System for monitoring offset during navigation-assisted surgery

Abstract

A surgical system comprises a navigation system comprising a control console and a localizer; the navigation system in communication with first data representing a surgical instrument, the surgical instrument including a tool tip, and second data representing a patient’s anatomy; the navigation system operable to track the surgical instrument and the anatomy in a virtual space during a surgical operation based on information gathered by the localizer from an instrument tracker coupled to the surgical instrument and a patient tracker coupled to the anatomy; wherein the navigation system is configured to: track the surgical instrument and the anatomy and store data representing a tracked surgical instrument pose and a tracked anatomy pose in a common coordinate system; determine the tool tip is within a predefined proximity to the anatomy based on the tracked surgical instrument pose and the tracked anatomy pose; determine the tool tip does not depart the predefined proximity by more than a predefined magnitude over a predefined duration; determine an offset distance based on the tracked surgical instrument pose and the tracked anatomy pose in the common coordinate system; and compare the offset distance to a predefined threshold. 62 20 26 25 38 84 14 O ct 2 02 6 2 0 2 6 2 5 3 8 8 4 1 4 O c t 2 0 2 6

Description

comparing the monitored motor operation to the defined motor operation; determining a contact time between the instrument tool tip and the bone when the monitored motor operation deviates from the defined first motor operation; determining, with the navigation system at the contact time, a tool-to-bone offset as a distance between the instrument tool tip and a surface of the bone in the localizer coordinate system; and triggering an action when the tool-to-bone offset exceeds a predefined magnitude. 2026253884   14 Oct 2026 VIII. The method of clause VII, wherein triggering an action comprises one of sounding an audible alert, displaying a visual alert, activating a tactile alert, cutting off power to the surgical instrument, or combinations thereof. IX.    The method of clause VII, wherein the predefined magnitude is 0.5 millimeters. X.     The method of clause VII, further comprising displaying, on a display device, the determined tool-to-bone offset. XI. The method of clause VIII, wherein monitoring the position of the instrument tool tip relative to the bone comprises tracking the instrument location of the instrument tool tip and the bone location of the bone during the medical procedure; the method further comprising detecting, with the navigation system, each occurrence during the operation of the monitored position of the instrument tool tip being in contact with the surface of the bone and logging a series of tool-to-bone offset values determined during the medical procedure upon each occurrence. XII. The method of clause VII, further comprising displaying, on a display device, a series of tool-to-bone offsets as a serially updating value. XIII. The method of clause XII, further comprising defining a first level magnitude and a second level magnitude, wherein the step of displaying the determined tool-to-bone offset comprises displaying the offset in a first color when the offset is less than the first level magnitude, displaying the offset in a second color, different from the first color, when the offset is between the first level and the second level magnitude; and displaying the offset in a third color, different from the first and the second colors, when the offset is greater than the second level magnitude. XIV. The method of clause XIII, wherein the predefined magnitude for triggering an action is equal to the second level magnitude. 2026253884   14 Oct 2026 XV. The method of clause XIII, wherein the predefined magnitude for triggering an action is greater than the second level magnitude. XVI. The method of clause XIII, further comprising defining a third level magnitude, the method further comprising disabling power from the controller to the surgical instrument when the tool-to-bone offset is greater than the third level magnitude. XVII. The method of clause VII, further comprising prompting a user to enter a value for the predefined magnitude. XVIII. The method of clause XVII, further comprising disabling power from the controller to the surgical instrument when the tool-to-bone offset is greater than the predefined value. XIX. The method of clause XII, further comprising displaying the series of tool-to-bone offsets as a chart of offset values over time. XX. The method of clause VII , wherein triggering an action comprises prompting a user to update a model of the bone. XXI. The method of clause XX, wherein updating the model of the bone comprises contacting a resected surface of the bone with the instrument tool tip while power is disabled from the controller to the surgical implement. XXII. A method of operating a surgical system during a surgical operation to verify a tracking registration, the surgical system including a navigation system including a localizer having a localizer coordinate system, an instrument tracker coupled to a surgical instrument, the surgical instrument including a tool tip, a patient tracker coupled to a patient’s anatomy, a control console in communication with the localizer, the control console