Tool driver axial displacement detection

Abstract

A tool driver for a robotic system may include a sensor that allows the surgical robotic system to determine whether a tool or sterilization adapter is fully coupled to the tool driver. The tool driver may include a rotational output that can manipulate the tool and translate perpendicularly to the surface of the tool driver body. The tool driver may include a drive mechanism for rotating the rotational output.

Description

Technical Field

[0001] The systems and methods disclosed herein relate to robotic systems, and more particularly, to displacement sensing of robotic systems.

Background Art

[0002] Minimally invasive procedures enable access to target sites within a patient with minimal trauma to the patient. A medical robotic system can provide a mechanism for performing surgery using one or more robotic arms. For example, laparoscopic surgery can enable surgical access to a patient's cavity through a small incision in the patient's abdomen.

[0003] The robotic arm of a robotic system can be coupled to one or more tools, such as a cannula or other device used to perform surgery on a patient. Each robotic arm can include an instrument or tool driver for engaging with a respective surgical tool. In some applications, a surgical tool and / or a sterilization adapter can be attached to or otherwise coupled to a tool driver by sliding or positioning the tool or adapter along the surface of the tool driver to engage it.

[0004] A tool driver can include one or more rotational outputs for operating or otherwise actuating a surgical tool. The rotational output may be keyed to a mating input of a sterilization adapter or tool to enable torque transmission.

[0005] The rotary output of the tool driver can be retracted axially to allow the tool or sterilization adapter to slide along the surface of the tool driver to which it is coupled. The rotary output can be extended axially to engage with the mating input of the tool or sterilization adapter when properly engaged with the tool driver. In some applications, the rotary output can be rotated to align the keyed portion of the rotary output with the corresponding rotary input to enable operation after the sterilization adapter and tool have been mounted to the tool driver. [Overview of the project] [Means for solving the problem]

[0006] Some predicate systems may operate by assuming that, after a predetermined number of rotations of the rotational output, the rotational output aligns with the rotational input of the sterilization adapter in the direction of rotation and fully engages with it. Furthermore, certain predicate systems may first lock or otherwise prevent the rotation of the rotational input of the sterilization adapter, and then detect an increase in motor current when the rotational output engages with the locked rotational input of the sterilization adapter. Similarly, certain predicate systems may detect an increase in motor current when the rotational output engages with the rotational input of the attached tool.

[0007] According to some embodiments disclosed herein, as the robotic systems developed by the applicant continue to evolve and provide previously unavailable functions, significant and unexpected changes to the structure and architecture of the robotic systems have been discovered, which have been found to provide remarkably important and advantageous results in facilitating the effective and simple operation of the robotic systems. Furthermore, according to some embodiments disclosed herein, there is a recognition that faster and more accurate confirmation of engagement between the tool driver and the sterilization adapter and / or surgical tool is desired. Accordingly, this disclosure addresses these and other challenges.

[0008] For example, the unique architecture of the embodiment of the robotic system developed by the applicant enables the robotic system to determine more quickly and accurately whether the sterilization adapter and / or surgical tool is properly attached to the tool driver. As a result, the robotic system can prevent operation until the sterilization adapter and surgical tool are properly attached. Furthermore, the robotic system can verify the engagement of each individual rotational output of the tool driver or identify any malfunction.

[0009] Accordingly, embodiments disclosed herein provide a tool driver incorporating a sensor for determining the axial position of the rotational output of the tool driver. In addition to determining the axial position of the rotational output, the tool driver sensor may be used to quickly determine whether the rotational output, and by extension the tool driver, is properly engaged with the sterile adapter and surgical tool.

[0010] Advantageously, some embodiments of the sensor devices disclosed herein can enable a robotic system and / or a user to determine whether a sterilization adapter or tool is properly mounted to a tool driver. Furthermore, the robotic system can verify the engagement of each individual rotational output of the tool driver or identify any malfunction thereof. Such sensor devices can provide solutions to the above-mentioned problems, and such systems are not disclosed or implemented in the Predicate Systems, given that the applicant had not implemented or otherwise considered any unique improvements to the new technology up to the discovery and development of the embodiments of the sensor devices described herein.

[0011] According to some embodiments, the tool driver includes a motor coupled to a rotary output. The rotary output may include a disc extending from the body of the tool driver and engaging with the input of a surgical tool. The disc may define a keyed portion.

[0012] In some embodiments, the tool driver includes a biasing member for biasing the rotational output to engage with a sterilization adapter and / or surgical tool.

[0013] In some embodiments, the sensor may be implemented as an inductive sensor and / or an optical sensor. An embodiment of the sensor implemented as an inductive sensor may include an iron component coupled to a rotational output and a conductive coil for providing a signal corresponding to the movement of the iron component and thus the rotational output. An embodiment of the sensor implemented as an optical sensor may include a rotational output having a reflective surface that provides a signal to the optical sensor.

[0014] In some embodiments, the tool driver may include a translatable peg for separating the sterilization adapter from the tool driver.

[0015] In some embodiments, the tool driver includes multiple rotation outputs. [Brief explanation of the drawing]

[0016] The disclosed embodiments will be described below in conjunction with the attached drawings, and the disclosed embodiments will be illustrative but not limited to them, and the same reference numerals will indicate the same elements. [Figure 1] An embodiment of a cart-based robotic system deployed for diagnostic and / or therapeutic bronchoscopy procedures is illustrated. [Figure 2] Further aspects of the robot system shown in Figure 1 are depicted. [Figure 3] An example of the robotic system shown in Figure 1, which is positioned for ureteroscopy, will be illustrated. [Figure 4] An example of the robotic system shown in Figure 1, configured for vascular procedures, is illustrated. [Figure 5] An embodiment of a table-based robotic system positioned for bronchoscopy procedures is illustrated. [Figure 6] An alternative diagram of the robot system shown in Figure 5 is provided. [Figure 7]An example of a system configured to accommodate a robotic arm is illustrated. [Figure 8] An embodiment of a table-based robotic system configured for ureteroscopy procedures is illustrated. [Figure 9] An embodiment of a table-based robotic system configured for laparoscopic procedures is illustrated. [Figure 10] An embodiment of the table-based robotic system of FIGS. 5-9 having pitch or tilt adjustment is shown. [Figure 11] A detailed illustration of the interface between the table and column of the table-based robotic system of FIGS. 5-10 is provided. [Figure 12] An alternative embodiment of a table-based robotic system is illustrated. [Figure 13] FIG. 12 is an end view of a table-based robotic system. [Figure 14] An end view of a table-based robotic system with a robotic arm attached is illustrated. [Figure 15] An exemplary instrument driver is illustrated. [Figure 16] An exemplary medical instrument having a pair of instrument drivers is illustrated. [Figure 17] An alternative design of an instrument driver and instrument is illustrated where the axis of the drive unit is parallel to the axis of the elongated shaft of the instrument. [Figure 18] An instrument having an instrument base insertion architecture is illustrated. [Figure 19] An exemplary controller is illustrated. [Figure 20] A block diagram illustrating a location identification system for estimating the location of one or more elements of the robotic system of FIGS. 1-10, such as the location of the instrument of FIGS. 16-18, according to an exemplary embodiment is illustrated. [Figure 21] According to some embodiments, a part of a medical robotic system including a tool driver is illustrated. [Figure 22]Figure 21 illustrates the disassembled and assembled diagrams of the tool driver, sterilization adapter, and instrument. [Figure 23] Figure 21 illustrates the disassembled and assembled diagram of the tool driver and sterilization adapter. [Figure 24] Figure 21 illustrates the cross-sectional view of the instrument and sterilization adapter. [Figure 25] Figure 21 illustrates the cross-sectional view of the tool driver and sterilization assembly. [Figure 26] This chart shows the axial displacement of the rotational output of the tool driver as a function of the inductance value of the tool driver sensor, according to several embodiments. [Figure 27] The rotation output of a tool driver having an optical sensor is illustrated in several embodiments. [Figure 28] This chart shows the axial displacement of the tool driver's rotation output relative to the sensor readout of the optical sensor in Figure 27, according to several embodiments. [Modes for carrying out the invention]

[0017] 1. Overview Aspects of this disclosure may be integrated into a robot-enabled medical system capable of performing a variety of medical procedures, including both minimally invasive procedures such as laparoscopy and non-invasive procedures such as endoscopy. This system can perform endoscopic procedures such as bronchoscopy, ureteroscopy, and gastroscopy.

[0018] In addition to performing a wide range of procedures, the system can offer additional benefits such as enhanced imaging and guidance to assist physicians. Furthermore, the system can provide physicians with the ability to perform procedures from an ergonomic position without requiring awkward arm movements and positions. Moreover, the system can provide physicians with improved ease of use, allowing one or more of the system's instruments to be controlled by a single user.

[0019] Various embodiments are described below, accompanied by drawings, for illustrative purposes. While many other implementations of the concepts of this disclosure are conceivable, it should be understood that various advantages may be achieved by the implementations of this disclosure. This specification includes headings for reference and to help locate the various sections. These headings are not intended to limit the scope of the concepts described therein. Such concepts may be applied throughout this specification.

[0020] A. Robot System - Cart Robot-enabled medical systems can be configured in various ways depending on the specific procedure. Figure 1 illustrates one embodiment of a cart-based robot-enabled system 10 positioned for a diagnostic and / or therapeutic bronchoscopy procedure. During a bronchoscopy, the system 10 may include a cart 11 with one or more robotic arms 12 for delivering medical instruments, such as a maneuverable endoscope 13 which may be a procedure-specific bronchoscope for bronchoscopy, to a natural opening access point (i.e., the patient's mouth positioned on a table in this example) for delivering diagnostic and / or therapeutic tools. As shown, the cart 11 may be positioned close to the patient's upper torso to provide access to the access point. Similarly, the robotic arms 12 may be actuated to position the bronchoscope relative to the access point. The configuration of Figure 1 can also be used when performing gastrointestinal (GI) procedures using a gastroscopy, which is an endoscope specifically designed for GI procedures. Figure 2 shows an example of a cart embodiment in more detail.

[0021] Continuing to refer to Figure 1, once the cart 11 is properly positioned, the robotic arm 12 can insert the maneuverable endoscope 13 into the patient robotically, manually, or a combination thereof. As shown, the maneuverable endoscope 13 may include at least two nesting parts, such as an inner leader portion and an outer sheath portion, each portion coupled to a separate instrument driver from a set of instrument drivers 28, each instrument driver coupled to the distal end of an individual robotic arm. This linear arrangement of the instrument drivers 28, which facilitates the coaxial alignment of the leader portion with the sheath portion, creates a “virtual rail” 29 that can be repositioned in space by manipulating one or more robotic arms 12 at different angles and / or positions. The virtual rail described herein is shown in the figure using dashed lines, and therefore the dashed lines do not indicate any physical structure of the system. Translation of the instrument drivers 28 along the virtual rail 29 causes the inner leader portion to nest with the outer sheath portion, or to advance or retract the endoscope 13 from the patient. The angle of the virtual rail 29 can be adjusted, translated, or pivoted based on clinical use or physician preference. For example, in bronchoscopy, the angle and position of the illustrated virtual rail 29 represent a compromise between providing physician access to the endoscope 13 and minimizing friction resulting from bending the endoscope 13 into the patient's mouth.

