Mako Surgical Corporation

Stryker Corporation

Michael Dale Dozeman

Patrick Roessler

David Gene Bowling

Michael C Ferko

Paul M Hoekstra

Gregory Garcia

Douglas Alan Staunton

Richard Thomas DeLuca

Mark Ellsworth Nadzadi

Helmut Rohs

Hans-Ulrich Becker

Vladimir Gershuni

Rishabh Khurana

Michael R Wildgen

Bharat Arora

Donald W Malackowski

José Luis Moctezuma De La Barrera

Don Malackowski

Jeremy L Dunn

Paul Hoekstra

Systems and methods are provided for guiding movement of a tool. The system includes a tool and a manipulator. A guide handler obtains a target state for the tool and generates virtual constraints based on the target state and a current state of the tool. A constraint solver calculates a constraint force adapted to attract the tool toward the target state or repel the tool away from the target state based on the virtual constraints. A virtual simulator simulates dynamics of the tool in a virtual simulation based on the constraint force and input from one or more sensors, to output a commanded pose. The control system commands the manipulator to move the tool based on the commanded pose to thereby provide haptic feedback to the user that guides the user toward placing the tool at the target state or away from the target state.

Systems and methods for guiding movement of a tool

A surgical system and method of operating the same. A manipulator supports and facilitates movement of a surgical tool along a tool path relative to a surgical site. A navigation system includes a localizer to monitor states of the manipulator and the surgical site. Controller(s) determine a commanded state of the surgical tool and an actual state of the surgical tool relative to the tool path for a given time step. The controller(s) detect a deviation between the commanded state and the actual state of the surgical tool for the given time step. The controller(s) respond to the deviation by modification of one or both of: a feed rate of the surgical tool; and the tool path. In some implementations, the controller(s) predict, based on the deviation, a future deviation between a future commanded state and a future actual state of the surgical tool for a given future time step.

Techniques for modifying tool operation in a surgical robotic system based on comparing actual and commanded states of the tool relative to a surgical site

Surgical systems, computer-implemented methods, and software programs for generating a milling path for a bone. The implementations involve obtaining a virtual model of the bone, a resection volume defined relative to the virtual model of the bone, and a reference guide defined with respect to the resection volume. Section planes are successively arranged along the reference guide, and each section plane intersects the reference guide and intersects the resection volume. A section path is generated within each section plane and is defined relative to the resection volume. Transition segments are generated to connect section paths of section planes. The milling path is then generated by combining the section paths and the transition segments.

Techniques for patient-specific milling path generation

Robotic surgical systems and methods for controlling movement of a tool relative to a tool path. An input is received from a force/torque sensor in response to user forces/torques manually applied to the tool by a user. A component of force is calculated tangential to the path based on the input. An effective feed rate is calculated to advance the tool along the path based on the tangential component. Virtual constraints are defined on movement of the tool along the path with respect to three degrees of freedom and based on the effective feed rate to promote movement of the tool along the path. Dynamics of the tool are virtually simulated based on the virtual constraints and the input from the force/torque sensor. The manipulator is commanded to advance the tool along the path based on the virtual simulation.

Systems and methods for controlling movement of a surgical tool along a predefined path class

A surgical system and method involve a robotic system with a base and a localizer that monitors a tracker supported by the robotic system. Sensor(s) are coupled to the robotic system and/or the localizer. Controller(s) determine a relationship between the base and the localizer. The controller(s) monitor the relationship to detect an error related to one or both of the robotic system and the localizer. The controller(s) utilize the sensor(s) to determine a cause of the error.

Techniques for detecting errors or loss of accuracy in a surgical robotic system

Systems and methods are provided for controlling robotic movement of a tool based on one or more virtual boundaries. The system comprises a tool and a manipulator to support the tool. A control system controls operation of the manipulator and movement of the tool based on a relationship between the tool and the one or more virtual boundaries associated with a target site. The control system includes a boundary handler to determine whether the tool is in compliance with the one or more virtual boundaries or is in violation of the one or more virtual boundaries.

Systems and methods for controlling robotic movement of a tool based on a virtual boundary

A robotic surgical system and method of operating the same. A manipulator supports a tool that has a TCP and manipulates a target bone. A navigation system has a localizer to monitor states of the manipulator and the target bone. Controller(s) determine commanded states of the TCP to move the tool along a cutting path relative to the target bone to remove material from the target bone. The controller(s) determine actual states of the TCP responsive to commanded movement of the tool along the cutting path, wherein each one of the commanded states of the TCP has a corresponding one of the actual states of the TCP for a given time step. The controller(s) compare the corresponding commanded and actual states of the TCP for one or more given time steps to determine a deviation and modify operation of the tool to account for the deviation.

