Patent Description:
Robotic technologies have a range of applications. In particular, robotic arms help complete tasks that a human would normally perform. For example, factories use robotic arms to manufacture automobiles and consumer electronics products. Additionally, scientific facilities use robotic arms to automate laboratory procedures such as transporting microplates. Recently, physicians have started using robotic arms to help perform surgical procedures. For instance, physicians use robotic arms to control surgical instruments such as laparoscopes.

Laparoscopes with movable tips help perform surgical procedures in a minimally invasive manner. A movable tip can be directed through the abdominal wall to a more remote location of a patient, such as the intestines or stomach. The movable tips in a robotically controlled laparoscope have several degrees of freedom that mimic a surgeon's wrist in traditional surgical operations. These movable tips, also referred as a robotic wrist or simply as a wrist, have evolved with technology and encompass a variety of technologies for creating motion about as many degrees of freedom as possible while using a minimal number of motors the surgical instrument.

Many such robotic wrists use a pre-tensioned loop of cable. This allows for the instrument to be driven with a minimum of motors relative to instruments that are tensioned with a motor for each cable. Such a "closed loop" cabling system makes it more difficult to map motor torque to cable tension. This is partly because of the preload in the system and partly due to the frictions the preload causes. End of life for a pre-tensioned instrument is usually because the cables loose tension over time due to a combination of mechanical wear, effects of cleaning chemicals, and stretch of the cables.

Documents <CIT>, <CIT>, and <CIT> relate to cable-driven robotic surgical wrists.

The invention is defined in appended independent claim <NUM>. Further embodiments are defined in appended dependent claims.

This description relates to a robotic surgical wrist with three degrees of freedom (DOF) that maintains the length and tension of the cables that control those DOF throughout the surgical operation.

The surgical robotic system controlling the wrist uses a master / slave system in which a master device controls motion of a slave device at a remote location. Generally, the slave device is a robotic surgical instrument that approximates a classical surgical tool for a surgical operation, e.g. a forceps in a laparoscopy.

In one embodiment, the slave surgical instrument has a surgical effector for performing surgical operations at a surgical site with three degrees of freedom in motion, a pitch angle, a first yaw angle, and a second yaw angle. Additionally, the surgical effector has a 'fourth degree of freedom' which is a measure of the relative yaw angles and the tension of their respective cables in the surgical effector. The surgical effector also a translation degree of freedom along an operation axis controlled by an external arm and a rotation degree of freedom about the operation axis controlled by an external instrument device manipulator.

To control the degrees of freedom of the surgical effector the surgical instrument has a set of four input controllers, four cables, a reciprocal pantograph, a cable shaft, and a surgical effector. Two of the cables couple two pairs of input controllers via the surgical effector such that their actuation, e.g. spooling or unspooling, manipulates the length of the cable's segment to create motion of the surgical effector about the degrees of freedom. The other two cables couple the two pairs of input controllers to the reciprocal pantograph such that the actuation creating motion of the surgical effectors creates a reciprocal motion in the reciprocal pantograph. The reciprocal pantograph maintains a constant length of cable between each pair of input controllers by rotating the reciprocal pantograph.

The surgical wrist may be controlled by a computer program designed to interpret motions of a user into surgical operations at the surgical site. This computer program interprets user motion and creates a set of instructions for appropriately manipulating the four cables via spooling and unspooling the input controllers to translate the user motion to motion of the surgical effector.

The disclosed embodiments have other advantages and features which will be more readily apparent from the following detailed description of the invention and the appended claims, when taken in conjunction with the accompanying drawings, in which:.

<FIG> illustrates an example representation of a master / slave surgical robotic system <NUM> consisting of a master device <NUM> and a slave device <NUM>. Generally, the master device is a command console for a surgical robotic system <NUM>. The master device <NUM> includes a console base <NUM>, display modules <NUM>, e.g., monitors, and control modules, e.g., a keyboard <NUM> and joystick <NUM>. In some embodiments, one or more of the master device <NUM> functionality may be integrated into the slave device <NUM> of the surgical robotic system <NUM> or another system communicatively coupled to the surgical robotic system <NUM>. A user <NUM>, e.g., a physician, remotely controls the surgical robotic system <NUM> from an ergonomic position using the master device <NUM>.

The slave device <NUM> has a table base <NUM> to support a surgical table <NUM> upon which a patient <NUM> is positioned for a surgical procedure at a surgical site <NUM>. At least one robotic arm <NUM> mounted to at least one locatable base <NUM> for manipulating surgical effectors <NUM>, is positioned in close proximity to the table base <NUM> and the surgical table <NUM>. Rather than having an independent and movable locatable base <NUM>, the robotic arms <NUM> may be coupled to the table base <NUM>. The table base <NUM> and the surgical table <NUM> may include motors, actuators, or other mechanical or electrical means for changing the orientation of the surgical table. In some embodiments the table base <NUM> and the surgical table <NUM> may be configured to change the orientation of the patient <NUM> and the surgical table for different types of surgical procedures at different surgical sites.

The slave device <NUM> may include a central processing unit, a memory unit, a data bus, and associated data communication ports that are responsible for interpreting and processing signals such as camera imagery and tracking sensor data, e.g., from the robotic manipulators. The console base <NUM> may include a central processing unit, a memory unit, a data bus, and associated data communication ports that are responsible for interpreting and processing signals such as camera imagery and tracking sensor data, e.g., from the slave device. In some embodiments, both the console base <NUM> and the slave device <NUM> perform signal processing for load-balancing.

The console base <NUM> may also process commands and instructions provided by the user <NUM> through the control modules <NUM> and <NUM>. In addition to the keyboard <NUM> and joystick <NUM> shown in <FIG>, the control modules may include other devices, for example, computer mice, trackpads, trackballs, control pads, video game controllers, and sensors (e.g., motion sensors or cameras) that capture hand gestures and finger gestures.

The user <NUM> can control a surgical effector <NUM> coupled to the slave device <NUM> using the master device <NUM> in a velocity mode or position control mode. In velocity mode, the user <NUM> directly controls pitch and yaw motion of the surgical instrument based on direct manual control using the control modules. For example, movement on the joystick <NUM> may be mapped to yaw and pitch movement of the surgical effectors <NUM>. The joystick <NUM> can provide haptic feedback to the user <NUM>. For example, the joystick <NUM> vibrates to indicate that the surgical effectors <NUM> cannot further translate or rotate in a certain direction. The command console <NUM> can also provide visual feedback (e.g., pop-up messages) and/or audio feedback (e.g., beeping) to indicate that the surgical effectors <NUM> have reached maximum translation or rotation.

