Robotic surgery control system

Abstract

The present invention relates to a system and method for controlling the motion of a multi-axis robot to perform surgery on at least the spinal region within the human body. The system includes control and software coding to move the robot in a desired pattern to complete the surgery, which may include the removal of bone, intervertebral disc and tissue, and may also include the insertion of hardware for fusing adjacent bony structures.

Description

Technical Field

[0001] The present invention relates to robotic surgical procedures and, more particularly, to a software system for configuring a computer system that controls the motion of a multi-axis robot to perform orthopedic surgical procedures. Background Art

[0002] Performing orthopedic surgery on the spine with the aid of robots is known in the art. However, previously performed procedures were only small parts of the surgery, or very small steps in the completion of the entire surgery. Therefore, known control systems configured by software for controlling the movements of the robot are insufficient for complex and delicate procedures such as bone removal, disc removal, etc.

[0003] Therefore, the present invention provides a software-configured control system that overcomes the shortcomings of the prior art robotic surgical systems. The robotic surgical control system of the present invention is not only relatively easy to set up the program and control the robot during the actual operation, but also provides warnings and monitors the surgical process to detect, warn and prevent harm to the patient during the operation. Summary of the invention

[0004] Briefly, the present invention relates to a system and method for controlling the motion of a multi-axis robot to perform surgery on at least the spinal region within a human body. The system includes control and software coding to move the robot in a desired pattern to complete the surgery, which may include the removal of bone, disc and tissue, and may also include the insertion of hardware to fuse adjacent bony structures.

[0005] It is therefore an object of the present invention to provide a system for controlling a multi-axis robot for performing surgical operations.

[0006] It is another object of the present invention to provide software for controlling the motion of a multi-axis robot to perform surgical procedures.

[0007] It is yet another object of the present invention to provide a method of controlling a multi-axis robot for performing a surgical procedure.

[0008] Other objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings, in which certain embodiments of the present invention are illustrated by way of illustration and example. The accompanying drawings constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a screenshot showing the opening screen of the present system.

[0010] Figure 2is a screenshot showing the login screen of the present system.

[0011] Figure 3 is a screen shot showing the patient selection screen of the present system.

[0012] Figure 4 is a screen shot showing the patient information screen of the present system.

[0013] Figure 5 is a screen shot showing the process selection screen of the present system.

[0014] Figure 6 is a screen shot showing the cutting plan screen of the present system.

[0015] Figure 7 is a screen shot showing the cutting tool path screen of the present system.

[0016] Figure 8 is a screen shot showing the screw insertion planning screen for the present system.

[0017] Fig. 9 is a screenshot showing another screw insertion planning screen of the present system.

[0018] Fig.10 is a screen shot showing the system's Digital Imaging and Communications in Medicine (DICOM) screen for viewing a patient's anatomy.

[0019] Fig.11 is a screenshot showing the DICOM slice view screen of the present system.

[0020] Fig.12 is a screenshot showing an operation preview screen of the present system.

[0021] Fig.13 is a screenshot showing an operation preview screen of the slice format of the present system.

[0022] Fig.14 This is the general flow chart of this system.

[0023] Fig.15 is a diagram of a robot control system including one embodiment of a robot.

[0024] Other objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings, in which certain embodiments of the present invention are illustrated by way of illustration and example. The accompanying drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features of the present invention. DETAILED DESCRIPTION

[0025] Although the present invention can be implemented in various forms, the presently preferred embodiment is shown in the drawings and will be described below, it being understood that the present disclosure is considered to be exemplary of the present invention and is not intended to be limiting of the present disclosure. The present invention is in accordance with the specific embodiments shown in the drawings.

