Positioning robot system

Abstract

Disclosed herein are positioning robot systems and methods of operating the same. The robotic end effectors of these systems need to be very precise in manipulating tissue or tools, and need to be able to operate alongside real-time medical imaging guidance. The system therefore includes a multitude of drivetrain assemblies providing precise manipulation, and is made of non-magnetic materials. More specifically, the system includes a structural frame in a space defined by orthogonal X, Y and Z axes; a tool mount mounted to the frame and configured for receiving a medical tool system; and a motion transmission assembly for selectively effecting motion unto the tool mount. The motion transmission assembly includes: a first drivetrain assembly for translational motion unto the tool mount about a vertical plane defined by the X and Y axes; a second drivetrain assembly for rotational motion unto the tool mount about a first axis of rotation parallel to the X axis; a third drivetrain assembly for rotational motion unto the tool mount about a second axis of rotation parallel to the Y axis; and a fourth drivetrain assembly for translational motion unto the tool mount in a direction parallel to the Z axis.

Description

POSITIONING ROBOT SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims all benefit including priority to U.S. Provisional Patent Application 63 / 511 ,879, filed July 4, 2023, and entitled “POSITIONING ROBOT SYSTEM”; the entire contents of which are hereby incorporated by reference herein.FIELD

[0002] This disclosure relates generally to robotics for medical procedures, and more specifically to a positioning robot system for medical procedures.BACKGROUND

[0003] Positioning robots are devices that may be used in medical procedures to position tools such as robotic medical end effectors for the manipulation of tissue and / or tools. The use of robotic end effectors is becoming more prevalent in a variety of medical procedures such as biopsies, minimally invasive surgery, laparoscopic surgery, and robotic surgery, and so on. Robotic end effectors need to be very precise in manipulating tissue or tools, creating implementation challenges, for instance in their positioning. Further, some medical procedures rely on real-time medical imaging guidance, and thus require robotic end effectors and positioning robots to operate within such settings, such as for example within a magnetic resonance imaging (MRI) machine, which creates further implementation challenges.SUMMARY

[0004] According to an aspect, there is provided a positioning robot system comprising: a structural frame disposed in a space defined by orthogonal X, Y and Z axes; a tool mount mounted to the structural frame and configured for receiving a medical tool system; and a motion transmission assembly for selectively effecting motion unto the tool mount, the motion transmission assembly including: a first drivetrain assembly for selectively effecting translational motion unto the tool mount about a vertical plane defined by the X and Y axes; a second drivetrain assembly for selectively effecting rotational motion unto the tool mount about a first axis of rotation parallel to the X axis; a third drivetrain assembly for selectively effecting rotational motion unto the tool mount about a second axis of rotation parallel to the Y axis; and a fourth drivetrain assembly for selectively effecting translational motion unto the tool mount in a direction parallel to the Z axis.

[0005] According to another aspect, there is provided positioning robot system comprising: a structural frame disposed in a space defined by orthogonal X, Y and Z axes; a tool mount mounted configured for receiving a medical tool system; and a motion transmission assembly operatively coupling the tool mount to the structural frame and configured for effecting motion unto the tool mount in up to five degrees of freedom.

[0006] According to yet another aspect, there is provided method of operating a positioning robot system, the method comprising: positioning the positioning robot system in a medical procedure environment adjacent a clinical workspace, the positioning robot system having a medical tool system mounted thereto; manipulating the positioning robot system to displace the medical tool system into the clinical workspace to begin a medical procedure; and after the medical procedure is complete, manipulating the positioning robot system to displace the medical tool system outside of the clinical workspace.

[0007] Many further features and combinations thereof concerning the present improvements will appear to those skilled in the art following a reading of the instant disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In the figures which illustrate example embodiments,

[0009] FIG. 1 is a top rear perspective view of a positioning robot system, in accordance an embodiment;

[0010] FIG. 2 is a top rear perspective view of an XY module for the positioning robot system of FIG. 1 , in accordance with an embodiment;

[0011] FIG. 3 is a bottom rear perspective view of a pitch module for the positioning robot system of FIG. 1 , in accordance with an embodiment;

[0012] FIG. 4 is a front top perspective view of a yaw module for the positioning robot system of FIG. 1 , in accordance with an embodiment;

[0013] FIG. 5 is a rear top perspective view of a Z module for the positioning robot system of FIG. 1 , in accordance with an embodiment; and

[0014] FIG. 6 is a flowchart of an example operation of a positioning robot system, in accordance with an embodiment;

[0015] These drawings depict example embodiments for illustrative purposes, and variations, alternative configurations, alternative components and modifications may be made to these example embodiments.DETAILED DESCRIPTION

[0016] Improved positioning robot systems for use in medical procedures are disclosed herein. Embodiments may be used to assist in the positioning of tools such as end effector systems for the performance of medical procedures such as biopsies, surgeries, or other medical procedures that require a medical tool to be manipulated into human tissue (or other animal tissue) or for otherwise manipulating such tissue. Embodiments may be configured for positioning of various medical tools such as a biopsy needle, a biopsy hand-piece, an anesthesia needle, another type of medical needle, other needle-like devices, a trocar, a cutter, an introducer, or the like. Embodiments may also be used in the positioning of various supporting tools such as needle sheaths, needle guides, or the like.