[0022] The endoscope 13 can be directed downstream of the patient's trachea and lungs after insertion using precise commands from the robotic system until it reaches the target destination or surgical site. To enhance navigation through the patient's lung network and / or reach the desired target, the endoscope 13 can be manipulated to extend a portion of the inner leader in a nested manner from a portion of the outer sheath, thereby enhancing articulation and increasing the bending radius. The use of a separate instrument driver 28 also makes it possible for the portion of the leader and the portion of the sheath to be driven independently of each other.

[0023] For example, the endoscope 13 may be directed to deliver a biopsy needle to a target such as a lesion or nodule in the patient's lung. The needle may be positioned downstream of the working channel along the length of the endoscope to obtain a tissue sample to be analyzed by a pathologist. Depending on the pathological results, additional tools may be positioned downstream of the working channel of the endoscope for additional biopsies. After identifying the nodule as malignant, the endoscope 13 can deliver tools endoscopically to excise the potentially cancerous tissue. In some cases, diagnostic and therapeutic procedures may be delivered in separate procedures. In these situations, the endoscope 13 may also be used to deliver a reference to "mark" the location of the target nodule. In other cases, diagnostic and therapeutic procedures may be delivered during the same procedure.

[0024] System 10 may also include a movable tower 30 connected to the cart 11 via support cables, which can provide support for control, electronics, fluid elements, optics, sensors, and / or power to the cart 11. Placing such functions in the tower 30 can reduce the form factor of the cart 11 and make it easier for the surgeon and their staff to adjust and / or reposition the cart 11. Furthermore, the functional separation between the cart / table and the support tower 30 reduces clutter in the operating room and facilitates improvements in the clinical workflow. The cart 11 may be positioned close to the patient, while the tower 30 may be housed in a more distant location so as not to interfere during the procedure.

[0025] To support the robotic system described above, the tower 30 may include components of a computer-based control system that store computer program instructions in a non-temporary computer-readable storage medium, such as a persistent magnetic memory drive or a solid-state drive. The execution of these instructions can control the entire system or its subsystems, whether the execution takes place within the tower 30 or within the cart 11. For example, when executed by the processor of the computer system, the instructions may cause components of the robotic system to actuate associated carriages and arm mounts, actuate a robotic arm, and control medical devices. For example, in response to receiving a control signal, a motor in the joint of the robotic arm may position the arm in a particular posture.

[0026] The tower 30 may also include a pump, flow meter, valve control, and / or fluid access to provide controlled irrigation and suction functions to a system that can be deployed through the endoscope 13. These components may also be controlled using the computer system of the tower 30. In some embodiments, irrigation and suction capabilities may be brought directly to the endoscope 13 via separate cables.

[0027] The tower 30 may include voltage and surge protectors designed to provide filtered and protected power to the cart 11, thereby avoiding the need to place power transformers and other auxiliary power components within the cart 11, making the cart 11 smaller and more portable.

[0028] Tower 30 may also include support equipment for sensors deployed throughout the robotic system 10. For example, Tower 30 may include optoelectronic equipment for detecting, receiving, and processing data received from optical sensors or cameras throughout the robotic system 10. In combination with a control system, such optoelectronic equipment can be used to generate real-time images for display on any number of consoles deployed throughout the system, including within Tower 30. Similarly, Tower 30 may also include electronic subsystems for receiving and processing signals from deployed electromagnetic (EM) sensors. Tower 30 may also be used to house and position EM field generators for detection by EM sensors within or on medical devices.

[0029] Tower 30 may also include console 31, in addition to other consoles available in the rest of the system, such as a console mounted on top of a cart. Console 31 may include a user interface and a display screen, such as a touch screen, for the operator physician. The consoles of system 10 are typically designed to provide both robotic control and pre-operative and real-time information of the procedure, such as navigation and positioning information for the endoscope 13. If console 31 is not the only console available to the physician, a second operator, such as a nurse, may use console 31 to monitor the patient's health or life and the operation of the system, as well as to provide procedure-specific data such as navigation and positioning information. In other embodiments, console 30 is housed in a separate body from tower 30.

[0030] The tower 30 can be coupled to the cart 11 and the endoscope 13 via one or more cables or connectors (not shown). In some embodiments, support functions from the tower 30 may be provided to the cart 11 through only one cable, simplifying and organizing the operating room. In other embodiments, specific functions may be coupled through separate wiring and connectors. For example, power may be supplied to the cart through only one power cable, while support for control, optics, fluid elements, and / or navigation may be provided through separate cables.

[0031] Figure 2 provides a detailed diagram of one embodiment of a cart from the cart-based robot-enabled system shown in Figure 1. The cart 11 typically includes an elongated support structure 14 (often referred to as the “column”), a cart base 15, and a console 16 located at the top of the column 14. The column 14 may include one or more carriages, such as carriages 17 (alternatively “arm supports”), for supporting the deployment of one or more robot arms 12 (three are shown in Figure 2). The carriages 17 may include individually configurable arm mounts that rotate along orthogonal axes to adjust the base of the robot arms 12 for better positioning relative to the patient. The carriages 17 also include a carriage interface 19 that allows the carriages 17 to translate vertically along the column 14.

[0032] The carriage interface 19 is connected to the column 14 through slots such as slots 20 positioned on both sides of the column 14 to guide the vertical translation of the carriage 17. The slots 20 contain vertical translation interfaces for positioning and holding the carriage at various vertical heights relative to the cart base 15. The vertical translation of the carriage 17 allows the cart 11 to adjust the reach of the robotic arm 12 to meet various table heights, patient sizes, and physician preferences. Similarly, individually configurable arm mounts on the carriage 17 allow the robotic arm base 21 of the robotic arm 12 to be angled in various configurations.

[0033] In some embodiments, a slot cover may be added to the slot 20, which is coplanar and parallel to the slot surface, to prevent dirt and fluid from entering the internal chamber of the column 14 and the vertical translation interface as the carriage 17 translates vertically. The slot cover may be deployed through a pair of spring spools positioned near the vertical top and bottom of the slot 20. The cover is coiled within the spools until it unfolds to extend and retract from a coiled state as the carriage 17 translates vertically up and down. The spring mechanism of the spools provides a force to retract the cover into the spool when the carriage 17 translates toward the spools, while also maintaining a seal when the carriage 17 translates toward the spools. The cover may be attached to the carriage 17, for example, using a bracket located at the carriage interface 19, to ensure that the cover extends and retracts appropriately as the carriage 17 translates.

[0034] Column 14 may contain internal mechanisms such as gears and motors, designed to use vertically aligned main screws to mechanically translate the carriage 17 in response to control signals generated in response to user input, such as input from a console 16.

[0035] The robotic arm 12 may generally include a robotic arm base 21 and an end effector 22 separated by a series of linkage mechanisms 23 connected by a series of joints 24, each joint including an independent actuator, and each actuator including an independently controllable motor. Each separately controllable joint represents an independent degree of freedom that the robotic arm can use. Each arm 12 has seven joints, resulting in seven degrees of freedom. The numerous joints result in numerous degrees of freedom, enabling "redundant" degrees of freedom. Redundant degrees of freedom allow the robotic arm 12 to position its respective end effector 22 in space at a specific position, orientation, and trajectory using different linkage mechanism positions and joint angles. This allows the system to position and orient medical instruments from a desired point in space, while also allowing a physician to move the arm joints to clinically advantageous positions away from the patient to provide greater access while avoiding arm collisions.

[0036] The cart base 15 balances the weight of the column 14, carriage 17, and arm 12 on the floor. Therefore, the cart base 15 houses heavier components, such as electronics, motors, power supplies, and other components that enable the cart to move and / or be fixed in place. For example, the cart base 15 includes casters 25 with rotatable wheels, allowing the cart to be easily moved around the room before treatment. Once in a suitable position, the casters 25 may be immobilized using wheel locks to hold the cart 11 in place during treatment.

[0037] Positioned at the vertical end of column 14, the console 16 provides both a user interface and a display screen (or a dual-purpose device such as a touch screen 26) for receiving user input, providing the physician user with both preoperative and intraoperative data. Potential preoperative data on the touch screen 26 may include preoperative planning, navigation and mapping data derived from preoperative computed tomography (CT) scans, and / or notes from preoperative patient interviews. Intraoperative data on the display may include essential patient statistics such as respiration, heart rate, and / or pulse, along with optical information provided from tools, sensor information and coordinate information from sensors. The console 16 can be positioned and tilted so that the physician can access the console from the column 14 side opposite the carriage 17. From this position, the physician can see the console 16, the robotic arm 12, and the patient while operating the console 16 from behind the cart 11. As shown in the figure, the console 16 also includes a handle 27 to help operate and stabilize the cart 11.

[0038] Figure 3 shows one embodiment of a robot-enabled system 10 configured for ureteroscopy. In a ureteroscopy procedure, the cart 11 may be positioned to deliver a ureteroscope 32, a procedure-specific endoscope designed to follow the patient's urethra and ureters, to the patient's lower abdominal region. In ureteroscopy, it may be desirable for the ureteroscope 32 to be directly aligned with the patient's urethra to reduce friction and force on sensitive anatomical structures in its range. As shown, the cart 11 may be positioned at the legs of a table to allow a robotic arm 12 to position the ureteroscope 32 for direct linear access to the patient's urethra. From the legs of the table, the robotic arm 12 may insert the ureteroscope 32 along a virtual rail 33 directly into the patient's lower abdomen through the urethra.

[0039] After being inserted into the urethra using control techniques similar to those used in bronchoscopy, the ureteroscope 32 can be navigated to the bladder, ureters, and / or kidneys for diagnostic and / or therapeutic purposes. For example, the ureteroscope 32 can be directed to the ureters and kidneys, and a laser lithotripsy or ultrasonic lithotripsy device deployed downstream of the working channel of the ureteroscope 32 can be used to break up formed kidney stones. After lithotripsy is complete, the resulting stone fragments can be removed using a basket deployed downstream of the ureteroscope 32.

[0040] Figure 4 shows one embodiment of a robot-enabled system similarly positioned for vascular procedures. In a vascular procedure, the system 10 may be configured such that a cart 11 can deliver a medical instrument 34, such as a maneuverable catheter, to an access point in the femoral artery in the patient's leg. The femoral artery presents both a larger diameter for navigation and a winding path with relatively little detour to the patient's heart, thereby facilitating navigation. As seen in a ureteroscopy procedure, the cart 11 may be positioned toward the patient's leg and lower abdomen so that a robotic arm 12 can provide a virtual rail 35 with direct linear access to the femoral artery access point in the patient's thigh / lumbar region. After insertion into the artery, the medical instrument 34 can be directed and inserted by translating the instrument driver 28. Alternatively, the cart may be positioned around the patient's upper abdomen to reach alternative vascular access points, such as the carotid and brachial arteries near the shoulder and wrist.

[0041] B. Robot System - Table Embodiments of robot-enabled medical systems may also incorporate a patient table. Incorporating a table reduces the amount of capital equipment in the operating room by removing the cart and allows for better access to the patient. Figure 5 illustrates one embodiment of such a robot-enabled system configured for a bronchoscopy procedure. System 36 includes a support structure or column 37 for supporting a platform 38 (illustrated as “table” or “bed”) across the entire floor. Similar to a cart-based system, the end effector of the robotic arm 39 of system 36 includes an instrument driver 42 designed to manipulate elongated medical instruments, such as a bronchoscope 40 in Figure 5, through or along a virtual rail 41 formed from the linear alignment of the instrument driver 42. In practice, the C-arm for obtaining fluoroscopic imaging may be positioned across the entire upper abdominal region of the patient by placing the emitter and detector around the table 38.

