Robotic handheld surgical instrument system and method

Abstract

A system is provided that includes a robotic instrument for use with a cutting tool. In some forms, the robotic instrument includes a handheld portion for being held by a user and a tool support movably coupled to the handheld portion to support the cutting tool. Multiple actuators operatively interconnect the tool support and the handheld portion to allow the tool support to move in three degrees of freedom relative to the handheld portion. Optional constraint components may operatively interconnect the tool support and the handheld portion to constrain the movement of the tool support in the three degrees of freedom relative to the handheld portion. A guide array assists the user in positioning the cutting tool and / or parts of the instrument.

Description

Technical Field

[0001] This disclosure generally relates to surgical robotic handheld instrument systems and methods of use. Background Technology

[0002] Physical cutting guides are used to restrain surgical instruments when removing tissue from a patient. In some cases, physical cutting guides restrain such surgical instruments to prepare a joint for receiving a replacement implant. The time required to position and secure the physical cutting guide to the patient can account for a significant portion of the total time required to perform surgery.

[0003] A navigation system (also known as a tracking system) is used to properly align and secure clamps, as well as to track the position and / or orientation of surgical instruments used to remove tissue from the patient. Tracking systems typically employ one or more trackers associated with the instrument and the tissue being removed. The user can then view a display to determine the current position of the instrument relative to the desired cutting path of the tissue to be removed. The display may be arranged in a way that requires the user to shift their gaze away from the tissue and surgical site to visualize the progress of the instrument. This can distract the user from the surgical site. Furthermore, the user may find it difficult to position the instrument in the desired manner.

[0004] Robot-assisted surgery typically relies on large robots with robotic arms capable of moving in six degrees of freedom (DOF). Operating and manipulating these large robots in the operating room can be cumbersome.

[0005] Systems and methods are needed to address one or more of these challenges. Summary of the Invention

[0006] A robotic instrument is provided for use with a cutting tool. The robotic instrument includes a handheld portion for user holding. A tool support is movably coupled to the handheld portion to support the tool. A plurality of actuators operatively interconnect the tool support and the handheld portion to move the tool support in three degrees of freedom relative to the handheld portion. Each of the plurality of actuators is actively adjustable. A constraint assembly has a passive linkage mechanism operatively interconnecting the tool support and the handheld portion. The passive linkage mechanism is coupled to the tool support and the handheld portion in a manner configured to constrain the movement of the tool support relative to the handheld portion in three degrees of freedom.

[0007] Another robotic instrument is provided for use with a saw blade. The robotic instrument includes a handheld portion for user holding. A blade support is movably coupled to the handheld portion to support the saw blade. Multiple actuators operatively interconnect the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion. A constraint assembly operatively interconnects the blade support and the handheld portion to constrain the movement of the blade support relative to the handheld portion in three degrees of freedom. A controller is coupled to the multiple actuators to control the adjustment of the multiple actuators thereby defining a virtual saw cutting guide.

[0008] Another system is provided for use with cutting tools. This system includes an instrument having a handheld portion for user retention and a tool support attached to the handheld portion to support the tool. A guide array is coupled to the instrument and is controllable to visually indicate to the user desired changes in the pitch, yaw, and translational orientation of the handheld portion in order to achieve a desired tool orientation. A controller is coupled to the guide array and configured to automatically adjust the guide array to visually indicate desired changes in pitch, yaw, and translational orientation as the user moves the handheld portion of the instrument.

[0009] Another system is provided for use with a cutting tool. This system includes an apparatus having a handheld portion for user retention and a tool support coupled to the handheld portion to support the tool. A guide array is coupled to the apparatus and is controllable to visually indicate to the user desired changes in the tool's pitch, yaw, and translational orientations to achieve a desired posture. The guide array is arranged to represent a plane of the tool. A controller is coupled to the guide array and configured to automatically adjust the guide array as the user moves the tool to visually indicate desired changes in pitch, yaw, and translational orientations.

[0010] Another robotic system for use with cutting tools is provided. This robotic system includes a handheld portion for being held and supported by a user. A tool support is movably coupled to the handheld portion to support the tool. Multiple actuators operatively interconnect the tool support and the handheld portion to move the tool support in three degrees of freedom relative to the handheld portion, thereby positioning the tool on a desired trajectory or plane. Each of the multiple actuators is adjustable between a maximum position and a minimum position and has an initial position between the maximum and minimum positions. A vision indicator is associated with the multiple actuators to indicate the desired movement of the handheld portion. A controller is coupled to the vision indicator to control the operation of the vision indicator for indicating the desired movement of the handheld portion.

[0011] Another robotic system is provided. The robotic system includes a handheld portion for user holding. A tool support is movably coupled to the handheld portion to support a tool. Multiple actuators are operatively interconnected with the tool support and the handheld portion to move the tool support in three degrees of freedom relative to the handheld portion, thereby positioning the tool on a desired trajectory or plane. Each of the multiple actuators is adjustable between a maximum position and a minimum position and has an initial position between the maximum and minimum positions. A vision indicator is associated with the multiple actuators to indicate the desired movement of the handheld portion. A controller is coupled to the multiple actuators and the vision indicator to control operation in several modes, including: an initial mode, in which the controller automatically adjusts each of the multiple actuators to their initial positions; a proximity mode, in which the controller indicates the desired movement of the tool to position the tool on the desired trajectory or plane while the multiple actuators are in their initial positions; and a aiming mode, in which the tool is approximately on the desired trajectory or plane and the controller indicates the desired movement of the handheld portion to hold the tool on the desired trajectory or plane.

[0012] A method is provided for using a robotic instrument with a cutting tool, the robotic instrument including a handheld portion for being held by a user, a tool support movably coupled to the handheld portion to support the cutting tool, a plurality of actuators operatively interconnecting the tool support and the handheld portion, and a constraint assembly having a passive linkage mechanism operatively interconnecting the tool support and the handheld portion. The method includes moving the tool support in three degrees of freedom relative to the handheld portion by actively adjusting one or more effective lengths of the plurality of actuators, and constraining the movement of the tool support in three degrees of freedom relative to the handheld portion.

