a2) United States Patent
`US 6,331,181 Bl
`(10) Patent No.:
`
` Tierneyet al. (45) Date of Patent: Dec. 18, 2001
`
`
`US006331181B1
`
`(75)
`
`(54) SURGICAL ROBOTIC TOOLS, DATA
`ARCHITECTURE, AND USE
`Inventors: Michael J. Tierney, Pleasanton;
`AnguiianLoeChoe:StephenJ. Chris
`.
`.
`>
`>
`:
`Blumenkranz, Redwood City; Gary S.
`Guthart, Foster City; Robert G.
`Younge, Portola Valley, all of CA (US)
`
`z
`
`1
`
`4,996,975
`3/1991 Nakamura.
`5,018,266
`5/1991 Hutchinson ct al. .
`5,078,140
`1/1992 Kwoh.
`ae 10099 Nott tal
`>
`*
`atsen,
`etal. .
`5174300
`12/1992 Bales et al.
`.
`§,217,003
`6/1993 Wilk .
`5,221,283
`6/1993 Chang.
`5,236,432
`8/1993 Matsen,IJ etal. .
`5,255,429
`10/1993 Nishietal. .
`
`(73) Assignee:
`
`(List continued on next page.)
`Intuitive Surgical, Inc., Mountain
`FOREIGN PATENT DOCUMENTS
`View, CA (US)
`WO 93/13916
`7/1993 (WO).
`Subject to anydisclaimer, the term ofthis
`(*) Notice:
`
`patent is extended or adjusted under 35 WO 94/26167=11/1994 (WO).
`U.S.C. 154(b) by 0 days.
`WO 95/16396
`6/1995 (WO).
`WO 95/30964
`11/1995 (WO).
`WO 96/39944
`12/1996 (WO).
`Primary Examiner—Gene Mancene
`Assistant Examiner—Michael B. Priddy
`(74) Altorney, Agent, or Firm—Jownsend and ‘lownsend
`and Crew LLP
`(57)
`
`(60)
`
`(21) Appl. No.: 09/418,726
`(22)
`Filed:
`Oct. 15, 1999
`‘
`,
`Related U.S. Application Data
`Provisional application No. 60/111,713, filed on Dec.8,
`1998.
`Tate C07 ieeeeeeesesescsceeennnneeeeceeeceeennee A61B 19/00
`(SV)
`(52) U.S. Cl.
`606/130: 600/429
`(58) Field of Searchews 606130: 600/429
`eee ,
`(56)
`References Cited
`
`4.981.447
`4.332066
`4,486,928
`4,500,065
`4,512,709
`4,706,372
`4,710,093
`4,793,053
`Tosecag
`Pynog
`4.943.939
`4,979,949
`
`U.S. PATENT DOCUMENTS
`8/1981 Miller et al
`6/1982 Hailey etal. .
`12/1984 Tuckeret al. .
`2/1985 Hennekesetal. .
`4/1985 Hennekesetal. .
`11/1987 Ferrero etal. .
`12/1987 Zimmeretal. .
`12/1988 Zuccaro etal. .
`21989 ruoly eval. .
`21080 ae ,
`7/1990 Hoover .
`12/1990 Matsen,II etal. .
`
`ABSTRACT
`
`.
`.
`.
`Robotic surgical tools, systems, and methods for preparing
`for and performing robotic surgery include a memory
`mounted on the tool. The memory can perform a numberof
`functions when the tool is loaded on the tool manipulator:
`first, the memory can provide a signal verifying that the tool
`is compatible with that particular robotic system. Secondly,
`the tool memory may identify the tool-type to the robotic
`system so that the robotic system can reconfigure its pro-
`gramming. Thirdly, the memory of the tool may indicate
`tool-specific information,
`including measured calibration
`offsets indicating misalignmentof the tool drive system, tool
`life data,or the like. This information maybestored in a read
`only memory (ROM), orin a nonvolatile memory which can
`be written to only a single time. The invention further
`provides improved engagement structures for coupling
`robotic surgical tools with manipulator structures.