[0042] Figure 6 provides an alternative diagram of the system 36 without a patient and medical equipment for consideration purposes. As shown, the column 37 may include one or more carriages 43, shown as a ring shape in the system 36, which may serve as the base for one or more robotic arms 39. The carriages 43 may translate along a vertical column interface 44 extending the length of the column 37, providing different viewpoints from which the robotic arms 39 can be positioned to reach the patient. The carriages 43 may rotate around the column 37 using a mechanical motor positioned within the column 37, allowing the robotic arms 39 to have access to multiple sides of a table 38, such as both sides of the patient. In embodiments with multiple carriages, the carriages may be positioned separately on the column and may translate and / or rotate independently of other carriages. The carriages 43 do not need to surround the column 37, nor do they even need to be circular, but the illustrated ring shape facilitates the rotation of the carriages 43 around the column 37 while maintaining structural balance. The rotation and translation of the carriage 43 allows the system to position medical instruments such as endoscopes and laparoscopes at different access points on the patient. In other embodiments (not shown), the system 36 may include a patient table or patient bed having adjustable arm supports in the form of bars or rails extending alongside it. One or more robotic arms 39 can be mounted on the adjustable arm supports that can be adjusted vertically (e.g., via shoulders having elbow joints). By providing vertical adjustment, the robotic arms 39 can be advantageously housed compactly under the patient table or patient bed and then raised during treatment.

[0043] The arm 39 may be mounted on the carriage via a set of arm mounts 45, which include a series of joints that can individually rotate and / or extend in a nesting manner to provide additional configurability for the robot arm 39. Furthermore, the arm mounts 45 may be positioned on the carriage 43, and when the carriage 43 rotates appropriately, the arm mounts 45 may be positioned on the same side of the table 38 (as shown in Figure 6), on both sides of the table 38 (as shown in Figure 9), or on adjacent sides of the table 38 (not shown).

[0044] Column 37 structurally provides support for the table 38 and a path for the vertical translation of the carriage. Internally, column 37 may be equipped with a main screw for guiding the vertical translation of the carriage and a motor for mechanizing the translation of the carriage based on the main screw. Column 37 may also transmit power signals and control signals to the carriage 43 and the robotic arm 39 mounted thereon.

[0045] The table base 46 performs a similar function to the cart base 15 of the cart 11 shown in Figure 2, and accommodates heavier components to balance the table / bed 38, column 37, carriage 43, and robot arm 39. The table base 46 may also incorporate rigid casters to provide stability during treatment. Casters extending from the bottom of the table base 46 extend in opposite directions on each side of the base 46 and can be retracted when it is necessary to move the system 36.

[0046] Continuing with Figure 6, system 36 may also include a tower (not shown) that divides the functions of system 36 between the table and the tower, thereby reducing the form factor and bulk of the table. As seen in previously disclosed embodiments, the tower may provide the table with various support functions such as processing power, computing power, and control power, power, fluid elements, and / or optical and sensor processing. The tower may also be movable to be positioned away from the patient to improve physician access and to keep the operating room tidy. Furthermore, by placing components in the tower, it becomes possible to expand storage space on the table base for possible accommodation of robotic arms. The tower may also include a master controller or console that provides both a user interface for user input, such as a keyboard and / or pendant, and a display screen (or touch screen) for preoperative and intraoperative information, such as real-time imaging, navigation, and tracking information. In some embodiments, the tower may also include a holder for a gas tank used for ventilation.

[0047] In some embodiments, the table base can house and store a robotic arm when not in use. Figure 7 illustrates a system 47 for housing a robotic arm in an embodiment of a table base system. In system 47, the carriage 48 can be vertically translated into the base 49 so that the robotic arm 50, arm mount 51, and carriage 48 are housed within the base 49. The base cover 52 can be translated and retracted to open, allowing the carriage 48, arm mount 51, and arm 50 to be deployed around the column 53, and the base cover 52 can be closed to house and protect them when not in use. The base cover 52 can be sealed with a membrane 54 along the edge of its opening to prevent the ingress of dirt and fluids when closed.

[0048] Figure 8 shows one embodiment of a robot-enabled table-based system configured for a ureteroscopy procedure. In a ureteroscopy, the table 38 may include a swivel portion 55 for positioning the patient at an off-angle from the column 37 and the table base 46. The swivel portion 55 may rotate or pivot around a pivot point (e.g., located below the patient's head) to position the bottom of the swivel portion 55 away from the column 37. For example, pivoting the swivel portion 55 may position a C-arm (not shown) across the patient's lower abdomen without competing for space with the column (not shown) below the table 38. By rotating a carriage 35 (not shown) around the column 37, a robotic arm 39 may insert a ureteroscope 56 directly into the patient's inguinal region along a virtual rail 57 to reach the urethra. In a ureteroscopy, stirrups 58 may also be fixed to the swivel portion 55 of the table 38 to support the patient's leg position during the procedure and to allow clear access to the patient's inguinal region.

[0049] In laparoscopic procedures, minimally invasive instruments can be inserted into the patient's anatomical structures through small incisions in the patient's abdominal wall. In some embodiments, the minimally invasive instruments include slender, rigid members such as shafts used to access anatomical structures within the patient. After the patient's abdominal cavity is expanded, the instruments can be directed to perform surgical or medical tasks such as grasping, cutting, ablation, and suturing. In some embodiments, the instruments can include scopes such as laparoscopes. Figure 9 shows one embodiment of a robot-enabled table-based system configured for laparoscopic procedures. As shown in Figure 9, the carriage 43 of the system 36 can be rotated and vertically adjusted to position a pair of robotic arms 39 on either side of the table 38 so that instruments 59 can be positioned using arm mounts 45 to reach the patient's abdominal cavity through minimal incisions on either side of the patient.

[0050] To accommodate laparoscopic procedures, the robot-enabled table system may also tilt the platform to a desired angle. Figure 10 shows one embodiment of a robot-enabled medical system having pitch or tilt adjustment. As shown in Figure 10, the system 36 may be positioned to accommodate the tilt of the table 38, with one portion of the table higher off the floor than the other. Furthermore, the arm mount 45 may rotate to match the tilt such that the arm 39 maintains the same planar relationship as the table 38. To accommodate steep angles, the column 37 may also include a nested portion 60 that allows for vertical extension of the column 37 to prevent the table 38 from contacting the floor or colliding with the base 46.

[0051] Figure 11 provides a detailed illustrative diagram of the interface between the table 38 and the column 37. The pitch rotation mechanism 61 may be configured to change the pitch angle of the table 38 relative to the column 37 in multiple degrees of freedom. The pitch rotation mechanism 61 may be activated by positioning orthogonal axes 1 and 2 in the column-table interface, each axis being actuated by separate motors 3 and 4 in response to an electrical pitch angle command. Rotation along one screw 5 would allow for tilt adjustment along one axis 1, while rotation along the other screw 6 would allow for tilt adjustment along the other axis 2. In some embodiments, ball joints can be used to change the pitch angle of the table 38 relative to the column 37 in multiple degrees of freedom.

[0052] For example, pitch adjustment is particularly useful when positioning the table in the Trendelenburg position, that is, when positioning the patient's lower abdomen higher off the floor than the patient's lower abdomen for lower abdominal surgery. The Trendelenburg position allows gravity to slide the patient's internal organs down to the patient's upper abdomen, emptying the abdominal cavity when minimally invasive tools are inserted to perform lower abdominal surgical or medical procedures such as laparoscopic prostatectomy.

[0053] Figures 12 and 13 are isometric and end views of alternative embodiments of the table-based surgical robot system 100. The surgical robot system 100 includes one or more adjustable arm supports 105 which may be configured to support one or more robot arms relative to the table 101 (see, for example, Figure 14). In the illustrated embodiment, only one adjustable arm support 105 is shown, but additional arm supports can be provided on the opposite side of the table 101. The adjustable arm supports 105 may be moved relative to the table 101 so that the position of the adjustable arm support 105 and / or any robot arm mounted thereon can be adjusted and / or changed relative to the table 101. For example, the adjustable arm support 105 may be adjustable with one or more degrees of freedom relative to the table 101. The adjustable arm supports 105 provide the system 100 with high versatility, including the ability to easily accommodate one or more adjustable arm supports 105 and any robot arms mounted thereon under the table 101. The adjustable arm support 105 can be raised from its retracted position to a position below the upper surface of the table 101. In another embodiment, the adjustable arm support 105 can be raised from its retracted position to a position above the upper surface of the table 101.

[0054] The adjustable arm support 105 can provide several degrees of freedom, including lift, lateral translation, and tilt. In the illustrated embodiments of Figures 12 and 13, the arm support 105 comprises four degrees of freedom, which are illustrated by arrows in Figure 12. The first degree of freedom allows for adjustment of the adjustable arm support 105 in the z-direction ("Z-lift"). For example, the adjustable arm support 105 may include a carriage 109 configured to move up and down along or relative to a column 102 supporting the table 101. The second degree of freedom may allow the adjustable arm support 105 to tilt. For example, the adjustable arm support 105 may include a pivot joint, which may allow the adjustable arm support 105 to be aligned with a Trendelenburg position bed. The third degree of freedom allows the adjustable arm support 105 to "pivot up," which can be used to adjust the distance between the side of the table 101 and the adjustable arm support 105. A fourth degree of freedom can be enabled to allow translation of the adjustable arm support 105 along the longitudinal length of the table.

[0055] The surgical robot system 100 shown in Figures 12 and 13 may include a table supported by a column 102 mounted on a base 103. The base 103 and column 102 support the table 101 with respect to a support surface. The floor axis 131 and support axis 133 are shown in Figure 13.

[0056] An adjustable arm support 105 can be mounted on the column 102. In other embodiments, the arm support 105 can be mounted on the table 101 or the base 103. The adjustable arm support 105 may include a carriage 109, a bar or rail connector 111, and a bar or rail 107. In some embodiments, one or more robot arms mounted on the rail 107 can translate and move relative to each other.

[0057] The carriage 109 can be attached to the column 102 by a first joint 113, which allows the carriage 109 to move relative to the column 102 (for example, up and down on the first axis, i.e., the vertical axis 123). The first joint 113 can provide the adjustable arm support 105 with a first degree of freedom ("Z-lift"). The adjustable arm support 105 may include a second joint 115 that provides the adjustable arm support 105 with a second degree of freedom (tilt). The adjustable arm support 105 may include a third joint 117 that can provide the adjustable arm support 105 with a third degree of freedom ("pivot up"). A further joint 119 (shown in Figure 13) can be provided to mechanically restrain the third joint 117 to maintain the orientation of the rail 107 as the rail connector 111 is rotated around the third axis 127. The adjustable arm support 105 may include a fourth joint 121 that can provide the adjustable arm support 105 with a fourth degree of freedom (translation) along a fourth axis 129.

[0058] Figure 14 illustrates an end view of a surgical robotic system 140A with two adjustable arm supports 105A and 105B mounted on either side of a table 101. A first robotic arm 142A is mounted on a bar or rail 107A of the first adjustable arm support 105B. The first robotic arm 142A includes a base 144A mounted on the rail 107A. The distal end of the first robotic arm 142A includes an instrument drive mechanism 146A that can be attached to one or more robotic medical instruments or robotic medical tools. Similarly, a second robotic arm 142B includes a base 144B mounted on the rail 107B. The distal end of the second robotic arm 142B includes an instrument drive mechanism 146B. The instrument drive mechanism 146B may be configured to be attached to one or more robotic medical instruments or robotic medical tools.

