Surgical Tool Drive Engagement Detection via Motor Parameters
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Solution Overview
Problem
Existing surgical robotic systems face challenges in ensuring that surgical tools are not only mechanically attached but also properly engaged with the actuators of the surgical robotic arm to avoid equipment malfunctions during procedures.
Innovation Solution
A control unit detects the successful engagement of surgical tools with tool drives in surgical robotic arms by monitoring motor operating parameters of actuators, using sensors to verify mechanical alignment and torque transfer between tool and drive disks, and employing calibration values to ensure precise alignment and engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If surgical tools are selectively attached to the same robotic arm, then versatility and adaptability are improved, but the risk of equipment malfunction increases due to potential improper engagement
Solution Approach 1:
The control unit continuously monitors motor operating parameters (current, torque, speed) during actuator operation. When a tool is attached to the robotic arm, the system automatically detects engagement status by analyzing these parameters, providing real-time feedback to confirm proper mechanical coupling between the tool and actuator, thereby ensuring reliability while maintaining tool interchangeability
Solution Approach 2:
The patent replaces manual verification of mechanical engagement with automated electronic detection. Instead of relying on mechanical indicators or visual inspection, the system uses electrical parameter monitoring (motor current, torque, speed) to detect engagement status, enabling automatic verification that maintains reliability while supporting frequent tool changes
2Reliability
If mechanical engagement detection is implemented, then reliability is improved, but device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The system uses the actuator's own operating parameters (motor current, torque, speed) to detect engagement status. Instead of adding separate sensors specifically for engagement detection, the control unit leverages existing motor feedback signals that are already present in the actuator system, allowing engagement detection without significant additional hardware complexity
Solution Approach 2:
The control unit performs multiple functions: it controls actuator operation, monitors motor performance, and detects tool engagement status all through the same sensor system. The existing motor feedback infrastructure serves dual purposes for both actuation control and engagement detection, avoiding the need for dedicated engagement sensors and reducing overall system complexity
3Measurement precision
If motor operating parameters are monitored for engagement detection, then measurement precision is improved, but energy consumption increases due to continuous monitoring
Solution Approach 1:
The system maintains continuous monitoring of motor parameters during actuator operation without interruption. This continuous measurement approach ensures precise engagement detection while the monitoring only becomes energetically significant when the actuator is actively running, which is when useful work is being performed anyway, so the additional energy consumption is minimal and justified by the improved measurement precision
Data Source
AI summary
A system and computerized method for detection of engagement of a surgical tool to a tool drive of a robotic arm of a surgical robotic system. The method may include activating an actuator of the tool drive to rotate a drive disk to be mechanically engaged with a tool disk in the surgical tool. One or more motor operating parameters of the actuator that is causing the rotation of the drive disk are monitored while activating the actuator. The method detects when the drive disk becomes mechanically engaged with the tool disk, based on the one or more monitored motor operating parameters. Other embodiments are also described and claimed.