Surgical Tool Calibration Accuracy Using Locked Joint References
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Solution Overview
Problem
Current surgical robotic systems face challenges in accurately evaluating the calibration of surgical tools attached to robotic arms, as repeated calibration tests only assess repeatability and not accuracy, potentially leading to consistently incorrect results.
Innovation Solution
A robotically-assisted surgical electro-mechanical system that includes a suite of compatible tools attached to an instrument driver on a robotic arm, featuring a lock mechanism and processors to identify lock identifiers, provide motor commands, determine motor positions, and store these positions for evaluation, allowing for precise calibration and accuracy assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repeated calibration tests are performed, then repeatability of calibration is assessed, but accuracy of calibration cannot be determined
Solution Approach 1:
The patent introduces locks as intermediary components that mechanically constrain the surgical tool at predetermined positions. These locks serve as mediators between the calibration process and the tool positioning system, providing known reference points that enable accuracy verification. The locks are associated with identifiers that link specific positions to expected motor positions, allowing the system to compare actual vs. expected positions for accuracy assessment.
Solution Approach 2:
The patent replaces purely mechanical calibration verification with an integrated electromechanical system. Instead of relying solely on mechanical repeatability tests, the system uses motor position feedback, lock identifiers, and processor-based comparison to evaluate both repeatability and accuracy. This substitution enables the system to detect and correct calibration drift by comparing actual motor positions against expected positions stored in memory.
2Reliability
If surgical tool is mechanically engaged to robot joint, then equipment malfunction is avoided, but calibration accuracy cannot be evaluated
Solution Approach 1:
The patent implements a feedback mechanism where the system continuously monitors motor positions and compares them against expected positions stored in memory. The processors receive position feedback from motors, retrieve corresponding expected positions based on lock identifiers, and generate feedback signals indicating whether calibration is accurate or drift has occurred. This feedback loop enables ongoing calibration verification without requiring mechanical disengagement of the tool.
Solution Approach 2:
The patent performs preliminary calibration and stores expected motor positions in memory before surgical operations begin. These pre-stored expected positions serve as reference values for subsequent accuracy evaluations. The system prepares calibration data in advance, creating a baseline against which actual positions can be compared during operation, enabling real-time accuracy assessment without interrupting the surgical workflow.
Data Source
AI summary
The disclosure relate to systems and methods for a surgical tool or a surgical robotic system. An example computer-implemented method for evaluating calibrations of a surgical tool includes fixating a joint of the surgical tool at a first angle, the joint being driven by an actuator, measuring an actuator position corresponding to the first angle, accessing a calibrated offset corresponding to the first angle, determining an expected joint angle based on the measured actuator position and the calibrated offset, and reporting a first difference between the expected joint angle and the first angle.