Improving Strength and Stability in Continuum Robots

Continuum robots, which are bio-inspired ’trunk-like’ robots, are characterized for their inherent compliance and range of motion. One of the key challenges in continuum robotics research is developing robots with sufficient strength and stability without adding additional weight or complexity to the design. The research conducted in this dissertation encompasses design and modeling strategies that address these challenges in strength and stability. This work improves three continuum robot actuation paradigms: (1) tendon-driven continuum robots (TDCR), (2) concentric tube robots (CTR), and (3) concentric push-pull robots (CPPR). The first chapter of contribution covers strategies for improving strength in TDCRs. The payload capacity and torsional stiffness of the robot can be improved by leveraging the geometry of the backbone design and tendon routing, with design choices experimentally validated on a robot prototype. The second chapter covers a new bending actuator, concentric precurved bellows (CPB), that are based upon CTR actuation. The high torsional stiffness of bellows geometry virtually eliminates the torsional compliance instability found in CTRs. Two bellows designs are developed for 3D printing and the mechanical properties of these designs are characterized through experiments on prototypes and in static finite element analysis. A torsionally rigid kinematic model is derived and validated on 3D printed prototypes. The third chapter of contribution covers the development and validation of a mechanics-based CPPR kinematics model. CPPRs are constructed from concentrically nested, asymmetrically patterned tubes that are fixed together at their distal tips. Relative translations between the tubes induces bending shapes from the robot. The model expands the possible design space of CPPRs by enabling the modeling of external loads, non-planar bending shapes, and CPPRs with more than two tubes. The model is validated on prototypes in loaded and unloaded experiments

Modeling, Sensorization and Control of Concentric-Tube Robots

Since the concept of the Concentric-Tube Robot (CTR) was proposed in 2006, CTRs have been a popular research topic in the field of surgical robotics. The unique mechanical design of this robot allows it to navigate through narrow channels in the human anatomy and operate in highly constrained environments. It is therefore likely to become the next generation of surgical robots to overcome the challenges that cannot be addressed by current technologies. In CSTAR, we have had ongoing work over the past several years aimed at developing novel techniques and technologies for CTRs. This thesis describes the contributions made in this context, focusing primarily on topics such as modeling, sensorization, and control of CTRs. Prior to this work, one of the main challenges in CTRs was to develop a kinematic model that achieves a balance between the numerical accuracy and computational efficiency for surgical applications. In this thesis, a fast kinematic model of CTRs is proposed, which can be solved at a comparatively fast rate (0.2 ms) with minimal loss of accuracy (0.1 mm) for a 3-tube CTR. A Jacobian matrix is derived based on this model, leading to the development of a real-time trajectory tracking controller for CTRs. For tissue-robot interactions, a force-rejection controller is proposed for position control of CTRs under time-varying force disturbances. In contrast to rigid-link robots, instability of position control could be caused by non-unique solutions to the forward kinematics of CTRs. This phenomenon is modeled and analyzed, resulting in design criteria that can ensure kinematic stability of a CTR in its entire workspace. Force sensing is another major difficulty for CTRs. To address this issue, commercial force/torque sensors (Nano43, ATI Industrial Automation, United States) are integrated into one of our CTR prototypes. These force/torque sensors are replaced by Fiber-Bragg Grating (FBG) sensors that are helically-wrapped and embedded in CTRs. A strain-force calculation algorithm is proposed, to convert the reflected wavelength of FBGs into force measurements with 0.1 N force resolution at 100 Hz sampling rate. In addition, this thesis reports on our innovations in prototyping drive units for CTRs. Three designs of CTR prototypes are proposed, the latest one being significantly more compact and cost efficient in comparison with most designs in the literature. All of these contributions have brought this technology a few steps closer to being used in operating rooms. Some of the techniques and technologies mentioned above are not merely limited to CTRs, but are also suitable for problems arising in other types of surgical robots, for example, for sensorizing da Vinci surgical instruments for force sensing (see Appendix A)

