[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62/180,124 filed June 16, 2015, the entire disclosure of which is incorporated by reference herein.

BACKGROUND

[0002] Robotic surgical systems have been used in minimally invasive medical procedures. During such a medical procedure, the robotic surgical system is controlled by a surgeon that interfaces with a user interface. The user interface allows the surgeon to manipulate an end effector that acts on a patient. The user interface has an input controller or handle that is moveable by the surgeon to control the robotic surgical system.

[0003] The end effectors of the robotic surgical system are positioned at the end of a surgical instrument that is connected to robotic arms. Each end effector can be manipulated by an Instrument Drive Unit (IDU). An IDU may have a drive motor associated with the end effector and be configured to move the end effector about a respective axis or to actuate a particular function of the end effector (e.g., approximate, pivot, etc. jaws of the end effector).

[0004] Safety systems in the robotic surgical system monitored the drive motor current. If the measured motor current exceeded a preset safety threshold a fault would be presumed and the motor would be turned off. These systems had limited ability to detect different types of faults as they did not take into account the actual forces at the motor output. [0005] There is a need for robust instrument drive unit fault detection that is capable of identifying different types of faults beyond those associated with pure high current draw.

SUMMARY

[0006] In an aspect of the present disclosure, verifying a torque measurement of a torque transducer of an instrument drive unit may include receiving a verification signal indicative of current drawn by a motor of the instrument drive unit. An acceptable torque range based on the verification signal may be identified. The torque measurement may be compared with the acceptable torque range. The motor may be stopped if the torque measurement is outside the acceptable torque range.

[0007] In aspects, the method may include measuring the torque being applied by the motor with a reaction torque transducer that is electrically isolated from the motor. The reaction torque transducer may transmit the torque signal to the controller. The method may also include generating a fault signal when the torque applied by the motor is outside of the acceptable range of torques. Generating the fault signal may include providing feedback to a clinician in the form of audible, visual, or haptic feedback to the clinician.

[0008] In some aspects, a sensor may transmit the verification signal to the controller. A sensor may measure current drawn by the motor to generate the verification signal.

[0009] In another aspect of the present disclosure, a control circuit for a motor of an instrument drive unit includes a sensor, a reaction torque transducer, and a controller. The sensor is configured to detect current drawn by the motor and the reaction torque transducer is configured to detect torque applied by the motor. The controller is in communication with the sensor and the reaction torque transducer and is configured to control the motor. The controller is configured to compare the detected current drawn by the motor to the detected torque applied by the motor to verify the detected torque is within an acceptable range of torque values for detected current drawn by the motor.

[0010] In aspects, the control circuit includes a motor energy source that is in electrical communication with the motor. The motor energy source may be electrically isolated from the reaction torque transducer. The sensor may be configured to detect current drawn by the motor from the motor energy source.

[0011] In some aspects, the reaction torque transducer is configured to detect a mechanical property induced by torque applied by the motor. The mechanical property may be strain.

[0012] In another aspect of the present disclosure, an instrument drive unit of a robotic surgical system includes a fixed plate, a first motor, a first reaction torque transducer, a first sensor, and a first controller. The first motor has a first drive shaft and the first reaction torque transducer is disposed about the first drive shaft to secure the first motor to the fixed plate. The first reaction torque transducer is configured to detect torque delivered by the first motor. The first sensor is configured to detect current drawn by the first motor. The first controller is configured to control the first motor. The first controller is in communication with the first sensor and the first reaction torque transducer. The first controller is configured to compare the detected current drawn by the first motor to the detected torque delivered by the first motor to verify that the detected torque is within an acceptable range of torque values for the detected current drawn by the first motor.

[0013] In aspects, the instrument drive unit includes a second motor, a second reaction torque transducer, and a second sensor. The second motor has a second drive shaft and the second reaction torque transducer is disposed about the second drive shaft to secure the second motor to the fixed plate. The second reaction torque transducer is configured to detect torque delivered by the second motor. The second sensor is configured to detect current drawn by the second motor. The first controller is configured to control the second motor. The first controller is in communication with the second sensor and the second reaction torque transducer. The first controller is configured to compare the detected current drawn by the second motor to the detected torque delivered by the second motor to verify that the detected torque is within an acceptable range of torque values for the detected current drawn by the second motor.

