Cable-driven parallel manipulator with mechanisms for transfer of mechanical steering between a controller and a detachable end effector attachment

Abstract

A cable-driven parallel manipulator having a reusable main body portion and a detachable attachment. The reusable main body portion receives steering inputs from the user that are transferred to the detachable attachment, which contains the steering cables and the end effector. Separation of a cable-driven parallel manipulator into these two parts allows for different components to be housed in each. It also allows for isolation of the two parts and the interchangeability of different detachable units. To transfer motion from the user input located on the reusable main body portion, a motion transfer mechanism, either mechanically, or magnetically, transmits motion to the detachable attachment. When uncoupled, the detachable attachment may have a set of brakes to maintain tension in the steering cables.

Description

CABLE-DRIVEN PARALLEL MANIPULATOR WITH MECHANISMS FOR TRANSFER OF MECHANICAL STEERING BETWEEN A CONTROLLER AND A DETACHABLE END EFFECTOR ATTACHMENTCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No.63 / 744,523, titled “CABLE-DRIVEN PARALLEL MANIPULATOR WITH MECHANISMS FOR TRANSFER OF MECHANICAL STEERING BETWEEN A CONTROLLER AND A DETACHABLE END EFFECTOR ATTACHMENT” and filed on January 13, 2025, the entire contents of which is incorporated herein by reference.TECHNICAL FIELD

[0002] The present disclosure relates to a divided cable-driven parallel manipulator including both a reusable portion that receives user inputs and an attachment that includes an end effector that can be directed when coupled to the reusable portion. More particularly, the disclosure relates to a divisible cable-driven parallel manipulator including components for a divided reusable main body portion and a detachable attachment including an end effector for limited or single procedure use, as well as related mechanisms, systems and methods.

[0003] Embodiments of these devices, mechanisms, and systems may have many medical, surgical, and procedural applications for steering and tracking of interventional devices for minimally invasive procedures. Embodiments can relate to the different components in the reusable main body portion and the detachable attachment that allow, when coupled, the movement of the end effector. Further, embodiments can relate to the different applications of the reusable main body portion and the detachable attachment. Examples ofapplications include: using a reusable main body portion of the cable-driven parallel manipulator with differently sized detachable manipulators, using a single-use detachable attachment in applications that affect biological agents, and using interchangeable detachable attachments that have different specialized end effectors. In addition, embodiments can relate to the control and navigation of medical interventional devices through detachable attachments, such as, guidewires, catheters, needles, as well as, imaging and ablative devices, and various minimally invasive interventions.

[0004] Throughout this disclosure, references to a “reusable main body portion” should generally be understood to broadly refer to the portion of the cable-driven parallel manipulator that receives user inputs as well as the other necessary components to operate. The reusable main body portion is generally constructed for repeated usage over time. References to a “detachable attachment” should be understood to broadly refer to the portion of the cable-driven parallel manipulator that contains the end effector and its necessary components to operate. The detachable attachment is generally constructed for limited or one-time procedure usage.BACKGROUND

[0005] Cable-driven mechanisms have been widely used for various purposes such as crane operation, camera positioning, painting and services, and, more recently, for medical applications. The low cost, low weight-to-size ratio, and fast dynamics of such mechanisms offer specific advantages over conventional rigid link robotic solutions or manipulators that have led to the growing widespread use of such systems. For minimally invasive medical procedures, cable actuated mechanisms have been used to facilitate access to the target areathrough a long, narrow, and tortuous path and make use of the benefits of cable-driven mechanisms.

[0006] In such systems, there has been a need to use different end effectors for different parts of a procedure or for different procedures. The cost associated with many limited use devices can be significant and impediments to sterility can be present when devices are modified or reused. Accordingly, a more versatile, cost effective, and useful cable driven parallel mechanism tool is needed. Namely, a cable driven parallel manipulator is needed that effectively overcomes the limitations of conventional cable-driven mechanisms of the past.SUMMARY

[0007] The present disclosure provides advancements in cable-driven parallel manipulators that include the mechanical division of a manipulator into a reusable main body portion and a detachable attachment. Various embodiments described or otherwise contemplated herein provide arrangements that transfer inputs from the reusable main body portion into the detachable attachment which contains a plurality of steering cables that direct movement of an end effector.

[0008] An embodiment relates to a cable-driven parallel manipulator that includes a reusable main body portion and a detachable attachment. The reusable main body portion receives user inputs and includes: an outer housing including a docking section; a user input steering controller at least partially projecting from the outer housing; at least one input cable coupled to the user input steering controller; and an input coupling assembly. The input coupling assembly includes at least one input coupler having axially aligned and interconnected components including an input pulley engaged with the at least one input cable such that cable displacements result in axial rotation of the input pulley. The input coupling assembly furtherincludes a first transfer structure that rotates based upon rotation of the input pulley. The detachable attachment is of elongate structure, equipped for releasable coupling to the reusable main body portion at the docking section and has a proximal end and a distal end. The detachable attachment includes: an end effector located at the distal end; at least one output cable attached to the end effector; and an output coupling assembly located at the proximal end. The output coupling assembly includes at least one output coupler having axially aligned and interconnected components. The output coupler, including: a second transfer structure that moves rotationally in correspondence to rotation of the first transfer structure when the reusable main body portion and the detachable attachment are releasably coupled; and an output pulley that rotates based upon rotation of the second transfer structure, the output pulley is engaged with the at least one output cable that effectuates movements of the end effector.

