EP4646165A2

EP4646165A2 - Autonomous tool exchange system for automated and semi-automated intraocular surgical procedures

Info

Publication number: EP4646165A2
Application number: EP24739024.8A
Authority: EP
Inventors: Peter Ferguson; Jacob Rosen; Nathan HAN
Original assignee: Horizon Surgical Systems Inc; University of California; University of California Berkeley; University of California San Diego UCSD
Current assignee: Horizon Surgical Systems Inc; University of California; University of California Berkeley; University of California San Diego UCSD
Priority date: 2023-01-05
Filing date: 2024-01-05
Publication date: 2025-11-12
Also published as: JP2026501782A; CN120882385A; WO2024148316A2; WO2024148316A3

Abstract

Devices, methods, and systems related to an autonomous tool exchange system for automated and semi-automated intraocular surgical procedures are provided. According to various embodiments of the present invention there is, for example, a tool exchange system for an autonomous intraocular surgical robot, having: a detachable rotary tool carousel configured to be releasably engaged to a rotating base, the tool carousel having a plurality of tool assembly docks each arranged around the tool carousel, in which each tool assembly dock is adapted for kinematic coupling to a kinematic coupling on a surgical tool holder assembly, further in which each surgical tool holder assembly comprises an end-effector kinematic coupling adapted and configured for coupling to a corresponding kinematic coupling on a robotic end effector while the surgical tool assembly is engaged with the tool assembly dock. Other embodiments are described herein.

Description

AUTONOMOUS TOOL EXCHANGE SYSTEM FOR AUTOMATED AND SEMIAUTOMATED INTRAOCULAR SURGICAL PROCEDURES

CLAIM OF PRIORITY

[0001] This application claims priority to U.S. Provisional Application No. 63/478,581, titled “AUTONOMOUS TOOL EXCHANGE SYSTEM FOR AUTOMATED AND SEMIAUTOMATED INTRAOCULAR SURGICAL PROCEDURES,” and filed January 5, 2023, the contents of which is incorporated herein by reference in its entirety.

INCORPORATION BY REFERENCE

[0002] All publications and patent applications mentioned in this specification are herein incorporated by reference in their entirety to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

FIELD

[0003] The present invention relates to automated tool changers and, more specifically, to automated tool changers for use in automated intraocular robotic surgery.

BACKGROUND

[0004] Automated tool exchange has been extensively developed in manufacturing applications such as CNC machines and automated assembly lines. While there have been some advancements within the field of medical robotics, improvements are still needed particularly in those surgeries where multiple tool exchanges are required, and the time of the tool exchange itself must be minimized, in the course of the surgery as well as coordination between two or more robotic end effectors.

[0005] In standard intraocular surgery, the surgeon frequently swaps between a number of surgical tools depending on the subtask being executed. This is typically achieved by a rapid hand-off between the surgeon and an assistant in the operating room or by the surgeon reaching for the tool on a prepared tray to the side or above the patient’s body. It is common for the same tool to be reused within a single surgery, and the sequence of tools used throughout a full procedure can vary from patient to patient and between different types of surgery.

[0006] In order to meet the requirements of robotically assisted, partially automated or fully automated intraocular robotic surgery, a number of challenges remain and further advancements in speed and reliability of tool exchange processes along with precise position control according to the surgical step, subset or overall surgical workflow.

SUMMARY OF THE DISCLOSURE

[0007] According to various embodiments of the present invention there is, for example, a tool exchange system for an autonomous intraocular surgical robot, having: a detachable rotary tool carousel configured to be releasably engaged to a rotating base, the tool carousel having a plurality of tool assembly docks each arranged around the tool carousel, in which each tool assembly dock is adapted for kinematic coupling to a kinematic coupling on a surgical tool holder assembly, further in which each surgical tool holder assembly comprises an end-effector kinematic coupling adapted and configured for coupling to a corresponding kinematic coupling on a robotic end effector while the surgical tool assembly is engaged with the tool assembly dock.

[0008] According to one example of this embodiment, the kinematic coupling on the surgical tool holder assembly adapted for coupling to the tool assembly dock is a bidirectional kinematic coupling configured to repeatedly withdraw and replace each of the surgical tool assembly from the rotary tool carousel.

[0009] According to one example of this embodiment, a first coupling direction is used by the robotic end-effector during removal or replacement of a surgical tool assembly, in which a second coupling direction is used by the rotary tool carousel to retain the surgical tool assembly.

[0010] According to one example of this embodiment, the first and second coupling directions are oriented such that a coordinated relative motion between the end-effector and the rotary tool carousel will exchange the surgical tool assembly from coupled to the tool assembly dock or coupled to the robotic end effector.

[0011] According to one example of this embodiment, the coordinated relative motion is a two-phase motion, in which the robotic end-effector first moves along the first coupling direction and subsequently along the second different coupling direction.

[0012] According to one example of this embodiment, the kinematic coupling includes one or more of: mechanical slots and pins, or magnets or a magnetic coupling.

[0013] According to one example of this embodiment, the surgical tool assembly comprising a memory chip configured to provide computer or machine-readable tool-specific information about the surgical tool or specific information of the surgical tool assembly coupled to the robotic end-effector. [0014] According to one example of this embodiment, the memory chip uses wireless communication including Radio Frequency Identification (RFID) or low power wireless communication or near field communication protocol, wherein the tool-specific information includes tool identification, wherein the tool-specific information includes manufacturing information such as calibration data and mechanical characteristics.

[0015] According to one example of this embodiment, the rotary tool carousel includes alignment hardware and attachment hardware for removable coupling and removal to a fixed portion of a tool exchanger of the tool exchange system.