Design and Modeling of Multi-Arm Continuum Robots

Continuum robots are snake-like systems able to deliver optimal therapies to pathologies deep inside the human cavity by following 3D complex paths. They show promise when anatomical pathways need to be traversed thanks to their enhanced flexibility and dexterity and show advantages when deployed in the field of single-port surgery. This PhD thesis concerns the development and modelling of multi-arm and hybrid continuum robots for medical interventions. The flexibility and steerability of the robot’s end-effector are achieved through concentric tube technology and push/pull technology. Medical robotic prototypes have been designed as proof of concepts and testbeds of the proposed theoretical works.System design considers the limitations and constraints that occur in the surgical procedures for which the systems were proposed for. Specifically, two surgical applications are considered. Our first prototype was designed to deliver multiple tools to the eye cavity for deep orbital interventions focusing on a currently invasive intervention named Optic Nerve Sheath Fenestration (ONSF). This thesis presents the end-to-end design, engineering and modelling of the prototype. The developed prototype is the first suggested system to tackle the challenges (limited workspace, need for enhanced flexibility and dexterity, danger for harming tissue with rigid instruments, extensive manipulation of the eye) arising in ONSF. It was designed taking into account the clinical requirements and constraints while theoretical works employing the Cosserat rod theory predict the shape of the continuum end-effector. Experimental runs including ex vivo experimental evaluations, mock-up surgical scenarios and tests with and without loading conditions prove the concept of accessing the eye cavity. Moreover, a continuum robot for thoracic interventions employing push/pull technology was designed and manufactured. The developed system can reach deep seated pathologies in the lungs and access regions in the bronchial tree that are inaccessible with rigid and straight instruments either robotically or manually actuated. A geometrically exact model of the robot that considers both the geometry of the robot and mechanical properties of the backbones is presented. It can predict the shape of the bronchoscope without the constant curvature assumption. The proposed model can also predict the robot shape and micro-scale movements accurately in contrast to the classic geometric model which provides an accurate description of the robot’s differential kinematics for large scale movements

Modeling, Analysis, Force Sensing and Control of Continuum Robots for Minimally Invasive Surgery

This dissertation describes design, modeling and application of continuum robotics for surgical applications, specifically parallel continuum robots (PCRs) and concentric tube manipulators (CTMs). The introduction of robotics into surgical applications has allowed for a greater degree of precision, less invasive access to more remote surgical sites, and user-intuitive interfaces with enhanced vision systems. The most recent developments have been in the space of continuum robots, whose exible structure create an inherent safety factor when in contact with fragile tissues. The design challenges that exist involve balancing size and strength of the manipulators, controlling the manipulators over long transmission pathways, and incorporating force sensing and feedback from the manipulators to the user. Contributions presented in this work include: (1) prototyping, design, force sensing, and force control investigations of PCRs, and (2) prototyping of a concentric tube manipulator for use in a standard colonoscope. A general kinetostatic model is presented for PCRs along with identification of multiple physical constraints encountered in design and construction. Design considerations and manipulator capabilities are examined in the form of matrix metrics and ellipsoid representations. Finally, force sensing and control are explored and experimental results are provided showing the accuracy of force estimates based on actuation force measurements and control capabilities. An overview of the design requirements, manipulator construction, analysis and experimental results are provided for a CTM used as a tool manipulator in a traditional colonoscope. Currently, tools used in colonoscopic procedures are straight and exit the front of the scope with 1 DOF of operation (jaws of a grasper, tightening of a loop, etc.). This research shows that with a CTM deployed, the dexterity of these tools can be increased dramatically, increasing accuracy of tool operation, ease of use and safety of the overall procedure. The prototype investigated in this work allows for multiple tools to be used during a single procedure. Experimental results show the feasibility and advantages of the newly-designed manipulators

Dynamic modeling of soft continuum manipulators using lie group variational integration