[0009] An embodiment relates to a cable-driven parallel manipulator attachment that includes an elongate structure, has a proximal end and a distal end, and is of disposable single procedure use construction. The cable-driven parallel manipulator attachment includes: an end effector located at the distal end; at least one output cable attached to the end effector; and an output coupling assembly located at the proximal end. The output coupling assembly includes at least one output coupler having axially aligned and interconnected components. The output coupler including: a transfer structure that rotates as directed by a physically separate device when coupled together without compromising sterility of the end effector and the output cable; and an output pulley that rotates based upon rotation of the transfer structure, the output pulley engaged with the at least one output cable that effectuates movements of the end effector.

[0010] An embodiment relates to a cable-driven parallel manipulator, including either a mechanical or electronic control unit containing the steering input, steering cables actuating the end effector, the end effector, and both a reusable portion and a detachable attachment, which is coupled or connected by various coupling mechanisms. Different embodiments mayhave different configurations of the aforementioned mechanisms, allowing for different use cases and design criteria. For example, an embodiment for a reusable steering input handle for a minimally-invasive surgical device may require a sterilized detachable attachment that can attach to an isolated reusable portion which minimizes the costs associated with disposable devices.

[0011] Different embodiments may have different coupling mechanisms. These coupling mechanisms allow the detachment and coupling of the reusable portion and detachable attachment of the cable-driven parallel manipulators. Reasons for doing so may include utilizing different detachable attachments with the same reusable portion, maintaining a sterilized environment around the detachable attachments, waterproofing or physical isolation between the environment of the reusable portion and the detachable attachment, or minimizing the costs and complexity of the detachable attachment that may expect a shorter useful life. Different coupling mechanisms may include using a magnetic system that transfers inputs from the reusable portion to the detachable attachment without a physical connection, or a friction-based or spline-based system that transfers inputs through a clutch or similar mechanism.

[0012] Different embodiments may have different input mechanisms. These input mechanisms may be mechanical or electrical. Mechanical embodiments may transfer steering input through movement of steering cables or rotations of shafts. Electrical embodiments may transfer steering input via motors. These input mechanisms, located in the reusable portion, shall transfer the input via the various coupling mechanisms.

[0013] An embodiment may require the detachable attachment to maintain a fixed amount of steering cable tension before coupling. This ensures that the coupling is consistent, such that the steering inputs in the reusable portion have the same expected effect on different detachable attachments. This embodiment consists of a brake mechanism that holds the initialsteering cable tension before coupling. Once coupled, the brakes may be manually removed or automatically removed.

[0014] In general, Applicant has recognized that in some cases, it may be beneficial to have a reusable main body portion of a cable-driven parallel manipulator that couples to different attachments. It may also be beneficial to have such an arrangement from a cost perspective. One embodiment may place the low-cost components in the detachable attachment which may have a shorter useful life and the high-cost components in the reusable main body with a longer life. Once the attachment is expended, the operator can replace it at a lower cost than complete device replacement.

[0015] In view of the foregoing, Applicants recognize that a solution is needed that allows the separation and connection of a reusable main body portion and a detachable attachment of a cable-driven parallel manipulator to effectively overcome the limitations of a conventional cable-driven mechanism.

[0016] The above summary is not intended to describe each illustrated embodiment or every implementation of the subject matter hereof. The figures and the detailed description that follow more particularly exemplify various embodiments.BRIEF DESCRIPTION OF THE FIGURES

[0017] Subject matter hereof may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying figures, in which:

[0018] FIG. 1A shows a coupled cable-driven parallel manipulator, according to an embodiment.

[0019] FIG. IB shows an uncoupled cable-driven parallel manipulator, according to an embodiment.

[0020] FIG. 1C shows an uncoupled cable-driven parallel manipulator, according to an embodiment.

[0021] FIG. 2 A shows the coupling mechanism for the cable-driven parallel manipulator from FIGS. 1A-1C, according to an embodiment.

[0022] FIG. 2B shows the coupling mechanism from FIG. 2A in a disengaged state, according to an embodiment.

[0023] FIG. 2C shows the coupling mechanism from FIG. 2A in an engaged state, according to an embodiment.

[0024] FIG. 2D shows an isolated coupler for one pair of input and output cables from the coupling mechanism in FIG. 2A, according to an embodiment.

[0025] FIG. 2E shows a magnet pulley from the coupling mechanism in FIG. 2A, according to an embodiment.

[0026] FIG. 3 A shows a disengaged coupling mechanism, according to an embodiment.

[0027] FIG. 3B shows an engaged coupling mechanism, according to an embodiment.

