U.S. patent application number 13/422492 was filed with the patent office on 2012-08-30 for compact capstan.
This patent application is currently assigned to Intuitive Surgical Operations, Inc.. Invention is credited to Thomas Cooper, Bruce Schena.
Application Number | 20120217457 13/422492 |
Document ID | / |
Family ID | 38919975 |
Filed Date | 2012-08-30 |
United States Patent
Application |
20120217457 |
Kind Code |
A1 |
Schena; Bruce ; et
al. |
August 30, 2012 |
COMPACT CAPSTAN
Abstract
A compact capstan includes a drum, a coupled hub, a passage
extending through the drum and hub, and a shaft extending through
the drum and hub. The shaft engages the passage such that the shaft
can transmit a torsional force to the drum and the hub which are
free to move along the length of the shaft. The drum includes a
spiral groove to receive a cable loop wound around the drum. The
hub has a thread with substantially the same pitch as the spiral
groove to engage a threaded support such that the hub and the drum
move laterally along their length relative to the threaded support
as the hub and the drum are rotated. The shaft has a length that is
substantially greater than the passage such that the shaft extends
beyond both ends of the passage.
Inventors: |
Schena; Bruce; (Menlo Park,
CA) ; Cooper; Thomas; (Menlo Park, CA) |
Assignee: |
Intuitive Surgical Operations,
Inc.
Sunnyvale
CA
|
Family ID: |
38919975 |
Appl. No.: |
13/422492 |
Filed: |
March 16, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11428251 |
Jun 30, 2006 |
8151661 |
|
|
13422492 |
|
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Current U.S.
Class: |
254/338 ;
254/266; 254/362 |
Current CPC
Class: |
Y10T 74/18848 20150115;
A61B 34/71 20160201; A61B 34/37 20160201; A61B 34/30 20160201; A61B
2017/00477 20130101 |
Class at
Publication: |
254/338 ;
254/266; 254/362 |
International
Class: |
B66D 1/74 20060101
B66D001/74; B66D 1/36 20060101 B66D001/36; B66D 1/12 20060101
B66D001/12 |
Claims
1.-28. (canceled)
29. A compact capstan comprising: a drum having a cylindrical
surface, a first end, and an opposite second end, the cylindrical
surface of the drum having a spiral groove to receive a cable loop
wound around the drum; a threaded hub coupled to the first end of
the drum, the threaded hub to engage a threaded support, the
threaded hub and the drum to move together laterally along their
length relative to the threaded support in response to being
rotated; a ball spline nut coupled to the drum and the hub; and a
splined shaft rotatably supported in a fixed relationship to the
threaded support, the splined shaft engaging the ball spline nut to
transmit a torsional force to rotate the drum and the hub, the ball
spline nut, the drum and the hub being free to move along the
length of the splined shaft.
30. The compact capstan of claim 29, wherein the ball spline nut
has a diameter that is similar to a diameter of the hub and the
ball spline nut is located substantially within the drum.
31. The compact capstan of claim 29, wherein the drum further
includes two cable attachment points, each cable attachment point
being at an end of the spiral groove for receiving an end of a
segment of the cable loop.
32. The compact capstan of claim 29, wherein the drum and hub
include a passage extending from an end of the drum through to an
end of the hub furthest from the drum, and the shaft has a length
that is substantially greater than a length of the passage, the
shaft passing through the passage and extending beyond both ends of
the passage.
33. The compact capstan of claim 29, the hub includes a thread with
substantially the same pitch as the spiral groove of the drum.
34. A compact capstan drive comprising: a capstan support having a
threaded portion; a motor coupled to the capstan support, the motor
having a drive shaft with an axis of rotation; and a capstan
coupled to the threaded portion of the capstan support, the capstan
including a drum having a spiral groove on a cylindrical surface,
the spiral groove to receive a cable loop wound around the drum; a
hub coupled to the drum, the hub having a thread to engage the
threaded portion of the capstan support, the hub and the drum to
move laterally along their length relative to the threaded support
in response to being rotated; a ball spline nut coupled to the drum
and the hub; and a splined shaft coupled to the drive shaft of the
motor, the splined shaft engaging the ball spline nut to transmit a
torsional force to rotate the drum and the hub, the ball spline
nut, the drum, and the hub being free to move along the length of
the splined shaft.
35. The compact capstan drive of claim 34, wherein the ball spline
nut has a diameter that is similar to a diameter of the hub and the
ball spline nut is located substantially within the drum.
36. The compact capstan drive of claim 34, wherein the drum further
includes two cable attachment points, each cable attachment point
being at an end of the spiral groove for receiving an end of a
segment of the cable loop.
37. The compact capstan drive of claim 34, further comprising two
take off pulleys rotatably coupled to the support structure.
38. The compact capstan drive of claim 34, wherein the spiral
groove of the drum has substantially the same pitch as the threaded
passage.