[0017] Embodiments may be reconfigurable by an end user to mount or otherwise attach various types of medical tools, as well as different models of medical tools, e.g., from different suppliers, having different shapes and sizes, and so on. Such medical tools may include commercially-available tools and / or tools customized for use with the robotic end effector systems disclosed herein.

[0018] Embodiments may be adapted for use proximate or within an MRI machine, and thus utilize robotics architectures and components that remain operable in the presence of timevarying magnetic fields and space constraints of an MRI machine, and conversely do not negatively impact the operation of the MRI machine. For example, embodiments may be formed to reduce conducting structures in which time-varying magnetic fields may induce electric currents. For example, embodiments may be formed of materials that are MRI-compatible, e.g., aluminium, plastic, suitable annealed steel, or the like. For example, embodiments may be formed to reduce electromagnetic interaction between an end effector system and an MRI machine. For example, embodiments may be formed of relatively compact size to fit space constraints.

[0019] FIG. 1 is a rear perspective view of a positioning robot system 100 disposed along orthogonal X, Y and Z axes, in accordance with an embodiment. In some embodiments, a tool system 200 such as an end effector system 200 is mounted on the positioning robot system 100. The positioning robot system 100 may be positionable adjacent a clinical workspace in a medicalprocedure environment, such as an MRI machine, and be operable to position the end effector system 200 in such a constrained three-dimensional workspace so that a medical procedure may be carried out. The positioning robot system 100 may be operable to displace the end effector system 200 in multiple degrees of freedom, for instance in up to five degrees of freedom, to provide accurate range of movement thereto.

[0020] As will be discussed in further detail below, the positioning robot system 100 includes a plurality of modules or stages for providing the desired maneuverability to the tool system 200, and a frame 300 for supporting the various modules. The frame 300 may, for instance, be made of aluminum with brass fasteners. In the shown embodiment, the positioning robot system 100 includes an XY module 400 for effecting the tool system 200 with translational movement within a vertical plane defined by the X and Y axes (see FIG. 2); a pitch module 500 for effecting the tool system 200 with rotational movement (i.e., pitch) about a pitch axis P (see FIG. 3); a yaw module 600 for effecting the tool system 200 with rotational movement (i.e., yaw) about a yaw axis W (see FIG. 4); and a Z module 700 for effecting the tool system 200 with translational movement along the Z axis (see FIG. 5). In the shown case, the positioning robot system 100 is operable to displace the tool system 200 in up to five degrees of freedom, although other numbers of degrees of freedom may be contemplated.

[0021] Various tool systems 200 may be operatively coupled to and displaceable by the positioning robot system 100. In the embodiment shown in FIG. 1 , the tool system 200 is an end effector system 200 includes a tool handling and insertion subsystem 210 (also referred to as a handler 210) configured to effect, under computer control, linear movement and rotational movement of a tool 220, as may be required for a medical procedure. End effector system 200 also may include one or more tool adapters, each configured to be selectively mechanically coupled to a corresponding tool 220 of a given type or a corresponding family of tools 220 of a given type. Each tool adapter is also configured to be selectively mechanically coupled to handler 210. When tool adapter is mechanically coupled to both a tool 220 and handler 210, linear movement and / or rotational movement may be effected by handler 210 on tool 220 via tool adapter 220. In some embodiments, but not the case in all embodiments, the end effector system 200 may be reconfigurable by an end user to be used with disparate types of tools 220. In an exemplary embodiment, the tool 220 may be a biopsy hand-piece (e.g., suitable for a breast biopsy) such as a ATEC™ breast biopsy device from Hologic. Tool 220 is mechanically coupled to a suitable tool adapter. In some embodiments, the end effector system 200 may be reconfigured to use a different tool 220, or a different type of tool 220. The handler 210, tooladapters and tools 220 may be formed of and / or enclosed in a housing formed of an MRI- compatible material.