[0028] FIG. 4A shows a disengaged coupling mechanism, according to an embodiment.

[0029] FIG. 4B shows an engaged coupling mechanism, according to an embodiment.

[0030] FIG. 5A shows a coupled cable-driven parallel manipulator, according to an embodiment.

[0031] FIG. 5B shows the cable-driven parallel manipulator from FIG. 5A with brakes inserted, according to an embodiment.

[0032] FIG. 5C shows the cable-driven parallel manipulator from FIG. 5A with brakes removed, according to an embodiment.

[0033] FIG. 5D shows the output coupling mechanism for the cable-driven parallel manipulator from FIG. 5 A with brakes inserted, according to an embodiment.

[0034] FIG. 5E shows the output coupling mechanism for the cable-driven parallel manipulator from FIG. 5 A with brakes removed, according to an embodiment.

[0035] FIG. 6A shows a coupled cable-driven parallel manipulator, according to an embodiment.

[0036] FIG. 6B shows an uncoupled cable-driven parallel manipulator, according to an embodiment.

[0037] FIG. 7A shows a detachable attachment with a brake holding the initial tension of the detachable attachment, according to an embodiment.

[0038] FIG. 7B shows the brake of FIG. 7A with cutouts to mate with the magnetic coupling pulleys to prevent rotation, according to an embodiment.

[0039] FIG. 7C shows the detachable attachment of FIG. 7 A with the brake engaged, according to an embodiment.

[0040] FIG. 7D shows the detachable attachment of FIG. 7A with the extrusions of the brake depressed, according to an embodiment.

[0041] FIG. 8 A shows a tension mechanism, according to an embodiment.

[0042] FIG. 8B shows a tension mechanism, according to an embodiment.

[0043] While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed subject matter to particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.DETAILED DESCRIPTION OF THE FIGURES

[0044] Disclosed herein are devices for controlling and actuating a cable-driven end effector with a cable-driven parallel manipulator that has been separated into a reusable main body portion and a detachable attachment. Embodiments can transfer steering inputs from the reusable main body portion to the detachable attachment through coupling mechanisms.

[0045] FIG. 1A shows a perspective view of a cable-driven parallel manipulator 100 that is divided into a reusable main body portion 110 and a detachable attachment 120. The reusable main body portion 110 includes an outer housing 111. The outer housing is multifaceted, non-uniform shape, and contains a variety of features including a docking section 112. The reusable main body portion 110 can receive user inputs via a user input steering controller 116 that projects from the outer housing 111. The interior portion of the user input steering controller 116 has at least one input cable 215 (not visible in FIG. 1A but see Fig. 2A for example) coupled to it mechanically or electrically via motors. In addition to the user input steering controller 116, a cable tension knob 114 is present on the exterior of the housing to control tension in the input cable(s) 215. Accordingly, the user input steering controller 116, with assistance of the cable tension knob 114, can convey user inputs that are ultimately used to remotely manipulate an end effector 121 at the end of the detachable attachment 120.

[0046] The detachable attachment 120 has an elongate structure and is equipped for releasable coupling to the reusable main body portion 110 at the docking section 112. The reusable main body portion 110 and detachable attachment 120 are shown coupled to one another in FIG. 1A. The detachable attachment 120 has a proximal end 130 and a distal end 140. The detachable attachment 120 includes the end effector 121 located at the distal end 140. The detachable attachment 120 includes a housing 142 at the proximal end 130 in which an output coupling assembly 220 (not shown in FIG. 1A) is present. At times throughout the specification and claims the various detachable attachment embodiments disclosed, includingdetachable attachment 120, may alternatively be referred to as a cable-driven parallel manipulator attachment.

[0047] FIG. IB shows a perspective view of the cable-driven parallel manipulator 100 with the detachable attachment 120 disconnected from the reusable main body portion 110. Magnet mounts 122 on the housing 142 of the detachable attachment 120 are used to connect it to the reusable main body portion 110. Magnet mounts 122 provide a particularly effective and efficient manner to align corresponding magnet mounts 113 and internal features of the input coupling assembly 210 of the reusable main body portion 110 with those of the output coupling assembly 220 of the detachable attachment 120.

[0048] FIG. 1C shows a planar view of the mating surfaces of the reusable main body portion 110 and detachable attachment 120. The magnet mounts 113 on the reusable main body portion 110 are found in the docking section 112 and are used to connect to the magnet mounts 122 on the detachable attachment 120 and align internal components.

