Stryker Corporation

Mako Surgical Corporation

Joel N Beer

David Gene Bowling

Patrick Roessler

Donald W Malackowski

John Michael Stuart

Jerry A Culp

José Luis Moctezuma De La Barrera

John S Ketchel

Hyosig Kang

Christopher Alan Lightcap

Jose-Luis Moctezuma De La Barrera

A surgical navigation system and method of operating the same involve a pointer tool and a localizer configured to track the pointer tool. Controller(s) is/are coupled to the localizer and are configured to generate a virtual boundary relative to a bone at a surgical site. The virtual boundary has a shape that delineates a region of the bone to be removed from a region to be avoided. The controller(s) identify, with the localizer, a position of one or more landmarks at the surgical site in response to the pointer tool touching the one or more landmarks at the surgical site. The controller(s) revise the shape of the virtual boundary based on the position of the one or more landmarks.

Surgical systems and methods for dynamic virtual boundary adjustment

Surgical systems and methods of operating the same involve controlling a robotic manipulator to move a cutting instrument to cut away material from a bone at a surgical site. A machine vision system uses a vision camera to detect an object at, or in proximity to, the surgical site. A control system associates a virtual boundary with the detected object and controls the robotic manipulator to move the cutting instrument based on the virtual boundary such that the cutting instrument avoids the detected object. In one example, the control system modifies a tool path of the cutting instrument based on the virtual boundary to avoid the detected object. Additionally, or alternatively, the control system can automatically adjust an orientation of the cutting instrument based on the virtual boundary to avoid the detected object.

Systems and methods for establishing virtual constraint boundaries

A user control device for a surgical system. The surgical system includes a robotic manipulator to support and move a surgical instrument that has an energy applicator. One or more controllers operate the robotic manipulator in a semi-autonomous mode and calculate an instrument feed rate, which is the velocity at which the energy applicator advances along a tool path in the semi-autonomous mode. The user control device includes a housing configured as a pendant configured to be held in one hand of a user. A first control member is mounted to the housing and can be depressed to initiate operation of the robotic manipulator in the semi-autonomous mode. A second control member is mounted to the housing and can be depressed to modify the instrument feed rate in the semi-autonomous mode.

Hand-held pendant for controlling a surgical robotic manipulator in a semi-autonomous mode

Surgical systems and methods for manipulating an anatomy includes a surgical tool, a robotic manipulator configured to support and move the surgical tool, and controller(s) that generate a virtual boundaries delineating a portions of the anatomy allowed to be removed by the surgical tool. The controller(s) control the robotic manipulator to autonomously move the surgical tool in relation to a first virtual boundary and according to a first feed rate or first frequency of path oscillations to remove a first portion. The controller(s) control the robotic manipulator to autonomously move the surgical tool in relation to a second virtual boundary that is spaced from the first virtual boundary, and according to a different feed rate or different frequency of path oscillations, to remove a second portion.

System and method for manipulating an anatomy

A surgical system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. A navigation system includes a localizer, a first tracker coupled to the robotic manipulator or the tool, and a second tracker coupled to a workpiece. Controller(s) determine, from the navigation system, a pose of the tool relative to the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a first portion from the workpiece with the tool and sense interaction between the tool and the workpiece during removal of the first portion to detect a density of the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a second portion from the workpiece with the tool, wherein a cutting depth for the second portion is based, at least in part, on the detected density.

Robotic systems and methods for controlling a tool to remove material from a workpiece

Surgical systems and methods for generating a tool path. A manipulator is configured to support and move a surgical instrument. Controller(s) obtain data that defines a volume of tissue to be removed from a surgical site. The controller(s) operate the manipulator to move the surgical instrument to remove first portions of the volume and acquire data defining the first portions removed from the volume. The controller(s) identify, based on the volume and the acquired data, additional portions of the volume of tissue that require removal. The controller(s) generate a tool path that passes through the additional portions and operate the manipulator to move the surgical instrument along the tool path to remove the additional portions.

Robotic system and method for removing a volume of material from a patient

A surgical system for manipulating an anatomy includes a surgical tool, a robotic manipulator configured to support and move the surgical tool, and one or more controllers that activate a first virtual boundary delineating a first portion of the anatomy that is allowed to be removed by the surgical tool from a second portion of the anatomy that is protected from removal by the surgical tool. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform fine cutting of the first portion in relation to the first virtual boundary. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform bulk cutting of the second portion of the anatomy.

