U.S. patent application number 15/983193 was filed with the patent office on 2018-11-22 for surgical robot.
The applicant listed for this patent is Joao Guilherme AMARAL, James DRAKE, Andrew A. GOLDENBERG, Thomas LOOI, Liang MA, Yi YANG. Invention is credited to Joao Guilherme AMARAL, James DRAKE, Andrew A. GOLDENBERG, Thomas LOOI, Liang MA, Yi YANG.
Application Number | 20180333212 15/983193 |
Document ID | / |
Family ID | 55587008 |
Filed Date | 2018-11-22 |
United States Patent
Application |
20180333212 |
Kind Code |
A1 |
GOLDENBERG; Andrew A. ; et
al. |
November 22, 2018 |
SURGICAL ROBOT
Abstract
A surgical robot for use in association with a tool kit includes
at least one rotary motion assembly; and a penetration module
operably connected to one of the rotary motion assembly. The
penetration module includes an adapter having a nut portion, a
removable front adapter portion connectable to the nut portion and
a removable front closure portion connectable to the removable
front adapter portion and the tool kit is attachable to the
adapter.
Inventors: |
GOLDENBERG; Andrew A.;
(Toronto, CA) ; YANG; Yi; (Toronto, CA) ;
MA; Liang; (Markham, CA) ; AMARAL; Joao
Guilherme; (Toronto, CA) ; DRAKE; James;
(Toronto, CA) ; LOOI; Thomas; (Markham,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GOLDENBERG; Andrew A.
YANG; Yi
MA; Liang
AMARAL; Joao Guilherme
DRAKE; James
LOOI; Thomas |
Toronto
Toronto
Markham
Toronto
Toronto
Markham |
|
CA
CA
CA
CA
CA
CA |
|
|
Family ID: |
55587008 |
Appl. No.: |
15/983193 |
Filed: |
May 18, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14619978 |
Feb 11, 2015 |
9974619 |
|
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15983193 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 2017/00477
20130101; A61B 2017/00911 20130101; A61B 2034/305 20160201; A61B
34/30 20160201; A61B 2017/3409 20130101; A61B 2034/304 20160201;
A61B 2090/374 20160201 |
International
Class: |
A61B 34/30 20160101
A61B034/30 |
Claims
1. A surgical robot for use in association with a tool kit, the
surgical robot comprising: at least one rotary motion assembly; a
penetration module operably connected to the at least one rotary
motion assembly the penetration module includes an adapter having a
nut portion, a removable front adapter portion directly connectable
to the nut portion and a removable front closure portion directly
connectable to the removable front adapter portion and the tool kit
is attachable to the adapter; wherein the removable front adaptor
portion is for guiding the tool kit; the removable front closure
portion is for locking the tool kit; and the removable front
adapter portion and the removable front closure portion are
sterilizable using existing medical sterilization systems.
2. The surgical robot of claim 1 wherein the surgical tool kit
includes a removable support and a slot plate, wherein the
removable support is releasably connectable to the slot plate.
3. The surgical robot of claim 2 wherein, the removable support and
the tool kit are all sterilizable using existing medical
sterilization systems.
4. The surgical robot of claim 3 wherein the at least one rotary
motion assembly is a turret motion assembly and further including a
second rotary motion assembly being an elbow roll motion assembly
operably connected to the turret motion assembly.
5. The surgical robot of claim 4 further including a third rotary
assembly being a wrist tilt motion assembly operably connected to
the first and second rotary motion assemblies.
6. The surgical robot of claim 5 further including a linear motion
assembly.
Description
FIELD OF THE DISCLOSURE
[0001] This disclosure relates to surgical robots and in particular
surgical robots for use inside a magnetic resonance imaging (MRI)
device.
BACKGROUND
[0002] It is well known that medical resonance imaging (MRI)
devices have excellent soft tissue resolution and generate minimal
radiation hazard. Because of these advantages MRI--guided
robotic-based minimally invasive surgery has become an important
surgical tool.
[0003] There are a number of surgical robots currently in use but
not all are compatible with an MRI. For example the Intuitive
Surgical robot called the da Vinci.TM. is not compatible with an
MRI. In contrast the Innomotion robot arm, the NeuroArm robot, and
the MRI-P robot are all MRI-compatible. However, even those robots
which are MR compatible, may not be able to be operated during
scanning.
[0004] The main reasons that the robots have not been widely used
in the MRI environment are MRI incompatibility, limitations of the
real-time intra-operative imaging, space constraints, and lack of
compatible modular surgical tools.
SUMMARY
[0005] A modular reconfigurable surgical robot for use in
association with a surgical tool is disclosed. The surgical robot
includes a linear module for linear movement; a turret module for
rotational movement, and elbow roll module for rotational movement,
and a wrist tilt module for rotational movement. The turret module
has a turret rotational axis. The elbow roll module for rotational
has an elbow roll rotational axis at an angle to the turret
rotational axis. The wrist tilt module has a wrist tilt rotational
axis at an angle to the turret rotational axis and at an angle to
the elbow roll rotational axis. The linear module, turret module,
elbow roll module and wrist tilt module are operably connectable
together to form the surgical robot and one of the modules is
operably connectable to the surgical tool.
[0006] The linear movement of the linear module may define a z
axis. The turret rotational axis may be an axis parallel to the z
axis. The elbow roll rotational axis may be around an x axis and
the x axis may be generally orthogonal to the z axis. The wrist
tilt rotational axis may be around a y axis and the y axis may be
generally orthogonal to the z axis and transverse to the x
axis.
[0007] The modular reconfigurable surgical robot may further
include a penetration module connectable thereto and the surgical
tool may be attachable to the penetration module.