[0049] FIG. 2A shows a perspective view a magnetic coupling system in the form of a magnetic coupling mechanism 200, according to an embodiment, comprised of the input coupling assembly 210 which is contained within the reusable main body portion 110 from FIGS. 1A-C, and the output coupling assembly 220 which is contained within the detachable attachment 120 from FIGS. 1A-C at the proximal end 130. The input coupling assembly 210 contains a set of four shafts 211, each mounted with an input pulley 212, an input magnet pulley 213 (that serves as a first transfer structure), and an encoder magnet 214. The pulleys are constrained to the shaft 211 and all rotate together. Each input pulley 212 has an input cable 215 connecting it to the steering system. The shafts 211 are mounted between a top plate 216 and a bottom plate 217. An encoder board 218 is mounted above the encoder magnets 214 on standoffs 219. Each combination of shaft 211, input pulley 212, and input magnet pulley 213 (or other first transfer structure) should be understood to be axially aligned and interconnectedand can be referred to as an input coupler 230 (see FIG. 2D). In various other embodiments, an input coupling assembly 210 must contain at least one input coupler 230 but is not restricted to embodiments having four input couplers 230 as shown in FIG. 2 A. In each input coupler, the input pulley 212 is engaged with input cable 215 so that cable displacements result in axial rotation of the input pulley 212. Further, the input magnet pulley 213 rotates based upon rotation of input pulley 212.

[0050] On the detachable output coupling assembly 220, each of the four shafts 221 contains an output pulley 222, and an output magnet pulley 223 (that serves a second transfer structure). Each combination of axially aligned shaft 221, output pulley 222, and output magnetic pulley 223 (or other transfer structure) should be understood to be axially aligned and interconnected and can be referred to as an output coupler 240 (See FIG. 2D). In various other embodiments, an output coupling assembly 220 must contain at least one output coupler 240 but is not restricted to embodiments having four output couplers 240 as shown in FIG. 2A. In FIG. 2A, each output pulley 222 is connected to the end effector 121 through an output cable 224 which is attached to the end effector 121. Magnet mounts 113 on the input coupling assembly 210 connect to the magnet mounts 122 on the output coupling assembly 220 and align the input magnet pulleys 213 (i.e. first transfer structure) with their corresponding output magnet pulley 223 (i.e. second transfer structure). The output magnet pulley 223 moves rotationally in correspondence to rotation of the input magnet pulley 213 when the reusable main body portion 110 and the detachable attachment 120 are releasably coupled. The output pulley 222 rotates based upon rotation of the output magnet pulley 223. The output pulley 222 is engaged with the output cable 224 that effectuates movements of the end effector 121.

[0051] FIG. 2B shows a perspective view of the magnetic coupling system in the form of a magnetic coupling mechanism 200 in a disengaged state, where the input coupling assembly 210 and the output coupling assembly 220 are disconnected.

[0052] FIG. 2C shows a perspective view of the magnet coupling system in the form of a magnetic coupling mechanism 200 in an engaged state, where the magnet mounts 113 on the input coupling assembly 210 are connected to the magnet mounts 122 on the output coupling assembly 220. When engaged, the input magnet pulleys 213 and output magnet pulleys 223 are able to transfer torque between the reusable main body portion 110 and the detachable attachment 120. As steering inputs are made by a user and translated into displacements on the input cables 215, they cause the input pulleys 212 to rotate and transfer torque to the output pulleys 222, creating displacements in the output cables 224, which steer the end effector 121. In this embodiment, the output cables 224 are wrapped around the output pulley 222 in the same direction as the input cables 215 are wrapped around the input pulleys 212. This means that if the steering system takes slack from the input cable 215, the output pulley 222 will invert the output and give slack to the output cable 224. The ratio of input to output is determined by the ratio of input pulley 212 and output pulley 222 diameters. In this embodiment, the ratio is 1 : 1 so the output will be an equivalent amount of displacement to the input but inverted due to the cable wrapping. In other embodiments, the pulley diameter ratio can be adjusted to scale the input to output displacement. As the input pulleys 212 rotate, the encoder board 218 measures the rotation of encoder magnet 214 to calculate the displacement of each input cable 215. The input magnet pulleys 213 serve as a first transfer structure and the output magnet pulleys 223 serve as a second transfer structure. The input magnet pulleys 213 and output magnet pulleys 223 are able to transfer torque without being in contact, allowing for the reusable main body portion 110 and detachable attachment 120 to be isolated from each other.

[0053] FIG. 2D shows a perspective view of an isolated pair of input cables 215 and output cables 224 and the coupling mechanism 250 linking them. As the input magnet pulley 213 and output magnet pulley 223 pull on each other, a ball thrust bearing 231 and plain thrustbearing 232 handle the thrust loads from the input pulley 212 and output pulley 222 respectively, allowing them to efficiently transfer torque.

[0054] FIG. 2E shows a perspective view of an isolated output magnet pulley 223. Individual magnets 225 are mounted in a ring on the pulley 223 around the shaft 221. The magnets 225 alternate in polarity. The order of polarity on the input magnet pulley 213 is reversed, allowing the input magnet pulleys 213 and output magnet pulleys 223 to pull on each other. The alternating polarity also resist slipping in the coupling. The number and strength of the magnets 225, as well as the gap between the input magnet pulleys 213 and output magnet pulleys 223, control the amount of torque transferred in the coupling. This creates an internal torque limiter where the input 213 and output magnet pulleys 223 will slip with respect to each other if the torque is too high.