39. The compact capstan drive of claim 34, wherein the drum and the
hub include a passage extending from an end of the drum through to
an end of the hub furthest from the drum, and the shaft has a
length that is substantially greater than a length of the passage,
the shaft passing through the passage and extending beyond both
ends of the passage.
40. A compact capstan drive comprising: a cable receiving means to
receive a cable loop; a moving means to move a take off point of
the cable receiving means laterally as the cable receiving means is
rotated; and a transmitting means to transmit a torsional force to
rotate the cable receiving means, as it is rotated the cable
receiving means is free to move laterally with respect to the
transmitting means, the transmitting means including a splined
shaft and a ball spline nut that engages the splined shaft.
41. The compact capstan drive of claim 40, wherein the ball spline
nut is located substantially within the cable receiving means.
42. The compact capstan drive of claim 40, wherein the cable
receiving means further includes an end receiving means to receive
an end of a segment of the cable loop.
43. The compact capstan drive of claim 40, further including a
providing means to provide the torsional force to the cable
receiving means.
44. The compact capstan drive of claim 40, further including a
supporting means to support the providing means and the cable
receiving means, wherein the providing means being fixed to the
supporting means and the cable receiving means being fixed axially
but not laterally to the supporting means.
45. The compact capstan drive of claim 44, further including a
guiding means to guide the cable loop to and from the cable
receiving means.
46. The compact capstan drive of claim 45, wherein the guiding
means is fixed laterally to the supporting means.
47. A method of controlling a cable loop, the method comprising:
receiving the cable loop in a spiral groove on a cylindrical
surface of a drum; rotating a splined shaft that engages a ball
spline nut coupled to the drum to transmit a torsional force while
leaving the drum free to move laterally on the splined shaft; and
moving the drum laterally on the splined shaft by a threaded hub
coupled to the first end of the drum, the threaded hub engaging a
threaded support such that the ball spline nut, the threaded hub
and the drum move together laterally along their length relative to
the threaded support in response to the ball spline nut, the
threaded hub and the drum being rotated by the splined shaft.
48. The method of claim 47, further including guiding the cable
loop to and from the drum with two takeoff pulleys, one end of the
loop portion of the cable loop extending from a first of the two
take off pulleys and the opposite end of the loop portion of the
cable loop extending from a second of the two take off pulleys.
49. The method of claim 47, further including energizing a motor
coupled to the splined shaft to rotate the splined shaft.
Description
FIELD
[0001] The embodiments of the invention are generally related to
robotic surgical systems. More particularly, the embodiments of the
invention relate to cable drive systems for robotic surgical
arms.
BACKGROUND OF THE INVENTION
[0002] Minimally invasive surgery (MIS) provides surgical
techniques for operating on a patient through small incisions using
a camera and elongate surgical instruments introduced to an
internal surgical site, often through trocar sleeves or cannulas.
The surgical site often comprises a body cavity, such as the
patient's abdomen. The body cavity may optionally be distended
using a clear fluid such as an insufflation gas. In traditional
minimally invasive surgery, the surgeon manipulates the tissues
using end effectors of the elongate surgical instruments by
actuating the instrument's handles while viewing the surgical site
on a video monitor.
[0003] A common form of minimally invasive surgery is endoscopy.
Laparoscopy is a type of endoscopy for performing minimally
invasive inspection and surgery inside the abdominal cavity. In
standard laparoscopic surgery, a patient's abdomen is insufflated
with gas, and cannula sleeves are passed through small (generally
1/2 inch or less) incisions to provide entry ports for laparoscopic
surgical instruments. The laparoscopic surgical instruments
generally include a laparoscope (for viewing the surgical field)
and working tools.
[0004] The working tools are similar to those used in conventional
(open) surgery, except that the working end or end effector of each
tool is separated from its handle by a tool shaft. As used herein,
the term "end effector" means the actual working part of the
surgical instrument and can include clamps, graspers, scissors,
staplers, image capture lenses, and needle holders, for example. To
perform surgical procedures, the surgeon passes these working tools
or instruments through the cannula sleeves to an internal surgical
site and manipulates them from outside the abdomen. The surgeon
monitors the procedure by means of a monitor that displays an image
of the surgical site taken from the laparoscope. Similar endoscopic
techniques are employed in other types of surgeries such as
arthroscopy, retroperitoneoscopy, pelviscopy, nephroscopy,
cystoscopy, cisternoscopy, sinoscopy, hysteroscopy, urethroscopy,
and the like.
[0005] Endoscopy may be performed with robotically controlled
working tools. Robotic control may provide an improved control
interface to the surgeon. Robotically controlled working tools may
be driven by servo mechanisms, such as servo motors, that are
coupled to the working tool by mechanical cables. Each servo
mechanism may be coupled to a cable by a capstan that draws in and
pays out the cable wound around the capstan. The cable may be
routed to and from the capstan by one or more pulleys. The cable
may rotate a driver that is coupled to the robotically controlled
working tool to drive and control movement of the tool. As space in
the surgical field where robotically controlled working tools are
being used is at a premium, it is desirable to have a compact
mechanism to drive and control the robotically controlled working
tools.