[0016] According to one example of this embodiment, the fixed portion is a fixed cylindrical body of the tool exchanger.

[0017] According to another embodiment of the present invention there is, for example, an autonomous tool exchange system for managing the exchange of tool assemblies, including: a tool carousel having a plurality of surgical tool assemblies; a controller configured to relay information about a requested one of the plurality of surgical tool assemblies mounted on the tool carousel; and an actuation system configured to rotate the tool carousel to present the requested one of the plurality of tool assemblies to a position for access by a robotic end-effector.

[0018] According to one example of this embodiment, the actuation system is in a fixed portion of a tool carousel.

[0019] According to another embodiment of the present invention there is, for example, a method for tool exchange, including: verifying a surgical tool assembly via non-contact communication between an end-effector of a surgical robot and a memory of a surgical tool assembly; and removing or replacing the surgical tool assembly onto a tool carousel via bidirectional kinematic coupling.

[0020] According to one example of this method, removing or replacing the surgical tool assembly is performed by the end-effector of a surgical robot.

[0021] According to one example of this embodiment, removing or replacing the surgical tool assembly is performed manually.

[0022] According to another embodiment of the present invention there is, for example, a method for tool exchange, comprising: requesting a tool assembly for a robot end-effector; moving an empty robot end-effector into a tool exchange position adjacent to a rotary tool carousel; rotating the rotary tool carousel to position the requested tool assembly into the tool exchange position adjacent to the empty robot end-effector; moving the empty robot endeffector according to an engagement motion to couple the requested tool assembly to the robotic end-effector; moving the robot end-effector according to a disengagement motion to uncouple the requested tool assembly from the rotary tool carousel; performing a step of a surgical procedure by maneuvering the robot end-effector and manipulating the tool assembly; moving, pursuant to performing the step of the surgical procedure, the robot endeffector into the tool exchange position adjacent to the rotary tool carousel; rotating the rotary tool carousel to position an empty tool assembly dock at the tool exchange position; moving the robot end-effector according to an engagement motion to couple the requested tool assembly to the rotary tool carousel at the empty tool assembly dock; moving the robot endeffector according to a disengagement motion to uncouple the tool assembly from the robotic end-effector; and moving the robot end-effector according to a disengagement motion to uncouple the tool assembly from the robotic end-effector.

DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 A is a section view through a rotary tool carousel having eight tool assembly docks 1 through 8 on which are coupled eight surgical tool holder assemblies. A robot end-effector is empty and shown in an exchange position relative to the rotary tool carousel.

[0024] FIG. IB is a section view through a rotary tool carousel of FIG. 1 A showing the rotation of the rotary tool carousel to position the requested surgical tool holder assembly adjacent to the exchange location and the robot end effector.

[0025] FIG. 1C is a section view through a rotary tool carousel of FIG. IB with the endeffector moving through the exchange space to perform a movement to interrogate or couple to the surgical tool holder assembly.

[0026] FIG. ID is a section view through a rotary tool carousel of FIG. 1C after the end effector has performed a movement to uncouple the surgical tool holder assembly from a tool assembly dock on the rotary tool carousel.

[0027] FIG. 2 is a perspective view of a detachable rotary tool carousel.

[0028] FIG. 3 is a cross section view of the detachable rotary tool carousel of FIG. 2.

[0029] FIG. 4A is a side view of a detachable tool carousel showing the magnetic coupling locations on the tool assembly dock. A surgical tool holder assembly is shown adjacent to the tool assembly dock. The kinematic features of the surgical tool holder assembly adapted to couple with the end effector are also visible in this view. The kinematic features adapted to couple to the tool assembly dock are also visible in this view.

[0030] FIG. 4B is a view of a top coupling plate along an upper surface of the tool assembly housing that covers the components of the tool assembly shown in FIG. 4A. [0031] FIG. 5 A is a side view of a robotic end effector moving across an exchange zone adjacent to an engagement plate of a surgical tool holder assembly.

[0032] FIG. 5B is a side view of the end effector and surgical tool holder assembly in FIG. 5 A with the end effector in contact with the tool assembly engagement plate.

[0033] FIG. 5C is a side view of the end effector and surgical tool holder assembly in FIG. 5B showing the end effector motion to couple with the surgical tool holder assembly. [0034] FIG. 5D is a side view of the end effector - tool assembly of FIG. 5C completing the motion to uncouple the surgical tool holder assembly from the tool assembly dock of the rotary tool carousel.

[0035] FIG. 6 is an exemplary method of verifying a selected surgical tool holder assembly for coupling to a tool carousel.

[0036] FIG. 7 illustrates an exemplary method of coupling a selected surgical tool holder assembly to a robotic end effector.

DETAILED DESCRIPTION

[0037] Embodiments of the automated tool exchanger described herein have a range of capabilities intended to meet the requirements of robotically assisted, partially automated or fully automated intraocular robotic surgery. As detailed hereinbelow, the automatic tool exchanger provides the speed and reliability needed in complex tool exchange process sequences including precise position control according to the surgical step, subset or overall surgical workflow. The automated tool changer is capable of rapidly delivering a variety of surgical tools to the surgical robot as needed. Still further, the automatic tool exchanger is able to receive tools that have been used and tracks the locations of all tools for the duration of the surgery. Moreover, the reliability and precision of the tool exchange procedure ensures that the held surgical tool is always located in the intended position.

[0038] As a result, embodiments of the automatic tool exchanger meet the requirements of automated tool exchange for automated intraocular robotic surgery by way of electromechanical systems and a control framework to manage the exchange of surgical tools.

