Tool grip calibration for robotic surgery Number:7,386,365 from the United States Patent and Trademark Office (PTO) owispatent Telerobotic, telesurgical, and surgical robotic devices, systems, and methods selectively calibrate end effector jaws by bringing the jaw elements into engagement with each other. Commanded torque signals may bring the end effector elements into engagement while monitoring the resulting position of a drive system, optionally using a second derivative of the torque/position relationship so as to identify an end effector engagement position. Calibration can allow the end effector engagement position to correspond to a nominal closed position of an input handle by compensating for wear on the end effector, the end effector drive system, then manipulator, the manipulator drive system, the manipulator/end effector interfacing, and manufacturing tolerances.<H calibration, surgery, Tool, grip, calib, 7386365.html, Patent, pto, 7386365

Title: Tool grip calibration for robotic surgery

Abstract: Telerobotic, telesurgical, and surgical robotic devices, systems, and methods selectively calibrate end effector jaws by bringing the jaw elements into engagement with each other. Commanded torque signals may bring the end effector elements into engagement while monitoring the resulting position of a drive system, optionally using a second derivative of the torque/position relationship so as to identify an end effector engagement position. Calibration can allow the end effector engagement position to correspond to a nominal closed position of an input handle by compensating for wear on the end effector, the end effector drive system, then manipulator, the manipulator drive system, the manipulator/end effector interfacing, and manufacturing tolerances.

Patent Number: 7,386,365 Issued on 06/10/2008 to Nixon

Inventors: Nixon; Tom (Santa Clara, CA)
Assignee: Intuitive Surgical, Inc. (Sunnyvale, CA)

Appl. No.: 10/839,805

Filed: May 4, 2004

Current U.S. Class: 700/245 ; 606/139; 700/254; 700/259; 901/8

Field of Search: 700/245,259 318/568.11 901/8 606/139

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Primary Examiner: Tran; Khoi H.
Assistant Examiner: Marc; McDieunel

Claims

What is claimed is:

1. A telesurgical system comprising: an input handle having a first grip member movable relative to a second grip member in response to a hand gripping the handle; an end effector comprising surgical jaws with a first end effector element movable relative to a second end effector element; a manipulator transmitting a signal in response to mounting thereon of the end effector; and a processor coupling the input device to the manipulator, the processor configured to calibrate the mounted end effector and manipulator in response to the signal by effecting a calibration movement of at least one of the elements so as to bring the elements into mutual engagement, the processor configured to effect articulation of the jaws of the mounted end effector in response to the gripping of the handle per the calibration; wherein an input linkage supports the handle and a robotic arm of the manipulator supports the mounted end effector, the input linkage and the robotic arm each having a plurality of degrees of freedom, the processor effecting movement of the robotic arm in response to articulation of the input linkage; wherein the processor effects the calibration in response to mounting of the mounted end effector onto the robotic arm and before use of the end effector in a robotic surgical procedure; and wherein the processor does not determine calibration from a calibration movement of at least one degree of freedom of the robotic arm between mounting of the mounted end effector and the robotic procedure, so that the processor selectively calibrates articulation of the jaws.

2. A telesurgical system comprising: an input handle having a first grip member movable relative to a second grip member in response to a hand gripping the handle; an end effector comprising surgical jaws with a first end effector element movable relative to a second end effector element; a manipulator transmitting a signal in response to mounting thereon of the end effector; and a processor coupling the input device to the manipulator, the processor configured to calibrate the mounted end effector and manipulator in response to the signal by effecting a calibration movement of at least one of the elements so as to bring the elements into mutual engagement, the processor configured to effect articulation of the jaws of the mounted end effector in response to the gripping of the handle per the calibration; wherein an input linkage supports the handle and a robotic arm of the manipulator supports the mounted end effector, the input linkage and the robotic arm each having a plurality of degrees of freedom, the processor effecting movement of the robotic arm in response to articulation of the input linkage; wherein the processor effects the calibration in response to mounting of the mounted end effector onto the robotic arm and before use of the end effector in a robotic surgical procedure; and wherein the processor does not determine calibration from a calibration movement of at least one degree of freedom of the robotic arm between mounting of the mounted end effector and the robotic procedure, so that the processor selectively calibrates articulation of the jaws; and wherein the processor does not effect a calibration movement of any degree of freedom of the robotic arm between mounting of the mounted end effector and the robotic procedure other than articulation of the jaws.

