many conventional tool exchange systems coupled to the end effector 102, an embodiment of the rotatable tool carousel 104 of the present invention is not fixed to the surgical end effector 102, but rather is positioned adjacent to the surgical field. FIG. 1A is a cross-sectional view of the rotatable tool carousel 102 with eight surgical assemblies 105 (docks 1-8) arranged around the periphery of the rotatable tool carousel 104, each coupled to one of eight surgical tool holder assemblies a-h (and 202 (see FIG. 2)) containing the required tool assembly c / 106. An empty robotic end effector 102 is shown in an exchange position relative to the rotatable tool carousel 104, in preparation for a tool holder assembly exchange (102E) at the top of the rotatable tool carousel 104. When the surgical system requests a new tool c / 106, an empty end effector 102 is positioned adjacent to the exchange zone of the rotary tool carousel 104, as shown in Figure 1A. However, the requested surgical tool holder assembly 106 of the empty end effector 102 is not in the proper position for exchange.

[0057]

[0078] FIG. 1B is a cross-sectional view of the rotating tool carousel 104 of FIG. 1A, illustrating the rotation (108) of the rotating tool carousel 104 to position the requested surgical tool holder assembly c / 106 adjacent to the exchange location and the robot end effector 102.

[0058]

[0079] As a result of the rotational movement of the tool carousel, the requested surgical tool holder assembly c / 106 is in a known configuration relative to the surgical robot end effector 102 in the exchange zone. As previously described, the surgical robot end effector 102 is commanded to move to a position adjacent the exchange zone and above the surgical tool holder assembly 106 in preparation for tool holder assembly exchange 102E.

[0059]

[0080] FIG. 1C is a cross-sectional view of the rotating tool carousel 104 of FIG. 1B, with the end effector 102 moving through the exchange space to interrogate or couple (109) with the surgical tool holder assembly c / 106.

[0060]

[0081] The surgical end effector 102 then moves to engage the bidirectional kinematic coupling described in the bidirectional kinematic coupling subsection above and performs the coordinated movement described in Figures 5A-5D to remove the surgical tool holder assembly c / 106 from the rotary tool carousel 104.

[0061]

[0082] 1D is a cross-sectional view of the rotary tool carousel 104 of FIG. 1C after the end effector 102 has performed a movement to decouple (110) the surgical tool holder assembly c / 106 from a tool assembly dock (e.g., tool assembly dock 3) on the rotary tool carousel 104. Thus, the surgical tool assembly is coupled to the end effector 102, leaving an empty tool assembly dock 3 / 105.

[0062]

[0083] After contacting the surgical tool holder assembly 106, the system electronically exchanges information between the surgical end effector 102 and the surgical tool holder assembly 106. Each surgical tool holder assembly 106 is calibrated at the factory to correct for inaccuracies during manufacturing and assembly. This calibration information, along with the identity of the tool held, is stored on the surgical tool holder assembly 106's wireless tag. With this information available, each tool 204 (from FIG. 2) used during a procedure can be specially adapted for the specific performance characteristics of a given surgical tool holder assembly 106.

[0063]

[0084] FIG. 6 is an exemplary method 600 for validating a surgical tool holder assembly selected for coupling with a tool carousel.

[0085] First, at step 605, there is a process of verifying the surgical tool assembly via contactless communication between the end effector of the surgical robot and the memory of the surgical tool assembly.

[0064]

[0086] Next, at step 610, there is a process of removing or replacing the surgical tool assembly from the tool carousel via the bidirectional kinematic coupling.

[0087] According to one example of method 600, removal or replacement of the surgical tool assembly is performed by an end effector of a surgical robot.

[0065]

[0088] According to one example of method 600, removal or replacement of the surgical tool assembly is performed manually.

[0089] FIG. 7 illustrates an exemplary method 700 for coupling a selected surgical tool holder assembly with a robotic end effector.

[0066]

[0090] First, in step 705, there is the step of requesting a surgical tool holder assembly for the robotic end effector as part of an intraocular surgical procedure using the robotic end effector.

[0067]

[0091] Next, in step 710, there is a process of moving the empty robot end effector to a tool change position adjacent to the rotating tool carousel.

[0092] Next, at step 715, there is a process of rotating the rotatable tool carousel to place the requested surgical tool holder assembly in a tool change position adjacent the empty robot end effector.

[0068]

[0093] Next, at step 720, there is a process of moving the empty robot end effector according to the engagement motion to couple the requested surgical tool holder assembly with the robot end effector.

[0069]

[0094] Next, at step 725, there is a process of moving the robot end effector through a disengagement motion to decouple the requested surgical tool holder assembly from the rotary tool carousel.

[0070]

[0095] Next, at step 730, there is a process of manipulating the robotic end effector and manipulating the surgical tool holder assembly to perform the steps of the surgical procedure.

[0096] Next, at step 735, there is a process performed to move the robot end effector to a tool exchange position adjacent the rotating tool carousel in accordance with performing the steps of the surgical procedure.

[0071]

[0097] Next, at step 740, there is a process of rotating the rotating tool carousel to place the empty tool assembly dock in the tool change position.

[0098] Next, at step 745, there is a process of moving the robot end effector according to an engagement motion to couple the requested surgical tool holder assembly with the rotatable tool carousel at the empty tool assembly dock.

[0072]

[0099] Next, at step 750, there is a process of moving the robot end effector through a disengagement motion to decouple the surgical tool holder assembly from the robot end effector.

[0073]

[0100] Next, in step 755 there is a process of placing the empty robot end effector in a tool change position adjacent to the rotating tool carousel.

[0101] It should be understood that the example process 700 outlined above and in FIG. 7 may be modified depending on the particular implementation or to facilitate the use of multiple rotating tool carousels or robotic end effectors.

