Compact ergonomic universal surgical console for robotic surgery

Abstract

This invention relates to a universal robotic surgical console (100) designed for optimal ergonomics and precision in minimally invasive surgical procedures. The console features a pair of telescopic columns (2,3) that allow adjustable height for surgeon comfort, a roll-base assembly (5) with a counterbalance system to offset weight, and a multi-axis angular controller (MAAC) that closely mimics the surgeon's wrist movements. It includes a grip assembly (7) equipped with an inertial measurement unit (IMU) to enable precise pitch, yaw, and roll control. The pedal board (9) allows foot-operated adjustments, enhancing functionality. The robotic manipulator, offering seven degrees of freedom, facilitates fine and gross instrument movements. Additionally, the motor-transducer unit reduces surgeon fatigue by providing dynamic weight counterbalance. This advanced console design promotes flexibility, precision, and safety, facilitating enhanced control and reduced strain during complex surgical procedures.

Description

[0001] TITLE: COMPACT ERGONOMIC UNIVERSAL SURGICAL CONSOLE FOR ROBOTIC SURGERY

[0002] CROSS REFERENCE

[0003] The patent application claims the priority date benefit of Indian Patent Application no.

[0004] 202431091955 filed on Dec 25, 2024.

[0005] FIELD OF THE INVENTION

[0006] This invention relates to robotic systems, specifically to a robotic surgical console designed to facilitate minimally invasive surgeries (MIS) and other surgical procedures. The console captures and replicates the complex, precise hand movements of a surgeon, enabling telemanipulation of a surgical robotic manipulator.

[0007] BACKGROUND OF THE INVENTION

[0008] In recent years, robotics has transformed industries such as engineering, healthcare, logistics, and agriculture. This growth has been driven by the availability of advanced modelling software, design tools, cost-effective electronic components, machine learning, artificial intelligence, and control systems, which have allowed for the development of highly complex and capable robots. These robots integrate mechanical, electronic, and software engineering, enabling them to perform sophisticated, precise, and repetitive tasks. Some of the patent literature discussing robotic assisted surgery are enlisted herein:

[0009] WO1995001757A1 discloses robotic system for observing and remote treatment of moving parts. It relates to a minimally invasive robotic surgical (MIS) system that integrates automated target tracking of a moving body part by robotic surgical tools with stereoscopic video-image guided control of these tools by the surgeon.

[0010] US5397323A discloses an apparatus that can position and re-position a centre-of-motion mechanism at a working point location remote from the apparatus. It permits a surgeon to position the centre-of-motion mechanism in a patient at the working point at a distance from the main parts of the apparatus, thereby keeping the main parts out of the surgeon's field of view of the work area and out of the work area in general.US5631973A discloses a telemanipulation system for manipulating objects located in a workspace at a remote worksite by an operator at an operator's station, such as in a remote surgical system, the remote worksite having a manipulator or pair of manipulators each with an end effector for manipulating an object at the workspace.

[0011] In healthcare, robotic-assisted surgery has ushered in the era of minimally invasive surgery (MIS), which offers numerous benefits, including reduced pain, minimal scarring, decreased blood loss, and shorter recovery times. However, MIS places high demands on surgeons, requiring both intense concentration and physical endurance to sustain extended procedures. And despite advances in MIS, surgeons still face challenges with long, physically demanding procedures that require steady, precise hand movements and control. Existing robotic consoles often lack ergonomic features that accommodate prolonged use, leading to physical strain and increased risk of fatigue, which can affect surgical outcomes. Further the current MIS systems also involve lengthy training periods due to the manual dexterity needed.

[0012] The inventors in the present invention considering all the above shortcomings had devised a universal robotic surgical console that captures a surgeon’s precise hand and finger movements with micron-level accuracy and translates these inputs to control a robotic manipulator during MIS procedures.

[0013] OBJECT OF THE INVENTION

[0014] The main object of the invention is to provide an ergonomic and precise control interface that translates the surgeon's hand and finger movements into highly accurate robotic manipulations, enhancing precision in minimally invasive surgeries (MIS).

[0015] A further object of the invention is to offer a modular and adjustable console design that can be easily transported, reassembled, and adjusted in height and width, accommodating different workspaces and surgeon preferences.

[0016] Yet another object of the invention is to integrate advanced multi-axis movement tracking through technologies like the Multi-Axis Angular Controller (MAAC) or gimbal mechanisms, allowing natural, intuitive control over robotic instruments.

[0017] A further object of the invention is to reduce surgeon fatigue with a gravity counterbalance system, minimizing the physical load on the hands during prolonged operations.Another object of the invention is to enhance safety and operational stability with features such as a link dock mechanism for secure calibration and a stable, maneuverable base that allows easy positioning.

[0018] Yet another object of the invention is to provide enhance safety with mechanism for detecting if the console has left the hand of the surgeon and stops the motion to prevent accidents.

[0019] SUMMARY OF THE INVENTION

[0020] The present invention advances the field of surgical robotics by providing a user-friendly and ergonomically optimized solution that enables high accuracy in surgical procedures with reduced physical demand on the surgeon.

[0021] The invention provides a surgical console designed to interface with robotic manipulators, specifically for minimally invasive surgery. The console includes:

[0022] A base structure and telescopic columns that provide stability, portability, and height adjustability.

[0023] A roll-base assembly with multiple degrees of freedom (DOF) that mimics the hand movements of a surgeon, translating these into precise manipulations by the robotic system.

[0024] - Ergonomic grips and a hand-rest that allow the surgeon to comfortably control the robotic manipulator over extended periods.

[0025] A gravity counterbalance system that relieves stress from the surgeon’s hands, using either weights and / or a BLDC motor-admittance control system.

[0026] - Docking mechanisms for securing the console parts when not in use, facilitating easy transport and reassembly.

[0027] A VR headset serving as a visual display for rendering immersive surgical environment.