Systems and methods for detecting an error in a surgical system. The surgical system includes a manipulator with a base and a plurality of links and the manipulator supports a surgical tool. The system includes a navigation system with a tracker and a localizer to monitor a state of the tracker. Controller(s) determine values of a first transform between a state of the base of the manipulator and a state of one or both of the localizer and the tracker of the navigation system. The controller(s) determine values of a second transform between the state of the localizer and the state of the tracker. The controller(s) combine values of the first transform and the second transform to determine whether an error has occurred relating to one or both of the manipulator and the localizer.

Systems and methods for operating a robotic surgical system are provided. The system includes a surgical tool, a manipulator comprising links for controlling the tool, a navigation system includes a tracker and a localizer to monitor a state of the tracker. Controller(s) determine a relationship between one or more components of the manipulator and one or more components of the navigation system by utilizing kinematic measurement data from the manipulator and navigation data from the navigation system. The controller(s) utilize the relationship to determine whether an error has occurred relating to at least one of the manipulator and the navigation system. The error is at least one of undesired movement of the manipulator, undesired movement of the localizer, failure of any one or more components of the manipulator or the localizer, and/or improper calibration data.

A robotic surgical system comprises a surgical tool, a manipulator configured to support the surgical tool, a force/torque sensor to measure forces and torques applied to the surgical tool, and a control system. The control system obtains a three-dimensional milling path for the surgical tool. The control system also receives one or more signals from the force/torque sensor in response to a user manually applying user forces and torques to the surgical tool. The control system determines a commanded pose to which to command the manipulator to advance the surgical tool along the milling path based on a tangential component of the user forces and torques, based on a virtual simulation using virtual constraints, and/or based on other suitable factors to promote guided, manual movement of the surgical tool along the milling path.

Systems and methods for controlling movement of a surgical tool along a predefined path

Systems, methods, software and techniques for generating a milling path for a tool of a surgical system are provided. The milling path is designed to remove a resection volume associated with an anatomical volume. A reference guide is defined with respect to the resection volume. Sections are defined along the reference guide in succession. Each section intersects the reference guide at a different intersection point and is at a specified orientation relative to the reference guide at the intersection point. Each section further intersects the resection volume. A section path is generated to be bounded within each section and defined relative to the resection volume. A plurality of transition segments are generated and each transition segment connects section paths of successive sections along the reference guide.

Systems and methods for operating a robotic surgical system are provided. The system comprises a surgical tool for interacting with a surgical target, a manipulator comprising a plurality of links and supporting the tool, a navigation system comprising a manipulator tracker coupled to the manipulator and a patient tracker coupled to the surgical target and a localizer for monitoring states of the trackers. A controller determines commanded states for moving the tool relative to the surgical target using data (filtered according to a first filter length) from the manipulator and/or navigation system. The controller determines actual states of the tool while commanding the tool relative to the surgical target using data (filtered according to a second filter length being shorter than the first filter length) from the manipulator and/or navigation system. The controller compares the commanded and actual states and modifies tool operation based on an outcome of the comparison.

Systems and methods for operating a robotic surgical system are provided. The system includes a surgical tool, a manipulator comprising links for controlling the tool, a navigation system comprising a tracker coupled to the manipulator or the tool and a localizer to monitor a state of the tracker. Controller(s) determine a raw (or lightly filtered) relationship between one or more components of the manipulator and one or more components of the navigation system by utilizing one or more of raw kinematic measurement data from the manipulator and raw navigation data from the navigation system. The controller(s) utilize the raw (or lightly filtered) relationship to determine whether an error has occurred relating to at least one of the manipulator and the navigation system.

A powered surgical tool system capable of providing energization signals to plural powered surgical handpieces. The system includes a console to which at least one footswitch is attached. The footswitch can be mapped to control any one of the handpieces connected to the console. The console includes a display on which representations of the footswitch and handpieces connected to the console are presented. The representations of the handpieces are in different colors. When the footswitch is mapped to a specific handpiece, the representation of the footswitch is presented in the same color as the representation of the handpiece to which the footswitch is mapped. When plural footswitches are attached to the console, the representation of each footswitch is presented in a color corresponding to the color of the representation of the handpiece to which the footswitch is mapped.

Surgical tool assembly including a console, plural surgical tools and a footswitch, wherein the console is able to custom map the footswitch to each surgical tool

Systems and methods for operating a robotic surgical system are provided. The system includes a surgical tool, a manipulator comprising a base supporting links for controlling the tool, a navigation system comprising a tracker coupled to the tool and a localizer to monitor a state of the tracker. A controller acquires raw kinematic measurement data about a state of the tool relative to the base from the manipulator, known relationship data about the state of the tracker relative to the tool, and raw navigation data about the state of the tracker relative to the localizer from the navigation system. The controller combines this data to determine a raw relationship between the base and the localizer. The raw relationship is filtered for controlling the manipulator. The raw relationship or a less filtered version of the raw relationship is utilized to determine whether an error has occurred in the system.

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Portage, MI, United States of America

Michael Dale Dozeman