[0039] For example, there is a tool exchange system for an autonomous intraocular surgical robot, including: an end-effector of the robot; and a detachable rotary tool carousel (tool exchanger) configured to hold a plurality of tool assemblies, the plurality of surgical tool assemblies containing: a plurality of surgical tools, and a mechanical interface on at least one of the plurality of surgical tool assemblies configured to provide kinematic calibration between an end-effector of the surgical robot and the plurality of surgical tools. [0040] According to a certain example, each of the plurality of surgical tool assemblies has a bidirectional kinematic coupling configured to repeatedly withdraw and replace each of the plurality of tool assemblies from the rotary tool carousel.

[0041] According to a certain example, a first coupling direction is used by end-effector during removal or replacement of the plurality of surgical tool assemblies, in which a second coupling direction is used by the rotary tool carousel to retain the plurality of surgical tool assemblies.

[0042] According to a certain example, the first and second coupling directions are oriented such that a coordinated relative motion between the end-effector and the rotary tool carousel successfully exchanges the plurality of surgical tool assemblies.

[0043] According to a certain example, the coordinated relative motion is a two-phase motion, in which the end-effector first moves along the first coupling direction and subsequently along the second coupling direction.

[0044] According to a certain example, the kinematic coupling includes one or more of: mechanical slots and pins, and magnetic coupling.

[0045] According to a certain example, each of the plurality of surgical tool assemblies has a memory chip configured to provide tool-specific information about one or more of the plurality of surgical tools being held by the end-effector.

[0046] According to a certain example, the memory chip uses wireless communication including Radio Frequency Identification (RFID), in which the tool-specific information includes tool identification, wherein the tool-specific information includes manufacturing information such as calibration data and mechanical characteristics.

[0047] According to a certain example, the rotary tool carousel includes alignment hardware and attachment hardware for removable coupling and removal to a fixed portion of a tool exchanger of the tool exchange system.

[0048] According to a certain example, the fixed portion is a fixed cylindrical body of the tool exchanger.

[0049] According to another example of the present invention, there is an autonomous tool exchange system for managing the exchange of tool assemblies, including: an endeffector of a robot; a tool carousel having a plurality of tool assemblies; a controller configured to relay information about a requested one of the plurality of tool assemblies; and an actuation system configured to rotate the tool carousel to present the requested one of the plurality of tool assemblies to the end-effector.

[0050] According to a certain example, the actuation system is in a fixed portion of a tool carousel (tool exchanger). [0051] Each of the major elements of the automated tool exchanger will now be described in turn.

Rotary Tool Carousel (FIGS. 2 and 3)

[0052] FIG. 2 is a perspective view of a detachable rotary tool carousel 200 coupled to a fixed base portion 201B. The rotary tool carousel 200 is a mechanical assembly that holds several tool subassemblies 202 configured to hold surgical tools 204. Each tool subassembly 202 can be detached from and reattached to the carousel 200 during the course of a surgery, for example via carousel attachment hardware 206 which may include a coupler. According to certain examples, rotary tool carousel 200 may be positioned over or on the outside of a barrel, rotational platform, or other socket on a surgical robot. Also shown here is a carousal actuation system 201B, tool assembly dock 201 A, and a tool assembly interface to robotic end-effector 202A (see FIGS. 4A-4B). Also shown is base of fixed portion 20 IB, electronics mounting plate 20 IE, carrying handle 20 ID, and carousel side plate 201C.

[0053] FIG. 3 is a cross section view 300 of the detachable rotary tool carousel 200 of FIG. 2. The carousel 200 itself can be loaded into position before surgery and unloaded after surgery. In the operating room workflow, a sterile nurse will be able to load and unload the tool exchanger as needed according to the clinical need or surgical plan. The new collection of tool holders is coupled to a tool carousel - either loading the tool assemblies 302 by hand while the carousel 200 installed on the cart or installing the tool assemblies 302 onto the carousel 200 prior to installing the carousel 200 onto the cart. Advantageously, specific tool carousels may be pre-loaded with the surgical tools preferred by a particular surgeon or as needed for performing a particular procedure. Additionally or optionally, surgical tool holder assemblies may be loaded onto the carousel in order aid in the efficiency of the rotation/exchange operation (See FIGS. 1 A-1D). According to certain examples, carousel actuation system 30 IB may be pre-loaded with surgical tools and ready to use for a particular surgery, with the identity and proper orientation of surgical tools configured to be recognized and/or indexed by a surgical robot. According to yet other examples, there is a fixed portion of tool exchanger 310, to which rotary carousel 200 may attach via carousel attachment hardware 306 which also couples the carousel 200 with the carousal actuation system 301B. According to other examples, carousel actuation system 30 IB may be coupled to a surgical robot and rotary tool carousel 300 via carousel alignment hardware 307 and carousel attachment hardware 306 such as a coupler. In such an example, pursuant to such coupling, information about the surgical tools loaded and other data is transmitted to the surgical robot. Also shown are actuator 301G, brake/encoder 301F, carousel bottom plate 301G, carousel side plate 301H, base of fixed portion 301B, attachment hardware handle 306A, and carousel rotary shaft 308.