[0026] refer to Figure 1-15 , the robotic surgical system includes a computer system 11 operably connected or interfaced with a multi-axis robot 12 for controlling the movement of components of the multi-axis robot 12 to perform surgical procedures on a human patient 14. The computer system 11 includes a user interface 16 displayed as two touch screen displays 18. The main visual display 20 is located above the working display 22 and can provide horizontal tilt to the operator 68 to facilitate easier tactile interaction. It is contemplated that these touch screen displays have built-in multi-touch support for scrolling, zooming and rotating viewpoints and target objects in addition to standard click-based selection functions. The displays 20, 22 are operable to display one or more digital images from one or more image files in a memory 83. The computer system 11 includes a computer 82 having a memory 83 and a processor 84. The computer 82 is operably connected to the robot 12 wirelessly or by suitable wiring 85. The storage device 83 can have a primary storage device (commonly referred to as memory) and / or an auxiliary storage device, which can be read by the processor 84 to transfer digital images between the primary storage device and the auxiliary storage device for subsequent long-term storage as an image file (e.g., a jpeg file). Primary storage and secondary storage are collectively referred to herein as storage, and the term storage may include one or both of primary storage and secondary storage. It should be understood that image files may be wirelessly transferred between primary storage and long-term storage. It should also be understood that long-term storage may be remote, such as cloud storage or other remote storage.

[0027] Although the operation information can be input by the user (e.g., a surgeon) via the displays 20, 22, it can also be input by other input devices (e.g., a keyboard 87, a joystick or mouse 86, and a touch screen display 18). The user operates by touching the screen on the displays 20, 22 with a finger, a stylus, or other suitable tool. According to the command input into the computer 82, the computer outputs an electrical signal to the multi-axis robot 12 so that the motor in the robot moves the component arm 89 of the robot 12 to the desired position at the desired speed. The tool holder 91 is also associated with the robot 12 for holding a suitable surgical tool 92. The motor of the robot (not shown) can be a servo system or any other type of motor that is suitable for providing feedback to the computer system 11 and thus to the control system 10. The control system 10 ensures that the movement of the various robotic arms 89 moves according to the command of the control system. Therefore, it is desirable that the robot motor is provided with, but not limited to, an encoder to provide feedback signals to the control system 10. In this way, the control system 10 can modify the electrical signal provided to the robot 12 to meet the control level required for the surgical procedure. Additionally, the robot 12 may be equipped with torque sensors, gravity sensors, speed sensors, direction sensors, etc. to provide additional feedback data to the control system 10 to further enhance control of the robot's motion.

[0028] In at least one embodiment, the multi-axis robot 12 is provided with a movable base assembly 90. The movable base assembly 90 allows the control system 10 to reposition the robot 12 to a more ideal position to complete the desired operation based on the reference landmarks. In the patient's anatomy, it can be marked to provide electromagnetic induction or other types of signals to allow the control system to position the robot. These movements can be based on the limitations of the robot's ability to move in a desired trajectory, etc. In at least one embodiment, the base assembly 90 is provided with a Mecanum wheel that allows the robot to move in any direction without rotating the wheels about a vertical axis. Like the robot axes, the Mecanum wheels should be equipped with motors and / or sensors to provide feedback to the control system 10, which can monitor the movement in real time and modify the movement based on differences such as wheel slippage, etc.

[0029] Reference Figure 1 and Figure 2, showing the startup and login screens. When the system boots up, the startup screen 24 is initially viewed. Once booted up, the login screen 26 becomes visible. To log in, the user or operator 68 selects their name from a list of registered users and places their name in the user box. Thereafter, the operator 68 enters a numeric or other suitable password using the keypad 30 or keyboard 87 to open the system. Data is entered into the computer using the login button 32, or cleared using the clear button 34. It should also be noted that other types of logins may be utilized without departing from the scope of the present invention, and these may include, but are not limited to, retinal scans, facial scans, fingerprint scans, RFID and other methods of determining the true identity of the operator 68.

[0030] Reference Figure 3 , showing a patient selection screen. To select a patient, the operator 68 can type or scroll through a list of pre-loaded patient profiles. The patient's name is then entered into the patient selection box 38, and the "Load Patient" button 39 selects the named patient. Once selected, the operator 68 can use the patient's imaging and medical data ( Figure 4 ) and the system advances to the next screen.

[0031] Reference Figure 4 , a patient information screen 40 is shown. In this screen, patient details 42 are viewed on the working display 22. Various surgical procedure types 46 are listed in the navigation toolbar 44 for the operator 68 to select.