In position control mode, the command console <NUM> uses a three-dimensional (3D) map of a patient and pre-determined computer models of the patient to control the slave device <NUM>. The command console <NUM> provides control signals to robotic arms <NUM> of the surgical robotic system <NUM> to manipulate the surgical effectors to the surgical site <NUM>. Due to the reliance on the 3D map, position control mode requires accurate mapping of the anatomy of the patient.

In some embodiments, users <NUM> can manually manipulate robotic arms <NUM> of the surgical robotic system <NUM> without using the master device <NUM>. During setup in a surgical operating room, the users <NUM> may move the robotic arms <NUM>, surgical effectors <NUM>, and other surgical equipment to access a patient. The surgical robotic system <NUM> may rely on force feedback and inertia control from the users <NUM> to determine appropriate configuration of the robotic arms <NUM> and equipment.

The display modules <NUM> may include electronic monitors, virtual reality viewing devices, e.g., goggles or glasses, and/or other means of display devices. In some embodiments, the display modules <NUM> are integrated with the control modules, for example, as a tablet device with a touchscreen. Further, the user <NUM> can both view data and input commands to the surgical robotic system <NUM> using the integrated display modules <NUM> and control modules.

The display modules <NUM> can display 3D images using a stereoscopic device, e.g., a visor or goggle. The 3D images provide a "surgical view," which is a computer 3D model illustrating the anatomy of a patient at the surgical site <NUM>. The "surgical view" provides a virtual environment of the patient's interior and an expected location of the surgical effectors <NUM> inside the patient. A user <NUM> compares the "surgical view" model to actual images captured by a camera to help mentally orient and confirm that the surgical effectors <NUM> are in the correct-or approximately correct-location within the patient. The "surgical view" provides information about anatomical structures, e.g., the shape of an intestine or colon of the patient, around the surgical site. The display modules <NUM> can simultaneously display the 3D model and computerized tomography (CT) scans of the anatomy at the surgical site. Further, the display modules <NUM> may overlay pre-determined optimal navigation paths of the surgical effectors <NUM> on the 3D model and CT scans.

In some embodiments, a model of the surgical effectors is displayed with the 3D models to help indicate a status of a surgical procedure. For example, scans identify a region in the anatomy where a suture may be necessary. During operation, the display modules <NUM> may show a reference image captured by the surgical effectors <NUM> corresponding to the current location of the surgical effectors at the surgical site <NUM>. The display modules <NUM> may automatically display different views of the model of the endoscope depending on user settings and a particular surgical procedure. For example, the display modules <NUM> show an overhead fluoroscopic view of the surgical end effector during a navigation step as the surgical end effector approaches an operative region of a patient.

<FIG> illustrates a slave robotic device <NUM> from a surgical robotic system <NUM> according to one embodiment. The slave device <NUM> includes a slave base <NUM> coupled to one or more robotic arms, e.g., robotic arm <NUM>. The slave base <NUM> is communicatively coupled to the master device <NUM>. The slave base <NUM> can be positioned such that the robotic arm <NUM> has access to perform a surgical procedure on a patient, while a user such as a physician may control the surgical robotic system <NUM> from the master device. In some embodiments, the slave base <NUM> may be coupled to a surgical operating table for supporting the patient. Though not shown in <FIG> for purposes of clarity, the slave base <NUM> may include subsystems such as control electronics, pneumatics, power sources, optical sources, and the like. The robotic arm <NUM> includes multiple arm segments <NUM> coupled at joints <NUM>, which provides the robotic arm <NUM> multiple degrees of freedom. The slave base <NUM> may contain a source of power <NUM>, pneumatic pressure <NUM>, and control and sensor electronics <NUM>-including components such as a central processing unit, data bus, control circuitry, and memory-and related actuators such as motors to move the robotic arm <NUM>. The electronics <NUM> in the slave base <NUM> may also process and transmit control signals communicated from the command console.

In some embodiments, the slave base <NUM> includes wheels <NUM> to transport the slave robotic device <NUM>. Mobility of the slave robotic device <NUM> helps accommodate space constraints in a surgical operating room as well as facilitate appropriate positioning and movement of surgical equipment. Further, the mobility allows the robotic arms <NUM> to be configured such that the robotic arms <NUM> do not interfere with the patient, physician, anesthesiologist, or any other equipment. During procedures, a user may control the robotic arms <NUM> using control devices such as the master device.

In some embodiments, the robotic arm <NUM> includes set up joints that use a combination of brakes and counter-balances to maintain a position of the robotic arm <NUM>. The counter-balances may include gas springs or coil springs. The brakes, e.g., fail safe brakes, may be include mechanical and/or electrical components. Further, the robotic arms <NUM> may be gravity-assisted passive support type robotic arms.

The robotic arm may be coupled to a surgical instrument, e.g. a laparoscope <NUM>, with the robotic arm positioning the surgical instrument at a surgical site. The robotic arm may be coupled to the surgical instrument with a specifically designed connective apparatus <NUM> that allows communication between the surgical instrument and the base, the base configured to control of the surgical instrument via the robotic arm.

<FIG> illustrates an embodiment of the end of a robotic arm <NUM> in a master / slave surgical system. At the end of each robotic arm, a mechanism changer interface (MCI) <NUM> may couple an instrument device manipulator (IDM) <NUM> to the robotic arm. The MCI <NUM> can be a set screw or base plate connector. The MCI <NUM> includes connectors to transfer pneumatic pressure, electrical power, electrical signals, and optical signals from the robotic arm to the IDM <NUM>.

The MCI <NUM> removably or fixedly mounts the IDM <NUM> to a surgical robotic arm of a surgical robotic system. The IDM is configured to attach the connective apparatus <NUM> (e.g., via a support bracket and mounting bracket as described in <FIG> below) of a surgical tool to a robotic surgical arm in a manner that allows the surgical tool to be continuously rotated or "rolled" about an axis of the surgical tool. The IDM <NUM> may be used with a variety of surgical tools (not shown in <FIG>), which may include a housing and an elongated body, and which may be for a laparoscope, an endoscope, or other types of endeffectors of surgical instruments.