This paper presents the derivation and experimental validation of algorithms for modeling and estimation of soft continuum manipulators using Lie group variational integration. Existing approaches are generally limited to static and quasi-static analyses, and are not sufficiently validated for dynamic motion. However, in several applications, models need to consider the dynamical behavior of the continuum manipulators. The proposed modeling and estimation formulation is obtained from a discrete variational principle, and therefore grants outstanding conservation properties to the continuum mechanical model. The main contribution of this article is the experimental validation of the dynamic model of soft continuum manipulators, including external torques and forces (e.g., generated by magnetic fields, friction, and the gravity), by carrying out different experiments with metal rods and polymer-based soft rods. To consider dissipative forces in the validation process, distributed estimation filters are proposed. The experimental and numerical tests also illustrate the algorithm's performance on a magnetically-actuated soft continuum manipulator. The model demonstrates good agreement with dynamic experiments in estimating the tip position of a Polydimethylsiloxane (PDMS) rod. The experimental results show an average absolute error and maximum error in tip position estimation of 0.13 mm and 0.58 mm, respectively, for a manipulator length of 60.55 mm

Integrating Optimization and Sampling for Robot Motion Planning with Applications in Healthcare

Robots deployed in human-centric environments, such as a person's home in a home-assistance setting or inside a person's body in a surgical setting, have the potential to have a large, positive impact on human quality of life. However, for robots to operate in such environments they must be able to move efficiently while avoiding colliding with obstacles such as objects in the person's home or sensitive anatomical structures in the person's body. Robot motion planning aims to compute safe and efficient motions for robots that avoid obstacles, but home assistance and surgical robots come with unique challenges that can make this difficult. For instance, many state of the art surgical robots have computationally expensive kinematic models, i.e., it can be computationally expensive to predict their shape as they move. Some of these robots have hybrid dynamics, i.e., they consist of multiple stages that behave differently. Additionally, it can be difficult to plan motions for robots while leveraging real-world sensor data, such as point clouds. In this dissertation, we demonstrate and empirically evaluate methods for overcoming these challenges to compute high-quality and safe motions for robots in home-assistance and surgical settings. First, we present a motion planning method for a continuum, parallel surgical manipulator that accounts for its computationally expensive kinematics. We then leverage this motion planner to optimize its kinematic design chosen prior to a surgical procedure. Next, we present a motion planning method for a 3-stage lung tumor biopsy robot that accounts for its hybrid dynamics and evaluate the robot and planner in simulation and in inflated porcine lung tissue. Next, we present a motion planning method for a home-assistance robot that leverages real-world, point-cloud obstacle representations. We then expand this method to work with a type of continuum surgical manipulator, a concentric tube robot, with point-cloud anatomical representations. Finally, we present a data-driven machine learning method for more accurately estimating the shape of concentric tube robots. By effectively addressing challenges associated with home assistance and surgical robots operating in human-centric environments, we take steps toward enabling robots to have a positive impact on human quality of life.Doctor of Philosoph

On the Statics, Dynamics, and Stability of Continuum Robots: Model Formulations and Efficient Computational Schemes

This dissertation presents advances in continuum-robotic mathematical-modeling techniques. Specifically, problems of statics, dynamics, and stability are studied for robots with slender elastic links. The general procedure within each topic is to develop a continuous theory describing robot behavior, develop a discretization strategy to enable simulation and control, and to validate simulation predictions against experimental results.Chapter 1 introduces the basic concept of continuum robotics and reviews progress in the field. It also introduces the mathematical modeling used to describe continuum robots and explains some notation used throughout the dissertation.The derivation of Cosserat rod statics, the coupling of rods to form a parallel continuum robot (PCR), and solution of the kinematics problem are reviewed in Chapter 2. With this foundation, soft real-time teleoperation of a PCR is demonstrated and a miniature prototype robot with a grasper is controlled.Chapter 3 reviews the derivation of Cosserat rod dynamics and presents a discretization strategy having several desirable features, such as generality, accuracy, and potential for good computational efficiency. The discretized rod model is validated experimentally using high speed camera footage of a cantilevered rod. The discretization strategy is then applied to simulate continuum robot dynamics for several classes of robot, including PCRs, tendon-driven robots, fluidic actuators, and concentric tube robots.In Chapter 4, the stability of a PCR is analyzed using optimal control theory. Conditions of stability are gradually developed starting from a single planar rod and finally arriving at a stability test for parallel continuum robots. The approach is experimentally validated using a camera tracking system.Chapter 5 provides closing discussion and proposes potential future work