[0008] The modular reconfigurable surgical robot may include a
turret elbow connection module connectable to the turret module and
the elbow roll module.
[0009] The modular reconfigurable surgical robot may include a roll
connection unit connectable to the wrist tilt module and the elbow
roll module.
[0010] The linear module may include a lead screw and nut and gear
mechanism operably connected to a motor. The gear mechanism of the
linear module may include a worm and worm gear and the motor may be
an ultrasonic rotary motor.
[0011] The linear module may include a hard stop to limit movement
of the nut.
[0012] The turret module may include a shaft and a gear mechanism
operably connected to a motor. The gear mechanism of the turret
module may include a worm and a worn gear and the motor of the
turret module may be an ultrasonic rotary motor. The turret module
may include a hard stop to limit the rotation of the shaft.
[0013] The elbow roll module may include a shaft and a gear
mechanism operably connected to a motor. The gear mechanism of the
elbow roll module may include a worm and a worm gear and the motor
of the elbow roll module may be an ultrasonic rotary motor. The
elbow roll module may include a hard stop to limit the rotation of
the shaft.
[0014] The wrist tilt module may include a pair of shafts and a
pair of gear mechanism operably connected to a pair of motor. Each
gear mechanism of the wrist tilt module may include a worm and a
worm gear and the motor of the wrist tilt module may be an
ultrasonic rotary motor. The wrist tilt module may include a hard
stop to limit the rotation of the shaft.
[0015] The penetration module may include a lead screw and nut and
gear mechanism operably connected to a motor. The gear mechanism of
the penetration module may include a pair of spur gears and the
motor of the penetration module may be an ultrasonic rotary motor.
The surgical tool may be a surgical tool module connectable to the
penetration module and the surgical tool module may include a lead
screw and nut and gear mechanism operably connected to a motor.
[0016] The surgical tool module may be operably connected to a
drill kit. The surgical tool module further may include a timing
belt and pulleys operably connect to the drill kit. The surgical
tool module may include a pneumatic unit operably connected to the
drill kit. The drill kit may include a trocar, a drill, and a guide
stylet.
[0017] The penetration module may further include an adapter and
the surgical tool module is attachable to the adapter. The adapter
may include a nut portion, a removable front adapter portion
connectable to the nut portion and a removable front closure
portion connectable to the removable front adapter portion. The
surgical tool kit may include a removable support releasably
connectable to a slot plate. The removable front adapter portion,
the removable front closure portion, the removable support and the
drill kit are all sterilizable. The motor of the surgical tool
module may be an ultrasonic rotary motor.
[0018] The modular reconfigurable surgical robot may include an
arch device unit operably attachable to one of the linear module,
the turret module, the elbow roll module and the wrist tilt module.
The arch device unit may include a pair of linear actuators at
either end of an arch frame. Each linear actuator of the arch
device unit may include an ultrasonic motor operably connected to a
lead screw and a pair of carriages moveably connected to the lead
screw and whereby the pair of carriages may be connected to the
arch frame and activating the ultrasonic motor moves the carriage
along the lead screw. Each linear actuator may be connected to a
base plate and the base plate may be connectable to a surgical
table.
[0019] The modular reconfigurable surgical robot may include a
quick connector module connectable to one of the linear module, the
turret module, the elbow roll module and the wrist tilt module. The
arch device unit may include a rail and the surgical robot may be
movably attached to the rail. The surgical robot may be moved
manually along the rail. The arch device unit may include an arch
motor to driven surgical robot along the rail.
[0020] All of the elements of the modular reconfigurable surgical
robot may be MRI compatible.
[0021] A surgical robot assembly for use in association with a
surgical tool or a surgical tool module is disclosed. The surgical
robot assembly includes an arch unit having an arch frame and a
surgical robot moveably attachable to the arch unit at different
locations along the arch frame.
[0022] The arch unit further may include a pair of linear actuators
at either end of the arch frame. Each linear actuator may include
an ultrasonic motor operably connected to a lead screw and a pair
of carriages moveably connected to the lead screw and whereby the
pair of carriages may be connected to the arch frame and activating
the ultrasonic motor moves the pair of carriages along the lead
screw. Each linear actuator may be connected to a base plate and
the base plate may be connectable to a surgical table. The arch
unit may include a rail and the surgical robot is movably attached
to the rail. The surgical robot is moved manually along the rail.
The arch device may include an arch motor to driven surgical robot
along the rail.
[0023] A surgical robot for use in association with a tool kit is
disclosed. The surgical robot includes at least one rotary motion
assembly; and a penetration module operably connected to one of the
rotary motion assembly. The penetration module may include an
adapter having a nut portion, a removable front adapter portion
connectable to the nut portion and a removable front closure
portion connectable to the removable front adapter portion. The
tool kit is attachable to the adapter.
[0024] The surgical tool kit may include a removable support
releasably connectable to a slot plate. The removable front adapter
portion, the removable front closure portion, the removable support
and the tool kit may all be sterilizable.