[0006] In a typical cable drive system for a robotically controlled
working tool, a cable is guided by a pulley and wound onto a
capstan that is rigidly fixed to a shaft. The capstan being rigidly
fixed to the shaft it can only be rotated with the shaft. As a
result, the point at which the cable comes onto the capstan moves
along the length of the capstan as the capstan rotates. If the
capstan is close to the pulley guiding the cable, a large angle can
be created in the cable at a take off point at the capstan. If this
angle is too large, the cable may wear excessively, incur physical
damage to its cable strands, run off the take off pulley, or run
out of a groove in the capstan. By increasing a distance between
the capstan and the pulley, the angle at the take off point may be
reduced and be acceptable. However, this makes the cable drive
system less compact. It is desirable to minimize the angle in the
cable at the take off point of the capstan while at the same time
providing a compact mechanism to drive and control movement of a
robotically controlled working tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a plan view of a surgical suite in which
embodiments of the invention are used.
[0008] FIG. 2 is a pictorial view of a robotic surgical arm and
surgical instrument from the operating suite of FIG. 1.
[0009] FIG. 3 is a plan view of a portion of the robotic surgical
arm of FIG. 2 that supports the surgical instrument.
[0010] FIG. 4 is a schematic of a cable loop that provides lateral
motion.
[0011] FIG. 5 is a schematic of a cable loop that provides rotary
motion.
[0012] FIG. 6 is a schematic of another cable loop that provides
lateral motion.
[0013] FIG. 7 is a side view of a capstan with a portion of a cable
loop.
[0014] FIG. 8 is a pictorial view of a portion of the robotic
surgical arm of FIG. 2 that supports the surgical instrument in
which a cable drive system may be seen.
[0015] FIG. 9 is a pictorial view of a portion of FIG. 8 in which
the cable drive system may be seen.
[0016] FIG. 10 is a pictorial view of a portion of the cable drive
system of FIG. 9.
[0017] FIG. 11 is a plan view of the portion of the cable drive
system of FIG. 10.
[0018] FIG. 12 is a side view of a capstan and take-off pulley.
[0019] FIG. 13 is an end view of a compact capstan assembly.
[0020] FIG. 14 is a side view of the compact capstan assembly of
FIG. 13.
[0021] FIG. 15 is a side section view of the compact capstan
assembly of FIG. 13 along section line 15-15.
[0022] FIG. 16 is an end view of another compact capstan
assembly.
[0023] FIG. 17 is an end view of another compact capstan
assembly.
[0024] FIG. 18A is a side view of the compact capstan assembly of
FIG. 14 at a first position in a threaded support structure with a
portion shown as a section view.
[0025] FIG. 18B is a side view of the compact capstan assembly of
FIG. 14 at a second position in the threaded support structure with
a portion shown as a section view.
[0026] FIG. 19 is an end view of another compact capstan
assembly.
[0027] FIG. 20 is a side view of another capstan and take off
pulley with a portion shown as a section view.
[0028] FIG. 21 is a side view of another capstan and take off
pulley with a substantial distance between them.
[0029] It will be appreciated that all the drawings of Figures
provide for herein are for illustrative purposes only and do not
necessarily reflect the actual shape, size, or dimensions of the
elements being illustrated.
DETAILED DESCRIPTION OF THE INVENTION
[0030] In the following detailed description of the embodiments of
the invention, numerous specific details are set forth in order to
provide a thorough understanding of the embodiments of the
invention. However, it will be obvious to one skilled in the art
that the embodiments of the invention may be practiced without
these specific details. In other instances well known methods,
procedures, components, and circuits have not been described in
detail so as not to unnecessarily obscure aspects of the
embodiments of the invention.
[0031] The embodiments of the invention include methods, apparatus,
and systems for a compact capstan.
[0032] In one embodiment of the invention, a method of controlling
a cable loop is provided using a slideable capstan. The method
includes guiding a first portion of a cable loop to a slideable
capstan using a first takeoff pulley and guiding a second portion
of the cable loop to the slideable capstan using a second takeoff
pulley; coupling the rotation of a shaft to the slideable capstan
to rotate the slideable capstan; rotating the shaft in a first
direction to draw in the first portion of the cable loop and feed
out the second portion of the cable loop; and in response to the
rotation of the capstan, moving the slideable capstan along the
shaft to substantially maintain the positions of the first takeoff
point and the second takeoff point relative to the first takeoff
pulley and the second takeoff pulley, respectively.
[0033] In another embodiment of the invention, a capstan drive is
provided that includes a cable receiving means to receive a cable
loop; a moving means to move a take off point of the cable
receiving means laterally as the cable receiving means is rotated;
and a transmitting means to transmit a torsional force to rotate
the cable receiving means. As the cable receiving means is rotated
it is free to move laterally with respect to the transmitting
means.