in communication with data representing the surgical instrument and data representing the patient’s anatomy, the method comprising: 2026253884   14 Oct 2026 tracking, with the navigation system, the surgical instrument and the anatomy and storing, with the control console, first data representing the tracked surgical instrument and second data the tracked anatomy in a common coordinate system; determining the tool tip is within a predefined proximity to the tracked anatomy based on the first data representing the tracked surgical instrument and second data representing the tracked anatomy; determining the tool tip does not depart the predefined proximity by more than a predefined magnitude over a predefined duration; determining an offset distance based on the first data representing the tracked surgical instrument and the second data representing the tracked anatomy; comparing the offset distance to a predefined threshold; and triggering an action when the offset distance is greater than the predefined threshold. XXIII. The method of clause XXII, further comprising prompting a user to verify a tracking registration by one of displaying a prompt on a display; sounding an audible alert; generating a haptic sensation; or combinations thereof. XXIV. The method of clause XXII, wherein determining the tool tip is within a predefined proximity to the anatomy includes defining a surface area of the anatomy not to be resected, and determining the tool tip is within a predefined proximity to the defined surface area. XXV. The method of clause XXII, wherein the offset distance is defined as a magnitude of minimum separation between the tool tip and the tracked anatomy in the common coordinate system, or as a magnitude of greatest overlap between the tool tip and the tracked anatomy in the common coordinate system. XXVI. The method of clause XXII, wherein determining the tool tip is within a predefined proximity to the tracked anatomy includes the surgical instrument positioned at a first pose with respect to the tracked anatomy, the surgical instrument defining a first proximal point of the tool tip and wherein determining the offset distance includes determining a first offset distance; 2026253884   14 Oct 2026 the method further comprising determining the tool tip is within a predefined proximity to the tracked anatomy including the surgical instrument positioned at a second pose with respect to the tracked anatomy, the surgical instrument defining a second proximal point of the tool tip and wherein determining the offset distance includes determining a second offset distance. XXVII. The method of clause XXVI, wherein comparing the offset distance to a predefined threshold includes comparing the first offset distance to the predefined threshold, and comparing the second offset distance to the predefined threshold, and wherein initiating an action includes initiating an action when the first offset distance, the second offset distance, or both the first and second offset distances are greater than the predefined threshold. XXVIII. The method of clause XXVI, wherein the surgical instrument includes an elongated aspect terminating at the tool tip, the elongated aspect defining a longitudinal axis extending substantially parallel to the elongated aspect; and wherein the second proximal point is at least 90° from the first proximal point relative to a rotation about a centerline. XXIX. The method of clause XXVI, wherein the surgical instrument includes the tool tip having a spherical aspect defining a centerpoint, wherein the second proximal point is at least 90° away from the first proximal point relative to a rotation about the centerpoint. XXX. The method of clause XXVI, wherein determining the tool tip is within a predefined proximity to the tracked anatomy includes the surgical instrument positioned at a third pose with respect to the tracked anatomy, the surgical instrument defining a third proximal point, the third proximal point being different from the first proximal point and different from the second proximal point, and wherein determining the offset distance further includes determining a third offset distance. XXXI. The method of clause XXX, wherein comparing the offset distance to a predefined threshold includes comparing the first offset distance to the predefined threshold, comparing the second offset distance to the predefined threshold, and comparing the third offset distance to the predefined threshold, and wherein initiating an action includes initiating an action when the first 2026253884   14 Oct 2026 offset distance, the second offset distance, the third offset distance or combinations thereof are greater than the predefined threshold. XXXII. The method of clause XXX, wherein the surgical instrument includes an elongated aspect terminating at the tool tip, the elongated aspect defining a longitudinal axis extending substantially parallel to the elongated aspect; and wherein the second proximal point is at least 90° from the first proximal point relative to a rotation about the longitudinal axis, and wherein the third proximal point is at least 90° away from the first and second proximal points relative to a rotation about the longitudinal axis. XXXIII. The method of clause XXX, wherein the surgical instrument includes the tool top having a spherical aspect defining a centerpoint, wherein the second proximal point