[0055] FIG. 3A shows a perspective view of a single cable coupling mechanism 300, according to another embodiment. It is also divided into an input coupler 310 and output coupler 320. The input coupler 310 consists of an input shaft 311 mounted on the input plate 312 with an input pulley 313, input friction plate 314, and an input compression spring 315. The input pulley 313 is connected to a steering system through input cable 316. The output coupler 320 consists of an output shaft 321 mounted on the output plate 322 with an output pulley 323, output friction plate 324, and an output compression spring 325. The output pulley 323 is connected to a steering system through output cable 326. The input friction plate 314 and output friction plates 324 are made of high friction materials. The coupling mechanism 300 is shown in a disengaged state where the input coupler 310 and output coupler 320 are disconnected.

[0056] FIG. 3B shows the coupling mechanism 300 in an engaged state where the clips on input plate 312 mate to the output plate 322, connecting the input couplers 310 and output couplers 320. Alternatively, these two couplers could be connected with another method suchas the other embodiment shown in FIG. 2. As the input plate 312 and output plate 322 connect, the input compression spring 315 and output compression spring 325 are compressed, pushing the input friction plate 314 and output friction plate 324 together. The friction between them causes the input shafts 311 and output shafts 321 to rotate together, transferring the displacement of the input cable 316 to the output cable 326. In this embodiment, the output cable 326 is wrapped around the output pulley 323 counter to the direction the input cable 316 is wrapped around the input pulley 313. This means that the output displacement will not be inverted from the input displacement, unlike in the embodiment shown in FIG. 2.

[0057] FIG. 4 A shows a perspective view of a single cable coupling mechanism 400, according to another embodiment. It is also divided into an input coupler 410 and output coupler 420. The input coupler 410 consists of an input shaft 411 mounted on the input plate 412. The input shaft 411 is connected to a steering system through input cable 413. The output coupler 420 consists of an output shaft 421 mounted on the output plate 422. The output shaft 421 is connected to an end effector, such as the one shown in FIG. 1, through output cable 423. The input shaft 411 terminates in a male spline 414 which can mate with the female spline 424 at the end of the output shaft 421. The coupling mechanism 400 is shown in a disengaged state where the input coupler 410 and output coupler 420 are disconnected.

[0058] FIG. 4B shows the coupling mechanism 400 in an engaged state where the clips on input plate 412 mate to the output plate 422, connecting the input coupler 410 and output coupler 420. As the input plate 412 and output plate 422 connect, the male spline 414 is inserted into the female spline 424 causing the input shaft 411 and output shaft 421 to rotate together, transferring the displacement of the input cable 413 to the output cable 423.

[0059] FIG. 5A shows a perspective view of another embodiment of the cable-driven parallel manipulator shown in FIG. 1. The cable-driven parallel manipulator 500 consists of a reusable main body portion 510 and a detachable attachment 520. In some embodiments thecoupling mechanisms within the reusable main body portion 510 and detachable attachment 520 can only be connected in discrete positions and may need to be aligned prior to connection, such as in the embodiments shown in FIG. 2 and FIG. 4. A removable brake 521 can be used to maintain alignment of the detachable attachment 520 before attachment to the reusable main body portion 510. In this embodiment, the alignment of the reusable main body portion 510 is maintained by an internal steering mechanism. In another embodiment, the reusable main body portion 510 may also need brakes to lock the alignment of its internal coupling mechanism.

[0060] FIG. 5B shows a top-down view of the cable-driven parallel manipulator 500 with the removable brakes 521 inserted.

[0061] FIG. 5C shows a top-down view of the cable-driven parallel manipulator 500 with the removable brakes 521 removed. In this embodiment shown, the brakes are removed manually by the user. In other embodiments the brakes may be removed automatically when the reusable main body portion 510 and detachable attachment 520 are connected. In one embodiment this may be done through mechanical engagement, and in another embodiment, it may be a motorized brake.

[0062] FIG. 5D shows a perspective view of a magnetic output coupler 530 that could be within the detachable attachment 520, such as the embodiment shown in FIG. 2. In this embodiment, removable brakes 521 are used to hold the alignment of the output magnet pulleys 531. The removable brakes 521 are shown inserted.

[0063] FIG. 5E shows a perspective view of the magnetic output coupler 530 with removable brakes 521 removed. When inserted, the arms of the removable brakes 521 grip onto the square base of the output magnet pulleys 531 and prevent their rotation.

[0064] FIG. 6A shows a perspective view of a cable-driven parallel manipulator 600, such as the one in FIG. 1, according to another embodiment. The cable-driven parallel manipulator 600 is divided into a reusable main body portion 610 and a detachable attachment620. The reusable main body portion contains the controller mechanisms and the user input 611 to steer the end effector 621 on the detachable attachment 620. The two portions are shown connected.

[0065] FIG. 6A shows the cable-driven parallel manipulator 600 with the reusable main body portion 610 and detachable attachment 620 disconnected. In this embodiment the two portions are connected using the magnets 622 on each portion’s face. In other embodiments they may be connected by alternate methods such as the clips shown in the embodiment of FIG. 3.