3. A telesurgical system comprising: an input handle having a first grip member movable relative to a second grip member in response to a hand gripping the handle; an end effector comprising surgical jaws with a first end effector element movable relative to a second end effector element; a manipulator transmitting a signal in response to mounting thereon of the end effector; and a processor coupling the input device to the manipulator, the processor configured to calibrate the mounted end effector and manipulator in response to the signal by effecting a calibration movement of at least one of the elements so as to bring the elements into mutual engagement, the processor configured to effect articulation of the jaws of the mounted end effector in response to the gripping of the handle per the calibration; wherein the processor comprises programming to effect calibration by monitoring commanded torque signals to at least one motor of the manipulator, by monitoring position of a drive system coupled to the end effector, and by identifying a change in the commanded torque and the drive position.

4. The telesurgical system of claim 3, wherein the processor comprises a filter, the processor determining the relationship by applying the filter to the commanded torque.

5. The telesurgical system of claim 3, wherein the processor determines an end-effector element initial engagement configuration using a second derivative of the commanded torque.

6. The telesurgical system of claim 5, wherein the input device applies a feedback force to the hand at a nominal closed position of the handle, and wherein the processor effects the calibration so that the end effector initial engagement configuration corresponds to the nominal closed position of the handle.

7. The telesurgical system of claim 5, wherein the handle comprises a biasing means for increasing resistance to gripping of the handle at the nominal closed position.

8. The telesurgical method of claim 5, further comprising performing the calibration once per robotic procedure for each end-effector mounted on the manipulator.

9. The telesurgical system of claim 3, wherein the processor is configured to effect the calibration once per robotic surgical procedure for each end-effector mounted on the manipulator.

10. A telesurgical system comprising: an input handle having a first grip member movable relative to a second grip member in response to a hand gripping the handle; an end effector comprising surgical jaws with a first end effector element movable relative to a second end effector element; a manipulator transmitting a signal in response to mounting thereon of the end effector; and a processor coupling the input device to the manipulator, the processor configured to calibrate the mounted end effector and manipulator in response to the signal by effecting a calibration movement of at least one of the elements so as to bring the elements into mutual engagement, the processor configured to effect articulation of the jaws of the mounted end effector in response to the gripping of the handle tier the calibration; the system further comprising a single element end-effector, wherein a signal is transmitted by die manipulator when the single element end-effector is mounted thereon, and wherein the processor effects no grip calibration in response to the signal.

11. A telesurgical method comprising: mounting a first surgical end effector to a manipulator, the end effector comprising jaws with a first end effector element movable relative to a second end effector element; calibrating the mounted first end effector and manipulator by moving at least one of the end effector elements so as to bring the elements into mutual engagement; gripping a handle with a hand so that a first member moves relative to a second grip member; computing an articulation signal in response to the gripping of the handle per the calibration; and articulating the jaws in response to the articulation signal so that the jaws of the first end effector move in correlation with the gripping of the handle; wherein the calibration is performed in response to mounting of the first end effector onto the manipulator and before use of the first end effector in a robotic surgical procedure, the method further comprising: articulating an input linkage supporting the handle by moving the handle with the hand, and robotically moving an arm of the manipulator supporting the mounted first end effector in response to movement of the handle, the input linkage and the robotic arm moving with a plurality of degrees of freedom; wherein the processor does not effect a calibration movement of at least one degree of freedom of the robotic arm between mounting of the first end effector and the robotic procedure, so that the calibration comprises selective calibration of jaw articulation.

12. The telesurgical method of claim 11, and wherein the processor does not effect a calibration movement of any degree of freedom of the robotic arm between mounting of the fist end effector and the robotic procedure other than articulation of the jaws.

13. A telesurgical method comprising: mounting a first surgical end effector to a manipulator, the end effector comprising jaws with a first end effector element movable relative to a second end effector element; calibrating the mounted first end effector and manipulator by moving at least one of the end effector elements so as to bring the elements into mutual engagement; gripping a handle with a hand so that a first grip member moves relative to a second grip member; computing an articulation signal in response to the gripping of the handle per the calibration; and articulating the jaws in response to the articulation signal so that the jaws of the first end effector move in correlation with the gripping of the handle; wherein the calibration comprises transmitting commanded torque signals to at least one motor of the manipulator, monitoring movement of a drive system coupled to the first end effector, and identifying an end-effector element initial engagement drive position from a change in a relationship between the commanded torque and the movement.