<FIG> illustrates an example representation of the surgical instrument in a master / slave surgical system <NUM>. The surgical instrument is coupled to the IDM <NUM> via a support bracket <NUM> and mounting bracket <NUM>. The support bracket <NUM> and mounting bracket <NUM> are disk shaped, with a cable shaft <NUM> centrally located on the disk of the support bracket and extending outward normal to the plane of the support bracket <NUM> opposite the mounting bracket <NUM> along an operation axis <NUM>. The cable shaft <NUM> couples the surgical effector <NUM> to the support bracket <NUM> allowing control of the surgical effector by the slave base via the robotic arm and the IDM.

<FIG> illustrates an isometric view of an embodiment of the support bracket, with the mounting bracket not shown, demonstrating its constituent components. The support bracket <NUM> includes a support base <NUM> which is approximately disk shaped with at least one connective through-hole <NUM> coupled to the outer edge of the disk to assist coupling the support bracket to the mounting bracket. In some embodiments, there is no connective through-hole for coupling the support bracket to the mounting bracket. In other embodiments, there is no mounting bracket and the support bracket directly couples to the IDM. One face of the support base, hereafter the coupling face <NUM>, acts as a support structure for the input controllers <NUM>, the guidance pulleys <NUM>, and the reciprocal pantograph <NUM>. The opposite face of the support base <NUM>, hereafter the operation face <NUM> (not visibly shown), acts as a support structure for the cable shaft <NUM>.

In the center of the support base is an operative through-hole <NUM> through the support base <NUM> from the coupling face <NUM> to the operation face <NUM> along the operation axis <NUM> for coupling the input controllers <NUM> to the surgical effectors <NUM> via the cable shaft <NUM>. The operative through-hole <NUM> has a diameter large enough to allow at least four cable <NUM> segments to pass unimpeded through the support base <NUM> from the coupling face <NUM> to the operation face <NUM>.

Along the outer edge of the operative through-hole are a set of four guidance pulleys <NUM>, two outer 530a, 530d and two inner 530b, 530c that are at least partially recessed below the plane of the coupling face. The plane of each guidance pulley <NUM> is orthogonal to the plane of the coupling face <NUM>, with the plane of a pulley is the plane of pulley's disc. The pulleys are positioned such that the plane of each guidance pulley is normal to the edge of the operative through-hole <NUM> with at least a portion of the guidance pulley extended into the operative through-hole. The guidance pulleys <NUM> are coupled to the support base <NUM> and configured to rotate about a central guidance axis coplanar to the plane of the support base <NUM>. In one embodiment, the guidance pulleys <NUM> are connected to the support base <NUM> via bearings. The guidance pulleys allow cables <NUM> to move through the operative through-hole <NUM> without tangling with one another or chaffing against the edge of the operative through-hole.

The rays from the operation axis <NUM> outwards along the plane of the guidance pulleys create a set of four cable axes <NUM>, two outer axes 550a, 550d and two inner axes 550b, 532c. The guidance pulleys <NUM> are positioned such that the outer cable axes 550a, 550d form a line along the support bracket diameter, the angle between an outer cable axis (e.g. 550a) and the nearest inner cable axis (e.g. 550b) is a non-zero angle between <NUM> and <NUM> degrees, an example of which is illustrated in <FIG> as being approximately <NUM> degrees. Similarly, the angle between two inner cable axes (e.g. 550b and 550c) is an angle between <NUM> and <NUM> degrees, an example of which is illustrated as approximately <NUM> degrees.

The cable shaft <NUM> couples the surgical effector <NUM> to the support bracket <NUM> allowing control of the surgical effector by the slave base via the robotic arm and the IDM. In one embodiment, the cable shaft is a long hollow cylinder with an action end and a driver end, the action end coupling to the surgical effector <NUM> and the driver end coupling to the operation face <NUM> of the support bracket <NUM>. The cable shaft is coupled to the support bracket <NUM> such that the cable shaft <NUM> extends orthogonally from the support bracket along the operation axis <NUM>. The cable shaft <NUM> houses the cables <NUM> which couple the input controllers <NUM> to the surgical effector <NUM>.

Two outer input controllers 520a, 520d and two inner input controllers 520b, 520c are coupled to the support base and extend orthogonally outwards from the coupling face <NUM>. The input controllers <NUM> are positioned along a concentric half ring about the operation axis <NUM> with each input controller radially equidistant from the operation axis along one of the cable axes <NUM>. The input controllers <NUM> may be a similarly shaped to an inverted tiered cylindrical pyramid, with cylinders of increasing radii coupled atop one another. The coupled cylinders of the input controllers <NUM> are centrally aligned along a spooling axis <NUM> associated with that particular input controller that is orthogonal to the coupling face <NUM> and parallel to the operation axis <NUM>. The input controllers are positioned such that the two spooling axes <NUM> of the outer input controllers 520a, 520d form a form a line along the diameter of the support bracket similarly to the two outer cable axes, and forming similar angles with their closest respective inner input controllers with respect to the operation axis <NUM> accordingly. The two inner input controllers similarly are located at an angle with respect to each other similarly to the two inner cable axes, as described above.

The support base <NUM> contains four circularly shaped rotary joints <NUM>. The rotary joints <NUM> are configured to allow each input controller to rotate about its spooling axis, such as <NUM>. The rotary joints <NUM> are formed such that the top of each rotary joint is substantially flush to or slightly recessed from the coupling face <NUM> of the support base <NUM>. The rotary joints <NUM> are similarly positioned to the input controllers <NUM> with each input controller coupled to the center of a rotary joint such that the rotation axis of the rotary joint is coaxial with the spooling axis <NUM> of the associated input controller. In one embodiment, the rotary joint is a bearing.

While not pictured in <FIG>, the support bracket is further coupled to the mounting bracket <NUM> via the input controllers. The mounting bracket couples to the input controllers such that the top of the input controllers pass through the mounting bracket and the top of the input controllers are substantially flush with the top of the mounting bracket. The mounting bracket is further configured with a similar set of rotary joints coaxial to the rotary joints of the support bracket which allows the input controllers to rotate. The input controllers <NUM> and mounting bracket <NUM> are configured to be coupled to the IDM and actuate the cables <NUM> to control motion of the surgical effector <NUM>, described in detail in later sections. The cables <NUM> are coupled to the input controllers <NUM> such that the cables are at least partially wrapped around the input controllers and may spool or unspool around controllers as they rotate about the spooling axis. Each input controller is coupled to a single cable.