`
`28 Claims, 22 Drawing Sheets
`
`
`
`IS 1009
`
`1
`
`IS 1009
`
`

`

`US 6,331,181 B1
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`5,257,998
`5,271,384
`5,294,209
`5,305,203
`5,312,212
`5,313,935
`5,343,385
`5,354,314
`5,355,743
`5,359,993
`5,372,147
`5,397,323
`5,399,951
`
`11/1993
`12/1993
`3/1994
`4/1994
`5/1994
`5/1994
`8/1994
`10/1994
`10/1994
`11/1994
`12/1994
`3/1995
`3/1995
`
`Ota et al. .
`McEwenetal. .
`Nakaetal. .
`Raab .
`Naumec.
`Kortenbachetal. .
`Joskowicz et al.
`.
`Hardy etal. .
`Tesar .
`.
`Slater et al.
`Lathrop, Jr. et al.
`Taylor .
`Lavallee et al.
`
`.
`
`.
`
`5,400,267
`5,402,801
`5,403,319
`5,417,210
`5,427,097
`5,451,368
`5,649,956 *
`5,697,939 *
`5,762,458
`5,792,135
`5,800,423
`6,132,368
`
`3/1995
`4/1995
`4/1995
`5/1995
`6/1995
`9/1995
`T/997
`12/1997
`6/1998
`8/1998
`9/1998
`10/2000
`
`Denenet al. .
`Taylor .
`Matsen, II et al. oe. 606/88
`Fundaet al. .
`Depp.
`Jacob .
`Jensen et al. ween 606/205
`
`Kubota et al.
`.
`. 606/130
`Wang et al. ceeeeeeeeeerees 414/1
`Madhanietal. .
`Jensen .
`COOPEL ceeseeseseceeecseeseseeeceeeeee 600/102
`
`* cited by examiner
`
`2
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 1 of 22
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`US 6,331,181 B1
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`150
`
`:
`
`3
`
`

`

`a aa
`
`4
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 3 of 22
`
`US 6,331,181 B1
`
`
`
`FIG. 2A.
`
`5
`
`

`

`U.S. Patent
`
`US 6,331,181 B1
`
`Dec. 18, 2001
`
`Sheet 4 of 22
`
`
`
`
`6
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 5 of 22
`
`US 6,331,181 B1
`
`
`
`FIG. 3.
`
`7
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 6 of 22
`
`US 6,331,181 B1
`
`
`
`
`ang
`ar ~D -
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`8
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`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 7 of 22
`
`US 6,331,181 B1
`
`
`
`9
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 8 of 22
`
`US 6,331,181 B1
`
`FIG.
`
`4B.
`
`10
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 9 of 22
`
`US 6,331,181 B1
`
`
`
`11
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 10 of 22
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`US 6,331,181 B1
`
`12
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 11 of 22
`
`US 6,331,181 B1
`
` A-A
`
`A
`FIG. 7E.
`
`FIG. 7D
`
`13
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 12 of 22
`
`US 6,331,181 B1
`
`
`
`
`
`
`
`
`
`FIG. 7H.
`
`FIG. 77.
`
`14
`
`14
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 13 of 22
`
`US 6,331,181 B1
`
`15
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 14 of 22
`
`US 6,331,181 B1
`
`ELBOW PCE
`£36 [RED E37
`
`FORCE SENSOR #
`
`HALF BRIDGE
`
`SHIELD
`
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`RED jE26|£47
`SLAVE_CLUTCH_ SW2
`—
`
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`
`TOOL CHANGE SWITCH
`
`SLAVE CLUTCHING SWITCH
`
`FIG 8.
`
`16
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 15 of 22
`
`US 6,331,181 B1
`
`
`
`FIG. 8A.
`
`17
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 16 of 22
`
`US 6,331,181 B1
`
`vS
`
`cl
`
`8S
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`9S
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`
`18
`
`6Old
`
`18
`
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 17 of 22
`
`US 6,331,181 B1
`
`
`MIDDLEMAN(CTP)
`
`SUPERVISOR (UMC)
`EXECUTES
`
`
`CONTROLS LOGICAL
`
`
`INSTRUCTIONS FROM
`
`FLOW
`
`SUPERVISOR
`
`
`
`
`
`
`PROCEDURE
` KERNEL (CTP AND CEs)
`
`MANAGEMENT/DATA
`HANDLER (MDC)
`
`
`
`LOCAL TOOL
`
`
`DETECTION (RIA)
`
`
`FIG. 10.