[0066] FIGS. 7A-C relate to auto brakes that can be used in various embodiments. Specifically, FIG. 7A shows a perspective view of one embodiment of a detachable attachment 710 where the brake 720 holding the initial tension of the detachable attachment disengage upon attaching or coupling the reusable main body portion. This embodiment has a spring-loaded brake with springs 711 pushing the brake into the magnet coupling pulleys 712. The brake has extrusions 721 that allow the reusable main body portion to press into and displace the brake. Once the brake is released, the output pulleys 713 which may be coupled to the steering mechanism are free to be actuated by the reusable main body portion.

[0067] FIG. 7B shows a perspective view of the brake 720 from the embodiment shown in FIG. 7A. The square cutouts 722 on the brakes each mate with one of the magnet coupling pulleys 712, shown in FIG. 7A, preventing their rotation.

[0068] FIG. 7C shows a perspective view of the embodiment shown in FIG. 7A with the brake 720 engaged.

[0069] FIG. 7D shows a perspective view of the embodiment shown in FIG. 7 A with the extrusions 721 of the brake 720 depressed, causing it to disengage from the magnet coupling pulleys 712. In this state the magnet coupling pulleys 712 are free to rotate. The extrusions 721 of brake 720 can be depressed when coupling to a reusable main body portionthrough embodiments of coupling methods shown in FIG. 1A and FIG. IB, or other embodiments which involve contacting surfaces during coupling.

[0070] Another embodiment may use a friction surface instead of the cutouts 722 shown in FIG. 7B to hold the shafts in place. While another embodiment may use either the friction surface or the engagement surface with a set of repelling magnets on the reusable to disengage the brake.

[0071] FIGS. 8A and 8B related to a tensioning mechanism. In one embodiment, as the local environment limits the size of the expandable frame, there may be excess cable or cable slack in the plurality of steering cables 801. To operate a cable-driven mechanism, the slack must be minimized. A tensioning mechanism 800 may be required to minimize the cable slack.

[0072] The tensioning mechanism may have a series of movable pulleys 802 that when translated, increase or decrease the amount of cable released.

[0073] FIG. 8A and FIG. 8B show perspective views of an embodiment of a tensioning mechanism 800.

[0074] In this embodiment, the steering cables 801 enter the tensioning mechanism 800 and wrap around a plurality of fixed input pulleys 802, followed by wrapping around a plurality of movable pulleys 803. Finally, the cables wrap around a plurality of fixed output pulleys 804 and exit the tensioning mechanism 800 towards the end effector. Other embodiments may utilize shafts or pins instead of pulleys to redirect the cables. They may also have a different orientation or ratio of fixed pulleys to movable pulleys such as the use or lack of fixed output pulleys to redirect the cables toward the end effector.

[0075] The tensioning mechanism 800 shall not interfere with the steering of the cable-driven manipulator. In the previously described embodiment, the movable pulleys 802 may interfere with the steering mechanism. To mitigate this, one embodiment of the tensioningmechanism may have a self-locking feature or brake to the movable pulleys. In this embodiment, the movable pulleys are attached to a gear rack 805 that is driven by a worm 806 or a screw in other embodiments. The user actuates the screw dial 807 which is linked to the worm 806 or the screw in other embodiments to shift the gear rack 805, and therefore, the movable pulleys 803 to manually adjust the tension in the cable-driven manipulator. The nature of this mechanism is self-locking, which eliminates the effect on the steering mechanism. Other embodiments may use a self-locking brake or an additional actuated brake to hold the movable pulleys in place. Further embodiments may use a sliding mechanism to adjust the positions of the movable pulleys instead of using a dial.

[0076] In the previously mentioned embodiment of the tensioning mechanism 800, the plurality of movable pulleys are actuated simultaneously. This does not allow for individual adjustments of cable tension. To remedy this, one embodiment may allow for individual adjustments of the movable pulleys. One embodiment accomplishes this by individually shifting each pulley until the optimal tension is achieved. Another embodiment accomplishes this by using springs attached to the movable pulleys that can allow for minor variations in cable displacement through actuating the same dial or sliding mechanism.

[0077] In another related embodiment, an electromechanical control system may be used to minimize the excess cable or cable slack. This embodiment may optimize for a minimum tension value in each cable through feedback from strain gauges.

[0078] The below examples represent possible configurations of a cable-driven parallel manipulator that achieve at least some of the advantages and features described above.

[0079] In accordance with a first example, a cable-driven parallel manipulator including a reusable main body portion and a detachable attachment. The reusable main body portion receives user inputs, including: an outer housing including a docking section; a user input steering controller at least partially projecting from the outer housing; at least one inputcable coupled to the user input steering controller; and an input coupling assembly. The input coupling assembly including at least one input coupler having axially aligned and interconnected components. The at least one input coupler including: an input pulley engaged with the at least one input cable so that cable displacements result in axial rotation of the input pulley; and a first transfer structure that rotates based upon rotation of the input pulley. The detachable attachment is of elongate structure, equipped for releasable coupling to the reusable main body portion at the docking section, having a proximal end and a distal end. The detachable attachment including: an end effector located at the distal end; at least one output cable attached to the end effector; and an output coupling assembly located at the proximal end. The output coupling assembly including at least one output coupler having axially aligned and interconnected components. The at least one output coupler including: a second transfer structure that moves rotationally in correspondence to rotation of the first transfer structure when the reusable main body portion and the detachable attachment are releasably coupled; and an output pulley that rotates based upon rotation of the second transfer structure, the output pulley engaged with the at least one output cable that effectuates movements of the end effector.