The reciprocal pantograph <NUM> is a physical structure containing multiple physical components that is named as such because it is configured to move in a reciprocal manner to the surgical effector, discussed in sections X and XI. Thus, the reciprocal pantograph allows the surgical instrument as a whole, the wrist specifically, and the cables within more specifically, to be length conservative. The cables are tightened using traditional techniques such as a fixed clamp or spooling around a cylinder, which is subject to becoming loose (less tensioned) over time through normal wear and tear. While cable wear may cause a change in the overall length of the cable, this change is compensated for by the IDM, robotic arm, and controlling computer to maintain a length conservative system. The reciprocal pantograph is further configured to maintain the length of the cables in the surgical instrument when not being controlled by the input controllers and IDM, for example when the surgical instrument is detached from the slave surgical device.

The reciprocal pantograph has two modes of operation: attached mode, in which the surgical instrument is attached to the IDM and robotic arm such that the IDM and robotic arm are able to actuate the input controllers and control the motion of the surgical effectors; and detached mode, in which the surgical instrument is detached from the IDM and robotic arm such that the reciprocal pantograph and input controllers passively maintain the length of the surgical cables of the surgical effector, thereby preventing it from coming loose/falling off.

The reciprocal pantograph <NUM> is coupled to the support base <NUM> on the half of the coupling face <NUM> opposite the inner input controllers <NUM>. The reciprocal pantograph <NUM>, shown with an expanded view in <FIG>, includes two coupled differentials, a rotation shaft, and an armature. The rotation shaft extends orthogonally outward from the coupling face <NUM> with the central axis of the rotation shaft, hereafter reciprocal axis <NUM>, being parallel to the operation axis <NUM>. The rotation shaft is positioned a radial distance away from the operation axis <NUM>. Additionally, the angle between an outer spooling axis <NUM>, the operation axis <NUM>, and the reciprocal axis <NUM> is approximately <NUM> degrees, though in other embodiments it may be at a different angle.

<FIG> is an isometric view of the example reciprocal pantograph <NUM>. The reciprocal pantograph consists of an armature <NUM> coupling two differentials 610a and 610b. The first differential 610a couples of a pair of pulleys, the first pulley being a reciprocal wrist pulley 612a with two grooves and the second pulley being a reciprocal member pulley 614a with one groove. The second differential 610b is similarly constructed with a wrist pulley 612b and a member pulley 614b. In another embodiment, the reciprocal wrist pulleys 612a and 612b may comprise two separate coaxial single groove pulleys or a single pulley with a single groove large enough to allow for two cables. The armature <NUM> couples the differentials 610a and 610b to each other such that the reciprocal wrist pulleys 612a and 612b are coaxial to each other and to the reciprocal axis <NUM>. Additionally, the armature <NUM> couples the reciprocal member pulleys 614a and 614b of each differential an equal distance from the reciprocal wrist pulleys 612a and 612b. The armature <NUM> further couples the reciprocal member pulleys 614a and 614b such that they are located a non-zero angle apart from each other about the reciprocal axis <NUM>. In other embodiments, the reciprocal member pulleys <NUM> are a dissimilar distance away from the reciprocal wrist pulleys <NUM>. The reciprocal member pulleys <NUM> are rotated about a tensile axis <NUM>, the tensile axis forming an acute angle to the reciprocal axis <NUM>.

Within each differential <NUM>, the reciprocal wrist pulley <NUM> and reciprocal member pulley <NUM> are further coupled by a cable <NUM>. For sake of discussion the cable may be described as having an inbound segment 616a and an outbound segment 616b, with the inbound segment extending from the reciprocal axis <NUM> towards the tensile axis <NUM> and the outbound segment extending from the tensile axis toward the reciprocal axis. As the cables move during use, the segment definitions are arbitrary, and are defined here for sake of clarity relative to the pulleys, rather than being at fixed locations on the cables themselves.

On the inbound segment 616a, the cable at least partially loops around the reciprocal wrist pulley <NUM> in its first groove. The cable then at least partially loops around the reciprocal member pulley <NUM>, coupling the reciprocal member pulley to the reciprocal wrist pulley <NUM> transitioning to the outbound segment. On the outbound segment 616b, the cable then further at least partially loops around the reciprocal member pulley <NUM>, thereby reverses the direction of the cable after which it is directed away from the tensile axis <NUM>. The outbound segment of the cable at least partially loops around the second groove of the reciprocal member wrist pulley <NUM>, after which it is directed away from the reciprocal axis <NUM>.

<FIG> illustrates an example of how the input controllers are coupled to the restraint pantograph. The top tier of each input controller <NUM>, i.e. the cylinder furthest removed from the coupling face of the support bracket, is configured to removably attach the input controller to a corresponding actuator of the IDM such that the IDM can manipulate the rotation of the input controller about their independent spooling axes 556a 556b 556c, 556d. Additionally, each pair of input controllers <NUM> is coupled to one of the differentials <NUM> of the reciprocal pantograph <NUM> by a cable <NUM> such that the inbound segment and outbound segment of the cable couples the first input controller to the second input controller of an input controller pair. In the illustrated embodiment, an outer 520a and an inner 520b input controller are paired by a first cable and the inner 520c and outer 520d are paired by a second cable, but one knowledgeable in the art will recognize that any two input controllers may be paired together.

While the laparoscopic tool is attached to the IDM to perform operations at the surgical site, the reciprocal pantograph is in attached mode. While in attached mode, the differentials of the reciprocal pantograph maintain a constant length in each of the cables coupling each pair of input controllers. The total length in a cable is manipulated by the interplay of spooling and unspooling the pair of input controllers associated with a given cable, as well as by the rotation of the restraint pantograph about the reciprocal axis. To maintain the length of the cables, the pulleys in the differentials and the armature rotate about the reciprocal and tensile axes to create an equal and opposite lengthening (or shortening) to compensate for the shortening (or lengthening) created by spooling or unspooling input controllers about their spooling axes.

