Rotating Switch Sensor for Ergonomic Robotic End Effectors

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Solution Overview

Problem

Conventional robotic surgical systems face issues with handles that are either fixed relative to the end effector, limiting ergonomics and causing fatigue, or have direct wiring that restricts movement and introduces friction, complicating cleaning and sterilization.

Innovation Solution

A rotatable handle system with a conductive element that senses a target wirelessly, allowing unrestricted rotation and easy disassembly for cleaning, using a sensor system with a conductive element disposed circumferentially about a body member and a handle that is rotatably mounted, enabling ergonomic alignment and reducing friction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the button is directly wired to the fixed portion of the end effector, then the wiring is simple, but the range of motion of the handle is limited

Engineering Contradiction:

Improverange of motionVSAvoidwiring complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical direct wiring system with a wireless sensor system. The conductive element on the handle interacts with a target on the body member through electromagnetic sensing, eliminating physical wiring that would constrain handle rotation and range of motion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a conductive element as an intermediary between the handle and the controller. This conductive element, when actuated by the tactile interface, creates a detectable signal with the target without requiring direct mechanical wiring, thus enabling wireless communication and unrestricted rotation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the handle is rotatable about a fixed portion, then ergonomics are improved, but friction is introduced between the handle and fixed portion

Engineering Contradiction:

ImproveergonomicsVSAvoidfriction

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent eliminates mechanical contact and friction by replacing the mechanical button-actuation system with a wireless conductive sensing system. The conductive element senses the target through electromagnetic interaction without physical contact, thereby removing friction between the handle and end effector.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If the handle is fixed relative to the end effector, then the structure is simple, but ergonomics deteriorate and fatigue increases

Engineering Contradiction:

ImproveergonomicsVSAvoidstructural complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent transforms the fixed handle structure into a rotatable handle system. The handle can rotate about the body member to accommodate different ergonomic positions, and the conductive sensing system dynamically adapts to this rotation without requiring mechanical complexity, using electromagnetic field interaction instead.

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If the handle is rotatable with direct wiring, then movement is enabled, but cleaning and sterilization become complicated

Engineering Contradiction:

Improverotational movementVSAvoidcleaning and sterilization

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical wired connection system with a wireless conductive sensing system. This eliminates wires and mechanical connectors that would trap contaminants and complicate sterilization processes, while still enabling rotational movement through electromagnetic interaction between the conductive element and target.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system permits ergonomic handle rotation, reduces friction, and facilitates easy disassembly for cleaning and sterilization, enhancing the longevity and usability of the robotic surgical system.

Implementation Method 1

the conductive element is configured to sense the target in response to actuation of the tactile interface

Methodology Applied

Scientific EffectElectromagnetic sensing: Electromagnetic Induction

Data Source

PatentUS12544930B2Rotating switch sensor for a robotic system

Publication Date: 2026.02.10 MAKO SURGICAL CORP

AI summary

The end effector of a surgical robotic manipulator includes a body member and a conductive element disposed circumferentially about a portion of the body member. The end effector includes a handle being rotatably mounted to the body member and being rotatable about the conductive element. The handle includes a tactile interface that is operatively coupled to a target and, for any rotational position of the handle, the conductive element is configured to sense the target in response to actuation of the tactile interface.