[0025] Further features will be described or will become apparent
in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The embodiments will now be described by way of example
only, with reference to the accompanying drawings, in which:
[0027] FIG. 1 is a perspective view of a surgical robot assembly
adapted for use in an MRI;
[0028] FIG. 2A is a perspective view of the surgical robot of the
surgical robot assembly of FIG. 1;
[0029] FIG. 2B is a blown apart perspective view of the surgical
robot of FIG. 2a;
[0030] FIG. 3A is a perspective view of the vertical translation
module of the surgical robot and showing the cover plate
removed;
[0031] FIG. 3B is a blown apart perspective view of the translation
module of FIG. 3A;
[0032] FIG. 4 is a perspective view of the turret module of the
surgical robot of FIG. 2 and showing the turret housing as
transparent;
[0033] FIG. 5 is a perspective view of the elbow roll module of the
surgical robot of FIG. 2 and showing the elbow roll housing as
transparent;
[0034] FIG. 6A is a perspective view of the wrist tilt module of
the surgical robot of FIG. 2 and showing the cover plate
removed;
[0035] FIG. 6B is a perspective view of the wrist tilt module of
FIG. 6A but viewed from a different angle;
[0036] FIG. 7 is a perspective view of the penetration module of
the surgical robot of FIG. 2;
[0037] FIG. 8 is a side view of the turret and elbow connection
unit of the surgical robot of FIG. 2;
[0038] FIG. 9 is a perspective view of the turret and elbow
connection unit of FIG. 7;
[0039] FIG. 10 is a cross sectional view of the roll connection
unit of the surgical robot of FIG. 2;
[0040] FIG. 11 is a perspective view of the roll connection unit of
FIG. 10 with a portion of the housing broken away;
[0041] FIG. 12 is a perspective view of the wrist tilt module of
FIG. 6 connected to the roll connection unit of FIGS. 10 and
11;
[0042] FIG. 13 is a perspective view of the arch device unit of the
surgical robot assembly of FIG. 1;
[0043] FIG. 14A is a perspective view of a surgical tool module for
use with the surgical robot of FIG. 2;
[0044] FIG. 14B is a perspective view of the trocar locking and
retracing unit of the surgical tool module of FIG. 14A;
[0045] FIG. 14C is a section view of the trocar locking and
retracing unit of the surgical tool module of FIG. 14A;
[0046] FIG. 15A is a perspective view of an alternate surgical tool
module for use with surgical robot of FIG. 2;
[0047] FIG. 15B is a section view of the alternate surgical tool
module of FIG. 15A;
[0048] FIG. 15C is a bottom view of the alternate surgical tool
module of FIGS. 15A and B;
[0049] FIG. 16 is a partially exploded perspective view of the
surgical tool similar to that shown in FIG. 13 but showing the
drill kit in an exploded view;
[0050] FIG. 17 is a front view of surgical tool of FIG. 16;
[0051] FIG. 18 is an exploded perspective view of surgical tool and
the penetration module;
[0052] FIG. 19 is a side view of surgical tool and penetration
module of FIG. 17;
[0053] FIG. 20 is a perspective view of the biopsy procedure with a
3-piece drill kit with a) being step 1, b) step 2 and c) step
3;
[0054] FIG. 21 is a perspective view of the surgical robot assembly
of FIG. 1 shown in an MRI and showing a portion of the MRI broken
away;
[0055] FIG. 22 is a perspective view of the surgical robot assembly
similar to that shown in FIG. 21 but also showing the legs of a
patient;
[0056] FIG. 23 is a perspective view of an alternate arch device
similar to that shown in FIG. 13 but including an arch guide rail
module;
[0057] FIG. 24A is a perspective view of an alternate embodiment of
a surgical robot assembly that is similar to that shown in FIG. 1
but including the arch device of FIG. 23 and a robot rotary module
for moving the surgical robot along the arch device;
[0058] FIG. 24B is a perspective view of the alternate embodiment
of a surgical robot assembly of FIG. 24A but viewed from another
direction;
[0059] FIG. 25 is a perspective view of the surgical robot assembly
of FIG. 1 but showing the surgical robot attached at an alternate
location along the arch device;
[0060] FIG. 26 is a front view of the surgical robot assembly of
FIG. 25;
[0061] FIG. 27A is a perspective view of the surgical robot of FIG.
2A but showing the modules configured differently;
[0062] FIG. 27B is a blown apart perspective view of the surgical
robot of FIG. 27A;
[0063] FIG. 28A is a perspective view of the surgical robot of FIG.
2A but showing the modules configured differently from FIG. 2A and
FIG. 27A; FIG. 28B is a blown apart perspective view of the
surgical robot of FIG. 28A;
[0064] FIG. 29A is a perspective view of a the elbow roll module of
FIG. 5 connected to the turret and elbow connection unit of FIGS. 8
and 9;
[0065] FIG. 29B is a side view of the elbow roll module and elbow
turret connection unit of FIG. 29A; and
[0066] FIG. 30 is a blown apart view of an alternate embodiment of
the surgical robot.
DETAILED DESCRIPTION
[0067] Referring to FIG. 1, the surgical robot assembly adapted for
use in an MRI (magnetic resonance imaging) device is shown
generally at 10. The surgical robot assembly 10 includes a surgical
robot 12, a surgical tool module 14, and an arch device unit 16.
The surgical robot 12 is releasably attachable to the arch device
unit 16 at different locations along the arch unit 16. The surgical
tool module 14 is releasably attached to the surgical robot 12. The
arch unit 16 includes a pair of rails 20 at each end thereof. The
rails 20 are affixed or affixable to the MRI scanner roll-up table
(not shown). Surgical robot assembly 10 is modular, reconfigurable
and capable of fitting into an MRI environment. The
re-configurability can provide a means of finding best possible
configuration for specific procedures.
[0068] The surgical robot assembly 10 is MRI compatible and each
component used therein is similarly MRI compatible. The surgical
robot assembly 10 which includes a small surgical robot 12 is
designed to fit within the specific space limitations of an MRI
bore. The surgical robot 12 is mounted on an arched device unit 16.
The surgical robot 12 includes self-contained modules that can be
removed, exchanged and re-configured. The surgical tool module 14
includes a snap-on modular surgical tool an example of which is a
tool for paediatric bone biopsy.
[0069] Where possible the components of the surgical robot 10 are
made out of plastic. Preferably the plastic provides structural
strength, is lightweight and is MR-compatible. By way of example
the plastic is PEEK (Polyetheretherketone) material or Delrin.RTM.
or SOMOS 11122xc or NEXT resin where rapid prototyping is used.
