Patent Description:
<CIT> discloses a power supply for a robotic system using uninterruptible power supplies according to the prior art. <CIT> discloses a power supply using uninterruptible power supplies for an industrial system.

The invention is defined in independent claims <NUM> and <NUM>, further embodiments are described in the dependent claims.

The present disclosure provides a power management system for surgical robotic systems. Certain power supplies for powering robots include multiple powered components controlled by a single shut-off switch (e.g., <NUM>-pole switch) to turn power on and off to all of the multiple loads simultaneously. However, this configuration is inflexible in certain respects and prevents selective activation and deactivation of certain loads in response to situations where some of the loads needed to be turned off while the remaining loads need to be turned on. The present disclosure provides for a power management architecture that allows for independent activation and deactivation of powered components energizing the loads.

In addition, single shut-off switch architectures that include uninterruptible power supplies ("UPS"), which includes one or more electrical batteries, also tend to suffer due to the batteries becoming drained if unpowered for prolonged periods of time. Even though the shut-off switch isolates the loads from the UPSs, since the UPSs remain in a running condition their batteries are depleted after AC mains are disconnected. The present power management architecture provides for communication between individual components of the power supply and their respective UPSs to turn off each UPS based on demands of the load.

According to one embodiment of the present disclosure, a surgical robotic system is disclosed, which includes a robotic arm having at least one surgical instrument and a control device coupled to the robotic arm and configured to control the robotic arm, the control device including one or more components. The surgical robotic system also includes a power supply having: a tower power supply chassis configured to supply first direct current to the robotic arm; a power distribution unit configured to supply second direct current to the one or more components; a first uninterruptable power supply device coupled to the tower power supply chassis and configured to receive a first alternating current from a first alternating current input; and a second uninterruptable power supply device coupled to the power distribution unit and configured to receive a second alternating current from a second alternating current input.

According to one aspect of the above embodiment, the surgical robotic system also includes a power ingress module interconnecting the first alternating current input and the second alternating current input with the first uninterruptible power supply device and the second uninterruptible power supply device, respectively. The power ingress module is configured to disconnect the first alternating current input and the second alternating current input from the first uninterruptible power supply device and the second uninterruptible power supply device, respectively.

According to another aspect of the above embodiment, the component is one of a core controller, a safety controller, a visualization controller, a visualization system, a display, a network adapter, a light source, or a camera control unit.

According to another aspect of the above embodiment, the component is a core controller and each of the core controller and the tower power supply chassis is configured to detect connection or disconnection of the power supply to at least one of the first alternating current input or the second alternating current input. The surgical robotic system also includes one of a stationary support base or a movable support base, wherein the robotic arm is coupled to one of the stationary support base or the movable support base. The core controller and the tower power supply chassis are configured to detect connection or disconnection of the power supply to at least one of the stationary support base or the movable support base.

According to one aspect of the above embodiment, the surgical robotic system also includes an electrosurgical generator and a foot switch emulator interconnecting the electrosurgical generator and the power ingress module. The foot switch emulator is configured to receive a third alternating current from a third alternating current input.

According to another embodiment of the present disclosure, a power supply for a surgical robotic system is disclosed. The power supply includes: a tower power supply chassis configured to supply first direct current to a robotic arm; a power distribution unit configured to supply second direct current to a control device configured to control the robotic arm; a first uninterruptable power supply device coupled to the tower power supply chassis and configured to receive a first alternating current from a first alternating current input; and a second uninterruptable power supply device coupled to the power distribution unit and configured to receive a second alternating current from a second alternating current input.

According to one aspect of the above embodiment, the power supply further includes a power ingress module interconnecting the first alternating current input and the second alternating current input with the first uninterruptible power supply device and the second uninterruptible power supply device, respectively. The power ingress module is configured to disconnect the first alternating current input and the second alternating current input from the first uninterruptible power supply device and the second uninterruptible power supply device, respectively. The power distribution unit is coupled to at least one component selected from a core controller, a safety controller, a visualization controller, a visualization system, a display, a network adapter, a light source, or a camera control unit. In embodiments, the at least one component is a core controller and each of the core controller and the tower power supply chassis is configured to detect connection or disconnection of the power supply to at least one of the first alternating current input or the second alternating current input. In embodiments, each of the core controller and the tower power supply chassis is configured to detect connection or disconnection of the power supply to a support base.

