CN112568997B

CN112568997B - Direct blade guidance system

Info

Publication number: CN112568997B
Application number: CN202011068472.2A
Authority: CN
Inventors: S·科斯切夫斯基; O·沙皮伊
Original assignee: Globus Medical Inc
Current assignee: Globus Medical Inc
Priority date: 2019-09-27
Filing date: 2020-09-27
Publication date: 2024-12-31
Anticipated expiration: 2040-09-27
Also published as: CN112568997A; JP7263300B2; JP2021053395A

Abstract

The present application relates to a direct blade guidance system. A passive end effector of a surgical system includes a base, a first mechanism, and a second mechanism. The base is attached to an end effector connector of a robotic arm positioned by a surgical robot. The first mechanism extends between a rotatable connection to the base and a rotatable connection to a tool attachment mechanism. The second mechanism extends between a rotatable connection to the base and a rotatable connection to the tool attachment mechanism. The first mechanism and the second mechanism pivot about the rotatable connection to limit the movement of the tool attachment mechanism to a range of movement within a working plane. The tool attachment mechanism is configured to be connected to a surgical saw, which includes a saw blade for cutting.

Description

Direct blade guide system

Cross Reference to Related Applications

The present application is a continuation-in-part application from U.S. application Ser. No. 16/587,203, filed on date 2019, month 9, and date 30. The application also claims the benefit of U.S. provisional application No. 62/906,831 filed on 2019, 9, 27. The contents of each of these applications are incorporated by reference herein in their entirety for all purposes.

Technical Field

The present disclosure relates to medical devices and systems, and more particularly, to robotic systems and related end effectors for controlling the cutting of an anatomical structure of a patient, and related methods and devices.

Background

There are many surgical interventions that require osteotomies, i.e., cutting anatomical structures such as bones along a target plane. Total knee arthroplasty typically requires resection of the femoral and tibial epiphyses to remove damaged bone and cartilage and install the knee prosthesis. The surgeon may make five or more cuts on the femur and one or more cuts on the tibia using an oscillating surgical saw.

During orthopedic surgery, which involves joints and knees, it is important to precisely align and stabilize the saw while cutting the desired location on the bone. The limited visibility of the surgical site by the surgeon coupled with the difficulty in controlling the movement of the saw creates the risk of undesirable portions of bone or adjacent tissue being cut. Vibrations generated by the saw during cutting may reduce the cutting accuracy. During knee surgery, the accuracy of bone cuts (planar cuts) can affect the accuracy with which an implant can be attached to exposed bone.

During some knee surgeries, clamps are screwed onto the bone for guiding the surgeon in the movement of the saw during the cut. Errors in clamp placement and limited stability of the blade during cutting can limit the accuracy of the cut. Furthermore, contact between the saw blade and the clamp may create debris that runs the risk of entering the patient.

In conventional orthopedic surgery involving cutting of bone with a saw, one of the following methods may be used to guide the saw (1) manually by the surgeon, (2) a bone grafting jig, and (3) a robotic system to hold the saw head.

The clamp may have a slot that engages the saw blade to prevent it from being guided away from the desired plane. This approach has several drawbacks. First, it may require that the clamp be attached to the bone, typically with staples. Second, it may require a gap between the clamp and the saw blade, which may reduce accuracy. Third, there is friction between the oscillating blade and the clamp, which can create debris that can potentially impact the clinical outcome, dulling the blade and removing a portion of the important force feedback.

Several known robotic systems can hold and guide the saw head. These robotic systems may assume that the blade vibrates in some predetermined plane with respect to the handpiece. This approach includes drawbacks. For example, the blade swing mechanism and blade attachment stiffness directly affect the stiffness of the blade guide. In addition, it may be difficult to integrate different power tools/saw heads with the robotic system due to the complexity of the outer surface that needs to be maintained by the robot. As a result, users of robotic systems need to develop and acquire new saws for robotic systems. Furthermore, for the safety of the whole system, there is a potential risk of loss of precision if the blade is not moved in the assumed plane (e.g. due to incorrect assembly) with respect to the handpiece.

Thus, there is a need for a direct saw blade guidance system that does not involve jig or saw head guidance in orthopedic surgery.

Disclosure of Invention

Some embodiments of the present disclosure relate to a direct blade guide system. The direct blade guide system includes a robotic arm positionable by a surgical robot, an end effector arm including a base configured to be attached to an end effector coupler of the robotic arm. The end effector arm includes a plurality of linkages connected by a plurality of joints including a distal joint disposed at a distal end of the end effector arm. The blade guide system may also include a blade adapter connected to the end effector arm by the distal joint, a blade connected to the blade adapter, and a handpiece connected to the blade.

Some embodiments of the present disclosure relate to a surgical system having a tracking system configured to determine a pose of an anatomical structure to be cut by a saw blade and to determine the pose of the saw blade. The surgical system also includes a surgical robot having a robot base, a robotic arm connected to the robot base, and at least one motor operatively connected to move the robotic arm relative to the robot base. The surgical system also includes a blade guide system having an end effector arm including a base configured to be attached to an end effector coupler of the robotic arm. The end effector arm includes a plurality of linkages connected by a plurality of joints including a distal joint disposed at a distal end of the end effector arm. The blade guide system also includes a blade adapter connected to the end effector arm by the distal joint, a blade connected to the blade adapter, and a handpiece connected to the blade.

Drawings

The accompanying drawings, which are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate certain non-limiting embodiments of the inventive concepts. In the drawings:

FIG. 1 illustrates an embodiment of a surgical system according to some embodiments of the present disclosure;

FIG. 2 illustrates a surgical robotic assembly of the surgical system of FIG. 1, according to some embodiments of the present disclosure;

FIG. 3 illustrates a camera tracking system component of the surgical system of FIG. 1, according to some embodiments of the present disclosure;

FIG. 4 illustrates an embodiment of a passive end effector that is connectable to a robotic arm and configured in accordance with some embodiments of the present disclosure;

FIG. 5 illustrates a medical procedure in which a surgical robot and camera system are positioned around a patient;

Fig. 6 illustrates an embodiment of an end effector coupler configured to be connected to a robotic arm of a passive end effector, in accordance with some embodiments of the present disclosure;

FIG. 7 illustrates an embodiment of a cross-sectional view of the end effector coupler of FIG. 6;

FIG. 8 illustrates a block diagram of components of a surgical system, according to some embodiments of the present disclosure;

FIG. 9 illustrates a block diagram of a surgical system computer platform that contains a surgical planning computer that may be separate from and operatively connected to, or at least partially integrated with, a surgical robot herein, in accordance with some embodiments of the present disclosure;

FIG. 10 illustrates an embodiment of a C-arm imaging device that may be used in conjunction with a surgical robot and a passive end effector, in accordance with some embodiments of the present disclosure;

FIG. 11 illustrates an embodiment of an O-arm imaging device that may be used in conjunction with a surgical robot and a passive end effector, and in accordance with some embodiments of the present disclosure

Fig. 12-19 illustrate alternative embodiments of passive end effectors configured in accordance with some embodiments of the present disclosure.

Fig. 20 is a screen shot showing the progress of bone cutting during surgery.

Fig. 21 illustrates an exemplary embodiment of a direct blade guide system consistent with the principles of the present disclosure.

Fig. 22 illustrates an exemplary embodiment of a direct blade guide system consistent with the principles of the present disclosure.

23-24 Illustrate exemplary embodiments of a portion of a direct blade guide system consistent with the principles of the present disclosure.

Fig. 25 illustrates an exemplary embodiment of a direct blade guide system consistent with the principles of the present disclosure.

Fig. 26 illustrates an exemplary embodiment of a direct blade guide system consistent with the principles of the present disclosure.

Fig. 27 illustrates an exemplary embodiment of a direct blade guide system consistent with the principles of the present disclosure.

Fig. 28 illustrates an exemplary embodiment of a portion of a direct blade guide system consistent with the principles of the present disclosure.

29-30 Illustrate exemplary embodiments of a direct blade guide system consistent with the principles of the present disclosure.

Fig. 31 illustrates an exemplary embodiment of a blade adapter consistent with the principles of the present disclosure.

Fig. 32 illustrates an exemplary embodiment of a direct blade guide system consistent with the principles of the present disclosure.

Detailed Description

The inventive concept will now be described more fully hereinafter with reference to the accompanying drawings, in which examples of embodiments of the inventive concept are shown. The inventive concept may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the various inventive concepts to those skilled in the art. It should also be noted that these embodiments are not mutually exclusive. Components in one embodiment may be defaulted to exist in or for another embodiment.

Various embodiments disclosed herein relate to improvements in the operation of a surgical system in performing surgical interventions requiring osteotomies. A passive end effector connectable to a robotic arm positioned by a surgical robot is disclosed. The passive end effector has a pair of mechanisms that limit movement of the tool attachment mechanism to a range of movement. The tool attachment may be connected to a surgical saw for cutting, such as a sagittal saw with an oscillating saw blade. The mechanism may be configured to constrain the cutting plane of the saw blade to be parallel to the work plane. The surgical robot may determine a pose of the target plane based on a surgical plan defining a location at which an anatomical structure is to be cut and based on a pose of the anatomical structure, and may generate steering information based on a comparison of the pose of the target plane and the pose of the surgical saw. The steering information indicates where the passive end effector needs to be moved so that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade is positioned at a distance from the anatomy to be cut that is within the range of movement of the tool attachment mechanism of the passive end effector.

These and other related embodiments may operate to improve the accuracy of blade guiding as compared to other robotic and manual (e.g., clamp) solutions for surgery. The mechanism of the passive end effector may allow the surgeon to concentrate on interpreting direct force feedback when sawing bone using a surgical saw guided by the passive end effector. The mechanism may be a planar mechanism, such as an end fitting having 1 to 3 appropriately selected degrees of freedom (e.g., one translation or rotation, two rotations, three rotations, or other combinations, etc.) configured to limit the cutting plane to align with the target plane. The surgeon may also more accurately detect and control the rate of bone removal based on audio and/or visual notification feedback provided by the surgical robot.

These embodiments may provide guidance in joint surgery with high precision, high rigidity, sufficient working space, and direct force feedback, and particularly during knee joint surgery. As will be explained in detail below, the tracking system may be used to precisely align the cutting plane with the target plane to cut bone. By limiting the planar mechanism by which the cutting plane remains aligned with the target plane, high precision cutting can be achieved as the surgeon moves the blade along the cutting plane and directly senses the force feedback of the blade cutting bone. Furthermore, these embodiments may be quickly adopted into surgical practice through defined changes in the existing accepted surgical workflow.

Fig. 1 illustrates an embodiment of a surgical system 2 according to some embodiments of the present disclosure. Prior to performing the orthopedic surgery, the planned surgical area of the patient may be scanned in three dimensions ("3D") using, for example, the C-arm imaging device 104 of fig. 10 or the O-arm imaging device 106 of fig. 11, or from another medical imaging device such as a Computed Tomography (CT) image or MRI. The scan may be performed preoperatively (e.g., weeks prior to surgery, most commonly) or intraoperatively. However, any known 3D or 2D image scan may be used depending on the various embodiments of the surgical system 2. The image scan is sent to a computer platform in communication with the surgical system 2, such as surgical system computer platform 900 of fig. 9, which contains a surgical robot 800 (e.g., robot 2 in fig. 1) and a surgical planning computer 910. The surgeon views one or more image scans on a display device of a surgical plan computer 910 (fig. 9), generating a surgical plan defining a target plane in which to cut the patient's anatomy. The plane is a function of patient anatomy constraints, the selected implant, and its size. In some embodiments, a surgical plan defining a target plane is planned on a 3D image scan displayed on a display device.

The surgical system 2 of fig. 1 may be used to assist a surgeon during a medical procedure by, for example, holding a tool, aligning a tool, using a tool, guiding a tool, and/or positioning a tool. In some embodiments, surgical system 2 includes surgical robot 4 and camera tracking system 6. The two systems may be mechanically coupled together by any of a variety of mechanisms. Suitable mechanisms may include, but are not limited to, mechanical latches, tethers, clamps or supports, or magnetic or magnetized surfaces. The ability to mechanically couple the surgical robot 4 and the camera tracking system 6 may allow the surgical system 2 to be maneuvered and moved as a single unit and allow the surgical system 2 to have a small footprint in an area, allow easier movement through narrow passageways and around turns, and allow storage within a smaller area.

The orthopedic surgery may begin with the surgical system 2 moving from the medical storage room to the medical procedure room. The surgical system 2 may be maneuvered through doorways, halls, and elevators to reach a medical procedure room. Within the medical procedure room, the surgical system 2 may be physically separated into two separate and distinct systems (surgical robot 4 and camera tracking system 6). Surgical robot 4 may be positioned adjacent to the patient in any suitable location to properly assist medical personnel. The camera tracking system 6 may be positioned at the bottom of the patient, at the patient's shoulder, or any other location suitable for tracking the current pose and pose movements of the surgical robot 4 and the trajectory portion of the patient. Surgical robot 4 and camera tracking system 6 may be powered by an on-board power source and/or plugged into an exterior wall outlet.