[0013] A method is provided for guiding the movement of an instrument having a handheld portion for being held by a user, a tool support attached to the handheld portion to support a tool, and a guide array attached to the instrument and arranged to represent a plane of the tool. The method includes visually indicating to the user desired changes in the tool's pitch orientation, yaw orientation, and translation to achieve a desired posture.

[0014] Another method is provided for guiding the movement of a robotic instrument having a handheld portion for being held and supported by a user, a tool support movably coupled to the handheld portion to support a tool, a plurality of actuators operatively interconnecting the tool support and the handheld portion to move the tool support in three degrees of freedom relative to the handheld portion to position the tool on a desired trajectory or plane, and a vision indicator associated with the plurality of actuators. The method includes adjusting each of the plurality of actuators to an initial position between a maximum and a minimum position, and using the vision indicator to indicate the desired movement of the handheld portion.

[0015] Another method is provided for guiding the movement of a robotic instrument having a handheld portion for user-held operation, a tool support movably coupled to the handheld portion to support a tool, a plurality of actuators operatively interconnecting the tool support and the handheld portion to move the tool support in three degrees of freedom relative to the handheld portion to position the tool on a desired trajectory or plane, and a visual indicator associated with the plurality of actuators. The method includes controlling the operation of the robotic instrument in several modes, including: an initial mode in which the controller automatically adjusts each of the plurality of actuators to an initial position between a maximum and a minimum position; a proximity mode in which the controller instructs a desired movement of the tool to position the tool on the desired trajectory or plane while the plurality of actuators are in their initial positions; and a aiming mode in which the tool is approximately on the desired trajectory or plane, and the controller instructs a desired movement of the handheld portion to hold the tool on the desired trajectory or plane.

[0016] In one example, a robotic surgical instrument is provided. The robotic surgical instrument includes a handheld body for user-held use, a tool support movably coupled to the handheld body, a tool connector supported by the tool support, and a plurality of actuators for moving the tool support relative to the handheld body in multiple degrees of freedom. The plurality of actuators includes a pair of linear actuators operatively interconnecting the tool support and the handheld body. Each of the pair of linear actuators has a first portion connected to the handheld body and a second portion connected to the tool support, arranged to control the lifting and pitching of the tool support relative to the handheld body. The plurality of actuators also includes a rotary actuator arranged to control the oscillating movement of the tool connector relative to the tool support and the handheld body.

[0017] In another example, a robotic surgical instrument for use with surgical instruments is provided. The surgical instrument includes a handheld body for user retention, a tool support movably coupled to the handheld body to support the tool, and a plurality of actuators for moving the tool support in multiple degrees of freedom relative to the handheld body. The plurality of actuators includes a lifting actuator having a first portion connected to the handheld body and a second portion connected to the tool support, and a pair of auxiliary actuators. Each of the pair of auxiliary actuators includes an actuator portion operatively connected to the lifting actuator and a support portion operatively connected to the tool support, such that each of the pair of auxiliary actuators is arranged to effectively operate between the lifting actuator and the tool support to move the tool support relative to the lifting actuator. The lifting actuator is arranged to allow both the tool support and the auxiliary actuators to move relative to the handheld body in one degree of freedom.

[0018] In another example, a robotic surgical instrument for use with a cutting tool is provided. The surgical instrument includes a pistol grip for being held by a user, the pistol grip having a distal and proximal end, a tool support movably coupled to the pistol grip to support a cutting tool, and a plurality of actuators operatively interconnecting the tool support and the pistol grip to move the tool support in multiple degrees of freedom relative to the pistol grip. The plurality of actuators include: a lifting actuator comprising a motor located in the pistol grip connected to an axis, and a carriage connected to the tool support and translating along the axis when the motor is activated. The plurality of actuators also include a pair of auxiliary actuators, each auxiliary actuator coupled to the carriage and the tool support, located distal to the lifting actuator.

[0019] One general aspect includes a handheld robotic system used with a saw blade during surgical procedures. The handheld robotic system also includes an instrument that may include a handheld portion for being held by a user; a blade support coupled to the handheld portion to support the saw blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion, the actuator assembly including a plurality of actuators. The system also includes a guide array that may include a plurality of visual indicators coupled to the instrument and controllable to visually indicate to the user one or more desired changes in pitch orientation, yaw orientation, and translation of the handheld portion to achieve a desired posture of the handheld portion; and a controller configured to control the adjustment of the plurality of actuators to hold the saw blade along a desired plane. The system also includes the controller further configured to control the guide array based on actuator information of a single actuator among the plurality of actuators to visually indicate one or more desired changes in pitch orientation, yaw orientation, and translation position as the user moves the instrument.

[0020] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system also includes an apparatus that may include a handheld portion for being held and supported by a user; a blade support movably coupled to the handheld portion to support the saw blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion, thereby positioning the saw blade on a desired plane; the actuator assembly including a plurality of actuators; a visual indicator for indicating the desired movement of the handheld portion; and a controller configured to control the adjustment of the plurality of actuators to hold the saw blade along the desired plane, the controller being configured to control the visual indicator based on actuator information relating to one of the plurality of actuators to visually indicate changes in pitch orientation, yaw orientation, and translational position as the user moves the apparatus.

[0021] One general aspect includes a method for controlling movement. This method may include determining the orientation of a saw blade using a locator and a tracker; determining a desired orientation of the saw blade; determining the position of each of a plurality of actuators; determining the orientation of a handheld portion based on the position of each of the plurality of actuators; determining a command orientation of the saw blade based on the orientation of the saw blade determined by the locator, the desired orientation of the saw blade, and the orientation of the handheld portion; determining a command position of each of the plurality of actuators based on the command orientation and the position of each of the plurality of actuators; and controlling each of the plurality of actuators based on the command position. One general aspect includes controlling each of the plurality of actuators based on the command position. This method of controlling movement may include determining the orientation of the saw blade using a locator via a first tracker; determining the orientation of the handheld portion using a locator via a second tracker; and controlling one or more of the plurality of actuators to move toward a desired plane based on the orientation of the saw blade and the orientation of the handheld portion.