[0034] In another embodiment of the invention, a compact capstan
drive is provided including a capstan support, a motor coupled to
the capstan support, and a capstan coupled to the threaded portion
of the capstan support. The capstan support has a threaded portion
to receive a hub of the capstan. The motor has a drive shaft with
an axis of rotation to rotate the capstan. The capstan includes a
drum, a hub coupled to the drum, and a shaft coupled to the drive
shaft of the motor. The drum of the capstan has a spiral groove on
a cylindrical surface to receive a cable loop wound around the
drum. The hub has a thread to engage the threaded portion of the
capstan support. As the hub and the drum are rotated together, they
move laterally along their length relative to the threaded support.
The shaft of the capstan engages the drum and the hub to transmit a
torsional force to rotate the drum and the hub. As they rotate, the
drum and the hub are free to move along the length of the
shaft.
[0035] In another embodiment of the invention, a compact capstan is
provided including a drum, a threaded hub, and a shaft rotatably
supported in a fixed relationship to a threaded support. The drum
has a cylindrical surface, a first end, and an opposite second end.
The cylindrical surface of the drum has a spiral or helical groove
to receive a cable loop that is wound around the drum. The threaded
hub is coupled to the first end of the drum and engages the
threaded support. The threaded hub and the drum move together
laterally along their length relative to the threaded support in
response to their being rotated. The shaft engages the drum and the
hub to transmit a torsional force to rotate the drum and the hub.
The drum and the hub are free to move along the length of the shaft
as they are rotated.
[0036] The detailed description describes the invention as it may
be used in a laparoscopic surgery. It is to be understood that this
is merely one example of the types of surgeries in which the
invention may be used. The invention is not limited to laparoscopy
nor to the particular structural configurations shown which are
merely examples to aid in the understanding of the invention.
Traditional minimally invasive surgery requires a high degree of
surgical skill because the surgeon's hand movements are controlling
a surgical tool at a substantial distance from the surgeon's hands,
often requiring unnatural and non-intuitive hand motions. In
robotically assisted surgery, a surgeon may operate a master
controller to control the motion of surgical instruments at the
surgical site. Servo mechanisms may move and articulate the
surgical instrument based on the surgeon's manipulation of the hand
input devices. The robotic assistance may allow the surgeon to
control the motion of surgical instruments more easily and with
greater precision.
[0037] FIG. 1 shows a schematic plan view of a surgical suite in
which the invention may be used. A patient 110 is shown on an
operating table 112 undergoing robotically assisted laparoscopic
surgery. A surgeon 120 may use a master controller 122 to view a
video image of the internal surgical site and control one or more
surgical instruments and a laparoscopic camera by means of robotic
servo mechanisms. The master controller 122 will typically include
one or more hand input devices (such as joysticks, exoskeletal
gloves, or the like) which are coupled by a servo mechanism to a
surgical instrument. One or more robotic surgical arms 100, 102 may
be used to support and move surgical instruments 104 at the
surgical site during robotically assisted surgery.
[0038] FIG. 2 shows a robotic surgical arm 102 supporting a
surgical instrument 104. The surgical instrument 104 may include a
head end 200 coupled to an end effector 204 by a tool shaft 202.
The end effector 204 may be inserted into a surgical site through a
cannula 206 that is supported by the robotic surgical arm 102. The
end effector 204 at an internal end of the tool shaft 202 may
provide any of a variety of surgical tools which may be actuated by
servo mechanisms 210 which may be supported by the robotic surgical
arm 102. The end effector 204 is coupled to a head end 200 of the
surgical instrument 104 through the tool shaft 202. The head end
200 may include one or more drivers that control the movement of
the end effector 204. Rotation of the drivers may be used to
control the movement of the end effector 204.
[0039] The head end 200 of the surgical instrument 104 may be
coupled to a tool carriage 220 on the robotic surgical arm 102.
This may facilitate exchange of the surgical instrument 104 during
the course of a surgical procedure. The tool carriage 220 may be
slidingly supported by a spar 222 that is supported by the robotic
surgical arm 102. The tool carriage 220 may be moved along the spar
222 to change the depth of insertion of the end effector 204 by
moving the entire surgical instrument 104.
[0040] Referring to FIGS. 1 and 2, the robotic surgical arm 102 may
include one or more servo motors 210 to move the surgical
instrument 104 and/or the end effector 204 on the surgical
instrument. One or more control wires 124 may provide signals
between the computer 123 in the master controller 122 and the servo
motors 210 on the robotic surgical arm 102. The master controller
122 may include a computer 123 to provide signals that control the
servo mechanisms 210 of the surgical instrument 104 based on the
surgeon's input and received feedback from the servo
mechanisms.
[0041] FIG. 3 shows the spar 222, the tool carriage 220, and the
servo motors 210 removed from the robotic surgical arm. The servo
motors 210 may move the tool carriage 220 laterally along the spar
222. Movement of the tool carriage 220 along the spar 222 controls
the depth of insertion of the surgical instrument that is connected
to the tool carriage. The servo motors 210 may further move the end
effector 204.