[0070] Referring to FIGS. 2A and 2B, the surgical robot 12,
includes a linear motion assembly being a linear module 22, a first
rotary motion assembly being a turret module 24, a second rotary
motion assembly being an elbow roll module 26, a third rotary
motion assembly being a wrist tilt module 28 and another linear
motion assembly being a penetration module 30. The turret module 24
and the elbow roll module 26 are connected with a turret and elbow
connection unit 150. The elbow roll module 26 and the wrist tilt
module 28 are connected with the roll connection unit 170.
Alternatively the elbow roll module could include a connector and
similarly the wrist tilt module could include a connector and
thereby the surgical robot would include a linear module, a turret
module, an elbow roll module and a wrist module as described in
more detail below with reference to FIG. 30
[0071] Referring to FIGS. 3A and 3B, the linear module 22 is a one
degree of freedom joint. In the configuration shown in FIGS. 1, 2
and 3 it is provides for vertical translation or translation in the
y axis. However, it will be appreciated that as the surgical robot
moves around the arch device unit 16 the orientation of the linear
module 22 will change and it will generally provide movement along
a radius of the arch. The linear module includes an ultrasonic
motor 21 with an encoder 23, a gear mechanism 25, a lead screw 27,
a nut 29 and a support plate 36. In addition, the linear module 22
also includes a housing 31, a housing cover 32, a motor plate 38
and a pair of linear guide shafts 34. In addition, bearings are
used as needed. Preferably the ultrasonic motor 21 is a combined
ultrasonic rotary motor and encoder. Alternatively an ultrasonic
motor and a separate encoder could be used. By way of example, a
USR30 E3N motor may be used. Preferably the gear 26 is a worm gear.
The ultrasonic motor 21 is operably connected to the worm gear 26.
The worm gear 26 engages the nut 29 and the nut 29 moves along the
lead screw 27. The worm gear 26 is used to increase the torque of
the motor. In addition, worm gears are preferred because of their
self-locking feature and their gear ratio. The lead screw 27 is
attached to the support plate 36. Thus when the ultrasonic motor 21
is activated it causes the support plate to move in a linear
direction as determined by the position of the nut 29 along the
lead screw 27. In the embodiment herein the linear motion stroke is
0-30 mm. The lead screw 27 and the pair of guide shafts 34 are
attached to the support plate 36 and are moveable relative to the
housing 31. Preferably an ACME or Trapezoidal lead screw is used
and since the ACME or Trapezoidal lead screw 27 is not
back-driveable, it is reverse self-locking. The housing cover 32
and the motor plate 38 each attach to the housing 31 and together
enclose the worm gear 26 and nut 29. The housing cover 32 has a
shaft hole 40 and a pair of guide holes 42 such that the lead screw
27 and linear guides 34 can move freely therethrough. The housing
31 includes a quick connect attachment portion 44.
[0072] The quick connect portion 44 includes screw holes 46 and
alignment pin holes 48. The quick connect portion 44 is connectable
to the arch device unit 16 by inserting alignment pins (not shown)
into alignment pin holes 48 on the quick connect portion 44 and the
arch support 16 and then connecting them with screws (not shown)
through the screw holes 46. The quick connect attachment allows the
user to easily connect the surgical robot 12 at various locations
along the arch device 16 as shown in FIGS. 1 and 24 and 25.
[0073] The turret module 24 is shown in FIG. 4. The turret module
24 includes an ultrasonic motor 50, an encoder 51, a gear
mechanism, a shaft 54, and a support plate 58. The turret module 24
also includes a housing 60 and a motor plate 62. Bearings are
included where needed. Preferably the gear mechanism includes a
worm 52 and a worm gear 56. Preferably the ultrasonic motor is a
ultrasonic rotary motor and is a combined ultrasonic motor and
optical encoder. By way of example a USR60-3EN or UST30-3EN
ultrasonic rotary motor may be used. By way of example, the static
torque rating of the worm gear 56 is 20 Nm. The cables (not shown),
for the motor 50 and encoder, are outside the turret module 24. In
the embodiment herein, the overall weight of the turret module is
about 0.25 kg. The worm 52 and worm gear 56 provide a self-locking
function. The self-locking function reduces the possibility of the
output driving the input. Preferably the range of motion of the
turret joint is -65 degrees to +65 degrees.
[0074] Elbow roll module 26, shown in FIG. 5, has a structure that
is somewhat similar to that of the turret module 24 described
above. The elbow roll module 26 includes an ultrasonic motor 70, an
encoder 71, a gear mechanism, a shaft 74, and a support plate 78.
The elbow roll module 26 also includes a housing 80 and a motor
plate 82. Bearings 84 are included where needed. Preferably, the
gear mechanism includes a worm r 72 and a worm gear 76 operably
connected to the shaft 74 to the ultrasonic motor 70. Preferably
the ultrasonic motor is a USR ultrasonic rotary motor and is a
combined ultrasonic motor and optical encoder. By way of example,
the static torque rating of the worm gear 72 is about 4 Nm.
Preferably the range of motion of the elbow roll joint is -70
degrees to +70 degrees.
[0075] The wrist tilt module 28, shown in FIGS. 6A and B, is built
with a symmetrical structure and includes a pair of ultrasonic
motors 90, a pair of encoders 91, a pair of gear mechanisms, a pair
of shafts 94, and a support plate 98. The wrist tilt module 28 also
includes a housing 100, two housing covers 102 and two motor plates
104. Bearings 106 are included where needed. Preferably the
ultrasonic motor is a USR ultrasonic rotary motor and is a combined
ultrasonic motor and optical encoder. Preferably, the gear
mechanism includes a worm 72 and a worm gear 96. Hard stop 105 and
hard stop 107 limit the rotation angle of the support plate 98
which are fixed to the shafts 94 and rotate with the shafts 94. A
hard stop 108 engages hard stop 173 on the roll connection unit 170
as shown in FIG. 12. Ultrasonic motors 90 work in parallel as the
driving mechanisms to get the required rotating and stalling
torque. By way of example, the static torque rating of the worm
gears is about 15.times.2 Nm. Preferably the range of motion of the
wrist tilt joint is -20 degrees to +20 degrees.