`
`19
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 18 of 22
`
`US 6,331,181 B1
`
`SEQUENCE FLOW
`
`DETAILED SEQUENCE
`BLOCKS
`
`(20)
`HARDWARESTATE Grae
`
`TO INDICATE CHANGE IN
`
`CHECK
`FOR
`
`147 *.SIGNIFIES MESSAGESENT
`TOOL TOOL DALLAS
`
`TOOL DALLAS
`
`PRESET* onPRESENT*
`
`FIG. 11.
`
`20
`
`20
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 19 of 22
`
`US 6,331,181 B1
`
`POWER ON
`
`INITIALIZATION
`
`
` TOOL IS
`Initialization
`
`complete
`
`off > 500
`
`
` TOOL IS
`
`
`BEING INSERTED
`
`
`(S4)
`OUT(S2)
` Sadapter Dichip
`ms
`
`
`
`
`
`ADAPTER
`OFF (S1)
`
`1114
`
`D = Dallas chip ( 1 = present, 0 = not present)
`E = End ofuse indicator (0 = Open, 1 = Shorted)
`R = Reed Switch ( 0= open, 1 = shorted)
`
`Events occur in DER order
`
`e.g. 101 means Dallas chip present, End of use
`indicator is open, Reed switch is closed)
`
`A= 110, 100, 010, 110, 101, 111
`B=011, 101, 001
`C= 001, 010, 011, 100, 101, 110, 111
`FIG. 12.
`
`
`Logging occursif the situation
`
`persists for more than 1 second
`
`21
`
`21
`
`

`

`Sheet 20 of 22
`
`US 6,331,181 B1
`
`TOOL
`CHANGE
`B
`
`U.S. Patent Dec. 18, 2001
`
`ENGAGE
`
`OU
`
`CHANGE
`DONE
`
`22
`
`22
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 21 of 22
`
`US 6,331,181 B1
`
`FIG. 140.
`
`23
`
`23
`
`

`

`U.S. Patent
`
`Dec. 18, 2001
`
`Sheet 22 of 22
`
`US 6,331,181 B1
`
`- 166 ALGORITHM
`
`164
`
`TOOL PRODUCTION
`
`TOOL COMPATIBILITY VERIFICATION
`
`166
`
`ALGORITHM
`
`TOOL
`
`PROCESSOR
`
`FIG. 15.
`
`24
`
`24
`
`

`

`US 6,331,181 Bl
`
`1
`SURGICAL ROBOTIC TOOLS, DATA
`ARCHITECTURE, AND USE
`CROSS-REFERENCES TO RELATED
`APPLICATIONS
`
`This application claims priority to U.S. Provisional Patent
`Appl. No. 60/111,713 filed on Dec. 8, 1998, the entirety of
`which is herein incorporated by reference.
`BACKGROUND OF THE INVENTION
`
`10
`
`2
`further improvements would be desirable. In particular, each
`tool change which occurs during a surgical procedure
`increases the overall surgery time. While still further
`improvements in the mechanical tool/manipulator interface
`may help reduce a portion of this tool change time, work in
`connection with the present invention has shown that the
`mechanical removal and replacement of the tool may rep-
`resent only one portion of the total interruption for a tool
`change. U.S. Pat. No. 5,400,267 describes a memory feature
`for electrically powered medical equipment, and is also
`incorporated herein by reference.
`As more and more different surgical tools are provided for
`use with a robotic system, the differences between the tool
`structures (and the interaction between the tool and the other
`components of the robotic system) become more pro-
`nounced. Manyofthese surgical tools will have one or more
`degrees of motion between the surgical end effectors and the
`proximal interface which engages the tool to the holder of
`the manipulator. The desired and/or practicable ranges of
`motion for an electrosurgical scalpel may be significantly
`different than those of a clip applier, for example. Work in
`connection with the present invention has found that even
`after a tool is properly placed on the surgical manipulator,
`the time involved in reconfiguring the robotic system to take
`advantage of a different tool, and to perfect
`the master
`controller’s effective control over the degrees of motion of
`the tool, may add significantly to the total tool change delay.