[0022] One general aspect includes a method for controlling the movement of a handheld robotic system used with a saw blade. The method of controlling movement further includes determining the position of the saw blade using a locator in a known coordinate system; determining the position of a reference locator associated with a skeleton in the known coordinate system. The movement also includes determining a distance parameter based on the position of the reference locator and the position of the saw blade; controlling a plurality of actuators to move the saw blade toward a desired plane with a first value of the motion parameter between the saw blade and the handheld portion; and controlling the plurality of actuators to move the saw blade toward the desired plane with a second value of the motion parameter between the saw blade and the handheld portion, wherein the first value differs from the second value, and a controller is operable to change the operation from the first value to the second value based on the distance parameter.

[0023] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system also includes a device that may include a handheld portion for being held by a user and a blade support coupled to the handheld portion to support the saw blade; an actuator assembly that operatively interconnects the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion. The system also includes a guide array that may include a plurality of visual indicators coupled to the device and controllable to visually indicate to the user one or more desired changes in pitch orientation, yaw orientation, and translation of the handheld portion to achieve a desired posture of the handheld portion. The system may include a controller coupled to the plurality of actuators to control the adjustment of the plurality of actuators based on the posture of the saw blade and the posture of the handheld portion to hold the saw blade along a desired plane; the controller is further coupled to the guide array and configured to control the guide array based on the desired plane of the blade to visually indicate one or more desired changes in pitch orientation, yaw orientation, and translational position as the user moves the device.

[0024] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system also includes an apparatus that may include a handheld portion for being held and supported by a user; a blade support movably coupled to the handheld portion to support the blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion, thereby positioning the saw blade on a desired plane; the actuator assembly includes a plurality of actuators. The system also includes a vision indicator for indicating the desired movement of the handheld portion; and a controller coupled to the plurality of actuators to control the adjustment of the plurality of actuators based on the attitude of the saw blade and the attitude of the handheld portion to hold the saw blade along the desired plane. The controller may be coupled to the vision indicator and configured to control the vision indicator based on the desired plane of the blade to visually indicate changes in the pitch orientation, yaw orientation, and translational position of the handheld portion in order to achieve the desired handheld portion attitude.

[0025] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system also includes an apparatus that may include a handheld portion for being held by a user and a blade support coupled to the handheld portion, the blade support including a saw drive motor for driving the movement of the saw blade; an actuator assembly that operatively interconnects the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion to position the saw blade on a desired plane, the actuator assembly including a plurality of actuators. The system also includes a positioner configured to determine the position of the saw blade in a known coordinate system and a reference position associated with the skeleton; and a controller coupled to the plurality of actuators, the controller operable to control the plurality of actuators to move the saw blade toward the desired plane at a first value of motion parameters between the saw blade and the handheld portion, and the controller further operable to control the plurality of actuators to move the saw blade toward the desired plane at a second value of motion parameters between the saw blade and the handheld portion, wherein the first value differs from the second value, and the controller operable to change the operation from the first value to the second value based on the position of the saw blade and the reference position associated with the skeleton.

[0026] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system includes an apparatus comprising a handheld portion for being held by a user and a blade support coupled to the handheld portion, the blade support including a saw drive motor for driving movement of the saw blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion to position the saw blade on a desired plane, the actuator assembly including a plurality of actuators. The system also includes a positioner configured to determine the position of the saw blade in a known coordinate system and a reference position associated with a skeleton. The system may include a controller coupled to the plurality of actuators operable to control the plurality of actuators to move the saw blade toward the desired plane, and the controller is further operable to control motor parameters of the saw drive motor to a first value and a second value, wherein the first value differs from the second value, and the controller is operable to change the operation from the first value to the second value based on the position of the saw blade and the reference position associated with the skeleton.

[0027] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system includes an apparatus comprising a handheld portion for being held by a user and a blade support coupled to the handheld portion, the blade support including a saw drive motor for driving movement of the saw blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion to position the saw blade on a desired plane, the actuator assembly including a plurality of actuators. The system also includes a positioner configured to determine the position of the saw blade in a known coordinate system and a reference position associated with a skeleton to determine distance parameters. The system may include a controller coupled to the plurality of actuators operable to control the plurality of actuators to move the saw blade toward the desired plane, and the controller is further operable to control motor parameters of the saw drive motor for a first value and a second value, wherein the first value differs from the second value, and the controller is operable to change the operation from the first value to the second value based on the distance parameters.

[0028] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system includes an apparatus having a handheld portion for being held by a user and a blade support coupled to the handheld portion, the blade support including a saw drive motor for driving the movement of the saw blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion to position the saw blade on a desired plane, the actuator assembly including a plurality of actuators. The system also includes a controller coupled to the plurality of actuators, operable to determine the orientation of the saw blade, the desired orientation of the saw blade, the position of each of the plurality of actuators, and the orientation of the handheld portion based on the current position of each of the plurality of actuators; to determine a command orientation of the saw blade based on the orientation of the saw blade, the desired orientation of the saw blade, and the orientation of the handheld portion; and to determine a command position of each of the plurality of actuators based on the command orientation and the position. The system also includes a controller operable to control each of the plurality of actuators based on the command position.

[0029] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system includes a device having a handheld portion for being held by a user and a blade support coupled to the handheld portion to support the saw blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion, the actuator assembly including a plurality of actuators. The system also includes a guide array comprising a plurality of visual indicators coupled to the device and controllable to visually indicate to the user one or more desired changes in the pitch, yaw, and translational orientations of the saw blade to achieve a desired posture of the handheld portion. The system may include a controller coupled to the guide array and configured to control the guide array based on actuator information regarding one or more of the plurality of actuators to visually indicate one or more desired changes in the pitch, yaw, and translational positions of the saw blade as the user moves the device.

[0030] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system includes a device having a handheld portion for being held and supported by a user; a blade support movably coupled to the handheld portion to support the blade; and an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion to position the saw blade on a desired plane. The actuator assembly may include multiple actuators. The system also includes a vision indicator for indicating the desired movement of the saw blade. The system includes a controller coupled to the vision indicator and configured to control the vision indicator based on actuator information regarding multiple actuators to visually indicate changes in the pitch orientation, yaw orientation, and translational position of the saw blade as the user moves the device.