[0028] In various embodiments as discussed in the following description part, the console includes a Multi-Axis Angular Controller (MAAC) or gimbal mechanism for capturing angular displacements of the hand, mimicking the dexterity of the human wrist. The grip controls allow easy operation of the end effectors of the robotic manipulator, with intuitive button controls for jaw actuation and clutching.BRIEF DESCRIPTION OF DRAWINGS

[0029] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following description thereof. Such description makes references to the annexed drawings wherein:

[0030] Figure-1: Diagram of the console chassis.

[0031] Figure-2: Diagram of the roll base assembly with attached gimbal.

[0032] Figure-3: Diagram of the roll base assembly with multi-axis angular controller.

[0033] Figure-4: Diagram of the right-hand grip.

[0034] Figure-5: Diagram of the Robotic manipulator.

[0035] Figure-6: Diagram of Left roll base with setup for counterbalancing using admittance control

[0036] Figure-7: Diagram of Robotic manipulator end effector (Surgical tool tip).

[0037] Figure-8: Diagram of Counterweight counterbalance system.

[0038] Figure-9: Diagram of Horn configuration of the MAAC.

[0039] Figure- 10: Diagram of the surgical console with a VR headset and VR stand and all the degrees of freedom for the same.

[0040] Figure-11: Diagram depicts the VR headset along with the quick release buttons from a perspective view.

[0041] Figure- 12: Diagram depicting the wireless hand controller retrofitted with a pinch grip mechanism.

[0042] DETAILED DESCRIPTION OF THE INVENTION

[0043] The following description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. This description is not intended to be a detailed catalogue of all the different ways in which the invention may be implemented, or all the features that may be added to the instant invention.

[0044] The terms “for example” and “such as,” and grammatical equivalences thereof, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise.As used herein, the term “about” is meant to account for variations due to any experimental errors which may be commonly accepted in the field for a numeric value, for example such a variation can be considered as a ±10% of the said numeric value. All measurements reported herein are understood to be modified by the term “about,” whether or not the term is explicitly used, unless explicitly stated otherwise. Further for the purposes of the present invention, ranges may be expressed as from “about” one particular value to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value to the other particular value. The recitation of numerical ranges by endpoints includes all the numeric values subsumed within that range.

[0045] As used herein, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

[0046] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Methods and materials are described herein for use in the present disclosure; other suitable methods and materials known in the art can also be used. The materials, methods and examples are illustrative only and not intended to be limiting by any means. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. In case of a conflict, the present specification, including definitions, will control.

[0047] Throughout this specification, unless the context requires otherwise the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

[0048] The term “including” is used to mean “including but not limited to”, “including” and “including but not limited to” are used interchangeably.

[0049] As used herein, the phrases “robotic surgical console” or “robotic tele-manipulator” or “system” or “Device” is used interchangeably and refers to the robotic surgical console (100), which is to captures the intricate movements of a surgeon's hands and fingers and transmits them to robotic manipulators, performing delicate tasks with ease, accuracy and unlimited repetition. It acts as a controller used by a surgeon to instruct the robotic manipulator to perform certain tasks essential for surgery.As used herein, the term “MAAC joint” refers to a joint with 3 or more degrees of freedom. It has a construction similar to that of a universal joint / coupling with 2 yokes connected by a spider. The MAAC joint couples the MAAC to the linkage system.

[0050] As used herein, the term “grip” refers to an assembly that is directly held by the surgeon. It can be held by the fingers or by the hand itself. The grip can be in the pinch or power format. The console is actuated by motion of the grip.

[0051] The present invention is a universal robotic surgical console that captures a surgeon’s precise hand and finger movements with micron-level accuracy and translates these inputs to control a robotic manipulator during MIS procedures.

[0052] In some embodiment the present invention features an adjustable, ergonomic design that adapts to the surgeon’s position, reducing physical strain.

[0053] In some embodiment according to the present invention the console includes a counterbalance system to relieve load on the surgeon’s hands, along with various embodiments that improve the control and precision of surgical movements. This makes it more feasible for surgeons to perform lengthy and complex surgeries without significant physical fatigue. The surgical console also reduces the mental and physical burden on surgeons, allowing them to perform MIS with enhanced precision and efficiency. By incorporating advanced ergonomic features, the device minimizes fatigue, making MIS more accessible and efficient.

[0054] The below embodiments of the present invention universal surgical console focus on enhancing accessibility, ergonomic flexibility, control precision, and safety, aiming to improve the overall usability and effectiveness of minimally invasive surgeries for a broad range of surgeons and environments.

[0055] In one embodiment the surgical console comprises of multiple independently detachable modules, enabling compact storage and convenient transport through confined spaces, such as narrow doorways or hallways. Each module is designed to seamlessly reconnect, ensuring full functionality and operational stability when reassembled in diverse surgical environments.In one aspect of the said embodiment the modular design of the console includes a specific locking mechanism that prevents accidental disassembly during operation, ensuring consistent performance even when assembled in restricted or non-ideal spaces.

[0056] In another embodiment the console according to the present invention comprises a height-adjustable platform that can be modified using either a manual crank or an electronic motor system, allowing ergonomic adjustments based on surgeon height or comfort. Additionally, the console has extendible linkages or telescoping arms that permit width customization to suit different workspace constraints.

[0057] In one related aspect of the above embodiment the surgical console includes side-mounted telescopic columns designed to improve workspace efficiency. This configuration minimizes obstruction in front of the surgeon, allowing for an open area that facilitates additional instrument placement, enhanced visual accessibility, and unrestricted movement during surgery.

[0058] In one aspect of the said embodiment the height and width adjustment mechanisms are designed to support weight tolerances up to a defined load capacity to maintain stability and prevent tilting, enhancing user safety during adjustments.

