Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of robotic surgical systems and, more particularly, to a surgical calibration assembly and a method for calibrating a surgical instrument.
BACKGROUND
[0002] Robotic surgical systems have revolutionized modern surgical procedures by enabling minimally invasive approaches with enhanced precision and control. The robotic surgical systems typically employ sophisticated robotic arms that manipulate specialized surgical instruments through small incisions in the patient's body. The success of such procedures heavily relies on the precise control and positioning of these surgical instruments, which must operate with exceptional accuracy within confined anatomical spaces.
[0003] Current robotic surgical systems utilize sterile adapters as interfaces between the surgical instruments and drive systems. The sterile adapters maintain sterility while enabling mechanical power transmission across multiple axes of motion. However, the mechanical coupling between instruments and adapters introduces various challenges that affect system accuracy. Manufacturing variations, assembly tolerances, and mechanical wear may create inconsistencies in instrument positioning. Additionally, the complex drive trains necessary for multi-axis motion inherently introduce mechanical backlash, which may compromise the precision of surgical movements. Existing calibration approaches often rely on basic initialization routines or manual procedures that may not adequately address the systemic variations. Furthermore, current methods typically lack real-time monitoring capabilities and cannot dynamically adjust for changes in mechanical behaviour during surgical procedures.
[0004] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks of existing surgical instrument calibration systems and methods.
SUMMARY
[0005] The present disclosure provides a surgical calibration assembly and a method for calibrating a surgical instrument. The present disclosure provides a solution to the technical problem of how to achieve precise calibration and backlash compensation in multi-axis surgical instruments while maintaining accurate positional control during surgical procedures. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art by providing an automated calibration method and an improved surgical calibration assembly that utilizes physical stops and real-time monitoring of position, torque, and force to determine precise positional offsets for each axis of motion.
[0006] One or more objectives of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
[0007] In one aspect, the present disclosure provides a method for calibrating a surgical instrument, comprising:
mounting the surgical instrument on a sterile adapter removably connected to a drive system, wherein the surgical instrument is configured to operate in a plurality of axes;
identifying one or more physical stops associated with the surgical instrument that define limits for each axis of the plurality of axes;
monitoring position, torque, and force in real time while moving the surgical instrument along each axis to detect contact with the one or more physical stops;
determining engagement of the surgical instrument with the one or more physical stops by analysing positional changes of actuators by detecting a cessation of movement or a mechanical resistance greater than a threshold indicating contact with the physical stops;
calculating a positional offset for each axis based on the detected contact with the one or more physical stops; and
calibrating the surgical instrument by applying the calculated offset to movement commands provided to the surgical instrument to compensate for backlash of the surgical instrument.
[0008] The mounting of the surgical instrument on a removably connected sterile adapter enables quick instrument changes while maintaining sterility during surgical procedures. Thus, eliminating the need for complex permanent mounting mechanisms and reducing setup time. Furthermore, the use of physical stops to define limits for each axis provides a reliable, mechanical-based calibration reference that is independent of electronic sensors, thereby reducing calibration errors and improving repeatability. The mechanical approach demonstrates superior robustness against environmental factors and wear compared to traditional electronic limit switches.
[0009] The simultaneous real-time monitoring of multiple parameters, including position, torque, and force, while moving the instrument enables the detection of true mechanical limits rather than estimated positions. The comprehensive monitoring prevents damage to the instrument by identifying mechanical resistance before component failure, ensures accurate calibration across different operating conditions and wear states, and allows for dynamic adjustment during the calibration process.
[0010] Additionally, the approach for determining physical stop engagement through cessation of movement and/or mechanical resistance threshold provides reliability in stop detection. The approach enables discrimination between true mechanical limits and temporary obstructions and ensures precise calibration points for each axis.
[0011] The calculation of axis-specific positional offsets based on detected contact points enables individual compensation for manufacturing variations in each axis while adapting to wear-related changes in mechanical limits. This results in optimized performance across the full range of motion for each axis of the surgical instrument.
[0012] Moreover, the application of calculated offsets to movement commands provides real-time backlash compensation during surgical procedures, improving positioning accuracy without manual adjustment. The automated compensation ensures consistent performance across different surgical instruments while automatically adapting to instrument-specific mechanical characteristics.
[0013] The holistic approach of combining physical stop detection, multi-parameter monitoring, and automated offset calculation significantly improves the accuracy and reliability of surgical procedures while reducing setup time and maintenance requirements. The comprehensive calibration method demonstrates marked improvements in both precision and efficiency compared to existing calibration approaches.
[0014] In an implementation, the detecting of the cessation of movement of the surgical instrument with the one or more physical stops comprises monitoring a difference between a target position and an actual position. In such implementations, continuous comparison of target position to actual position identifies microscopic discrepancies indicating mechanical resistance, allowing for more accurate calibration even when force sensors might be less reliable due to varying tissue interactions or instrument wear.
[0015] In another implementation, the detecting of the cessation of movement of the surgical instrument with the one or more physical stops comprises simultaneously measuring the actual torque and force applied to each axis. In such implementations, correlation of both torque and force measurements across all axes differentiates between legitimate physical stop engagement and false positives caused by temporary resistance, tissue interaction, or mechanical anomalies, resulting in more robust calibration in challenging surgical environments.
[0016] In yet another implementation, calculating of the positional offset comprises rotating each axis to a first mechanical limit; storing a first position value; rotating each axis to a second mechanical limit in an opposite direction; storing a second position value; computing a difference between the first and second position values; and computing a second difference between the first difference and a predefined value. In such implementations, recording position values at both mechanical limits and computing differences against predefined values identifies nonlinearities and asymmetries in mechanical response, enabling more precise calibration that accounts for the unique mechanical properties of each instrument.
[0017] In yet another implementation, movement commands are generated from a predefined set of rules, the rules comprising: a predetermined surgical procedure protocol; motion sequences specific to a surgical instrument type; and predefined spatial and angular movement constraints. In such implementations, predetermined surgical procedure protocols, instrument-specific motion sequences, and movement constraints ensure consistent and repeatable calibration performance while maintaining safety boundaries for different surgical applications and anatomical regions.
[0018] In yet another implementation, the movement commands are input by a surgeon, comprising real-time manual trajectory specification; dynamic adjustment of instrument movement during a surgical procedure; and interactive input through a surgical control interface. In such implementations, real-time trajectory specification, dynamic adjustment during procedures, and interactive control through the surgical interface accommodate surgeon preferences while responding to patient-specific anatomical variations that standardized approaches might not adequately address.