According to another aspect of the above embodiment, the power supply further includes a foot switch emulator interconnecting an electrosurgical generator and the power ingress module. The foot switch emulator is configured to receive a third alternating current from a third alternating current input.

Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:.

Embodiments of the presently disclosed surgical robotic systems are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein the term "distal" refers to the portion of the surgical robotic system and/or the surgical instrument coupled thereto that is closer to the patient, while the term "proximal" refers to the portion that is farther from the patient.

Although the following description is specific to a surgical robotic system, the power supply described below may be used in any suitable medical device requiring electrical power. Referring initially to <FIG>, a surgical robotic system <NUM> includes a plurality of robotic arms <NUM>, each having a surgical instrument <NUM> removably attached thereto; a control device <NUM>; and an operating console <NUM> coupled to control device <NUM>. Surgical robotic system <NUM> is configured for use on a patient "P" lying on a stationary support base, such as a surgical table 3a to be treated in a minimally invasive manner using the surgical instrument <NUM>. The robotic arm <NUM> may be attached either to a stationary support base, such as the table 3a or a movable support base, such as a movable cart 3b. The surgical robotic system <NUM> also includes a power supply <NUM> configured to provide electrical power to the robotic arm <NUM> and the control device <NUM>. In embodiments, depending on the proximity of the operating console <NUM> (e.g., whether the operating console <NUM> is disposed in the operating room or remotely) the power supply <NUM> may be also coupled to the operating console <NUM>.

Operating console <NUM> includes a display device <NUM>, which displays the surgical site and manual input devices <NUM>, <NUM>, by which a clinician is able to remotely control robotic arms <NUM>. Each of the robotic arms <NUM> may be composed of a plurality of links, which are connected through joints. Robotic arms <NUM> may be driven by electric drives (not shown) that are connected to control device <NUM>. Control device <NUM> (e.g., a computer, a logic controller, etc.) is configured to activate the drives, based on a set of programmable instructions stored in memory, in such a way that robotic arms <NUM> and surgical instruments <NUM> execute a desired movement according to a movement in response to input from manual input devices <NUM>, <NUM>.

The control device <NUM> may include one or more processors (not shown) operably connected to a memory (not shown), which may include one or more of volatile, non-volatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically-erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM), or flash memory. The processors may be any suitable processor (e.g., control circuit) adapted to perform the operations, calculations, and/or set of instructions described in the present disclosure including, but not limited to, a hardware processor, a field programmable gate array (FPGA), a digital signal processor (DSP), a central processing unit (CPU), a microprocessor, and combinations thereof. Those skilled in the art will appreciate that the processors may be substituted for by using any logic circuit adapted to execute algorithms, calculations, and/or set of instructions described herein.

Control device <NUM> may control a plurality of motors <NUM>. n, each of which is configured to actuate the surgical instrument <NUM> to effect operation and/or movement of surgical instrument <NUM>. It is contemplated that control device <NUM> coordinates the activation of the motors <NUM>. n to coordinate a clockwise or counter-clockwise rotation of drive members (not shown) to coordinate operation and/or movement of the surgical instrument <NUM>. In embodiments, each motor of the plurality of motors <NUM>. n can be configured to actuate a drive rod, cable, or a lever arm (not shown) to effect operation and/or movement of each surgical instrument <NUM>. In embodiments, motors <NUM>. n may include embedded control electronics integrated within the motor housings obviate the reliance on the control device <NUM>.

For a detailed discussion of the construction and operation of a surgical robotic system, reference may be made to <CIT>.