[0054] The fixed portion of the tool exchanger 310 is rigidly mounted to the frame of the robot, for example to the robotic end-effector. The tool assemblies 302 are attached to the carousel 300 through kinematic coupling. The carousel 300 with all of the tool assemblies 302 attached, slides over the fixed portion 310 and aligns with the carousel rotary shaft 308 through the carousel alignment hardware 307 which radially constrains the rotary tool carousel 300. When the robot needs to grab a tool, the rotary shaft 308, and thus the carousel 300 as a whole, rotates to orient the tool assemblies 302 in the correct position. Then the robot end effector 102 (from FIGS. 1A-1D) picks up or drops off the selected tools 204. In this process, the robot end effector 102 does not interface directly with the carousel 300 as it only interfaces with the tool assemblies 302.

[0055] The tool carousel is shaped as a cylinder so that all tool assemblies 302 are mounted at a fixed distance from the rotation axis. Each one of the tool assembly docks has a similar form factor so that each surgical tool holder assembly 302 is mounted in a similar location on a tool assembly dock regardless of the surgical tool holder assembly function. This standardization of the tool assembly dock and fixed rotational indexing by the rotary motion of the carousel, allows each surgical tool holder assembly 302 to be moved to a configuration which is constant and known relative to the surgical end-effector. These aspects of the rotary tool carousel enable improved reliability and accuracy of the tool exchange system. Advantageously, the rotary carousel is accurately moved by only a single motor. The repeatable positioning of tool subassemblies 302 allows for repeatable and pre-defined end-effector motion during the tool exchange.

[0056] In view of the above, there are provided various embodiments of an improved tool exchange system for an autonomous intraocular surgical robot having a detachable rotary tool carousel 200 that holds a plurality of tool assemblies 202. Each of the individual tool assemblies contains a mechanical interface that provides a repeatable kinematic interface between the surgical robot end-effector and each surgical tool holder assembly positioned on the rotary tool carousel. Additionally, each surgical tool holder assembly carries a surgical tool. Each surgical tool holder assembly has a bi-directional kinematic coupling 400 A so that the surgical tool holder assembly may be repeatedly withdrawn from and returned to a position on the rotary tool carousel. There is also provided a common set of movements between the robotic end-effector, a selected surgical tool holder assembly and the rotary tool carousel. There is a first coupling direction to be used during removal or replacement of the surgical tool holder assembly by the robot end-effector. There is a second coupling direction to be used by the rotary tool carousel to retain the surgical tool holder assembly. In use, the coupling directions are oriented such that a coordinated relative motion between the surgical end-effector and the rotary tool carousel successfully exchanges a surgical tool holder assembly from (a) being coupled to a dock assembly on the rotary tool carousel to being coupled to the robotic end-effector and (b) being coupled to a robotic end-effector to being coupled to a dock assembly on the rotary tool carousel. The coordinated relative motion is a two-phase motion where the end-effector first moves along the first coupling direction, and subsequently along the second coupling direction. In one embodiment, the kinematic coupling includes mechanical slots and pins 406 alone or in combination with a kinematic coupling implementation that includes specifically aligned magnetic couplings 404A.

[0057] In still other alternative embodiments, each surgical tool holder assembly includes a memory chip. The memory chip may include computer readable code including toolspecific information about the surgical tool 204 being held. In one aspect, the memory chip can use wireless communication such as RFID, low power wireless communication or other near field communication (NFC) protocol as appropriate to the operating room procedures and capabilities. In another aspect, the tool-specific information includes tool identification, use information and unique characteristics and any user specific preference from prior uses or intended use in a surgical plan such as designation of a particular instrument. Additionally or optionally, the tool-specific information may include manufacturing information such as calibration data and mechanical characteristics.

[0058] In still other embodiments, the rotary tool carousel 300 includes alignment hardware 307 and attachment hardware 306. Uses for the alignment hardware 307 and attachment hardware 306 include the accurate and reliable installation and removal of the tool carousel 300 onto a fixed portion of the tool exchanger 310. As such, there is a fixed cylindrical body of the tool exchanger 310, to which the rotary tool carousel 300 is removably mounted using the alignment hardware 307 and attachment hardware 306.

[0059] In one embodiment, there is an autonomous system that manages the exchange of tool assemblies between the end-effector and the rotary tool carousel. The autonomous exchange system includes a controller that relays information about the requested surgical tool holder assembly and an actuation system that rotates the tool carousel to present the requested surgical tool holder assembly to the end-effector. In one aspect, the actuation system resides in the fixed portion of the tool exchanger. There is also provided a method for an exchange procedure whereby the surgical tool holder assembly is verified by non-contact communication between the surgical end-effector and the memory of the surgical tool holder assembly. Still further, there is also an exchange procedure whereby the surgical tool holder assembly is removed from or replaced onto the tool carousel using the bi-directional kinematic coupling. In one aspect, the exchange procedure is performed autonomously by the surgical robot end-effector. Additionally or optionally, the exchange procedure may be performed manually.

Bidirectional Kinematic Coupling (FIGS. 4A-4B and 5A-5D)

[0060] According to various examples, there are different instances where kinematic coupling may occur, including (1) kinematic coupling: end-effector (coupling between the end-effector and tool holder assembly) and (2) kinematic coupling: rotary tool carousel (coupling between the rotary tool carousel and surgical tool assembly). Both kinematic couplings may occur through the use of mechanical holes/slots and pins and magnetic coupling.

Kinematic coupling: End-effector.

[0061] The surgical tool assembly may couple to the rotary tool carousel through magnets and its orientation is constrained through the use of pins on the carousel and holes on the surgical tool assembly.

Kinematic Coupling: Rotary Tool Carousel.

[0062] When the surgical robot picks up a tool, it aligns and engages a slot on the surgical robot with a second set of pins on the surgical tool assembly and magnets on both assemblies align with one another. The robot then disengages the tool holder assembly from the set of pins and magnets on the carousel to remove the surgical tool assembly from the carousel. To place back a tool, the reverse of this procedure is performed.