[0059] In some embodiments, one or more of the robot arms 142A, 142B have seven or more degrees of freedom. In some embodiments, one or more of the robot arms 142A, 142B may have eight degrees of freedom, including an insertion axis (one degree of freedom including insertion), a wrist (three degrees of freedom including wrist pitch, yaw, and roll), an elbow (one degree of freedom including elbow pitch), a shoulder (two degrees of freedom including shoulder pitch and yaw), and a base 144A, 144B (one degree of freedom including translation). In some embodiments, the insertion degree of freedom can be provided by the robot arms 142A, 142B, but in other embodiments, the instrument itself provides insertion via an insertion architecture of the instrument base.

[0060] C. Appliance Drivers and Interfaces The end effector of the system's robotic arm includes (i) an instrument driver (alternatively referred to as “instrument drive mechanism” or “instrument device manipulator”) incorporating electromechanical means for operating a medical instrument, and (ii) a removable or detachable medical instrument which may lack any electromechanical components such as a motor. This dichotomy may arise from the need to sterilize medical instruments used in medical procedures and the inability to adequately sterilize expensive capital equipment due to the complex mechanical assembly and sensitive electronics of the medical instruments. Therefore, medical instruments may be designed to be separated, detached, and replaced from the instrument driver (and by extension, the system) during individual sterilization or disposal by the physician or physician's staff. The instrument driver, on the other hand, does not need to be replaced or sterilized and may be draped for protection.

[0061] Figure 15 illustrates an exemplary instrument driver. Positioned at the distal end of a robotic arm, the instrument driver 62 consists of one or more drive units 63 arranged in parallel axes to provide controlled torque to a medical instrument via a drive shaft 64. Each drive unit 63 includes a separate drive shaft 64 for interacting with the instrument, a gearhead 65 for converting motor shaft rotation into a desired torque, a motor 66 for generating the drive torque, an encoder 67 for measuring the motor shaft speed and providing feedback to the control circuit, and a control circuit 68 for receiving a control signal and operating the drive unit. Each drive unit 63 is controlled and motorized independently of others, and the instrument driver 62 may provide multiple (four shown in Figure 15) independent drive outputs to the medical instrument. When operating, the control circuit 68 receives a control signal, transmits a motor signal to the motor 66, compares the resulting motor speed measured by the encoder 67 to a desired speed, modulates the motor signal to generate the desired torque.

[0062] For procedures requiring a sterile environment, robotic systems may incorporate drive interfaces such as sterilization adapters connected to a sterilization drape, positioned between the instrument driver and the medical instrument. The primary purpose of the sterilization adapter is to transmit angular motion from the instrument driver's drive shaft to the instrument's drive input while maintaining physical separation of the drive shaft and drive input, and thus sterility. Thus, an example of a sterilization adapter may consist of a set of rotational inputs and outputs intended to be opposed to the instrument driver's drive shaft, and a drive input to the instrument. The sterilization drape connected to the sterilization adapter is made of a thin, flexible material such as clear or translucent plastic and is designed to cover the instrument driver, robotic arm, and capital equipment such as a cart (in a cart-based system) or table (in a table-based system). The use of the drape allows the capital equipment to be positioned close to the patient while still being located in an area that does not require sterilization (i.e., a non-sterilized field). On the other side of the sterilization drape, the medical instrument can interact with the patient in an area that requires sterilization (i.e., a sterile field).

[0063] D. Medical devices Figure 16 shows an exemplary medical instrument having a pair of instrument drivers. Like other instruments designed for use in robotic systems, the medical instrument 70 includes an elongated shaft 71 (or elongated body) and an instrument base 72. The instrument base 72, also referred to as an “instrument handle” due to its design intended for manual interaction by a physician, may include a rotary drive input 73, such as a receptacle, pulley, or spool, which is designed to face a drive output 74 that penetrates the drive interface on the instrument driver 75 at the distal end of a robotic arm 76. When physically connected, latched, and / or coupled, the opposing drive input 73 of the instrument base 72 may share a rotation axis with the drive output 74 in the instrument driver 75, allowing for the transmission of torque from the drive output 74 to the drive input 73. In some embodiments, the drive output 74 may include a spline designed to face a receptacle on the drive input 73.

[0064] The slender shaft 71 is designed to be delivered through either an anatomical opening or lumen, such as in endoscopy, or a minimally invasive incision, such as in laparoscopy. The slender shaft 71 can be either flexible (e.g., having properties similar to an endoscope) or rigid (e.g., having properties similar to a laparoscope), or it may include a customized combination of both flexible and rigid components. When designed for laparoscopy, the distal end of a rigid slender shaft may be connected to an end effector extending from an articulated list formed from a clevis having at least one degree of freedom, and which can be actuated based on force from a tendon as the drive input rotates in response to torque received from the drive output 74 of the instrument driver 75, for example, a surgical tool or medical instrument such as a grasping instrument or scissors. When designed for endoscopy, the distal end of a flexible slender shaft may include a maneuverable or controllable bend that can articulate and bend based on torque received from the drive output 74 of the instrument driver 75.

[0065] Torque from the instrument driver 75 is transmitted downstream of the elongated shaft 71 via tendons along the shaft 71. These individual tendons, such as pull wires, can be individually secured to individual drive inputs 73 within the instrument handle 72. From the handle 72, the tendons travel one or more pull lumens along the elongated shaft 71 and are secured to a distal portion of the elongated shaft 71 or to a wrist located on a distal portion of the elongated shaft. During surgical procedures such as laparoscopy, endoscopic procedures, or hybrid procedures, these tendons may be coupled to distally attached end effectors such as wrists, grasping instruments, or scissors. In such arrangements, the torque applied to the drive inputs 73 will actuate the end effectors in some way by transmitting tension to the tendons. In some embodiments, during surgical procedures, the tendons may move the end effectors in one direction or another by rotating the joints around an axis. Alternatively, the tendon may be connected to one or more jaws of a gripping device at the distal end of the elongated shaft 71, and the gripping device will be closed by tension from the tendon.

[0066] In endoscopy, tendons may be coupled to flexures or articulation points positioned along an elongated shaft 71 (e.g., distal end) via adhesive, control rings, or other mechanical fixation. When fixed and attached to the distal end of a flexure, the torque applied to the drive input 73 is transmitted to the tendon, causing the softer flexure (sometimes referred to as an articulation point or articulation area) to bend or articulate. Along the non-flexure, it may be convenient to equilibrium the radial forces resulting from tension in the pull wire by making individual pull lumens that direct individual tendons along (or inward) the wall of the endoscope shaft threaded or spiral. The angle of the threads and / or spacing between these may be modified or designed for a specific purpose; narrower threads result in inferior shaft compression under load, while fewer threads result in superior shaft compression under load, but also exhibit bending limitations. At the other end of the spectrum, by orienting the lumen parallel to the longitudinal axis of the elongated shaft 71, controlled joint movement at a desired bending or jointing portion can be enabled.

[0067] In endoscopic procedures, the elongated shaft 71 houses several components to support robotic procedures. This shaft may consist of working channels for positioning surgical tools (or medical instruments), irrigation, and / or aspiration into the surgical area at the distal end of the shaft 71. The elongated shaft 71 may also house wires and / or optical fibers that transmit signals to and from an optical assembly at the distal tip, which may include an optical camera. The shaft 71 may also house optical fibers for transporting light from a proximal light source, such as a light-emitting diode, to the distal end of the shaft.

[0068] At the distal end of the instrument 70, the distal tip may also include an opening for a working channel for delivering the tool to the surgical site for diagnosis and / or treatment, irrigation, and aspiration. The distal tip may also include a port for a camera, such as a fiberscope or digital camera, to capture images of the internal anatomical space. In this regard, the distal tip may also include a port for a light source to illuminate the anatomical space when using the camera.

[0069] In the example shown in Figure 16, the drive shaft axis, and therefore the drive input axis, is perpendicular to the axis of the elongated shaft. However, this arrangement complicates the rolling capability of the elongated shaft 71. As the elongated shaft 71 is rolled along its axis while the drive input 73 is stationary, undesirable tendon entanglement occurs as the tendon exits the drive input 73 and enters the lumen within the elongated shaft 71. Such resulting tendon entanglement can interfere with any control algorithm intended to predict the movement of the flexible elongated shaft during endoscopic procedures.

[0070] Figure 17 illustrates an alternative design for a tool driver and tool in which the axes of the drive units are parallel to the axes of the tool's elongated shafts. As shown, the circular tool driver 80 comprises four drive units whose drive outputs 81 are aligned parallel to the end of the robot arm 82. The drive units and their respective drive outputs 81 are housed in a rotary assembly 83 of the tool driver 80, which is driven by one of the drive units within the assembly 83. In response to the torque provided by the rotary drive units, the rotary assembly 83 rotates along a circular bearing that connects the rotary assembly 83 to a non-rotating portion 84 of the tool driver. Power and control signals may be transmitted from the non-rotating portion 84 of the tool driver 80 to the rotary assembly 83 through electrical contacts and may be maintained through rotation by brushed slip ring connections (not shown). In other embodiments, the rotary assembly 83 may be integrated with a non-rotating portion 84 and therefore respond to a separate drive unit that is not parallel to the other drive units. The rotation mechanism 83 enables the device driver 80 to rotate the drive unit and its respective drive outputs 81 as a single unit centered on the device driver shaft 85.

[0071] Similar to the embodiments disclosed previously, the instrument 86 may include a portion of an elongated shaft 88 and an instrument base 87 (shown by a transparent outer skin for consideration purposes) which includes a plurality of drive inputs 89 (such as receptacles, pulleys, and spools) configured to receive drive outputs 81 in the instrument driver 80. Unlike the embodiments disclosed previously, the instrument shaft 88 extends from the center of the instrument base 87, with its axis substantially parallel to the axis of the drive inputs 89, rather than being orthogonal as seen in the design of Figure 16.

[0072] When coupled to the rotating assembly 83 of the instrument driver 80, the medical instrument 86, including the instrument base 87 and instrument shaft 88, rotates together with the rotating assembly 83 around the instrument driver shaft 85. Because the instrument shaft 88 is positioned at the center of the instrument base 87, the instrument shaft 88 becomes coaxial with the instrument driver shaft 85 when mounted. Therefore, the rotation of the rotating assembly 83 causes the instrument shaft 88 to rotate around its own longitudinal axis. Also, because the instrument base 87 rotates together with the instrument shaft 88, none of the tendons connected to the drive input 89 on the instrument base 87 become entangled during rotation. Thus, the parallelism of the axes of the drive output 81, drive input 89, and instrument shaft 88 allows for shaft rotation without any control tendons becoming entangled.

[0073] Figure 18 shows a device having an insertable device-based architecture according to several embodiments. The device 150 can be coupled to any of the device drivers discussed above. The device 150 comprises an elongated shaft 152, an end effector 162 connected to the elongated shaft 152, and a handle 170 coupled to the elongated shaft 152. The elongated shaft 152 includes a tubular member having a proximal portion 154 and a distal portion 156. The elongated shaft 152 includes one or more channels or grooves 158 along its outer surface. The grooves 158 are configured to receive one or more wires or cables 180 passing through them. Thus, one or more cables 180 run along the outer surface of the elongated shaft 152. In other embodiments, the cables 180 can also run along the elongated shaft 152. The operation of one or more cables 180 (e.g., via a device driver) results in the operation of the end effector 162.