`In light of the above, it would be desirable to provide
`improved robotic surgery tools, systems, and method. It
`would further be desirable to provide techniques for reduc-
`ing the total delay associated with each tool change. It would
`be especially desirable if these enhanced, and often more
`rapid, robotic tool change techniquesresulted in still further
`improvementin the safety and reliability of these promising
`surgical systems.
`SUMMARY OF THE INVENTION
`
`invention generally provides improved
`The present
`robotic surgical devices, systems, and methods for preparing
`for and performing robotic surgery. The robotic tools of the
`present invention will often make use of a memorystructure
`mounted on a tool, manipulator arm, or movable support
`structure. The memorycan, for example, perform a number
`of important functions when a tool is loaded on the tool
`manipulator: first, the memory can provide a signal verify-
`ing that the tool is compatible with that particular robotic
`system. Secondly, the tool memory mayidentify the tool-
`type (whether it is a scalpel, needle grasper, jaws, scissors,
`clip applier, electrocautery blade, or the like) to the robotic
`system so that the robotic system can reconfigure its pro-
`gramming to take full advantage of the tools’ specialized
`capabilities. This tool-type data may simply be an identifi-
`cation signal referencing further data in a look-up table of
`the robotic system. Alternatively, the tool-type signal pro-
`vided by the tool may define the tool characteristics in
`sufficient detail
`to allow reconfiguration of the robotic
`programming without having to resort to an external table.
`Thirdly, the memory of the tool may indicate tool-specific
`information, including (for example) measured calibration
`offsets indicating misalignment between the tool drive sys-
`tem and the tool end effector elements, tool life data (such
`as the number of times the tool has been loaded onto a
`surgical system,
`the number of surgical procedures per-
`formed with the tool, and/or the total time the tools has been
`used), or the like. The information may be stored in some
`form of non-volatile memory such as one-time program-
`mable EPROM,Flash EPROM, EEPROM,battery-backed-
`
`15
`
`5
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`This invention relates to robotically assisted surgery, and
`more particularly provides surgical tools having improved
`mechanical and/or data interface capabilities to enhance the
`safety, accuracy, and speed of minimally invasive and other
`robotically enhanced surgical procedures.
`In robotically assisted surgery, the surgeon typically oper-
`ates a master controller to remotely control the motion of
`surgical instrumentsat the surgical site. The controller may
`be separated from the patient by a significant distance (e.g.,
`across the operating room,
`in a different room, or in a
`completely different building than the patient).
`Altermatively, a controller may be positioned quite near the
`patient in the operating room. Regardless, the controller will
`typically include one or more hand input devices (such as _,
`joysticks, exoskeletol gloves, master manipulators, or the
`like) which are coupled by a servo mechanism tothe surgical
`instrument. More specifically, servo motors move a manipu-
`lator or “slave” supporting the surgical instrument based on
`the surgeon’s manipulation of the hand input devices. Dur-
`ing an operation, the surgeon may employ, via the robotic
`surgery system, a variety of surgical instruments such as
`tissue graspers, needle drivers, electrosurgical cautery
`probes, etc. Each of these structures performs functions for
`the surgeon, for example, holding or driving a needle,
`grasping a blood vessel, or dissecting, cauterizing, or coagu-
`lating tissue.
`This new method of performing robotic surgery has, of
`course, created many new challenges. One such challenge is
`that a surgeon will typically employ a significant number of
`different surgical instruments during each surgical proce-
`dure. The numberof independent surgical manipulators will
`often be limited due to space constraints and cost.
`Additionally, patient trauma can generally be reduced by
`eliminating the number of tools used at any given time.
`Morespecifically, in minimally invasive procedures,
`the
`number of entry ports into a patient is generally limited
`because of space constraints, as well as a desire to avoid
`unnecessary incisions in the patient. Hence, a number of
`different surgical instruments will typically be introduced
`through the sametrocar sleeve into the abdomen during,for
`example,
`laparoscopic procedures. Likewise,
`in open
`surgery,
`there is typically not enough room adjacent
`the
`surgical site to position more than a few surgical
`manipulators, particularly where each manipulator/tool
`combination has a relatively large range of motion. As a
`result, a number of surgical
`instruments will often be
`attached and detached from a single instrument holder of a
`manipulator during an operation.