[0059] In some embodiment the ergonomic design of the hand support (4) includes an angled top connector that naturally aligns with the surgeon's hands in a resting position. This configuration reduces wrist fatigue, enhances ergonomic comfort, and increases workspace by positioning the hands perpendicular to the support's contact point, optimizing tool manipulation efficiency.

[0060] In another embodiment the console integrates a Multi-Axis Angular Controller (MAAC) and a gimbal mechanism to capture the surgeon’s wrist motions (roll, pitch, and yaw). This enables accurate, real-time control of the robotic manipulator, enhancing surgical precision. The gimbal configuration comprises the axes of the gimbal intersect at the surgeon wrist thereby making it feel like all the links of the gimbal are rotating about the surgeon’s wrist, while the MAAC configuration has its axis intersecting at the centre of the MAAC joint for versatility in user preference and comfort.

[0061] In one aspect of the said embodiment the MAAC and gimbal systems are calibrated to specific angular ranges to avoid overextension or unintended rotation, providing controlled manipulation within safe operational limits.In some embodiment the console's adjustable width provides adaptability to various surgical room setups. Extension linkages can be securely added or retracted at the base connection and top beam. Alternatively, extendible linear mechanisms enable smooth, precise width adjustments. These features allow the console to accommodate both confined and expansive surgical spaces without compromising stability. In one aspect of the above embodiment the system further comprises secure locking mechanisms for extension linkages and the precision components of extendible linear mechanisms.

[0062] In another embodiment the console characteristically incorporates a gravity counterbalance system to reduce hand strain by using either a pulley-weighted mechanism and / or electronically controlled BLDC motor-transducer units, compensating for the weight exerted by the surgeon's hands on the controls. This system is configured to minimize fatigue, enabling surgeons to maintain precision during extended procedures.

[0063] In one aspect of the said embodiment the counterbalance system is pre-set to operate within a defined weight range that balances effectively without resistance, allowing prolonged use without excessive strain on the surgeon's hands.

[0064] In another embodiment, the console according to the present invention includes an inertial measurement unit (IMU) is integrated into the grip. This unit monitors the spatial orientation of the surgeon’s hand in real time. The IMU enhances the system's ability to adapt to the surgeon's natural hand movements, reducing the learning curve associated with robotic-assisted surgical tools. Further to improve the reliability of the orientation tracking system, the rotational joint data from the hand controller is correlated with IMU data. This crossreferencing process reduces measurement drift and noise, resulting in higher precision and stability of the robotic manipulator during prolonged surgical procedures.

[0065] In a related aspect of the above embodiment, the rotational sensor and the IMU integrates with the system’s computational processor to provide real-time feedback, and includes algorithms to reduce drift and noise.

[0066] In a further embodiment the console according to the present invention features a link dock mechanism, a secure docking system for the linkage arms and sensors, which automatically engages when the system is not in use. This mechanism ensures proper homing of all components, and it initiates calibration protocols to verify sensor accuracy and alignment prior to each surgical operation.In a related aspect of the above embodiment the said docking mechanism includes an interlocking sensor that signals proper calibration and disables the system once docking is completed, ensuring safe re-engagement of the robotic system.

[0067] In one embodiment according to the present invention the console comprises a grip (7) incorporating a dual-lever system comprising:

[0068] Primary levers: Ergonomically positioned for easy actuation by the surgeon’s thumb or index finger to control essential functions, such as tool jaw actuation.

[0069] Secondary levers: Designed for ring, middle, or index finger control, enabling auxiliary functions like clutch engagement.

[0070] In one aspect this design improves functionality by reducing the need for repositioning the grip during operation. In another aspect there is a provision on the grip to place the index finger securely to prevent the motion of the grip while actuating the levers.

[0071] In another embodiment according to the present invention the console comprises a specialized finger-grip control on the console that further provides ergonomic support, mimicking the surgeon’s wrist movements to control the robotic manipulator with high precision. This grip includes strategically placed control buttons for functions such as jaw actuation and clutch activation, allowing for intuitive and precise manipulation during surgery.

[0072] In one aspect of the said embodiment the said grip design includes a failsafe mechanism that detects and prevents unintended movements or accidental button presses, thereby reducing the risk of control errors during operation.

[0073] In yet another aspect of the said embodiment the surgical console further features interchangeable hand controllers including options for power grip and pinch grip configurations, and such configuration can be achieved with or without a gimbal interface. In a further embodiment the system according to the present invention further is equipped with a rotational sensor positioned between a grip and the MAAC joint, enabling precise detection and measurement of roll angulation. This feature ensures that every subtle hand movement is accurately transmitted to the robotic manipulator, improving the surgeon’s control during delicate procedures.In some embodiments according to the present invention the console is equipped with an integrated monitor display that provides real-time endoscopic visualization of the surgical site, enhancing the surgeon’s spatial awareness and accuracy. The display is positioned within the console’s visual range to minimize head movement and maintain focus on the surgical field.

[0074] In one aspect of the said embodiment the said integrated monitor display system includes adjustable brightness and contrast controls specifically calibrated for high-contrast visuals in low-light surgical environments, ensuring optimal image clarity.

[0075] In some embodiment according to the present invention for operational stability and enhanced mobility, the console’s base includes standoffs or retractable wheels, providing both stability and manoeuvrability. This feature allows the console to be securely positioned near the operating table and easily transported between operating rooms when necessary. In a related aspect of the above embodiment the wheels feature locking mechanisms that can be engaged to prevent movement once the console is positioned, maintaining stability during operation and reducing the risk of unintentional movement.