Surgical robot 4 may be used to assist a surgeon by holding and/or using tools during a medical procedure. To properly utilize and hold the tool, surgical robot 4 may rely on multiple motors, computers, and/or actuators to function properly. As illustrated in fig. 1, the robot body 8 may serve as a structure in which multiple motors, computers, and/or actuators may be fixed within the surgical robot 4. The robot body 8 may also provide support for a robotic telescoping support arm 16. In some embodiments, the robot body 8 may be made of any suitable material. Suitable materials may be, but are not limited to, metals such as titanium, aluminum or stainless steel, carbon fiber, fiberglass or heavy duty plastics. The robot body 8 may be sized to provide a stable platform for supporting the attachment assembly and may house, hide, and protect a plurality of motors, computers, and/or actuators that may operate the attachment assembly.

The robot base 10 may serve as a lower support for the surgical robot 4. In some embodiments, the robot base 10 may support the robot body 8 and may attach the robot body 8 to a plurality of driven wheels 12. This attachment to the wheels may allow the robot body 8 to move efficiently in space. The robot base 10 may run along the length and width of the robot body 8. The robot base 10 may be about two inches to about 10 inches high. The robot base 10 may be made of any suitable material. Suitable materials may be, but are not limited to, metals such as titanium, aluminum or stainless steel, carbon fiber, fiberglass or heavy duty plastics or resins. The robot base 10 may cover, protect and support the driven wheel 12.

In some embodiments, as illustrated in fig. 1, at least one driven wheel 12 may be attached to the robot base 10. The driven wheel 12 may be attached to the robot base 10 at any location. Each individually driven wheel 12 can rotate in any direction about a vertical axis. The motor may be positioned above, within, or adjacent to the driven wheel 12. The motor may allow the surgical system 2 to be maneuvered to any position and stabilize and/or level the surgical system 2. The rod located within or adjacent to the driven wheel 12 may be pressed into the surface by a motor. The rod, not shown, may be made of any suitable metal to elevate the surgical system 2. Suitable metals may be, but are not limited to, stainless steel, aluminum, or titanium. Additionally, the lever may include a bumper (not shown) at the contact surface side end that may prevent the lever from sliding and/or create a suitable contact surface. The material may be any suitable material that acts as a buffer. Suitable materials may be, but are not limited to, plastic, neoprene, rubber, or textured metal. The bar may lift the driven wheel 10, which may lift the surgical system 2 to any height required to level or otherwise fix the orientation of the surgical system 2 relative to the patient. The weight of the surgical system 2 is supported by the small contact area of the rods on each wheel, preventing the surgical system 2 from moving during the medical procedure. This rigid positioning may prevent objects and/or persons from accidentally moving the surgical system 2.

The robotic track 14 may be used to facilitate movement of the surgical system 2. The robot track 14 provides the person with the ability to move the surgical system 2 without grasping the robot body 8. As illustrated in fig. 1, the length of the robot track 14 may be as long as the robot body 8, shorter than the robot body 8, and/or may be longer than the robot body 8. The robot track 14 may be made of any suitable material. Suitable materials may be, but are not limited to, metals such as titanium, aluminum or stainless steel, carbon fiber, fiberglass or heavy duty plastics. The robot track 14 may further provide protection to the robot body 8 from objects and/or medical personnel contacting, striking or hitting the robot body 8.

The robot body 8 may provide support for a selectively compliant articulating robotic arm, hereinafter referred to as "SCARA". The use of SCARA 24 within surgical system 2 may be advantageous due to the repeatability and compactness of the robotic arm. The compactness of SCARA may provide additional space within the medical procedure, which may allow a medical professional to perform the medical procedure without excessive clutter and limited area. SCARA 24 may include robotic telescoping support 16, robotic support arm 18, and/or robotic arm 20. A robot telescoping support 16 may be positioned along the robot body 8. As illustrated in fig. 1, the robotic telescoping support 16 may provide support for the SCARA 24 and the display 34. In some embodiments, the robotic telescoping support 16 may extend and retract in a vertical direction. The robotic telescoping support 16 may be made of any suitable material. Suitable materials may be, but are not limited to, metals such as titanium or stainless steel, carbon fiber, fiberglass, or heavy duty plastics. The body of the robotic telescoping support 16 may be any width and/or height to support the stresses and weights placed thereon.

In some embodiments, the medical personnel may move the SCARA 24 through commands submitted by the medical personnel. The commands may originate from inputs received on the display 34 and/or tablet computer. The command may come from a press of a switch and/or a press of a plurality of switches. As best shown in fig. 4 and 5, the activation assembly 60 may include a switch and/or a plurality of switches. The activation assembly 60 may be operable to transmit movement commands to the SCARA 24, allowing an operator to manually manipulate the SCARA 24. Medical personnel have the ability to easily move the SCARA 24 when the switch or switches are pressed. Additionally, when the SCARA 24 does not receive a command to move, the SCARA 24 may be locked in place to prevent accidental movement by medical personnel and/or other objects. By locking in place, the SCARA 24 provides a secure platform upon which the passive end effector 1100 and attached surgical saw 1140 are ready for medical operations as shown in fig. 4 and 5.

The robotic support arm 18 may be mounted on the robotic telescoping support 16 by a variety of mechanisms. In some embodiments, as best seen in fig. 1 and 2, the robotic support arm 18 rotates in any direction relative to the robotic telescoping support 16. The robotic support arm 18 may rotate three hundred sixty degrees around the robotic telescoping support 16. The robotic arm 20 may be coupled to the robotic support arm 18 at any suitable location. The robotic arm 20 may be attached to the robotic support arm 16 by a variety of mechanisms. Suitable mechanisms may be, but are not limited to, nuts and bolts, ball and socket joints, press-fit, welds, adhesives, screws, rivets, clamps, latches, and/or any combination thereof. The robotic arm 20 may rotate in any direction relative to the robotic support arm 18, in an embodiment the robotic arm 20 may rotate three hundred sixty degrees relative to the robotic support arm 18. This free rotation may allow an operator to position the robotic arm 20 as planned.

The passive end effector 1100 of fig. 4 and 5 may be attached to the robotic arm 20 at any suitable location. As will be explained in further detail below, the passive end effector 1100 includes a base, a first mechanism, and a second mechanism. The base is configured to attach to an end effector coupler 22 of a robotic arm 20 positioned by a surgical robot 4. The various mechanisms by which the base may be attached to end effector coupler 22 may include, but are not limited to, latches, clamps, nuts and bolts, ball and socket fits, press fits, welds, adhesives, screws, rivets, and/or any combination thereof. The first mechanism extends between a rotatable connection to the base and a rotatable connection to a tool attachment mechanism. The second mechanism extends between a rotatable connection to the base and a rotatable connection to the tool attachment mechanism. The first and second mechanisms pivot about the rotatable connection and may be configured to limit movement of the tool attachment mechanism to a range of movement within a working plane. The rotatable connection may be a pivot joint allowing 1 degree of freedom (DOF) movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement. The tool attachment mechanism is configured to connect to a surgical saw 1140 having a saw blade or directly to the saw blade. The surgical saw 1140 may be configured to swing a saw blade for cutting. The first and second mechanisms may be configured to constrain a cutting plane of the saw blade to be parallel to the work plane. The pivot joint may preferably be used to connect a planar mechanism when the passive end effector is to be configured to limit the movement of the saw blade to a cutting plane.

The tool attachment mechanism may be connected to the surgical saw 1140 or saw blade by a variety of mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press-fit, or magnets. In some embodiments, the dynamic reference array 52 is attached to the passive end effector 1100, e.g., to a tool attachment mechanism, and/or to the surgical saw 1140. Dynamic reference arrays (also referred to herein as "DRAs") are rigid bodies that may be disposed on a patient, a surgical robot, a passive end effector, and/or a surgical saw during a navigated surgical procedure. Camera tracking system 6 or other 3D positioning system is configured to track the pose (e.g., position and rotational orientation) of the tracking markers of the DRA in real-time. The tracking marks may comprise an arrangement of balls or other optical marks as shown. Such tracking of the 3D coordinates of the tracking markers may allow the surgical system 2 to determine the pose of the DRA 52 in any space relative to the target anatomy of the patient 50 in fig. 5.

As illustrated in fig. 1, the light indicator 28 may be positioned on top of the SCARA 24. The light indicator 28 may be illuminated as any type of light to indicate a "condition" in which the surgical system 2 is currently operating. For example, green illumination may indicate that all systems are normal. The bright red color may indicate that surgical system 2 is not operating properly. Pulsing the light may mean that surgical system 2 is performing a function. The combination of light and pulsing may produce an almost infinite number of combinations in which the current operating conditions, status or other operating indication is conveyed. In some embodiments, the light may be generated by an LED bulb, which may form a ring around the light indicator 28. The light indicator 28 may comprise a fully permeable material that allows light to pass through the entirety of the light indicator 28.

The light indicator 28 may be attached to a lower display support 30. As illustrated in fig. 2, the lower display support 30 may allow an operator to manipulate the display 34 to any suitable position. The lower display support 30 may be attached to the light indicator 28 by any suitable mechanism. In an embodiment, the lower display support 30 may rotate about the light indicator 28. In an embodiment, the lower display support 30 may be rigidly attached to the light indicator 28. The light indicator 28 may then be rotated three hundred sixty degrees about the robotic support arm 18. The lower display support 30 may be any suitable length, and a suitable length may be about eight inches to about thirty-four inches. The lower display support 30 may serve as a base for the upper display support 32.

Upper display support 32 may be attached to lower display support 30 by any suitable mechanism. The upper display support 32 may be any suitable length, and a suitable length may be about eight inches to about thirty-four inches. In an embodiment, as illustrated in fig. 1, upper display support 32 may allow display 34 to be rotated three hundred sixty degrees relative to upper display support 32. Likewise, upper display support 32 may be rotated three hundred sixty degrees relative to lower display support 30.

The display 34 may be any device supported by the upper display support 32. In an embodiment, as illustrated in FIG. 2, display 34 may produce color and/or black and white images. The width of the display 34 may be about eight inches to about thirty inches wide. The height of the display 34 may be about six inches to about twenty-two inches high. The depth of the display 34 may be about one-half inch to about four inches.

In embodiments, a tablet may be used in conjunction with the display 34 and/or without the display 34. In an embodiment, the table may be placed on the upper display support 32 in place of the display 34 and may be removed from the upper display support 32 during a medical procedure. Additionally, the tablet may be in communication with the display 34. The tablet computer can be connected to the surgical robot 4 by any suitable wireless and/or wired connection. In some embodiments, the tablet computer is capable of programming and/or controlling the surgical system 2 during a medical procedure. When the surgical system 2 is controlled with a tablet computer, all input and output commands can be replicated on the display 34. The use of a tablet computer may allow an operator to manipulate surgical robot 4 without having to move around patient 50 and/or surgical robot 4.

As illustrated in fig. 5, the camera tracking system 6 works in conjunction with the surgical robot 4 through a wired or wireless communication network. Referring to fig. 1 and 5, the camera tracking system 6 may include some components similar to the surgical robot 4. For example, the camera body 36 may provide functions found in the robot body 8. The robot body 8 may provide a structure on which the camera 46 is mounted. The structure within the robot body 8 may also provide support for electronics, communication devices, and power supplies for operating the camera tracking system 6. The camera body 36 may be made of the same material as the robot body 8. The camera tracking system 6 may communicate directly with the tablet and/or display 34 via a wireless and/or wired network to enable the tablet and/or display 34 to control the functions of the camera tracking system 6.

The camera body 36 is supported by a camera mount 38. The camera mount 38 may be used as the robot mount 10. In the embodiment of fig. 1, the camera mount 38 may be wider than the robot mount 10. The width of the camera mount 38 may allow the camera tracking system 6 to be coupled with the surgical robot 4. As illustrated in fig. 1, the width of the camera mount 38 may be large enough to fit outside of the robot mount 10. The additional width of the camera mount 38 may allow the surgical system 2 to provide additional operability and support for the surgical system 2 when the camera tracking system 6 is connected with the surgical robot 4.

As with the robot base 10, a plurality of driven wheels 12 may be attached to the camera base 38. Similar to the operation of the robot base 10 and the driven wheel 12, the driven wheel 12 may allow the camera tracking system 6 to stabilize and level or set a fixed orientation relative to the patient 50. Such stabilization may prevent the camera tracking system 6 from moving during a medical procedure and may prevent the camera 46 from losing tracking of one or more DRAs 52 connected to the anatomy 54 and/or tool 58 within the designated area 56 as shown in fig. 5. This stability and maintenance of tracking enhances the ability of surgical robot 4 to operate effectively with camera tracking system 6. Additionally, the wide camera mount 38 may provide additional support for the camera tracking system 6. In particular, as illustrated in fig. 5, the wide camera mount 38 may prevent the camera tracking system 6 from tipping when the camera 46 is placed on the patient. Without the wide camera mount 38, the extended camera 46 may unbalance the camera tracking system 6, which may cause the camera tracking system 6 to tip over.

The camera telescoping support 40 may support a camera 46. In an embodiment, the telescoping support 40 may move the camera 46 higher or lower in a vertical direction. The telescoping support 40 may be made of any suitable material in which the camera 46 is supported. Suitable materials may be, but are not limited to, metals such as titanium, aluminum or stainless steel, carbon fiber, fiberglass or heavy duty plastics. The camera handle 48 may be attached to the camera telescoping support 40 at any suitable location. The camera handle 48 may be of any suitable handle configuration. Suitable configurations may be, but are not limited to, bar, circle, triangle, square, and/or any combination thereof. As illustrated in fig. 1, the camera handle 48 may be triangular, allowing the operator to move the camera tracking system 6 to a planned position prior to a medical procedure. In an embodiment, the camera handle 48 may be used to lower and raise the camera telescoping support 40. The camera handle 48 may perform the raising and lowering of the camera telescoping support 40 by pressing a button, switch, lever, and/or any combination thereof.