[0032] Reference Figure 5 , showing the Operation Generator screen 48. Each surgical procedure 46 is provided with a picture icon 50. Selecting the desired procedure and pressing the Add Procedure button 52 appends the operation sequence in the Operation Sequence List 54 to the steps associated with the selected procedure. The selections made on this screen determine the options available on the Planner screen, see Figure 6 and 7 . Press the navigation toolbar 44 ( Figure 4 ) on the process type 46, the operator 68 can switch back and forth between the operation of the control system 10 and the generator screen 48 throughout the operation.

[0033] Reference Figure 6 and 7, cut planner screens 56, 58 are shown. In these screens 56, 58, the control system 10 allows the operator 68 to select a vertebra 62 and edit a cutting path 60 for the procedure. As described above, the suggested surgical tool path 60 is entered by the operator on the screen on at least one of the displays 20, 22. The specific procedure to be edited is selected from the list of operating steps 64 on the left side of the screen. Each procedure may include operations on any number of vertebrae 62. The tool selection button 66 allows the user to select the type of tool to be used for cutting. Each tool selected has an associated tool offset length and diameter to automatically offset and determine the tool's cutting depth relative to the tool path selected and directed by the operator 68 for the procedure. All selected tools are stored to generate tool paths. The navigation bar 44 allows the operator 68 to switch to and jump out of this screen as needed throughout the procedure. In this way, the operator 68 can change the surgical tool path and the tool used for the operation as needed. The view of the vertebra 62 on the screen can be rotated and enlarged to allow the surgical tool path 60 to be placed as desired by the operator 68. In this manner, the operator 68 may view the surgical tool path 60 from various angles and may zoom in on specific features that may be desired to be retained or deleted.

[0034] Reference Figure 8 and 9 , showing the planned insertion of spiral screens 70, 72. In these screens, the control system 10 allows the operator 68 to edit the operation step list 54 ( Figure 5) in a specific step selected in the operator 68 screen. This screen allows the operator 68 to select the desired vertebra 62 to be inspected, rotated and positioned to allow the insertion axis 76 to be oriented in the vertebra. Each procedure may include operations performed on any number of vertebrae and may include the insertion of a pedicle screw 74. The pedicle screw 74 typically includes a threaded handle 78 and a tulip-shaped portion 80. The tulip-shaped portion 80 is typically formed to have two upright arms 82 for accommodating a rod member (not shown) for connecting multiple screws together to fuse the vertebra 62 to an adjacent vertebra 62. The pedicle screw 74 is connected to a tubular or non-tubular member (not shown) of a fixed or oriented column. The arms 82 of the tulip-shaped portion 80, while engaged with the handle 78, allow the screw to be inserted along the axis 76 selected by the operator 68 and inserted into the vertebra 62 to the desired depth, while the upright arms 82 are oriented to allow the rod to be inserted across multiple pedicle screws 74. Like other tools 92 (commonly referred to as effectors), the tool 92 for inserting the screw includes a length and diameter (which can be changed over its length) stored in the screw offset, and the system can know the length and diameter of the tool to plan and insert the screw. Therefore, if there is an interference with the selected path, or if the screw will protrude from the bone in an undesirable manner, the structure provides warnings and attention to the operator 68. In one embodiment, the control system 10 uses the volume of the vertebrae to predict fractures or collisions to protect the patient from injury, and can also track neural spaces, other vertebrae, other tools, and sensitive tissue areas of the patient to avoid injury. It should also be noted that although pedicle screws are shown herein, any type of bone screw can be inserted in a similar manner without departing from the scope of the present invention.