[0063] FIG. 4A is a side view of a detachable tool carousel 400 showing the magnetic coupling locations on the tool assembly dock. A surgical tool holder assembly 402 is shown adjacent to the tool assembly dock. The kinematic features of the surgical tool holder assembly 402 adapted to couple to the end effector 402A (not shown) and to couple to rotary tool carousel 400A are also visible in this view. The kinematic features adapted to couple to the tool assembly dock are also visible in this view.

[0064] The tool subassemblies 402 contain two sets of attachment hardware for kinematic coupling 400A/402A. FIG. 4B is a view of a top coupling plate along an upper surface of the tool assembly housing 450 that covers the components of the tool assembly 402 shown in FIG. 4A.

[0065] As shown in FIG. 4B, the first set of attachment hardware may in certain examples include alignment cutouts 404B, and is used to kinematically couple or attach the tool subassembly to the rotary tool carousel 400A. The second set of attachment hardware may in certain examples include pins and slots 406 and is used by the surgical robot end- effector (not shown) to remove and replace the tool subassembly 402 through kinematic coupling between the tool subassembly and the robot end-effector 402A.

[0066] FIG. 4B is a view of a top coupling plate along an upper surface of the tool assembly housing that covers the components of the tool assembly shown in FIG. 4A. The top coupling plate includes three alignment cutouts 404B and three magnets 404A. One alignment cutout 404B is in a middle portion on the left side of the assembly. The other two alignment cutouts 404B are in the front right comer and the left right corner. One magnet 404A is positioned on the middle portion on the right side. Two magnets 404A are positioned on the left front corner and the left rear comer.

[0067] According to certain examples, the tool holder housing has a bottom coupling plate (not shown) with a configuration similar to those described above. A pair of pins 406 are positioned along the sides of the base adjacent to the front and rear comers. Additionally, a magnet 404M is positioned in a middle portion of each of the left and the right sides. In one illustrative embodiment, the pins 406 may slide perpendicularly into cutouts appropriately sized and positioned in an end effector plate in order to kinematically constrain motion via kinematic coupling 402A. It is to be appreciated that several differently sized and arranged clearances and chamfers are built into the interface between tool holder assembly housing and the end effector plate to allow for easy placement. Moreover, one or a series of magnets 404M/404A may be installed in the holder housing and plate to not only repeatably and accurately align the holder with respect to the plate but to also provide a unique coupling configuration. In one exemplary coupling operation, the magnets 404A/404M are arranged to push/pull the tool holder assembly 402 to one side of the end effector plate and pull the tool holder assembly 402 to the back of the plate, securing the above-mentioned pins 406 in the cutouts of the plate.

[0068] Considering the top and bottom coupling plates together, it is to be appreciated that the upper surface of the surgical tool holder contains a series of magnets 404A, pins/extrusions 406, and/or cutouts/holes 404B that match up to their counterparts on various surfaces of an appropriately configured tool exchanger or rotary tool carousel 400. When placed in proximity to the tool exchanger 402, the magnets 404A work to pull the tool holder against the exchanger 402 and insert dowel pins 406 into dowel holes on each part. Advantageously, these pins/holes 406 and coupling motion 402A of the upper coupling plate are arranged such that they kinematically prevent the motion that is used to connect/ disconnect the robot end-effector (at the plate) to the tool holder (at the holder housing) as accomplished by the coupling action of the lower coupling plate. As such, embodiments of the surgical tool assembly may use a set of coupling motions for an upper coupling plate and a different and non-conflicting set of coupling motions for a lower coupling plate. In this way, embodiments of the various surgical tool holder assemblies provide a surgeon with a wide array of different tools and functionalities all with a common set of unique coupling exchanges to each of a tool exchanger 402 and a robot end effector. [0069] Additionally or optionally, depending on the number and configuration of the surgical tool holder assemblies for a given robotic surgical procedure, the bi-directional kinematic coupling feature of a tool assembly may be adapted for top-bottom coupling (as shown in FIGS. 5A-5D) or on a left-right or “side coupling” as shown and further described in FIGS. 1 A, IB and 2 of U.S. Provisional Patent Application No. 63/478,770, titled “SURGICAL TOOL HOLDER FOR INTRAOCULAR ROBOTIC SURGICAL SYSTEMS,” filed on January 6, 2023, and in Patent Cooperation Treaty Application No.

PCT/US2024/XXXXX, titled “SURGICAL TOOL HOLDER FOR INTRAOCULAR ROBOTIC SURGICAL SYSTEMS,” and filed concurrently on January 5, 2024, with Attorney Docket Number 14843-701.600, each of which are incorporated herein by reference in their entirety.

[0070] The two sets of hardware are designed such that only a coordinated motion by the surgical robot end-effector/carousel actuation system 50 IB can successfully exchange the tool subassembly 502 between the carousel 500 and the end-effector/carousel actuation system 501B. This coordinated motion is summarized in FIGS. 5A-5D.

[0071] FIG. 5 A is a side view of a robotic end effector/carousel actuation system 50 IB moving across an exchange zone adjacent to an engagement plate of a surgical tool holder assembly 502 on a detachable rotary tool carousel 500, with alignment of pins and slots 506 on the robotic end effector/carousel actuation system 50 IB and surgical tool holder assembly 502. In some examples, the robotic end effector/carousel actuation system 50 IB may be directly over the surgical tool holder assembly 502.