The lower camera support arm 42 may be attached to the camera telescoping support 40 in any suitable location, in an embodiment, as illustrated in fig. 1, the lower camera support arm 42 may be rotated three hundred sixty degrees around the telescoping support 40. Such free rotation may allow an operator to position the camera 46 in any suitable location. The lower camera support arm 42 may be made of any suitable material in which the camera 46 is supported. Suitable materials may be, but are not limited to, metals such as titanium, aluminum or stainless steel, carbon fiber, fiberglass or heavy duty plastics. The cross-section of the lower camera support arm 42 may be any suitable shape. Suitable cross-sectional shapes may be, but are not limited to, circular, square, rectangular, hexagonal, octagonal, or i-beams. The length and width of the cross section may be about one to ten inches. The length of the lower camera support arm may be about four inches to about thirty-six inches. The lower camera support arm 42 may be connected to the telescoping support 40 by any suitable mechanism. Suitable mechanisms may be, but are not limited to, nuts and bolts, ball and socket joints, press-fit, welds, adhesives, screws, rivets, clamps, latches, and/or any combination thereof. The lower camera support arm 42 may be used to provide support for a camera 46. The camera 46 may be attached to the lower camera support arm 42 by any suitable mechanism. Suitable mechanisms may be, but are not limited to, nuts and bolts, ball and socket joints, press-fit, welds, adhesives, screws, rivets, and/or any combination thereof. The camera 46 may pivot in any direction at the attachment area between the camera 46 and the lower camera support arm 42. In an embodiment, the curved track 44 may be disposed on the lower camera support arm 42.

The curved track 44 may be positioned at any suitable location on the lower camera support arm 42. As illustrated in fig. 3, the curved track 44 may be attached to the lower camera support arm 42 by any suitable mechanism. Suitable mechanisms may be, but are not limited to, nuts and bolts, ball and socket joints, press-fit, welds, adhesives, screws, rivets, clamps, latches, and/or any combination thereof. The curved track 44 may be any suitable shape, which may be crescent-shaped, circular, flat, oval, and/or any combination thereof. In embodiments, curved track 44 may be any suitable length. Suitable lengths may be about one foot to about six feet. The camera 46 may be movably positioned along the curved track 44. The camera 46 may be attached to the curved track 44 by any suitable mechanism. Suitable mechanisms may be, but are not limited to, rollers, brackets, braces, motors, and/or any combination thereof. Motors and rollers, not shown, may be used to move the camera 46 along the curved track 44. As illustrated in fig. 3, during a medical procedure, if an object prevents the camera 46 from viewing one or more DRAs 52, the motor may use rollers to move the camera 46 along the curved track 44. Such motorized movement may allow the camera 46 to move to a new position that is no longer obstructed by the object without moving the camera tracking system 6. When the camera 46 is blocked from viewing the DRA 52, the camera tracking system 6 may send a stop signal to the surgical robot 4, display 34, and/or tablet. The stop signal may prevent the SCARA 24 from moving until the camera 46 reacquires the DRA 52. Such stopping may prevent SCARA 24 and/or end effector coupler 22 from moving and/or using medical tools without being tracked by surgical system 2.

As illustrated in fig. 6, end effector coupler 22 is configured to connect various types of passive end effectors to surgical robot 4. End effector coupler 22 may include saddle joint 62, activation assembly 60, load cell 64 (fig. 7), and connector 66. Saddle joint 62 may attach end effector coupler 22 to SCARA 24. Saddle joint 62 may be made of any suitable material. Suitable materials may be, but are not limited to, metals such as titanium, aluminum or stainless steel, carbon fiber, fiberglass or heavy duty plastics. Saddle joint 62 may be made from a single piece of metal, which may provide additional strength and durability to the end effector. Saddle joint 62 may be attached to SCARA24 by attachment points 68. There may be a plurality of attachment points 68 disposed about the saddle joint 62. Attachment points 68 may be countersunk, flush, and/or seated on saddle joint 62. In some examples, screws, nuts and bolts and/or any combination thereof may pass through the attachment points 68 and secure the saddle joint 62 to the SCARA 24. Nuts and bolts may connect saddle joint 62 to a motor (not shown) within SCARA 24. The motor may move saddle joint 62 in any direction. The motor may further prevent saddle joint 62 from moving due to accidental bumps and/or accidental contact by actively servo in the current position or passively by applying a spring actuated brake.

The end effector coupler 22 may include a load cell 64 interposed between the saddle joint 62 and the attached passive end effector. As illustrated in fig. 7, the load cell 64 may be attached to the saddle joint 62 by any suitable mechanism. Suitable mechanisms may be, but are not limited to, screws, nuts and bolts, threads, press fit, and/or any combination thereof.

Fig. 8 illustrates a block diagram of components of a surgical system 800, according to some embodiments of the present disclosure. Referring to fig. 7 and 8, load cell 64 may be any suitable instrument for detecting and measuring forces. In some examples, the load cell 64 may be a six-axis load cell, a three-axis load cell, or a single-axis load cell. Load cell 64 may be used to track the force applied to end effector coupler 22. In some embodiments, the load cell 64 may be in communication with a plurality of motors 850, 851, 852, 853, and/or 854. When the load cell 64 senses a force, information regarding the amount of force applied may be distributed from the switch array and/or the plurality of switch arrays to the controller 846. The controller 846 may obtain force information from the load cells 64 and process it with a switching algorithm. The controller 846 uses a switching algorithm to control the motor driver 842. The motor driver 842 controls the operation of one or more motors. The motor driver 842 may direct a particular motor to generate an equal amount of force as measured by the load cell 64 through the motor, for example. In some embodiments, the force generated may be from multiple motors, such as 850-854, as directed by the controller 846. Additionally, the motor driver 842 may receive input from the controller 846. The controller 846 may receive information from the load cell 64 regarding the direction of the force sensed by the load cell 64. Controller 846 may process this information using a motion controller algorithm. The algorithm may be used to provide information to a particular motor driver 842. To replicate the direction of the force, the controller 846 may activate and/or deactivate certain motor drives 842. The controller 846 may control one or more motors, such as one or more of 850-854, to induce movement of the passive end effector 1100 in the direction of the force sensed by the load cells 64. Such force-controlled movement may allow an operator to move the SCARA 24 and the passive end effector 1100 with little effort and/or with very little resistance. Movement of the passive end effector 1100 may be performed to position the passive end effector 1100 in any suitable pose (i.e., position and angular orientation relative to a defined three-dimensional (3D) orthogonal reference axis) for use by medical personnel.

The connector 66 is configured to be connectable to a base of the passive end effector 1100 and to the load cell 64. The connector 66 may include attachment points 68, sensor buttons 70, tool guides 72, and/or tool connectors 74. As best illustrated in fig. 6 and 8, there may be a plurality of attachment points 68. Attachment points 68 may connect connector 66 to load cell 64. Attachment points 68 may be countersunk, flush, and/or seated on connector 66. Attachment points 68 and 76 may be used to attach connector 66 to load cell 64 and/or passive end effector 1100. In some examples, attachment points 68 and 76 may include screws, nuts and bolts, press fits, magnetic attachments, and/or any combination thereof.

As illustrated in fig. 6, the sensor button 70 may be disposed about the center of the connector 66. When the passive end effector 1100 is connected to the SCARA 24, the sensor button 70 may be pressed. Pressing the sensing button 70 may alert the surgical robot 4, and in turn alert medical personnel that the passive end effector 1100 has been attached to the SCARA 24. As illustrated in fig. 6, the guide 72 may be used to facilitate proper attachment of the passive end effector 1100 to the SCARA 24. The guide 72 may be countersunk, flush, and/or seated on the connector 66. In some examples, there may be multiple guides 72, and there may be any suitable pattern, and there may be any suitable orientation. The guide 72 may be any suitable shape to facilitate attachment of the passive end effector 1100 to the SCARA 24. Suitable shapes may be, but are not limited to, circular, flat, square, polyhedral, and/or any combination thereof. Additionally, the guide 72 may be cut with a bevel, a straight line, and/or any combination thereof.

The connector 66 may have an attachment point 74. As illustrated in fig. 6, the attachment points 74 may form a protrusion and/or a plurality of protrusions. Attachment points 74 may provide connector 66 with a surface upon which passive end effector 1100 may clamp. In some embodiments, attachment points 74 are disposed about any surface of connector 66 and are oriented in any suitable manner relative to connector 66.

As best shown in fig. 6 and 7, the activation assembly 60 may encircle the connector 66. In some embodiments, activation assembly 60 may take the form of a bracelet wrapped around connector 66. In some embodiments, activation assembly 60 may be located in any suitable area within surgical system 2. In some examples, the activation assembly 60 may be located on any portion of the SCARA 24, any portion of the end effector coupler 22, may be worn (and wirelessly communicated) by medical personnel, and/or any combination thereof. The activation assembly 60 may be made of any suitable material. Suitable materials may be, but are not limited to, neoprene, plastic, rubber, gel, carbon fiber, fabric, and/or any combination thereof. The activation assembly 60 may include a primary button 78 and a secondary button 80. The primary button 78 and the secondary button 80 may encircle the entirety of the connector 66.

The primary button 78 may be a single ridge, as illustrated in fig. 6, that may encircle the connector 66. In some examples, the primary button 78 may be disposed on the activation assembly 60 along the end furthest from the saddle joint 62. The primary button 78 may be positioned on a primary activation switch 82, as best illustrated in fig. 7. A primary activation switch 82 may be disposed between the connector 66 and the activation assembly 60. In some examples, there may be a plurality of primary activation switches 82 that may be disposed adjacent to and below the primary button 78 along the entire length of the primary button 78. Pressing the primary button 78 on the primary activation switch 82 may allow the operator to move the SCARA 24 and the end effector coupler 22. Once in place, as described above, the SCARA 24 and end effector coupler 22 may not be moved until the operator programs the surgical robot 4 to move the SCARA 24 and end effector coupler 22, or to move using the primary buttons 78 and primary activation switches 82. In some instances, it may be desirable to press at least two non-adjacent primary activation switches 82 before the SCARA 24 and end effector coupler 22 will respond to an operator command. Pressing the at least two primary activation switches 82 may prevent inadvertent movement of the SCARA 24 and end effector coupler 22 during a medical procedure.

Activated by the primary button 78 and primary activation switch 82, the load cell 64 may measure the magnitude and/or direction of force exerted by an operator, i.e., medical personnel, on the end effector coupler 22. This information may be transferred to a motor within the SCARA24, which may be used to move the SCARA24 and end effector coupler 22. Information about the magnitude and direction of the force measured by the load cell 64 may cause the motor to move the SCARA24 and end effector coupler 22 in the same direction as the load cell 64 senses. Such force-controlled movement may allow an operator to easily move the SCARA24 and the end effector coupler 22, and may not require significant effort because the motor moves the SCARA24 and the end effector coupler 22 while the operator moves the SCARA24 and the end effector coupler 22.

As shown in fig. 6, a secondary button 80 may be disposed at the end of the activation assembly 60 closest to the saddle joint 62. In some examples, the secondary button 80 may include a plurality of ridges. The plurality of ridges may be disposed adjacent to one another and may surround the connector 66. Alternatively, the secondary button 80 may be positioned on the secondary activation switch 84. As illustrated in fig. 7, a secondary activation switch 84 may be disposed between the secondary button 80 and the connector 66. In some examples, the operator may use the secondary button 80 as a "select" device. During a medical procedure, surgical robot 4 may notify medical personnel of certain conditions via display 34 and/or light indicator 28. The surgical robot 4 may prompt medical personnel to select functions, modes, and/or evaluate the condition of the surgical system 2. Pressing the secondary button 80 on the secondary activation switch 84 a single time may activate certain functions, modes, and/or confirm information communicated to medical personnel via the display 34 and/or light indicator 28. Additionally, pressing the secondary button 80 multiple times in rapid succession on the secondary activation switch 84 may initiate additional functions, modes, and/or select information communicated to medical personnel via the display 34 and/or light indicator 28. In some examples, at least two non-adjacent secondary activation switches 84 may be pressed before the secondary button 80 may function properly. This requirement may prevent unintended use of the secondary button 80 by medical personnel upon activation of the assembly 60. The primary button 78 and the secondary button 80 may use a software architecture 86 to communicate medical personnel commands to the surgical system 2.

Fig. 8 illustrates a block diagram of components of a surgical system 800 configured in accordance with some embodiments of the present disclosure, and which may correspond to surgical system 2 above. Surgical system 800 includes a platform subsystem 802, a computer subsystem 820, a motion control subsystem 840, and a tracking subsystem 830. Platform subsystem 802 includes a battery 806, a power distribution module 804, a connector panel 808, and a charging station 810. Computer subsystem 820 includes a computer 822, a display 824, and speakers 826. The motion control subsystem 840 includes drive circuitry 842, motors 850, 851, 852, 853, 854, stabilizers 855, 856, 857, 858, end effector connector 844, and controller 846. Tracking subsystem 830 includes a position sensor 832 and a camera transducer 834. Surgical system 800 may also include a removable foot pedal 880 and a removable tablet 890.