[0042] The end effector 204 may be moved by rotating receiving
elements provided in the head end 200 of the surgical instrument
104. Each receiving element of the surgical instrument 104 may be
coupled to a rotatable driver 324 provided on the tool carriage
220. The end effector 204 may be arranged such that approximately
one revolution or less of the rotatable driver 324 moves the
controlled motion of the end effector 204 through its full range.
Thus, one or more servo motors 210 may be coupled to the surgical
instrument 104 to control a motion of the end effector 204 or a
rotation of the tool shaft 202.
[0043] FIG. 4 shows a schematic of a cable loop 400 that may be
used to provide the lateral motion of the tool carriage 220 along
the spar 222. For the purposes of this invention, a cable loop is
used to describe a mechanical power transmission by means of a long
flexible "cable", such as a wire or fiber cable or a thin flexible
belt or band, that is driven such that one part of the cable is
drawn in by the driving mechanism while an equal amount of the
cable is fed out. This results in a motion of the cable comparable
to the motion of a continuous loop of cable. However, for the
purposes of this invention, the "cable loop" need not physically be
in the form of a continuous loop of cable. The cable may also be
tubing that transports fluids or gases to or from the surgical
tool.
[0044] As shown in FIG. 4, the "cable loop" 400 may advantageously
be provided by one or more cable segments 402, 404 that are coupled
to provide the motion of a continuous loop of cable. In the
schematic cable loop 400 of FIG. 4, the cable loop is provided by
two cable segments 402, 404 each of which has an end 406, 408 that
is coupled to the tool carriage 220. As a first end 410 of the
cable is drawn in, a second end 412 of the cable is fed out and
passed around an outboard pulley 414. This arrangement provides a
controlled lateral movement of the tool carriage 220.
[0045] FIG. 5 shows a schematic of a cable loop 500 that may be
used to provide the rotary motion of a rotatable driver 324. A
single cable segment is shown with each of the two ends 502, 504
coupled to one of two coupled driver pulleys such that the pulleys
are rotated as a first portion 508 of the cable 500 is drawn in
while a second portion 510 of the cable is fed out and passed
around an outboard pulley 514. It will be appreciated that two or
more cable segments could be used to control the rotation of the
rotatable driver 324 in an arrangement similar to that shown in
FIG. 4. Likewise, a single cable segment in the arrangement shown
in FIG. 5 could be used to control lateral movement of the tool
carriage 220.
[0046] FIG. 6 shows a schematic of a cable loop 600 that may be
used to provide a lateral movement of the tool carriage 220. The
first 602 and second 604 ends of the cable loop 600 are wound
around a capstan 606 and secured thereto. The capstan 606 provides
a positive drive for drawing in a first portion 608 of the cable
loop 600 while feeding out a second portion 609 of the cable at the
same rate. The capstan 606 further provides spooling of the cable
loop 600 as it is drawn in and unspooling of the cable as it is fed
out. Two take off pulleys 610, 612 may be provided adjacent the
capstan 606 to provide a stable path for the cable loop 600 as it
passes to the outboard pulley 614 and to the tool carriage 220.
Each end 602, 604 of the cable loop 600 may make one or more turns
around the capstan 606 and then pass around one of the take off
pulleys 610, 612 adjacent the capstan. Additional pulleys (not
shown) may be provided between the take off pulleys 610, 612 and
the tool carriage 220 to direct the cable loop 600 as required.
[0047] FIG. 7 shows a side elevation of the capstan 606 and a
portion of the cable loop 600. The portions of the cable 608, 609
that extend to the take off pulleys 610, 612 have been shown as
extending to the sides so that the point of take off 616 from the
capstan 606 can be more easily seen. The point at which one end 604
of the cable may be secured to the capstan 606 is visible while the
other end 602 of the cable may be secured to the capstan at the
opposite end and on the opposite side such that it is not visible
in this elevation. Alternatively, the cable may be attached at
different places on the capstan or may not be attached to the
capstan.
[0048] A coupled device, such as the tool carriage 220 or the
rotatable driver 324, may be moved by rotating the capstan 606 to
cause one portion 608 of the cable loop 600 to be drawn in and
wound onto the capstan while unwinding and feeding out a second
portion 609 of the cable loop. The capstan 606 may include a spiral
or helical groove having a shape that receives the cable as it is
wound onto the capstan. The spiral or helical groove may have a
pitch, longitudinal spacing of adjacent sections of the groove,
that allows the cable to be wound onto the capstan without
overlaying adjacent turns of the cable. It will be appreciated that
the take off point 616 for the cable loop 600 will move laterally
along the capstan 606 as the cable is wound onto and around the
capstan.
