Asymmetric Pin Coupler for Robotic End Effector Alignment
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Solution Overview
Problem
Current surgical robotic systems face challenges in maintaining precise and repeatable alignment of end effectors with robotic arms, particularly when the end effector needs to be removed for maintenance or replacement, leading to difficulties in tracking its location accurately and requiring recalibration of navigation systems.
Innovation Solution
A coupling system comprising a first coupler portion with alignment pins and a second coupler portion with sockets, along with a clamp mechanism, ensures a precise and repeatable attachment of the end effector to the robotic arm, facilitating accurate tracking and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a removable connection is used to allow end effector exchange, then ease of operation is improved, but connection precision and repeatability deteriorate
Solution Approach 1:
The coupling system is divided into two separate coupler portions (first coupler portion on the robotic arm, second coupler portion on the end effector) that can be independently manufactured and assembled. Each portion contains specialized alignment features (alignment pins with specific configurations and corresponding alignment sockets) that ensure precise positioning when mated together, resolving the contradiction between removability and precision.
Solution Approach 2:
The alignment pins are designed with specific asymmetric configurations (different diameters, lengths, or shapes) that correspond to uniquely shaped alignment sockets. This asymmetric design ensures that the coupler portions can only be mated in the correct orientation, providing inherent alignment precision and repeatability while maintaining easy exchange capability.
2Measurement precision
If alignment pins with different configurations are used, then tracking accuracy is improved, but device complexity increases
Solution Approach 1:
The alignment pin configuration system serves multiple functions simultaneously: (1) provides precise alignment between coupler portions, (2) enables easy visual identification of correct orientation during assembly, and (3) ensures repeatable positioning for navigation tracking. The same structural elements achieve these multiple objectives without requiring separate mechanisms for each function.
Solution Approach 2:
Different alignment pins have locally differentiated configurations tailored to their specific positions and functions within the coupling system. Each alignment pin's unique configuration (different diameter, length, or shape) is optimized for its specific alignment requirement, providing precise tracking accuracy while keeping the overall device structure relatively simple and modular.
Data Source
AI summary
A coupling system for removably attaching an end effector to a distal end of a surgical robotic arm. The coupling system includes a first coupler portion including a boss coupled to the surgical robotic arm and a second coupler portion coupled to the end effector. The first coupler portion further includes a first alignment pin extending from the boss and having a first configuration, and a second alignment pin extending from the boss in spaced relation from the first alignment pin and having a second configuration different from the first configuration. The second coupler portion includes a socket body defining a receiver with a floor surface. A first alignment socket and a second alignment socket are defined in the floor surface and configured for engagement with the first and second alignment pins.