Input power is supplied to surgical system 800 by a power source, which may be provided to power distribution module 804. The power distribution module 804 receives input power and is configured to generate different supply voltages that are provided to other modules, components, and subsystems of the surgical system 800. The power distribution module 804 may be configured to provide different voltage supplies to the connector panel 808, which may be provided to other components, such as the computer 822, the display 824, the speaker 826, the driver 842, for example, to power the motors 850-854 and the end effector coupler 844, and to the camera converter 834 and other components for the surgical system 800. The power distribution module 804 may also be connected to a battery 806 that acts as a temporary power source if the power distribution module 804 does not receive power from an input power source. At other times, the power distribution module 804 may be used to charge the battery 806.

The connector panel 808 may be used to connect different devices and components to the surgical system 800 and/or related components and modules. The connector panel 808 may contain one or more ports that receive wires or connectors from different components. For example, connector panel 808 may have a ground port to ground surgical system 800 to other devices, a port to connect foot pedal 880, a port to connect tracking subsystem 830, which may contain position sensor 832, camera transducer 834, and marker tracking camera 870. The connector panel 808 may also contain other ports to allow USB, ethernet, HDMI communications with other components, such as the computer 822.

Control panel 816 may provide various buttons or indicators that control the operation of surgical system 800 and/or provide information from surgical system 800 for viewing by an operator. For example, control panel 816 may include buttons for opening or closing surgical system 800, lifting or lowering vertical column 16, and lifting or lowering stabilizers 855-858, which may be designed to engage casters 12 to lock surgical system 800 from physical movement. Other buttons may stop the surgical system 800 in the event of an emergency, which may remove all motor power and apply a mechanical brake to stop all movement from occurring. The control panel 816 may also have indicators for informing the operator of certain system conditions, such as line power indicators or the state of charge of the battery 806.

The computer 822 of computer subsystem 820 contains an operating system and software for operating the designated functions of surgical system 800. The computer 822 may receive and process information from other components (e.g., the tracking subsystem 830, the platform subsystem 802, and/or the motion control subsystem 840) to display information to an operator. Further, computer subsystem 820 may provide an output to an operator through speaker 826. The speaker may be part of the surgical robot, part of the head mounted display assembly, or within another component of the surgical system 2. The display 824 may correspond to the display 34 shown in fig. 1 and 2, or may be a head mounted display that projects an image onto a see-through display screen that forms an Augmented Reality (AR) image overlaid on a real world object visible through the see-through display screen.

Tracking subsystem 830 may include a position sensor 832 and a camera transducer 834. Tracking subsystem 830 may correspond to camera tracking system 6 of fig. 3. The tag tracking camera 870 operates with the position sensor 832 to determine the pose of the DRA 52. Such tracking may be performed in a manner consistent with the present disclosure, including using infrared light or visible light technology, such as LEDs or reflective markers, that track the position of the active or passive elements of DRA52, respectively. The computer 822 is provided with the location, orientation and positioning of structures such as DRA52 having these types of indicia and may be shown to an operator on a display 824. For example, as shown in fig. 4 and 5, a surgical saw 1240 having a DRA52 or connected to an end effector coupler 22 having a DRA52 (which may be referred to as a navigation space) tracked in this manner may be shown to an operator with respect to a three-dimensional image of the patient's anatomy.

The motion control subsystem 840 may be configured to physically move the vertical column 16, the upper arm 18, the lower arm 20, or rotate the end effector coupler 22. Physical movement may be performed by using one or more motors 850-854. For example, the motor 850 may be configured to vertically raise or lower the vertical column 16. As shown in fig. 2, motor 851 may be configured to move upper arm 18 laterally about the point of engagement with vertical column 16. As shown in fig. 2, motor 852 may be configured to move lower arm 20 laterally about an engagement point with upper arm 18. Motors 853 and 854 may be configured to move end effector coupler 22 to provide translational movement along a three-dimensional axis and rotation thereabout. The surgical planning computer 910 shown in fig. 9 may provide control inputs to the controller 846 that directs movement of the end effector coupler 22 to position the passive end effector coupled thereto in a planned pose (i.e., position and angular orientation relative to a defined 3D orthogonal reference axis) relative to the anatomy to be cut during the surgical procedure. The motion control subsystem 840 may be configured to measure the position of the passive end effector structure using an integrated position sensor (e.g., encoder). In one of the described embodiments, the position sensor is directly connected to at least one joint of the passive end effector structure, but may also be positioned at another location in the structure and the joint position measured remotely by timing belts, wires, or any other interconnection of synchronous transmission interconnections.

Fig. 9 illustrates a block diagram of a surgical system computer platform 900 that contains a surgical planning computer 910, which may be separate from and operatively connected to, or at least partially incorporated with, the surgical robot 800 herein, in accordance with some embodiments of the present disclosure. Alternatively, at least a portion of the operations disclosed herein for surgical planning computer 910 may be performed by components of surgical robot 800 (e.g., by computer subsystem 820).

Referring to fig. 9, a surgical planning computer 910 includes a display 912, at least one processor circuit 914 (also referred to as a processor for brevity), at least one memory circuit 916 (also referred to as a memory for brevity) containing computer readable program code 918, and at least one network interface 920 (also referred to as a network interface for brevity). The network interface 920 may be configured to connect to the C-arm imaging device 104 of fig. 10, the O-arm imaging device 106 of fig. 11, another medical imaging device, an image database 950 of medical images, components of the surgical robot 800, and/or other electronics.

When the surgical planning computer 910 is at least partially integrated within the surgical robot 800, the display 912 may correspond to the display 34 of fig. 2 and/or the tablet 890 and/or head-mounted display of fig. 8, the network interface 920 may correspond to the platform network interface 812 of fig. 8, and the processor 914 may correspond to the computer 822 of fig. 8.

Processor 914 may comprise one or more data processing circuits, such as a general-purpose and/or special-purpose processor, e.g., a microprocessor and/or a digital signal processor. Processor 914 is configured to execute computer-readable program code 918 in memory 916 to perform operations that may include some or all of the operations described herein as being performed by a surgical planning computer.

Processor 914 is operable to display an image of bone on display device 912, which is received from one of imaging devices 104 and 106 and/or from image database 950 through network interface 920. Processor 914 receives operator definition of the location at which the anatomy (i.e., one or more bones) shown in the one or more images is to be cut, such as by operator touch selection of a location on display 912 for the planned surgical cut, or using a mouse-based cursor to define a location for the planned surgical cut.

The surgical planning computer 910 is capable of making anatomical measurements useful for knee surgery, similar to measurements for determining various angles of hip center, angular center, natural landmarks (e.g., femoral condyle line (transepicondylar line), white line (WHITESIDES LINE), femoral posterior condyle line (posterior condylar line), etc.). Some measurements may be automatic, while some others involve human input or assistance. The surgical planning computer 910 allows the operator to select the correct implant for the patient, including the selection of size and alignment. The surgical planning computer 910 can perform automatic or semi-automatic (involving human input) segmentation (image processing) of CT images or other medical images. The patient's surgical plan may be stored in a cloud-based server for retrieval by surgical robot 800. During a surgical procedure, the surgeon will select which cuts (e.g., posterior femur, proximal tibia, etc.) to make using a computer screen (e.g., touch screen) or augmented reality interaction, for example, via a head mounted display. The surgical robot 4 may automatically move the surgical saw blade to the planned position such that the target plane of the planned cut is optimally placed within the working space of the passive end effector interconnecting the surgical saw blade and the robotic arm 20. The user may use various means (e.g., foot pedals) to give commands to effect movement.

In some embodiments, the surgical system computer platform 900 may use two DRAs to track patient anatomical locations, one on the patient's tibia and one on the patient's femur. Platform 900 may use standard navigation instruments for registration and inspection (e.g., a pointer similar to that used in Globus ExcelsiusGPS systems for spinal surgery). Tracking markers that allow detection of DRA movement with reference to the anatomy being tracked may also be used.

An important difficulty with knee surgery is how to plan the position of the implant in the knee, and many surgeons strive to do this on a computer screen, which is a 2D representation of the 3D anatomy. Platform 900 may address this problem by using an Augmented Reality (AR) head mounted display to create implant coverage around the actual patient's knee. For example, the surgeon may operatively display a virtual handle to grasp and move the implant to a desired pose and adjust the planned implant placement. Thereafter, during surgery, platform 900 may provide navigation through the AR head mounted display to show the surgeon what is not directly visible. In addition, progress of bone removal, such as depth or cut, may be displayed in real time. Other features that may be displayed by AR may include, but are not limited to, gap or ligament balance along the range of articulation, contact lines on the implant along the range of articulation, ligament tension and/or sag covered by color or other graphics, and the like.

In some embodiments, the surgical planning computer 910 may allow for planning the use of standard implants, such as posterior stabilized implants and cruciate retaining implants, bone cement-type and non-bone cement-type implants, revision systems for surgical procedures related to, for example, total or partial knee replacement and/or hip replacement and/or trauma.

The processor 912 may graphically present on the display 912 one or more cutting planes intersecting the displayed anatomy at a location selected by the operator for cutting the anatomy. The processor 912 also determines one or more sets of angular orientations and positions in which the end effector coupler 22 must be positioned such that the cutting plane of the surgical saw blade will be aligned with the target plane to perform the operator defined cut, and stores the sets of angular orientations and positions as data in the surgical planning data structure. The processor 912 uses the known range of movement of the tool attachment mechanism of the passive end effector to determine where the end effector coupler 22 attached to the robotic arm 20 needs to be positioned.

The computer subsystem 820 of the surgical robot 800 receives data from the surgical planning data structure and receives information from the camera tracking system 6 indicating the current pose of the anatomy to be cut and indicating the current pose of the passive end effector and/or surgical saw tracked by the DRA. Computer subsystem 820 determines the pose of the target plane based on a surgical plan defining the location at which the anatomical structure is to be cut and based on the pose of the anatomical structure. Computer subsystem 820 generates steering information based on a comparison of the pose of the target plane and the pose of the surgical saw. The steering information indicates where the passive end effector needs to be moved so that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade is positioned at a distance from the anatomy to be cut that is within the range of movement of the tool attachment mechanism of the passive end effector.

As explained above, a surgical robot includes a robot base, a robot arm connected to the robot base, and at least one motor operatively connected to move the robot arm relative to the robot base. The surgical robot also includes at least one controller, such as a computer subsystem 820 and a motion control subsystem 840, connected to the at least one motor and configured to perform operations.

As will be explained in further detail below with respect to fig. 12-19, the passive end effector includes a base configured to be attached to an activation assembly of a robotic arm, a first mechanism, and a second mechanism. The first mechanism extends between a rotatable connection to the base and a rotatable connection to a tool attachment mechanism. The second mechanism extends between a rotatable connection to the base and a rotatable connection to the tool attachment mechanism. The first and second mechanisms pivot about the rotatable connection, which may be configured to limit movement of the tool attachment mechanism to a range of movement within a working plane. The rotatable connection may be a pivot joint allowing 1 degree of freedom (DOF) movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement. The tool attachment mechanism is configured to connect to the surgical saw including a saw blade for cutting. The first and second mechanisms may be configured to constrain a cutting plane of the saw blade to be parallel to the work plane.

In some embodiments, the operations performed by the at least one controller of the surgical robot further include controlling movement of the at least one motor based on the manipulation information to reposition the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade is positioned at the distance from the anatomical structure to be cut that is within a range of movement of the tool attachment mechanism of the passive end effector. Manipulation information may be displayed to guide an operator in moving the surgical saw and/or the at least one controller may use it to automatically move the surgical saw.

In one embodiment, the operations performed by the at least one controller of the surgical robot further include providing the manipulation information to a display device for display to guide an operator to move the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade is positioned at the distance from the anatomical structure to be cut that is within a range of movement of the tool attachment mechanism of the passive end effector. The display device may correspond to display 824 (fig. 8), display 34 of fig. 1, and/or a head mounted display.

For example, the manipulation information may be displayed on a head mounted display that projects an image onto a see-through display screen that forms an augmented reality image overlaid on a real world object visible through the see-through display screen. The operations may display a graphical representation of the target plane having a pose overlaid on the bone with a relative orientation therebetween corresponding to a surgical plan of how to plan cutting of the bone. The operation may alternatively or additionally display a graphical representation of the blade cutting plane so that the operator may more easily align the cutting plane with the intended target plane for cutting bone. Thus, the operator can visually observe and perform the movement to align the cutting plane of the saw blade with the target plane such that the saw blade is positioned in a planned pose relative to the bone and within the range of movement of the tool attachment mechanism of the passive end effector.

An automated imaging system may be used in conjunction with the surgical planning computer 910 and/or the surgical system 2to acquire pre-operative, intra-operative, post-operative, and/or real-time image data of the patient. Fig. 10 and 11 illustrate an example automated imaging system. In some embodiments, the automated imaging system is a C-arm 104 (FIG. 10) imaging device or106 (FIG. 11). (Medun force pilot (Medtronic Navigation, inc.) with place of business in Louisville, colo., USA) in Colorado, U.S. has The copyright of (c) may desire to perform x-ray examinations of a patient from many different locations without requiring frequent manual repositioning of the patient, which may be required in an x-ray system. The c-arm 104 x-ray diagnostic device can address frequent manual repositioning issues and is well known in the medical arts of surgical and other interventional procedures. As shown in fig. 10, the C-arm includes an elongated C-shaped member terminating in opposite distal ends 112 of a "C" shape. The C-shaped member is attached to an x-ray source 114 and an image receiver 116. The space within the C-arm 104 of the arm provides a doctor with room to care for the patient that is substantially undisturbed by the X-ray support structure.