[0014] In some aspects, the instrument drive unit includes a third motor, a third reaction torque transducer, a third sensor, and a second controller. The third motor has a third drive shaft and the third reaction torque transducer is disposed about the third drive shaft to secure the third motor to the fixed plate. The third reaction torque transducer is configured to detect torque delivered by the third motor. The third sensor is configured to detect current drawn by the third motor. The second controller is configured to control the third motor. The second controller is in communication with the third sensor and the third reaction torque transducer. The second controller is configured to compare the detected current drawn by the third motor to the detected torque delivered by the third motor to verify that the detected torque is within an acceptable range of torque values for the detected current drawn by the third motor.

[0015] Further details and aspects of exemplary embodiments of the present disclosure are described in more detail below with reference to the appended figures. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Various aspects of the present disclosure are described hereinbelow with reference to the drawings, which are incorporated in and constitute a part of this specification, wherein:

[0017] FIG. 1 is a schematic illustration of a user interface and a robotic system;

[0018] FIG. 2 is a side, cross-sectional view of an instrument drive unit of the robotic system of FIG. 1;

[0019] FIG. 3 is a cross-sectional view taken along the section line 3-3 of FIG. 2;

[0020] FIG. 4 is a schematic illustration of a control circuit of the instrument drive unit of FIG. 2; and

[0021] FIG. 5 is a flowchart illustrating a method of controlling the instrument drive unit of FIG. 1.

DETAILED DESCRIPTION

[0022] Embodiments of the present disclosure are now described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term "clinician" refers to a doctor, a nurse, or any other care provider and may include support personnel. Throughout this description, the term "proximal" refers to the portion of the device or component thereof that is closest to the clinician and the term "distal" refers to the portion of the device or component thereof that is farthest from the clinician. [0023] The present disclosure generally relates to an instrument drive unit (IDU) for a robotic surgical system that includes a torque transducer (e.g., primary sensor) that measures the torque applied by a motor and provides a torque signal to a controller that drives the motor. The IDU also includes a secondary sensor that measures an input to the motor to provide a verification signal to the controller. The controller compares the torque signal and the verification signal to ensure the torque transducer is functioning properly. If the torque signal is outside of an acceptable range of values for a given verification signal, the controller generates a fault signal and/or stops the robotic surgical system.

[0024] As detailed herein, the IDU includes a reaction torque transducer as the primary sensor. However, it is contemplated that the primary sensor may be an inline torque transducer.

[0025] Referring to FIG. 1, a robotic surgical system 1, is shown and includes a robotic system 10, a processing unit 30, and a user interface 40. The robotic system 10 generally includes linkages 12 and a robot base 18. The linkages 12 moveably support a surgical instrument having an end effector or tool 20 which is configured to act on tissue. The linkages 12 may be in the form of arms each having a plurality of members 13. A member 13a of the plurality of members 13 has an end 14 that supports end effector or tool 20 which is configured to act on tissue. In addition, the end 14 of the member 13a may include an imaging device 16 for imaging a surgical site "S". Each of the plurality of members 13 of the linkages 12 may be connected to one another about joints 15. The user interface 40 is in communication with robot base 18 through the processing unit 30.

[0026] The user interface 40 includes a display device 44 which is configured to display three-dimensional images. The display device 44 displays three-dimensional images of the surgical site "S" which may include data captured by imaging devices 16 positioned on the end 14 of the member 13a and/or include data captured by imaging devices that are positioned about the surgical theater (e.g., an imaging device positioned within the surgical site "S", an imaging device positioned adjacent the patient "P", imaging device 56 positioned at a distal end of an imaging arm 52). The imaging devices (e.g., imaging devices 16, 56) may capture visual images, infra-red images, ultrasound images, X-ray images, thermal images, and/or any other known real-time images of the surgical site "S". The imaging devices transmit captured imaging data to the processing unit 30 which creates three-dimensional images of the surgical site "S" in real-time from the imaging data and transmits the three-dimensional images to the display device 44 for display.