[0031] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system also includes an instrument having a handheld portion for being held by a user. The system also includes a blade support movably coupled to the handheld portion to support the saw blade. The system further includes an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion to position the saw blade on a desired plane. The actuator assembly may include a plurality of actuators, each adjustable between a maximum and a minimum position and having an initial position between the maximum and minimum positions. The system also includes a vision indicator for indicating the desired movement of the handheld portion. The system also includes a controller coupled to the plurality of actuators and the vision indicator to control operation in several modes, including: a first mode in which the controller automatically adjusts each of the plurality of actuators to their initial positions, and a second mode in which the saw blade is substantially on the desired plane and the controller indicates the desired movement of the handheld portion to hold the saw blade on the desired plane.

[0032] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system includes an apparatus that may include: a handheld portion for being held and supported by a user; a blade support movably coupled to the handheld portion to support the blade; and an actuator assembly that operatively interconnects the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion to position the saw blade on a desired plane. The actuator assembly may include multiple actuators. The system also includes a locator configured to determine the position of the saw blade in a known coordinate system and a reference positioning associated with a skeleton, and a visual indicator. The system includes a controller coupled to a vision indicator, configured to control the vision indicator in a first mode based on actuator information about multiple actuators to visually indicate changes in the pitch, yaw, and translational positions of the saw blade as the user moves the instrument. The controller is also configured to control the vision indicator in a second mode based on actuator information about multiple actuators to visually indicate changes in the pitch, yaw, and translational positions of the handheld part as the user moves the instrument. The controller is configured to switch between the first and second modes based on the position of the saw blade and a reference positioning position or based on input signals received from an input device.

[0033] One general aspect includes a handheld robotic system for use with a saw blade. The handheld robotic system includes an apparatus having a handheld portion for being held by a user and a blade support coupled to the handheld portion to support the saw blade; an actuator assembly operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion, the actuator assembly including multiple actuators. The system may include a positioner configured to determine the position of the saw blade in a known coordinate system and a reference position associated with a skeleton. The system also includes a guide array that may include multiple visual indicators and a controller coupled to the guide array. The controller can be configured to control the guide array in a first mode based on actuator information about one or more of the plurality of actuators to visually indicate one or more desired changes in pitch orientation, yaw orientation, and translation position of the saw blade as the user moves the instrument, and the controller is also configured to control the guide array in a second mode based on actuator information about the plurality of actuators to visually indicate one or more changes in pitch orientation, yaw orientation, and translation position of the handheld part as the user moves the instrument, and the controller is configured to switch between the first mode and the second mode based on the position of the saw blade and the position of the reference positioning or based on input signals received from the input device. Attached Figure Description

[0034] The advantages of this disclosure can be better and more readily understood when considered in conjunction with the accompanying drawings, by referring to the following detailed description.

[0035] Figure 1 This is a perspective view of the robot system.

[0036] Figure 2 This is a perspective view of five planes cut on the femur using robotic instruments to receive a total knee implant.

[0037] Figures 3A-3C These are diagrams illustrating various pitch and orientation parameters of robotic instruments.

[0038] Figures 4A-4C These are illustrations of various swinging and orientation methods for robotic instruments.

[0039] Figures 5A-5C It is a diagram showing the various z-axis translation positions of the robot.

[0040] Figure 6 This is a front perspective view of the robotic instrument, showing a specific posture of the tool support relative to the handheld part.

[0041] Figure 7 It is a block diagram of the control system, and also shows various software modules.

[0042] Figure 8 This is a rear perspective view of the robotic device.

[0043] Figure 9 This is a side view of the robotic device.

[0044] Figure 10 This is a rear view of the robotic device.

[0045] Figure 11 This is a front view of the robotic device.

[0046] Figure 12 This is a top rear perspective view of the tool support component of a robotic instrument.

[0047] Figure 13 This is a bottom rear perspective view of the tool support component of a robotic instrument.

[0048] Figure 14 This is an exploded view showing the body of the tool support and the joint connections associated with multiple actuators.

[0049] Figure 15 This is an exploded view showing the base of the handheld part and the connectors associated with multiple actuators.

[0050] Figure 16 It is roughly along Figure 10 A partial sectional view taken from line 16-16 in the figure.

[0051] Figure 17This is a top-down perspective view of the base of the handheld part.

[0052] Figure 18 This is a bottom-view perspective view of the base of the handheld part.

[0053] Figure 19 This is a perspective view of the shaft of a passive linkage mechanism.

[0054] Figure 20 It is a perspective view of the alternative actuator and linkage arrangement.

[0055] Figure 21 It is a cross-sectional view of the alternative actuator and linkage arrangement.

[0056] Figure 22 The diagram illustrates the various areas where robotic equipment is used.

[0057] Figures 23A-23D This illustrates the use of the guide array.

[0058] Figure 23E This illustrates an example scheme for the status of a visual indicator used to guide the array.

[0059] Figures 24A-24C This illustrates the use of the guide array.

[0060] Figures 25A-25C The illustration shows the use of a guide array and the adjustment of multiple actuators to keep the tool on the desired plane.

[0061] Figures 26A-26B The diagram illustrates the movement of a tool that deviates from the desired plane and how a guide array is used to position the tool on the desired plane.

[0062] Figure 27 This illustration shows the use of robotic instruments to remove bone along the desired plane.

[0063] Figure 28 This is a perspective view of another robotic instrument, with its handle shown in dashed lines.

[0064] Figure 29 yes Figure 28 Another perspective view of the robotic device.

[0065] Figure 30 and 31 Is Figure 28 A perspective view of the flexible circuits used in robotic devices.

[0066] Figure 32 It is used for anchoring. Figure 30 and 31 The image shows a bottom perspective view of the flexible circuit support for each part of the flexible circuit.

[0067] Figure 33 It is used for Figure 28 A bottom perspective view of the weighted end cap of the handheld part of a robotic instrument.

[0068] Figure 34 yes Figure 28 Perspective view of the grip of a robotic instrument

[0069] Figure 35 This is a perspective view of an alternative configuration for robotic instruments.

[0070] Figure 36 yes Figure 35 Side view of an alternative configuration of the robotic instrument.

[0071] Figure 37 yes Figure 35 Rear perspective view of the alternative configuration of the robotic instrument.