[0019] In yet another implementation, the offset compensates for variances in tolerances, backlash, alignment, assembly, or manufacturing discrepancies. In such implementations, compensation for manufacturing tolerances, mechanical backlash, alignment issues, and assembly variations ensures consistent and precise operation regardless of the unique mechanical characteristics of individual instruments, extending the usable lifespan of surgical instruments despite wear or minor manufacturing inconsistencies.
[0020] In another aspect, the present disclosure provides a surgical calibration assembly comprises:
a surgical instrument configured to operate in a plurality of axes;
a sterile adapter removably connected to the surgical instrument and a drive system, wherein the sterile adapter comprises one or more physical stops associated with the surgical instrument and configured to define limits for each axis of the plurality of axes; and
a controller operatively connected to the drive system and configured to:
monitor position, torque, and force in real time while moving the surgical instrument along each axis to detect contact with the one or more physical stops;
determine engagement of the surgical instrument with the one or more physical stops by analysing positional changes of actuators by detecting a cessation of movement or a mechanical resistance greater than a threshold indicating contact with the physical stops;
calculate a positional offset based on the detected contact with the one or more physical stops; and
calibrate the surgical instrument by applying the calculated offset to movement commands provided to the surgical instrument to compensate for backlash of the surgical instrument.
[0021] The surgical calibration assembly achieves all the advantages and technical effects of the method of the present disclosure.
[0022] In an implementation, the sterile adapter comprises a plurality of discs configured to engage with the surgical instrument. In such implementations, multiple engagement discs create redundant connection points that distribute mechanical forces evenly, reducing wear at any single contact point while providing stable and reliable power transmission across all axes of movement.
[0023] In another implementation, the sterile adapter is configured in a pre-calibrated home condition, comprising: a predetermined geometric configuration of the plurality of discs, wherein each disc is positioned at a predefined spatial coordinate, and wherein the pre-calibrated home condition is indicative of a predefined alignment for quick coupling of the surgical instrument. In such implementations, positioning each disc at predefined spatial coordinates in a predetermined geometric configuration enables quick coupling with minimal alignment effort, reducing setup time and ensuring proper initial positioning before the calibration procedure begins.
[0024] In yet another implementation, the plurality of discs of the sterile adapter is constrained to a predefined position range, including: a spatially bounded mounting zone, geometric tolerances defining acceptable disc positioning, and a deviation envelope from the predefined alignment. In such implementations, establishing a spatially bounded mounting zone with defined geometric tolerances and a permissible deviation envelope allows for manufacturing flexibility while ensuring disc positioning remains within functional parameters for proper engagement and calibration.
[0025] In yet another implementation, in order to detect the cessation of movement of the surgical instrument with the one or more physical stops, the controller is further configured to monitor a difference between a target position and an actual position. In such implementations, continuous monitoring of the difference between target and actual positions autonomously identifies when mechanical limits have been reached without additional input, allowing for automated calibration cycles that maintain precise positional awareness throughout the procedure.
[0026] In yet another implementation, in order to detect the cessation of movement of the surgical instrument with the one or more physical stops, the controller is further configured to simultaneously measure the actual torque and force applied to each axis. In such implementations, processing both torque and force data across all axes simultaneously implements advanced algorithms that distinguish between various types of mechanical resistance, improving stop detection accuracy and calibration precision in complex surgical environments.
[0027] In yet another implementation, in order to calculate the positional offset based on the detected contact with the one or more physical stops, the processor is further configured to: rotate each axis to a first mechanical limit; store a first position value; rotate each axis to a second mechanical limit in an opposite direction; store a second position value; compute a first difference between the first and second position values; and compute a second difference between the first difference and a predefined value. In such implementations, rotating each axis to both mechanical limits, storing position values, and performing sequential difference calculations establishes a complete mechanical profile of the instrument, enabling precise compensation for unique characteristics of each axis and instrument.
[0028] In yet another implementation, the movement commands are generated from a predefined set of rules, the rules comprising: a predetermined surgical procedure protocol; motion sequences specific to a surgical instrument type; and predefined spatial and angular movement constraints. In such implementations, incorporation of predetermined surgical protocols, instrument-specific motion sequences, and movement constraints generates appropriate calibration commands tailored to specific surgical contexts, enhancing both safety and procedural consistency.
[0029] In yet another implementation, the movement commands are input by a surgeon, comprising real-time manual trajectory specification; dynamic adjustment of instrument movement during a surgical procedure; and interactive input through a surgical control interface. In such implementations, enabling surgeons to provide real-time trajectory specifications, make dynamic adjustments during procedures, and interact through a dedicated surgical control interface supports seamless integration of expert judgment with automated calibration procedures, enhancing overall system flexibility and responsiveness.
[0030] It is to be appreciated that all the aforementioned implementation forms can be combined.
[0031] It has to be noted that all devices, elements, circuitry, units and means described in the present application could be implemented in the software or hardware elements or any kind of combination thereof. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. Even if, in the following description of specific embodiments, a specific functionality or step to be performed by external entities is not reflected in the description of a specific detailed element of that entity which performs that specific step or functionality, it should be clear for a skilled person that these methods and functionalities can be implemented in respective software or hardware elements, or any kind of combination thereof. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
[0032] Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
[0034] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a diagram illustrating a robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 2 is a diagram illustrating an exemplary surgical instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 3 is a diagram illustrating an exploded view of a surgical calibration assembly of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 4A is a diagram illustrating an isometric view of a portion of the surgical calibration assembly corresponding to the exemplary surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 4B is a diagram illustrating an isometric view of a portion of the surgical calibration assembly corresponding to an exemplary sterile adaptor for the exemplary surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 5A is a diagram illustrating a front view of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 5B is a diagram illustrating a front view of the exemplary sterile adapter, in accordance with an embodiment of the present disclosure;
FIG. 6 is a diagram illustrating a front view of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 7 is a diagram illustrating a front view of an instrument cover of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 8 is a diagram illustrating a front view of gears of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 9 is a diagram illustrating an exemplary graphical representation between torque and time for detecting physical stops, in accordance with an embodiment of the present disclosure;
FIG. 10 is a diagram illustrating an exemplary graphical representation between position and time for detecting physical stops, in accordance with an embodiment of the present disclosure;
FIG. 11A is a diagram illustrating a distal end of the exemplary surgical instrument before calibration, in accordance with an embodiment of the present disclosure;
FIG. 11B is a diagram illustrating jaws of the exemplary surgical instrument in an open configuration, in accordance with an embodiment of the present disclosure;