[0022] As discussed above, in the shown case, a frame 300 is provided for supporting the positioning robot system 100. In the shown embodiment, the frame 300 includes a bottom wall 310 and a pair of side walls 320 defining an enclosure 330 therewithin, the enclosure 330 being open-ended at top, front and rear ends thereof. In other embodiments, the enclosure 330 may include four side walls 320 and only be open-ended at a top thereof. Other configurations may be contemplated, for instance the XY module having the necessary frame components disposed internally therewithin, which may provide for a more compact robot system 100. Various components of the positioning robot system 100 are housed within the enclosure 330 while others extend above, and / or are displaceable in and out of, the enclosure 330. In addition, various components of the positioning robot system 100, as well as the tool system 200, are displaceable in front and / or behind the enclosure relative to the Z axis. Various means for supporting the frame 300 may be contemplated, for instance one or more legs (not shown) which may rest directly on a ground surface. Alternatively, the frame 300 may be provided with wheels, such as castors, to facilitate displacement of the positioning robot system 100, for instance to approach the positioning robot system 100 to an MRI machine. Additional struts 340 and other supports 350 may be provided in the enclosure 330 for joining the bottom wall 310 to the side walls 320 and to otherwise provide additional stiffness and support to the positioning robot system 100. The frame 300 may further be provided with navigation markers 360, illustratively two navigation markers 360 made of plastic, each disposed on a respective side wall 320. In some embodiments, each navigation marker 360 includes infrared (IR) markers identifiable by a navigation camera (not shown) for tracking a position of the positioning robot system 100 in a three-dimensional space (e.g., a medical procedure environment).

[0023] FIG. 2 is a top rear perspective view of the XY module 400 for the positioning robot system 100 of FIG. 1 , according to an embodiment. As discussed above, the XY module 400 is operable for effecting displacement of the tool system 200 within a vertical plane defined by the X and Y axes. Stated differently, the XY module 400 is operable for displacing the tool system 200 along two degrees of freedom. With additional reference to FIG. 1 , the XY module 400 effect such displacement via the pitch module 500 which is operatively coupled to movable components of the XY module 400, as will be discussed in further detail below. Other displacement transmission means between the XY module and the tool system 200 may be contemplated.

[0024] In the shown embodiment, the XY module 400 includes two distinct XY drivetrain assemblies 410, each mounted in parallel to a respective side wall 320. In the shown embodiment, the drivetrain assemblies 410 are identical, and will thus be described together. In other embodiments, different drivetrain assembly configurations on each side wall 320 may be contemplated. In the shown embodiment, each drivetrain assembly 410 includes one or more linear rails 412 (illustratively two linear rails 412) mounted to a respective side wall 320. The rails 412 may, for instance, be made of aluminum. An XY carriage 414 is disposed in each set of XY linear rails 412 and is operable to displace along the linear rails 412, i.e. , along the Y axis. The carriage 414 may, for instance, be made of aluminum, with bronze bushings and plastic sensor triggers. An XY motor 416, illustratively disposed in an XY motor mount 418 (for instance, made of plastic or aluminum) at the intersection of the bottom wall 310 and each side wall 320, is drivingly engaged to each XY carriage 414, illustratively via XY lead screw and nut assembly 420, for displacing each XY carriage along respective linear rails 412. The lead screw may be made of annealed stainless steel, while the nut may be made of plastic. Alternatively, the drivetrain assembly 410 may use a non-ferrous ball screw and nut to provide the linear motion. In the shown embodiment, the lead screw is supported axially and radially by a bearing assembly fixed to the bottom wall 310. In one embodiment, the bearing assembly may use bronze sleeve bushings (i.e., for radial loads) and bronze thrust washers (for axial loads). In another embodiment, the bearing assembly may use pairs of angular contact ball bearings (e.g., made of ceramic) to handle both radial and axial loads. XY arms 422 are operatively connected to each XY carriage 414 at first or proximal ends 422a thereof and are operatively connectable to the pitch module 500 at second or distal ends 422b thereof. The XY arms 422 may, for instance, be made of aluminum. Alternatively, the XY arms 422 could be made of non-ferrous stainless steel. XY linear bushings 424, for instance made of bronze (or oil-embedded bronze), may be provided at the junctions of the XY carriages 414 and the linear rails 412 for maintaining tight tolerances therebetween. In the shown case, XY carriage-arm joints 426 (for instance made of brass and bronze) between the XY carriages 414 and the XY arms may be precision shoulder bolts fit into machined bronze bushings.

[0025] In operation, each XY carriage 414 is independently displaceable by a respective XY motor 416 along respective linear rails 412. In the shown embodiment, each XY motor 416 is a piezoelectric, non-magnetic motor drivingly engaged to respective lead screws for transferring rotational motion of a rotating shaft of a respective XY motor 416 to translational motion of a respective XY carriage 414 along the Y axis. In other embodiments, the XY motors 416 could be linear piezo-electric actuators or linear hydraulic or pneumatic cylinders. Each XY motor 416 mayoperate under control of an encoder (not shown). The encoders are communicatively coupled with a controller (not shown) that provides control signals to the encoder. Such control signals may, for example, cause the XY motors 416 to activate or deactivate, or to control a speed, direction, or other operational parameter of the XY motor 416. In the shown embodiment, XY limit switches 428, for instance optical end stop switches, are provided for delimiting the range of each XY carriage 414 along the Y axis. Other types of XY limit switches may be contemplated, for instance resistive and capacitive sensors that mechanically contact a conductive annular ring, plate, or switch to form a closed electrical circuit to detect a tool presence. Alternatively, the XY limit switches 428 may be optical-based sensors, such as proximity, through beam, retro reflective, or diffuse reflective based sensors.