[0074] The fixture handle 170, sometimes also referred to as the fixture base, may include one or more mechanical inputs 174, such as a mounting interface 172 having a receptacle, pulley, or spool, which are typically designed to face one or more torque couplers on the mounting surface of the fixture driver.

[0075] In some embodiments, the instrument 150 includes a series of pulleys or cables that allow the elongated shaft 152 to translate relative to the handle 170. In other words, the instrument 150 itself constitutes an insertion architecture of the instrument base that is adapted to the insertion of the instrument, thus minimizing reliance on the robotic arm to perform the insertion of the instrument 150. In other embodiments, the robotic arm may be primarily responsible for the insertion of the instrument.

[0076] E. Controller Any of the robotic systems described herein may include an input device or controller for operating an instrument attached to a robotic arm. In some embodiments, the controller may be linked to the instrument (e.g., communicatively, electronically, electrically, wirelessly, and / or mechanically) so that operation of the controller triggers a corresponding operation of the instrument, for example, via master-slave control.

[0077] Figure 19 is a perspective view of an embodiment of the controller 182. In this embodiment, the controller 182 includes a hybrid controller that can incorporate both impedance control and admittance control. In other embodiments, the controller 182 may utilize only impedance control or passive control. In other embodiments, the controller 182 may utilize only admittance control. Being a hybrid controller, the controller 182 has the advantage of being able to reduce perceived inertia during use.

[0078] In the illustrated embodiment, the controller 182 is configured to enable the operation of two medical devices and includes two handles 184. Each of the handles 184 is connected to a gimbal 186. Each gimbal 186 is connected to a positioning platform 188.

[0079] As shown in Figure 19, each positioning platform 188 includes a SCARA arm (selective compliance assembly robot arm) 198 coupled to a column 194 by a linear joint 196. The linear joint 196 is configured to translate along the column 194 (e.g., along the rail 197) to allow each of the handles 184 to translate in the z direction, providing a first degree of freedom. The SCARA arm 198 is configured to allow the handles 184 to move in the xy plane, providing two additional degrees of freedom.

[0080] In some embodiments, one or more load cells are positioned within the controller. For example, in some embodiments, load cells (not shown) are positioned on each body of the gimbal 186. By providing load cells, a portion of the controller 182 can operate under admittance control, thereby advantageously reducing the perceived inertia of the controller during use. In some embodiments, the positioning platform 188 is configured for admittance control, while the gimbal 186 is configured for impedance control. In other embodiments, the gimbal 186 is configured for admittance control, and the positioning platform 188 is configured for impedance control. Thus, in some embodiments, the translational or positional degrees of freedom of the positioning platform 188 may depend on admittance control, while the rotational degrees of freedom of the gimbal 186 may depend on impedance control.

[0081] F. Navigation and Control Conventional endoscopy may involve the use of fluoroscopy (e.g., delivered via a C-arm) and other forms of radiation-based imaging modalities to provide intracavitary guidance to the operating physician. In contrast, the robotic systems intended by this disclosure can provide non-radiation-based navigation and localization means to reduce physician exposure to radiation and reduce the amount of equipment in the operating room. As used herein, the term “localization” may mean determining and / or monitoring the position of an object within a reference coordinate system. Techniques such as preoperative mapping, computer vision, real-time EM tracking, and robot command data can be used individually or in combination to achieve a radiation-free surgical environment. In other cases where radiation-based imaging modalities are still used, preoperative mapping, computer vision, real-time EM tracking, and robot command data can be used individually or in combination to improve information that can only be obtained through radiation-based imaging modalities.

[0082] Figure 20 is a block diagram illustrating a positioning system 90 for estimating the position of one or more elements of a robot system, such as the position of an instrument, according to an exemplary embodiment. The positioning system 90 may be a set of one or more computer devices configured to execute one or more instructions. The computer devices may be embodied by one (or more) processors and computer-readable memory in one or more components considered above. For example, the computer devices may be, but are not limited to, the tower 30 shown in Figure 1, the carts shown in Figures 1 to 4, and the beds shown in Figures 5 to 14.

[0083] As shown in Figure 20, the positioning system 90 may include a positioning module 95 that processes input data 91-94 to generate position data 96 for the distal end of a medical device. The position data 96 may be data or logic representing the position and / or orientation of the distal end of the device relative to a reference frame. The reference frame may be a reference frame relative to the anatomical structure of a patient or to a known object such as an EM field generator (see the following discussion on EM field generators).

[0084] Here, various input data 91-94 are described in more detail. Preoperative mapping can be achieved through the use of low-dose CT scan acquisition. Preoperative CT scans are reconstructed into three-dimensional images that are visualized, for example, as "slices" of the patient's internal anatomical structures. When analyzed as a whole, it is possible to generate image-based models targeting anatomical cavities, anatomical spaces, and anatomical structures of the patient's anatomical structures, such as the patient's lung network. Techniques such as the centerline shape can be determined from the CT images and approximated to create a three-dimensional volume of the patient's anatomical structures, referred to as model data 91 (also referred to as "preoperative model data" if generated using only preoperative CT scans). The use of the centerline shape is discussed in U.S. Patent Application No. 14 / 523,760, the entirety of which is incorporated herein. Network phase models can also be derived from CT images and are particularly suitable for bronchoscopy.

[0085] In some embodiments, the instrument may be equipped with a camera to provide visual data 92. A localization module 95 may process the visual data to enable one or more vision-based position tracking. For example, preoperative model data may be used in conjunction with the visual data 92 to enable computer vision-based tracking of a medical instrument (e.g., an endoscope, or an instrument that advances through the working channel of an endoscope). For example, using preoperative model data 91, a robotic system may generate a library of endoscopic images predicted from the model based on the expected movement path of the endoscope, with each image linked to a position in the model. During surgery, this library may be referenced by the robotic system to aid in localization by comparing real-time images captured by a camera (e.g., a camera at the distal end of the endoscope) with those in the image library.

[0086] Other computer vision-based tracking techniques use feature tracking to determine the movement of the camera, and consequently, the endoscope. Some features of the localization module 95 can identify circular geometric shapes corresponding to anatomical lumens in preoperative model data 91, track changes in these geometric shapes, and determine which anatomical lumen was selected, as well as the relative rotation and / or translational movement of the camera. The use of phase maps can further enhance vision-based algorithms or techniques.

[0087] Optical flow, another computer vision-based technique, can analyze the displacement and translation of image pixels in a video sequence within visual data92 to infer camera movement. Examples of optical flow techniques include motion detection, object segmentation calculation, luminance, motion compensation coding, and stereoscopic disparity measurement. By comparing multiple frames across multiple iterations, the movement and position of the camera (and therefore the endoscope) can be determined.

[0088] The positioning module 95 can generate the real-time position of the endoscope in a global coordinate system that can be registered in the patient's anatomical structure represented by a preoperative model, using real-time EM tracking. In EM tracking, an EM sensor (or tracker) consisting of one or more sensor coils embedded in the medical instrument (e.g., the endoscopic instrument) at one or more positions and orientations measures fluctuations in the EM field produced by one or more static EM field generators positioned at known locations. The position information detected by the EM sensor is stored as EM data 93. The EM field generator (or transmitter) may be placed near the patient to produce a low-intensity magnetic field that the embedded sensor can detect. The magnetic field induces a small current in the sensor coil of the EM sensor, which can be analyzed to determine the distance and angle between the EM sensor and the EM field generator. These distances and orientations can be intraoperatively "oriented" to the patient's anatomical structure (e.g., preoperative model) to determine a geometric transformation that aligns the position in the preoperative model of the patient's anatomical structure with only one position in the coordinate system. Once registered, an EM tracker embedded in one or more locations on the medical instrument (e.g., the distal tip of an endoscope) can provide a real-time display of the instrument's progression through the patient's anatomical structure.

[0089] Robot command and kinematic data 94 may also be used by a positioning module 95 to provide positioning data 96 for the robotic system. During preoperative calibration, device pitch and yaw derived from joint motion commands may be determined. Intraoperatively, these calibration measurements may be used in combination with known insertion depth information to estimate the position of the instrument. Alternatively, these calculations may be analyzed in combination with EM, vision, and / or phase modeling to estimate the position of the medical instrument within the network.

[0090] As shown in Figure 20, several other input data may be used by the positioning module 95. For example, although not shown in Figure 20, an instrument utilizing a shape-sensing fiber may provide shape data that the positioning module 95 can use to determine the position and shape of the instrument.

[0091] The positioning module 95 may use a combination of input data 91-94. In some cases, such a combination may use a probabilistic approach in which the positioning module 95 assigns confidence weights to locations determined from each of the input data 91-94. Therefore, if the EM data is unreliable (for example, if there is EM interference), the reliability of the location determined by the EM data 93 may decrease, and the positioning module 95 may rely more heavily on the visual data 92 and / or the robot command and kinematic data 94.

[0092] As discussed above, the robotic systems discussed herein may be designed to incorporate one or more combinations of the above technologies. A computer-based control system for a tower, bed, and / or cart-based robotic system may store computer program instructions in a non-temporary computer-readable storage medium, such as a persistent magnetic memory drive or a solid-state drive, which, when executed, cause the system to receive and analyze sensor data and user commands, generate control signals for the entire system, and display navigation and localization data such as the position of instruments in a global coordinate system and an anatomical map.

[0093] G. Tool driver with axial displacement sensing According to some embodiments, the robotic arm of a robotic system may be coupled to one or more tools, such as cannulas or other devices used to perform surgical procedures on a patient. Each robotic arm may include an instrument or tool driver for engaging with its respective surgical tool. In some applications, the surgical tool and / or sterile adapter may be attached to or coupled to the tool driver by sliding the tool or adapter along the surface of the tool driver to engage with it.

[0094] A tool driver may include one or more rotary outputs for manipulating or otherwise operating a surgical tool. The rotary outputs may be keyed to a sterile adapter or tool mating input to allow for torque transmission.

[0095] The rotary output of the tool driver can be retracted axially to allow the tool or sterilization adapter to slide along the surface of the tool driver to which it is coupled. The rotary output can be extended axially to engage with the mating input of the tool or sterilization adapter when properly engaged with the tool driver. In some applications, the rotary output can be rotated to align the keyed portion of the rotary output with the corresponding rotary input to enable operation after the sterilization adapter and tool have been mounted to the tool driver. However, in certain robotic systems, it may be difficult to quickly and accurately verify that the rotary output of the tool driver is properly engaged with the rotary input of the sterilization adapter and / or surgical tool.

[0096] Figure 21 illustrates a portion of a medical robotic system 200, including a tool driver 220, according to several embodiments. In the illustrated example, the medical robotic system 200 can perform robotic surgery by operating a surgical tool 240 coupled to a robotic arm 210. During operation, the robotic arm 210 can move the surgical tool 240 to a desired position and orientation by manipulating a series of segments or links 212 connected to a series of joints 214. Each of the joints 214 may include an independent actuator having an independently controllable motor to control the positioning of the links 212 of the robotic arm 210.