`Published PCT application WO098/25666, filed on Dec.
`10, 1997 and assigned to the present assignee (the full
`disclosure of which is incorporated herein by reference)
`describes a Multicomponent Telepresence System and
`Method which significantly improves the safety and speed
`with which robotic surgical
`tools can be removed and
`replaced during a surgical procedure. While this represents
`a significant advancementof the art, as is often true, still
`
`60
`
`65
`
`25
`
`25
`
`

`

`US 6,331,181 Bl
`
`3
`up SRAM,or similar memory technology where data can be
`updated and retained in either a serial or random access
`method, or with any of a wide variety of alternative
`hardware, firmware, or software. The invention further pro-
`vides improved engagementstructures for coupling robotic
`surgical tools with manipulator structures.
`In a first aspect, the invention provides a robotic surgical
`tool for use in a robotic surgical system. The robotic surgical
`system has a processor which directs movement of a tool
`holder. The tool comprises a probe having a proximal end
`and a distal end. A surgical end effector is disposed adjacent
`the distal end of the probe. An interface is disposed adjacent
`to the proximal end of the probe. The interface can be
`releasably coupled with the tool holder. Circuitry is mounted
`on the probe. The circuitry defines a signal for transmitting
`to the processor so as to indicale compatibility of the tool
`with the system.
`The tool will often comprise a surgical instrumentsuitable
`for manipulating tissue, an endoscope or other image cap-
`ture device, or the like. Preferably, the signal will comprise
`unique tool
`identificr data. The processor of the robotic
`surgical system may include programming to manipulate the
`tool
`identifier according to a predetermined function or
`algorithm so as to derive verification data. The signal
`transmitted to the processor will often include the verifica-
`tion data. Alternative compatibility signals may include a
`signal which islisted in a table accessible to the processor,
`an arbitrary compatibility data string, or the like.
`In another aspect, the invention provides a robotic surgi-
`cal componentfor use in a robotic surgical system having a
`processor and a component holder. The component com-
`prises a component body having an interface mountable to
`the component holder. The body supports a surgical cnd
`effector, and a drive system is coupled to the body for
`moving the end effector per commands from the processor.
`Circuitry is mounted on the body and defines a signal for
`transmitting to the processor. The signal may indicate com-
`patibility of the component with the system, may define a
`componenttype of the component, may indicate coupling of
`the component to the system, and/or may indicate calibra-
`tion of the component. Typically, the component will com-
`prise a surgical tool, a manipulator arm, a pre-positioning
`linkage supporting the manipulator arm, or the like.
`In another aspect, the invention provides a method for
`installing a robotic surgical componentin a robotic surgical
`system. The method comprises mounting the componentto
`a componentholder. A signal is transmitted from the com-
`ponent to a processor of the robotic surgical system. The
`component
`is articulated in response to the signal per
`commands of the processor.
`In many embodiments, compatibility of the component
`with the robotic surgical system will be verified using the
`signal transmitted from the componentto the processor. This
`can be accomplished by providing unique identification data
`on the component, and deriving verification data from the
`identification data according to an algorithm. The verifica-
`tion data is stored with a memory of the component, the
`signal transmitted to the processor including both the iden-
`tification and verification data. The algorithm maythen be
`performed on the transmitted unique identification data with
`the processor, and the results compared with the verification
`data. Advantageously, this method can take advantage of
`unique identification data which is often unalterably stored
`in a memory of commercially available integrated circuits.
`In another aspect, the invention provides a robotic surgi-
`cal tool for use in robotic surgical systems having a proces-
`
`
`
`4
`sor. The tool comprises a shaft having a proximal end and a
`distal end. A surgical end effector is disposed adjacent the
`distal end of the shaft. The end effector has a plurality of
`degrees of motionrelative to the proximal end. An interface
`is disposed adjacent the proximal end of the shaft. The
`interface can be releasably coupled with a robotic probe
`holder. The interface comprises a plurality of driven ele-
`ments. A plurality of tool drive systems couple the driven
`elements to the degrees of motion of the end effector. The
`tool drive system has calibration offsets between a nominal
`relative position of the end effector and the driven elements,
`and a measured relative position of the end effector and
`driven elements. Amemorystores data indicating the offsets.