[0080] In accordance with a second example, the first example may be modified one or more of the first transfer structure and the second transfer structure including a plurality of magnets that enable rotational movement of the second transfer structure in response to movements of the first transfer structure.

[0081] In accordance with a third example, the first through second examples may be modified by the reusable main body portion having a first plurality of stationary magnet mounts and the detachable attachment has a second plurality of stationary magnet mounts, wherein the reusable main body portion and the detachable attachment are held together when releasably coupled by connection of the first plurality of stationary magnet mounts with the second plurality of stationary magnet mounts.

[0082] In accordance with a fourth example, the first through third examples may be modified by the first transfer structure including a friction surface for rotationally moving the second transfer structure.

[0083] In accordance with a fifth example, the first example may be modified by the first transfer structure including a spine or dog-clutch feature for moving the second transfer structure.

[0084] In accordance with a sixth example, the first through fifth examples may be modified by the input coupling assembly including a plurality of input couplers and a plurality of input cables.

[0085] In accordance with a seventh example, the first through sixth examples may be modified by including a brake component that releasably attaches to the detachable attachment to mechanically interfere with the output pulley to prevent rotation and thereby maintain output cable tension.

[0086] In accordance with an eighth example, the seventh example may be modified by the brake component automatically detaches from the detachable attachment upon attachment of the detachable attachment to the reusable main body portion.

[0087] In accordance with a ninth example, the first through sixth examples may be modified by a brake component that magnetically locks the output pulley from rotation to maintain cable tension.

[0088] In accordance with a tenth example, the first through ninth examples may be modified by including a sterile barrier between the reusable main body portion and both the at least one output cable and the end effector of the detachable attachment when the reusable main body portion and the detachable attachment are engaged.

[0089] In accordance with an eleventh example, the first through tenth examples may be modified so the reusable main body portion contains an encoder that obtains position data of the detachable attachment.

[0090] In accordance with a twelfth example, the first through eleventh examples may be modified by the input coupling assembly includes four input couplers.

[0091] In accordance with a thirteenth example, the first through twelfth examples may be modified by both the first transfer structure and the second transfer structure each including at least one magnet to align movements with one another.

[0092] In accordance with a fourteenth example, the first through thirteenth examples may be modified by the reusable main body portion including a tension control knob on the outer housing that is user-manipulable.

[0093] In accordance with a fifteenth example, the first through fourteenth examples may be modified by the first transfer structure and second transfer structure designed to releasably couple and uncouple adjacent one another and shield the internal and proximal sterile proximal features from contact when they releasably couple.

[0094] In accordance with a sixteenth example, the first through fifteenth examples may be modified by each of the at least one input cables form a pair with one of the at least one output cables.

[0095] In accordance with a seventeenth example, the first through sixteenth examples may be modified by including a plurality of output cables attached to the end effector.

[0096] In accordance with an eighteenth example, the first through seventeenth examples may be modified by the output coupling assembly including four output couplers, each output coupler having axially aligned and interconnected components.

[0097] In accordance with a nineteenth example, a cable-driven parallel manipulator attachment includes an elongate structure, having a proximal end and a distal end, of disposablesingle procedure use construction. The elongate structure includes: an end effector located at the distal end; at least one output cable attached to the end effector; and an output coupling assembly, located at the proximal end. The output coupling assembly includes at least one output coupler having axially aligned and interconnected components. The at least one output coupler includes a transfer structure that rotates as directed by a physically separate device when coupled together without compromising sterility of the end effector and the output cable. The at least one coupler further includes an output pulley that rotates based upon rotation of the transfer structure, the output pulley engaged with the at least one output cable that effectuates movements of the end effector.

[0098] In accordance with a twentieth example, the nineteenth examples may be modified by the transfer structure including a plurality of magnets for rotational movement.

[0099] In accordance with a twenty -first example, the nineteenth through twentieth examples may be modified by the transfer structure including a friction surface.

[0100] In accordance with a twenty-second example, the nineteenth through twenty-first examples may be modified by the transfer structure including a spine or dog-clutch.

[0101] In accordance with a twenty-third example, the nineteenth through twenty-second examples may be modified by a brake component that releasably attaches to mechanically interfere with the output pulley to prevent rotation and thereby maintain output cable tension.

[0102] In accordance with a twenty-fourth example, the nineteenth through twenty-third examples may be modified by a brake component that magnetically locks the output pulley from rotation to maintain cable tension.