FIGs. 11C-11D are diagrams illustrating the jaws of the exemplary surgical instrument in a closed configuration, in accordance with an embodiment of the present disclosure;
FIG. 11E is a diagram illustrating the distal end of the exemplary surgical instrument after calibration, in accordance with an embodiment of the present disclosure; and
FIG. 12 is a flowchart illustrating a method for calibrating a surgical instrument, in accordance with an embodiment of the present disclosure.
[0035] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[0036] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[0037] FIG. 1 is a diagram illustrating a robotic surgical system, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown a robotic surgical system 100 including a patient-side cart 110, a vision cart 120, and a surgeon console 130.
[0038] The patient-side cart 110 is a mobile unit having a base mounted on wheels. The base includes locking mechanisms for securing the patient-side cart 110 in position. The patient-side cart 110 includes a vertical column extending upward from the base. The vertical column comprises a linear actuator enabling height adjustment. The patient-side cart 110 includes multiple robotic arms that extend from the vertical column. In some implementations, the multiple robotic arms include four robotic arms in which three robotic arms 112 are configured for surgical instrument manipulation and one robotic arm 113 is configured for endoscopic imaging. The robotic arms 112 include primary segments, secondary segments, and tertiary segments connected by rotational joints. The rotational joints contain servo motors enabling precise angular positioning. The robotic arms 112 include surgical instrument holders 114 at distal ends. The surgical instrument holders 114 comprise mechanical interfaces and electrical connectors. The mechanical interfaces include spring-loaded clamps for instrument attachment. The electrical connectors transmit power and signals to mounted instruments. The patient-side cart 110 further includes at least one surgical instrument 140 mounted to the surgical instrument holders 114 at one of the robotic arms 112. The surgical instrument includes elongated shafts with end effectors at distal tips. The end effectors include articulation mechanisms enabling pitch and yaw movements. The surgical instrument 140 includes internal drive cables connecting to motor units in the instrument holders. The drive cables actuate the end effector movements. The robotic arm 113 supports an endoscopic imaging system. Each of the robotic arms 112 includes additional degrees of freedom for camera positioning. The endoscopic imaging system includes dual high-definition camera sensors mounted at a distal end of the robotic arm 113. The dual camera sensors enable stereoscopic image capture. The endoscopic imaging system includes fibre optic light transmission bundles surrounding the camera sensors for illuminating the surgical field. The endoscopic imaging system enables both white light imaging and near-infrared fluorescence visualization. The endoscopic imaging system comprises glass rod lenses for controlling chromatic aberration and enhancing image quality.
[0039] The vision cart 120 is a mobile unit comprising a base with wheels and a vertical housing. The base contains power supply units and cooling systems. The vertical housing contains processing units and displays. The vertical housing includes ventilation channels for thermal management. The vision cart 120 includes a primary display 122 mounted at an upper portion of the vertical housing, wherein the primary display 122 comprises a high-definition LCD monitor with anti-glare coating. The vision cart 120 includes an electrosurgical unit (ESU) 124 mounted within the vertical housing. The vision cart 120 further includes endoscope light sources. The endoscope light sources comprise one or two light source units mounted within the vertical housing. The vision cart 120 includes an insufflator unit mounted within the vertical housing for creating and maintaining pneumoperitoneum. The vision cart 120 includes an uninterruptible power supply (UPS) system mounted within the base for providing backup power. The vision cart 120 further includes a video processing unit and a central processing unit within the vertical housing. The video processing unit includes dedicated graphics processors. The central processing unit comprises multiple processing cores. The vision cart 120 further includes data storage devices mounted within the vertical housing. In some implementations, the vision cart 120 comprises image enhancement processors for contrast adjustment and noise reduction. In some implementations, the vision cart 120 includes fluorescence imaging processors for tissue identification. In some implementations, the vision cart 120 includes augmented reality processors for data overlay generation.
[0040] The surgeon console 130 includes a base structure supporting an operator seat and control interfaces. The base structure includes levelling mechanisms for stable positioning. The operator seat comprises height adjustment mechanisms and lumbar support systems. A display housing extends upward and forward from the base structure. The display housing contains a stereoscopic display system 134. The stereoscopic display system 134 includes dual display panels and optical elements. The optical elements include focusing mechanisms and eye tracking sensors. The surgeon console 130 further includes master control manipulators 132 mounted on sides of the base structure in front of the operator seat. The master control manipulators 132 include primary arms, secondary arms, and tertiary arms connected by joints. The joints include force feedback actuators and position sensors. The master control manipulators 132 terminate in ergonomic hand grips. The hand grips contain pressure sensors and multi-function triggers. In some implementations, the surgeon console 130 further includes foot pedals mounted on a lower portion of the base structure. The foot pedals 136 include position sensors and tactile feedback mechanisms. A user interface comprising touchscreens mounts on the base structure between the master control manipulators 132. The touchscreens display system status information and configuration controls.
[0041] The patient-side cart 110, the vision cart 120, and the surgeon console 130 connect through a communication network. The communication network comprises fibre optic cables for high-speed data transmission. The communication network includes redundant data pathways. The communication network transmits control signals from the master control manipulators 132 to the robotic arms 112. The control signals include position commands and gripper actuation commands. In some implementations, the communication network transmits imaging data from the endoscopic imaging system to the stereoscopic display system 134. The imaging data includes calibration parameters and camera position data. The robotic surgical system 100 includes monitoring systems connected to the communication network. The monitoring systems comprise voltage sensors, current sensors, temperature sensors, and position sensors.
[0042] In some implementations, the robotic surgical system 100 includes emergency stop mechanisms mounted on each component. The emergency stop mechanisms include physical switches and software-triggered stops. The robotic surgical system 100 includes power backup systems within each component. The power backup systems include batteries and uninterruptible power supplies. The robotic surgical system 100 includes fault detection processors within the vision cart 120. The fault detection processors monitor system parameters and component status.
[0043] In some implementations, the robotic surgical system 100 executes autonomous and semi-autonomous functions. In some implementations, the robotic surgical system 100 enables system upgrades through modular component replacement. The modular component replacement includes instrument interface upgrades and processing unit upgrades.
[0044] The robotic surgical system 100 enables minimally invasive surgical procedures. Exemplary surgical procedures may include, but not limited to, general surgery procedures, gynaecological procedures, urological procedures, cardiothoracic procedures, and otolaryngological procedures.
[0045] FIG. 2 is a diagram illustrating an exemplary surgical instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure. FIG. 2 is described in conjunction with the elements of FIG. 1. With reference to FIG. 2, there is shown the surgical instrument 140 for use with the robotic surgical system 100 described in FIG. 1. The surgical instrument 140 comprises a proximal housing 200 and a distal end effector 210 connected by an elongated shaft 220. The proximal housing 200 includes a generally rectangular configuration with rounded edges for ergonomic handling. The proximal housing 200 comprises a top surface 230 having access apertures. The proximal housing 200 further includes side panels 232 with mounting fixtures positioned for secure attachment to instrument holders on the robotic arms 112. The proximal housing 200 contains internal drive mechanisms for actuating the distal end effector 210. In some implementations, the proximal housing 200 includes electronic components for receiving control signals from the robotic surgical system 100.