[0049] FIG. 8 shows a pictorial view of the spar 222, the tool
carriage 220, and the servo motors 210 with the supporting
structure removed so that capstans 800 which are driven by the
servo motors may be seen. The capstans 800 are illustrated facing
upward for clarity but they would typically face downward toward
the patient in use. FIG. 9 shows a closer view of just the portion
with the capstans 800. Five servo motors are shown driving five
capstans. Two take off pulleys are provided for each capstan.
Additional pulleys are provided to guide the cable through the
spar.
[0050] Referring to FIG. 8, each of the servo motors 210 may
provide a rotary motion that is coupled to the tool carriage 220 by
a cable loop 830. For example, the cable loop 830 may pass over a
pulley 832 at the end of the spar 222 remote from the servo motors
210. One of the instrument drivers 324 (see FIG. 3) on the tool
carriage 220 may be coupled to the cable loop 830 such that
movement of the cable loop by one of the servo motors 210 rotates
the instrument driver. Additional cable loops (not shown) may be
coupled to the remaining instrument drivers 324 on the tool
carriage and to the tool carriage 220 itself such that movement of
the additional cable loops by the associated servo motors 210
rotates the remaining drivers and moves the tool carriage along the
spar 222.
[0051] Each servo motor 210 may drive one of the capstans 800,
possibly through a gearbox (not shown). It may be appreciated from
FIG. 8, which shows five servo motors 210 with their associated
capstans and take off pulleys and additional pulleys for guiding
the cables, that space is at a premium.
[0052] Referring to FIG. 9, it will be seen that the cables are
directed from the capstans toward the spar (not shown) which is
located toward the left in FIG. 9. Two of the capstans 904, 906 are
adjacent the spar, two capstans 908, 910 are remote from the spar,
and a fifth capstan 902 is between the other four capstans. For a
capstan 908 that is remote from the spar, the take off pulleys 912,
914 may be a substantial distance from the capstan.
[0053] As shown in FIG. 21, the lateral shift in the take off point
2106 of the cable loop 2100 from the capstan 908 as the cable loop
is wound and unwound from the capstan creates only an acceptably
small angle 2104 between the portion of the cable loop extending to
the take off pulley 914 and the plane 2102 of the take off pulley,
even when the cable is at the extremes of its travel on the
capstan. A small angle 2104 between the cable 2100 and the plane
2102 of the take off pulley 914 is acceptable. An angle of
approximately five degrees may be acceptable for a typical
configuration.
[0054] In contrast, the remaining three capstans 902, 904, 906 are
close to their take off pulleys 916, 918, 920, 922, 1024, 1026 that
receive the cable loops from these capstans.
[0055] FIG. 10 shows these three capstans and their take off
pulleys. FIG. 11 is a plan view of these three capstans and their
take off pulleys which shows the short distance between the capstan
and the take off pulleys. The distance between each capstan and its
associated take off pulleys may be comparable to the distance
between the take off points when the cable is at the extremes of
its travel on the capstan.
[0056] FIG. 12 is a side elevation of a capstan 904 that is close
to its take off pulley 922. This creates a relatively large angle
1204 between the cable 1200 and the plane 1202 of the take off
pulley 922 when the cable is at the extremes of its travel on the
capstan 904. It will be appreciated that a large angle 1204 between
the cable 1200 and the plane 1202 of the take off pulley 922 causes
unbalanced forces on the take off pulley that can increase friction
and cause wear in the system. The size of angle 1204 between the
cable 1200 and the plane 1202 of the take off pulley 922 that
becomes unacceptable depends on a variety of factors, such as the
load on the cable and configuration of the pulleys. The cable 1200
may run off the capstan groove or the take off pulley 922 if the
angle between the cable and the plane of the take off pulley 1202
is too great. An angle 1204 between the cable 1200 and the plane
1202 of the take off pulley 922 increases the length of the cable
loop, which may require some form of tension compensating device.
The capstan 904 and take off pulley 922 configuration shown may be
unworkable if the cable 1200 is allowed to form the angle 1204
shown to the plane 1202 of the take off pulley 922.
[0057] FIGS. 13 through 15 show a compact capstan 1300 with FIG. 13
being an end view, FIG. 14 being a side view, and FIG. 15 being a
sectioned view from the side. The compact capstan 1300 includes a
drum 1310 that is generally in the form of a cylinder having a
cylindrical surface 1302, a first end 1304, and an opposite second
end 1306. A spiral or helical groove 1308 is provided in the
cylindrical surface 1302 of the drum into which a cable loop may be
wound. The cable loop may be discontinuous with two ends of
segments of the cable loop being secured to opposite ends 1312,
1318 of the spiral or helical groove 1308. This configuration of
the cable loop may permit the two segments of the cable loop to
take off from the capstan at approximately the same lateral
position along the length of the drum as may be seen in FIG.
10.
[0058] A threaded hub 1314 is coupled to the first end 1304 of the
drum 1310. The threaded hub 1314 may include a synchronization
thread with substantially the same pitch as the spiral or helical
groove 1308. In the configuration shown, the thread is an external
thread but an internal thread may be used in other configurations.