The C-arm is mounted such that the arm is capable of rotational movement in two degrees of freedom (i.e., about two perpendicular axes in a spherical motion). The C-arm is slidably mounted to the x-ray support structure, which allows for orbital rotational movement of the C-arm about its center of curvature, which may allow for selective vertical and/or horizontal orientation of the x-ray source 114 and the image receiver 116. The C-arm may also be rotatable in a lateral direction (i.e., in a perpendicular direction relative to the orbiting direction to enable selective adjustment of the position of the X-ray source 114 and the image receiver 116 relative to the width and length of the patient). The spherical rotation aspect of the C-arm device allows the physician to perform x-ray examinations on the patient at an optimal angle determined with respect to the particular anatomical condition being imaged.

Shown in FIG. 11106 Includes a gantry housing 124 that may enclose an image capture portion that is not shown. The image capturing section comprises an x-ray source section and/or an x-ray emitting section and an x-ray receiving section and/or an image receiving section, which sections may be positioned about one hundred eighty degrees from each other and mounted on a rotor (not shown) with respect to the orbit of the image capturing section. The image capturing portion may be operatively rotated three hundred sixty degrees during image acquisition. The image capturing section may be rotated about a center point or axis, allowing image data of the patient to be acquired from multiple directions or in multiple planes.

With a gantry housing 124106 Has a central opening for positioning around an object to be imaged, a radiation source rotatable around the interior of the gantry housing 124, which may be adapted to project radiation from a plurality of different projection angles. The detector system is adapted to detect radiation at each projection angle, thereby acquiring an image of the object from a plurality of projection planes in a quasi-simultaneous manner. The gantry may be attached to the support structure in a cantilever mannerSupport structures such as wheeled mobile carts with wheels. The positioning unit preferably translates and/or tilts the gantry to a planned position and orientation under the control of the computerized motion control system. The gantry may include a source and a detector disposed opposite each other on the gantry. The source and detector may be fixed to a motorized rotator that can rotate the source and detector in combination with each other about the interior of the gantry. The source may be pulsed in multiple positions and orientations in a partial and/or full three hundred sixty degree rotation for multi-planar imaging of a target object located inside the gantry. The gantry may further include a track and bearing system for guiding the rotor as it rotates, which may carry the source and detector. Both and/or one of 106 and C-arm 104 may be used as an automated imaging system to scan a patient and send information to surgical system 2.

The image captured by the automated imaging system may be displayed on a display device of the surgical planning computer 910, the surgical robot 800, and/or another component of the surgical system 2.

Various embodiments of a passive end effector configured for use with a surgical system are now described in the context of fig. 12-19.

As will be explained in further detail below, the various passive end effectors shown in fig. 12-19 each include a base, a first planar mechanism, and a second planar mechanism. The base is configured to attach to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. Various clamping mechanisms can be used to securely attach the base to the end effector coupler to remove the gap and ensure proper stiffness. The irreversible clamping mechanism that can be used to attach the base to the end effector coupler can include, but is not limited to, a toggle mechanism or one or more irreversible locking screws. The user may use another tool such as, but not limited to, a screwdriver, torque wrench, or screwdriver to activate or tighten the clamping mechanism. The first mechanism extends between a rotatable connection to the two bases and a rotatable connection to the tool attachment mechanism. The second mechanism extends between a rotatable connection to the base and a rotatable connection to the tool attachment mechanism. The first mechanism and the second mechanism pivot about the rotatable connection. The rotatable connection may be a pivot joint allowing 1 degree of freedom (DOF) movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement. When a pivot joint is used, the first and second mechanisms may be configured to limit movement of the tool attachment mechanism to a range of movement within the working plane. The tool attachment mechanism is configured to connect to a surgical saw having a saw blade configured to swing for cutting. The first and second mechanisms may be configured to constrain a cutting plane of the saw blade to be parallel to the work plane, for example, by a pivot joint having 1 DOF motion. The tool attachment mechanism may be connected to the surgical saw or blade by a variety of mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press fit, or magnets. The DRA may be connected to a tool attachment mechanism or surgical saw to enable tracking of the pose of the saw blade by a camera tracking system 6 (fig. 3).

As explained above, the surgical system (e.g., surgical system 2 in fig. 1 and 2) includes a surgical robot (e.g., surgical robot 4 in fig. 1 and 2) and a tracking system (e.g., camera tracking system 6 in fig. 1 and 3) configured to determine the pose of the anatomical structure to be cut by the saw blade and to determine the pose of the saw blade. The surgical robot includes a robot base, a robotic arm rotatably coupled to the robot base and configured to position a passive end effector. At least one motor is operatively connected to move the robotic arm relative to the robotic base. At least one controller is connected to the at least one motor and configured to perform operations including determining a pose of a target plane based on a surgical plan defining a location at which the anatomical structure is to be cut and based on the pose of the anatomical structure, wherein the surgical plan may be generated by the surgical plan computer 910 of fig. 9 based on input from an operator (e.g., a surgeon or other surgical personnel). The operations further include generating steering information based on a comparison of the pose of the target plane and the pose of the surgical saw. The manipulation information indicates where the passive end effector needs to be moved to position the working plane of the passive end effector such that a cutting plane of the saw blade is aligned with the target plane.

In some further embodiments, the operations performed by at least one controller further include controlling movement of the at least one motor based on the manipulation information to reposition the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade is positioned at a distance from the anatomy to be cut that is within a range of movement of the tool attachment mechanism of the passive end effector.

The operations may include providing the manipulation information to a display device for display to guide an operator to move the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and such that the saw blade is positioned at a distance from the anatomical structure to be cut that is within a range of movement of the tool attachment mechanism of the passive end effector.

As explained above, some surgical systems may include a head mounted display device that may be worn by a surgeon, a medical nurse, and/or other person assisting in the surgical procedure. The surgical system may display information that allows the wearer to more accurately position the passive end effector and/or confirm that it has been accurately positioned with the saw blade aligned with the target plane for cutting the planned location on the anatomy. Providing the manipulation information to the display device may include configuring the manipulation information for display on a head mounted display device having a see-through display screen displaying the manipulation information as a covering over the anatomy to be cut to guide an operator to move the passive end effector such that a cutting plane of the saw blade becomes aligned with a target plane and the saw blade is positioned at the distance from the anatomy within a range of movement of a tool attachment mechanism of the passive end effector.

The operation of configuring the steering information for display on the head mounted display device may include generating a graphical representation of the target plane that is displayed as an overlay anchored to and aligned with the anatomy to be cut, and generating another graphical representation of the cutting plane of the saw blade that is displayed as an overlay anchored to and aligned with the saw blade. The wearer may thereby move the surgical saw to provide a visually observed alignment between the graphically presented target plane and the graphically presented cutting plane.

The operation of configuring the manipulation information for display on the head mounted display device may include generating a graphical representation of a depth of cut produced by the saw blade as a graphical representation of the anatomical structure being cut. Thus, the wearer may use a graphical representation of the depth of cut to better monitor how the saw blade cuts through bone, although direct observation of the cut is hindered by tissue or other structures.

The tracking system may be configured to determine a pose of the anatomical structure to be cut by the saw blade based on determining a pose of a tracking marker, such as a DRA, attached to the anatomical structure, and may be configured to determine a pose of the surgical saw based on determining a pose of a tracking marker connected to at least one of the surgical saw and the passive end effector. The tracking system may be configured to determine the pose of the surgical saw based on a rotational position sensor configured to measure rotational positions of the first and second mechanisms during movement of the tool attachment mechanism within the working plane. As explained above, the position sensor may be directly connected to at least one joint of the passive end effector structure, but may also be positioned at another location in the structure and the joint position measured remotely by timing belts, wires, or any other interconnection of synchronous transmission interconnections. Additionally, the pose of the saw blade may be determined based on tracking markers attached to the structure base, position sensors in the passive structure, and a kinematic model of the structure.

The various passive end effectors disclosed herein may be sterilizable or non-sterilizable (covered by a sterile drape) passive 3 DOF (degree of freedom) mechanical structures that allow mechanical guidance of a surgical saw or blade, such as a sagittal saw, along two translations in a plane parallel to the blade (defining a cutting plane) and one rotation (instrument orientation) perpendicular to this cutting plane. During surgery, surgical robot 4 automatically moves end effector coupler 22, and the passive end effector and surgical saw attached thereto, to a position proximate to the knee or other anatomy such that all bone to be cut is within the working space of the passive end effector. The position depends on the cutting and surgical plan to be performed and the implant structure. The passive end effector may have 3 DOF to guide a sagittal saw or saw blade on a cutting plane that provides two translations (X and Y directions) and one rotation (about the Z axis) as shown in fig. 12.

When the surgical robot 4 reaches the planned position, it maintains the position (controlled by a brake or active motor) and does not move during a particular bone cut. The passive end effector allows the blade of the surgical saw to move along a planned target plane. Such planar cuts are particularly useful for conventional total knee arthroplasty where all bone cuts are planar. In partial knee arthroplasty, there is a special type of implant called "covering" which can be used in combination with sawn bone surfaces. Various passive end effectors have mechanical structures that can ensure guiding accuracy during cutting, have higher accuracy than conventional jigs, and provide sufficient working space to cut all planned bones, and at the same time provide sufficient lateral stiffness (corresponding to locked DOF), although there may be a large amount of vibrations originating from the surgical saw in addition to forces and bone reaction forces applied by the surgeon.

At the same time, it is preferable to measure the passive end effector position, as it enables the surgical robot 4 to inform the surgeon how much bone has been removed (procedure advancement). One way to provide real-time information about bone removal is to have the surgical robot 4 measure the position of the saw blade with respect to bone passage, since the saw blade can only pass the position where the bone has been cut. To measure blade position, the DRA may be mounted to a surgical saw and/or a passive end effector. This enables the saw position to be measured directly or indirectly in 3D space. An alternative method of measuring the position of the saw blade is to integrate a position (rotation or translation) sensor (e.g., encoder, resolver) into the position information of the passive end effector in order to calculate the position of the saw blade using a mathematical model of the defined relationship between the position of the passive end effector geometry and the tip of the saw blade.

In one embodiment, a conventional sagittal saw mechanism may be used with the surgical system computer platform 900 with little or no modification. A potential variation would involve adjusting the outer shield to enable the surgical saw to be easily attached to the passive end effector, but would not necessarily involve a variation in the internal structure. The passive end effector may be configured to connect to a conventional sagittal saw provided by, for example, horse head company (DeSoutter company). In addition, the saw blade may be directly attached to the passive end effector without the need for a saw head.

To prevent the saw from being affected by unintended passive end effector movement when the surgical robot 4 positions the passive end effector, for example, to prevent the surgical saw from falling onto the patient due to gravity, the passive end effector may include a locking mechanism that moves between an engaged and disengaged operation. When engaged, the locking mechanism prevents movement of the saw blade relative to the robotic end effector coupler, either directly through locking the degree of freedom (DOF) of the surgical saw, or indirectly through braking or locking a particular joint of the passive end effector. When disengaged, the first and second mechanisms of the passive end effector can move relative to the base without interference from the locking mechanism. The locking mechanism may also be used when the surgeon holds the surgical saw and controls the movement of the surgical robot 4 by applying force and torque to the surgical saw. Surgical robot 4 uses load cells 64 of fig. 6 and 7 integrated into the distal end of robotic arm 22 to measure applied force and torque and create a response force and torque on robotic arm 22 so that the surgeon can more easily move the passive end effector back and forth, side-to-side, applying rotation about various axes.

Fig. 12 illustrates a first embodiment of a passive end effector. Referring to fig. 12, a passive end effector 1200 includes a base 1202 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. Passive end effector 1200 further includes a first mechanism and a second mechanism that extend between the rotatable connection to base 1202 and the rotatable connection to the tool attachment mechanism. The rotatable connection may be a pivot joint allowing 1 degree of freedom (DOF) movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement. The first mechanism and the second mechanism form a parallel architecture that positions the surgical saw rotation axis in the cutting plane.

The first and second link sections 1210a and 1220a form a first planar mechanism, and the third and fourth link sections 1210b and 1220b form a second planar mechanism. The first link segment 1210a extends between a rotatable connection to a first location on the base 1202 and a rotatable connection to an end of the second link segment 1220 a. The third link segment 1210b extends between a rotatable connection to a second location on the base 1202 and a rotatable connection to an end of the fourth link segment 1220 b. When rotated by the robotic arm, the first and second positions on the base 1202 are spaced apart on opposite sides of the base's axis of rotation. The tool attachment mechanism is formed by a fifth link segment that extends relative to the base 1202 between rotatable connections with the distal ends of the second link segment 1220a and the fourth link segment 1220 b. The first and second mechanisms (first and second link segments 1210a-1220a and third and fourth link segments 1210b-1220 b) pivot about their rotatable connections to limit movement of the tool attachment mechanism 1230 to a range of movement within the working plane. The tool attachment mechanism 1230 is configured to connect to a surgical saw 1240 having a saw blade 1242 configured to swing for cutting. The first and second mechanisms (first and second link sections 1210a-1220a and third and fourth link sections 1210b-1220 b) may be configured to constrain the cutting plane of the saw blade 1242 to be parallel to the work plane, for example, by a pivot joint having 1 DOF movement. The tool attachment mechanism 1230 may be connected to the surgical saw 1240 by a variety of mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press-fit, or magnets. DRA 52 may be connected to a tool attachment mechanism 1230 or a surgical saw 1240 to enable tracking of the pose of saw blade 1242 by camera tracking system 6 (fig. 3).

