White PaperMedical
Advanced Polymer Gears Provide Backlash-free, Quiet Performance in Surgical Robot
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A surgical robot’s precision of movement depends primarily on the precision delivered by the gear drive of the robotic arm. Traditionally used metal gears require backlash, have higher mass, and are noisy. This study details how Intech Corporation’s engineers designed lightweight, precision-machined, backlash-free polymer gears, significantly improving the surgeons’ control. Other benefits include low inertia, noise reduction, and eliminating the need for lubrication — significant advantages in motion control applications across industries.
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Overview
The document discusses the advancements in gear technology developed by Intech Corporation, specifically focusing on their Power-Core™ gears used in surgical robots. These gears are designed to address critical challenges in robotic surgery, such as noise reduction, inertia, backlash elimination, and maintenance-free operation.
Intech's Power-Core™ gears are made from high-performance polymers reinforced with an integral aluminum core. This unique combination ensures a secure transmission of drive torque while providing a low coefficient of friction and shock-absorbing capacity, which enhances torque transmission efficiency by at least 3%. Unlike conventional plastic gears, which can absorb moisture and require undercuts that introduce backlash, Intech's gears maintain dimensional stability and virtually eliminate backlash, crucial for the precision required in surgical applications.
The design of these gears also focuses on reducing inertia, which is vital for the responsiveness of robotic systems. The lightweight nature of the polymer and aluminum gear train reduces inertia by a factor of seven compared to traditional steel gears, allowing for more accurate positioning of surgical instruments. This is particularly important in delicate procedures where even minor movements can lead to significant complications.
In addition to performance improvements, the document highlights the noise reduction achieved through the use of these advanced gears. The precision machining and material properties of the Power-Core™ gears contribute to a 50% reduction in noise output, addressing concerns from surgeons about distracting sounds during operations.
The gears are engineered to meet AGMA Class 11 accuracy standards and are designed for a typical five-year life cycle in medical applications. They are also lubrication-free, which minimizes maintenance needs and the risk of contamination from lubricants or metal particles, making them ideal for sterile environments.
Overall, Intech's innovative gear technology represents a significant advancement in the field of robotic surgery, enhancing the capabilities of surgical robots by improving precision, reducing noise, and ensuring reliability. This development not only benefits surgeons but also contributes to better patient outcomes through less invasive procedures, faster recovery times, and reduced pain and scarring.