[0103] In accordance with a twenty-fifth example, the nineteenth through twentyfourth examples may be modified by the output coupling assembly including four output couplers, each output coupler having axially aligned and interconnected components.

[0104] In accordance with a twenty-sixth example, the nineteenth through twenty-fifth examples may be modified by a plurality of output cables being attached to the end effector.

[0105] In accordance with a twenty-seventh example, the nineteenth through twentysixth examples may be modified by the output coupling assembly containing an encoder that obtains position data.

[0106] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed subject matter. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations, and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed subject matter.

[0107] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0108] Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of oneor more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0109] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0110] For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.

Claims

CLAIMS:

1. A cable-driven parallel manipulator, comprising:a reusable main body portion that receives user inputs, including:an outer housing including a docking section;a user input steering controller at least partially projecting from the outer housing; at least one input cable coupled to the user input steering controller; andan input coupling assembly including:at least one input coupler having axially aligned and interconnected components, including:an input pulley engaged with the at least one input cable so that cable displacements result in axial rotation of the input pulley; and a first transfer structure that rotates based upon rotation of the input pulley; anda detachable attachment of elongate structure, equipped for releasable coupling to the reusable main body portion at the docking section, having a proximal end and a distal end, including:an end effector located at the distal end;at least one output cable attached to the end effector; andan output coupling assembly located at the proximal end, including:at least one output coupler having axially aligned and interconnected components, including:a second transfer structure that moves rotationally in correspondence to rotation of the first transfer structure when the reusable main body portion and the detachable attachment are releasably coupled; andan output pulley that rotates based upon rotation of the second transfer structure, the output pulley engaged with the at least one output cable that effectuates movements of the end effector.

2. The cable-driven parallel manipulator of claim 1, wherein one or more of the first transfer structure and the second transfer structure include a plurality of magnets that enable rotational movement of the second transfer structure in response to movements of the first transfer structure.

3. The cable-driven parallel manipulator of claim 1, wherein the reusable main body portion has a first plurality of stationary magnet mounts and the detachable attachment has a second plurality of stationary magnet mounts, wherein the reusable main body portion and the detachable attachment are held together when releasably coupled by connection of the first plurality of stationary magnet mounts with the second plurality of stationary magnet mounts.

4. The cable-driven parallel manipulator of claim 1, wherein the first transfer structure includes a friction surface for rotationally moving the second transfer structure.

5. The cable-driven parallel manipulator of claim 1, wherein the first transfer structure includes a spine or dog-clutch feature for moving the second transfer structure.

6. The cable-driven parallel manipulator of claim 1, wherein the input coupling assembly includes a plurality of input couplers and a plurality of input cables.

7. The cable-driven parallel manipulator of claim 1, further including a brake component that releasably attaches to the detachable attachment to mechanically interfere with the output pulley to prevent rotation and thereby maintain output cable tension.

8. The cable-driven parallel manipulator of claim 7, wherein the brake component automatically detaches from the detachable attachment upon attachment of the detachable attachment to the reusable main body portion.

9. The cable-driven parallel manipulator of claim 1, further including a brake component that magnetically locks the output pulley from rotation to maintain cable tension.

10. The cable-driven parallel manipulator of claim 1, wherein a sterile barrier is present between the reusable main body portion and both the at least one output cable and the end effector of the detachable attachment when the reusable main body portion and the detachable attachment are engaged.

11. The cable-driven parallel manipulator of claim 1, wherein the reusable main body portion contains an encoder that obtains position data of the detachable attachment.

12. A cable-driven parallel manipulator attachment, comprising:an elongate structure, having a proximal end and a distal end, of disposable single procedure use construction, including:an end effector located at the distal end;at least one output cable attached to the end effector; andan output coupling assembly, located at the proximal end, including:at least one output coupler having axially aligned and interconnected components, including:a transfer structure that rotates as directed by a physically separate device when coupled together without compromising sterility of the end effector and the output cable; andan output pulley that rotates based upon rotation of the transfer structure, the output pulley engaged with the at least one output cable that effectuates movements of the end effector.

13. The cable-driven parallel manipulator attachment of claim 10, wherein the transfer structure includes a plurality of magnets for rotational movement.

14. The cable-driven parallel manipulator attachment of claim 10, wherein the transfer structure includes a friction surface.

15. The cable-driven parallel manipulator attachment of claim 10, wherein the transfer structure includes a spine or dog-clutch.

16. The cable-driven parallel manipulator attachment of claim 10, further including a brake component that releasably attaches to mechanically interfere with the output pulley to prevent rotation and thereby maintain output cable tension.

17. The cable-driven parallel manipulator attachment of claim 10, further including a brake component that magnetically locks the output pulley from rotation to maintain cable tension.

18. The cable-driven parallel manipulator attachment of claim 10, wherein the output coupling assembly includes four output couplers, each output coupler having axially aligned and interconnected components.

19. The cable-driven parallel manipulator attachment of claim 10, wherein a plurality of output cables are attached to the end effector.

20. The cable-driven parallel manipulator attachment of claim 10, wherein the output coupling assembly contains an encoder that obtains position data.

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