[0046] The proximal housing 200 comprises a circular coupling interface 234 located on a front face. The circular coupling interface 234 includes mechanical registration features ensuring precise alignment during instrument mounting. The circular coupling interface 234 contains electrical contact arrays enabling signal transmission between the surgical instrument 140 and the robotic arm 112.
[0047] The elongated shaft 220 extends from the circular coupling interface 234 of the proximal housing 200. The elongated shaft 220 comprises a rigid cylindrical structure having a substantially uniform diameter. The elongated shaft 220 includes an outer sheath fabricated from biocompatible materials. The elongated shaft 220 contains internal drive cables, electrical wiring, and mechanical linkages for transmitting forces and signals from the proximal housing 200 to the distal end effector 210. In some implementations, the elongated shaft 220 includes articulation segments enabling angular positioning of the distal end effector 210.
[0048] The distal end effector 210 mounts to a distal end of the elongated shaft 220. The distal end effector 210 comprises a wrist mechanism 250 providing additional degrees of freedom. The wrist mechanism 250 includes articulation joints enabling pitch and yaw movements of grasping jaws 252. The wrist mechanism 250 contains gearing assemblies for converting linear actuation into rotational movement. The grasping jaws 252 include opposed members with tissue-interfacing surfaces. The tissue-interfacing surfaces comprise grip-enhancing textures for secure tissue manipulation. In some implementations, the grasping jaws 252 include integrated sensors for force feedback. In some implementations, the grasping jaws 252 incorporate electrosurgical elements for tissue coagulation.
[0049] The surgical instrument 140 includes mechanical registration features ensuring proper orientation when mounted to the robotic arm 112. The surgical instrument 140 comprises sealing elements preventing fluid ingress during surgical procedures. The surgical instrument 140 includes sterilization-compatible materials enabling repeated reprocessing cycles.
[0050] In some implementations, the surgical instrument 140 comprises specialized end effectors for specific surgical tasks including tissue cutting, needle driving, clip application, and suturing. In some implementations, the surgical instrument 140 includes integrated cameras for additional visualization capabilities. The surgical instrument 140 operates under control of the surgeon console 130 via the robotic arm 112 to enable precise tissue manipulation during minimally invasive surgical procedures.
[0051] FIG. 3 is a diagram illustrating an exploded view of a surgical calibration assembly of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure. With reference to FIG. 3, there is shown an exploded view of a surgical calibration assembly 300, which includes a portion of the surgical instrument 140 (connected to the surgical instrument holders 114 of FIG. 1) and a sterile adapter 302. The surgical instrument 140 is configured to be removably coupled to the sterile adapter 302 through a plurality of engagement interfaces. The sterile adapter 302 acts as an intermediary connection mechanism between the surgical instrument 140 and a drive system 304, facilitating sterile operation while enabling precise motion control and power transmission. The sterile adapter 302 includes specialized coupling mechanisms that maintain a sterile barrier while allowing mechanical power transmission between the drive system 304 and the surgical instrument 140. The drive system 304 refers to a main motorized system that powers the surgical instrument 140 connected to the sterile adapter 302. In some implementations, the drive system 304 refers to a system or mechanism that provides the power and control required to operate the surgical instrument 140, typically involving components such as motors, controllers, and transmission elements, often integrated with processors and memory for precise control and automation.
[0052] FIG. 4A is a diagram illustrating an isometric view of a portion of the surgical calibration assembly corresponding to the exemplary surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 4A is described in conjunction with the elements of FIGs. 1 to 3. With reference to FIG. 4A, there is shown the surgical instrument 140 of the surgical calibration assembly 300 of FIG. 3. The surgical instrument 140 includes an elongated shaft 402 with a proximal end 404 and a distal end (not shown in FIG. 4A). At the proximal end 404, an instrument housing 408 contains drive transmission components. The distal end 406 includes an end effector (shown in FIG. 2 with articulating components for surgical manipulation. The instrument housing 408 includes mounting interfaces 410 configured for secure attachment to the sterile adapter 302.
[0053] FIG. 4B is a diagram illustrating an isometric view of a portion of the surgical calibration assembly corresponding to an exemplary sterile adaptor for the exemplary surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 4B is described in conjunction with the elements of FIGs. 1 to 4A. With reference to FIG. 4B, there is shown a sterile adapter 302. The sterile adapter 302 includes a housing structure 420 with a drive interface 422 on one side for connection to the drive system and an instrument interface 424 on the opposite side for engaging with the surgical instrument 140 (shown in FIG. 2). in some implementations, the housing structure 420 includes alignment features and locking mechanisms that ensure precise positioning and secure attachment of the surgical instrument 140.
[0054] FIG. 5A is a diagram illustrating a front view of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 5A is described in conjunction with the elements of FIGs. 1 to 4B. With reference to FIG. 5A, there is shown the front view of the surgical instrument 140, showing four corresponding instrument discs 502, 504, 506, and 508 that are configured to align with discs of the sterile adapter 302. Each instrument disc includes alignment features that mate precisely with corresponding features on the discs of the sterile adapter 302 (as shown in FIG. 3). The proper alignment of the corresponding instrument discs 502, 504, 506, and 508 is for accurate power transmission and motion control. When correctly aligned, notches on each of the corresponding instrument discs 502, 504, 506, and 508 align with corresponding protrusions on the discs of the sterile adapter 302, establishing a precise mechanical coupling. In some implementations, the alignment features include keyed interfaces that ensure one-way assembly and prevent incorrect orientation.
[0055] FIG. 5B is a diagram illustrating a front view of the exemplary sterile adapter, in accordance with an embodiment of the present disclosure. FIG. 5B is described in conjunction with the elements of FIGs. 1 to 5A. With reference to FIG. 5B, there is shown the sterile adapter 302 (shown in FIG. 3). The sterile adapter 302 includes four drive discs 520, 522, 524, and 526 arranged in a specific configuration for power transmission. The sterile adapter 302 further includes tactile switches including a first tactile switch 528 and a second tactile switch 530 protruding from an adapter surface 532 of the sterile adapter 302, positioned to detect proper instrument mounting. The tactile switches provide digital feedback signals indicating correct engagement with the surgical instrument 140. In some implementations, the first tactile switch 528 and the second tactile switch 530 are connected to the drive system and output a digital value of 1 when proper alignment is achieved.
[0056] FIG. 6 is a diagram illustrating a front view of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 6 is described in conjunction with the elements of FIGs. 1 to 5B. With reference to FIG. 6, there is shown the exemplary surgical instrument 140, showing the allowable range of disc positions after assembly. The instrument discs 502, 504, 506, and 508 may deviate from the ideal positions due to assembly variations but remain within a deviation zone. The deviation zone represents the maximum acceptable offset from the ideal position while still enabling successful engagement with the sterile adapter 302. Each instrument disc includes position markers 602A, 602B, 602C, 602D that may remain within corresponding deviation zones 604A, 604B, 604C, 604D to ensure proper functionality. The deviation is typically caused by mechanical tensioning during assembly and minor manufacturing variations.