<FIG> illustrate this process and the following paragraphs further detail the interaction between the inbound and outbound cable segments, the reciprocal pantograph, and the input controller pairs. For clarity, hereafter, the inbound segment of the first cable within the first differential is the first segment 660a, the outbound segment of the first cable within the first differential is the second segment 660b, the inbound segment of the second cable within the second differential is the third segment 660c, and the outbound segment of the second cable within the second differential is the fourth segment 660d.

Additionally, the first input controller of the first controller pair controls the length of the first segment 660a; the second input controller of the first controller pair controls the length of the second segment 660b; the first input controller of the second controller pair controls the length of the third segment 660c; and, the second input controller of the second controller pair controls the length of the fourth segment 660d. Any pair of cable segments introduced above could be described as an inbound/outbound segment pair depending on the spooling/unspooling being performed on one the input controllers of the pair at that moment in time. In the illustrated embodiment, an inner and an outer input controller (e.g. 520a and 520b) are paired, but one knowledgeable in the art will appreciate that the input controllers may be configured in different pairings.

In the illustrated embodiment, there are five possible states in attached mode for a given cable of an input controller pair coupled by a differential. In a first state the input controller pair concurrently decreases length of the first segment and increases length of the second segment. In a second state the input controller pair concurrently increases length of the second segment and decreases length of the first segment. In a third state the input controller pair concurrently unspools of the first and second segments, resulting in a compensatory rotation of the reciprocal pantograph about the reciprocal axis to conserve cable length. In a fourth state the input controller pair concurrently spools the first and second segment, resulting in a compensatory rotation of the reciprocal pantograph about the reciprocal axis to conserve cable length. In a fifth "neutral" state the input controller pair does not manipulate the cable segments. In all possible states, the length of the cable from the first input controller to the second controller of an input controller pair is conserved.

<FIG> is a planar view of the support bracket which illustrates the input controllers and the reciprocal pantograph in the first state for the cable associated with the first 660a and second 660b segments. The first input controller 520a unspools the cable, increasing length 670a (illustrated as an arrow) in the first segment 660a while the second input controller 520b spools the same cable decreasing length 670b of the second segment 660b. This yields rotation of the reciprocal member pulley <NUM> about the tensile axis <NUM>, no rotation of the reciprocal wrist pulley <NUM> about the reciprocal axis <NUM>, no rotation of the armature <NUM> about the reciprocal axis <NUM>, and a reciprocal movement of the cables in the operative through-hole <NUM>. In this embodiment of the first state, the contact area 640a of the cable in contact with the reciprocal wrist pulley is unchanged. The second state is similar to the first with the first and the second input controllers being reversed.

<FIG> is a planar view of the support bracket which illustrates the input controllers and the reciprocal pantograph in the third tensile state. The first input controller of an input controller pair, e.g. an outer input controller 520a, pair spools around its spooling axis 556a (attempting to decrease the length 680a in the first segment 660a) while the second input controller, e.g. an inner input controller 520b, of the input controller pair spools around its spooling axis 556b (attempting to decrease the length 680a of the third segment 660b). This yields rotation of the reciprocal member pulley <NUM> about the tensile axis <NUM>, rotation of the reciprocal wrist pulley about the reciprocal axis <NUM>, and rotation of the differential about the reciprocal axis <NUM>. In this embodiment of the third state, the differential rotates <NUM> about the reciprocal axis <NUM> by an amount that compensates for the spooling of the cable segments about the input controller pairs such that the contact area 640b of the cable with the reciprocal wrist pulley reduces and the total length of the cables in the pantograph is maintained. The fourth state is similar to the third state with the first and the second input controllers simultaneously unspooling the first and second segment with the unspooling offset by a rotation of the differential about the reciprocal axis.

<FIG> illustrates and embodiment of the surgical effector for laparoscopy in a master / slave surgical system. The surgical effector consists of two working members <NUM>, a surgical wrist <NUM>, and an effector housing <NUM>. <FIG> is an illustration of the surgical effector with the effector housing removed.

The two working members <NUM> may be designed as robotic version of an existing surgical tool for performing surgical operations, for example the small robotic forceps illustrated <FIG>. Each working member consists of a member pulley <NUM> with a single groove and forceps half <NUM>. The member pulleys have an outer face and an inner face and are able to rotate around a centrally located rotation axis, hereafter the member axis <NUM>, which is orthogonal to the inner and outer faces. The member pulleys may have centrally located member bore <NUM> coaxial to the member axis passing from the inner face to the outer face and orthogonal to the operation axis <NUM>.

Each forceps half <NUM> has a substantially flat side and a rounded side, the flat side for interacting with tissues in a surgical operation. The substantially flat side may be textured to allow for easier interaction with tissues in a surgical operation. In another embodiment, the forceps are configured to interact with needles in a surgical procedure. Each forceps half <NUM> is independently coupled to a member pulley <NUM> such that the forceps half is normal to the edge of the member pulley and extends radially away from the member axis <NUM> in the plane of the member pulley <NUM>. The member pulley <NUM> is further coupled to the forceps half <NUM> such that the forceps half also rotates around the member axis <NUM>.

The working members <NUM> are coupled such that the inner faces of the member pulleys are substantially flush with the member bores <NUM> and member axes <NUM> being coaxial. The working members <NUM> are further coupled such that the flat side of each forceps half are facing one another and may be coplanar.

The surgical wrist is a set of two wrist pulleys with four grooves. The first wrist pulley <NUM> may have a larger radius than the second wrist pulley <NUM>. The wrist pulleys have a front face and a back face and are able to rotate around a centrally located rotation axis that is orthogonal to the front and back faces, hereafter the wrist axes <NUM>. Herein, the four grooves of the wrist pulley will be sequentially referenced as one through four from the back side to the front side. The wrist pulleys <NUM> may have a centrally located wrist bore <NUM> coaxial to the wrist axes <NUM> passing from the front face to the back face of the wrist pulleys. The wrist axes <NUM> of each wrist pulley are parallel to one another, orthogonal to the member axes <NUM>, and orthogonal to the operation axis <NUM> such that the three types of axes are an orthogonal set <NUM>. The wrist pulleys are positioned such that the front faces are coplanar, with the first wrist pulley <NUM> being nearer the action end of the cable shaft <NUM> along the operation axis <NUM> than the second wrist pulley <NUM>.

