Method and system for engagement of a surgical tool with actuators of a tool drive in a surgical robotic system

Patent metadata

Field	Value
Publication number	US-12409000-B2
Application number	US-202217881316-A
Country	US
Kind code	B2
Filing date	Aug 4, 2022
Priority date	Aug 20, 2018
Publication date	Sep 9, 2025
Grant date	Sep 9, 2025

Abstract

A system and computerized method for detection of engagement of a surgical tool to a tool drive of a robotic arm of a surgical robotic system. The method may include activating an actuator of the tool drive to rotate a drive disk to be mechanically engaged with a tool disk in the surgical tool. One or more motor operating parameters of the actuator that is causing the rotation of the drive disk are monitored while activating the actuator. The method detects when the drive disk becomes mechanically engaged with the tool disk, based on the one or more monitored motor operating parameters. Other embodiments are also described and claimed.

First claim

The invention claimed is:

1. A method for engaging a surgical tool with a tool drive of a surgical robotic system, the method comprising:
activating an actuator of a tool drive that is mounted to a surgical robotic arm to rotate a drive disk in the tool drive, wherein the drive disk is to be mechanically engaged with a tool disk in a surgical tool, by
activating the actuator to rotate the drive disk at a first velocity until the actuator or the drive disk reaches within a threshold angle away from a reference position at which point the actuator is activated to rotate the drive disk at a second velocity lower than the first velocity;

while the actuator is activated, causing the rotation of the drive disk, monitoring one or more operating parameters of the actuator; and
detecting when the drive disk becomes mechanically engaged with the tool disk based on monitoring the one or more operating parameters.

2. The method of claim 1 , wherein detecting when the drive disk becomes mechanically engaged with the tool disk comprises:
determining that the one or more operating parameters satisfies a condition.

3. The method of claim 2 , wherein the operating parameters comprises torque, motor current, motor velocity, or a combination thereof.

4. The method of claim 2 , wherein determining that the one or more operating parameters satisfies the condition comprises:
determining that measured torque of the actuator exceeds a threshold torque and measured velocity of the actuator is below a threshold velocity, wherein the threshold torque is greater than friction between the drive disk and the tool disk during rotation without mechanical engagement, and wherein the threshold velocity is zero.

5. The method of claim 2 , wherein the reference position is a factory determined position stored in an information storage unit of the surgical tool and that corresponds to a hard stop or physical constraint against further rotation of the tool disk and wherein the condition represents the actuator reaching the hard stop or physical constraint.

6. The method of claim 5 , wherein the tool disk is winding a cable, and wherein the hard stop or physical constraint comprises a movement constraint caused by a second drive disk in the tool drive that is also winding the cable or holding a position of the cable.

7. The method of claim 1 , wherein the one or more operating parameters are collected by one or more sensors.

8. The method of claim 1 , wherein the drive disk and the tool disk comprise one or more pairs of coupling features wherein each pair of coupling features becomes interlocked to each other to rotate as one, when mechanical engagement is achieved.

9. The method of claim 1 , further comprising:
detecting that another drive disk in the tool drive has failed to mechanically engage with another tool disk; and
generating a notification for an operator of the surgical robotic system indicating unsuccessful engagement.

Assignees

• Verb Surgical Inc

Inventors

• Yu Haoran
• Hariri Alireza
• Nia Kosari Sina
• Zhou Renbin
• Sen Hasan Tutkun
• Asadian Ali

Classifications

• B25J17/02

  Wrist joints · CPC title

• A61B2017/00398

  using powered actuators, e.g. stepper motors, solenoids · CPC title

• A61B2034/305

  Details of wrist mechanisms at distal ends of robotic arms · CPC title

• B25J9/1633

  compliant, force, torque control, e.g. combined with position control · CPC title

• A61B2017/00477

  Coupling (A61B2017/0046 takes precedence) · CPC title