[0076] In one embodiment, the present invention provides an ergonomic surgical console (100) for robotic-assisted surgery using robotic system, comprising:

[0077] a console base (1) with standoffs or wheels for mobility and stability, housing electronic components;

[0078] a plurality of telescopic columns (2, 3), each having an upper and lower section, attached to the console base (1), configured to provide height adjustment (10);

[0079] a roll-base assembly (5) connected to an upper column (3) via a roll connector (15), configured for rotational movement;

[0080] a Multi-Axis Angular Controller (MAAC) or gimbal mechanism (8) located at the linkage assembly link (14) which is connected to the roll-base assembly (5), enabling roll, pitch, and yaw motions for controlling a robotic manipulator;

[0081] a grip (7) ergonomically positioned on the MAAC, equipped with a jaw actuation lever (21) and clutch button (43), to capture and transmit the surgeon's wrist movements to the robotic manipulator for precise tool manipulation; wherein the console base (1) comprises detachable modules to facilitate compact storage and transport, and the MAAC and gimbalmechanism (8) allow controlled manipulation within specific angular ranges to prevent overextension.

[0082] In another embodiment, the ergonomic surgical console (100) is configured to operate in a surgical simulation and training mode. In this embodiment, the console (100) comprises a Virtual Reality (VR) headset (46), a VR stand (50), a foot pedal board (45), wireless hand controllers, and an onboard computer.

[0083] The VR headset (46), serves as a visual display for rendering immersive surgical environments. The VR headset (46) is operable in two modes. In a first mode, the VR headset (46) is docked onto the VR stand (50) to emulate a closed-console immersive display, wherein the user positions their head relative to the console (100). In a second mode, the VR headset (46) is undocked from the VR stand (50) and worn directly by the user using straps, thereby emulating an open-console configuration.

[0084] The VR stand (50), provides three degrees of freedom including vertical adjustment (47), horizontal adjustment (48), and rotational movement, enabling ergonomic positioning of the VR headset (46). These movements may be electro-mechanically actuated using switches or buttons integrated into the console (100).

[0085] In another embodiment, the VR headset (46) is detachably coupled to the VR stand (50) using a spring-loaded finger-actuated quick-release mechanism, allowing rapid docking and removal of the VR headset (46).

[0086] In some embodiment, the ergonomic surgical console (100) comprises wireless hand controllers configured to track translational motion along X, Y, and Z axes and rotational motion including roll, pitch, and yaw. The wireless hand controllers are configured to communicate with the onboard computer and VR headset (46) to control robotic end effectors within a simulated or real surgical environment.

[0087] In one aspect of the above embodiment, the wireless hand controllers are retrofitted with mechanical attachments configured to emulate pinch grip, gun grip, open-hand grip, or freehand grip, enabling simulation of multiple robotic surgical platforms.

[0088] In one embodiment according to the present invention the roll-base assembly (5) features a pulley-based counterweight system that offsets the torque created by linkages and components. This counterweight is suspended from the roll base, enabling smoothermovements and reducing strain on the motorized mechanisms. This design ensures consistent performance and prolonged operational reliability.

[0089] In one aspect of the above embodiment the materials and weight calibration processes are used to create an effective counterweight system balances operational efficiency and compactness of the overall system (100).

[0090] In a further embodiment the system further comprises three compact, high-precision motors - integrated at the base of the master arm assembly to control arm movements entirely from the base. These motors electronically counterbalance the arm links against gravitational forces, enabling effortless movement and adjustable motion dynamics for a customized user experience tailored to the surgeon's preferences.

[0091] In one aspect of the above embodiment the system incorporates software interfaces or control panels allowing surgeons to adjust motor settings and motion dynamics on the fly. In yet another embodiment according to the present invention each link extending from the roll base assembly is weight-balanced for optimal motion control. By strategically placing a mass at specific distances along the link, the center of gravity is aligned at the joint connecting it to the next link. This feature minimizes strain on the surgeon’s hand and enhances the precision of movements transmitted to the robotic manipulator.

[0092] Further details of the present invention ergonomic surgical console are described herein below in view of various descriptions of the figures as referred in the present specification:

[0093]

[0094]

[0095] Figure - 1, illustrates the foundational structure of the surgical console (100), encompassing the console base (1), telescopic columns, and key connection points. The console base (1) forms an inverted U-shaped structure, housing core electronic components and offering stability to the console. It has standoffs or wheels to interface with the ground, allowing for mobility. Each side of the console is connected to a telescopic column that consists of a bottom column (2) and an upper column (3), enabling vertical adjustment (10) of the console. This adjustability provides ergonomic positioning for surgeons of varying heights. The hand-rest (4) beam spans between the upper columns, supporting the surgeon’s hands during operation, while a pedal board attachment point (9) on the inner face provides foot control functionality. The console base may be separated into two modular parts for ease oftransportation through narrow spaces. The upper column (3) also holds the roll assembly (5) at the top. In another device embodiment, the base also holds the mount for a surgical display unit.

[0096] Figure - 2, presents the roll-base assembly (5), an essential mechanism within the robotic console (100). The roll-base assembly is connected to the upper column via a roll connector (15), allowing rotational movement essential for maneuvering the console’s functional elements. At the top, a parallelogram linkage system (11, 12, 13, 14) enhances stability and control, ensuring precise replication of the surgeon’s hand movements. The roll-base assembly also houses the linkages (6) that help convey the linear and angular motions of the surgeon's hand, further enhancing accuracy in tool manipulation. The finger-grip (7), positioned at the free end of this assembly, acts as the main interface for the surgeon’s manual inputs. The gimbal mechanism (8) at the free end of link 2 (14), is a pivoted support system that allows an object to remain level or maintain its orientation while rotating freely along one or more axes. At the free end of the last link of the gimbal (16), sits the fingergrip (7).

[0097] Figure - 3, shows a Multi -Axis Angular Controller (MAAC), a gimbal-like mechanism (8) enabling pitch, yaw, and roll motions. Located at the end of Link 2 (14), the MAAC includes a universal joint comprising two yokes: a bottom yoke (17) and a top yoke (18), connected by a cross or spider (19). The universal joint facilitates movement along multiple axes, simulating the range of motion in a human wrist. The finger-grip (7) is attached to the top yoke, transmitting the surgeon’s hand orientation and movement to the robotic manipulator. This setup allows the console to detect and replicate the surgeon’s wrist motions, which are critical in precision surgical tool manipulation.