The passive end effector 1200 provides passive guidance for the surgical saw 1240 to constrain the saw blade 1242 to a defined cutting plane and reduce its mobility to three degrees of freedom (DOF) two translations Tx and Ty in a plane parallel to the cutting plane of the saw blade 1242, and one rotation Rz about an axis perpendicular to the cutting plane.

In some embodiments, the tracking system is configured to determine the pose of the saw blade 1242 based on a rotational position sensor of a rotary joint connected to at least some of the linkage sections of the passive end effector 1200. The rotational position sensor is configured to measure a rotational position of the engaged link segment during movement of the tool attachment mechanism within the work plane. For example, a rotational position sensor may be configured to measure rotation of the first link segment 1210a relative to the base 1202, another rotational position sensor may be configured to measure rotation of the second link segment 1220a relative to the first link segment 1210a, and another rotational position sensor may be configured to measure rotation of the tool attachment mechanism 1230 relative to the second link segment 1220 a. The surgical saw 1240 may be connected to have a fixed orientation relative to the tool attachment mechanism 1230. The tandem kinematic chain connecting the saw blade 1242 and the passive end effector 1200 of the robotic arm 22 has tandem linkage sections and pivot joints that provide the required maneuverability for the surgical saw 1240. The position of the tip of the saw blade 1242 in the plane defined by the passive kinematic chain may be fully determined by the joint angle sensed by the rotational position sensor and the structural geometry of the interconnected link segments. Thus, by measuring the relative angle between each connected linkage segment, for example along one or more interconnection paths between the base 1202 and the surgical saw 1240, the proposed forward kinematic model can be used to calculate the position of the tip of the saw blade 1242 in the cutting space. When the position and orientation of the distal end of the robotic arm 22 relative to the bone is known, the position and orientation of the saw blade 1242 relative to the bone may be calculated and displayed as feedback to the surgeon. For exemplary embodiments in which the blade is directly attached to the passive end effector, the frequency of the measurements provided by the rotational position sensor may be at least two times higher than the blade oscillation frequency so that the blade position may be measured even during oscillation.

Example types of rotational position sensors that may be used with a passive end effector herein may include, but are not limited to, potentiometers, optical, capacitive, rotary Variable Differential Transformers (RVDTs), linear Variable Differential Transformers (LVDTs), hall effects, and encoders.

Potentiometer-based sensors are passive electronic components. Potentiometers operate by changing the position of the sliding contact on a uniform resistance. In a potentiometer, the entire input voltage is applied over the entire length of the resistor, and the output voltage is the voltage drop between the fixed contact and the sliding contact. To receive an absolute position, a calibration position is required. The measurement range of the potentiometer may be less than 360 °.

The optical encoder may comprise a rotating disc, a light source and a light detector (photosensor). The disk mounted on the rotating shaft has a pattern of opaque and transparent sectors encoded on the disk. These patterns interrupt the light emitted onto the photodetector as the disk rotates, thereby producing a digital signal or pulse signal output. By encoding the disk signals, both absolute and relative measurements and multi-turn measurements are possible.

The capacitive encoder detects a change in capacitance using a high frequency reference signal. This is accomplished with three main parts, a stationary transmitter, a rotor and a stationary receiver. The capacitive encoder may also be provided in a two-part configuration with one rotor and one combined transmitter/receiver. The rotor may be etched with a sinusoidal pattern and the pattern modulates the high frequency signal of the transmitter in a predictable manner as it rotates. The encoder may be multi-turn, but absolute measurements are difficult to achieve. Calibration is required at start-up.

The RVDT and LVDT sensors operate with the core of the transformer at zero, the output voltages of the two primary and secondary windings being equal in magnitude, but opposite in direction. The total output of the zero bits is always zero. Angular displacement relative to the zero position induces a total differential output voltage. Thus, the total angular displacement is proportional to the linear differential output voltage. The differential output voltage increases in a clockwise direction and decreases in a counterclockwise direction. The encoder functions in absolute measurement and may not be compatible with multiple-turn measurements. Calibration is required during assembly.

In a hall effect sensor, a current is applied to a thin metal strip along it. In the presence of a magnetic field, electrons in the metal strip deflect towards one edge, creating a voltage gradient on the short side of the metal strip (i.e. perpendicular to the feed current). The sensor operates in its simplest form as an analog transducer, returning the voltage directly. With a known magnetic field, its distance from the hall plate can be determined. Using the sensor set, the relative position of the magnets can be deduced. By combining multiple sensor elements with a patterned magnet plate, absolute and relative positions can be detected similar to an optical encoder.

The encoder sensor operates in a similar manner as a rotary variable transformer sensor, a brushless resolver or a synchronous machine. The stator receives DC power and generates a low power AC electromagnetic field between the stator and the rotor. The electromagnetic field is modified by the rotor according to its angle. The stator senses the generated electromagnetic field and outputs the rotation angle as an analog signal or a digital signal. Unlike the resolver, the encoder uses a laminated circuit rather than a wound wire spool. The technology makes the encoder compact in shape, low in mass, low in inertia and high in precision, and high-precision installation is not needed. A signal (Z) is transmitted for counting one complete rotation. Multiple turns of sensing and absolute sensing are possible.

Fig. 13 illustrates a second embodiment of a passive end effector. Referring to fig. 13, a passive end effector 1300 includes a base 1302 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. The passive end effector 1300 further includes a first mechanism and a second mechanism that extend between the rotatable connection to the base 1302 and the rotatable connection to the tool attachment mechanism. The rotatable connection may be a pivot joint allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement. The first and second link sections 1310a and 1320a form a first planar mechanism and the third and fourth link sections 1310b and 1320b form a second planar mechanism. The first link segment 1310a extends between a rotatable connection to a first location on the base 1302 and a rotatable connection to an end of the second link segment 1320 a. The third link segment 1310b extends between a rotatable connection to a second location on the base 1302 and a rotatable connection to an end of the fourth link segment 1320 b. When rotated by the robotic arm, the first and second positions on the base 1302 are spaced apart on opposite sides of the base's axis of rotation. Distal ends of the second and fourth linkage sections 1320a, 1320b, distal from the base 1302, are rotatably connected to each other and to the tool attachment mechanism 1330. The first and second mechanisms (first and second link segments 1310a-1320a and third and fourth link segments 1310b-1320 b) may be configured to rotate about their rotatable connections, for example, through a pivot joint having 1 DOF motion, to limit movement of the tool attachment mechanism 1330 to a range of movement within a working plane. The tool attachment mechanism 1330 is configured to connect to a surgical saw 1240 having a saw blade 1242 configured to swing for cutting. The first and second mechanisms (first and second link segments 1310a-1320a and third and fourth link segments 1310b-1320 b) limit the cutting plane of the saw blade 1242 to be parallel to the work plane. The tool attachment mechanism 1330 may be connected to the surgical saw 1240 by a variety of mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press-fit, or magnets. The DRA may be connected to a tool attachment mechanism 1330 or a surgical saw 1240 to enable tracking of the pose of saw blade 1242 by camera tracking system 6 (fig. 3).

Fig. 14 illustrates a third embodiment of a passive end effector. Referring to fig. 14, a passive end effector 1400 includes a base 1402 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. The base 1402 includes first and second elongate base sections 1404a and 1404b that extend from spaced apart locations on opposite sides of a rotational axis of the base 1402 when rotated by a robotic arm. The first and second elongate base sections 1404a and 1404b extend in a direction away from the end effector coupler of the robotic arm when attached to the passive end effector 1400. The passive end effector 1400 further includes a first mechanism and a second mechanism that extend between rotatable connections to the elongated base sections 1404a and 1404b and rotatable connections to the tool attachment mechanism. The one or more rotatable connections disclosed for this embodiment may be a pivot joint allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement.

The first mechanism includes a first link section 1411a, a second link section 1410a, a third link section 1420a, and a fourth link section 1430a. The first and second link sections 1411a and 1410a extend parallel to each other between rotatable connections to spaced apart locations on the first elongated base section 1404a and spaced apart locations on the third link section 1420 a. The end of the third link section 1420a is rotatably connected to the end of the fourth link section 1430a.

The second mechanism includes a fifth link section 1411b, a sixth link section 1410b, and a seventh link section 1420b. The fifth and sixth link sections 1411b and 1410b extend parallel to each other between rotatable connections to spaced apart locations on the second elongated base section 1404b and spaced apart locations on the seventh link section 1420b. The tool attachment mechanism includes an eighth link segment 1440 extending between rotatable connections to distal ends of the fourth and seventh link segments 1430a and 1420b distal from the base 1402. In further embodiments, the eighth link section 1440 of the tool attachment mechanism includes an attachment member 1442 that extends in a direction away from the base 1402 to a rotatable connector configured to connect to the surgical saw 1240. The attachment member 1442 extends from a position on the eighth link section 1440 that is closer to the fourth link section 1430a than the seventh link section 1420b.

The first and second mechanisms (the set of link sections 1411a, 1410a, 1420a, 1430a and the set of link sections 1411b, 1410b, 1420 b) may be configured to pivot about their rotatable connections to limit movement of the tool attachment mechanism 1440 to a range of movement within a working plane. The tool attachment mechanism 1440 is configured to connect to a surgical saw 1240 having a saw blade 1242 configured to swing for cutting. The first and second mechanisms may be configured to constrain the cutting plane of the saw blade 1242 to be parallel to the work plane, for example, by a pivot joint having 1 DOF movement. The tool attachment mechanism 1440 may be connected to the surgical saw 1240 by a variety of mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press-fit, or magnets. The DRA may be connected to a tool attachment mechanism 1440, such as to an attachment member 1442 or a surgical saw 1240 to enable tracking of the pose of saw blade 1242 by camera tracking system 6 (fig. 3).

The passive end effector 1400 of fig. 14 has a parallel architecture that enables the surgical saw to be positioned about a rotational axis in a cutting plane. The synchronous and/or different movements of the lateral parallelogram allow the surgical saw rotation axis to be positioned in the cutting plane.

Fig. 15 shows a fourth embodiment of a passive end effector. The passive end effector 1500 includes a base 1502 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. The base 1502 may include a first elongate base section and a second elongate base section that extend from spaced apart locations on opposite sides of a rotational axis of the base 1502 when rotated by a robotic arm. The first and second elongate base sections extend away from each other. The passive end effector 1500 further includes a first mechanism and a second mechanism that extend between a rotatable connection to the base 1502 and a rotatable connection to a tool attachment mechanism. The one or more rotatable connections disclosed for this embodiment may be a pivot joint allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement.

The first mechanism includes a first link section 1510a. The second mechanism includes a second section 1510b. The tool attachment mechanism includes a third link segment 1520, a fourth link segment 1530, a fifth link segment 1540a, a sixth link segment 1540b, and a seventh link segment 1550. The first and second link sections 1510a and 1510b extend to rotatable connections at opposite ends of the third link section 1520 between rotatable connections to first and second locations on the base 1502 (e.g., to first and second elongate base sections extending away from the base 1502), respectively. When rotated by the robotic arm, the first and second positions on the base 1502 are spaced apart on opposite sides of the base's axis of rotation. The fourth link segment 1530 extends from the third link segment 1520 in a direction toward the base 1502. Fifth and sixth link segments 1540a and 1540b extend parallel to each other between rotatable connections to spaced apart locations on fourth link segment 1530 and spaced apart locations on seventh link segment 1550. Seventh link segment 1550 is configured to have a rotatable connector configured to connect to surgical saw 1240.

The first through sixth link segments 1510a-b, 1520, 1530, and 1540a-b can be configured to pivot about their rotatable connections to limit movement of the seventh link segment 1550 to a range of movement within a working plane. Seventh link segment 1550 is configured to be connected to surgical saw 1240 having saw blade 1242 configured to swing for cutting. The first through sixth link segments 1510a-b, 1520, 1530, and 1540a-b may be configured to constrain the cutting plane of the saw blade 1242 to be parallel to the work plane, for example, by a pivot joint having 1 DOF movement. Seventh link segment 1550 may be connected to surgical saw 1240 by a variety of mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press-fit, or magnets. The DRA may be connected to seventh link section 1550 or surgical saw 1240 to enable tracking of the pose of saw blade 1242 by camera tracking system 6 (fig. 3).

Fig. 16 shows a fifth embodiment of a passive end effector. Passive end effector 1600 includes a base 1602 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. Passive end effector 1600 further includes a first mechanism and a second mechanism that extend between a rotatable connection to base 1502 and a rotatable connection to a tool attachment mechanism. The first mechanism includes a first link section 1610a. The second mechanism includes a second section 1610b. The tool attachment mechanism includes a third link segment 1620, a fourth link segment 1630, a fifth link segment 1640a, a sixth link segment 1640b, and a seventh link segment 1650. The one or more rotatable connections disclosed for this embodiment may be a pivot joint allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement.