[0057] FIG. 7 is a diagram illustrating a front view of an instrument cover of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 7 is described in conjunction with the elements of FIGs. 1 to 6. With reference to FIG. 7, there is shown an instrument cover 700 of the surgical instrument 140. The instrument cover 700 includes integrated mechanical stops including a first mechanical stop 702 and a second mechanical stop 704 that limit the roll axis rotation. The mechanical stops 702, 704 are positioned at precise angular intervals, with the first mechanical stop 702 limiting clockwise rotation and the second mechanical stop 704 limiting counterclockwise rotation. The mechanical stops 702, 704 engage with corresponding features 706 on the internal mechanism to provide definitive end-of-travel positions for calibration purposes. In some implementations, the mechanical stops 702, 704 are designed with hardened contact surfaces to maintain calibration accuracy over repeated use.
[0058] FIG. 8 is a diagram illustrating a front view of gears of the exemplary surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 8 is described in conjunction with the elements of FIGs. 1 to 7. With reference to FIG. 8, there is shown an internal gear assembly 800 of the surgical instrument 140. The gear assembly 800 includes primary drive gear 802 with integrated mechanical stops including a first mechanical stop 804 and a second mechanical stop 806. The mechanical stops 804 and 806 interface with mating features on the instrument housing to create precise mechanical limits. The gear assembly 800 includes position encoders 810 that monitor rotational position relative to the mechanical stops. The position encoders 810 utilize instrument design parameters and encoder resolution with gear head ratios to calculate theoretical rotation counts, thereby enabling precise position monitoring while maintaining the safety constraints of the mechanical stops. In some embodiments, the gear assembly 800 includes output encoders for direct calculation of rotation counts, providing additional flexibility in position monitoring. In some implementations, the gear ratio between the drive input and output is precisely controlled through compound gear sets to achieve the desired motion reduction and torque multiplication.
[0059] FIG. 9 is a diagram illustrating an exemplary graphical representation between torque and time for detecting physical stops, in accordance with an embodiment of the present disclosure. FIG. 9 is described in conjunction with the elements of FIGs. 1 to 8. With reference to FIG. 9, there is shown a graphical representation 900 of torque versus time for detecting physical stops during use of the surgical instrument 140 mounted with the sterile adapter 302. The graphical representation 900 includes a torque measurement curve plotted against time, wherein the curve exhibits distinct behavioural regions corresponding to different phases of stop detection. A first region of the curve, designated as approach curve 902, represents an initial movement phase characterized by torque values below a predetermined operational threshold. The torque values are indicative of normal operational friction and movement resistance of the surgical instrument 140. In some examples, the predetermined operational threshold for the torque values may be between 0.1 and 0.3 Newton-meters. The graphical representation 900 further includes a filtered torque curve 902A depicting filtered torque values of the initial movement phase of the surgical instrument 140.
[0060] The approach curve 902 transitions into a contact curve 904 at a contact point 910, wherein said contact curve 904 is characterized by a rapid increase in measured torque. The rate of torque increase in the contact curve 904 exceeds 1.0 Newton-meters per second, thereby distinguishing the stop engagement from normal operational resistance. The contact curve 904 subsequently transitions into a confirmation curve 906, wherein the measured torque maintains an elevated value exceeding a predetermined threshold 908 of 0.8 Newton-meters.
[0061] The graphical representation 900 further includes a threshold band 914 defining an acceptable torque variation range of ±0.1 Newton-meters around the predetermined threshold 908. Time markers 916A and 916B are disposed along the time axis to demarcate temporal boundaries between the approach curve 902, the contact curve 904, and the confirmation curve 906 respectively. The sustained torque level (steady state value of torque applied) provides primary verification of continuous stop engagement, which is further corroborated by position data obtained from position sensors positioned on the surgical instrument 140.
[0062] FIG. 10 is a diagram illustrating an exemplary graphical representation between position and time for detecting physical stops, in accordance with an embodiment of the present disclosure. FIG. 10 is described in conjunction with the elements of FIGs. 1 to 9. With reference to FIG. 10, there is shown a graphical representation 1000 of position versus time for detecting physical stops of the surgical instrument 140. The graphical representation 1000 includes a position measurement curve plotted against time, wherein the curve demonstrates position changes of the surgical instrument 140 during stop detection. The graphical representation 1000 includes a movement curve 1002 representing normal operational movement and a commanded movement curve 802A representing a commanded movement of the surgical instrument 140. The movement curve 1002 exhibits position changes corresponding to user-commanded movement of the surgical instrument 140.
[0063] The movement curve 1002 transitions into a static position curve 1006, wherein the measured position remains substantially constant within a predetermined threshold band 1008. In some implementations, the movement curve 1002 may transition into a deceleration curve, wherein the deceleration curve is characterized by a progressive reduction in the rate of position change. The rate of position change in the deceleration curve decreases below 0.1 millimetres per second, wherein the decrease is indicative of contact with a physical stop. Further, in such implementation, the deceleration curve may subsequently transition into the static position curve 1006.
[0064] The graphical representation 1000 further comprises a contact point 1010 at which the rate of position change approaches zero, thereby indicating initial stop engagement. The threshold band 1008 defines an acceptable position variation range of ±0.05 millimetres around a final resting position 1014. Time correlation markers 1012A, 1012B are disposed along the time axis to facilitate temporal correlation with corresponding torque measurements from the graphical representation 900 of FIG. 9, wherein said correlation provides verification of stop engagement through multiple measurement methodologies.
[0065] The static position curve 1006 maintains position values within the threshold band 1008, wherein said maintained position values are utilized to establish reference positions for the surgical instrument 140 during the calibration process. The final resting position 1014 serves as a calibration reference point from which subsequent position measurements and movement commands are calculated, thereby enabling precise control of the surgical instrument 140 with backlash compensation.
[0066] FIG. 11A is a diagram illustrating a distal end of the exemplary surgical instrument before calibration, in accordance with an embodiment of the present disclosure. FIG. 11A is described in conjunction with the elements of FIGs. 1 to 10. With reference to FIG. 11A, there is shown a distal end 1100 of the surgical instrument 140 inside a cannula 1112 before calibration. The distal end 1100 includes an end effector 1102 including a first jaw 1104A and a second jaw 1104B pivotally coupled to each other. A pitch joint 1106 is disposed between the end effector 1102 and an elongated shaft 1108. The pitch joint 1106 enables angular displacement of the end effector 1102 relative to a longitudinal axis of the elongated shaft 1108. Prior to calibration, the end effector 1102 may occupy any random position within its range of motion, necessitating a systematic calibration procedure to establish reference positions.
[0067] FIG. 11B is a diagram illustrating jaws of the exemplary surgical instrument in an open configuration, in accordance with an embodiment of the present disclosure. FIG. 11B is described in conjunction with the elements of FIGs. 1 to 11A. With reference to FIG. 11B, there is shown the distal end 1100 during an initial phase of calibration. In the illustrated embodiment of FIG. 11B, the first jaw 1104A and the second jaw 1104B are configured in an open position. The jaws 1104A, 1104B are actuated to contact interior walls 1110A, 1110B of the cannula 1112. The cannula 1112 serves as a physical reference frame. In some implementations, a first position sensor and a second position sensor may be configured to detect contact between the respective jaws and the cannula walls 1110A, 1110B. The measured positions at maximum jaw separation provide initial reference points for the calibration procedure.