[0072] Figure 38A yes Figure 35 A side view of an alternative configuration of the robotic instrument, showing linear actuator and rotary actuator assemblies.

[0073] Figure 38B yes Figure 35 A cross-sectional view of an alternative configuration of the robotic instrument, showing the rotary actuator assembly and tool support.

[0074] Figure 38C This is a perspective view of a tool support with a rotary actuator motor.

[0075] Figure 39A and 39B A tool support with a motor separate from the head of a robotic instrument is shown, the head including a ring gear.

[0076] Figure 40A and 40B yes Figure 35 A perspective view of the tool support component of a robotic instrument.

[0077] Figure 41 This is an exploded view showing the body of the tool support and the joint connections associated with multiple actuators.

[0078] Figure 42 This is an exploded view showing the base of the handheld part and the connectors associated with multiple actuators.

[0079] Figure 43 This is a top-down perspective view of the base of the handheld part.

[0080] Figure 44 This is a perspective view of the shaft of a passive linkage mechanism.

[0081] Figure 45A and 45B It shows Figure 35 A perspective view of the robotic instrument, showing the different actuation positions of the tool support and head.

[0082] Figure 46 This is a perspective view of an alternative configuration for robotic instruments.

[0083] Figure 47 yes Figure 46 A front perspective view of the robotic device.

[0084] Figure 48 yes Figure 46 Rear perspective view of the robotic instrument.

[0085] Figure 49 yes Figure 46 A side view of a robotic instrument having an actuator assembly including a lifting actuator.

[0086] Figure 50 yes Figure 46 Rear perspective view of the robotic instrument.

[0087] Figure 51A and 51B yes Figure 46 A perspective view of the tool support component of a robotic instrument.

[0088] Figure 52 This is an exploded view showing the body of the tool support and the joint connection associated with the lifting actuator.

[0089] Figure 53A The actuator assembly, including a lifting actuator and a pair of auxiliary actuators, is shown in a side perspective view.

[0090] Figure 53B An exploded view of the actuator assembly is shown.

[0091] Figure 54A This is a perspective view of the actuator assembly attached to the tool support.

[0092] Figure 54B This is a cross-sectional view of the lifting actuator.

[0093] Figures 55A-55C This is a schematic diagram of an actuator assembly that allows the tool support to move relative to a hand-held body.

[0094] Figures 56A-56C The swing of the auxiliary actuator relative to the adjustable tool support of the handheld body is shown.

[0095] Figure 57 A perspective view shows an alternative configuration of a robotic instrument with a modular tooling system.

[0096] Figures 58A-58D Depicting and Figure 57 A perspective view of multiple modular tool attachments used together with robotic instruments.

[0097] Figure 59 This is a perspective view of a robotic instrument configured as a cutting guide.

[0098] Figure 60 A perspective view illustrating an alternative configuration of the robotic instrument.

[0099] Figure 61A and 61B The diagram illustrates the various areas where the robotic instruments are used with different actuator behaviors.

[0100] Figures 62A-62C This illustrates an example of actuator control in a selected mode.

[0101] Figure 63A and 63B A schematic diagram of a robotic instrument performing a cutting operation is shown.

[0102] Figure 64 This diagram illustrates a portion of the navigation system that relates to the patient's anatomy and surgical robotic instruments.

[0103] Figure 65 The illustration shows a device with a guide array located on the handheld part.

[0104] Figure 66 The diagram illustrates a device with a guide array that serves as a display screen.

[0105] Figure 67 and Figure 68 An alternative configuration is shown where the actuator is mounted in the handheld part.

[0106] Figure 69 An alternative grip with an input device is shown.

[0107] Figure 70 This is a perspective view of an alternative configuration for the robotic system. Detailed Implementation

[0108] summary

[0109] refer to Figure 1A robotic system 10 is illustrated. The robotic system 10 is shown for performing a total knee surgery on a patient 12 to remove portions of the femur (F) and tibia (T) of the patient 12, allowing the patient 12 to receive a total knee implant (IM). The robotic system 10 can be used to perform other types of surgical procedures, including procedures involving the removal of hard / soft tissue, or other forms of manipulation. For example, manipulation may include cutting tissue, coagulating tissue, ablating tissue, stapling tissue, suturing tissue, etc. In some examples, the surgical procedures involve knee surgery, hip surgery, shoulder surgery, spinal surgery, and / or ankle surgery, and may involve the removal of tissue to be replaced by a surgical implant, such as a knee implant, hip implant, shoulder implant, spinal implant, and / or ankle implant. The robotic system 10 and techniques disclosed herein can be used to perform other surgeries, surgical or non-surgical, and can be used in industrial applications or other applications using robotic systems.

[0110] refer to Figure 1 and 2 The robotic system 10 includes a robotic instrument 14. In some examples, the user manually holds and supports the instrument 14 (e.g., Figure 1 (As shown). In some examples, refer to Figure 70 When the instrument is at least partially or entirely composed of a passive arm (e.g., a linkage arm with a locking joint), a movable arm, and / or similar (e.g., see...) Figure 70 When supported by the auxiliary device of the passive arm 15 (shown by dashed lines), the user can manually hold the device 14. Figure 1 and Figure 2 As best shown, the device 14 includes a handheld portion 16 for manual gripping and / or support by a user and / or assistive devices.

[0111] Instrument 14 can be freely moved and supported by a user without the assistance of a guide arm, for example, configured to be held by a human user while achieving physical removal of material, such that the weight of the instrument in surgery is supported only by the user's hand. In other words, instrument 14 can be configured to be held such that the user's hand supports instrument 14 against gravity. Instrument 14 may weigh 8 pounds or less, 6 pounds or less, 5 pounds or less, or even 3 pounds or less. Instrument 14 may have a weight corresponding to ANSI / AAMI HE75:2009. Instrument 14 also includes an instrument support 18 for receiving the instrument 20. Methods for operating instrument 14 may include suspending the weight of instrument 14 by a user without any assistance from a passive arm or robotic arm. The contents of the passive arm and U.S. Patent No. 9,060,794 to Kang et al. are incorporated herein by reference. In some examples, robotic system 10 may be without a robotic arm, which has more than one continuously arranged joint.