[0026] As discussed above, the distal ends 422b of each XY arm 422 are operatively coupled to the pitch module 500. Stated differently, the distal ends 422b of the XY arms 422 are fixed to one another, and thus their displacement is intimately linked (i.e. , an over-constrained system). As such, movement of each of the XY carriages 414 along the Y axis is imparted to the transversely-oriented XY arms 422, and respective movement of each XY arm 422 imparts movement to their joined distal ends 422b (and thus to the pitch module 500) in directions along both the X and Y axes. For example, movement of the XY carriages 414 in a same direction along the Y axis (i.e., upwardly or downwardly) may impart solely movement to the pitch module 500 in the Y direction, while oppositely-directed movements of the XY carriages 414 along the Y axis may impart movement both along the X and Y axes, or solely along the X axis. In the shown embodiment, the dual drivetrain assemblies 410 may be able to displace the pitch module 500 (and thus, indirectly, the tool system 200) at speeds of up to 23 mm / s and within a grid of 180 mm by 180 mm along the X and Y axes (i.e., the vertical plate), although other speeds and ranges may be contemplated.

[0027] FIG. 3 is a bottom rear perspective view of a pitch module 500 for the positioning robot system 100 of FIG. 1 , according to an embodiment. As discussed above, the pitch module 500 is operable for effecting the tool system 200 with rotational movement about a pitch axis P. In some cases, the pitch axis P may be aligned with the X axis (i.e. when the positioning robot system 100 is in a normal or resting position). In addition, the pitch module 500 is operable for indirectly transferring, to the tool system 200, the translational movement along the X and Y axes imparted by the XY module 400. The depicted pitch module 500 includes a pitch module frame 502 having four pitch module side walls 504 (two of which are hidden in FIG. 3) and a pitch module top wall 506. A pitch module bottom wall (not shown) may be provided as well.

[0028] In the shown embodiment, the pitch module 500 includes a pitch module drivetrain assembly 510 within the pitch module frame 502. In the shown embodiment, the drivetrain assembly 510 includes one or more linear rails 512 (illustratively two linear rails 512) mounted to and extending between respective side walls 504. The rails 512 may, for instance, be made of aluminum. A pitch module carriage 514 is operatively coupled to the linear rails 512 and is operable to displace along the linear rails 512, i.e. , in a direction perpendicular to the pitch axis P. The carriage 514 may, for instance, be made of aluminum, with bronze bushings and plastic sensor triggers. Additional plates 516 are disposed outwardly and in parallel with the side walls 504, the additional plates 516 acting as a mount for a pitch module motor (not shown), as well as an interface for connecting the pitch module 500 to the XY arms 422. The pitch module motor is drivingly engaged to the pitch module carriage 514, via a pitch module lead screw and nut assembly including a pitch module lead screw 520 and pitch module nut 521 , for displacing the pitch module carriage 514 along the linear rails 512. The lead screw 520 may be made of annealed stainless steel, while the nut 521 may be made of plastic. An output link illustratively in the form of a pitch module control arm 522 (for instance made of aluminum and bronze) is operatively connected to the pitch module carriage 514 at a first or proximal end 522a thereof and is operatively connectable to the yaw module 600 at a second or distal end 522b thereof. In the shown embodiment, the pitch module control arm 522 is for instance in the form of a four bar mechanism, although other output links may be contemplated. For example, output pitch motion could be realized through a non-magnetic gearbox between the pitch module motor and a pitch output axis. Alternatively, the motion could be realized by a non-magnetic gear train, such as a brass worm gear and / or rubber timing belts. Pitch motion could also be realized by a directly driven non-magnetic rotational motor, such as a “walking” piezo motor, which can provide linear motion at a large radial distance to deliver high torque rotational motion. Pitch module linear bushings 524, for instance made of oilite bronze, may be provided at the junctions of the pitch module carriage 514 and the linear rails 512 for maintaining low clearances therebetween. As will be discussed in further detail below, a main pitch joint 526 (for instance made of aluminum and bronze) disposed above the pitch module top wall 506 may operatively and rotatably couple the pitch module 500 to the yaw module 600, with the main pitch joint 526 rotatable about the pitch axis P defined and extending therethrough. In some cases, the main pitch joint 526 is made from aluminum and bronze for increased rigidity and minimal friction, although other materials may be contemplated.

