Powering the surgical robotics revolution

It’s expected that over the coming decade millions of people will have robotic surgery in an effort to speed up treatments and reduce waiting times and there will be a massive expansion in surgeons using robots in the treatment of diseases like cancer or carrying out standard forms of surgery like joint replacements.

According to figures from the NHS patients expected to undergo robot-assisted surgery is expected to surge from 70,000 at present, to over 500,000 by 2035.

NHS England’s chief executive, Sir Jim Mackay, said that robots would play a crucial part in reducing waiting times and that, “Expanding the use of new and exciting tech such as robotic surgery will play a huge part in this. It means better outcomes, a faster recovery and shorter hospital stays for patients.”

By 2035 90 percent of keyhole surgery could involve a robot and will be, “the default” for many procedures, according to Mackay. The surgeon will either be at a console using a 3D camera or the robot will be pre-programmed to help the surgeon by being more precise.

“Faster recovery and a shorter time in hospital will help to relieve pressure on services and reduce waiting times,” according to John McGrath, a consultant surgeon who chairs NHS England’s steering group for robotic-assisted surgery.

Robot-assisted surgery can help with complex operations by making them less physically demanding for surgeons and, by taking the strain, they should make it possible for surgeons to carry out a far greater number of complex surgeries.

At present the UK’s National Institute for Health and Care Excellence (NICE), has approved robotic systems for use in a variety of soft tissue procedures, as well as orthopaedic surgery for full and partial knee and hip replacements.

“These technologies have the potential to transform both soft tissue and orthopaedic surgical care. The data gathered over the next few years will allow us to evaluate exactly how these technologies can improve patient care and help ensure NHS resources are directed toward interventions that deliver meaningful clinical benefits and long-term value to our health service,” explained Dr Anastasia Chalkidou, director of NICE’s HealthTech programme.

Robotic surgery will help to address a variety of diseases and, in part, is set to spark a revolution in the treatment and care of patients.

Neurological surgery

While surgical robots have improved procedures in general surgery, one area – neurosurgery – continues to present challenges due to the delicate and complex structures of the brain and spinal cord. Today, a few robotic systems assist in some neurosurgeries, such as stereotactic procedures, which use imaging to position surgical instruments with minimal invasiveness, but most surgical robots still only play an assistive or non-existent role.

Neurosurgery demands extreme accuracy as the risks posed to the patients are high and surgical robots must, therefore, be exceptionally precise to be viable in neurosurgery.

The drive system of a surgical robot arm needs to transmit exact, controlled motion so that grippers or other end effectors don’t end up overshooting and even when they are static, they need to continuously provide high torque to retain absolute stability.

Brushless drives with integrated gears and encoders can deliver much smoother levels of operation, while high-resolution encoders enable sub-millimetre positioning and gears can enhance torque output to ensure steady holding force even at a standstill. Advanced motor design with these integrated technologies will be crucial in developing surgical robots tailored to neurosurgery’s demands.

Another priority will be enabling reliable haptic feedback as this is critical for accurate force application. The tactile sensation experienced by surgeons allows them to feel subtle changes in tissue resistance, enabling them to distinguish between healthy and abnormal tissue.

Many current robotic systems lack the haptic feedback necessary to gauge the pressure and sensitivity needed for different actions and here the drive system can play a core role in effectively delivering haptic feedback to the surgeon.

“FAULHABER has developed precise and compact micromotors which offer responsive control, smooth torque and 4-quadrant operation,” said Dave Walsha, sales and marketing director at Electro Mechanical Systems a leading supplier of these types of motor.

“These cogging-free motors enable realistic feedback that helps the surgeon gauge the pressure to apply and they allow for exceptionally precise drives without sacrificing size or manoeuvrability. In the delicate field of neurosurgery, this opens up the potential for more minimally invasive procedures that require sensitive, reliable feedback.”

Above: Innovation in surgical robots needs to be matched by similar developments in power technology Credit: adobe.stock.com

The one critical element

The one critical element in using robots in surgery, and that is often overlooked, is the provision of reliable and efficient power solutions capable of delivering uninterrupted operations in the most critical medical environments.

Robotic systems are machines integrated with high-quality equipment that need to operate in a high-stakes environment but one that is also very demanding. They need a consistent and dependable power source. Any loss of power, however slight, could have significant consequences for the patient.

Surgical robots are complex and comprise of interconnected wires, high-performance motors that drive sophisticated sensors that provide real-time feedback, advanced imaging systems and powerful computer processing units – each will need large amounts of power.

Uninterrupted operation is essential, as many surgical procedures can run for several hours, so they will need a stable and consistent flow of power to ensure that the robot operates seamlessly and without delay. Uninterruptible power supplies and redundant power architectures are structures that look to take over in the event of a power failure, providing a crucial buffer that allows surgeons to safely complete critical stages of the operation.