`The memoryis coupled to the interface so as to transmit the
`offsets to the processor.
`In yet another aspect, the invention provides a robotic
`surgical system comprising a plurality of tools of different
`tool-types. Each tool comprises an elongate shaft with a
`cross-section suitable for introduction into an internal sur-
`gical site within a patient body via a minimally invasive
`opening. A distal surgical end effector is coupled to the shaft
`by at least one joint. The joint is drivingly coupled to a
`proximal interface by a tool drive system. Circuitry of the
`tool transmits a tool-type via the interface. The tool types
`may optionally differ in at least one characteristic such as
`joint geometry, end effector geometry, drive system
`characteristics, end effector or drive system strength, or the
`like. The system also includes a robotic manipulator includ-
`ing a linkage supporting a tool holder. The tool holder
`releasably receives the interface. A manipulator drive motor
`drivingly engages the linkage so as to move the tool holder
`relative to the opening and position the shaft within the
`surgical site. A tool drive motor is coupled to the tool holder
`so as to drivingly engage the tool drive system andarticulate
`the joint. A processor is coupled to the tool holder. The
`processor has programmingthat effects a desired movement
`of the end effector by transmilling drive signals to the tool
`drive motors of the manipulator. The processor reconfigures
`the program for the different joint geometries based on the
`tool-type signals.
`In another aspect, the invention provides a robotic surgi-
`cal system comprising a surgical tool having a surgical end
`effector and an interface. A manipulator assembly has a base
`and a tool holder for releasably engaging the interface. A
`plurality of tool engagement sensors are coupled to the tool
`holder. Each tool sensor produces a signal whenthe interface
`engages the holder. A processor is coupled to the tool
`engagement sensors. The processor has a tool change mode
`and a tissue manipulation mode. The processor requires tool
`signals from each of the sensors before changing the tool
`change modeto the tissue manipulation mode. The proces-
`sor remains in the tissue manipulation mode whenat least
`one, but not all, of the tool signals is lost.
`The tools used in robotic surgery will be subjected to
`significant structural stress during use. The stress may result
`in temporary loss of an engagementsignal from an engage-
`ment sensor. By providing at least two, and preferably three
`engagement sensors, the surgical procedure can continue
`safely with the loss of an engagement signal
`from an
`individual sensor so long as the system canstill verify proper
`engagement between the manipulator andtool. This arrange-
`mentresults in a robust tool engagement sensing system that
`avoids frequent delays during the surgical procedure as
`might occur from the loss of an individual signal.
`In yet another aspect, the invention provides a robotic
`surgical system comprising a manipulator assembly having
`a base and tool holder which movesrelative to the base. The
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`US 6,331,181 Bl
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`FIG. 11 is a logic flow chart illustrating an exemplary
`method for sensing engagement of a tool with the manipu-
`lator.
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`5
`tool holder has a plurality of drive elements. A sterile drape
`coversat least a portion of the manipulator. A sterile tool has
`a proximal interface and distal end effector. The distal end
`effector has a plurality of degrees of motionrelative to the
`FIG. 12 is a flow diagram illustrating how the tool
`proximal interface. The degrees of motion are coupled to
`engagementsignals are used to change the operating state of
`drive elements of the interface. An adapter is disposed
`the robotic system.
`adjacent the stcrile drape between the holder and the inter-
`FIG. 13 illustrates the tool engagement method steps
`face. The adapter comprises a plurality of movable bodies.
`initiated by the processor in response to a change in oper-
`Each movable bady hasa first surface driven by the drive
`ating state during tool changes.
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`elements of the holder, and a second surface driving the
`FIGS. 14AthroughCillustrate mounting of the adapter of
`driven elements of the tool.
`FIGS. 7A through E to a manipulator arm, and of mounting
`the tool of FIG. 4 onto the adapter.
`FIG. 15 schematically illustrates an exemplary tool com-
`patibility verification algorithm according to the principles
`of the present invention.