[0097] As illustrated, the surgical tool 240 may be coupled to the robotic arm 210 via a stage 218 located at the distal end of the robotic arm 210. In some embodiments, the stage 218 may include a tool driver 220 for receiving and operating the surgical tool 240. In some embodiments, the surgical tool 240 may be directly coupled to the tool driver 220. As illustrated, a sterile adapter 230 may be positioned between the surgical tool 240 and the tool driver 220. As described herein, the tool driver 220 may include one or more rotary outputs 224 (see Figure 22) for controlling the function of the attached surgical tool 240. In the illustrated example, the surgical tool 240 may be any suitable tool, including, but not limited to, laparoscopic tools such as grippers or scissors. As illustrated, the surgical tool 240 may include a tool shaft 245 extending into the patient's body through the lumen of the cannula 216.

[0098] Figure 22 illustrates an exploded assembly diagram of the tool driver 220, sterilization adapter 230, and instrument or surgical tool 240 of Figure 21. Figure 23 illustrates an exploded assembly diagram of the tool driver 220 and sterilization adapter 230 of Figure 21. Figure 24 illustrates a cross-sectional view of the surgical tool 240 and sterilization adapter 230 of Figure 21. Referring to Figures 21 to 24, the tool driver 220 may be configured to operate the mechanism of the surgical tool 240 and control the operation of the surgical tool 240. As shown, the tool driver 220 can receive the surgical tool 240 and provide an interface for coupling to a robotic arm. During operation, the body 221 of the tool driver 220 can be coupled to the body 241 of the surgical tool 240, allowing the mating surface 226 of the tool driver 220 to contact or be adjacent to the mating surface 246 of the surgical tool 240. The mating surface 246 of the surgical tool 240 may be axially positioned to engage with (or be adjacent to) the mating surface 226 of the tool driver 220. In some embodiments, the mating surface 246 of the surgical tool 240 may be tilted or slid to engage with the mating surface 226 of the tool driver 220. The surgical tool 240 and / or the tool driver 220 may include engaging features 242, 222 for holding or attaching the surgical tool 240 to the tool driver 220. As described herein, in some embodiments, a sterilization adapter 230 may be positioned between the surgical tool 240 and the tool driver 220 to provide a sterilization barrier.

[0099] In the illustrated example, the tool driver 220 can control the operation of the mounted surgical tool 240 via one or more drive or rotational outputs 224. As illustrated, one or more rotational outputs 224 of the tool driver 220 can actuate one or more inputs 244 of the surgical tool 240. In some embodiments, the inputs 244 of the surgical tool 240 may be coupled to pull wires, gears, screws, and / or other mechanisms to convert the rotational motion of the inputs 244 into translational, rotational, articulating, or any other preferred motion of the components of the surgical tool 240.

[0100] As illustrated, the tool driver 220 may include one or more rotary outputs 224 arranged in parallel axes to provide controlled torque to the input 244 of the surgical tool 240. Each of the rotary outputs 224 may include a drive mechanism for transmitting torque to each input of the surgical tool 240. In some embodiments, the drive mechanism may include a motor for generating drive torque and a drivetrain for transmitting torque to each input of the surgical tool 240. The drivetrain of the rotary output 224 may include one or more gears and drive shafts. In some embodiments, each of the rotary outputs 224 may include an encoder for measuring the rotational speed of the rotary output 224 and providing feedback to a control circuit to adjust the operation of the drive mechanism. During operation, the control circuit may receive a control signal, excite the motor of the drive mechanism, compare the resulting motor speed measured by the encoder with a desired speed, and modulate the motor signal to generate a desired torque. In the illustrated example, each rotary output 224 may be independently controlled and motorized.

[0101] As shown in the figure, the rotary output 224 of the tool driver 220 can be physically connected, latched, and / or coupled to the mating input 244 of the surgical tool 240, enabling the transmission of torque from the rotary output 224 to the mating input 244. The rotary output 224 can share a rotation axis with the input 244 of the surgical tool 240.

[0102] In some embodiments, the rotary output 224 may include features that engage with or otherwise mate with corresponding features of the mating input 244. As illustrated, the rotary output 224 may be formed as a disk including keyed features that engage with or otherwise mate with corresponding features of the mating input 244 to transmit torque. In some embodiments, the rotary output 224 includes or defines a spline designed to mate with a receptacle defined on the corresponding input portion 244.

[0103] Optionally, the features of the rotary output 224 may engage with the mating input 244 in one or more rotational orientations relative to a fixed reference point (e.g., 0 degrees, 90 degrees, 180 degrees, and / or 270 degrees of rotation) to enable torque transmission between the tool driver 220 and the surgical tool 240. In some applications, the rotary output 224 may be rotated until the features of the rotary output 224 align and engage with the features of the mating input 244, enabling torque transmission from the tool driver 220 and the surgical tool 240. Optionally, the rotary output 224 may be rotated either clockwise or counterclockwise to align with the features of the mating input 244.

[0104] During operation, the rotational outputs 224 of the tool driver 220 can articulate or move axially relative to the mating surface 226 of the tool driver 220 to facilitate engagement or coupling of the tool driver 220 with the surgical tool 240 or other components. For example, one or more rotational outputs 224 can retract axially relative to the mating surface 226 to present a profile that does not interfere with the engagement of the tool driver 220 with the surgical tool 240 or other components. In some applications, one or more rotational outputs 224 can retract to be coplanar with the mating surface 226. In some applications, one or more rotational outputs 224 may partially retract from their extended position or extend beyond the mating surface 226. For example, when the features of the rotational outputs 224 are not rotationally aligned or engaged with the features of the mating input 244, one or more rotational outputs 224 can retract axially relative to the mating surface 226 to present a profile that does not interfere with the engagement of the tool driver 220 with the surgical tool 240.

[0105] After the surgical tool 240 or other components are coupled to the tool driver 220, the rotary output 224 can extend axially toward the mating input 244 of the surgical tool 240 to facilitate the operation of the surgical tool 240. The rotary output 224 may include a biasing member, such as a spring, to bias the rotary output 224 toward the extended position. In some applications, the rotary output 224 can extend toward the mating input 244 and engage with the mating input 244. In some applications, one or more rotary outputs 224 may extend toward the mating input 244 but remain partially retracted relative to the mating surface 226 until the features of the rotary output 224 are rotatably aligned with or engaged with the features of the mating input 244. In some embodiments, one or more rotary outputs 224 may extend and be rotatably aligned with and engage with the mating input 244 of the surgical tool 240, but remain in a partially retracted position.

[0106] For procedures or applications requiring a sterile environment, the robotic system 200 may include a sterile adapter 230 to provide a sterile barrier between the surgical tool 240 and the robotic arm 210. In the illustrated example, the sterile adapter 230 includes a base plate or floating plate 231 and a sterile drape positioned between the robotic arm 210 and the surgical tool 240 to provide a physical barrier. In some embodiments, the sterile drape can be coupled to the floating plate 231. In some embodiments, the sterile drape comprises a thin, flexible material such as transparent or translucent plastic and is designed to cover capital equipment such as the tool driver 220, the robotic arm 210, and a cart (cart-based system) or a table (table-based system). Advantageously, the use of the sterile adapter allows capital equipment such as the robotic arm 210 and the tool driver 220 to be positioned close to the patient while still being located in an area that does not require sterilization (i.e., a non-sterile field). Furthermore, on the other side of the sterile drape, the surgical tool 240 may come into contact with the patient in an area that requires sterilization (i.e., a sterile field).

[0107] In the illustrated example, the sterilization adapter 230 may be coupled to the tool driver 220 and the surgical tool 240. In some embodiments, the sterilization adapter 230 may be coupled first to the tool driver 220, and then the surgical tool 240 may be coupled to the sterilization adapter 230 (and the attached tool driver 220). In some applications, the sterilization adapter 230 may be coupled to the surgical tool 240, and then the surgical tool 240 (and the attached sterilization adapter 230) may be coupled to the tool driver 220. As illustrated, the floating plate 231 of the sterilization adapter 230 may be coupled to the body 221 of the tool driver 220 so as to allow the floating plate 231 to contact or be adjacent to the mating surface 226 of the tool driver 220. The floating plate 231 of the sterilization adapter 230 may be positioned axially to engage with (or be adjacent to) the mating surface 226 of the tool driver 220. In some embodiments, the floating plate 231 of the sterilization adapter 230 may be tilted or slid to engage with the mating surface 226 of the tool driver 220. In some embodiments, the sterilization adapter 230 may include engaging features 232, 233 for engaging with engaging features 222, 223 of the tool driver 220 to hold or attach the sterilization adapter 230 to the tool driver 220. As shown, the engaging features 232, 233 may extend from the floating plate 231 of the sterilization adapter 230.

[0108] In some applications, the tool driver 220 can align the floating plate 231 of the sterilization adapter 230 with respect to the mating surface 226 of the tool driver 220. As shown, the tool driver 220 may include one or more translationable pegs 228 extending perpendicularly from the mating surface 226. The translationable pegs 228 may include biasing members to provide a biasing force away from the mating surface 226. During mating of the sterilization adapter 230 and the tool driver 220, the translational pegs 228 can engage with or otherwise contact the floating plate 231 to align the floating plate 231 to a desired orientation and / or move it away from the mating surface 226. In some embodiments, the translational pegs 228 can bias the floating plate 231 to align parallel to the mating surface 226.

[0109] Furthermore, the opposite side of the floating plate 231 of the sterilization adapter 230 may be coupled to the body 241 of the surgical tool 240 so as to allow the floating plate 231 to contact or be adjacent to the mating surface 246 of the surgical tool 240. The mating surface 246 of the surgical tool 240 may be axially positioned to engage with (or be adjacent to) the floating plate 231 of the sterilization adapter 230. In some embodiments, the mating surface 246 of the surgical tool 240 may be tilted or slid to engage with the floating plate 231 of the sterilization adapter 230. In some embodiments, the sterilization adapter 230 may include an engagement feature 235 for holding or attaching the surgical tool 240 to the sterilization adapter 230 by engaging with the engagement feature of the surgical tool 240. Similarly, the surgical tool 240 may include an engagement feature 242 for holding or attaching the surgical tool 240 to the sterilization adapter 230.

[0110] During operation, the sterilization adapter 230 allows the surgical tool 240 to be driven through the sterilization adapter 230 by the tool driver 220, thereby maintaining physical separation between the surgical tool 240, the tool driver 220, and the robotic arm 210, and thus maintaining sterility. In the illustrated example, the sterilization adapter 230 includes one or more rotating throughs 234 to allow the rotational output 224 of the tool driver 220 to operate the corresponding input 244 of the surgical tool 240.

[0111] As illustrated, one or more rotary outputs 224 of the tool driver 220 can operate one or more through-holes 234 of the sterilization adapter 230. The through-holes 234 of the sterilization adapter may be arranged to have parallel axes to receive torque from the rotary outputs 224 of the tool driver. As illustrated, the through-holes 234 of the sterilization adapter 230 can be physically connected, latched, and / or coupled to the rotary outputs 224 of the tool driver 220 to enable the transmission of torque from the rotary outputs 224 to the through-holes 234.

[0112] In some embodiments, the through-hole 234 may include features that engage with or otherwise mate to a corresponding feature of the rotational output 224. As shown, the through-hole 234 may be formed as a disk including a keyed feature that engages with or otherwise mate to a corresponding feature of the rotational output 224 to transmit torque. In some embodiments, the through-hole 234 includes or defines a spline designed to mate to a receptacle defined on the corresponding rotational output 224.