With reference to <FIG>, the robotic arm <NUM> includes a plurality of movable links, a first link <NUM>, a second link <NUM>, a third link <NUM>, and a holder <NUM>, which are coupled to each other by actuators (not shown) allowing for movement of the robotic arm <NUM> into various configurations. The holder <NUM> is configured to receive an instrument drive unit which is configured to couple to an actuation mechanism of the surgical instrument <NUM>. Instrument drive unit transfers actuation forces from its motors to the surgical instrument <NUM> to actuate components (e.g., end effectors) of the surgical instrument <NUM>.

The first link <NUM> includes a curved base <NUM> configured to secure the robotic arm <NUM> to the table 3a or the movable cart 3b (<FIG>). The second link <NUM> is rotatable at a joint <NUM> and about an axis "X-X" relative to the first link <NUM>, such that an angle α defined by the first and second links <NUM> and <NUM> is from about <NUM>° to about <NUM>°. The third link <NUM> is rotatable at a joint <NUM> and about an axis "Y-Y" relative to the second link <NUM>, such that an angle β defined by the second and third links <NUM> and <NUM> is from about <NUM>° to about <NUM>°. The holder <NUM> is rotatable relative to the third link <NUM> such that an angle θ defined by the holder <NUM> and the third link <NUM> is from about <NUM>° to about <NUM>°.

The robotic arm <NUM> is coupled to the power supply <NUM> (<FIG>), which provides electrical regulated power to the robotic arm <NUM> as well as the motors <NUM>. With reference to <FIG>, a power supply <NUM> includes a power ingress module <NUM>, which is coupled to one or more AC line inputs 204a, 204b, 204c. Each of the AC line inputs 204a-c includes line and neutral connections which are coupled to each other through a fuse 205a, 205b, 205c, respectively, to provide for overcurrent protection. In addition, each of the AC line inputs 204a-c also includes a protective earth connection 207a, 207b, 207c, respectively. The power ingress module <NUM> also includes an equipotential terminal <NUM> to provide for common ground.

Each of the AC line inputs 204a and 204b is also coupled to a corresponding isolation transformer 206a and 206b of the power supply and the control device <NUM>, respectively, for electrical safety purposes and to uninterruptible power supplies ("UPS") 208a and 208b, which provide backup electrical power. In particular, the UPSs 208a and 208b are coupled to a tower power supply chassis ("TPSC") <NUM> and power distribution unit ("PDU") <NUM>, respectively. In some embodiments, the TPSC <NUM> may be also configured to couple to the table 3a or the movable cart 3b. Thus, the TPSC <NUM> powers motors and other electromechanical actuators of the robotic arm <NUM>.

The AC line input 204a supplies electrical power to the TPSC <NUM>, the AC line input 204b supplies electrical power to the PDU <NUM>, and the AC line input 204c supplies electrical power to an electrosurgical generator <NUM> through a foot switch emulator 208c, which is used to provide an activation signal to the electrosurgical generator <NUM>. Each of the UPS 208a and 208b as well as the foot switch emulator 208c is coupled to a corresponding emergency power off connections 209a, 209b, 209c, respectively, allowing for disconnection of the UPSs 208a and 208b.

The PDU <NUM> powers various control, input, and communication components of the control device <NUM>, such as a core controller 216a, a safety controller 216b, a visualization controller 216c, a visualization system 216d, a display 216e, a network adapter 216f, a light source <NUM>, a camera control unit <NUM>, and other auxiliary equipment 216i.

The power supply <NUM> also includes a first network switch <NUM> coupled to the UPS 208a and a second network switch <NUM> coupled to the UPS 208b. The first and second network switches <NUM> and <NUM> may be any suitable local area networking device, either wired, such as ethernet, or wireless, such as WiFi. The core controller 216a is coupled to the first and second network switches <NUM> and <NUM>. In addition, the first network switch <NUM> is coupled to the TPSC <NUM>. Thus, the first network switch <NUM> provides for bidirectional communication with the UPS 208a, the TPSC <NUM>, and the core controller 216a and the second network switch <NUM> provides for bidirectional communication with the UPS 208b and the core controller 216a. In addition, the first and second network switches 218a and 218b also interconnect the control device <NUM>, the operating console <NUM>, the robotic arm <NUM>, and the power supply <NUM>.