[0068] FIGs. 11C-11D are diagrams illustrating the jaws of the exemplary surgical instrument in a closed configuration, in accordance with an embodiment of the present disclosure. FIGs. 11C-11D are described in conjunction with the elements of FIGs. 1 to 11B. With reference to FIG. 11C, there is shown the distal end 1100 during a subsequent phase of calibration. In the illustrated embodiment of FIG. 11C, the first jaw 1104A and the second jaw 1104B are actuated toward a closed position. The first jaw 1104A establishes a contact with a first reference point 1116 on the cannula wall 1110A. The contact is detected through monitoring of position and torque parameters. With reference to FIG. 11D, there is shown a further movement wherein the second jaw 1104B establishes contact with a second reference point 1118 on the opposite cannula wall 1110B. The drive system records the angular displacement between the first reference point 1116 and the second reference point 1118, thereby establishing the total range of jaw motion. The sequential contact measurements enable calculation of backlash parameters in both closing and opening directions of jaw movement.
[0069] FIGs. 11A-11D collectively illustrate the use of external physical stops, specifically the cannula walls 1110A, 1110B, as reference points for instrument calibration. The external physical stop approach using the cannula or trocar provides additional mechanical references beyond the internal stops of the instrument, enabling a more comprehensive calibration process. The cannula walls serve as consistent, reliable physical boundaries that can be used to calibrate multiple degrees of freedom, including jaw angles and positions.
[0070] FIG. 11E is a diagram illustrating the distal end of the exemplary surgical instrument after calibration, in accordance with an embodiment of the present disclosure. FIG. 11E is described in conjunction with the elements of FIGs. 1 to 11D. With reference to FIG. 11E, there is shown the distal end 1100 in a fully calibrated configuration. In the illustrated embodiment of FIG. 11E, the end effector 1102 is positioned in a predetermined home position. The first jaw 1104A and the second jaw 1104B are centred relative to a shaft axis 1120. The shaft axis 1120 serves as a reference line for subsequent movement calculations. The pitch joint 1106 is aligned to a computed centre point, determined through a similar process of bidirectional movement between mechanical limits. The calibration procedure establishes absolute position references for each movable component through contact with physical stops, thereby enabling compensation for mechanical backlash and ensuring precise control during surgical procedures.
[0071] The calibration sequence proceeds systematically through detection of physical limits in each axis of movement. For the roll axis, calibration utilizes mechanical stops integrated within the instrument housing. The pitch axis calibration employs the cannula walls 1110A, 1110B as reference surfaces, requiring the end effector 1102 to be positioned appropriately within the cannula 1112. The jaw axis calibration combines both cannula wall references and internal mechanical stops to establish precise position control. Throughout the calibration sequence, the drive system simultaneously monitors position feedback from encoders and torque feedback from sensors to verify proper contact with reference surfaces and mechanical stops.
[0072] The calibration procedure incorporates multiple verification steps to ensure accuracy. The drive system compares measured ranges of motion against predetermined theoretical values stored in a memory of the drive system. Position and torque thresholds for stop detection are dynamically adjusted based on the specific axis being calibrated. Upon completion of the calibration sequence, the drive system stores computed backlash values and position references in non-volatile memory, enabling consistent performance across multiple procedure sessions.
[0073] FIG. 12 is a flowchart illustrating a method for calibrating a surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 12 is described in conjunction with the elements of FIGs. 1 to 11E. With reference to FIG. 12, there is shown a method 1200 for calibrating the surgical instrument 104. The method 1200 is executed at the drive system. The method 1200 may include steps 1202 to 1212.
[0074] At step 1202, the surgical instrument 140 is mounted on the sterile adapter 302 removably connected to the drive system. The surgical instrument 140 is configured to operate in a plurality of axes. The mounting procedure includes aligning engagement features of the surgical instrument with corresponding features on the sterile adapter. Proper mounting is verified through tactile switch activation providing digital confirmation signals.
[0075] At step 1204, one or more physical stops associated with the surgical instrument that define limits for each axis of the plurality of axes are identified. The physical stops include mechanical features integrated within the instrument housing for the roll axis, cannula walls serving as reference surfaces for the pitch axis, and a combination of internal stops and cannula surfaces for the jaw axes. The identification process includes accessing stored geometric parameters defining the location and characteristics of each physical stop relative to the instrument's coordinate system.
[0076] At step 1206, position, torque, and force are monitored in real time while moving the surgical instrument 140 along each axis to detect contact with one or more physical stops. Position monitoring is accomplished through encoder feedback from each actuator, torque monitoring through motor current measurements, and force monitoring through dedicated force sensors integrated within the drive system. The monitoring occurs continuously during instrument movement with sampling rates sufficient to detect rapid changes in measured parameters.
[0077] At step 1208, engagement of the surgical instrument 140 with one or more physical stops is determined by analysing positional changes of actuators by detecting a cessation of movement or a mechanical resistance greater than a threshold indicating contact with the physical stops. The determination process includes comparing the rate of position change against predetermined threshold values, wherein a rate below 0.1 millimetres per second indicates potential stop contact. Simultaneously, torque measurements are compared against threshold values ranging from 0.8 to 1.0 Newton meters, wherein sustained torque above the threshold confirms stop engagement.
[0078] At step 1210, a positional offset is calculated for each axis based on the detected contact with the one or more physical stops. The calculation process includes recording absolute positions at both extremes of movement for each axis, computing the difference between a measured range of motion and a theoretical range of motion, and determining the midpoint position that will serve as the reference position. The offset calculation accounts for mechanical tolerances and assembly variations specific to each instrument.
[0079] At step 1212, the surgical instrument 140 is calibrated by applying the calculated offset to movement commands provided to the surgical instrument to compensate for backlash of the surgical instrument. The calibration process includes storing the computed offsets in non-volatile memory, updating the drive system parameters with the new offset values, and verifying proper compensation through test movements. The backlash compensation is applied dynamically during operation, adjusting the commanded position based on the direction of movement and the stored offset values.
[0080] The method 1200 further includes verification steps between each major operation, ensuring that each calibration phase is completed before proceeding to subsequent phases. The calibration sequence is executed according to a predetermined hierarchy, starting with the roll axis, proceeding to pitch calibration, and concluding with jaw calibration. This hierarchical approach ensures that each axis is calibrated relative to a known reference frame established by previously calibrated axes.
[0081] In an implementation, the detection of the cessation of movement of the surgical instrument 140 with the one or more physical stops comprises monitoring a difference between a target position and an actual position. In such implementations, the detection of cessation of movement utilizes a sophisticated position monitoring system that continuously tracks the difference between the target position commanded to the surgical instrument and its actual achieved position. When the surgical instrument encounters a physical stop, this difference becomes significant as the instrument cannot reach its commanded target position. The drive system employs position sensors and encoders to measure the actual position with high precision. A predetermined position threshold is established, and when the difference between target and actual position exceeds this threshold while maintaining a consistent actual position, the system determines that a physical stop has been encountered. This method ensures reliable detection of mechanical limits without risking damage to the instrument or compromising patient safety.