The thread may be a sixty degree Unified National thread, a metric
thread, an Acme thread, or other form of screw thread.
[0059] As shown in FIGS. 18A and 18B, the threaded hub 1314 engages
a threaded support 1800. As the threaded hub 1314 and the drum 1310
are rotated, they move laterally along their length relative to the
threaded support 1800. As discussed further below, this may
maintain a substantially constant angle between the cable and the
plane of the take off pulley.
[0060] A splined passage 1500 extends through the drum 1310 and
threaded hub 1314 from an end 1306 of the drum to an opposing end
1316 of the hub. A splined shaft 1330 has a length that is greater
than a length of the splined passage 1500. The splined shaft 1330
passes through the splined passage 1500 extend. The splined shaft
1330 extends beyond both ends 1206, 1316 of the splined passage
1500. The splined shaft 1330 transmits a torsional force to the
drum 1310 and the threaded hub 1314 which remain free to move
laterally along the splined shaft.
[0061] The splined shaft 1330 may provide one or more grooves 1832
or projections that extend along the length of the splined shaft.
The splined passage 1500 may provide one or more projections or
grooves that mate with the respective grooves or projections of the
splined shaft 1330 to provide positive transmission of torsional
forces to the drum 1310 and the threaded hub 1314.
[0062] A particularly advantageous form of splined shaft and
passage for use in the present invention is a ball spline assembly.
As may be seen in FIG. 15, a ball spline assembly may include a
splined shaft 1330 and a ball spline nut 1502. The ball spline nut
may include a number of recirculating balls 1500 as the projections
that mate with a groove 1832 in the splined shaft 1330. Ball spline
assemblies provide nearly friction-free linear motion while
simultaneously transmitting torsional loads. The spline nut 1502
may be preloaded to decrease the radial play in the ball spline
assembly and provide low backlash.
[0063] FIG. 15 is a section view of the side elevation of the
compact capstan assembly 1300. A portion 1504 of the splined
passage 1500 that is within the drum 1310 may be enlarged to
receive the spline nut 1502, which may have a diameter that is
similar to the diameter of the hub portion 1314. The spline nut
1502 may be fixed within the splined passage 1500 by any of a
variety of means, such as a set screw. The spline nut 1502 may move
in unison with the drum 1310. The portion of the splined passage
1500 within the threaded hub 1314 may have a diameter that is only
sufficient to receive the splined shaft 1330.
[0064] FIG. 16 shows an end view of a hub 1600 that includes a
conventional splined passage 1602. FIG. 17 shows an end view of a
hub 1700 that includes a hexagonal shaped passage 1702. It will be
appreciated that the shaft and passage can take any of a variety of
forms. The passage will engage the shaft such that the shaft can
transmit a torsional force to the drum and the hub which are free
to move along the length of the shaft.
[0065] FIGS. 18A and 18B show a compact capstan assembly 1300 in a
threaded support structure 1800. The threaded support structure
1800 provides a threaded passageway 1806 to receive the threaded
hub 1314 of the capstan assembly 1300. The threaded support
structure 1800 may also support a motor assembly 210, two take off
pulleys 1802, 1804, and the end 1334 of the splined shaft 1330 that
emerges from the drum end 1306 of the capstan assembly 1300. The
portion of the threaded support structure 1800 providing the
threaded passageway 1806 and the support and coupling 1810 of the
motor assembly 210 are shown in cross-section along the diameter of
the threaded passageway and the remainder of the elements are shown
in full elevations.
[0066] The motor assembly 210 may include a gear box such that the
shaft that emerges from the assembly provides a higher torque and a
slower rotational speed than the shaft of the motor itself. The
splined shaft 1330 is fixedly coupled to a shaft of the motor
assembly 210 such that the splined shaft is an extension of the
motor assembly shaft. It may be appreciated that the threaded
support structure 1800 may hold all the components in a fixed
relationship to one another except for the compact capstan assembly
1300.
[0067] As may be seen in FIGS. 18A and 18B the threaded hub 1314
and drum 1310 move laterally along the length of the splined shaft
1330 as the capstan assembly 1300 is rotated. This is because the
threads of the hub 1314 couple to the threaded passageway 1806 of
the threaded support structure 1800. FIGS. 18A and 18B may
represent the two extremes of travel of the threaded hub 1314 and
drum 1310 with respect to the support structure.
[0068] It will be seen that the take off point 1808A, 1808E for the
cable moves along the length of the drum 1310 as the drum rotates
between the two extremes of travel. It will further be seen that
the drum 1310 moves laterally at a similar rate as the take off
point 1808A, 1808E for the cable moves because the threaded hub
1314 has substantially the same pitch as the spiral or helical
grove 1308 on the drum 1310 in which the cable is wound. As a
result, the take off point 1808A, 18088 for the cable remains at
substantially the same lateral position relative to the threaded
support structure 1800 and more particularly relative to the take
off pulleys 1802, 1804. This permits the take off pulleys 1802,
1804 to be placed a short distance away from the capstan 1300
because rotation of the capstan will not result in a large angle
between the cable and the plane of the take off pulleys. Moreover
the angle between the cable and the plane of the take off pulleys
may be essentially constant over the entire range of motion of the
compact capstan 1300.