The first and second link segments 1610a and 1610b extend between rotatable connections at first and second positions on the base 1602 to rotatable connections at opposite ends of the third link segment 1620, respectively. The first and second positions on the base 1602 are spaced apart on opposite sides of the rotational axis of the base 1602 when rotated by the robotic arm. The fourth link segment 1630 extends from the third link segment 1620 in a direction away from the base 1602. The fifth and sixth link segments 1640a and 1640b extend parallel to each other between rotatable connections to spaced apart locations on the fourth link segment 1630 and spaced apart locations on the seventh link segment 1650. Seventh link segment 1650 is configured with a rotatable connector configured to connect to surgical saw 1240.

The first through sixth link segments 1610a-b, 1620, 1630 and 1640a-b may be configured to pivot about their rotatable connections to limit movement of the seventh link segment 1650 to a range of movement within the working plane. Seventh link segment 1650 is configured to be connected to a surgical saw 1240 having a saw blade 1242 configured to swing for cutting. The first through sixth link segments 1610a-b, 1620, 1630 and 1640a-b may be configured to pivot while limiting the cutting plane of the saw blade 1242 to be parallel to the work plane. Seventh link segment 1650 may be connected to surgical saw 1240 by various mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press-fit, or magnets. The DRA may be connected to seventh link section 1650 or surgical saw 1240 to enable tracking of the pose of saw blade 1242 by camera tracking system 6 (fig. 3).

Passive end effector 1600 provides two vertical translational movements for positioning the surgical saw rotation axis in the cutting plane, and two of the translations are performed by a parallelogram.

Fig. 17 shows a sixth embodiment of a passive end effector. Passive end effector 1700 includes a base 1702 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. Passive end effector 1700 further includes a first mechanism and a second mechanism extending between a rotatable connection to base 1702 and a rotatable connection to a tool attachment mechanism. The one or more rotatable connections disclosed for this embodiment may be a pivot joint allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement. The first and second mechanisms are coupled to provide translation along the radius of the parallelogram. The first mechanism includes first and second link sections 1710 and 1720b. The first link segment 1710 extends between a rotatable connection to the base 1702 and a rotatable connection to the end of the second link segment 1720b. The second mechanism includes a third link segment 1720a. The tool attachment mechanism includes a fourth link segment 1730. The second and third link segments 1720b and 1720a extend away from the base 1702 and extend parallel to each other between rotatable connections to spaced apart locations on the first link segment 1710 and spaced apart locations on the fourth link segment 1730. Fourth link section 1730 includes attachment member 1732 that extends in a direction away from the base to a rotatable connector configured to connect to surgical saw 1240. Attachment member 1732 extends from a location on fourth link segment 1730 that is closer to third link segment 1720a than second link segment 1720b.

The first through third link segments 1710, 1720b, 1720a may be configured to pivot about their rotatable connections to limit movement of the fourth link segment 1730 to a range of movement within a working plane. The fourth link segment 1730 is configured to connect to a surgical saw 1240 having a saw blade 1242 configured to swing for cutting. The first through third link sections 1710, 1720b, 1720a may be configured to constrain the cutting plane of the saw blade 1242 to be parallel to the work plane. The fourth link segment 1730, e.g., its attachment member 1732, may be connected to the surgical saw 1240 by various mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press fits, or magnets. The DRA may be connected to a fourth link section 1730, for example to an attachment member 1732 or a surgical saw 1240 to enable tracking of the pose of the saw blade 1242 by a camera tracking system 6 (fig. 3).

Fig. 18 shows a seventh embodiment of a passive end effector. The passive end effector 1800 includes a base 1802 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. The passive end effector 1800 further includes a first mechanism and a second mechanism that extend between the rotatable connection to the base 1802 and the rotatable connection to the tool attachment mechanism. The one or more rotatable connections disclosed for this embodiment may be a pivot joint allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement. The first mechanism includes a first link section 1810a. The second mechanism includes a second link segment 1810b. The tool attachment mechanism includes a third link section 1820. The first and second link sections 1810a and 1810b extend between rotatable connections at first and second positions on the base 1802 to rotatable connections at opposite ends of the third link section 1820, respectively. When rotated by the robotic arm, the first and second positions on the base 1802 are spaced apart on opposite sides of the rotational axis of the base 1802. The third link section 1820 includes an attachment member 1822 that extends in a direction away from the base 1802 to a rotatable connector configured to connect to the surgical saw 1240. The attachment member 1822 extends from a location on the third link section 1820 that is closer to the first link section 1810a than the second link section 1810b. The one or more rotatable connections disclosed for this embodiment may be a pivot joint allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement.

The first and second link sections 1810a and 1810b may be configured to pivot about their rotatable connection between the base 1802 and the third link section 1820 to limit movement of the attachment member 1822 within a range of movement within a working plane. In some other embodiments, one or more of the rotatable connections may be a universal joint allowing 2 DOF movement or a ball joint allowing 3 DOF movement such that movement is not limited to a work plane. The tool attachment mechanism 1822 is configured to connect to a surgical saw 1240 having a saw blade 1242 configured to swing for cutting. The first and second link sections 1810a and 1810b pivot while limiting the cutting plane of the saw blade 1242 to be parallel to the work plane. The attachment member 1822 may be connected to the surgical saw 1240 by various mechanisms, which may include, but are not limited to, screws, nuts and bolts, clamps, latches, tethers, press-fit, or magnets. The DRA may be connected to a third link section 1820, for example to an attachment member 1822 or a surgical saw 1240 to enable tracking of the pose of the saw blade 1242 by a camera tracking system 6 (fig. 3).

Fig. 19 shows an eighth embodiment of a passive end effector. Passive end effector 1900 includes a base 1902 configured to be attached to an end effector coupler (e.g., end effector coupler 22 in fig. 4 and 5) of a robotic arm (e.g., robotic arm 18 in fig. 1 and 2) positioned by a surgical robot. The passive end effector 1900 further includes a first link section 1910 and a second link section 1920. The first link segment 1910 extends between a rotatable connection to the base 1902 and a rotatable connection to one end of the second link segment 1920. The other end of the second link section 1920 is rotatably connected to the tool attachment mechanism. The axes of rotation q1, q2, and q3 are parallel to one another to provide a planar cutting plane for blade 1242. Thus, the 3 DOF motions of saw 1240 include an x-direction Tx, a y-direction Ty, and a rotational direction about the z-axis Rz. The one or more rotatable connections disclosed for this embodiment may be a pivot joint a allowing 1 DOF movement, a universal joint allowing 2 DOF movement, or a ball joint allowing 3 DOF movement.

Tracking markers 52 attached to the end effector base 1902 and saw 1240 and to bones (e.g., tibia and femur) can be used to accurately and continuously monitor the real-time position of the blade 1242 and blade tip relative to the patient's bone being cut. Although not explicitly shown in other figures, in all embodiments tracking markers may be attached to the saw 1240 and all end effectors 1902 to track the position of the blade relative to the patient's bone being cut. Although not shown, alternatively or in addition to tracking markers, an encoder may be positioned at each of the link segments 1910 and 1920 to always accurately determine where the blade tip is.

Example surgical procedure

An example surgical procedure using surgical robot 4 in an Operating Room (OR) may include:

an optional step of preoperatively planning a surgical procedure based on the medical image.

1. The surgical robot 4 system is outside the Operating Room (OR). The nurse brings the system to OR when the patient is ready to perform the surgical procedure.

2. The nurse energizes the robot and deploys the robot arm. The nurse verifies the accuracy of the robotic system and tracking system.

3. In the case of a sterilized passive end effector, the scrub nurse places the sterile drape over the robotic arm and mounts the passive end effector with sagittal saw thereon. The scrub nurse locks the passive end effector with a locking mechanism. The scrub nurse attaches the DRA to the passive structure via a drape (if necessary). For an unsterilized passive end effector, a drape is placed after attaching the passive end effector to the robotic arm, a DRA is attached to the passive end effector with the drape therebetween, and a sterilizing saw or saw blade is attached to the passive end effector with the drape therebetween. To fix the position of the saw blade relative to the end effector coupler, a locking mechanism is engaged.

4. The surgeon attaches the navigation markers to one or more bones of the patient, such as the tibia and femur. Bones are registered to the camera tracking system 6 using, for example, a hornpoint-to-point algorism (hornpoint-to-point algorism), surface matching, or other algorithm. Soft tissue balance assessment may be performed whereby the system allows the surgeon to assess the balance of soft tissue in the operating room, for example, by tracking the relative movement of the femur and tibia as the surgeon applies forces in different directions (e.g., varus/valgus stress). The soft tissue balance information may be used to change the surgical plan (e.g., move implant components, change implant types, etc.).

5. When the surgeon is ready to cut bone, the scrub nurse brings the surgical robot 4 to the operating table close to the knee joint to be operated and stabilizes the surgical robot 4 on the floor. The system may operate to guide the nurse to find the position of the robot 4 so that all cutting planes are in the robot and passive structure workspaces.

6. The surgeon selects different parameters on the screen of the surgical robot 4 to make the first cut (bone to be cut, desired cutting plan, etc.) according to the plan of the surgical procedure.

7. Surgical robot 4 automatically moves robotic arm 22 to reposition the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade is positioned at a distance from the anatomy to be cut that is within the range of movement of the tool attachment mechanism of the passive end effector.

8. The surgeon unlocks the passive end effector.

9. The surgeon performs the cut limited to the cutting plane provided by the passive end effector. The surgical robot 4 may provide a real-time display of the tracked position of the saw blade relative to the bone so that the surgeon may monitor the progress of the bone removal. In one manner, the tracking subsystem processes the saw's position relative to the bone in real-time based on the camera images and various tracking markers attached to the saw, robotic arm, end effector, femur, and tibia. The surgeon may then lock the passive end effector using a locking mechanism when the cut is completed.

10. The surgeon selects the next cut to be performed on the screen and proceeds as before.

11. The surgeon may perform trial implant placement and intermediate soft tissue balance assessment and based thereon alter the implant plan and associated cuts.

12. After all cuts are made, the nurse removes the surgical robot 4 from the operating table and detaches the passive end effector from the robotic arm.

13. The surgeon places the implant and completes the procedure.

In step 9 above, it may be difficult for the physician to visually confirm the progress of the cut due to tissue and ligaments surrounding the bone and fragments generated by the cut, as well as other surgical instruments in the vicinity of the bone. Even if visual confirmation is acceptable, there are areas of bone that are not visible to the physician, such as the rear of the bone being cut.

Advantageously, one robotic system embodiment of the present invention provides a method for a physician to confirm progress of a bone being cut in multiple dimensions. The camera tracking system 6 and tracking markers attached to the end effector mounts (1100, 1202, 1302, 1402, 1502, 1602, 1702, 1802, 1902), robotic arm 20, and saw (1140, 1240) allow the tracking subsystem 830 and computer subsystem 820 to calculate the precise position of the saw blade relative to the bone in real time so that the surgeon can monitor the progress of the bone removal.

Fig. 20 is a screen shot showing the progress of bone cutting during surgery. Fig. 20 shows subsystems 830 and 820 displaying three images, side view, a-P view and top view. In each image, the real-time position of the saw blade 1242 relative to the bone (e.g., tibia 2000) is displayed on the display 34. Side and top views are particularly useful to the physician because they show the position of the saw blade, which is not easily visible. At the top of the display, the computer subsystems 830, 820 display the number of cutting programs and the programs it is currently running. For example, as shown in the screen shot, the physician may have programmed 6 plane cuts and the current cutting program is the first. Further, because subsystems 830 and 820 can track the location where the blade may have traveled with tracking markers, they can determine how much bone cutting (the area being cut) for a particular cutting procedure has been completed, and the percentage of progress is shown in display 34. The bone image itself is preferably derived from an actual image of the patient's body to obtain an accurate representation. The bone image is enhanced by subsystem 820 with contours showing cortical bone 2004 and cancellous bone 2002. This is important for the physician because the resistance to cutting varies greatly between the two types of bone.

If an Augmented Reality (AR) head mounted display is used, the computer subsystem 820 may generate the same contour lines showing the cortical bone and cancellous bone, and continuously superimpose them on the actual legs as the physician moves his/her head. The already cut areas can be overlaid on the actual bone with shadows. In addition, the implant to be inserted onto the cutting area may also be overlaid onto the bone to show the physician that the cut was made correctly along the plane of the implant. This is possible because the subsystems 830 and 820 can track the position of the blade and its history of movement relative to the bone with tracking markers and camera subsystems.