[0112] The blade 20 is coupled to the blade support 18 to interact with anatomical structures in certain operations of the robotic system 10, as further described below. The blade 20 may also be referred to as an end effector. The blade 20 may be removable from the blade support 18, allowing new / different blades 20 to be attached as needed. The blade 20 may also be permanently fixed to the blade support 18. The blade 20 may include an energy applicator designed to contact the tissue of the patient 12. In some examples, the blade 20 may be a saw blade, such as... Figure 1 and 2 As shown, or other types of cutting attachments. In this case, the tool support may be referred to as a blade support. It should be understood that in any instance where a blade support is mentioned, it may be replaced by the term "tool support" and vice versa. However, other tools may be considered, such as those described in Bozung's U.S. Patent No. 9,707,043, which is incorporated herein by reference. In some examples, tool 20 may be a drill bit, an ultrasonic vibrating tip, a drill, a stitcher, etc. Tool 20 may include the blade assembly shown in Walen et al.'s U.S. Patent No. 9,820,753 or U.S. Patent No. 10,687,823, both of which are incorporated herein by reference. Tool support 18 may include a drive motor M and other drive components shown in Walen et al.'s U.S. Patent No. 9,820,753 to drive the oscillating motion of the blade assembly. Such drive components may include a transmission TM coupled to the drive motor M to convert the rotational motion from the drive motor M into the oscillating motion of the tool 20.

[0113] An actuator assembly 400, including one or more actuators 21, 22, 23, moves the tool support 18 relative to the handheld portion 16 in three degrees of freedom to provide robotic motion that helps position and / or orient the tool 20 in a desired location (e.g., in a desired posture relative to the femoral F and / or tibia T during resection), while the user manually holds the handheld portion 16. The actuator assembly 400 may include actuators 21, 22, 23 arranged in parallel, series, or both. In some examples, the actuators 21, 22, 23 move the tool support 18 relative to the handheld portion 16 in three or more degrees of freedom. In some examples, the actuator assembly 400 is configured to move the tool support 18 relative to the handheld portion 16 in at least two degrees of freedom, such as pitch and z-axis translation. In some examples, such as those shown herein, actuators 21, 22, and 23 cause the tool support 18 and its associated tool support coordinate system TCS to move in only three degrees of freedom relative to the handheld part 16 and its associated base coordinate system BCS. For example, the tool support 18 and its tool support coordinate system TCS can: rotate about its y-axis to provide pitch motion; rotate about its x-axis to provide yaw motion; and translate along an axis Z coinciding with the z-axis of the base coordinate system BCS to provide z-axis translational motion. Figure 2 Arrows are used in the middle and in Figures 3A-3C The schematic diagrams for 4A-4C and 5A-5C show the permissible pitch, yaw, and z-axis translation movements, respectively. Figure 6 An example of the orientation of the tool support 18 and the handheld portion 16 within the range of motion of the device 14 is provided. In some examples not shown in the figure, the actuator can move the tool support 18 relative to the handheld portion 16 in four or more degrees of freedom.

[0114] Return to reference Figure 2 The constraint assembly 24, with passive linkage 26, can be used to constrain the movement of the tool support 18 relative to the handheld portion 16 in the remaining three degrees of freedom. The constraint assembly 24 may include any suitable linkage mechanism (e.g., one or more links of any suitable shape or configuration) to constrain the movement as described herein. Figure 2 In the example shown, constraint component 24 operates to limit the movement of the tool support coordinate system TCS by: constraining rotation about the z-axis of the base coordinate system BCS to constrain yaw motion; constraining translation in the x-axis direction of the base coordinate system BCS to constrain x-axis translation; and constraining translation in the y-axis direction of the base coordinate system BCS to constrain y-axis translation. In some cases further described below, actuators 21, 22, 23 and constraint component 24 are controlled to effectively mimic the function of a physical cutting guide PCG, such as a physical saw cutting guide (see...). Figure 2 (The dashed line in the middle).

[0115] refer to Figure 7 The device 14 is controlled by a device controller 28 or other type of control unit. The device controller 28 may include one or more computers, or any other suitable form of controller that directs the operation of the device 14 and the movement of the tool support 18 (and the tool 20) relative to the handheld portion 16. The device controller 28 may have a central processing unit (CPU) and / or other processors, memory, and storage devices (not shown). The device controller 28 is loaded with software as described below. The processor may include one or more processors for controlling the operation of the device 14. The processor may be any type of microprocessor, multiprocessor, and / or multicore processing system. The device controller 28 may additionally or alternatively include one or more microcontrollers, field-programmable gate arrays, systems-on-a-chip, discrete circuitry, and / or other suitable hardware, software, or firmware capable of performing the functions described herein. The term processor is not intended to limit any embodiment to a single processor. The device 14 may also include a user interface (UI) having one or more displays and / or input devices (e.g., triggers, buttons, foot switches, keyboards, mice, microphones (voice-activated), gesture control devices, touchscreens, etc.).

[0116] The instrument controller 28 controls the operation of the cutting tool 20, for example by controlling the power supplied to the cutting tool 20 (e.g., to the drive motor M of the cutting tool 20 that controls the cutting motion) and controlling the movement of the cutting tool support 18 relative to the handheld portion 16 (e.g., by controlling actuators 21, 22, 23). The instrument controller 28 controls the state (e.g., position and / or orientation) of the cutting tool support 18 and the cutting tool 20 relative to the handheld portion 16. The instrument controller 28 can control the speed (linear speed or angular velocity), acceleration, or other rate of change of the movement of the cutting tool 20 relative to the handheld portion 16 and / or relative to the anatomical structure caused by the actuators 21, 22, 23.

[0117] like Figure 2As shown, the instrument controller 28 may include a control housing 29 mounted to the tool support 18, wherein one or more control boards 31 (e.g., one or more printed circuit boards and associated electronic components) are disposed within the control housing 29. The control board 31 may include a microcontroller, driver, memory, sensor, or other electronic components for controlling the actuators 21, 22, 23, and drive motors M (e.g., via a motor controller). The instrument controller 28 may also include an off-board console 33 that communicates data and power with the control board 31. The sensors S, actuators 21, 22, 23, and / or drive motors M described herein may feed signals to the control board 31, which transmits data signals to the console 33 for processing, and the console 33 may feed power and / or position commands back to the control board 31 to provide power to the actuators 21, 22, 23, and / or drive motors M and control their positioning. It is conceivable that this processing may also be performed on the control board within the control housing. Of course, it is contemplated that a separate control housing is not necessary.