[0113] Optionally, the features of the through-hole 234 may engage with the rotational output 224 in one or more rotational orientations relative to a fixed reference point (e.g., 0 degrees, 90 degrees, 180 degrees, and / or 270 degrees of rotation) to enable torque transmission between the tool driver 220 and the sterilization adapter 230. In some applications, the rotational output 224 may be rotated until the features of the rotational output 224 align with and engage with the features of the through-hole 234, enabling torque to be transmitted from the tool driver 220 and the surgical tool 240. Optionally, the rotational output 224 may be rotated either clockwise or counterclockwise to align with the features of the through-hole 234.

[0114] Furthermore, the opposite ends of each through-hole 234 of the sterilization adapter 230 can actuate one or more inputs 244 of the surgical tool 240. The through-holes 234 of the sterilization adapter may be arranged with parallel axes to transmit torque to the inputs 244 of the surgical tool 240. As shown, the through-holes 234 of the sterilization adapter 230 may be physically connected, latched, and / or coupled to the inputs 244 of the surgical tool 240 to enable the transmission of torque from the through-holes 234 to the inputs 244 of the surgical tool 240.

[0115] In some embodiments, the through-hole 234 may include features that engage with or otherwise mate to a corresponding feature of the input 244. As illustrated, the through-hole 234 may be formed as a disk including a keyed feature that engages with or otherwise mate to a corresponding feature of the input 244 of a surgical tool 240 for transmitting torque. In some embodiments, the through-hole 234 includes or defines a spline designed to mate to a receptacle defined on the corresponding input 244.

[0116] Optionally, the features of the through-hole 234 may engage with the input 244 in one or more rotational orientations relative to a fixed reference point (e.g., rotations of 0, 90, 180, and / or 270 degrees) to enable the transmission of torque between the sterile adapter 230 and the surgical tool 240. In some applications, the through-hole 234 may be rotated until the features of the through-hole 234 align and engage with the features of the input 244, enabling the transmission of torque from the sterile adapter 230 and the surgical tool 240. Optionally, the through-hole 234 may be rotated either clockwise or counterclockwise to align with the features of the input 244.

[0117] During operation, the through-holes 234 of the sterilization adapter 230 can articulate or move axially with respect to the mating surface 226 of the tool driver 220 and the mating surface 246 of the surgical tool 240, facilitating the engagement or coupling of the tool driver 220 with the surgical tool 240. For example, one or more through-holes 234 can retract axially relative to the mating surface 226 to present a profile that does not interfere with the engagement of the sterilization adapter 230 with the tool driver 220. For example, one or more through-holes 234 can be partially retracted axially relative to the mating surface 226 to present a profile that does not interfere with the engagement of the sterilization adapter 230 with the tool driver 220 when the features of the rotational output 224 are not aligned or engaged with the features of the through-holes 234 in the rotational direction.

[0118] Similarly, one or more through-holes 234 can be axially retracted relative to the mating surface 246 to present a profile that does not interfere with the engagement of the sterilization adapter 230 and the surgical tool 240. For example, one or more through-holes 234 can be partially axially retracted relative to the mating surface 246 to present a profile that does not interfere with the engagement of the sterilization adapter 230 and the surgical tool 240 when the features of the input 244 are not rotationally aligned with or engaged with the features of the through-holes 234.

[0119] In some embodiments, the through-hole 234 of the sterilization adapter 230 may be biased toward a neutral position between the surgical tool 240 and the tool driver 220. Optionally, the through-hole 234 may be coupled to the floating plate 231 by an elastic material that allows axial displacement but biases the through-hole 234 toward a neutral position relative to the floating plate 231. In some applications, the through-hole 234 may move toward a neutral position after engaging with the features of the rotational output 224 and / or input 244.

[0120] An exemplary process for attaching a surgical tool 240 to a tool driver 220 is described herein. First, the sterile adapter 230 can be coupled to the tool driver 220. The rotational output 224 of the tool driver 220 can be retracted so that the floating plate 231 of the sterile adapter 230 slides over the mating surface 226 of the tool driver 220 or otherwise engages with the mating surface 226. In some applications, after the sterile adapter 230 is coupled to the tool driver 220, the rotational output 224 of the tool driver 220 does not need to be aligned with the through-hole 234 in the rotational direction, and the rotational output 224 may be pushed down or otherwise pushed in to remain in the retracted position. After the sterile adapter 230 is coupled to the tool driver 220, the rotational output 224 may be rotated until they extend axially and engage with the through-hole 234 of the sterile adapter 230.

[0121] Next, the surgical tool 240 can be coupled to the tool driver 220 via the sterile adapter 230. The rotational output 224 of the tool driver 220, together with the through-hole 234 of the sterile adapter 230, can be retracted so that the mating surface 246 of the surgical tool 240 slides over the floating plate 231 of the sterile adapter 230 or otherwise engages with the floating plate. In some applications, after the surgical tool 240 is coupled to the tool driver 220, the through-hole 234 of the sterile adapter 230 (and the rotational output 224 of the tool driver 220) does not need to be rotationally aligned with the input 244 of the surgical tool 240, and the rotational output 224 is pushed down or otherwise held in the retracted position. After the surgical tool 240 is coupled to the tool driver 220, the rotary output 224 may be rotated until the through-hole 234 of the sterilization adapter 230 engages with the rotary input 244 of the surgical tool 240, allowing the through-hole 234 (and rotary output 224) to extend axially. In some embodiments, the rotary output 224 may be “homed” to calibrate the tool driver 220 using the mounted surgical tool 240.

[0122] In some applications, the surgical tool 240 can be removed from the tool driver 220 by pressing down on the release mechanism or acting in another manner to release the engagement features 222, 242 between the surgical tool 240 and the tool driver 220. Similarly, the sterile adapter 230 can be removed from the tool driver 220 by pressing down on the release mechanism or acting in another manner to release the engagement features 232, 233 between the sterile adapter 230 and the tool driver 220.

[0123] H. Inductance-based displacement sensing In the illustrated example, the robot system 200 can detect whether the surgical tool 240 is properly or fully engaged with the tool driver 220. For example, the robot system 200 can detect whether the tool driver 220 and the rotary output 224 are properly engaged with the sterile adapter 230 and / or the surgical tool 240 during each stage of engagement. In some applications, the robot system 200 can detect whether the rotary output 224 is rotating or otherwise fully engaged with the through portion 234 of the sterile adapter 230. Similarly, in some applications, the robot system 200 can detect whether the rotary output 224 (and / or the engaged through portion 234 of the sterile adapter 230) is rotatably or otherwise fully engaged with the input 244 of the surgical tool 240. Furthermore, in some applications, the robot system 200 can detect the axial position (depressed / extended) of the floating plate 231 of the sterile adapter 230 relative to the mating surface 226 of the tool driver 220.

[0124] As described herein, the robotic system 200 can use the axial position of the rotational output 224 to determine the engagement of the tool driver 220 with the sterilization adapter 230 and / or the surgical tool 240. In some embodiments, the tool driver 220 may include one or more sensors for detecting the axial position of the rotational output 224. Advantageously, by detecting the axial position of the rotational output 224, the robotic system 200 and / or the clinician can quickly and accurately determine whether the tool driver 220 (and rotational output 224) is properly engaged with the sterilization adapter 230 and / or the surgical tool 240. Furthermore, the robotic system 200 and / or the clinician can rotate the rotational output 224 of the tool driver 220 based on axial position feedback to quickly and accurately engage the rotational output 224 with the through-hole 234 of the sterilization adapter 230 and engage the through-hole 234 with the input 244 of the surgical tool 240.

[0125] Figure 25 illustrates a cross-sectional view of the tool driver 220 and sterilization adapter 230 shown in Figure 21. Referring to Figure 25, the tool driver 220 includes one or more position sensors 250 for detecting the axial position of each rotational output 224. In the illustrated example, the position sensors 250 provide the robot system 200 with a signal corresponding to the axial position of each rotational output 224.

[0126] In some embodiments, the position sensor 250 can measure inductance or changes in inductance to provide a position signal to the robot system 200. The position sensor 250 may include a coil for detecting inductance. In some applications, a change in the position of the shaft of the rotary output 224 relative to the coil (or generally the position sensor 250) can change the inductance of the coil of the position sensor 250. The coil may be arranged around the shaft of the rotary output unit 224. The coil may be a wound coil or a coil arranged on a printed circuit board. Optionally, the rotary output 224 may include an iron component 252 to increase or enhance the inductance of the position sensor 250.

[0127] Figure 26 is a chart showing the axial displacement of the rotational output 224 of the tool driver 220 in relation to the inductance value of the sensor 250 of the tool driver 220, according to several embodiments. As shown, the robot system 200 can map the inductance value received by the position sensor 250 to the axial displacement of the rotational output 224. In some embodiments, the inductance value received from the position sensor 250 can be measured by an integrated circuit and associated support circuits, or converted into displacement data.

[0128] I. Optical-based displacement sensing Figure 27 illustrates, in several embodiments, the rotational outputs 224 of a tool driver 220 having optical sensors 350. Referring to Figure 27, the tool driver 220 includes one or more optical sensors 350 for detecting the axial position of each rotational output 224. In the illustrated example, the optical sensors 350 provide the robot system 200 with signals corresponding to the axial position of each rotational output 224.

[0129] In some embodiments, the optical sensor 350 can emit light toward the rotation output 224 and measure the amount of reflected light to provide a position signal to the robot system 200. During operation, changes in the position of the rotation output 224 relative to the optical sensor 350 can change the amount of light received by the optical sensor 350. In some embodiments, the optical sensor 350 can emit a pulse of light and measure the "time of flight" of the pulse returning to the optical sensor 350 to provide a position signal to the robot system 200. During operation, changes in the position of the rotation output 224 relative to the optical sensor 350 can change the amount of time required to reflect the light pulse back to the optical sensor 350. The optical sensor 350 can be positioned below the flat surface of the rotation output 224. Optionally, the flat surface of the rotation output 224 may include a reflective surface 352 to increase, enhance, or otherwise facilitate the reflection of light to the optical sensor 350.

[0130] Figure 28 is a chart showing the axial displacement of the rotation output 224 of the tool driver 220 relative to the sensor readout of the optical sensor 350 in Figure 27, according to several embodiments. As shown, the robot system 200 can correlate the sensor value received by the optical sensor 350 with the axial displacement of the rotation output 224. In some embodiments, the sensor value received from the optical sensor 350 (either the amount of light received or time-of-flight data) can be measured or converted by an integrated circuit and associated support circuits to become displacement data.

[0131] As described herein, displacement data from sensors 250 and 350 can be used by the robotic system 200 to determine whether the tool driver 220 and the rotational output 224 are properly engaged with the sterilization adapter 230 and / or surgical tool 240 during each stage of engagement. For example, displacement data from sensors 250 and 350 can be used by the robotic system 200 to detect the axial position (downward / outward) of the floating plate 231 of the sterilization adapter 230 relative to the mating surface 226 of the tool driver 220.

[0132] In some applications, displacement data from sensors 250 and 350 can be used by the robotic system 200 to determine whether the rotational output 224 is aligned and engaged with the features of the through-hole 234 of the sterilization adapter 230, and whether the through-hole 234 is aligned and engaged with the features of the mating input 244 of the surgical tool 240.

[0133] Furthermore, in some applications, displacement data from sensors 250, 350 can be used by the robotic system 200 to control the rotation of the rotational output 224, facilitating engagement of the rotational output 224 with the through-hole 234 of the sterilization adapter 230, and engagement of the rotational output 224 (via the through-hole 234) with the input 244 of the surgical tool 240. For example, the rotational outputs 224 may be rotated until they extend axially and engage with the through-hole 234, and / or until the through-hole 234 engages with the input 244 of the surgical tool 240. The robotic system 200 may use sensor feedback and displacement data to rotate the rotational output 224 clockwise or counterclockwise to align with the features of the through-hole 234 and / or input 244. In some applications, the rotational output 224 may be aligned between two or more rotational orientations with respect to a fixed reference point (e.g., rotations of 0, 90, 180, and / or 270 degrees).