14. The telesurgical method of claim 13, wherein the change is identified at least in part by filtering torque/position data.

15. The telesurgical method of claim 13, wherein identifying the change comprises determining a second derivative of torque/position data.

16. The telesurgical method of claim 13, wherein the handle applies a feedback force to the hand at a nominally closed configuration of the handle, and wherein calibration is performed so that the end effector engagement position corresponds to the nominal closed position of the handle.

17. The telesurgical method of claim 16, further comprising increasing resistance to gripping of the handle at the nominal closed position during the surgical procedure.

18. A telesurgical method comprising: mounting a first surgical end effector to a manipulator, the end effector comprising jaws with a first end effector element movable relative to a second end effector element; calibrating the mounted first end effector and manipulator by moving at least one of the end effector elements so as to bring the elements into mutual engagement; gripping a handle with a hand so that a first grip member moves relative to a second grip member; computing an articulation signal in response to the gripping of the handle per the calibration; and articulating the jaws in response to the articulation signal so that the jaws of the first end effector move in correlation with the gripping of the handle; wherein the calibration is effected at least in part in response to a signal transmitted from the manipulator in response to mounting of the first end effector thereon, and further comprising removing the first end effector from the manipulator and mounting a second end effector having a single end effector element to the manipulator, wherein a single element end effector signal is transmitted by the manipulator when the second end effector is mounted thereon, and wherein no grip calibration is performed in response to the single element end effector signal.

Description

BACKGROUND OF THE INVENTION

The present invention is generally related to medical, telesurgical, and/or telerobotic devices, systems, and methods. In an exemplary embodiment, the invention provides structures and methods that calibrate an end effector/telerobotic manipulator combination when a new surgical robotic tool is mounted on a manipulator arm.

Minimally invasive medical techniques are intended to reduce the amount of extraneous tissue that is damaged during diagnostic or surgical procedures, thereby reducing patient recovery time, discomfort, and deleterious side effects. While many of the surgeries performed each year in the US could potentially be performed in a minimally invasive manner, only a portion of current surgeries use these advantageous techniques due to limitations in minimally invasive surgical instruments and the additional surgical training involved in mastering them.

Minimally invasive telesurgical systems for use in surgery have been developed to increase a surgeon's dexterity and avoid some of the limitations on traditional minimally invasive techniques. In telesurgery, the surgeon uses some form of remote control (such as a servomechanism or the like) to manipulate surgical instrument movements, rather than directly holding and moving the instruments by hand. In telesurgery systems, the surgeon can be provided with an image of the surgical site at the surgical workstation. While viewing a two or three dimensional image of the surgical site on a display, the surgeon performs the surgical procedures on the patient by manipulating master control devices, which in turn control the motion of servomechanically operated instruments. The servomechanism used for telesurgery will often accept input from two master controllers (one for each of the surgeon's hands) and may include two or more robotic arms or manipulators. Mapping of the hand movements to the image displayed from the image capture device can help the surgeon provide more direct control over movement of the surgical instruments.

While the new telesurgical systems and devices have proven highly effective and advantageous, still further improvements would be desirable. For example, work in connection with the present invention has shown that misalignment between a robotic surgical end effector and an input device can decrease the useful life of some tools, and efforts to limit such misalignment can make tool and manipulator fabrication more difficult than may be ideal. As many surgical tools may be mounted on any particular manipulator during a single surgical procedure, and as tool changes will be performed while a procedure is under way, it is generally preferable to avoid and/or minimize any tool-swap related delays to the surgical procedure.

For the reasons outlined above, it would be advantageous to provide improved devices, systems, and methods for robotic surgery, telesurgery, and other telerobotic applications. It would be particularly beneficial if these improved technologies enhanced the precision and alignment of sophisticated robotic systems without significantly increasing complexity or costs, ideally allowing greater tool useful life and reliability.

BRIEF SUMMARY OF THE INVENTION

The present invention generally provides improved telerobotic, telesurgical, and surgical robotic devices, systems, and methods. The present invention may calibrate end effectors having jaws or the like formed with two separate end effector elements. The grip calibration will often be performed selectively, without calibrating some or all of the other degrees of freedom of an end effector/manipulator assembly. Selective calibration of grip actuation can be performed by bringing the jaw elements into engagement with each other, such as by clamping a microforceps closed, fully closing an electrosurgical scissor, closing the jaws of a needle grasper (with no needle or other structure disposed between the grasper elements), and the like. Robotic systems employing commanded torque sign