[0098] The main purpose of the gimbal and MAAC is to transmit the angular motion namely, roll, pitch, and yaw of the surgeon's wrist to the robotic manipulator. The main differentiating feature between the two is that for the gimbal mechanism (8) the centre of roll, pitch, and yaw is located at the centre of the surgeon's wrist, and for the universal joint configuration, the centre is located at the centre of the spider or cross (19) of the universal joint.

[0099] Figure - 4, highlights the right-hand grip (41), designed ergonomically for the surgeon’s comfort and precise control. It features a jaw actuation lever (21) for manipulating the surgical tool's jaws, as well as a clutch button (43) that enables quick tool adjustments. The grip contains an inertial measurement unit (IMU) that tracks roll, pitch, and yaw angles,accurately capturing the surgeon’s intended motions. This component serves as the primary control interface, allowing the surgeon to make fine adjustments to the robotic manipulator through intuitive hand gestures.

[0100] Figure - 5: Shows the robotic manipulator, a sophisticated surgical tool with seven degrees of freedom (DOF) to facilitate complex operations. This manipulator is configured for both gross and tool manipulation. Gross manipulation enables the end effector to move along the X, Y, and Z axes, while tool manipulation provides angular displacements similar to human wrist movements. Key components include the tool’s pitch (24), roll (27), and linear motion capabilities (26), enabling precise control and orientation of the surgical tool tip (23). The figure illustrates the robotic manipulator’s extensive range of motion, vital for minimally invasive procedures.

[0101] Figure - 6, details the counterbalance system's motor-transducer units, integrated into the roll-base assembly (5) to reduce strain on the surgeon’s hands. Located at the roll base’s top, bottom, and roll points (29, 30, 31), these brushless DC (BLDC) motor-transducer units provide admittance control, automatically counteracting gravitational forces. This feature alleviates manual load and enhances the surgeon’s ability to maintain precise control over extended durations. By adjusting to the external force of gravity, the system stabilizes the roll-base, supporting the surgeon in performing prolonged surgical procedures.

[0102] Figure - 7, presents a focused view of the degrees of freedom (DOF) of the surgical tool, designed to mimic the range of motion of a human wrist. The surgical tool features four DOF along its roll (34), pitch (35), yaw (33), and tool-opening / closing motions (32). This configuration enables complex movements, allowing the tool to access various angles and orientations within the surgical field. The DOFs empower the tool to perform intricate tasks and to replicate delicate hand movements with high accuracy, enhancing the overall efficiency and precision of robotic-assisted surgery.

[0103] Figure - 8, illustrates an alternative counterbalance system configuration. A counterweight (36) is positioned within the upper column (3), attached to a pulley (37) via a cable (40) to generate counter-torque. As the weight moves along its guide rail (38), a counterforce is exerted, stabilizing the roll-base assembly (5) by counteracting gravitational forces. The system enables the roll connector (15) to maintain a balanced state, reducing strain on the surgeon’s hands. The depicted counterbalance system ensures smoother operation by mitigating the effects of weight and gravity, thus supporting sustained surgical procedures.Figure - 9, demonstrates an alternative “horn configuration” for the finger-grip (42), which is positioned upside down on the MAAC. This unique arrangement centres the roll, pitch, and yaw axes at the surgeon’s wrist, closely mirroring the tool’s orientation and motion on the robotic manipulator (23). In this configuration, the finger-grip is manipulated in the same way as the standard setup but with the axes centred to create a more intuitive alignment. The horn configuration allows the surgeon’s hand movements to directly translate to the robotic tool’s motions, increasing precision and control.

[0104] Figure - 10, illustrates an embodiment of the ergonomic surgical console (100) configured for surgical operation and simulation, comprising a Virtual Reality (VR) headset (46) supported on a VR stand (50). The VR stand (50) provides multiple ergonomically adjustable degrees of freedom including vertical adjustment (47), horizontal adjustment (48), and rotational movement, enabling precise positioning of the VR headset (46) relative to the console (100) for immersive or open-console visualization.

[0105] Figure - 11, illustrates a perspective view (44) of the VR headset (46) showing a spring-loaded, finger-actuated quick-release mechanism configured to detachably couple the VR headset (46) to the VR stand (50). The quick-release mechanism enables rapid docking and undocking of the VR headset (46), allowing selective use in a stand-mounted immersive display mode or a wearable open-console mode.

[0106] Figure - 12, illustrates an embodiment of a wireless hand controller used with the ergonomic surgical console (100), wherein the wireless hand controller is retrofitted with a pinch-grip mechanism. The wireless hand controller is configured to track translational and rotational movements of a user’s hand and transmit corresponding control inputs for robotic manipulation or surgical simulation within a virtual or robotic surgical environment.

[0107] Some of the key attributes of the robotic system (100) that contribute to a more responsive, ergonomic, and efficient surgical experience, potentially improving both surgeon performance and patient outcomes and also distinguish the said system over other existing system includes:

[0108] Enhanced Ergonomics and Comfort

[0109] The console is designed to support a neutral body posture, which reduces strain and fatigue, especially for prolonged surgical procedures.- Height-adjustable hand-rests allow surgeons to customize their setup, ensuring optimal hand positioning and reducing repetitive strain on muscles.

[0110] Precise and Intuitive Control Mechanism

[0111] The Multi-Axis Angular Controller (MAAC) or gimbal provides natural, multi-axis freedom of movement, closely replicating the dexterity and fluidity of hand movements. The grip design includes a power-grip feature and dedicated support for index and thumb positioning, enabling secure and controlled manipulation of end-effectors with minimal hand fatigue.

[0112] Integrated Safety Features

[0113] A clutch button, which must be held down to activate / deactivate the robotic manipulator, ensures that only deliberate movements are transmitted, preventing accidental actions. Safety feedback mechanisms provide subtle resistance to guide movements, helping surgeons avoid accidental overreach or overshooting.