[0076] The penetration module 30, shown in FIG. 7, includes an
ultrasonic motor 120, an encoder 121, a force sensor 122, a lead
screw 124, a nut 126 and gears 128. In addition, the penetration
module 30 includes a pair of guide shafts 130, a swivel block 132
and a front support part 134. The swivel block 132 supports the
lead screw 124 and the other parts of the linear mechanism. The
swivel block 132 includes connection ribs 133 which are connected
to the support plate 98 of the wrist tilt module 28. As well the
penetration module 30 includes a housing 136 and motor plate 138.
Bearings 140 are included where needed. Preferably the ultrasonic
motor is a combined ultrasonic rotary motor and encoder. The nut
126 is adapted to be connectable to a surgical tool. In the
embodiment shown in FIG. 7 the nut 126 includes an adapter portion
142 adapted to receive a surgical tool. The adapter portion 142
includes a plurality of threaded holes 143. The motor 120 is
operably connected to a pair of gears 128, which are operably
connected to the lead screw 124. Thus when the motor 120 is
activated the gears 128 cause the lead screw 124 to rotate thus
causing the nut 126 to moves linearly along the lead screw 124. The
movement of the nut 126 produces thrust. By way of example the
force sensor 122 is a FlexiForce A201 force sensor. The force
sensor 122 is used to measure the penetration and drilling force.
The FlexiForce A201 sensor is an ultra-thin flexible printed
circuit that is integrated into the penetration module. The force
sensor 122 allows for haptic control of the surgical robot 12.
Preferably the range of motion of the penetration joint is 0-90
mm.
[0077] A turret and elbow connection unit 150 is shown in FIGS. 8
and 9. This unit connects the turret module 24 and elbow roll
module 26 and is a slewing bearing. FIGS. 29A and 29B show elbow
roll module 26 connected to turret and elbow connection unit 150.
Unit 150 includes a support plate 152 with a first slewing ring 154
on one side thereof and a second slewing ring 156 on the other side
thereof. A first hard stop 158 is attached on first slewing ring
154 and a second hard stop 160 is attached to the support plate
152. The support plate 152 is provided with plurality of apertures
162 and the turret module 24 is attached thereto. The first slewing
ring 154 is provided with a plurality of apertures 164 and the
elbow role module 26 is attached thereto. The slewing bearing uses
self-lubricating, low-friction sliding elements in place of ball
bearings. Preferably these are made from low-cost, high-performance
plastic called Iglide J.TM. material, which is designed to be
lubrication and maintenance-free. The support plate 152 is made of
PEEK (Polyetheretherketone) material. The turret and elbow
connection unit 150 is designed to be low profile, low weight,
lubrication-free and easy to install. Alternatively an alternate
elbow roll module 500 may combine the features of the elbow roll
module of FIG. 5 and the features of the turret and elbow
connection unit of FIGS. 8 and 9, as shown in FIG. 30.
[0078] The elbow roll module 26 and the wrist tilt module 28 are
connected with the roll connection unit 170 that is shown in FIGS.
10 and 11. The roll connection unit 170 consists of a support part
or housing 172, shaft 171, bearings 174 and a shaft ring 176. The
housing 172 includes a hard stop 173. The shaft ring 176 includes a
plurality of apertures 178 and the elbow module 26 is connected
thereto. The shaft 171 has a plurality of apertures 175 and the
wrist tilt module 28 is connected thereto as shown in FIG. 12.
Alternatively an alternate wrist tilt module 400 may combine the
features of wrist tilt module of FIG. 6 and the features of the
roll connection unit of FIGS. 10 and 11, as shown in FIG. 30.
[0079] The arch unit 16 is shown in FIG. 13. The arch unit 16
includes an arch frame 190 that is moveable along a pair of linear
actuators 192 connected at each end thereof. Each linear actuator
192 includes an ultrasonic motor 194, an encoder 195, a motor plate
196, collar 198 and a lead screw 200. Preferably the ultrasonic
motor 194 and encoder 195 are a combined ultrasonic rotary motor
and encoder. A pair of carriages 202 is moveably attached to the
lead screw 200 and integrally formed in the arch frame 190.
Bearings are included where needed. Each linear actuator 192 is
connected to a base plate 204 which is connectable to an MRI table
206 (shown). In the embodiment shown herein the base plate 204 has
a central ridge 208 extending downwardly from the centre thereof.
The ridge is adapted to engage a slot in the MRI table. A thumb
screw (not shown) may be used for locking the base plates 204 in
place. The arch 190 is provided with a cable connector plate 209.
(Note, the cables are not shown in the drawings so as to simplify
the drawings.) The linear actuators 192 control the position of the
arch frame 190 along the linear axis of the lead screws 200 or base
plates 204. Since the base plates 204 are attached to the MRI table
and the table 206 is insertable into the MRI, the motion of the
arch frame 190 along the lead screws 200 will be along the
longitudinal axis of the MRI scanner. Preferably, the stroke of the
linear motion is 0-100 mm, however, this can be varied depending on
the length of the MRI. The arch unit has two linear actuators that
work in parallel and they slide the arch unit 16 along the
longitudinal axis of the scanner.
