Surgical robotic tools, data architecture, and use

Abstract

Robotic surgical tools, systems, and methods for preparing for and performing robotic surgery include a memory mounted on the tool. The memory can perform a number of functions when the tool is loaded on the tool manipulator: first, the memory can provide a signal verifying that the tool is compatible with that particular robotic system. Secondly, the tool memory may identify the tool-type to the robotic system so that the robotic system can reconfigure its programming. Thirdly, the memory of the tool may indicate tool-specific information, including measured calibration offsets indicating misalignment of the tool drive system, tool life data, or the like. This information may be stored in a read only memory (ROM), or in a nonvolatile memory which can be written to only a single time. The invention further provides improved engagement structures for coupling robotic surgical tools with manipulator structures.

What is claimed is: 
     
         1 . A surgical system comprising:
 a surgical instrument;   an interface comprising at least one electrical connector for transferring an electrical signal to said surgical instrument, said surgical instrument detachably coupled to said interface, said interface further comprising motion feedthroughs for actuating said surgical instrument for motion in at least two degrees of freedom;   said surgical instrument further comprising a counting mechanism for determining the number of times said surgical instrument has been coupled to said interface.   
     
     
         2 . The system of  claim 1 , wherein said counting mechanism is configured to count the number of times said surgical instrument has been coupled to said adaptor. 
     
     
         3 . The system of  claim 1 , wherein said counting mechanism is configured to count the number of times said surgical instrument has been decoupled from said adaptor. 
     
     
         4 . The system of  claim 1 , wherein said counting mechanism comprises an electromagnetic sensing mechanism and an integrated circuit. 
     
     
         5 . The system of  claim 1 , further comprising a warning module for detecting when said number of times exceeds a threshold, said warning module configured to issue an indication in response to said number of times exceeding said threshold. 
     
     
         6 . The system of  claim 5 , wherein said issuing an indication comprises preventing actuation of said surgical instrument by said adaptor. 
     
     
         7 . The system of  claim 1 , wherein said surgical instrument is an elongate shaft comprising a proximal end and a distal end, and said adaptor is detachably coupled to said proximal end of said shaft. 
     
     
         8 . The system of  claim 1 , said motion feedthroughs comprising rotatable shafts. 
     
     
         9 . The system of  claim 8 , wherein said motion feedthroughs are configured to actuate said surgical instrument for motion in at least four degrees of freedom. 
     
     
         10 . The system of  claim 1 , further comprising a master manipulator, wherein motions of said master manipulator are transferred to said surgical instrument through said adaptor. 
     
     
         11 . The system of  claim 10 , said adaptor further comprising at least one electrical connector for transferring an electrical signal from said surgical instrument to said interface. 
     
     
         12 . The system of  claim 11 , wherein said electrical signal from said surgical instrument to said interface comprises a force indication signal. 
     
     
         13 . The system of  claim 12 , wherein said master manipulator is configured to increase an apparent backlash in response to said number of times exceeding a threshold. 
     
     
         14 . The system of  claim 1 , said interface further comprising at least one electrical connector for transferring an electrical signal from said surgical instrument to said interface. 
     
     
         15 . The system of  claim 1 , further comprising a manipulator assembly comprising a manipulator arm having a proximal end and a distal end operably coupled to said interface. 
     
     
         16 . The system of  claim 15 , further comprising a sterile drape covering at least the manipulator arm of the manipulator assembly. 
     
     
         17 . A surgical system comprising:
 a surgical instrument;   an interface means for receiving said surgical instrument and transferring motion to said surgical instrument;   said surgical instrument comprising a counting means for counting the number of times said surgical instrument is received by said interface means.   
     
     
         18 . A method for performing a surgical procedure comprising:
 coupling a surgical instrument to an interface;   transferring an electrical signal from said interface to said surgical instrument;   transferring motion from said interface to said surgical instrument for actuating said surgical instrument;   decoupling said surgical instrument from said interface; and   incrementing a counter.   
     
     
         19 . The method of  claim 18 , wherein incrementing said counter is in response to coupling said instrument to said interface. 
     
     
         20 . The method of  claim 18 , wherein incrementing said counter is in response to decoupling said instrument from said interface. 
     
     
         21 . The method of  claim 18 , further comprising providing an indication when said counter exceeds a threshold. 
     
     
         22 . The method of  claim 21 , wherein providing an indication comprises stopping transfer of motion from said interface to said surgical instrument. 
     
     
         23 . The method of  claim 18 , further comprising manipulating a master manipulator to generate said motion transferred from said interface to said surgical instrument.