[0029] In operation, the pitch module carriage 514 is displaceable by the pitch module motor along the pitch module linear rails 512. The pitch module motor may be, for instance, a piezoelectric, non-magnetic motor drivingly engaged to the pitch module lead screw 520 for transferring rotational motion of a rotating shaft of the pitch module motor to translational motion of the pitch module carriage 514 along the pitch module linear rails 512. In other embodiments, the pitch module motor may be be a linear piezo-electric actuator, or a hydraulic or pneumatic cylinder. The pitch module motor may operate under control of an encoder (not shown). The encoders are communicatively coupled with a controller (not shown) that provides control signals to the encoder. Such control signals may, for example, cause the pitch module motor to activate or deactivate, or to control a speed, direction, or other operational parameter of the pitch module motor. In the shown embodiment, pitch module limit switches 528, for instance optical end stop switches, are provided for delimiting the range of the pitch module carriage 514 along the pitch module linear rails 512.

[0030] As discussed above, the distal ends 522b of the pitch module control arm 522 are operatively coupled to the yaw module 600. In addition, the yaw module 600 is rotatably mounted to the pitch module 500 via the main pitch joint 526. Therefore, the translational displacement of the pitch module carriage 514 along the pitch module linear rails 512 between side walls 504 may be converted to rotational movement of the yaw module 600 about the pitch axis P by way of the control arm 522 pivoting the yaw module 600 about the main pitch joint 526. Other pivoting or pitching means may be contemplated. In the shown embodiment, the pitch module may be operable for rotating, or tilting, the tool system 200 (by way of the yaw module 600) by about 7.5 degrees from a neutral position (e.g., aligned with the Z axis) with respect to the pitch axis P, although other ranges of rotation may be contemplated.

[0031] FIG. 4 is a front top perspective view of a yaw module 600 for the positioning system 100 of FIG. 1 , in accordance with an embodiment. As discussed above, the yaw module 600 is operable for effecting the tool system 200 with rotational movement about a yaw axis W. In addition, the yaw module 600 is operable for transferring, to the tool system 200, the translational movement along the X and Y axes imparted by the XY module 400 and the rotational (i.e. , pitch) movement about the pitch axis P imparted by the pitch module 500. The depicted yaw module 600 includes a yaw module frame 602 having spaced apart and parallel yaw module side walls 604. In the depicted embodiment, each side wall 604 includes a connector 606 for operative coupling to the pitch module 500 via the main pitch joint 526, and a connector 608 for operativecoupling to the pitch module control arm 522. Other connecting means to the various components of the pitch module 500 may be contemplated.

[0032] In the shown embodiment, the yaw module 600 includes a yaw module drivetrain assembly 610 within the yaw module frame 602. In the shown embodiment, the yaw module drivetrain assembly 610 includes one or more yaw module linear rails 612 (illustratively two linear rails 612) mounted to and extending between respective side walls 604. The rails 612 may, for instance, be made of aluminum. A yaw module carriage 614 is operatively coupled to the linear rails 612 and is operable to displace along the linear rails 612 between the side walls 604. The carriage 414 may, for instance, be made of aluminum with bronze bushings. A yaw module motor 616, illustratively disposed in an yaw module motor mount 618 (for instance, made of plastic) disposed outwardly of one of the side walls 604, is drivingly engaged to the yaw module carriage 614. The yaw module motor 616 is drivingly engaged to the yaw module carriage 614 via a yaw module lead screw and nut assembly including a yaw module lead screw 620 and yaw module nut 621 , for displacing the yaw module carriage 614 along the linear rails 612. The lead screw 620 may be made of annealed stainless steel, while the nut 621 may be made of plastic. An output link illustratively in the form of a yaw module control arm 622 (for instance made of aluminum) is operatively connected to the yaw module carriage 614 at a first or proximal end 622a thereof and is operatively connectable to the Z module 700 at a second or distal end 622b thereof. In the shown embodiment, the yaw module control arm 522 is for instance in the form of a horizontal bar, although other output links may be contemplated. Yaw module linear bushings 624, for instance made of oilite bronze, may be provided at the junctions of the yaw module carriage 614 and the linear rails 612 for maintaining low clearance and friction therebetween. As will be discussed in further detail below, a main yaw joint 626 disposed between the side walls 604 at the control arm distal end 622b may operatively and rotatably couple the yaw module 600 to the Z module 700, with the main yaw joint 526 rotatable about the yaw axis W defined and extending therethrough. In some cases, the main yaw joint 626 is made from aluminum and bronze for increased rigidity and minimal friction, although other materials may be contemplated.