[0082] In an implementation, the detection of the cessation of movement of the surgical instrument 140 with the one or more physical stops comprises simultaneously measuring the actual torque and force applied to each axis. In such implementation, the drive system implements a multi-parameter approach to detecting physical stop engagement by simultaneously monitoring both torque and force measurements across each axis of movement. Force sensors integrated into the drive system measure the resistive forces encountered during instrument movement, while torque sensors monitor the rotational resistance. When the instrument contacts a physical stop, there is a characteristic spike in both torque and force measurements. The system employs predetermined thresholds for both parameters when the actual torque exceeds the torque threshold and the actual force exceeds the force threshold simultaneously, while the position remains relatively constant, the system confirms contact with a physical stop. This dual-parameter verification ensures robust and reliable detection of mechanical limits while preventing false positives that could occur from monitoring either parameter alone.
[0083] In some implementations, the calculating of the positional offset comprises rotating each axis to a first mechanical limit, storing a first position value, rotating each axis to a second mechanical limit in an opposite direction, storing a second position value, computing a difference between the first and second position values, and computing a second difference between the first difference and a predefined value. In such implementation, the positional offset calculation implements a comprehensive calibration sequence that precisely determines the total range of motion and backlash characteristics for each axis. The process begins by rotating each axis until it contacts the first mechanical limit, at which point the absolute position value is recorded in the system's memory. The axis is then rotated in the opposite direction until it contacts the second mechanical limit, and this position value is also stored. The drive system calculates the total range of motion by computing the difference between these two position values. This measured range is then compared against a predefined theoretical value based on the instrument's design specifications, with the difference representing the positional offset. The offset value accounts for manufacturing variations, assembly tolerances, and mechanical wear, enabling precise compensation during operation. The predefined value is determined based on the instrument's design parameters, including gear ratios and mechanical constraints, and serves as the reference for the ideal movement range.
[0084] In some implementations, the movement commands are generated from a predefined set of rules, the rules comprising a predetermined surgical procedure protocol, motion sequences specific to a surgical instrument type, and predefined spatial and angular movement constraints. In such implementations, the movement command generation system operates based on a sophisticated rule-based framework that ensures safe and effective instrument operation. The predetermined surgical procedure protocol comprises a set of standardized movement sequences and safety parameters specific to different surgical procedures. The protocols define acceptable ranges of motion, approach vectors, and speed limitations appropriate for each surgical task. The motion sequences specific to surgical instrument type incorporate the unique mechanical characteristics and operational constraints of different instruments, ensuring optimal performance while preventing potentially damaging movements. The predefined spatial and angular movement constraints establish safety boundaries within the surgical workspace, preventing collisions and ensuring the maintenance of sterile field integrity. These rules work in concert to create a comprehensive framework that guides instrument movement while maintaining surgical safety and efficiency.
[0085] In some implementations, the movement commands are input by a surgeon, comprising real-time manual trajectory specification, dynamic adjustment of instrument movement during a surgical procedure, and interactive input through a surgical control interface. In such implementations, the surgeon input interface provides multiple modalities for direct control over instrument movement during surgical procedures. The real-time manual trajectory specification allows surgeons to define precise movement paths through a master control interface, translating their hand movements into scaled, precise instrument movements. Dynamic adjustment capabilities enable immediate modification of instrument position and orientation during active procedures, providing necessary flexibility for adapting to changing surgical conditions. The surgical control interface incorporates ergonomic input devices and intuitive visualization systems that provide immediate feedback on instrument position and movement, enabling precise control while maintaining surgical workflow. This multi-modal input system ensures that surgeons maintain complete control over instrument movement while benefiting from the system's precision and stability enhancements.
[0086] In some implementations, the offset compensates for variances in tolerances, backlash, alignment, assembly or manufacturing discrepancies. During manufacturing and assembly, components inherently possess dimensional tolerances that, while within acceptable manufacturing specifications, can accumulate to create slight variations in movement characteristics. The system's offset compensation specifically accounts for these manufacturing tolerances by measuring and adjusting for the actual range of motion achieved by each axis, rather than relying solely on theoretical design values.
[0087] The mounting of the surgical instrument 140 on a removably connected sterile adapter 302 enables quick instrument changes while maintaining sterility during surgical procedures. Thus, eliminating the need for complex permanent mounting mechanisms and reducing setup time. Furthermore, the use of physical stops to define limits for each axis provides a reliable, mechanical-based calibration reference that is independent of electronic sensors, thereby reducing calibration errors and improving repeatability. The mechanical approach demonstrates superior robustness against environmental factors and wear compared to traditional electronic limit switches.
[0088] The simultaneous real-time monitoring of multiple parameters including position, torque, and force while moving the instrument enables detection of true mechanical limits rather than estimated positions. The comprehensive monitoring prevents damage to the instrument by identifying mechanical resistance before component failure, ensures accurate calibration across different operating conditions and wear states, and allows for dynamic adjustment during the calibration process.
[0089] Additionally, the dual-criteria approach for determining physical stop engagement through both cessation of movement and mechanical resistance threshold provides higher reliability in stop detection compared to single-parameter methods. The approach reduces false positives in limit detection, enables better discrimination between true mechanical limits and temporary obstructions, and ensures more precise calibration points for each axis.
[0090] The calculation of axis-specific positional offsets based on detected contact points enables individual compensation for manufacturing variations in each axis while adapting to wear-related changes in mechanical limits. This results in optimized performance across the full range of motion for each axis of the surgical instrument.
[0091] Moreover, the application of calculated offsets to movement commands provides real-time backlash compensation during surgical procedures, improving positioning accuracy without manual adjustment. The automated compensation ensures consistent performance across different surgical instruments while automatically adapting to instrument-specific mechanical characteristics.
[0092] The holistic approach of combining physical stop detection, multi-parameter monitoring, and automated offset calculation significantly improves the accuracy and reliability of surgical procedures while reducing setup time and maintenance requirements. The comprehensive calibration method demonstrates marked improvements in both precision and efficiency compared to existing calibration approaches.
[0093] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure. , Claims:CLAIMS
We Claim:
1. A method (1200) for calibrating a surgical instrument (102), comprising:
mounting the surgical instrument (140) on a sterile adapter (302) removably connected to a drive system (304), wherein the surgical instrument (140) is configured to operate in a plurality of axes;
identifying one or more physical stops associated with the surgical instrument (140) that define limits for each axis of the plurality of axes;
monitoring position, torque, and force in real time while moving the surgical instrument (140) along each axis to detect contact with the one or more physical stops;
determining engagement of the surgical instrument (140) with the one or more physical stops by analyzing positional changes of actuators by detecting a cessation of movement or a mechanical resistance greater than a threshold indicating contact with the physical stops;
calculating a positional offset for each axis based on the detected contact with the one or more physical stops; and
calibrating the surgical instrument (140) by applying the calculated offset to movement commands provided to the surgical instrument (140) to compensate for backlash of the surgical instrument (140).