[0118] In some forms, console 33 may include a single console for powering and controlling actuators 21, 22, 23 and drive motor M. In some forms, console 33 may include a console for powering and controlling actuators 21, 22, 23 and a separate console for powering and controlling drive motor M. A console for powering and controlling drive motor M may be similar to that described in U.S. Patent No. 7,422,582, filed September 30, 2004, entitled “Control Console to which PoweredSurgical Handpieces are Connected, the Console Configured to Simultaneously Energy more than one and less than all of the Handpieces,” which is incorporated herein by reference. Flexible circuitry FC, also known as flexible circuitry, may interconnect actuators 21, 22, 23 and / or other components with instrument controller 28. For example, flexible circuitry FC may be provided between actuators 21, 22, 23 and control board 31. Other forms of connection, wired or wireless, may exist between components as supplementary or alternative forms.

[0119] Briefly back Figure 1The robot system 10 also includes a navigation system 32. An example of the navigation system 32 is described in U.S. Patent No. 9,008,757, filed September 24, 2013, entitled "Navigation System Including Optical and Non-Optical Sensors," which is incorporated herein by reference. The navigation system 32 tracks the movement of various objects. Such objects include, for example, instruments 14, tools 20, and anatomical structures such as the femur F and tibia T. The navigation system 32 tracks these objects to collect state information about each object with respect to the (navigation) locator coordinate system LCLZ. As used herein, the state of an object includes, but is not limited to, data defining the position and / or orientation of the tracked object (e.g., its coordinate system) or the equivalent / rate of change of that position and / or orientation. For example, the state may be the object's pose, and / or may include linear velocity data, angular velocity data, etc.

[0120] The navigation system 32 may include a cart assembly 34 housing a navigation controller 36 and / or other types of control units. A navigation user interface (UI) operatively communicates with the navigation controller 36. The navigation user interface (UI) includes one or more displays 38. The navigation system 32 is capable of displaying a graphical representation of the relative status of the tracked object to a user using the one or more displays 38. The navigation user interface (UI) also includes one or more input devices to input information into the navigation controller 36 or otherwise select / control certain aspects of the navigation controller 36. Such input devices include interactive touchscreen displays. However, input devices may include any one or more of buttons, foot switches, keyboards, mice, microphones (voice-activated), gesture control devices, etc.

[0121] The navigation system 32 also includes a navigation locator 44 coupled to the navigation controller 36. In one example, the locator 44 is an optical locator and includes a camera unit 46. The camera unit 46 has a housing 48 that houses one or more optical sensors 50. The locator 44 may include its own locator controller 49 and may further include a camera VC.

[0122] Navigation system 32 includes one or more trackers. In some examples, the trackers include a pointer tracker PT, a tool tracker 52, a first patient tracker 54, and a second patient tracker 56. Figure 1In the example shown, the tool tracker 52 is securely attached to the instrument 14, the first patient tracker 54 is securely attached to the femur F of the patient 12, and the second patient tracker 56 is securely attached to the tibia T of the patient 12. In this example, patient trackers 54 and 56 are securely attached to the bone portion. The pointer tracker PT is securely attached to the pointer 57, which is used to register anatomical structures to the locator coordinate system LCLZ and / or for other calibration and / or registration functions.

[0123] The tool tracker 52 can be attached to any suitable component of the instrument 14, and in some forms can be attached to the handheld part 16, the tool support 18, directly attached to the tool 20, or a combination thereof. Trackers 52, 54, 56, and PT can be secured to their respective components in any suitable manner, such as by fasteners, clamps, etc. For example, trackers 52, 54, 56, and PT can be rigidly fixed, flexibly connected (fiber optic), or have no physical connection at all (ultrasound), provided there is a suitable (complementary) method to determine the relationship (measurement) between the respective tracker and the associated object. Any one or more of trackers 52, 54, 56, and PT may include an active marker 58. The active marker 58 may include a light-emitting diode (LED). Alternatively, trackers 52, 54, 56, and PT may have passive markers, such as reflectors, that reflect light emitted from the camera unit 46. Printed markings or other suitable markings not specifically described herein may also be used.

[0124] Various coordinate systems can be used for object tracking. For example, these coordinate systems may include the locator coordinate system LCLZ, the tool support coordinate system TCS, the base coordinate system BCS, coordinate systems associated with each of trackers 52, 54, 56, and PT, one or more coordinate systems associated with anatomical structures, one or more coordinate systems associated with preoperative and / or intraoperative images (e.g., CT images, MRI images, etc.) and / or models (e.g., 2D or 3D models) of the anatomical structures, and the TCP (tool center point) coordinate system. After establishing relationships between coordinate systems (e.g., through registration, calibration, geometric relationships, measurement, etc.), transformations can be used to convert coordinates in each coordinate system to other coordinate systems.

[0125] like Figure 2As shown, in some examples, TCP is a predetermined reference point or origin of the TCP coordinate system defined at the distal end of tool 20. The geometry of tool 20 can be defined relative to the TCP coordinate system and / or relative to the tool support coordinate system TCS. Tool 20 may include one or more geometric features, such as perimeter, circumference, radius, diameter, width, length, height, volume, area, surface / plane, range of motion envelope (along any one or more axes), etc., which are defined and stored in navigation system 32 relative to the TCP coordinate system and / or relative to the tool support coordinate system TCS. In some examples, tool 20 has a blade plane (e.g., for a saw blade), which will be described for convenience and ease of illustration, but is not intended to limit tool 20 to any particular form. Points, other primitives, meshes, other 3D models, etc., can be used to virtually represent tool 20. The TCP coordinate system, the tool support coordinate system TCS, and the coordinate system of tool tracker 52 can be defined in various ways depending on the configuration of tool 20. For example, pointer 57 can be used with the calibration divot (CD) in tool support 18 and / or tool 20 to: determine (calibrate) the orientation of the tool support coordinate system TCS relative to the coordinate system of tool tracker 52; determine the orientation of the TCP coordinate system relative to the coordinate system of tool tracker 52; and / or determine the orientation of the TCP coordinate system relative to the tool support coordinate system TCS. Other techniques can be used to directly measure the orientation of the TCP coordinate system, such as by directly attaching and securing one or more additional trackers / markers to tool 20. In some forms, the trackers / markers can also be attached and secured to the handheld part 16, tool support 18, or both.