[0114] Customizable Setup for Real-Time Adjustments

[0115] The linear actuator system allows real-time height adjustments, even during procedures, enabling the surgeon to reposition the hand-rest without interrupting the operation.

[0116] This flexibility contrasts with conventional consoles, where height adjustments may be limited or require manual recalibration.

[0117] Improved Visual Alignment with the Surgical Field

[0118] The console is designed to position the surgeon directly parallel to the robotic arm’s movement, ensuring a more intuitive alignment between hand motions and endoscopic visuals.

[0119] The endoscopic view is displayed on a high-resolution monitor directly in front of the surgeon, reducing eye strain and providing a clear, magnified view of the surgical field. Reduced Risk of Surgeon Fatigue and Increased Endurance

[0120] The power-grip design and ergonomic support allow for prolonged operation without hand or finger fatigue, supporting endurance during lengthy procedures.

[0121] Customized support for individual fingers, including the index finger and thumb, further distributes hand pressure and decreases physical stress on joints.Increased Precision in Robotic Manipulation

[0122] The multi-axis gimbal enables smooth, controlled transitions across different angles, enhancing precision in complex surgical tasks like suturing or delicate tissue manipulation.

[0123] The tactile feedback system gives the surgeon a greater sense of control, allowing them to make micro-adjustments more accurately.

[0124] Streamlined Workflow and Quick Setup

[0125] The initial homing sequence calibrates the sensors and ensures readiness for precise operation without additional manual setup.

[0126] - Fast docking and undocking of the MAAC or gimbal reduce downtime and streamline the process of switching between tasks or setups.

[0127] Enhanced Endoscopic Visualization with Minimal Lag

[0128] - Real-time endoscopic imaging combined with high-definition displays provides clarity and accuracy, allowing the surgeon to anticipate and respond to tissue behaviour promptly.

[0129] - Minimal lag in visual feedback supports responsive adjustments, a crucial advantage over conventional systems where slight lags may impact the precision of delicate movements.

[0130] Comprehensive Safety and Stability

[0131] The console’s locking mechanism secures all components in place when not in use, preventing accidental movements or component misalignment.

[0132] - Built-in feedback mechanisms prevent unintentional movements from affecting the robotic manipulator, ensuring stability throughout the procedure.

[0133] Enhanced performance through onboard computation

[0134] The console has an onboard computational processing unit that filters / processes data going to the robotic manipulators.

[0135] Through the implementation of advanced algorithms the system is able to apply features such as improved stability, tremor detection and filtering and over all feel of the console.

[0136] EXAMPLEThe following example includes only exemplary embodiments to illustrate the practice of this disclosure. It will be evident to those skilled in the art that the disclosure is not limited to the details of the following illustrative examples and that the present disclosure may be embodied in other specific forms without departing from the essential attributes thereof, and it is therefore desired that the present embodiments and examples be considered in all respects as illustrative and not restrictive.

[0137] Example 1 : Operation of the Surgical Console

[0138] The surgical console (100) is designed for use by a surgeon seated in an ergonomic chair that supports a neutral body posture, minimizing fatigue during prolonged procedures. Positioned parallel to the legs of the U-shaped console base (1), the surgeon sits at the open end of this U-shape, allowing unrestricted access to the main control components. By combining robust controls with real-time endoscopic visualization, the surgical console facilitates delicate and complex rob otic -assisted surgeries with enhanced precision and safety.

[0139] Step 1 : Initial Setup and Adjustment

[0140] Upon seating, the surgeon rests their hands on the adjustable hand-rest (4), ensuring that the control linkages (6) are positioned directly in front for optimal alignment with the workspace. Using the control panel on the console, the surgeon adjusts the height of the hand-rest to suit their comfort level. This height adjustment is achieved through a linear actuator mechanism integrated within the telescopic columns (2, 3), allowing the upper column to move relative to the lower column. The linear actuator raises or lowers the handrest smoothly and precisely, ensuring that the surgeon’s arms are positioned at a relaxed angle, minimizing strain.

[0141] Step 2: Powering On and Initializing the System

[0142] Once the surgeon is seated and comfortable, they activate the console by pressing the power button located on the console base (1). This action powers up the console and initiates a homing sequence for the sensors and control elements, preparing the system for precise operation. The homing sequence calibrates the position of the MAAC (Multi-Axis Angular Controller) or gimbal mechanism (8), ensuring it is in a neutral starting position.

[0143] Step 3 : Preparing the Gimbal / MAAC and Endoscopic VisualizationAfter system initialization, the surgeon releases the gimbal or MAAC from the docking station, holding the finger-grip (7) to bring the control mechanism into the console workspace. The gimbal provides multi-axis freedom, allowing the surgeon to manipulate it across a range of positions and angles. An endoscopic camera attached to the robotic manipulator captures real-time visuals of the surgical field, displaying this output on a high-definition monitor directly in front of the surgeon. This setup provides the surgeon with a clear, magnified view of the operating site, enhancing accuracy and control over the robotic end-effectors.

[0144] Step 4: Operating the Finger-Grip Controls

[0145] The surgeon controls the end-effectors of the robotic manipulator by manipulating the finger-grip (7) within the workspace of the console. The finger-grip is designed to be held in a power-grip, providing ergonomic support that allows the surgeon to operate for extended periods without hand fatigue.

[0146] The index finger rests comfortably on the index finger support (22), allowing for steady and controlled movements.

[0147] The thumb is positioned on the jaw actuation lever (21), which enables fine control over gripping actions of the end-effector.

[0148] Additionally, a clutch button is positioned on the opposite surface to the top surface, accessible to the middle finger. This clutch button is an essential safety feature; it must be held down to activate the robotic manipulator, preventing unintended movements. If the clutch button is not pressed, any movement of the console controls does not affect the robotic manipulator, ensuring that only intentional actions are transmitted.