is at least 90° away from the first proximal point relative to a rotation about the centerpoint and wherein the third proximal point is at least 90° away from the first and second proximal points relative to a rotation about the centerpoint. XXXIV. The method of any of the preceding clauses XXII - XXXIII, wherein triggering an action includes one of sounding an audible alert, displaying a visual alert, activating a tactile alert, cutting off power to the surgical instrument or combinations thereof. XXXV. The method of any of the preceding clauses XXII - XXXIV, wherein the predefined threshold includes a first predefined threshold, and a second predefined threshold, and wherein triggering an action of the navigation system includes triggering a first action when the offset distance is greater than the first predefined threshold but less than the second predefined threshold, and triggering a second action when the offset distance is greater than the second predefined threshold, wherein the first action includes one of sounding a first audible alert, displaying a first visual alert, activating a first tactile alert or combinations thereof and wherein the second action includes one of sounding a second audible alert, displaying a second visual alert, activating a second tactile alert or combinations thereof. 2026253884   14 Oct 2026 XXXVI. A method of providing navigation guidance for a surgical procedure, the method comprising: registering a patient’s anatomy in a common coordinate system, the patient’s anatomy including at least a first bone and a second bone; registering a surgical instrument in the common coordinate system; tracking the patient’s anatomy and the surgical instrument with the navigation system during operation of the surgical instrument on the first bone of the patient’s anatomy; determining an offset distance according to claim 1 with respect to the second bone; and tracking the patient’s anatomy and the surgical instrument with the navigation system during operation of the surgical instrument on the second bone of the patient’s anatomy. XXXVII. A method of performing a surgical operation, the method comprising: coupling a patient tracker to a patient’s anatomy; coupling an instrument tracker to a surgical instrument, the surgical instrument including a tool tip; operating a navigation system to register the instrument tracker and the patient tracker in a common coordinate system and to track the surgical instrument and the patient’s anatomy; pausing the tool tip in contact with the anatomy for a predefined duration to initiate a registration verification; wherein the navigation system is configured to determine an offset distance based on the tracked surgical instrument and the tracked patient’s anatomy; and evaluating the offset distance against a predefined threshold. XXXVIII. The method of clause XXXVII, wherein the navigation system is configured to trigger an action when the offset distance is greater than the predefined threshold, wherein the action includes one of sounding an audible alert, displaying a visual alert, activating a tactile alert, cutting off power to the surgical instrument or combinations thereof. 2026253884   14 Oct 2026 XXXIX. The method of clause XXXVIII, further comprising providing an input to the navigation system to terminate the triggered action. XXXX. The method of clause XXXVII, wherein pausing the tool tip in contact with the anatomy includes pausing the tool tip in contact with a first anatomy contact point at a first time, the surgical instrument in a first pose and a first proximal point of the tool tip in contact with the first anatomy contact point, the method further comprising pausing the tool tip in contact with a second anatomy contact point at a second time, the surgical instrument in a second pose and a second proximal point of the tool tip in contact with the first anatomy contact point; and wherein the navigation system is configured to determine a first offset distance based on the first anatomy contact point and the first proximal point, and to determine a second offset distance based on the second anatomy contact point and the second proximal point. XXXXI. The method of clause XXXX, wherein evaluating the offset distance includes one of evaluating the first offset distance against the predefined threshold; evaluating the second offset distance against the predefined threshold, or combinations thereof. XXXXII. The method of clause XXXX, further comprising calculating a threedimensional offset value based on the first offset distance and the second offset distance, and a geometric relationship between the first proximal point and the second proximal point on the tool tip; and wherein evaluating the offset distance includes comparing the three-dimensional offset value to a predefined three-dimensional offset threshold. XXXXIII. The method of clause XXXVII, wherein the patient’s anatomy includes a first bone and a second bone; the method further comprising: operating the surgical instrument in application to the first bone; operating the surgical instrument in application to the second bone; and wherein pausing the tool to initiate a registration verification is performed in contact with the second bone subsequent to operating the surgical instrument in application to the first bone and prior to operating the surgical instrument in application to the second bone.