The core controller 216a is configured to operate in a low power mode and monitor the UPSs 208a and 208b to determine if the power supply <NUM> is still connected to AC line inputs 204a, 204b, 204c. Thus, when the surgical robotic system <NUM> is shut down, e.g., upon completion of a surgical procedure, allowing the core controller 216a to continue operation. In the event the AC line inputs 204a, 204b, 204c are disconnected, the core controller 216a is also configured to control the UPSs 208a and 208b to turn off completely to preserve the battery charge. In addition, the first and second network switches <NUM> and <NUM> are also configured to be powered on following disconnection from the AC line inputs 204a, 204b, 204c. This allows for a faster startup time since the first and second network switches <NUM> and <NUM> no longer would have to boot up.

In situations where AC line inputs 204a, 204b, 204c are disconnected from the power supply <NUM> during a surgical procedure, the UPSs 208a and 208b are configured to maintain AC power to the components connected to the power supply <NUM> until the core controller 216a initiates a shutdown of all system components including the UPSs208a and 208b under operator control, or if the UPSs 208a and 208b are about to be depleted.

If AC line inputs 204a, 204b, 204c are disconnected from the power supply <NUM>, the core controller 216a is configured to monitor the UPSs 208a and 208b and detect the disconnection of AC line inputs 204a, 204b, 204c. The core controller 216a is also configured to command the UPSs 208a and 208b to shut down following a short delay to allow for recovery from accidental disconnection.

The TPSC <NUM> is operational when it is connected to the AC line input 204a through the UPS 208a. The TPSC <NUM> is configured to connect to the table 3a and/or the movable cart 3b to provide power thereto and to the robotic arm <NUM>. The TPSC <NUM> is configured detect whether or not it is connected to the table 3a and/or movable cart 3b, such that electrical power is supplied to the table 3a and/or movable cart 3b after the TPSC <NUM> is attached thereto. Thus, if AC line input 204a is disconnected from the TPSC <NUM> and the TPSC <NUM> is not connected to either table 3a and/or movable cart 3b, the TPSC <NUM> commands the UPS 208a to turn off and preserve the battery charge.

When the movable cart 3b is connected to the TPSC <NUM>, the TPSC <NUM> is configured to detect which port the movable cart 3b is connected to and to enable the respective output from the AC/DC converter (not shown) to supply power to the movable cart 3b. Similarly, when the movable cart 3b is disconnected from the TPSC <NUM>, the TPSC <NUM> is configured to detect which port the movable cart 3b was disconnected from and disable the respective output from the AC/DC converter that powered the movable cart 3b.

The TPSC <NUM> is also configured to monitor the UPS 208a and detect the loss of the AC line inputs 204a, 204b, 204c. The TPSC <NUM> is configured to command the UPS 208a to shut down following a short delay period to allow for recovery from accidental disconnection.

The power supply <NUM> according to the present disclosure provides for a faster startup time and better preservation of the charged state of the batteries in the UPSs 208a and 208b. The first network switch <NUM> allows the TPSC <NUM> to communicate with the UPS 208a regardless of the powered state of the rest of the power supply <NUM>, e.g., the PDU <NUM>, since the UPSs 208a and 208b are controlled by their corresponding components that receive power therefrom. In addition, the UPSs 208a and 208b as well as the TPSC <NUM> are configured to monitor power consumption. This data is collected and is used during operation of the surgical robotic system <NUM> and during fault detection and handling. The core controller 216a is also configured to access this data through the first and second network switches 218a and 218b.

The power supply <NUM> is configured to operate in multiple operational states as described in further detail below. Initially, the AC line inputs 204a, 204b, 204c are connected to the power supply <NUM>, without the surgical robotic system <NUM> being set up or used for a surgical procedure. Since the AC line inputs 204a and 204b are connected the UPSs 208a and 208b are charging their respective batteries. The TPSC <NUM> and the core controller 216a are also operational at this time and monitor their respective UPSs 208a and 208b to determine whether the AC line inputs 204a and 204b are connected. The core controller 216a also monitors whether a system activation signal is received, e.g., from a system activation button, to initiate system startup. In embodiments, the system activation button (not shown) may be disposed on the control device <NUM> and/or the operating console <NUM>.