`DESCRIPTION OF THE SPECIFIC
`EMBODIMENTS
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`In yet another aspect, the invention provides a robotic
`surgical tool for use with a robotic manipulator having a tool
`holder. The tool holder has magnetically actuatable circuitry.
`The tool comprises a probe having a proximal end and a
`distal end. A surgical end effector is disposed adjacent the
`distal end of the probe. An interface adjacent the proximal
`end of the probe is releasably coupleable with the holder.
`The interface comprises a magnetpositionedso as to actuate
`the circuitry of the holder.
`
`The present invention provides robotic surgery systems,
`devices, and methods. Robotic surgery will generally
`involve the use of multiple robotic arms. One or moreof the
`robotic armswill often support a surgical tool which may be
`articulated (such as jaws,scissors, graspers, needle holders,
`microdissectors, staple appliers, tackers, suction/irrigation
`tools, clip appliers, or the like) or non-articulated (such as
`cutting blades, cautery probes, irrigators, catheters, suction
`orifices, or the like). One or more of the robotic arms will
`FIG. 2 is a perspective view of a robotic surgical arm cart
`often be used to support one or more surgical image capture
`system in which a series of passive set-up joints support
`devices such as an cndoscope (which may be any of the
`robotically actuated manipulators (typically, the center arm
`variety of structures such as a laparoscope, an arthroscope,
`would support a camera).
`a hysteroscope, or the like), or optionally, some other
`imaging modality (such as ultrasound, fluoroscopy, mag-
`FIG. 2A is a perspective view of a robotic surgical
`netic resonance imaging, orthe like). Typically, the robotic
`manipulator for use in the cart system of FIG. 2.
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`arms will support at least two surgical tools corresponding
`FIGS. 2B andCare side and front views, respectively, of
`to the two handsof a surgeon and one optical image capture
`the linkage of the robotic manipulator of FIG. 2, showing
`device.
`how the manipulator maintains a remote center of rotation
`along a shaft of the surgicaltool.
`FIGS. 3 and 3A are perspective views of exemplary cart
`structures with positioning linkages which support
`the
`robotic manipulators in the system of FIG. 2.
`FIG. 4 is a perspective view of an exemplarytool accord-
`ing to the principles of the present invention.
`FIGS. 4A and B are schematic viewsofalternative drive
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 illustrates a robotic surgical procedure in which a
`surgeon at a master station directs movement of robotic
`surgical tools effected by a slave manipulator, and shows an
`assistant preparing to change a tool mountedto a tool holder
`of the slave.
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`systems for the tool of FIG. 4.
`FIGS. 5A through H are illustrations of a variety of
`surgical end effectors of differing tool-types.
`FIG. 6 illustrates the mechanical and electrical interface
`of the tool of FIG. 4.
`
`FIGS. 7A through E illustrate an adapter for coupling the
`interface of FIG. 6 to the surgical manipulator.
`FIGS. 7G through I illustrate the adapter of FIGS. 7A
`through E mounted to a holder or carriage of the manipu-
`lator.
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`its driving
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`FIGS. 7J through L illustrate the holder,
`elements, and its electrical contacts.
`the
`FIG. 8 is a wiring diagram for the tool of FIG. 4,
`adapter of FIG. 7A-E,and related componentsof the robotic
`system.
`FIGS. 8A and B are rear and front views of the master
`console, respectively.
`FIG. 9 is a functional block diagram schematically illus-
`trating the signal path hardware of the tool change system.
`FIG. 10 is a schematic diagram illustrating the interaction
`between the software modules related to tool change.
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`The present invention will find application in a variety of
`surgical procedures. The most immediate applications will
`be to improve existing minimally invasive surgical
`procedures, such as coronary artery bypass grafting and
`mitral and aortic valve repair and/or replacement. The
`invention will also have applications for surgical procedures
`which are difficult
`to perform using existing minimally
`invasive techniques, such as Nissen Fundoplications.