[0149] Step 5 : Real-Time Manipulation and Task Execution

[0150] With the clutch button held down, the surgeon can control the robotic manipulator in realtime. Moving the finger-grip (7) to various positions within the console workspace translates to corresponding movements in the end-effector of the robotic manipulator. Tilting, rotating, and angling the finger-grip allow the surgeon to perform delicate and complex tasks, such as suturing or tissue manipulation, with high precision.

[0151] The gimbal’s multi-axis design allows smooth and intuitive motion, closely mirroring the natural movements of the surgeon’s wrist and hand.The system’s feedback mechanism provides subtle resistance, helping the surgeon feel the control boundaries and avoid accidental overshoots.

[0152] Step 6: Additional Control Features and Safety Mechanisms

[0153] The console includes additional built-in safety features and ergonomic support:

[0154] A push button on the finger-grip (7) serves as a secondary control for activating specific functions as needed. The console's linear actuator allows for real-time height adjustments, making it easy for surgeons to make positional changes even mid-procedure if needed. A feedback-based locking mechanism secures the console in place when not in use, ensuring the components stay protected and aligned.

[0155] Example 2: Operation of the Surgical Console in Virtual Reality (VR) Mode

[0156] The ergonomic surgical console (100) is configured to operate in a Virtual Reality (VR)-assisted mode for surgical simulation, training, or robotic procedure emulation, as illustrated in Figures 10-12. This mode enables the console (100) to replicate different robotic surgical platforms using immersive or open-console visualization.

[0157] Step 1 : VR System Setup and Ergonomic Positioning

[0158] Referring to Figure 10, the VR headset (46) is mounted on the VR stand (50), which is integrated with the surgical console (100). The VR stand (50) provides three electro-mechanically actuated degrees of freedom, including vertical adjustment (47), horizontal adjustment (48), and rotational positioning, allowing the VR headset (46) to be ergonomically aligned with the surgeon’s line of sight. The surgeon adjusts the VR stand (50) using dedicated switches or buttons to achieve a comfortable viewing posture that minimizes neck and upper-body strain.

[0159] Step 2: Selection of Visualization Mode

[0160] Referring to Figure 11, the VR headset (46) may be used in either an immersive display style or an open-console style. In the immersive display style, the VR headset (46) remains docked on the VR stand (50), constraining the surgeon’s head within the display to emulate a closed robotic surgical console. Alternatively, the surgeon may actuate the spring-loaded, finger-operated quick-release mechanism to detach the VR headset (46) from the VR stand (50), after which the headset (46) is worn using integrated straps, allowing free head movement to emulate an open robotic surgical console.Step 3 : Initialization of Simulation Environment

[0161] Once the VR headset (46) is positioned or worn, the onboard computer initializes the virtual surgical environment and loads predefined or customized surgical scenarios. The VR headset (46) displays stereoscopic two-dimensional or three-dimensional images corresponding to the simulated surgical field, synchronized with the console controls to provide real-time visual feedback.

[0162] Step 4: Hand Control Using Wireless Controllers

[0163] Referring to Figure 12, the surgeon operates a wireless hand controller configured to track translational movement along the X, Y, and Z axes and rotational movement in roll, pitch, and yaw. The wireless hand controller is retrofitted with a pinch-grip mechanism, allowing the surgeon to emulate natural instrument grasping and manipulation. Depending on the simulation requirements, the controller may be reconfigured to emulate alternative grip styles such as gun-grip or free-hand grip.

[0164] Step 5 : Foot Pedal and Multi-Modal Input Control

[0165] During operation, the surgeon may additionally use the foot pedal board (45) to actuate auxiliary functions such as clutching, camera reorientation, energy tool activation, or arm swapping within the simulated robotic system. The coordinated use of the VR headset (46), wireless hand controller, and foot pedal board (45) enables realistic replication of robotic surgical workflows.

[0166] Step 6: Real-Time Feedback and Training Execution

[0167] As the surgeon manipulates the wireless hand controller, corresponding movements are rendered in the VR environment in real time, allowing the execution of simulated surgical tasks such as camera navigation, tissue interaction, or instrument positioning. The VR-based operation mode allows repeated practice, procedural rehearsal, and platform-specific training without requiring physical robotic hardware, thereby enhancing skill acquisition and procedural familiarity.

Claims

WE CLAIM:

1. An ergonomic surgical console (100) for robotic-assisted surgery using robotic system, comprising:a console base (1) with standoffs or wheels for mobility and stability, housing electronic components;a plurality of telescopic columns (2, 3), each having an upper and lower section, attached to the console base (1), configured to provide height adjustment (10); a roll-base assembly (5) connected to an upper column (3) configured for rotational movement;a Multi-Axis Angular Controller (MAAC) or gimbal mechanism [8] located at the linkage assembly link (14) which is connected to the roll-base assembly (5), enabling roll, pitch, and yaw motions for controlling a robotic manipulator;a grip (7) ergonomically positioned on the MAAC, equipped with a jaw actuation lever (21) and clutch button (43), to capture and transmit the surgeon's wrist movements to the robotic manipulator for precise tool manipulation; wherein the console base (1) comprises detachable modules to facilitate compact storage and transport, and the MAAC and gimbal mechanism (8) allow controlled manipulation.

2. The ergonomic surgical console (100) of claim 1, further comprising a locking mechanism for the modular components that prevents accidental disassembly during operation, ensuring stable performance in various surgical environments.

3. The ergonomic surgical console (100) of claim 1, wherein the telescopic columns (2, 3) are adjustable through a manual mechanism or electronic motor system to achieve ergonomic positioning based on surgeon height or preference.

4. The ergonomic surgical console (100) of claim 1, wherein the roll-base assembly (5) attached to a counterbalance system comprising motor-transducer units (29, 30, 31) for gravitational compensation, reducing strain on the surgeon’s hands and enabling prolonged precision.