[0069] The take off pulleys 1802, 1804 and the splined shaft 1330
are coupled to the threaded support structure 1800 so they are free
to rotate while being constrained against lateral movement. It will
be appreciated that only the threaded hub 1314, drum 1310, and
spline nut 1502 can move laterally relative to the threaded support
structure 1800. This may simplify the connection between the motor
assembly 210 and the capstan assembly 1300 because the motor
assembly may be coupled to the splined shaft 1330 and supported by
the threaded support structure 1800. This is possible because there
is no lateral motion of the splined shaft 1330 relative to the
motor assembly 210 or the threaded support structure 1800.
[0070] FIG. 19 shows an end view of a capstan and shaft assembly
1900 that provides another form of coupling between the capstan
1902 and the shaft 1904. A disk-like flexure 1906 is attached to
the capstan at the outside diameter of the flexure. The shaft 1904
passes through a central hole in the flexure 1906 and is attached
to the flexure along the edge of the central hole. The flexure 1906
has a series of spokes that join the inner and outer portions of
the flexure. The spokes make the flexure 1906 compliant along the
axis of the shaft 1904 while maintaining a high torsional
stiffness. Thus the shaft 1904 can transmit a torsional force to
the drum and the hub of the capstan 1902 which is free to move
along the length of the shaft within the limits of the flexure's
1906 axial compliance.
[0071] The flexure 1906 may provide a limited range of axial motion
as compared to configurations that use a splined shaft.
Configurations employing a flexure 1906 to couple the capstan 1902
to the shaft 1904 may only provide a moderate shifting of the
capstan. In some configurations the hub may have a smaller pitch
than the groove in the hub. Thus the capstan will slide to reduce
some but not all of the angle between the cable and the plane of
the take off pulley. This may maintain the angle within an
acceptable range. An angle of approximately five degrees may be
acceptable for a typical configuration.
[0072] Two flexures 1906, spaced some distance apart, may couple
the capstan 1902 to the shaft 1904. This may provide radial support
for the capstan 1902.
[0073] In another configuration, a single flexure 1906 may couple
the capstan 1902 to the shaft 1904 at one end of the capstan 1902.
The capstan 1902 may include a passage with a slip fit on the shaft
that enables axial sliding and provides radial support.
[0074] FIG. 20 shows another compact capstan assembly 2000 in a
threaded support structure 2050. The threaded support structure
2050 provides a threaded post 2014 that engages a threaded
passageway of the capstan assembly 2000. The threaded support
structure 2050 may also support a motor assembly 2060, and two take
off pulleys 2002, 2004.
[0075] In comparison to the threaded support structure 1800 shown
in FIGS. 18A and 18B, the threaded post 2014 in the configuration
shown in FIG. 20 is on the opposite side of the support structure
2050 from the motor assembly 2060.
[0076] In the configuration shown, the shaft 2020 of the motor
assembly 2060 is coupled to the capstan 2000 by a bellows 2030. The
bellows can transmit a torsional force to the drum and the hub of
the capstan 2000 which is free to move along an axis defined by the
motor shaft 2020 within the limits of the bellows' extension.
[0077] It may be appreciated that the threaded support structure
2050 may hold all the components in a fixed relationship to one
another except for the compact capstan assembly 2000. The capstan
2010 moves laterally along the length of threaded post 2014 as the
capstan assembly 2000 is rotated. As in the previous configuration,
the take off point 2008 for the cable remains at substantially the
same lateral position relative to the threaded support structure
2050 and, more particularly, relative to the take off pulleys 2002,
2004. Only the capstan assembly 2000 moves laterally relative to
the threaded support structure 2050.
[0078] In another configuration (not shown), the threaded support
structure provides a threaded passageway rather than a threaded
post on the opposite side of the support structure from the motor
assembly. The compact capstan assembly in this configuration may be
similar to the compact capstan assembly 1800 shown in FIGS. 18A and
18B. However, the threaded passageway supports the threaded hub
that, in turn, supports the outboard end of the splined shaft. This
may eliminate the need for an outboard bearing to support the
outboard end of the splined shaft.
[0079] While certain exemplary embodiments have been described and
shown in the accompanying drawings, it is to be understood that
such embodiments are merely illustrative of and not restrictive on
the broad invention. For example, while an externally threaded hub
is shown coupled to an internally threaded passage in the support
structure, the capstan may provide an internally threaded hub that
is coupled to a threaded post on the support structure. This
invention is not limited to the specific constructions and
arrangements shown and described, since various other modifications
may occur to those ordinarily skilled in the art.
* * * * *