[0074]

[0102] In certain embodiments, the tool carousel is adapted and configured for all surgical tool assemblies that use a top-bottom linkage as shown and described in Figures 5A-5D and Figure 1B of the incorporated "SURGICAL TOOL HOLDER FOR INTRAOCULAR ROBOTIC SURGICAL SYSTEMS" application, and thus employs bidirectional kinematics. In yet another variation, depending on the type of surgical tool and robot interoperability, the tool carousel may have a mixture of both top-bottom and side-side kinematics.

[0075]

[0103] As used herein, when a feature or element is referred to as being "on" another feature or element, it can be directly on the other feature or element, or there may be intervening features and / or elements. In contrast, when a feature or element is referred to as being "directly on" another feature or element, there are no intervening features or elements. Also, when a feature or element is referred to as "connected," "attached," or "coupled" to another feature or element, it will be understood that it can be directly connected, attached, or coupled to the other feature or element, or there may be intervening features or elements. In contrast, when a feature or element is referred to as "directly connected," "directly attached," or "directly coupled" to another feature or element, there are no intervening features or elements. Although described or illustrated with respect to one embodiment, features and elements so described or illustrated can be applied to other embodiments. Also, it will be understood by those skilled in the art that references to structures or features disposed "adjacent" to another feature may include overlapping or underlying portions of the adjacent feature.

[0076]

[0104] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting of the invention. For example, as used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. Furthermore, it will be understood that the terms "comprise" and / or "comprising," as used herein, specify the presence of stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items and may be abbreviated as " / ."

[0077]

[0105] For ease of description, spatially relative terms such as "below," "below," "lower," "above," and "above" may be used herein to describe the relationship of one element or feature to another element or feature shown in the figures. It will be understood that spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures were inverted, an element described as "below" or "below" another element or feature would be oriented "above" the other element or feature. Thus, the exemplary term "below" can encompass both an "above" and "below" orientation. A device may be oriented in other ways (rotated 90 degrees or to other orientations), and the spatially relative descriptors used herein will be interpreted accordingly. Similarly, terms such as "upper," "lower," "vertical," "horizontal," and the like are used herein for descriptive purposes only, unless otherwise noted.

[0078]

[0106] In this specification, the terms "first" and "second" may be used to describe various features / elements (including steps), but these features / elements should not be limited by these terms unless the context dictates otherwise. These terms may be used to distinguish one feature / element from another. Thus, a first feature / element described below could be referred to as a second feature / element, and similarly, a second feature / element described below could be referred to as a first feature / element, without departing from the teachings of the present invention.

[0079]

[0107] Throughout this specification and the claims that follow, unless the context requires otherwise, the word "comprise," and variations such as "comprises" and "comprising," mean that various components can be used together in methods and articles (e.g., compositions and apparatuses that include devices and methods). For example, the term "comprising" will be understood to mean the inclusion of any specified element or step, but not the exclusion of any other element or step.

[0080]

[0108] In general, any apparatus and methods described herein should be understood to be inclusive, although all or a subset of the components and / or steps may alternatively be exclusive and may be expressed as "consisting of," or alternatively, "consisting essentially of," various components, steps, subcomponents, or substeps.

[0081]

[0109] As used in this specification and claims (including in the examples and unless expressly specified otherwise), all numbers may be read as if preceded by the word "about" or "approximately," even if that term does not explicitly appear. The phrase "about" or "approximately," when describing a size and / or location, may be used to indicate that the described value and / or location is within a reasonable expected range of value and / or location. For example, a numerical value may have a value that is + / - 0.1% of the stated value (or range of values), + / - 1% of the stated value (or range of values), + / - 2% of the stated value (or range of values), + / - 5% of the stated value (or range of values), + / - 10% of the stated value (or range of values), etc. Additionally, any numerical value provided herein should be understood to include about or approximately that value, unless the context dictates otherwise. For example, if the value "10" is disclosed, "about 10" is also disclosed. Any numerical ranges referred to herein are intended to include all subranges contained therein. It is also understood that when a value is disclosed, "less than or equal to" that value, "greater than or equal to" that value, and possible ranges between values ​​are also disclosed, as would be appropriately understood by one of ordinary skill in the art. For example, if a value "X" is disclosed, "less than or equal to X" and "greater than or equal to X" (e.g., X is a numeric value) are also disclosed. It is also understood that throughout the application, data is provided in several different formats, and this data represents endpoints and starting points, and may range between any combination of data points. For example, when a specific data point "10" and a specific data point "15" are disclosed, it is understood that not only values ​​between 10 and 15, but also values ​​greater than, greater than, less than, less than, and equal to 10 and 15, and values ​​greater than, equal to, and equal to 10 and 15 are disclosed. It is also understood that each unit between two specified units is disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0082]

[0110] While various exemplary embodiments have been described above, any of several modifications may be made to the various embodiments without departing from the scope of the claimed invention. For example, the order in which the various described method steps are performed may often be changed in alternative embodiments, and one or more method steps may be omitted entirely in other alternative embodiments. Optional features of the various device and system embodiments may be included in some embodiments and not in other embodiments. Therefore, the above description has been provided primarily for illustrative purposes and should not be construed as limiting the scope of the claimed invention.

[0083]

[0111] The examples and illustrations contained herein indicate, by way of illustration, not limitation, specific embodiments in which the subject matter may be practiced. As noted above, other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of the present disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively under the term "invention" merely for convenience, and without any intention to intentionally limit the scope of the present application to a single invention or inventive concept when multiple inventions or inventive concepts are actually disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiment shown. The disclosure is intended to cover any and all adaptations or variations of the various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those skilled in the art upon reviewing the above description.

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