[0027] The user interface 40 also includes input handles 42 which allow a clinician to manipulate the robotic system 10 (e.g., move the linkages 12, the ends 14 of the linkages 12, and/or the tools 20). Each of the input handles 42 is in communication with the processing unit 30 to transmit control signals thereto and to receive feedback signals therefrom. Each of the input handles 42 may include input devices which allow the surgeon to manipulate (e.g., clamp, grasp, fire, open, close, rotate, thrust, slice, etc.) the tools 20 supported at the end 14 of the member 13 a.

[0028] For a detailed discussion of the construction and operation of a robotic surgical system 1, reference may be made to U.S. Patent Publication No. 2012/0116416, entitled "Medical Workstation."

[0029] Referring also to FIGS. 2 and 3, an instrument drive unit (IDU) 60 is disposed within or supported on the member 13a adjacent the end 14. The IDU 60 is operatively associated with a tool 20 coupled to the end 14 to manipulate the tool 20 in response to tool signals transmitted from the processing unit 30. The IDU 60 includes motors 62 which are each operably coupled to a respective converter 64 and a respective reaction torque transducer 68. Each motor 62 rotates a drive shaft 63 that extends through a primary sensor or reaction torque transducer 68 in response to energy supplied to the motor 62. The converter 64 converts rotation of the drive shaft 63 of the motor 62 to linear movement of a drive rod and/or cable (not shown). The converter 64 may be secured to a fixed plate 61 of the IDU 60. The reaction torque transducer 68 measures torque applied or delivered by the motor 62 to the converter 64 and thus, measures force applied to the tools 20. The reaction torque transducer 68 is positioned about the drive shaft 63 of the motor 62 and secures the motor 62 to the fixed plate 61 of the IDU 60.

[0030] For a detailed discussion of the construction and operation of the reaction torque transducer 68, reference may be made to International Patent Application No. PCT/US 15/14542, filed on February 5, 2015, and entitled "Input Device Assemblies for Robotic Surgical Systems", the entire contents of which are incorporated herein by reference.

[0031] With reference to FIGS. 2 and 3, the IDU 60 includes one or more circuit boards 80 that each include a controller 126 which are provided in accordance with the present disclosure. As detailed below, the controllers 126 are detailed in terms of a singular controller 126; however, it will be appreciated that the IDU 60 may have one or more controllers 126. The controller 126 is in communication with one or more reaction torque transducers 68. As shown, the controller 126 is in communication with a reaction torque transducer 68 by a lead 142 and another reaction torque transducer 68 by a lead 144. Each lead 142, 144 carries a torque signal indicative of torque being applied by the motor 62 sensed by the respective torque transducer 68 to the controller 126.

[0032] While the torque being applied by the motor 62 may be precisely measured by the reaction torque transducer 68, the torque being applied by the motor 62 can also be calculated from the amount of current drawn by the motor 62. As detailed below, this calculated torque can be used to verify that the measured torque (i.e., torque detected by the reaction torque transducer 68) is within an acceptable range of values for a detected amount of current drawn by the motor 62. By verifying that the detected torque is in the acceptable range of values for a detected amount of current drawn, a fault may be generated and/or the motor 62 may be stopped if the detected torque is outside of the acceptable range of values for a detected amount of current drawn. It will be understood that when the detected torque is outside of the acceptable range of values for a detected amount of current drawn that the reaction torque transducer 68 may have failed.

[0033] Continuing to refer to FIGS. 2 and 3, the IDU 60 includes sensors 152, 154 that provide verification signals to the circuit board 80. The sensors 152, 154 are each associated with a respective motor 62 to detect an amount of current drawn by the respective motor 62. Each sensor 152, 154 then sends a respective verification signal to the controller 126 indicative of the amount of current drawn by the respective motor 62. The controller 126 compares the verification signal to the torque signal to verify that the torque signal is within an acceptable range of values with respect to the verification signal.

[0034] It is contemplated that the sensors 152, 154 may detect a torque and generate a current from the detected current. In such embodiments, the controller compares the current of the verification signal to the torque signal to verify that the torque signal is within an acceptable range of values with respect to the verification signal.

[0035] With reference to FIG. 4, a control circuit 120 compares the torque signal to the verification signal to verify that the detected torque is within an acceptable range of values for the amount current drawn by the motor 62. The control circuit 120 detects the reaction torque of the motor 62 and detects the amount of current drawn by the motor 62 to verify that the detected torque is within an acceptable range of values for the amount of current drawn by the motor 62.