A surgical manipulator and method of operating the same. The surgical manipulator includes an arm with a plurality of links and joints, wherein an angle between adjacent links forms a joint angle. The arm includes a distal end configured to support a surgical instrument with an energy applicator. At least one controller is coupled to the arm and models the surgical instrument and the energy applicator as a virtual rigid body. The controller(s) determine a commanded pose for the surgical instrument and the energy applicator based on a summation of a plurality of forces and/or torques, wherein the plurality of forces and/or torques are selectively applied to the virtual rigid body to emulate orientation and movement of the surgical instrument and the energy applicator. The controller(s) determine commanded joint angles for the arm that place the surgical instrument and the energy applicator according to the commanded pose.

Surgical manipulator and method of operating the same using virtual rigid body modeling preliminary

A surgical system, method, and non-transitory computer readable medium involving a robotic manipulator configured to move a surgical instrument relative to virtual boundaries. A navigation system tracks each of a first object, a second object, and the surgical instrument. The first object is moveable relative to the second object. One or more controllers associate a first virtual boundary with the first object and associate a second virtual boundary with the second object. The first virtual boundary is moveable in relation to the second virtual boundary. The controller(s) control the robotic manipulator in relation to the first virtual boundary to facilitate interaction of the surgical instrument with the first object. The controller(s) control the robotic manipulator in relation to the second virtual boundary to avoid interaction of the surgical instrument with the second object.

A surgical robotic system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. Controller(s) generate a first tool path to remove a first portion of material from the bone and control the manipulator to position the tool for movement along the first tool path to remove the first portion. The controller(s) sense interaction between the tool and the bone during movement of the tool along the first tool path and generate a second tool path to remove a second portion of material from the bone. Generation of the second tool path is based, at least in part, on the sensed interaction between the tool and the bone during movement along the first tool path. The controller(s) control the manipulator to position the tool for movement along the second tool path to remove the second portion.

Robotic systems and methods for tool path generation and control based on bone density

A surgical system for manipulating an anatomy includes a surgical tool, a robotic manipulator configured to support and move the surgical tool, and one or more controllers that activate a first virtual boundary delineating a first portion of the anatomy that is allowed to be removed by the surgical tool from a second portion of the anatomy that is protected from removal by the surgical tool. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform bulk cutting of the first portion in relation to the first virtual boundary. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform fine cutting of the second portion of the anatomy.

A tool path generator utilizes a solid body model of a volume to generate a tool path for a manipulator to remove material of the volume with an energy applicator in a semi-autonomous mode. A material logger monitors movement of the energy applicator according to a cutting path taken by a practitioner in the manual mode, identifies material of the volume to which the energy applicator has been applied in the manual mode, and updates the solid body model based on the identified material. The tool path generator modifies the tool path based on the updated solid body model such that, for the semi-autonomous mode, the modified tool path accounts for the identified material of the volume to which the energy applicator has been applied in the manual mode.

A robotic system and methods are disclosed. A common axis is defined for an instrument and an energy applicator extending from the instrument. A manipulator has a plurality of links and actuators configured to move the links to position the instrument and energy applicator. A force/torque sensor coupled to the manipulator generates an output in response to forces/torques applied to the instrument. Controller(s) defines a centering point that intersects the common axis. Controller(s) model the instrument and the energy applicator as a virtual rigid body and determine forces/torques to apply to the virtual rigid body, which are determined, in part, based on the output of the force/torque sensor. Controller(s) control the manipulator to advance the energy applicator based on the determined forces/torques applied to the virtual rigid body and reorient the instrument such that the common axis pivots about the centering point during advancement of the energy applicator.

Robotic system and method for reorienting a surgical instrument

A surgical system for applying an energy applicator to a target tissue and methods operating the same are disclosed. The energy applicator extends from a surgical instrument. The surgical system comprises a sensor to measure external forces and torques placed on the surgical instrument. A surgical manipulator is configured to move the energy applicator in a manual mode in response to the external forces and torques. At least one controller is configured to: model the surgical instrument and the energy applicator as a virtual rigid body having a virtual mass; calculate, using impulse modeling, constraining forces and torques to be applied to the virtual rigid body; determine total forces and torques based on the external forces and torques and the constraining forces and torques; and advance the energy applicator in the manual mode based on the total forces and torques.

Surgical system and method utilizing impulse modeling for controlling an instrument

Systems and methods are disclosed involving an instrument, an instrument tracking device for tracking movement of the instrument, a first boundary tracking device for tracking movement of a first virtual boundary associated with an anatomy of a patient to be treated by the instrument, and a second boundary tracking device for tracking movement of a second virtual boundary associated with a periphery of an opening in the patient to be avoided by the instrument. One or more controllers receive information associated with the tracking devices including positions of the instrument relative to the first and second virtual boundaries, detect movement of the first and second virtual boundaries relative to one another, and generate a response upon detecting movement of the first and second virtual boundaries relative to one another.

Growing community of inventors

Albuquerque, NM, United States of America

Joel N Beer