The effector housing <NUM> may be a cylindrical protective metal sheath which couples the wrist pulleys <NUM> to the member pulleys <NUM> while allowing movement of cables <NUM> through the sheath. In some embodiments, the effector housing may include a proximal clevis 730b and a distal clevis 730c, the proximal clevis coupled to the distal clevis by a connective pin. The first <NUM> and second <NUM> wrist pulleys are coupled to the effector housing <NUM> by independent set screws <NUM> that pass from one side of the housing to the other side of the housing along the wrist axes <NUM> through the wrist bores <NUM> in the wrist pulleys <NUM>. The member pulleys <NUM> are coupled to the effector housing by a singular set screw <NUM> that passes from one side of the housing to the other side of the housing along the coaxial member axes <NUM> through the central member bores <NUM> in the member pulleys <NUM>. The member pulleys <NUM> are further coupled to the effector housing with the forceps halves <NUM> extending away from the effector housing towards the active end of the cable shaft <NUM> along the operation axis <NUM>. The housing couples the wrist pulleys <NUM> and the member pulleys <NUM> such that the member pulleys are nearer the active end of the cable shaft <NUM> along the operation axis <NUM> than the wrist pulleys. The effector housing <NUM> couples the wrist pulleys <NUM> and member pulleys <NUM> to maintain the orthogonal set of the operation axis <NUM>, the member axes <NUM>, and the parallel wrist axes <NUM>, i.e. the outer face of the member pulley <NUM>, the front faces of the wrist pulleys <NUM>, and the operation axis <NUM> are orthogonal <NUM>.

Within the housing the wrist pulleys <NUM> and the member pulleys <NUM> are further coupled by two cables. In some embodiments, the cables within the effector housing are distinct from the two cables coupling the input controllers to the reciprocal pantograph, hereafter referred to as the third and the fourth cable for clarity. For sake of discussion the cables may be described as having inbound and outbound segments, with the inbound segments extending from driver end to the action end within the cable shaft and the outbound segments extending from the action end to the driver end within the cable shaft.

Hereafter, the inbound segment of the third cable is the fifth segment 750a and the outbound segment of the third cable is the sixth segment 750b. According to one possible cabling scheme, the inbound segment 650a, the cable at least partially loops around the second wrist pulley in its first groove. The fifth segment 650a then at least partially loops around the first grooves of within the housing the first wrist pulley <NUM>, coupling the first wrist pulley to the second wrist pulley. The inbound segment then at least partially loops around the first groove of the first member pulley <NUM>, coupling the first wrist pulley to the member pulley. The inbound segment 750a at least partially looping around the first member pulleys <NUM> reverses the direction of the cable away from the action end and begins the outbound segment 650b. On the outbound segment 650b, the cable at least partially loops around the third groove of the first wrist pulley <NUM>. The outbound segment 650b then at least partially loops around the third groove of the second wrist pulley <NUM>.

Similarly, the inbound segment of the fourth cable is the seventh segment 750c and the outbound segment of the fourth cable is the eighth segment750d. Continuing the same cabling scheme above, the inbound segment 750c at least partially loops around the second grooves of the wrist pulleys <NUM> on the inbound route, at least partially loops around the second member pulley <NUM> reversing the direction to begin the outbound segment 750d, and at least partially loops around the fourth grooves of the wrist pulleys.

In the illustrated embodiment, the inbound cables at least partially loop one half of the second wrist pulley and the opposite half of the first wrist pulley. It will be obvious to one skilled in the art that these halves may be reversed.

In the illustrated embodiment, the third cable at least partially loops around the wrist pulleys in the first groove on the inbound route and the third groove on the outbound route while the fourth cable at least partially loops around the wrist pulleys in the second groove on the inbound route and the fourth groove on the outbound route. It will be obvious to one skilled in the art that the grooves of the inbound and outbound routes for the third and fourth cables may be configured in a different manner.

<FIG> illustrates how the input controllers <NUM> are coupled to the surgical effector <NUM>. The bottom tier of each input controller <NUM> is coupled to a rotary joint <NUM> on the support bracket <NUM>. Each inner input controller and outer input controller pair (e.g. 520a and 520b) is coupled to the surgical effector <NUM> by a cable that passes through the operative through-hole <NUM> such that the inbound segment fifth segment 750a of the outer input controller is coupled to the outbound sixth segment 750b of the inner input controller via the surgical effector <NUM>. In alternative configurations, the inbound and outbound segments as well as the paired input controllers are interchangeable.

In the described configuration, the surgical effector has three controllable degrees of freedom: a first yaw angle <NUM>, a second yaw angle <NUM>, and a pitch angle <NUM> illustrated in <FIG>.

As illustrated in <FIG>, the first degree of freedom is motion of the first forceps half <NUM> as the first member pulley <NUM> rotates <NUM> about the member axis <NUM>, i.e. the yaw axis, moving the forceps half714 in the plane of the first member pulley such that the forceps half creates a first yaw angle <NUM> with the operation axis <NUM>.

Similarly, the second degree of freedom is motion of the second forceps half <NUM> as the second member pulley <NUM> rotates about the member axis <NUM>, i.e. the yaw axis, moving the second forceps half in the plane of the second member pulley such that the forceps half creates a second yaw angle <NUM> with the operation axis <NUM>.

As illustrated in <FIG>. the third degree of freedom is motion of the working members as the first wrist pulley rotates <NUM> about the first wrist axis <NUM>, i.e. the pitch axis, moving the working members in the plane of the first wrist pulley <NUM> such that the working members create first yaw angle <NUM> with the operation axis <NUM>.

In the described embodiment, the first and the second yaw angles are coplanar and the plane of the pitch angle is orthogonal to the plane of the yaw angles. In other embodiments, the first yaw angle, the second yaw angle, and the pitch angle may have different orientations to the operation axis. In still other embodiments, the first and second yaw angles may not be coplanar.

The surgical effector may also move in two additional degrees of freedom: a rotation angle and a translation distance. The rotation angle is created by rotation of the IDM and MCI about the operation axis. The translation distance is created by motion of the robotic arms such that the cable shaft translates along the operation axis.

Movement about the three degrees of freedom in this system is created by rotation of the member pulleys <NUM> and the wrist pulleys <NUM> about their respective axes. The rotation of the pulleys about their axes is caused by the input controllers spooling or unspooling the cables to control the length of the cables.