[0036] The control circuit 120 includes the motor 62, the reaction torque transducer 68, a voltage source 121, a filter 122, an amplifier 124, the controller 126, and a sensor 152. The reaction torque transducer 68 generates a torque signal that is carried by the leads 132 to the filter 122. The filter 122 is a low pass filter to remove noise from the torque signal. The filter 122 transmits the filtered torque signal to the amplifier 124 which transmits the amplified filtered torque signal to the controller 126. The controller 126 determines the reaction torque of the motor 62 from the torque signal.

[0037] The controller 126 sends a control signal to control the motor 62 (e.g., the rotational speed of the motor 62). The controller 126 may send the signal to the motor 62 or to a motor energy source 69 that supplies energy to the motor 62. As the motor 62 draws energy from the motor energy source 69, the sensor 152 detects the amount of current drawn by the motor 62 from the motor energy source 69. The sensor 152 generates the verification signal which is indicative of the amount of current drawn by the motor 62 and sends the verification signal to the controller 126. [0038] The controller 126 compares the torque signal from the reaction torque transducer 68 with the verification signal from the sensor 152. First, the controller 126 generates an acceptable range of values for the torque being applied by the motor 62 from the verification signal. For example, when the verification signal indicates that the motor 62 is drawing 0.80 amps of current, an acceptable range of values for the torque being applied by the motor 62 is about 0.20 N-m to about .030 N-m. It will be understood that as the amount of current drawn by the motor 62 increases, upper and lower limits of the acceptable range of values for the torque being applied by the motor increases. In addition, as the amount of current drawn by the motor 62 increases, the acceptable range of values can increase. If the torque signal is within the acceptable range of values, the controller 126 continues to send a control signal indicative of continued rotation of the motor 62.

[0039] When the torque signal is outside of the acceptable range of values, the reaction torque transducer 68 may be malfunctioning and thus, providing inaccurate measurement of the torque being applied by the motor 62, or the tools 20 may have hit an obstruction. Accordingly, if the torque signal is outside of the acceptable range of values, the controller 126 may generate a fault signal and/or send a control signal to stop rotation of the motor 62. The fault signal may provide visual, audible, or haptic feedback to a clinician interfacing with the user interface 40 (FIG. 1).

[0040] With reference to FIG. 5, a method 200 of verifying torque measurements of a primary sensor or reaction torque transducer 68 of an instrument drive unit 60 with a sensor 152 is disclosed in accordance with the present disclosure. Initially, the controller 126 receives an instruction signal to rotate the motor 62. In response to the instruction signal, the controller 126 sends a control signal to the motor 62 to rotate the drive shaft 63.

[0041] While the motor 62 is rotating, the motor 62 draws current from the motor energy source 69 (FIG. 4). This current is measured by sensor 152 (Step 210). The sensor 152 generates a verification signal indicative of the measured current (Step 212) and transmits the verification signal to the controller 126 (Step 214). In addition, while the motor 62 is rotating, the reaction torque transducer 68 measures torque applied by the motor 62 (Step 220). The reaction torque transducer 68 generates a torque signal indicative of the measured torque (Step 222) and transmits the torque signal to the controller 126 (Step 224).

[0042] The controller 126 receives the verification signal (Step 230) and generates an acceptable range of torques which may be applied by the motor 62 for the given verification signal (Step 240). As detailed above, the acceptable range of torques is proportional to current drawn by the motor 62. The controller 126 then receives the torque signal from the reaction torque transducer 68 and compares the torque signal to the acceptable range of torques (Step 250). If the torque signal is within the acceptable range of torques, the controller 126 continues to send a control signal to the motor 62 to rotate the drive shaft 63 (Step 255). In contrast, if the torque signal is outside of the acceptable range of torques, the controller 126 stops rotation of the motor 62 by sending a control signal or ceasing to send a control signal (Step 260). The controller 126 then generates a fault signal indicative of the torque applied by the motor 62 being outside of the acceptable range of torque values. The fault signal may be audible, visual, haptic, or any combination thereof to alert a clinician of the fault. [0043] While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Any combination of the above embodiments is also envisioned and is within the scope of the appended claims. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope of the claims appended hereto.