The first and second network switches 218a and 218b are also powered and operational. The safety controller 216b, the visualization controller 216c, the visualization system 216d, the display 216e, the network adapter 216f, the light source <NUM>, the camera control unit <NUM>, and other auxiliary equipment 216i may be turned off by the user to conserve power. The foot switch emulator 208c is also powered up, but the electrosurgical generator <NUM> is turned off.

As noted above, the control device <NUM> may be used to activate the surgical robotic system <NUM>. The activation process commences with the core controller 216a starting up the control device <NUM> and its computing components to prepare for the surgical procedure as well as any of the following systems that may have been previously powered down, the safety controller 216b, the visualization controller 216c, the visualization system 216d, the display 216e, the network adapter 216f, the light source <NUM>, the camera control unit <NUM>, and other auxiliary equipment 216i. In addition, the core controller 216a also notifies the operating console <NUM> that the startup process was initiated.

Since the first and second network switches 218a and 218b were previously powered on, the ready time for the control device <NUM> is shortened and depends on the boot up of the remaining systems, e.g., boot up time, operating system and application time load times, etc. At this point, the core controller 216a also attempts to communicate with the movable cart 3b as described above.

The operating console <NUM> may also be used to activate the surgical robotic system <NUM>. Once the user presses the system activation button on the operating console <NUM>, a signal is sent by the operating console <NUM> to the core controller 216a since the first and second network switches 218a and 218b are powered on and connect the operating consoler <NUM> to the core controller 216a. The core controller 216a then starts up the control device <NUM> and its computing components to prepare for the surgical procedure as well as any of the following systems that may have been previously powered down, the safety controller 216b, the visualization controller 216c, the visualization system 216d, the display 216e, the network adapter 216f, the light source <NUM>, the camera control unit <NUM>, and other auxiliary equipment 216i. The core controller 216a also attempts to establish communication with the movable cart 3b and send a message to the operating console <NUM> that the surgical robotic system <NUM>.

After the surgical robotic system <NUM> is activated through the control device <NUM> and/or the operating console <NUM>, the surgical robotic system <NUM> is used to perform a surgical procedure. Upon completion of the surgical procedure, the operating console <NUM> prompts the user to power off the electrosurgical generator <NUM>, the light source <NUM>, and the camera control unit <NUM>. The safety controller 216b and the visualization controller 216c may also enter a low power condition or power off completely. The core controller 216a also commands the operating console <NUM> to shut down.

During operation, the user may press an emergency power off button (not shown), which may be disposed on the control device <NUM> and/or the operation console <NUM> to activate emergency power off connections 209a, 209b, 209c, which disconnect the AC line inputs 204a, 204b, 204c from the TPSC <NUM>, the PDU <NUM>, and the electrosurgical generator <NUM>. More specifically, the UPSs 208a and 208b interrupt supply of AC from AC line inputs 204a, 204b, 204c being supplied to TPSC <NUM> and the PDU <NUM>. To recover from emergency power shut down, each of the UPSs 208a and 208b may then be powered on manually by the user.

Claim 1:
A surgical robotic system comprising:
a robotic arm (<NUM>) including at least one surgical instrument (<NUM>);
a control device (<NUM>) coupled to the robotic arm and configured to control the robotic arm, the control device including at least one component;
a power supply (<NUM>) including:
a tower power supply chassis (<NUM>) configured to supply first direct current to the robotic arm;
a power distribution unit (<NUM>) configured to supply second direct current to the at least one component;
a first uninterruptable power supply device (208a) coupled to the tower power supply chassis and configured to receive a first alternating current from a first alternating current input; and
a second uninterruptable power supply device (208b) coupled to the power distribution unit and configured to receive a second alternating current from a second alternating current input.