[0080] In the embodiment shown in FIGS. 1 to 13, the surgical robot
12 is positioned along the arch unit 16 with a quick--connect
attachment and alignment pins. Quick connect attachments and
alignment pins 46 are located on the quick connect portion 44 of
the linear module 22 which provides for the connection of the
surgical robot 12 to the arch frame 190. The positioning on the
arch frame 190 and modules-based re-configurability of the surgical
robot 12 provide the means of finding optimal locations and poses
for specific surgical tasks.
[0081] Preferably the actuators or motors are ultrasonic motors
that are retentive. Preferably the gears are self-locking worm
mechanisms or non-back-drivable lead screws in order to lock the
joints of the surgical robot assembly 10 and the surgical tool into
position without brakes.
[0082] The hard stop 108 engages the hard stop 173 on roll
connection unit 170 and is used to stop the shaft 94 of the wrist
tilt module 28 rotating when the rotation joint reaches the hard
limit by absorbing the force of the impact. In addition hard stops
158 and 160 are provided on the turret and elbow connector unit
150. Since the hard stops are used, electronic sensors and their
cables need not be used to define the hard limit of the motors. The
linear motion module 22 uses the housing cover 32 and the plate
support 36 form the homing procedure described below. The advantage
of using a mechanical stop rather than electronic sensors is that
electronic sensors may distort the MR imaging and be affected by
the MR scanning. In use, when the motor is moving, a controller
keeps track of the encoder reading as a feedback of motor position.
If during a predetermined period of time, the encoder reading does
not change, it is deduced that the motor has hit the hard stop.
Then the controller will send a "stop" command to the motor to stop
the motion. Thereafter, only a motion command to the move in the
opposite direction will be accepted.
[0083] The homing mode is used to reset the encoder counter at each
boot up of the surgical robot assembly 10. More specifically, the
homing function is for determining the position of each joint after
power up. Without homing the controller will not know the current
position of each joint after power up. The homing procedure
includes the following steps: a) first move each joint in a known
direction at known speed and b) once the joint reaches homing
offset (a known location) the controller will then receive a signal
from the sensor. The homing offset is a known position and it is
the reference of home (zero) position of a joint. The homing offset
and homing speed are defined for each joint. The homing offset
allows setting the actual zero at a given distance from the hard
stop. For safety, a lower speed is imposed when approaching the
hard stop.
[0084] Preferably linear module 22, turret module 24, elbow roll
module 26, wrist module 28 and penetration module use worm gears as
their gears. The worm gears are high-ratio, non-back-drivable worm
mechanisms. By way of example the worm gear for the turret module
24 is a 20 ratio gear; for the elbow roll module 26 is a 18 gear
ratio; for the wrist tilt module 28 is a 24 gear ratio; and for the
linear module 22 is a 12.5 gear ratio, The worm gears provide good
load-carrying capabilities with relatively low-power actuators. By
way of example the turret module 24, the elbow roll module 26, the
wrist tilt module and the linear module 22 each have a 1.0 W
actuator. The worm gears provide a compact means of substantially
decreasing speed and increasing torque. Alternatively if spur gears
were used the surgical robot would be larger. Further the worm
gears are self-locking and are not back-drivable. When the lead
angle of the worm is smaller than the friction angle of the meshing
gear, worm mechanism generates the reverse self-locking. Thus, the
worm can drive the worm wheel, but the worm wheel cannot drive the
worm. The worm gear help to provide modules that are simpler and
smaller in volume.
[0085] An embodiment of the surgical tool module is shown in FIG.
14 at 210. The surgical tool module 210 includes an ultrasonic
motor 212, an encoder 213, a motor plate 214, a gear mechanism 226,
a timing belt and a pair of pulleys 216, and a lead screw 227.
Preferably the ultrasonic motor is an ultrasonic rotary motor and
includes an encoder and more specifically an optical encoder. The
surgical tool module 210 is for use with a drill kit 220.
Preferably the drill kit 220 includes a sterile serrated hollow
drill. The surgical tool module 210 includes a removable drill
support 222 for supporting the drill kit 220. Removable drill
support 222 is releasably connectable to slot plate 258. The
surgical tool module 210 also includes a support frame 224 and a
guide support 228. Guide support 228, best seen in FIGS. 14B and
14C includes a lead screw 227 with a nut 223. The lead screw can
linearly move up and down along the guide support 228 by using a
pin 229 that engages a slot on the lead screw 227. Bearings are
included where needed. The ultrasonic motor 212 is operably
connected to the timing belt and pulleys 216, which in turn are
operably connected to the drill kit 220 to rotate the drill. The
ultrasonic motor 212 is also operably connected to gears in the
gear box 226 which are operably connected to the lead screw 227
through pulley 216. The cables for the motor 212 and encoder 213
are outside the module (not shown). It should be noted that in this
embodiment the retracing mechanism and needle rotation are driven
by one ultrasonic motor.
[0086] An alternate embodiment of a surgical tool module 230 is
shown in FIG. 15. This embodiment is similar to that shown in FIG.
14 but rather than timing belt and pulleys it uses pneumatic
actuators. The surgical tool module 230 includes an ultrasonic
motor 232, an encoder 233, a motor plate 234, a timing belt and a
pair of pulleys 235, 236, and a pneumatic unit 238. Preferably the
ultrasonic motor includes an encoder and more specifically an
optical encoder. The surgical tool module 230 is also for use with
a drill kit 220. The surgical tool module 230 includes a combined
drill support and plate 231 for supporting the drill kit 220.
Bearings are included where needed. The ultrasonic motor 232 is
operably connected to the timing belt and pulleys 235,236, which in
turn are operably connected to the pneumatic unit 238 and the drill
kit 220 to rotate the drill. Thereby the ultrasonic motor 232 is
also operably connected to pneumatic unit 238. The pneumatic unit
238 is used for driving the trocar locking and retracting
mechanism.