[0033] In operation, the yaw module carriage 614 is displaceable by the yaw module motor 616 along the yaw module linear rails 612. The yaw module motor 616 may be, for instance, a piezoelectric, non-magnetic motor drivingly engaged to the yaw module lead screw 620 for transferring rotational motion of a rotating shaft of the yaw module motor 616 to translational motion of the yaw module carriage 614 along the yaw module linear rails 612. In other embodiments, the yaw module motor 616 could also be a linear piezo-electric actuator orhydraulic or pneumatic cylinder. The yaw module motor 616 may operate under control of an encoder (not shown). The encoders are communicatively coupled with a controller (not shown) that provides control signals to the encoder. Such control signals may, for example, cause the yaw module motor 616 to activate or deactivate, or to control a speed, direction, or other operational parameter of the yaw module motor 616. In the shown embodiment, yaw module limit switches 628, for instance optical end stop switches, are provided for delimiting the range of the yaw module carriage 614 along the yaw module linear rails 612.

[0034] As discussed above, the distal end 622b of the yaw module control arm 622 is operatively coupled to the Z module 700. In addition, the Z module 700 and distal end 622b are rotatably to the main yaw joint 626. Therefore, the translational displacement of the yaw module carriage 614 along the yaw module linear rails 612 between side walls 604 may be converted to rotational movement of the Z module 700 about the yaw axis W by way of the control arm 622 pivoting the Z module 700 about the main yaw joint 626. Other rotating or yawing means may be contemplated. For instance, the above-described yaw motion could be realized using a nonmagnetic gearbox or a non-magnetic gear train, for instance a brass worm gear with rubber timing belts and aluminum pulleys. In the shown embodiment, the yaw module 600 may be operable for rotating, or yawing, the tool system 200 (by way of the Z module 600) by about 7.5 degrees from a neutral position (e.g., aligned with the Y axis) with respect to the yaw axis W, although other ranges of rotation may be contemplated. In the depicted embodiment, the yaw module control arm 622 further includes, at the proximal end 622a, a control arm joint 630 (for instance made of out brass) for interfacing the yaw module control arm 622 with the yaw module carriage 614 to minimize any motion backlash in operation.

[0035] FIG. 5 is a rear top perspective view of a Z module 700 for the positioning system of FIG. 1 , in accordance with an embodiment. As discussed above, the Z module 700 is operable for effecting the tool system 200 with translational movement along the Z axis. It is understood that such translational direction may be relative to any rotation imparted by the pitch module 500 and yaw module 600, and as such the Z axis may be said to be operable to effect the tool system 200 with translational movement along a translation axis T which may or may not be aligned with the Z axis. Stated differently, the Z module 700 may be operable to displace the tool system 200 in and out of a clinical workspace such as an MRI machine. The depicted Z module 700 includes a Z module frame 702 having a side plate 704 and a bottom plate 706 supporting the various components of the Z module 700. In the depicted embodiment, the bottom plate 706 includes a connector 708 for operative coupling to the yaw module 600 via the yaw module control arm 622(at the distal end 622b thereof). Other connecting means to the yaw module 600 may be contemplated.

[0036] In the shown embodiment, the Z module 700 includes a Z module drivetrain assembly 710 within the Z module frame 702. In the shown embodiment, the Z module drivetrain assembly 710 includes one or more Z module linear rails 712 (illustratively two linear rails 712) mounted to the side plate 704. The rails 712 may, for instance, be made of aluminum. A Z module carriage 714 is operatively coupled to the linear rails 712 and is operable to displace along the linear rails 712 between a proximal rail end 712a and a distal rail end 712b. The carriage 714 may, for instance, be made of aluminum, with bronze bushings and plastic sensor triggers. A Z module motor 716, illustratively disposed in a Z module motor mount 718 (for instance, made of plastic) disposed below the bottom plate 706 towards the proximal rail end 712a, is drivingly engaged to the Z module carriage 714. The Z module motor 716 is drivingly engaged to the Z module carriage 714 via a belt drive assembly 717 (for instance made of aluminum, rubber and brass) and a Z module lead screw and nut assembly 720 for displacing the Z module carriage 714 along the linear rails 712, although other transmission means may be contemplated. The lead screw may be made of annealed stainless steel, while the nut may be made of plastic. Z module linear bushings 724, for instance made of bronze, may be provided at the junction of the Z module carriage 714 and the linear rails 712 for maintaining low clearance therebetween. In the shown embodiment, Z module limit switches 728, for instance optical end stop switches, are provided for delimiting the range of the Z module carriage 714 along the Z module linear rails 712. As will be discussed in further detail below, the tool system 200 may be operatively connected to the Z module carriage 714 at a tool mount 732, for instance a rigid mount, for effecting translational motion to the tool system 200 via the Z module along the translation axis extending in parallel with the direction of travel of the Z module carriage 714 along the Z module linear rails 712.