Referring now to fig. 21-32, an exemplary embodiment of a direct blade guide system in the context of an orthopedic surgery is described. As shown in fig. 21, 22, 29, and 30, the direct blade guide system 2100 may comprise a robotic system that holds an End Effector Arm (EEA) 2102. The EEA2102 may comprise a base configured to be attached to an end effector coupler of a robotic arm. Other exemplary embodiments of end effector arms consistent with the principles of the present disclosure are described with respect to fig. 12-19. To achieve planar cutting, the blade 2104 should be guided in the plane in which it vibrates. The high vibration frequency of the saw blade (e.g., 200-300 Hz) makes it difficult to achieve mechanical guidance. The EEA2102 may contain several joints and linkages 2106, 2108 that may be used to effect movement in the plane of the tip 2110 of the EEA 2102. Similar to the embodiment of FIGS. 12-18, the tip 2110 of the EEA2102 may have three (3) degrees of freedom, movement in two directions in a plane and rotation about an axis perpendicular to the plane. The EEA2102 may allow for planar cutting and access to the target bone from all angles. The system 2100 may also include a handpiece 2112 and a blade adapter 2114 connected to the EEA2102 and the blade 2104, respectively.

The concept of directly guiding the saw blade 2104 involves aligning the rotational axis of the distal end of the linkage 2110 (the distal rotational joint 2116 of the EEA 2102) with the blade vibration axis 2206. Sagittal saws are the mechanism of most embodiments that produce small rotational movements (vibrations/oscillations) of the blade about an axis near the attachment of the blade. By aligning the rotational axis with the distal rotational joint 2116 of the EEA2102 (at the distal end of the linkage 2108), the joint 2116 can be configured to effect general saw head rotation and blade vibration.

The saw blade 2104 may be configured to be connected to a distal joint rotation shaft of the EEA 2102 by a blade adapter 2114. Blade adapter 2114 may be configured to screw down on blade 2104. By adjusting the blade adapter 2114, a different sagittal saw may be integrated into the system 2100. Exemplary configurations of blade adapters 2114 consistent with the present disclosure are discussed below. An exemplary blade adapter is shown in fig. 31.

Permanently fixed

In a permanently secured configuration, the blade 2104 may be permanently clamped to the blade adapter 2114. When the surgeon is ready for a surgical field, a user (e.g., an operating room nurse) may assemble blade 2104 to blade adapter 2114. Exemplary permanent fixed configurations may include the following.

● The blade 2104 may be securely clamped to the blade adapter 2114 using an assembly, such as a screw or spring loaded latch, configured to provide a clamping force on the blade 2104.

● Blade 2104 may include an interface, such as a through hole, configured to secure blade 2104 to blade adapter 2114.

● The blade 2104 and blade adapter 2114 may be manufactured as a single reusable device that is later placed on the EEA 2102. Example embodiments relate to metal blades attached to PEEK or stainless steel blade adapters. The assembly of the blade to blade adapter is performed by the operating room nurse.

● The blade 2104 and blade adapter may also be manufactured as a disposable (single use) device for sterile delivery. Example embodiments relate to metal blades overmolded using plastic injection molding techniques.

Fig. 22 illustrates a system 2200, which is an exemplary embodiment consistent with the principles of the present disclosure. In this embodiment, the blade adapter is permanently secured to a saw blade in a mount that is rotatable about a saw blade rotation axis 2202 and a clamping assembly that clamps the blade to the blade adapter mount 2210 by screws. Fig. 23 shows blade 2204, blade adapter 2214, distal swivel 2216, and clamp 2218 consistent with this configuration. These components may be the same as or similar to those previously described with respect to fig. 21.

Detachable fixing

In a detachable securing configuration, the blade may be quickly attached to or detached from the blade adapter in the field. The blade adapter incorporates a clamping mechanism that may be either active (normally closed clamping mechanism opened by an electrical signal) or passive (quick-coupling and/or quick-release mechanism).

Moment of inertia

Blade adapter 2114 may significantly increase the moment of inertia of the coupled "blade/blade adapter" rotating about the blade rotation axis. Once the blade adapter 2114 vibrates with the blade 2104, the unbalanced inertia generates power and torque that is output to the mechanical structure and the surgeon's hand. To optimize the embodiment, the inertia of the vibrating element around the vibrating axis can be minimized. This means that the lighter the mass of the vibrating element and the closer to the vibrating axis the better. The moment of inertia of the blade element about the vibration axis for the head guide concept is:

●I_h＝I_d+MD²

Where D is the distance between the blade vibration axis and the distal joint rotation axis, M is the weight of the blade (the weight of the blade element), and I _d is the moment of inertia of the blade element about the blade vibration axis. The moment of inertia is then reduced by MD ² using the direct blade-guiding concept, which is minimal when the distance between the vibration axis and the blade vibration axis is 0 (axis combination).

Fig. 24 illustrates a system using standard clamps 2402. In accordance with the principles discussed herein, direct blade guiding may provide more blade effective cutting length than provided by standard clamps (such as clamp 2402 shown in fig. 24). L _G denotes a guide length (length of a guide blade), and L _E denotes an effective length of the blade. The effective length of the blade is longer because the guide length can be made shorter using the direct blade guide concept. This may be more comfortable for the surgeon and the surgeon may cut more bone.

The accuracy of the cut is given by the stiffness of the various elements that make up the robotic system, from the floor to the blade tip, including the robotic system, EEA2102, the nose sagittal saw, the blade swing mechanism (e.g., blade adapter 2114 or 2214), and the blades 2104, 2204. With direct blade guidance, the gap and inaccuracy of the handpiece can be significantly reduced or completely avoided because the saw blade is directly screwed down through the blade adapter.

Furthermore, the direct blade guide concept may be more easily integrated with various existing sagittal saws. Since the blade adapter is an element that only requires tightening of a simply shaped saw blade, it may not be necessary to construct a sagittal saw shape (manufacturer specific) specific assembly. In addition, the blade adapter is easily sterilized. It is a small, lightweight and relatively simple mechanical element that can be manufactured in such a way that it does not have any narrow space and can be easily disassembled. As previously described, the blade containing the blade adapter may be delivered as a single reusable device.

Tracking

Fig. 25 illustrates a direct blade guide system 2100 that may contain navigation markers or marker arrays 2500 attached to a handpiece 2112 of a sagittal saw. The marker 2500 allows the sagittal saw to be tracked by a camera (e.g., camera tracking system 6). Optical tracking enables measurement of saw position, but may be difficult to measure direct blade position during cutting (high frequency vibration of the blade). Furthermore, tracking will directly measure the deflection of saw head 2112 relative to blade 2104 due to the poor stiffness of the blade/saw head connection.

To measure the direct blade position, FIG. 26 illustrates a system 2100 in which encoders 2600, 2602, and 2604 are integrated into the joints of the EEA 2102. Encoder measurements can generally be made at higher frequencies and rotational accuracy than with optical tracking. For example, the measurement frequency may be at least two times higher than the blade oscillation. Additional useful information may be extracted using the blade position signal, such as saw vibration frequency, on/off status, blockage of the saw blade in the bone (e.g., by interpreting the signal and its derivative information).

In exemplary embodiments consistent with the principles of the present disclosure, vibrations of a sagittal saw handpiece held by a surgeon may be reduced. By reducing vibrations of the handpiece, haptic feedback can be improved and cutting efficiency can be improved. As previously described, the vibrations output to the surgeon's hand are caused by the power and torque output, which are generated by the unbalanced inertia of the coupled blade/blade adapter M _S about the blade rotation axis.

One method for reducing vibration may be by filtering the vibration. In fig. 27, a damping element 2700 having a vibratory dump arm 2702 can be connected between the nose 2112 and the EEA 2102. This may be implemented using a rubber sheet, pneumatic cylinder or hydraulic cylinder.

Another method for reducing vibrations may be achieved by dynamically balancing the inertia of the coupled saw/saw adapter M _B about the saw rotation axis. This may be implemented by dynamically compensating the output force and torque produced by the oscillating saw blade using a compensating inertia that performs precisely opposite movements with the same dynamics. Fig. 28 and 32 illustrate an exemplary embodiment in which the compensation inertia may be coupled to the main inertia to be balanced using a mechanical reverser 2800, wherein the material and geometry of the balancing inertia I _B,A may be adapted to the inertia I _S,A of the blade-plus-blade adapter.

Additional limitations and examples:

In the foregoing description of various embodiments of the inventive concept, it should be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the inventive concept. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this inventive concept belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

When an element is referred to as being "connected to" or "coupled to" another element or being "responsive to" another element or variations thereof, it can be directly connected, coupled or responsive to the other element or intervening elements may be present. In contrast, when an element is referred to as being "directly connected," "directly coupled," "directly responsive" to another element or variations thereof, there are no intervening elements present. Like numbers refer to like elements throughout. Further, "coupled," "connected," "responsive," or variants thereof as used herein may include wirelessly coupled, connected, or responsive. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Well-known functions or constructions may not be described in detail for brevity and/or clarity. The term "and/or" includes any and all combinations of one or more of the associated listed items.

It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements/operations, these elements/operations should not be limited by these terms. These terms are only used to distinguish one element/operation from another element/operation. Thus, a first element/operation in some embodiments could be termed a second element/operation in other embodiments without departing from the teachings of the present inventive concept. Throughout this specification, the same reference numerals or the same reference numerals indicate the same or similar elements.

As used herein, the terms "comprises/comprising/includes," "including/includes," "having/including," or variations thereof are open ended and include one or more stated features, integers, elements, steps, components, or functions, but do not preclude the presence or addition of one or more other features, integers, elements, steps, components, functions, or groups thereof. Furthermore, as used herein, the generic abbreviation "e.g." derived from the latin phrase "exempli gratia" may be used to introduce or designate one or more general instances of the previously mentioned items, and is not intended to limit such items. The generic abbreviation "i.e." from the latin phrase "id est" may be used to designate a particular item from a more general statement.

Example embodiments are described herein with reference to block diagrams and/or flowchart illustrations of computer-implemented methods, apparatus (systems and/or devices) and/or computer program products. It will be understood that blocks of the block diagrams and/or flowchart illustrations, and combinations of blocks in the block diagrams and/or flowchart illustrations, can be implemented by computer program instructions that are executed by one or more computer circuits. These computer program instructions may be provided to a processor circuit of a general purpose computer circuit, special purpose computer circuit, and/or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer and/or other programmable data processing apparatus, transform and control the transistors, values stored in memory locations, and other hardware components within such circuitry to implement the functions/acts specified in the block diagrams and/or flowchart block or blocks, and thereby create means (functions) and/or structure for implementing the functions/acts specified in the block diagrams and/or flowchart block or blocks.

These tangible computer program instructions may also be stored in a computer-readable medium that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instructions which implement the function/act specified in the block diagrams or flowchart block or blocks. Thus, embodiments of the inventive concept may be embodied in hardware and/or in software (including firmware, resident software, micro-code, etc.) that runs on a processor such as a digital signal processor, which may be referred to collectively as "circuitry," "modules," or variants thereof.

It should also be noted that, in some alternative implementations, the functions/acts noted in the blocks may occur out of the order noted in the flowcharts. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Furthermore, the functionality of a given block of the flowchart and/or block diagram may be divided into a plurality of blocks, and/or the functionality of two or more blocks of the flowchart and/or block diagram may be at least partially integrated. Finally, other blocks may be added/inserted between the illustrated blocks, and/or blocks/operations may be omitted, without departing from the scope of the inventive concepts. Furthermore, although some of the figures contain arrows on the communication paths to illustrate the primary direction of communication, it should be understood that communication may occur in a direction opposite to the depicted arrows.

Many variations and modifications may be made to the embodiments without departing substantially from the principles of the present inventive concepts. All such variations and modifications are intended to be included herein within the scope of the present inventive concepts. Accordingly, the above-disclosed subject matter is to be regarded as illustrative rather than restrictive, and the examples of the embodiments that follow are intended to cover all such modifications, enhancements, and other embodiments, which fall within the spirit and scope of the present inventive concepts. Thus, to the maximum extent allowed by law, the scope of the present inventive concept is to be determined by the broadest permissible interpretation of the present disclosure, including examples of the following embodiments and their equivalents, and shall not be restricted or limited by the foregoing detailed description.

Claims

1. A direct blade guiding system comprising:

a robotic arm configured to be positioned by a surgical robot;

an end effector arm comprising a base configured to be attached to an end effector coupler of the robotic arm, wherein the end effector arm comprises a plurality of linkages connected by a plurality of joints, the plurality of joints comprising a distal joint disposed at a distal end of the end effector arm;

a blade adapter adapted to be rotatably connected to the end effector arm through the distal joint about an axis of rotation;

a blade adapted to be connected to the blade adapter and having a swing axis aligned with the rotation axis when the blade adapter is connected to the distal hub; and

A handpiece is adapted to be connected to the blade and to oscillate the blade along the oscillation axis.

2. The system of claim 1, wherein the handpiece is a sagittal saw handpiece.

3. The system of claim 1, further comprising an encoder positioned on each joint to consistently track the position of the tip of the blade.

4. The system of claim 3, further comprising: a tracking camera, wherein the end effector comprises a tracking marker configured to be tracked by the tracking camera, and the surgical robot determines the position of the blade based on the tracking marker and the encoder of the end effector.

5. The system of claim 1, wherein the blade is clamped to the blade adapter.

6. The system of claim 1, wherein the blade is screwed to the blade adapter.

7. The system of claim 1, wherein the blade and blade adapter are integrated into a single unit.

8. The system of claim 1, wherein the blade adapter is directly attached to the distal joint of the end effector, and the handpiece is configured to rotate the blade adapter and the blade together along the rotational axis.

9. The system of claim 1, wherein the blade adapter and the blade are attached by an active clamping mechanism.

10. The system of claim 1, wherein the blade adapter and the blade are attached by a passive clamping mechanism.