`Additionally,it is anticipated that these surgical systems will
`find uses in entirely new surgeries that would be difficult
`and/or impossible to perform using traditionally open or
`known minimally invasive techniques. For example, by
`synchronizing the movements of the image capture device
`and/or surgical tools with a tissue undergoing physiological
`movement(such a beating heart), the moving tissue may be
`accurately manipulated and treated without halting the
`physiological movement. Additional potential applications
`include vascular surgery (such as for the repair of thoracic
`and abdominal aneurysms), general and digestive surgeries
`(such as cholecystectomy,
`inguinal hernia repair, colon
`resection, and the like), gynecology(forfertility procedures,
`hysterectomies, and the like), and a wide variety of alter-
`native procedures.
`Referring now to FIG. 1, the robotic surgical system 10
`generally includes master controller 150 and a robotic arm
`slave cart 50. Master controller 150 generally includes
`master controllers (not shown) which are grasped by the
`surgeon and manipulated in space while the surgeon views
`the procedure viewsa stereo display. The master controllers
`are manual input devices which preferably move with six
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`US 6,331,181 Bl
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`degrees of freedom, and whichoften further have an actu-
`atable handle for actuating tools (for example, for closing
`grasping saws, applying an electrical potential
`to an
`electrode, or the like).
`In this embodiment,
`the master
`control station 150 also includes a processor, as will be
`described in more detail hereinbelow.
`
`Robotic arm cart 50 is positioned adjacent to patient body
`P and movestools having shafts. The shafts extend into an
`internal surgical site within the patient body via openings O.
`As illustrated in FIG. 1, one or more assistant may be present
`during surgery to assist
`the surgeon, particularly during
`removal and replacementof tools. Robotic surgery systems
`and methodsare further described in co-pending U.S. patent
`application Ser. No. 08/975,617, filed Nov. 21, 1997, the full
`disclosure of which is incorporated herein by reference.
`Robotic arm cart 50 is shownin isolation in FIG. 2. Cart
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`50 includes a base 52 from which three surgical tools 54 are
`supported. More specifically, tools 54 are each supported by
`a series of manually articulatable linkages, generally
`referred to as set-up joints 56, and a robotic manipulator 58.
`It should be noted that these structures are here illustrated
`
`with protective covers extending over much of the robotic
`linkage. It should be understood that these protective covers
`are optional, and may be limited in size or entirely elimi-
`nated in some embodiments to minimize the inertia that is
`
`manipulated by the servo mechanism,to limit the volume of
`moving components so as to avoid collisions, and to limit
`the overall weight of cart 50.
`Cart 50 will generally have dimensionssuitable for trans-
`porting the cart between operating rooms. The cart will
`typically fit through standard operating room doors and onto
`standard hospital elevators. The cart should have a weight
`and wheel (or other transportation) system that allows the
`cart to be positioned adjacent an operating table by a single
`attendant. The cart should have sufficient stability in the
`transport configuration to avoid tipping at minor disconti-
`nuities of the floor, and to easily withstand overturning
`momentsthat will be imposedat the ends of the robotic arms
`during use.
`Reterring now to FIGS. 2A-C, robotic manipulators 58
`preferably include a linkage 62 that constrains movement of
`tool 54. More specifically, linkage 62 includes rigid links
`coupled together by rotational joints in a parallelogram
`arrangement so that tool 54 rotates around a point in space
`64, as more fully described in issucd U.S. Pat. No. 5,817,
`084, the full disclosure of which is incorporated herein by
`reference. The parallelogram arrangement constrains rota-
`tion to pivoting about an axis 64a, sometimes called the
`pitch axis. The links supporting the parallelogram linkage
`are pivotally mounted to set-up joints 56 so that tool 54
`further rotates about an axis 64b, sometimescalled the yaw
`axis. The pitch and yaw axesintersect at the remote center
`64, which is aligned along a shaft 66 of tool 54.
`Tool 54 has still further driven degrees of freedom as
`supported by manipulator 58, including sliding motion of
`the tool along insertion axis 64 (the axis of shaft 66),
`sometimes referred to as insertion. As tool 54 slides along
`axis 64c relative to manipulator 58,
`remote center 64
`remainsfixed relative to base 68 of manipulator 58. Hence,
`the entire manipulator is generally moved to re-position
`remote center 64.
`
`Linkage 62 of manipulator 58 is driven by a series of