[0037] In operation, the Z module carriage 714 is displaceable by the Z module motor 716 along the Z module linear rails 712. The Z module motor 716 may be, for instance, a piezoelectric, non-magnetic motor drivingly engaged to the Z module lead screw and nut assembly 720 via the belt drive assembly 717 for transferring rotational motion of a rotating shaft of the Z module motor 716 to translational motion of the Z module carriage 714 along the Z module linear rails 712. The Z module motor 716 may operate under control of an encoder (not shown). The encoders are communicatively coupled with a controller (not shown) that provides control signals to the encoder. Such control signals may, for example, cause the Z module motor 716 to activate ordeactivate, or to control a speed, direction, or other operational parameter of the Z module motor716.

[0038] As discussed above, the tool system 200 may be operatively coupled to the Z module carriage 714 via the tool mount 732. As such, translational motion of the Z module carriage 714 may be directly transferred to the tool system 200, via the tool mount 732, for effecting displacement of the tool system 200 along the translation axis T. Other means for effecting translation may be contemplated. In the shown embodiment, the Z module 600 may be operable for effecting translational movement of the tool system 200 by about 250 mm between start and end positions with respect to the yaw axis W, although other ranges of translation may be contemplated.

[0039] In various embodiments, the positioning robot system 100 may be said to include a motion transmission assembly for selectively effecting motion unto the tool system 200 in up to five degrees and that includes the various drivetrain assemblies 410, 510, 610, 710 and their associated components. In some cases, one or more of the drivetrain assemblies 410, 510, 610, 710 may be overridden manually, for instance in the case of malfunction. In various embodiments, all degrees of freedom may be self-locking. As such, in the case of power loss, the position of the tool system 200 may be maintained, unless manually overridden. In various embodiments, one or more positioning robot system 100 degrees of freedom may be selected to align with tool system 200 degrees of freedom, such that the positioning robot system 100 can provide redundant motion to the tool system 200 in the case of tool system 200 malfunction. For example, the final degree of freedom of one embodiment of the positioning robot system 100 may have a stage providing linear motion in the Z direction prior to, i.e., closer to the frame 300, than the tool system 200 which also provides Z motion. Furthermore, the positioning robot system 100 may be mounted on another mechanism (not shown), for instance a serial robotic or manual arm, capable of locating it in space close to a working area that may not be accessible by the reach of the disclosed device mounted to the robot frame 300. This may allow the system to be used in a broader range of applications, such as abdominal access procedures.

[0040] FIG. 6 is a flowchart depicting an exemplary method 1000 for operating a positioning robot system 100, in accordance with an embodiment.

[0041] At block 1002, an end user positions the positioning robot system 100 having a medical tool system 200 mounted thereto in a medical procedure environment adjacent a clinicalworkspace. For example, the clinical workspace is an MRI machine. In some embodiments, the positioning robot system 100 may use IR markers viewed by an IR navigation system to ensure the end user places the positioning robot system 100 at a close enough distance relative to the clinical workspace.

[0042] At block 1004, the end user manipulates the positioning robot system 100 to displace the medical tool system 200 into the clinical workspace to begin a medical procedure. For example, manipulating the medical tool system 200 includes effecting motion to the medical tool system in up to five degrees of freedom, such as translation in up to three directions and rotation in up to two directions. In some embodiments, the motions can occur along all degrees of freedom simultaneously, or along different degrees of freedom in series, or any combinations thereof. At any point during the motion, the motion can be paused (and resumed), or in emergencies, stopped. The motions can be performed with positional feedback from the robot encoders alone, or with additional sensor feedback, such as from a clinical navigation (IR) camera or a medical scanner (ex. MRI or CT).

[0043] At block 1006, the end user manipulates the positioning system robot to displace the medical tool system outside of the clinical workspace after the medical procedure is complete.

[0044] The present disclosure teaches a positioning robot system and a method for using said positioning robot system for effecting motion unto a medical tool system to be used in a clinical workspace such as an MRI machine. The medical tool system may thus be positioned to carry out a medical procedure such as a biopsies, surgeries, or other medical procedures that require a medical tool to be manipulated into human tissue (or other animal tissue) or for otherwise manipulating such tissue. The various components of the positioning robot system may thus be made of materials suitable for insertion into, or positioning adjacent, an MRI machine, for instance non-magnetic materials such as aluminum, austenitic stainless steel, titanium, brass, bronze, plastics, and ceramics. In some embodiments, the medical tool may be selectively displaced within a volume of up to about 180 x 180 x 250 mm and achieve angular displacements in pitch and yaw of about +- 7.5 degrees, offering clinicians or other end users flexibility in manipulating medical tools for various medical procedures in constrained spaces. While the positioning robot system as described above is shown to be able to selectively effect motion unto a medical tool system in up to five degrees of freedom, it is understood that in other embodiments the positioning robot system may be constrained to fewer degrees or freedom or provide movement in more than five degrees of freedom.

[0045] The above described embodiments are intended to be illustrative only and in no way limiting. The described embodiments are susceptible to many modifications of form, arrangement of parts, details and order of operation. The disclosure is intended to encompass all such modification within its scope, as defined by the claims..