Surgical robotic systems also need a power infrastructure that can support fast, low-latency communication and because surgical robotics need to be both precise and responsive, as they are increasingly required to perform intricate movements, their components will need precise power delivery from the motors that drive them. If there are variations in the voltage or current, for example, then that can result in unpredictable movements and lead to inaccuracy in the surgery.

According to Shravan Govindaraj, Product Marketing Manager at XP Power, “Surgical robotics are a revolutionary innovation – one of the most transformative technologies that we have seen in recent years. They are not just machines but are proven assistants to surgeons and need to be designed to enhance efficiency, safety, and precision when it comes to medical procedures that require the utmost delicacy.”

Robots come with a plethora of benefits for patients, from reduced blood loss during surgery, to faster recovery times, minimised scarring, and improved clinical outcomes.

“But while surgical robotics stand at the frontlines when it comes to medical innovation, they depend on efficient and reliable power solutions to drive the complex ecosystems that make up those robotics. Uninterruptible power supplies and redundant power architectures need to be designed to take over in the event of power failure, providing a crucial buffer.”

Robotic systems incorporate advanced sensors, real-time data processing, haptic feedback mechanisms, and increasingly AI so low-latency communication is critical.

“Having fail-safes as well as redundancy within the power infrastructure is necessary to maintain operational continuity, especially during long procedures,” explained Govindaraj.

Another factor that plays a major role in surgical robotics is the precision and responsiveness of robotic instruments, and that does rely on the quality of the power supply.

“The intricate movements that are executed by robotic manipulators require precise power delivery to the motors that drive them, so we need to avoid unwanted unpredictability in surgical tasks such as tissue manipulation, suturing, or the deployment of medical devices,” added Govindaraj.

“But energy efficiency also plays a key role when it comes to surgery. It’s not just beneficial for sustainability, but it’s also necessary for thermal management as efficient power solutions play a critical role in lowering the generation of excess heat within the robot’s complex systems.

“If a system suffers from excessive heat buildup, then that can impact the performance and longevity of sensitive electronic components. But it will also require bulky and large cooling systems.”

According to Govindaraj, both safety and reliability are non-negotiable factors when it comes to power solutions in medical environments, as surgical systems operate in environments that require the strictest safety standards.

“As a result, power solutions need to be engineered to meet these thorough demands, incorporating multiple layers of safety features. These include robust surge protection mechanisms to prevent leakage currents (the unintended flow of electrical currents due to unwanted conductive paths or insulation faults), as well as protect patients. Comprehensive grounding systems to minimise the risk of electrical hazards must also be applied for both the patient and the medical team.”

The evolution of surgical robotics depends on continuous innovation in power technology and while medical robotics are transforming healthcare by enabling precision surgeries, automated diagnostics, and robotic-assisted rehabilitation power supply challenges remain a concern for OEMs manufacturing medical robots.

The right power supply requires a deep understanding of energy efficiency, regulatory compliance, and thermal management in an environment where power instability can lead to errors in diagnosis, treatment, or surgical precision. Unlike industrial or consumer robotics, medical robots must adhere to strict regulatory and performance standards to ensure patient safety and system reliability.

Among the key challenges for OEMs are voltage instability, power supply failures, EMI, excessive heat generation from inefficient power supplies all of which can compromise robotic components and safety compliance.

To that end designers of surgical robotics needs to use high-efficiency power supplies to reduce energy waste and heat buildup; implement redundant power systems to prevent failure in mission-critical applications; select low-noise power solutions to minimise electromagnetic interference in sensitive medical environments and ensure compliance with IEC 60601-1 safety standards for medical electrical equipment

It is also critical that real-time power monitoring to detect voltage fluctuations and system failures is implemented and that customised power solutions, that optimise performance for specific robotic applications, are used.

By focusing on stability, energy efficiency, and compliance, OEMs can develop safer, more reliable power supply solutions.

Autonomy

Autonomy will be the next leap forward for surgical robotics and while current robotic systems primarily serve as highly controlled tools under a surgeon’s command, future systems could incorporate AI to handle specific tasks. AI-driven dynamic adaptability could help to reduce surgeon workloads and improve patient outcomes with faster, safer surgeries.

While still in the realms of science fiction, advancements in AI suggest it could be a reality for neurosurgeons in the not-too-distant future. Aided by machine learning, real-time data processing and advanced power systems, the future of surgery could be transformed.

But the evolution of surgical robotics does rely on continuous innovation when it comes to power technology and with growing complexity these systems will need intelligent and adaptable power solutions to keep robot systems running efficiently.

Surgical robots may win the applause but as Govindaraj pointed out, “it is the silent, unwavering reliability and efficiency of their power solutions that enable these machines to fulfil their true potential.”