5. The ergonomic surgical console (100) of claim 1, wherein the MAAC includes a MAAC joint with a bottom yoke (17), a top yoke (18), grip (7) and a spider (19),allowing multi-axis movements to accurately replicate the surgeon’s wrist motions, enabling control over the robotic manipulator.

6. The ergonomic surgical console (100) of claim 1, wherein the console base (1) features retractable wheels or wheels with locking mechanisms to secure the console’s position during operation, reducing the risk of unintentional movement.

7. The ergonomic surgical console (100) of claim 1, wherein the grip (7) includes a failsafe mechanism that detects and prevents unintended movements, ensuring precise control during surgical procedures.

8. The ergonomic surgical console (100) of claim 1, wherein the roll-base assembly (5) includes a parallelogram linkage system (11, 12, 13, 14) for precisely transmitting the surgeon’s hand movements to the robotic manipulator.

9. The ergonomic surgical console (100) of claim 1, further comprising a link dock mechanism that securely docks the linkage arms and sensors when the system is inactive, with an interlocking sensor to signal docking, and subsequent auoto- calibration.

10. The ergonomic surgical console (100) of claim 1, further comprising a wireless communication module integrated within the console base (1) for transmitting realtime data to an external monitoring system, enabling remote observation and diagnostics during surgery.

11. The ergonomic surgical console (100) of claim 1, wherein the telescopic columns (2, 3) include a memory function that records and automatically adjusts to the surgeon’s preferred height and position settings, enhancing ease of use in repeated surgeries.

12. The ergonomic surgical console (100) of claim 1, further comprising a modular battery backup integrated within the console base (1) to provide uninterrupted power supply to the entire system in case of external power failure, ensuring continuous operation during critical procedures.

13. The ergonomic surgical console (100) of claim 1, wherein the computational processor of the console includes a vibration dampening system that mitigates anyunintended tremors from the surgeon’s hand, enhancing precision in delicate operations.

14. The ergonomic surgical console (100) of claim 1, wherein the roll connector (15) includes a quick-release mechanism for rapid switch between MAAC or gimbal, facilitating modular reconfiguration or maintenance.

15. The ergonomic surgical console (100) as claimed in claim 1, wherein the roll-base assembly (5) is mounted on the telescopic columns (2, 3), positioned to the sides of the console, reducing clutter in front of the console to enhance the surgeon’s workspace and visibility.

16. The ergonomic surgical console (100) as claimed in claim 1, wherein the console width is adjustable by adding extension linkages to the base connection and top beam, or employing extendible linear mechanisms, allowing for customizable console width to fit various workspace constraints.

17. The ergonomic surgical console (100) as claimed in claim 1, wherein a top connector or hand rest (4) is angled such that, in the resting position:the operator’s hands are positioned perpendicularly to the support at the point of contact,thereby enhancing operator comfort and increasing the available workspace during operation.

18. The ergonomic surgical console (100) as claimed in claim 5, wherein the grip (7) of the MAAC includes multiple levers:primary levers positioned on the side and below the grip (7) for independent actuation by the surgeon’s thumb or index finger, enabling control of the main functions such as opening and closing the surgical tool; andsecondary levers positioned for actuation by the ring, middle, or index fingers, allowing for additional functions such as clutch control.

19. The ergonomic surgical console (100) as claimed in claim 4, wherein the roll-base assembly (5) includes a counterweight system, wherein the torque generated by the weight of the links and attached components is counteracted by:a counterweight (36) suspended from a pulley system connected to the roll base, ensuring balanced movement and reduced strain on the system.

20. The ergonomic surgical console (100) as claimed in claim 8, wherein each link extending from the roll base assembly (5) is weight-balanced with its center of gravity positioned at the joint connecting it to the subsequent link, and achieved by attaching a predetermined mass at a fixed distance along the link.

21. The ergonomic surgical console (100) as claimed in claim 8, further comprising three motors positioned at the base of the master arm assembly:enabling full control of the arm from its base,electronically counterbalancing the links against gravity, andallowing the operator to adjust the motion dynamics of the arm for a customized feel during operation.

22. The ergonomic surgical console (100) as claimed in claim 5, wherein the grip (7) includes a rotational sensor positioned between the grip and the universal joint, enabling the tracking of roll angulation for precise control of the robotic manipulator.

23. The ergonomic surgical console (100) as claimed in claim 7, wherein the grip (7) is equipped with an inertial measurement unit (IMU) configured to determine the orientation of the surgeon’s hand during operation.

24. The ergonomic surgical console (100) as claimed in claim 23, wherein the rotational joint data of the grip (7) is correlated with the inertial measurement unit (IMU) data to reduce drift and noise in IMU measurements, enhancing precision and reliability of the system’s responsiveness.

25. The ergonomic surgical console (100) as claimed in claim 1, further comprising a Virtual Reality (VR) headset (46) integrated with the console (100), the VR headset (46) being configured to provide a two-dimensional or three-dimensional visual interface for surgical operation or surgical simulation.

26. The ergonomic surgical console (100) as claimed in claim 25, further comprising a VR stand (50) configured to support the VR headset (46), wherein the VR stand (50) provides at least three degrees of freedom including vertical movement (47),horizontal movement (48), and rotational adjustment, enabling ergonomic positioning of the VR headset (46).

27. The ergonomic surgical console (100) as claimed in claim 25, wherein the VR headset (46) is detachably coupled to the VR stand (50) using a spring-loaded quickrelease mechanism, allowing the VR headset (46) to be selectively docked on the VR stand (50) or removed and worn by the user.

28. The ergonomic surgical console (100) as claimed in claim 1, wherein fine grip controllers are wireless controllers configured to operate without mechanical linkages, the wireless controllers being retrofittable with interchangeable mechanical attachments to emulate pinch grip, gun grip, open-hand grip, or free-hand grip configurations for robotic surgical manipulation or simulation.

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