Claims

WHAT IS CLAIMED IS:

1. A positioning robot system comprising: a structural frame disposed in a space defined by orthogonal X, Y and Z axes; a tool mount mounted to the structural frame and configured for receiving a medical tool system; and a motion transmission assembly for selectively effecting motion unto the tool mount, the motion transmission assembly including: a first drivetrain assembly for selectively effecting translational motion unto the tool mount about a vertical plane defined by the X and Y axes; a second drivetrain assembly for selectively effecting rotational motion unto the tool mount about a first axis of rotation parallel to the X axis; a third drivetrain assembly for selectively effecting rotational motion unto the tool mount about a second axis of rotation parallel to the Y axis; and a fourth drivetrain assembly for selectively effecting translational motion unto the tool mount in a direction parallel to the Z axis.

2. The positioning robot system of claim 1 , wherein the first drivetrain assembly includes a pair of movable arms, each arm having a first end coupled to a carriage selectively displaceable along the Y axis and a second end coupled to the second end of the other arm, wherein movement of the carriages effects the translational unto the tool mount about a vertical plane defined by the X and Y axes.

3. The positioning robot as defined in claim 2, wherein each of the carriages is operatively coupled to a motor via a lead screw and nut assembly and is selectively displaceable along one or more linear rails.

4. The positioning robot as defined in claim 1 , wherein the second drivetrain assembly includes a pitch joint operatively and rotatably coupling the tool mount to the frame, the pitch joint defining the first axis of rotation.

5. The positioning robot as defined in claim 4, wherein the second drivetrain assembly further includes a carriage selectively displaceable along one or more linear rails, the carriage operable to effect the rotational motion unto the tool mount about the first axis of rotation by converting translational motion along the linear rails to the rotational motion via a pivoting control arm.

6. The positioning robot as defined in claim 1 , wherein the third drivetrain assembly includes a yaw joint operatively and rotatably coupling the tool mount to the frame, the yaw joint defining the second axis of rotation.

7. The positioning robot as defined in claim 6, wherein the third drivetrain assembly further includes a carriage selectively displaceable along one or more linear rails, the carriage operable to effect the rotational motion unto the tool mount about the second axis of rotation by converting translational motion along the linear rails to the rotational motion via a yawing control arm.

8. The positioning robot as defined in claim 1 , wherein the fourth drivetrain assembly includes a carriage selectively displaceable in the direction parallel to the Z axis and having the tool mount disposed thereon.

9. The positioning robot as defined in claim 8, wherein the carriage is operatively coupled to a motor via a lead screw and nut assembly and a belt drive assembly and is selectively displaceable along one or more linear rails in the direction parallel to the Z axis.

10. The positioning robot system of claim 1 , wherein the structural frame, the tool mount, and the motion transmission assembly are made of non-magnetic materials.11 . The positioning robot system of claim 1 , wherein the tool mount is configured for receiving a medical tool to be manipulated into human or animal tissue.

12. The positioning robot system of claim 1 , wherein the motion transmission assembly is configured for selectively displacing the medical tool system mounted to the tool mount within a volume of up to about 180 x 180 x 250 mm.

13. A positioning robot system comprising: a structural frame disposed in a space defined by orthogonal X, Y and Z axes; a tool mount mounted configured for receiving a medical tool system; anda motion transmission assembly operatively coupling the tool mount to the structural frame and configured for effecting motion unto the tool mount in up to five degrees of freedom.

14. The positioning robot system of claim 13, wherein the structural frame, the tool mount, and the motion transmission assembly are made of non-magnetic materials.

15. The positioning robot system of claim 13, wherein the tool mount is configured for receiving a medical tool to be manipulated into human or animal tissue.

16. The positioning robot system of claim 13, wherein the motion transmission assembly is configured for selectively displacing the medical tool system mounted to the tool mount within a volume of up to about 180 x 180 x 250 mm.

17. A method of operating a positioning robot system, the method comprising: positioning the positioning robot system in a medical procedure environment adjacent a clinical workspace, the positioning robot system having a medical tool system mounted thereto; manipulating the positioning robot system to displace the medical tool system into the clinical workspace to begin a medical procedure; and after the medical procedure is complete, manipulating the positioning robot system to displace the medical tool system outside of the clinical workspace.

18. The method of claim 17, wherein the clinical workspace is magnetic resonance imaging (MRI) machine.

19. The method of claim 17, wherein manipulating the positioning robot system to displace the medical tool system into the clinical workspace includes effecting motion to the medical tool system in up to five degrees of freedom.

20. The method of claim 17, wherein manipulating the positioning robot system to displace the medical tool system into the clinical workspace includes selectively displacing the medical tool system within a volume of up to about 180 x 180 x 250 mm.

Images