[0035] Reference Figure 10-14 , showing digital imaging and communications of medical "DICOM" viewer screens 94, 96 and operation overview screens 98, 100. In these screens, a 3D simulated image of the patient is loaded into the control system 10 in DICOM format to facilitate viewing of oblique slices. Even though the 3D simulated image is displayed on a two-dimensional screen, it is often referred to simply as a 3D image. The tool 92 and surgical tool path 60 for each selected tool can be overlaid on the DICOM data to show exactly where the tool will go and move based on the tool path and the tool that has been selected and set up for the procedure ( Fig.12 and Fig.13). Electromagnetic or optical sensors can be used to align DICOM data with tool paths for robotic operations. In this way, the operator 68 can see exactly where the cut will be made and the depth to which the tool will travel in the patient's body. This allows for preliminary operation of the surgery to be modified as needed. In at least one embodiment, the control system 10 provides automatic segmentation and calibration of DICOM data. In this embodiment, the control system 10 will automatically associate previously acquired DICOM data with the current patient on the table to facilitate the generation and tracking of real-time surgical tool paths. Anchor positions or ultrasound scanning or a combination of both will allow the robot 12 to establish accuracy, associating DICOM data with real-time patient data until a sufficient match is obtained to begin operation. This structure also allows minimally invasive surgery "pathfinding". Therefore, the control system includes path generation and execution software that provides a minimally invasive mode. This mode will optimize the trajectory of the robotic tool so that the smallest incision can be used (ideally only one puncture). At the discretion of the operator, damage to the surface and / or internal tissues can be minimized or protected first.

Claims

1. A robotic surgery system, comprising: A multi-axis surgical robot having a plurality of movable components and operable to hold and manipulate at least one surgical tool; A computer system having a processor, a display device and an input device, the computer system operably interfaced with the robot to control the operation of the at least one surgical tool and the movement of the robot components to achieve the movement of the at least one surgical tool, the computer system being configured to receive one or more image files of one or more images of a surgical site and to display at least one of the images upon instruction, the one or more image files comprising at least one image taken before setting a suggested surgical path and at least one real-time image taken when setting the suggested surgical path, the previously taken image being aligned with the real-time image before the robot moves to complete the surgery, the display device being operable to receive information from a user about a suggested surgical tool path overlaid on the image taken before the suggested surgical path for at least one of the surgical tools, the suggested path instructions being processed by the processor and used to direct the movement of the at least one surgical tool of the surgical robot to perform a surgical procedure at the surgical site under the control of the processor, the suggested surgical path being visible with the image of the suggested tool on the display device relative to the aligned image before the robot moves.

2. The system according to claim 1, wherein: The display device comprises a touch screen operable to function as the input device, and the information is input by a user touching the touch screen, and the computer system is operable to display the input information for viewing by the user.

3. The system according to claim 2, wherein: The processor determines the surgical tool path and provides surgical tool path data to the robot to enable movement of the tool along the proposed surgical path.

4. The system according to claim 3, wherein: The processor is configured to determine motion of the robotic assembly to effectuate motion of the surgical tool along the surgical tool path, the robot providing feedback to the processor regarding the position of an effector.

5. The system according to claim 4, wherein: The processor is configured to analyze the suggested surgical tool path and, if interference with the suggested surgical tool path exists, effect a change to the surgical tool path.

6. The system according to claim 5, wherein: The computer system is configured to receive instructions from the user regarding surgical tool selection, and the processor is configured to analyze the proposed surgical tool path using the stored tool offsets to provide a warning of interference.

7. The system according to claim 6, wherein: The computer system is configured to determine a position of the surgical tool relative to the surgical site prior to performing a surgical procedure using the surgical tool.

8. The system according to claim 1, wherein: The computer system is configured to display an operation generator screen having a plurality of selectable operation courses for selection prior to initiation of the surgical procedure to at least partially program operation of the robot and the surgical tool.

9. The system according to claim 1, wherein: The computer system is configured to display at least one simulated image of the surgical site, display a currently predicted surgical tool path and surgical tool position on the image, and allow the user to adjust the current predicted path to a new predicted path, wherein the image includes a simulated 3D image.

10. The system according to claim 9, wherein: The computer system displays at least one image of the surgical site and displays a currently suggested surgical path and tool positions on the image, and allows at least one of the user and the computer system to adjust the suggested surgical path to a revised surgical path.

11. The system according to claim 10, wherein: The at least one image comprises a simulated 3D image.

12. The system according to claim 10, wherein: The surgical procedure is a plastic surgery procedure.

13. The system of claim 1, wherein: The surgical site includes at least one electromagnetic sensor in electrical communication with the computer system for aligning the surgical site image with the patient to control positioning of the multi-axis surgical robot.

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