<FIG> further demonstrate a method for causing motion of the surgical effector about the three controllable degrees of freedom by controlling length in the cables. In this embodiment, each input controller is coupled to either the input or output segment of the third cable or the input or output segment of the fourth cable in the surgical effector. The first input controller of the first controller pair controls the length of the fifth segment 750a; the second input controller of the first controller pair controls the length of the sixth segment 750b; the first input controller of the second controller pair controls the length of the seventh segment 750c; and, the second input controller of the second controller pair controls the length of the eighth segment 750d.

<FIG> illustrates the surgical effector in an example "neutral" state, i.e. the first yaw angle <NUM>, the second yaw angle <NUM>, and the pitch angle <NUM> have no offset from the operation axis <NUM> with no cable segment length being modified. The first yaw angle <NUM> is manipulated by controlling length in the fourth cable such that the length of the seventh segment increases <NUM> while the length of the eighth segment decreases <NUM>. This configuration causes the fourth cable to move which in turn causes first member pulley to rotate about the yaw axis <NUM> such that the first yaw angle <NUM> between the half forceps <NUM> and the operation axis <NUM> increases. In a reciprocal configuration, the first yaw angle <NUM> can be decreased by decreasing the length of the seventh segment and increasing the length of the eighth segment. In both configurations, the total length of the surgical cable is maintained.

Similarly, the second yaw angle is manipulated by controlling length in the third cable such that the length of the fifth segment 750a increases while the length of the sixth segment 750b decreases. This configuration causes the fourth cable to move which in turn causes second member pulley to rotate about the yaw axis <NUM> such that the second yaw angle <NUM> between the half forceps and the operation axis <NUM> increases. In a reciprocal configuration, the third cable moves such that the yaw angle can be decreased by increasing the length of the eighth segment and decreasing the length of the seventh segment. Additionally, motion of the forceps halves about the yaw axes can be in either direction away from the operation axis in the plane of member pulleys. In both configurations, the total length of the surgical cable is maintained.

In some embodiments, the manipulation of segment length of the cables creates an additional 'degree of freedom,' such as grip strength. In these embodiments, the motion about the first and second degrees of freedom may limit one another, i.e. one forceps half is unable to change its yaw angle <NUM> due to the position and yaw angle <NUM> of the other forceps half. This may occur, for example, due to an object being held between the forceps halves. The amount of electrical load measured in the system when the first and second degrees of freedom limit one another provides a measure of grip strength.

<FIG> illustrates the surgical effector in a neutral state, i.e. the first yaw angle <NUM>, the second yaw angle <NUM>, and the pitch angle <NUM> have no offset from the operation axis <NUM> with no cable segment being manipulated by an input controller. The pitch angle <NUM> is manipulated by controlling length in the third and fourth cables. Length in the fifth and sixth segments is increased <NUM> while length in the seventh and eighth segments is decreased <NUM> causing the first wrist pulley to rotate <NUM> about the pitch axis. This configuration causes the third and fourth cables to move which increases the pitch angle between the working members <NUM> and the operation axis <NUM> in the plane of the first wrist pulley <NUM>. Rotation of the effectors about the pitch angle compensates for the increasing and decreasing of length of the segments such that the first and second cables are length conservative. In a reciprocal configuration, the pitch angle can be decreased by decreasing length in the fifth and sixth segments while increasing length in the seventh and eighth segments. In all configurations, the length of the surgical cables is conserved. Additionally, motion of the working members about the pitch axis can be in either direction away from the operation axis in the plane of the wrist pulley.

The above description is a configuration controlling the degrees of freedom in which each movement is asynchronous and controlled independently, e.g. first opening one forceps half and then pitching the wrist, etc. However, in most robotic surgical operations the degrees of freedom are changed simultaneously, e.g. opening the forceps while concurrently rotating their orientation at the surgical site. One skilled in the art will note that simultaneous motion about the three controllable degrees of freedom is accomplished by a more complex control scheme for spooling and unspooling the input controllers to control the four cables and the segment lengths.

In one embodiment, this control scheme is a computer program running on the control base of the master device configured to interpret the motions of the user into corresponding actions of the surgical effector at the surgical site. The computer program may be configured to measure the electric load required to rotate the input controllers to compute the length and/or movement in the cable segments. The computer program may be further configured to compensate for changes in cable elasticity, (e.g. if the cables are a polymer), by increasing / decreasing the amount of rotation needed for the input controllers to change the length of a cable segment. The tension may be adjusted by increasing or decreasing the rotation of all the input controllers in coordination. The tension can be increased by simultaneously increasing rotation, and the tension can be decreased by simultaneously decreasing rotation. The computer program may be further configured to maintain a minimum level of tension in the cables. If the tension in any of the cables is sensed to drop below a lower minimum tension threshold, then the computer program may increase rotation of all input controllers in coordination until the cable tension in all cables is above the lower minimum tension threshold. If the tension in all of the cables is sensed to rise above a upper minimum tension threshold, then the computer program may decrease rotation of all input controllers in coordination until the cable tension in any of the cables is below the upper minimum tension threshold. The computer program may be further configured to recognize the grip strength of the operator based on the load of the motors actuating the input controllers coupled to the cable segments, particularly in a situation where the working members are holding on to an object or are pressed together. More generally, the computer program may be further configured to further control the translation and rotation of the surgical instrument via the robotic arm and IDM.

The reciprocal pantograph is configured to mimic the motion of the surgical effector in a reciprocal manner. <FIG> illustrate examples of the reciprocal motion in the surgical instrument.

<FIG> illustrates an example wiring of the slave device laparoscope in the neutral state. The outer input controller 520a and the inner input controller 520b of a first input controller pair are coupled by the first and the third cables and control the spooling and unspooling of cable segments. The first cable couples the input controller pair within the reciprocal pantograph <NUM> via the first 660a and second 660b cable segments. The third cable couples the input controller pair within the surgical effector <NUM> via the fifth 750a and sixth 750b segment. The length in the first and second cable segments is controlled by rotating the outer 520a and inner 520b input controllers about their spooling axes <NUM>, respectively. This rotation concurrently changes the length in the fifth and sixth cable segments in a reciprocal manner, respectively, e.g. increasing length in the first segment <NUM> decreases length in the fifth segment <NUM>, conserving the total cable length between the input controllers.