[0072] FIG. 5B is a side view of the end effector/carousel actuation system 50 IB and surgical tool holder assembly 502 in FIG. 5A with the end effector/carousel actuation system 50 IB in contact with the tool assembly engagement plate. In some examples, the end effector/carousel actuation system 50 IB moves downwards 510 to contact with the surgical tool assembly 502.

[0073] FIG. 5C is a side view of the end effector/carousel actuation system 50 IB and surgical tool holder assembly 502 in FIG. 5B showing the end effector/carousel actuation system motion to couple 512 with the surgical tool holder assembly 502. In some examples, mating occurs between pins and slots 506 on the end effector/carousel actuation system 50 IB and surgical tool holder assembly 502, with end effector/carousel actuation system 50 IB sliding forward 512 onto surgical tool holder assembly 502.

[0074] FIG. 5D is a side view of the end effector/carousel actuation system 50 IB - tool assembly 502 of FIG. 5C completing the motion to uncouple 514 the surgical tool holder assembly 502 from the tool assembly dock of the rotary tool carousel 500. In some examples, the uncoupling 514 is accomplished via detachment of pins and slots 506 on the end effector/carousel actuation system 50 IB and surgical tool holder assembly 502.

[0075] FIGS. 5A and 5B together illustrate this coordinated motion where the surgical end-effector/carousel actuation system 50 IB moves in a direction coinciding with the second set of attachment hardware on the surgical tool holder assembly 502. Meanwhile, the first set of attachment hardware that couples the surgical tool holder assembly 502 to a tool assembly dock stays fixed. As a result, the surgical tool holder assembly 502 is now firmly held by both the surgical end-effector/carousel actuation system 50 IB and the rotary tool carousel 500 as shown in FIG. 5C. FIG. 5D illustrates the coordinated motion of a second step where the surgical end-effector/carousel actuation system 50 IB moves in a direction coincident with the first set of attachment hardware. This second step releases 514 the surgical tool holder assembly 502 from the tool assembly dock on the rotary tool carousel 500. The surgical end- effector/carousel actuation system 508 is now free to move back to the surgical site and position the coupled surgical tool holder assembly 502 in accordance with the steps of the surgical procedure for the use of the selected surgical tool.

[0076] The replacement of a surgical tool holder assembly 502 onto the rotary tool carousel 500 by the surgical end-effector/carousel actuation system 50 IB uses the same motion as described in FIGS. 5A-5D but in reverse order. Beginning in FIG. 5D, the end effector/carousel actuation system 50 IB is positioned over an empty tool assembly dock designated by the control system to receive the surgical tool holder assembly 502 currently coupled to the end effector/carousel actuation system 50 IB. Next, moving the end effector/carousel actuation system 50 IB towards the tool assembly dock, the surgical tool holder assembly 502 will become coupled to the tool assembly dock while still coupled to the end effector/carousel actuation system 50 IB (FIG. 5C). The motion of the end effector/carousel actuation system 50 IB is reversed to that shown in FIG. 5C to first uncouple the pins and slots 506 and then once cleared as in FIG. 5B the end effector/carousel actuation system 50 IB may move clear of the surgical tool holder assembly 502 as in FIG.

5 A.

Method For Automated Exchange (FIGS. 1, 5, 6 and 7A-7B) [0077] The rotary tool carousel 104 (from FIG. 1) is positioned near the surgical site, and within the reachable workspace of the surgical end-effector 102. Unlike many conventional tool exchange systems coupled to the end effector 102, embodiments of the rotary tool carousel 104 of the present invention are not fixed to the surgical end-effector 102 but rather are positioned adjacent to the surgical field. FIG. 1 A is a section view through a rotary tool carousel 102 having eight tool assembly 105 (docks 1 through 8) arranged about a perimeter of the rotary tool carousel 104, on each of which are coupled one of eight surgical tool holder assemblies a through h (and 202, see FIG. 2), including a requested tool assembly c/106. In preparation for a tool holder assembly exchange 102E at the topmost portion of the rotary tool carousel 104, an empty robot end-effector 102 is shown in an exchange position relative to the rotary tool carousel 104. When the surgical system requests a new tool c/106, an empty end effector 102 is positioned adjacent to an exchange zone of the rotary tool carousel 104 as shown in FIG. 1 A. However, the requested surgical tool holder assembly 106 for the empty end-effector 102 is not in the proper position for an exchange.

[0078] FIG. IB is a section view through a rotary tool carousel 104 of FIG. 1 A showing the rotation 108 of the rotary tool carousel 104 to position the requested surgical tool holder assembly c/106 adjacent to the exchange location and the robot end effector 102.

[0079] As a result of the rotational movement of the tool carousel, the requested surgical tool holder assembly c/106 is at a known configuration relative to the surgical robot endeffector 102 in the exchange zone. As mentioned above, the surgical robot end-effector 102 is commanded to move to a position above the surgical tool holder assembly 106 adjacent to the exchange zone preparation for the tool holder assembly exchange 102E.

[0080] FIG. 1C is a section view through a rotary tool carousel 104 of FIG. IB with the end-effector 102 moving through the exchange space to perform a movement to interrogate or couple 109 to the surgical tool holder assembly c/106.

[0081] Thereafter, the surgical end-effector 102 moves to engage with the bi-directional kinematic coupling described above in the Bidirectional Kinematic Coupling subsection, and performs the coordinated motion described in FIGS. 5A-5D to remove the surgical tool holder assembly c/106 from the rotary tool carousel 104.