2. The method (1200) of claim 1, wherein the detecting of the cessation of movement of the surgical instrument (140) with the one or more physical stops comprises monitoring a difference between a target position and an actual position.

3. The method (1200) of claim 1, wherein the detecting of the cessation of movement of the surgical instrument (140) with the one or more physical stops comprises simultaneously measuring the actual torque and force applied to each axis.

4. The method (1200) of claim 1, wherein the calculating of the positional offset comprises:
rotating each axis to a first mechanical limit;
storing a first position value;
rotating each axis to a second mechanical limit in an opposite direction;
storing a second position value;
computing a difference between the first and second position values; and
computing a second difference between the first difference and a predefined value.

5. The method (1200) of claim 1, wherein the movement commands are generated from a predefined set of rules, the rules comprising: a predetermined surgical procedure protocol; motion sequences specific to a surgical instrument type; and predefined spatial and angular movement constraints.

6. The method (1200) of claim 1, wherein the movement commands are input by a surgeon, comprising: real-time manual trajectory specification; dynamic adjustment of instrument movement during a surgical procedure; and interactive input through a surgical control interface.

7. The method (1200) of claim 1, wherein the offset compensates for variances in tolerances, backlash, alignment, assembly or manufacturing discrepancies.

8. A surgical calibration assembly (300) comprises:
a surgical instrument (140) configured to operate in a plurality of axes;
a sterile adapter (302) removably connected to the surgical instrument (140) and a drive system (304), wherein the sterile adapter (302) comprises one or more physical stops associated with the surgical instrument (140) and configured to define limits for each axis of the plurality of axes; and
a controller operatively connected to the drive system (304) and configured to:
monitor position, torque, and force in real time while moving the surgical instrument (140) along each axis to detect contact with the one or more physical stops;
determine engagement of the surgical instrument (140) with the one or more physical stops by analyzing positional changes of actuators by detecting a cessation of movement or a mechanical resistance greater than a threshold indicating contact with the physical stops;
calculate a positional offset based on the detected contact with the one or more physical stops; and
calibrate the surgical instrument (140) by applying the calculated offset to movement commands provided to the surgical instrument (140) to compensate for backlash of the surgical instrument (140).

9. The surgical calibration assembly (300) of claim 8, wherein the sterile adapter (302) comprises a plurality of discs configured to engage with the surgical instrument (140).

10. The surgical calibration assembly (300) of claim 9, wherein the sterile adapter (302) is configured in a pre-calibrated home condition, comprising: a predetermined geometric configuration of the plurality of discs, wherein each disc is positioned at a predefined spatial coordinate, and wherein the pre-calibrated home condition is indicative of a predefined alignment for quick coupling of the surgical instrument (140).

11. The surgical calibration assembly (300) of claim 10, wherein the plurality of discs of the sterile adapter (302) is constrained to a predefined position range, including: a spatially bounded mounting zone, geometric tolerances defining acceptable disc positioning, and a deviation envelope from the predefined alignment.

12. The surgical calibration assembly (300) of claim 8, wherein, in order to detect the cessation of movement of the surgical instrument (140) with the one or more physical stops, the controller is further configured to monitor a difference between a target position and an actual position.

13. The surgical calibration assembly (300) of claim 8, wherein, in order to detect the cessation of movement of the surgical instrument (140) with the one or more physical stops, the controller is further configured to simultaneously measure the actual torque and force applied to each axis.

14. The surgical calibration assembly (300) of claim 8, wherein, in order to calculate the positional offset based on the detected contact with the one or more physical stops, the processor is further configured to:
rotate each axis to a first mechanical limit;
store a first position value;
rotate each axis to a second mechanical limit in an opposite direction;
store a second position value;
compute a first difference between the first and second position values; and
compute a second difference between the first difference and a predefined value.

15. The surgical calibration assembly (300) of claim 8, wherein the movement commands are generated from a predefined set of rules, the rules comprising: a predetermined surgical procedure protocol; motion sequences specific to a surgical instrument type; and predefined spatial and angular movement constraints.

16. The surgical calibration assembly (300) of claim 8, wherein the movement commands are input by a surgeon, comprising: real-time manual trajectory specification; dynamic adjustment of instrument movement during a surgical procedure; and interactive input through a surgical control interface.