Claims

1. A surgical system comprising:a navigation system comprising a control console and a localizer;the navigation system in communication with first data representing a surgical instrument, the surgical instrument including a tool tip, and second data representing a patient’s anatomy;the navigation system operable to track the surgical instrument and the anatomy in a virtual space during a surgical operation based on information gathered by the localizer from an instrument tracker coupled to the surgical instrument and a patient tracker coupled to the anatomy;wherein the navigation system is configured to:track the surgical instrument and the anatomy and store data representing a tracked surgical instrument pose and a tracked anatomy pose in a common coordinate system;determine the tool tip is within a predefined proximity to the anatomy based on the tracked surgical instrument pose and the tracked anatomy pose;determine the tool tip does not depart the predefined proximity by more than a predefined magnitude over a predefined duration;determine an offset distance based on the tracked surgical instrument pose and the tracked anatomy pose in the common coordinate system; andcompare the offset distance to a predefined threshold.

2. The surgical system of claim 1, wherein the navigation system is configured to trigger an action to alert a user when the offset distance is greater than the predefined threshold.

3. The surgical system of claim 2, wherein the action comprises one of sounding an audible alert, displaying a visible alert, activating a tactile alert, cutting off power to the surgical instrument, or combinations thereof.

4. The surgical system of claim 2, comprising a footswitch operable to generate a vibration, wherein the action is a vibration of the footswitch.2026253884   14 Oct 20265. The surgical system of any of claims 2-4, wherein the navigation system is configured to receive an input to cancel the triggered action.

6. The surgical system of any of claims 1-5, wherein the predefined threshold is 0.5 millimeters.

7. The surgical system of any of claims 1-6, comprising a display device in electronic communication with the navigation system, wherein the navigation system is configured to cause the display device to display the offset distance.

8. The surgical system of claim 7, wherein the offset distance is displayed in a first color when the offset distance is less than the predefined threshold and is displayed in a second color, different from the first color, when the offset distance is greater than the predefined threshold.

9. The surgical system of any of claims 1-8, wherein the navigation system is configured to prompt a user to verify a tracking registration by one of displaying a message on a display; sounding an audible alert; generating a haptic sensation; or combinations thereof.

10. The surgical system of claim 9, wherein the navigation system is configured to prompt the user to verify the tracking registration relative to a second bone upon completion of a phase of a surgical plan applied to a first bone and before beginning surgical intervention according to the surgical plan for the second bone.

11. The surgical system of any of claims 1-10, wherein the navigation system is configured to determine the tool tip is within a predefined proximity to the anatomy based on the tracked surgical instrument pose and the tracked anatomy pose by determining the tool tip is within the predefined proximity to a defined surface area of the anatomy that is not to be resected based on the tracked surgical instrument pose and the tracked anatomy pose.2026253884   14 Oct 202612. The surgical system of any of claims 1-11, wherein the offset distance is defined as a magnitude of minimum separation between the tool tip and the tracked anatomy in the common coordinate system, or as a magnitude of greatest overlap between the tool tip and the tracked anatomy in the common coordinate system.

13. The surgical system of any of claims 1-12, wherein the navigation system is configured to trigger a first action when the offset distance reaches or exceeds a first predefined threshold, and a second action, different from the first action, when the offset distance reaches or exceeds a second predefined threshold, different from the first predefined threshold.