[0082] FIG. ID is a section view through a rotary tool carousel 104 of FIG. 1C after the end effector 102 has performed a movement to uncouple 110 the surgical tool holder assembly c/106 from a tool assembly dock (for example tool assembly dock 3) on the rotary tool carousel 104. The surgical tool assembly is thus coupled to the end effector 102, leaving an empty tool assembly dock 3/105. [0083] After making contact with the surgical tool holder assembly 106, the system performs an electronic exchange of information between the surgical end-effector 102 and the surgical tool holder assembly 106. Each surgical tool holder assembly 106 is calibrated in the factory to correct for inaccuracies during manufacturing and assembly. This calibration information, along with the identity of the tool being held, is stored in the wireless tag on the surgical tool holder assembly 106. As a result of the availability of this information, each tool 204 (from FIG. 2) used during a procedure may be specially adapted for the particular performance characteristics of a given surgical tool holder assembly 106.

[0084] FIG. 6 is an exemplary method 600 of verifying a selected surgical tool holder assembly for coupling to a tool carousel.

[0085] First, at step 605, there is a process of verifying a surgical tool assembly via noncontact communication between an end-effector of a surgical robot and a memory of a surgical tool assembly.

[0086] Next, at step 610, there is the process of removing or replacing the surgical tool assembly onto a tool carousel via bi-directional kinematic coupling.

[0087] According to an example of method 600, removing or replacing the surgical tool assembly is performed by the end-effector of a surgical robot.

[0088] According to an example of method 600, removing or replacing the surgical tool assembly is performed manually.

[0089] FIG. 7 illustrates an exemplary method 700 of coupling a selected surgical tool holder assembly to a robotic end effector.

[0090] First, at step 705, there is a step of requesting a surgical tool holder assembly for a robot end effector as part of an intraocular surgical procedure using robotic end effector.

[0091] Next, at step 710, there is the process of moving an empty robot end effector into a tool exchange position adjacent to a rotary tool carousel.

[0092] Next, at step 715, there is the process of rotating the rotary tool carousel to position the requested surgical tool holder assembly into the tool exchange position adjacent to the empty robot end-effector.

[0093] Next, at step 720, there is the process of moving the empty robot end effector according to an engagement motion to couple the requested surgical tool holder assembly to the robotic end effector.

[0094] Next, at step 725, there is the process of moving the robot end effector according to a disengagement motion to uncouple the requested surgical tool holder assembly from the rotary tool carousel. [0095] Next, at step 730, there is the process of performing a step of a surgical procedure by maneuvering the robot end effector and manipulating the surgical tool holder assembly. [0096] Next, at step 735, there is the process performed pursuant to performing the step of the surgical procedure, for moving the robot end effector into the tool exchange position adjacent to the rotary tool carousel.

[0097] Next, at step 740, there is the process of rotating the rotary tool carousel to position an empty tool assembly dock at the tool exchange position.

[0098] Next, at step 745, there is the process of moving the robot end effector according to an engagement motion to couple the requested surgical tool holder assembly to the rotary tool carousel at the empty tool assembly dock.

[0099] Next, at step 750, there is the process of moving the robot end effector according to a disengagement motion to uncouple the surgical tool holder assembly from the robot end effector.

[00100] Next, at step 755, there is the process of positioning the empty robot end effector in the tool exchange position adjacent to a rotary tool carousel.

[00101] It is to be appreciated that the exemplary process 700 outlined above and in FIG. 7 may be modified according to specific implementation or to facilitate the use of more than one rotary tool carousel or robot end-effector.

[00102] In one particular aspect, the tool carousel is adapted and configured for all surgical tool assemblies to employ the bi-directional kinematic functionality as all using a top-bottom coupling as shown and described in FIGS. 5A-5D and in FIG. IB of the incorporated

“SURGICAL TOOL HOLDER FOR INTRAOCULAR ROBOTIC SURGICAL SYSTEMS” applications. In still another variation, depending on the types of surgical tools or robotic interoperability, a tool carousel may have a mixture of both to-bottom and side-side kinematics.

[00103] When a feature or element is herein referred to as being "on" another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being "directly on" another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being "connected", "attached" or "coupled" to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being "directly connected", "directly attached" or "directly coupled" to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed "adjacent" another feature may have portions that overlap or underlie the adjacent feature. [00104] Terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. For example, as used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items and may be abbreviated as "/".

[00105] Spatially relative terms, such as "under", "below", "lower", "over", "upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as "under" or "beneath" other elements or features would then be oriented "over" the other elements or features. Thus, the exemplary term "under" can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms "upwardly", "downwardly", "vertical", "horizontal" and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

[00106] Although the terms “first” and “second” may be used herein to describe various features/elements (including steps), these features/elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another feature/element. Thus, a first feature/element discussed below could be termed a second feature/element, and similarly, a second feature/element discussed below could be termed a first feature/element without departing from the teachings of the present invention.

[00107] Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising” means various components can be co-jointly employed in the methods and articles (e.g., compositions and apparatuses including device and methods). For example, the term “comprising” will be understood to imply the inclusion of any stated elements or steps but not the exclusion of any other elements or steps.