[0087] The pneumatic actuator 238 is MR compatible. The pneumatic
actuator 238 has a piston 237 which is connectable to the drill kit
220. Pulley 235 has a slot that is incorporated with the end of
serrated hollow drill 252 of the drill kit 220 for the drill
rotating. The guide stylet 254 of the drill kit 220 can be locked
with a small air actuator 239. The pneumatic actuator 238 can lock
the position of the piston 237 or move the position and thus the
position of the drill kit is similarly lockable or moveable. This
is actuated pneumatically with compressed air and vacuum. Thus with
the use of the pneumatic actuator 238 the movement of the drill kit
220 as described below in reference to FIG. 20 can be achieved. As
is well understood by those skilled in the art, in order to provide
such control the pneumatic unit 238 may include single or double
acting cylinders. The pneumatic cylinders could be actuated with
compressed air and/or vacuum. They could operate by simple ON-OFF
type control. Because the operating fluid is air, leakage from a
pneumatic cylinder will not contaminate the surroundings.
[0088] Referring to FIGS. 16 and 17, preferably the drill kit 220
includes a trocar 250, serrated hollow drill 252 and a guide stylet
254. Referring to FIGS. 18 and 19 the surgical tool 210 is shown
with penetration module 30. Penetration module is similar to that
shown in FIG. 7 but it includes an alternate adapter 260 as part of
nut 126. Adapter 260 includes a nut portion 262, a removable front
adapter portion 264 and a removable front closure portion 266. The
removable front adapter portion 264 is connectable to the nut
portion 262 and the removable front closure portion is connectable
to the removable front adapter portion 264. The front adapter
portion 264 is for guiding the drill kit 220 of the surgical tool
210, and the front closure portion 266 is for locking the surgical
tool 210. In the embodiment shown in FIGS. 18 and 19 a front
guiding part 268 is also included for guiding the drill kit 220
while sampling. In use, the drill kit 220 (trocar 250, serrated
hollow drill 252 and guide stylet 254), removable front adapter
portion 264, removable drill support 222, removable front closure
portion and removable front guiding part 268 are sterilized prior
to use. Then each item is installed or re-installed in their
respective module. Preferably the range of motion of the trocar
retracting stroke is 0-25 mm.
[0089] Referring to FIG. 17, following is the procedure for
inserting the drill kit into the surgical tool module of FIG. 14:
[0090] 1. Insert (P.sub.1) trocar 250 with end thread into surgical
tool module 210 and rotate it (R.sub.1) a few turns; [0091] 2.
Insert serrated hollow drill 252 into guide stylet 254, and push
(P.sub.2) them into the surgical tool module 210; and [0092] 3.
Push (P.sub.3) drill support 222 into the slot plate 258
[0093] Once the surgical tool 210 is assembled or reassembled after
sterilizing certain element it is then inserted in to the
penetration module 30 as shown in FIG. 19 and as described
following: [0094] 1. Push (P.sub.1) front adapter portion 264 into
the adapter nut portion 262; [0095] 2. Slide front guiding part 268
to stylet 254 of drill kit 220 (P.sub.2 and P.sub.3); [0096] 3.
Push (P.sub.4) surgical tool 210 with front guiding part 268 into
penetration module 30 (adapter 260 and front support part 134); and
[0097] 4. Push (P.sub.5) closure 266 into the adapter 260.
[0098] The surgical tool 210 described above is particularly useful
for automatic sampling. The protocol for automatic sampling is
similar to the current manual procedure. Referring to FIG. 20, the
drill kit 220 may be known as a bone biopsy tooling manifold. As
described above, the drill kit 220 includes a trocar 250, a sterile
serrated hollow drill 252 and a stationary (outer) sheath or guide
stylet 254. The stationary (outer) sheath or guide stylet 254 would
allow the serrated hollow drill to continue to spin while the
centre needle is used to make the puncture. The protocol is as
follows: [0099] 1. Penetrating (without rotating) the trocar 250,
serrated hollow drill 252 and guide stylet 254 to cortical bone
(linear motions). The pointed trocar 250 is inserted into the
serrated hollow drill 252, and they are inserted into guide stylet
254, and then inserted into the incision until the trocar tip comes
in contact with the bone. The tip of the trocar could be moved from
side to side to free adhering structures from the bony surface. The
drill kit is then pushed until guide stylet 254 rests firmly on the
bony surface (FIG. 20 (a)). [0100] 2. Holding the guide style 254
in place, then retracting the trocar 250 back about 20 mm or more
(linear motion) (FIG. 20 (b)). [0101] 3. Holding the guide stylet
254 in place, advancing (by rotating) the serrated hollow drill 252
to the target for sampling (linear and rotary motions) (FIG. 20
(c)). [0102] 4. Once the serrated hollow drill has been felt to
pass completely through the bone, the pushing is stopped, and the
serrated hollow drill is rotated through two complete revolutions.
This step would ensure that the medial surface of the specimen is
free from its periosteal attachments. [0103] 5. Then pull back out
the drill kit (not shown) such that the drill kit is pulled out of
the bone and skin.
[0104] Referring to FIGS. 21 and 22 the surgical robot assembly 10
is shown in situ in an MRI 270. The surgical robot assembly 10 is
shown attached to an MRI table 206. By way of example in FIG. 22
the surgical robot assembly is shown how it may be positioned
around the legs of a person 272.