[0134] 2. Implementation System and Terminology The implementations disclosed herein can, advantageously, provide systems, methods, and apparatus for providing an additional level of safety to a robot interacting with humans by enabling the joints to be fully unlocked and repositioned even under the condition of a complete electrical or software failure of the robot.

[0135] When used herein, the terms “join,” “joined,” “combined,” or other variations of the word “join” may indicate either indirect or direct connection. For example, when a first component is “joined” to a second component, the first component may be indirectly connected to the second component via another component, or directly connected to the second component.

[0136] The methods disclosed herein include one or more steps or actions for achieving the described method. The method steps and / or actions may be substituted for one another, as long as they do not deviate from the claims. In other words, the order and / or use of specific steps and / or actions may be modified without deviation from the claims, unless a specific sequence of steps or actions is required for the proper operation of the described method.

[0137] As used herein, the term “multiple” refers to two or more. For example, multiple components refer to two or more components. The term “determine” encompasses a wide variety of actions, and therefore “determine” may include calculating, computing, processing, deriving, investigating, looking up (e.g., referring to a table, database or another data structure), verifying, etc. “Determine” may also include receiving (e.g., receiving information), accessing (e.g., accessing data in memory), etc. “Determine” may also include resolving, selecting, electing, establishing, etc.

[0138] The phrase "based on" does not mean "based solely on" unless explicitly specified otherwise. In other words, the phrase "based on" describes both "based solely on" and "based at least on."

[0139] The foregoing description of the disclosed implementations is provided to enable any person skilled in the art to manufacture or use the present invention. Various modifications to these implementations will be readily apparent to a person skilled in the art, and the general principles set forth herein may be applied to other implementations without departing from the scope of the present invention. For example, a person skilled in the art will understand that many corresponding alternative and equivalent structural details can be employed, such as similar methods for fastening, mounting, joining, or engaging tool components, equivalent mechanisms for producing specific operating motions, and equivalent mechanisms for delivering electrical energy. Accordingly, the present invention is not intended to be limited to the implementations shown herein, but rather the broadest scope is given that is consistent with the principles and novel features disclosed herein.

[0140] [Implementation Method] (1) A tool driver for a surgical robotic system, wherein the tool driver is The main unit and A rotational output extending from the main body, wherein the rotational output is axially translatable along an axis perpendicular to the surface of the main body, A drive mechanism coupled to the rotational output, wherein the drive mechanism is configured to rotate the rotational output around the shaft, A sensor coupled to the main body and configured to determine the axial position of the rotation output relative to the main body, A tool driver equipped with the following features. (2) The tool driver according to Embodiment 1, wherein the drive mechanism comprises a motor coupled to the rotation output. (3) The tool driver according to Embodiment 1, wherein the rotational output comprises a disk extending from the body, the disk being configured to engage with the input of a surgical tool. (4) The tool driver according to Embodiment 3, wherein the disk defines a keyed portion configured to transmit torque from the rotational output to the input of the surgical tool. (5) The tool driver according to Embodiment 1, further comprising a biasing member coupled to the rotation output and configured to apply a biasing force to the rotation output so as to move away from the main body along the axis.

[0141] (6) The tool driver according to Embodiment 1, wherein the sensor further comprises an inductive sensor configured to receive signals from a component. (7) The tool driver according to Embodiment 6, wherein the rotation output further comprises an iron component, and the induction sensor further comprises a conductive coil, and the axial movement of the iron component relative to the conductive coil changes the inductance of the conductive coil, providing a signal to the controller corresponding to the axial movement of the rotation output. (8) The tool driver according to Embodiment 1, wherein the sensor includes an optical sensor. (9) The tool driver according to embodiment 8, wherein the rotation output comprises a reflective surface configured to provide a signal to the optical sensor. (10) The tool driver according to Embodiment 1, further comprising a translationable peg extending perpendicularly to the surface of the main body, wherein the translationable peg is biased to move away from the main body to separate the sterilization adapter from the main body.

[0142] (11) The tool driver according to Embodiment 1, further comprising multiple rotation outputs. (12) A method for operating a surgical robot system, the method being: The mating device is coupled to a tool driver, wherein the tool driver has a rotational output and the mating device has a corresponding input. The rotational output is biased axially toward the corresponding input, Rotating the aforementioned rotation output relative to the corresponding input, The axial position of the aforementioned rotation output is detected, Methods that include... (13) The method according to embodiment 12, further comprising determining the engagement between the rotation output and the corresponding input based on the axial position of the rotation output. (14) The method according to embodiment 12, further comprising determining the engagement between the mating device and the tool driver based on the axial position of the rotation output. (15) The method according to embodiment 12, wherein detecting the axial position of the rotational output further includes detecting an inductance value to determine the axial position of the rotational output.

[0143] (16) The method according to embodiment 12, further comprising detecting an optical signal to determine the axial position of the rotation output. (17) The mating device comprises a sterilization adapter having a sterilization adapter input and a floating plate that mechanically restrains the sterilization adapter input, and the method is The method according to embodiment 12, further comprising determining the axial position of the floating plate based on the axial position of the rotational output. (18) The method according to embodiment 17, further comprising determining the latch state of the floating plate based on the axial position of the rotation output. (19) A surgical robotic system, It is a tool driver, The main unit and A rotational output extending from the main body, wherein the rotational output defines a profile, is axially translatable along an axis perpendicular to the surface of the main body, and is rotatable around the axis, A tool driver comprising: a sensor coupled to the main body and configured to determine the axial position of the rotation output relative to the main body; It is a surgical tool, The movable tool part, A surgical tool comprising an input configured to move the tool portion, wherein the input defines a mating profile, A surgical robotic system wherein the surgical tool is coupled to the tool driver and configured to allow the rotational output to translate toward the input of the surgical tool, and the sensor is further configured to determine the rotational engagement between the profile of the rotational output and the mating profile of the input of the surgical tool. (20) Further comprising a sterilization adapter, the sterilization adapter is A movable base plate and A rotating through portion defining a tool driver profile on a first side and a tool profile on a second side on the opposite side, wherein the rotating through portion is axially translatable along a through axis perpendicular to the movable base plate and rotatable around the axis, The sterilization adapter is coupled to the tool driver and the surgical tool and configured to allow the rotational output of the tool driver to translate toward the rotational penetration of the sterilization adapter and to translate the rotational penetration toward the input of the tool portion, and the sensor is further configured to determine the rotational engagement between the profile of the rotational output and the tool driver profile of the rotational penetration, according to Embodiment 19 of the surgical robot system.

[0144] (21) The surgical robot system according to Embodiment 20, wherein the sensor is further configured to determine the rotational engagement between the tool profile of the rotating penetration and the mating profile of the input of the surgical tool.

Claims

1. A tool driver for a surgical robot system, wherein the tool driver is The main unit and A rotational output extending from the main body, wherein the rotational output is axially translatable along an axis perpendicular to the surface of the main body, A drive mechanism coupled to the rotational output, wherein the drive mechanism is configured to rotate the rotational output around the shaft, A sensor coupled to the main body and configured to determine the axial position of the rotation output relative to the main body, A tool driver equipped with the following features.

2. The tool driver according to claim 1, wherein the drive mechanism comprises a motor coupled to the rotation output.

3. The tool driver according to claim 1, wherein the rotational output comprises a disk extending from the main body, the disk being configured to engage with the input of a surgical tool.

4. The tool driver according to claim 3, wherein the disk defines a keyed portion configured to transmit torque from the rotational output to the input of the surgical tool.

5. The tool driver according to claim 1, further comprising a biasing member coupled to the rotational output and configured to apply a biasing force to the rotational output so as to move away from the main body along the axis.

6. The tool driver according to claim 1, further comprising an induction sensor configured to receive signals from a component.

7. The tool driver according to claim 6, wherein the rotation output further comprises an iron component, the induction sensor further comprises a conductive coil, and the axial movement of the iron component relative to the conductive coil changes the inductance of the conductive coil, providing a signal to the controller corresponding to the axial movement of the rotation output.

8. The tool driver according to claim 1, wherein the sensor includes an optical sensor.

9. The tool driver according to claim 8, wherein the rotation output comprises a reflective surface configured to provide a signal to the optical sensor.

10. The tool driver according to claim 1, further comprising a translationable peg extending perpendicularly to the surface of the main body, wherein the translationable peg is biased to move away from the main body, thereby separating the sterilization adapter from the main body.

11. The tool driver according to claim 1, further comprising multiple rotation outputs.

12. A method for operating a surgical robot system, wherein the method is The mating device is coupled to a tool driver, wherein the tool driver has a rotational output and the mating device has a corresponding input. The rotational output is biased axially toward the corresponding input, Rotating the aforementioned rotation output relative to the corresponding input, The axial position of the aforementioned rotation output is detected, Methods that include...

13. The method according to claim 12, further comprising determining the engagement between the rotation output and the corresponding input based on the axial position of the rotation output.

14. The method according to claim 12, further comprising determining the engagement between the mating device and the tool driver based on the axial position of the rotational output.

15. The method according to claim 12, wherein detecting the axial position of the rotational output further includes detecting an inductance value in order to determine the axial position of the rotational output.

16. The method according to claim 12, wherein detecting the axial position of the rotation output further includes detecting an optical signal to determine the axial position of the rotation output.

17. The fitting device comprises a sterilization adapter having a sterilization adapter input and a floating plate that mechanically restrains the sterilization adapter input, and the method is The method according to claim 12, further comprising determining the axial position of the floating plate based on the axial position of the rotation output.

18. The method according to claim 17, further comprising determining the latch state of the floating plate based on the axial position of the rotation output.

19. A surgical robotic system, It is a tool driver, The main unit and A rotational output extending from the main body, wherein the rotational output defines a profile, is axially translatable along an axis perpendicular to the surface of the main body, and is rotatable around the axis, A tool driver comprising: a sensor coupled to the main body and configured to determine the axial position of the rotation output relative to the main body; It is a surgical tool, The movable tool part, A surgical tool comprising an input configured to move the tool portion, wherein the input defines a mating profile, A surgical robotic system wherein the surgical tool is coupled to the tool driver and configured to allow the rotational output to translate toward the input of the surgical tool, and the sensor is further configured to determine the rotational engagement between the profile of the rotational output and the mating profile of the input of the surgical tool.

20. The sterilization adapter is further provided, and the sterilization adapter is A movable base plate and A rotating through portion defining a tool driver profile on a first side and a tool profile on a second side on the opposite side, wherein the rotating through portion is axially translatable along a through axis perpendicular to the movable base plate and rotatable around the axis, The surgical robot system according to claim 19, wherein the sterilization adapter is coupled to the tool driver and the surgical tool so as to enable the rotational output of the tool driver to translate toward the rotational penetration of the sterilization adapter, and the rotational penetration to translate toward the input of the tool portion, and the sensor is further configured to determine the rotational engagement between the profile of the rotational output and the tool driver profile of the rotational penetration.

21. The surgical robot system according to claim 20, wherein the sensor is further configured to determine the rotational engagement between the tool profile of the rotating penetration and the mating profile of the input of the surgical tool.

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