The inner input controller and the outer input controller of a second input controller pair are coupled by the second and the fourth cables and control the spooling and unspooling of cable segments. The inner input controller 520c and the outer input controller 520d of a first input controller pair are coupled by the second and the fourth cables and control the segment length. The second cable couples the input controller pair within the reciprocal pantograph <NUM> via the third 660c and fourth 660d cable segments. The fourth cable couples the input controller pair within the surgical effector <NUM> via the seventh 750c and eighth 750d segment. The length of the third and fourth cable segments is controlled by rotating the inner 520c and outer 520d input controllers about their spooling axes <NUM>, respectively. This rotation concurrently changes the length of the seventh and eighth cable segments in a reciprocal manner, respectively, e.g. increasing length in the third segment decreases length in the seventh segment.

<FIG> shows first an embodiment in which the first yaw angle <NUM> of the surgical effector <NUM> is increased. The yaw angle is controlled by spooling and unspooling the first input controller pair, 520a and 520b, such the length of the fifth segment decreases <NUM> while the length of the sixth segment increases <NUM>. As the yaw angle increases, the length in the first segment increases <NUM> while length in the second segment decreases <NUM> such that, within the restraint pantograph, the member pulley rotates about the tensile axis. In this configuration, the overall length of the third cable is maintained in the reciprocal pantograph <NUM>, and the length of the first cable is maintained in the surgical effector and cable shaft. The second yaw angle may be manipulated by similarly spooling the second pair of input controllers to manipulate the length of the segments of the third and fourth cables. Either yaw angle may be decreased by manipulating segment lengths with the input controllers in an inverse manner.

<FIG> shows an embodiment in which the pitch angle <NUM> of the surgical effector <NUM> is increased. The pitch angle of the surgical effector is controlled by unspooling the first cable such that the length of the fifth segment <NUM> and length of sixth segment <NUM> attempts to increase while simultaneously spooling the second cable such that the length of the seventh segment <NUM> and length of eighth segment <NUM> attempts to decrease The change of the pitch angle in the surgical effector compensates for the spooling and unspooling of the cables such that the first and second cables are length conservative. As the pitch angle <NUM> increases, the length of the first segment <NUM> and length of the second segment <NUM> increases while length of the third segment <NUM> and fourth segment <NUM> decreases such that, within the restraint pantograph, the wrist pulleys and armature rotate about the reciprocal axis <NUM>. In this configuration the overall length of the third cable is maintained in the reciprocal pantograph as discussed previously. The pitch angle may be decreased by manipulating segment length of the cables with the input controllers in an inverse manner.

While performing surgical operations at the surgical site the reciprocal pantograph and input controllers are operating in attached mode and the input controllers manipulate the degrees of freedom of the surgical effector.

The input controllers and reciprocal pantograph may also operate in detached mode in which the input controllers are configured to maintain the lengths of the cables in the restraint pantograph. This is useful when attaching or detaching the surgical instrument from the IDM and robotic arm. To remove the surgical instrument from the IDM and robotic arm, the cables may be manipulated to achieve a particular length that will be maintained through the period between uses of the surgical instrument.

In another embodiment, the length of the first through fourth cables are controlled during detached mode to achieve a desired result via actuation of a mechanism other than the input controllers; for example, the mechanism may be a switch, a button, a lever, a pin, or similar. In some embodiments, actuation of the alternate mechanism may release any held object from the effectors; move cable positions towards neutral positions; or, move the effectors to a neutral position for removal, etc..

In an alternative embodiment of attached mode operation, similarly configured to <FIG>, the restraint pantograph may be physically rotated about the reciprocal axis such that one degree of freedom of the surgical effector may be manipulated. The degree of freedom manipulated depends on how the input controller pairs are coupled.

<FIG> shows the surgical effector with the fifth through eighth cable segments labelled, 750a - 750d. The input controllers are coupled into two pairs by the differential and the surgical effector. With four cable segments there are three distinct pairing possibilities for the two cables in the surgical effector: (<NUM>) the fifth and sixth segments pairing the first input controller pair and the seventh and eighth segments pairing the second input controller pair, (<NUM>) the fifth and seventh segment pairs the first input controller pair and the sixth and eighth segment pairs the second input controller pair, and (<NUM>) the fifth and eighth segment pair the first input controller pair and the sixth and seventh segments part the second input controller pair.

The surgical instrument is configured such that rotation of the reciprocal pantograph spools and unspools the cable segments pairing one input controller pair while reciprocally unspooling and spooling the other input controller pair. With this configuration, rotation of the reciprocal pantograph yields three different motions of the surgical effector depending on the input controller pairings: the first possible pairing yields manipulation of the pitch angle, the second possible pairing yields simultaneous manipulation of both yaw angles in the same direction, and the third possible pairing yields simultaneous manipulation of both yaw angles in opposing directions.

These pairing combinations may be incorporated in to the tool for a potential mechanical override of the surgical instrument in specific situations, e.g. emergency release, power outage etc. For example the third pairing allows for an emergency command to cause the surgical effectors to automatically release an object being held, allowing more rapid removal of the surgical instrument in case of emergency.

Upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs through the disclosed principles herein. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the method and apparatus disclosed herein without departing from the scope defined in the appended claims.

The embodiments are not limited in this context unless otherwise explicitly stated.

Claim 1:
A surgical instrument comprising:
a surgical effector (<NUM>) with N degrees of freedom, the surgical effector (<NUM>) for manipulation of objects at a surgical site;
N+<NUM> input controllers (<NUM>) configured to control the surgical effector (<NUM>);
a reciprocal structure (<NUM>) comprising at least one armature (<NUM>) rotatable about a rotation shaft and a pair of differentials (610a, 610b) coupled to the at least one armature (<NUM>), the differentials (610a, 610b) configured to rotate with the at least one armature (<NUM>) about the rotation shaft;
a plurality of cables (<NUM>) configured such that actuation of the input controller (<NUM>) manipulates the cables (<NUM>), the cables further configured such that:
at least one cable (<NUM>) couples at least one input controller (<NUM>) to the surgical effector (<NUM>) such that manipulation of the cable (<NUM>) with the input controllers (<NUM>) moves the surgical effector (<NUM>); and
at least one cable (<NUM>) couples the reciprocal structure (<NUM>) to at least one of the input controllers (<NUM>) such that manipulation of the cable (<NUM>) with the input controller (<NUM>) moves the reciprocal structure (<NUM>).