[0105] An alternate embodiment of the surgical robot assembly 300
is shown in FIGS. 24A and 24B. Surgical robot assembly 300 is
similar to surgical robot assembly 10 but it includes an alternate
arch device unit 302 shown in FIG. 23. Arch device unit 302
includes an arch frame 304 with a rail 306 fixedly mounted on the
inner side of the arch frame 304. The remainder of the arch device
unit 302 is the same as described above with regard to arch unit
16. The surgical robot 308 is similar to that described above
except that its attachment device 310 is adapted to engage rail
306. Surgical robot 308 can be movably attached to the rail 306 of
the arch device unit 302 through a mounting mechanism 310 that is a
part of the Quick/Simple Connect Attachment.
[0106] Once the surgical robot 308 is attached to the rail 306 its
trajectory is constrained by the rail. The robot can move along the
rail to any position, either manually or driven by an arch
ultrasonic motor unit 312. Preferably ultrasonic motor unit 312,
includes a USR.TM. ultrasonic motor with encoder and a gear
mechanism. Ultrasonic motor unit 312 is part of attachment device
310 and operably attached to surgical robot 308. The attachment
device 310 engages the rail 306 and thus surgical robot 308 can
move along the arch device unit 302.
[0107] When the robot reaches a defined position on the rail, it
can be locked onto it by a locking mechanism. The position of the
robot on the rail can be measured by sensors. The measurement is
fed to the robot system for registration and kinematics
calculations.
[0108] It will be appreciated by those skilled in the art that the
surgical robot 12 is a modular reconfigurable robot and can be
reconfigured to suit different types of surgery, as shown in FIGS.
27 and 28. In the embodiment shown in FIGS. 27A and 27B, linear
module 22 is connected to turret module 24, which is connected to
elbow roll module 26, a wrist tilt module 28, a penetration module
30 and a surgical tool module 14. The turret module 24 and the
elbow roll module 26 are connected with a turret and elbow
connection unit 150. The elbow roll module 26 and the wrist tilt
module 28 are connected with the roll connection unit 170. The
orientation of turret module 24 and elbow roll module 26 is
different than that shown in FIGS. 1 to 26 so that the surgical
robot may be used for a different application.
[0109] Similarly, in the embodiment shown in FIGS. 28A and 28B,
turret module 24 is connected to elbow roll module 26, a wrist tilt
module 28, a penetration module 30 and a surgical tool module 14.
In addition a quick connector 180 may be provided. Quick connector
module 180 is attached to the turret module 24. The turret module
24 and the elbow roll module 26 are connected with a turret and
elbow connection unit 150. The elbow roll module 26 and the wrist
tilt module 28 are connected with the roll connection unit 170. The
orientation of wrist tilt module 28 is different than that shown in
FIGS. 1 to 26 and 27 so that the surgical robot may be used for a
different application. In addition the orientation of the surgical
tool module 14 is different and is generally horizontal in this
configuration.
[0110] It will be appreciated by those skilled in the art that the
modules of the surgical robot described herein may be modified. For
example the main modules such as the linear module, the turret
module, the elbow wrist tilt module, may be modified to include
connection features such that the module can then be connected
directly to another module. An example of this is shown in FIG. 30
wherein the elbow roll module 500 and the wrist tilt module 400
each include connection features.
[0111] It will be appreciated by those skilled in the art that the
surgical robot may have a plurality of coordinate systems that are
relevant to the operation thereof. For example the surgical robot
assembly 10 has an inertial or fixed frame coordinate system 11 as
shown in FIG. 1. This coordinate system has a z axis in the
direction of travel of the pair of rails 20 of the arch unit 16. In
addition there may be a surgical robot 12 coordinate system 13 as
shown in FIG. 2 wherein the linear module defines a z axis: the
turret module has rotational movement in an axis parallel to the z
axis; the elbow roll module has rotational movement around an x
axis and the x axis is generally orthogonal to the z axis; and the
wrist tilt module has rotational movement around a y axis and the y
axis is generally orthogonal to the z axis and transverse to the x
axis. It will be appreciated by those skilled in the art that the
inertial frame coordinate system 11 is fixed while the surgical
robot coordinate system travels as the robot travels.
[0112] In general, the systems described herein are directed to
medical robots for use in an MRI. Various embodiments and aspects
of the disclosure will be described with reference to details
discussed below. The following description and drawings are
illustrative of the disclosure and are not to be construed as
limiting the disclosure. Numerous specific details are described to
provide a thorough understanding of various embodiments of the
present disclosure. However, in certain instances, well-known or
conventional details are not described in order to provide a
concise discussion of embodiments of the present disclosure.
[0113] As used herein, the terms, "comprises" and "comprising" are
to be construed as being inclusive and open ended, and not
exclusive. Specifically, when used in the specification and claims,
the terms, "comprises" and "comprising" and variations thereof mean
the specified features, steps or components are included. These
terms are not to be interpreted to exclude the presence of other
features, steps or components.
[0114] As used herein, the term "exemplary" means "serving as an
example, instance, or illustration," and should not be construed as
preferred or advantageous over other configurations disclosed
herein.
[0115] As used herein, the terms "about" and "approximately" are
meant to cover variations that may exist in the upper and lower
limits of the ranges of values, such as variations in properties,
parameters, and dimensions. In one non-limiting example, the terms
"about" and "approximately" mean plus or minus 10 percent or
less.
[0116] As used herein, the term "substantially" refers to the
complete or nearly complete extent or degree of an action,
characteristic, property, state, structure, item, or result. For
example, an object that is "substantially" enclosed would mean that
the object is either completely enclosed or nearly completely
enclosed. The exact allowable degree of deviation from absolute
completeness may in some cases depend on the specific context.
However, generally speaking the nearness of completion will be so
as to have the same overall result as if absolute and total
completion were obtained. The use of "substantially" is equally
applicable when used in a negative connotation to refer to the
complete or near complete lack of an action, characteristic,
property, state, structure, item, or result.
* * * * *