14. The surgical system of any of claims 1-12, wherein the navigation system is configured to:determine the tool tip is within the predefined proximity to the tracked anatomy with the surgical instrument positioned at a first pose with respect to the tracked anatomy based on the tracked surgical instrument pose and the tracked anatomy pose;determine a first offset distance with the surgical instrument in the first pose based on the tracked surgical instrument pose and the tracked anatomy pose;determine the tool tip is within the predefined proximity to the tracked anatomy with the surgical instrument positioned at a second pose with respect to the tracked anatomy based on the tracked surgical instrument pose and the tracked anatomy pose;determine a second offset distance with the surgical instrument in the second pose based on the tracked surgical instrument pose and the tracked anatomy pose;compare the first offset distance and the second offset distance to the predefined threshold; andinitiate an action when the first offset distance, the second offset distance, or both the first and second offset distances are greater than the predefined threshold.

15. The surgical system of claim 14, wherein the navigation system is configured to: calculate a three-dimensional offset value based on the first and second offset distances and a geometric relationship between the first and second poses;compare the three-dimensional offset value with an allowed threshold; and2026253884   14 Oct 2026initiate an action to alert a user when the three-dimensional offset value is greater than the allowed threshold.

16. A surgical system comprising:a navigation system comprising a control console and a localizer;the navigation system in communication with first data representing a surgical instrument, the surgical instrument including a tool tip, and second data representing a patient’s anatomy;the navigation system operable to track the surgical instrument and the anatomy in a virtual space during a surgical operation based on information gathered by the localizer from an instrument tracker coupled to the surgical instrument and a patient tracker coupled to the anatomy;wherein the navigation system is configured to:track the surgical instrument and the anatomy and store data representing a tracked surgical instrument pose and a tracked anatomy pose in a common coordinate system;determine the tool tip is within a predefined proximity to the tracked anatomy with the surgical instrument positioned at a first pose with respect to the tracked anatomy based on the tracked surgical instrument pose and the tracked anatomy pose;determine a first offset distance with the surgical instrument in the first pose based on the tracked surgical instrument pose and the tracked anatomy pose;determine the tool tip is within the predefined proximity to the tracked anatomy with the surgical instrument positioned at a second pose with respect to the tracked anatomy based on the tracked surgical instrument pose and the tracked anatomy pose;determine a second offset distance with the surgical instrument in the second pose based on the tracked surgical instrument pose and the tracked anatomy pose; and compare the first offset distance and the second offset distance to a predefined threshold.2026253884   14 Oct 202617. The surgical system of claim 16, wherein the navigation system is configured to initiate an action to alert a user when the first offset distance, the second offset distance, or both the first and second offset distances are greater than the predefined threshold.

18. The surgical system of claim 17, wherein the navigation system is configured to receive an input to cancel the initiated action.

19. A surgical system comprising:a navigation system comprising a control console and a localizer;the navigation system in communication with first data representing a surgical instrument, the surgical instrument including a tool tip, and second data representing a patient’s anatomy;the navigation system operable to track the surgical instrument and the anatomy in a virtual space during a surgical operation based on information gathered by the localizer from an instrument tracker coupled to the surgical instrument and a patient tracker coupled to the anatomy;wherein the navigation system is configured to:track the surgical instrument and the anatomy and store data representing a tracked surgical instrument pose and a tracked anatomy pose in a common coordinate system;determine the tool tip is within a predefined proximity to the tracked anatomy with the surgical instrument positioned at a first pose with respect to the tracked anatomy based on the tracked surgical instrument pose and the tracked anatomy pose;determine a first offset distance with the surgical instrument in the first pose based on the tracked surgical instrument pose and the tracked anatomy pose;determine the tool tip is within the predefined proximity to the tracked anatomy with the surgical instrument positioned at a second pose with respect to the tracked anatomy based on the tracked surgical instrument pose and the tracked anatomy pose;determine a second offset distance with the surgical instrument in the second pose based on the tracked surgical instrument pose and the tracked anatomy pose;2026253884   14 Oct 2026calculate a three-dimensional offset value based on the first and second offset distances and a geometric relationship between the first and second poses; andcompare the three-dimensional offset value with an allowed threshold.

20. The surgical system of claim 19, wherein the navigation system is configured to initiate an action to alert a user when the three-dimensional offset value is greater than the allowed threshold.

Images