[00108] In general, any of the apparatuses and methods described herein should be understood to be inclusive, but all or a sub-set of the components and/or steps may alternatively be exclusive, and may be expressed as “consisting of’ or alternatively “consisting essentially of’ the various components, steps, sub-components or sub-steps. [00109] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word "about" or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/- 0.1% of the stated value (or range of values), +/- 1% of the stated value (or range of values), +/- 2% of the stated value (or range of values), +/- 5% of the stated value (or range of values), +/- 10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value "10" is disclosed, then "about 10" is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that "less than or equal to" the value, "greater than or equal to the value" and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value "X" is disclosed the "less than or equal to X" as well as "greater than or equal to X" (e.g., where X is a numerical value) is also disclosed. It is also understood that the throughout the application, data is provided in a number of different formats, and that this data, represents endpoints and starting points, and ranges for any combination of the data points. For example, if a particular data point “10” and a particular data point “15” are disclosed, it is understood that greater than, greater than or equal to, less than, less than or equal to, and equal to 10 and 15 are considered disclosed as well as between 10 and 15. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[00110] Although various illustrative embodiments are described above, any of a number of changes may be made to various embodiments without departing from the scope of the invention as described by the claims. For example, the order in which various described method steps are performed may often be changed in alternative embodiments, and in other alternative embodiments one or more method steps may be skipped altogether. Optional features of various device and system embodiments may be included in some embodiments and not in others. Therefore, the foregoing description is provided primarily for exemplary purposes and should not be interpreted to limit the scope of the invention as it is set forth in the claims. [00111] The examples and illustrations included herein show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. As mentioned, other embodiments may be utilized and derived there from, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept, if more than one is, in fact, disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.

Claims

What is claimed is:

1. A tool exchange system for an autonomous intraocular surgical robot, comprising: a detachable rotary tool carousel configured to be releasably engaged to a rotating base, the tool carousel having a plurality of tool assembly docks each arranged around the tool carousel, wherein each tool assembly dock is adapted for kinematic coupling to a kinematic coupling on a surgical tool holder assembly, further wherein each surgical tool holder assembly comprises an end-effector kinematic coupling adapted and configured for coupling to a corresponding kinematic coupling on a robotic end effector while the surgical tool assembly is engaged with the tool assembly dock.

2. The tool exchange system of claim 1, wherein the kinematic coupling on the surgical tool holder assembly adapted for coupling to the tool assembly dock is a bi-directional kinematic coupling configured to repeatedly withdraw and replace each of the surgical tool assembly from the rotary tool carousel.

3. The tool exchange system of claim 1, wherein a first coupling direction is used by the robotic end-effector during removal or replacement of a surgical tool assembly, wherein a second coupling direction is used by the rotary tool carousel to retain the surgical tool assembly.

4. The tool exchange system of claim 3, wherein the first and second coupling directions are oriented such that a coordinated relative motion between the end-effector and the rotary tool carousel will exchange the surgical tool assembly from coupled to the tool assembly dock or coupled to the robotic end effector.

5. The tool exchange system of claim 4, wherein the coordinated relative motion is a two-phase motion, wherein the robotic end-effector first moves along the first coupling direction and subsequently along the second different coupling direction.

6. The tool exchange system of any of the above claims wherein the kinematic coupling includes one or more of: mechanical slots and pins, or magnets or a magnetic coupling.

7. The tool exchange system of any of the above claims, the surgical tool assembly comprising a memory chip configured to provide computer or machine-readable tool-specific information about the surgical tool or specific information of the surgical tool assembly coupled to the robotic end-effector.

8. The tool exchange system of claim 7, wherein the memory chip uses wireless communication including Radio Frequency Identification (RFID) or low power wireless communication or near field communication protocol, wherein the tool-specific information includes tool identification, wherein the tool-specific information includes manufacturing information such as calibration data and mechanical characteristics.

9. The tool exchange system of claim 1, wherein the rotary tool carousel includes alignment hardware and attachment hardware for removable coupling and removal to a fixed portion of a tool exchanger of the tool exchange system.

10. The tool exchange system of claim 9, wherein the fixed portion is a fixed cylindrical body of the tool exchanger.

12. An autonomous tool exchange system for managing the exchange of tool assemblies, comprising: a tool carousel having a plurality of surgical tool assemblies; a controller configured to relay information about a requested one of the plurality of surgical tool assemblies mounted on the tool carousel; and an actuation system configured to rotate the tool carousel to present the requested one of the plurality of tool assemblies to a position for access by a robotic end-effector.

13. The tool exchange system of claim 12, wherein the actuation system is in a fixed portion of a tool carousel.

14. A method for tool exchange, comprising: verifying a surgical tool assembly via non-contact communication between an endeffector of a surgical robot and a memory of a surgical tool assembly; and removing or replacing the surgical tool assembly onto a tool carousel via bidirectional kinematic coupling.

15. The method of claim 14, wherein removing or replacing the surgical tool assembly is performed by the end-effector of a surgical robot.

16. The method of claim 14, wherein removing or replacing the surgical tool assembly is performed manually.

17. A method for tool exchange, comprising: requesting a tool assembly for a robot end-effector; moving an empty robot end-effector into a tool exchange position adjacent to a rotary tool carousel; rotating the rotary tool carousel to position the requested tool assembly into the tool exchange position adjacent to the empty robot end-effector; moving the empty robot end-effector according to an engagement motion to couple the requested tool assembly to the robotic end-effector; moving the robot end-effector according to a disengagement motion to uncouple the requested tool assembly from the rotary tool carousel; performing a step of a surgical procedure by maneuvering the robot end-effector and manipulating the tool assembly; moving, pursuant to performing the step of the surgical procedure, the robot endeffector into the tool exchange position adjacent to the rotary tool carousel; rotating the rotary tool carousel to position an empty tool assembly dock at the tool exchange position; moving the robot end-effector according to an engagement motion to couple the requested tool assembly to the rotary tool carousel at the empty tool assembly dock; moving the robot end-effector according to a disengagement motion to uncouple the tool assembly from the robotic end-effector; and moving the robot end-effector according to a disengagement motion to uncouple the tool assembly from the robotic end-effector.