[0126] Because the tool support 18 is movable in multiple degrees of freedom relative to the handheld part 16 via actuators 21, 22, and 23, the instrument 14 can employ encoders, Hall effect sensors (with analog or digital outputs), and / or any other position sensing method to measure the orientation of the TCP coordinate system and / or the tool support coordinate system TCS relative to the base coordinate system BCS. The instrument 14 can use measurements from sensors measuring the actuation of actuators 21, 22, and 23 to determine the orientation of the TCP coordinate system and / or the tool support coordinate system TCS relative to the base coordinate system BCS, as further described below.

[0127] Positioner 44 monitors trackers 52, 54, 56, and PT (e.g., their coordinate systems) to determine the state of each of trackers 52, 54, 56, and PT, which corresponds to the state of the object to which they are attached. Positioner 44 can perform known triangulation techniques to determine the state of trackers 52, 54, 56, and PT and the associated object. Positioner 44 provides the states of trackers 52, 54, 56, and PT to navigation controller 36. In some examples, navigation controller 36 determines the states of trackers 52, 54, 56, and PT and transmits them to instrument controller 28.

[0128] The navigation controller 36 may include one or more computers, or any other suitable form of controller. The navigation controller 36 has a central processing unit (CPU) and / or other processors, memory, and storage devices (not shown). The processor may be any type of processor, microprocessor, or multiprocessor system. The navigation controller 36 is loaded with software. For example, the software converts signals received from the locator 44 into data representing the position and / or orientation of the tracked object. The navigation controller 36 may additionally or alternatively include one or more microcontrollers, field-programmable gate arrays, systems-on-a-chip, discrete circuitry, and / or other suitable hardware, software, or firmware capable of performing the functions described herein. The term "processor" is not intended to limit any embodiment to a single processor.

[0129] Although one example of a navigation system 32 using triangulation to determine the state of an object is shown, the navigation system 32 can have any other suitable configuration for tracking the instrument 14, the scalpel 20, and / or the patient 12. In another example, the navigation system 32 and / or the locator 44 is ultrasound-based. For example, the navigation system 32 may include an ultrasound imaging device coupled to the navigation controller 36. The ultrasound imaging device images any of the aforementioned objects, such as the instrument 14, the scalpel 20, and / or the patient 12, and generates a state signal for the navigation controller 36 based on the ultrasound image. The ultrasound image can be 2D, 3D, or a combination of both. The navigation controller 36 can process the image in near real-time to determine the state of the object. The ultrasound imaging device can have any suitable configuration and can differ from, for example, Figure 1 The camera unit 46 shown.

[0130] In another example, navigation system 32 and / or locator 44 are radio frequency (RF) based. For example, navigation system 32 may include an RF transceiver coupled to navigation controller 36. Instrument 14, tool 20, and / or patient 12 may include an RF transmitter or repeater attached thereto. The RF transmitter or repeater may be passive or actively powered. The RF transceiver transmits RF tracking signals and generates status signals to navigation controller 36 based on the RF signals received from the RF transmitter. Navigation controller 36 can analyze the received RF signals to correlate with relevant statuses. The RF signals can have any suitable frequency. The RF transceiver can be positioned at any suitable location to effectively track objects using the RF signals. Furthermore, the RF transmitter or repeater may have... Figure 1 The trackers 52, 54, 56, and PT shown are very different from any suitable structural configuration.

[0131] In yet another example, the navigation system 32 and / or the locator 44 is electromagnetic. For example, the navigation system 32 may include an EM transceiver coupled to the navigation controller 36. The instrument 14, the scalpel 20, and / or the patient 12 may include EM components attached thereto, such as any suitable magnetic tracker, electromagnetic tracker, inductive tracker, etc. These trackers may be passive or actively powered. The EM transceiver generates an EM field and generates a status signal to the navigation controller 36 based on the EM signals received from the trackers. The navigation controller 36 can analyze the received EM signals to correlate a relative state with it. Similarly, such an example of a navigation system 32 may have... Figure 1 The navigation system 32 shown has different structural configurations.

[0132] Navigation system 32 may have any other suitable components or structures not specifically listed herein. Furthermore, any of the technologies, methods, and / or components described above with respect to the illustrated navigation system 32 may be implemented or provided for any other example of navigation system 32 described herein. For example, navigation system 32 may use inertial tracking or any combination of tracking technologies alone, and may additionally or alternatively include fiber-optic tracking, machine vision tracking, etc.

[0133] refer to Figure 7The robot system 10 includes a control system 60, which includes components such as an instrument controller 28 and a navigation controller 36. The control system 60 also includes one or more software programs and software modules. Software modules may be part of one or more programs running on the instrument controller 28, the navigation controller 36, or a combination thereof, for processing data to aid in the control of the robot system 10. The software programs and / or modules include computer-readable instructions stored in memory 64 on the instrument controller 28, the navigation controller 36, or a combination thereof, and executed by one or more processors 70 in the controllers 28, 36. Memory 64 may be any suitable memory configuration, such as non-transitory memory, RAM, non-volatile memory, etc., and may be implemented locally or from a remote database. Additionally, software modules for prompting and / or communicating with the user may be part of one or more programs and may include instructions stored in memory 64 on the instrument controller 28, the navigation controller 36, or a combination thereof. The user can interact with the navigation user interface (UI) or any other user interface (UI) input device to communicate with the software modules. The user interface software may run on a device separate from the instrument controller 28 and / or the navigation controller 36. The instrument 14 can communicate with the instrument controller 28 via a power / data connection. The power / data connection can provide a path for inputting and outputting control of the instrument 14 based on position and orientation data generated by the navigation system 32 and transmitted to the instrument controller 28.

[0134] The control system 60 may include inputs, outputs, and any suitable configuration of processing equipment adapted to perform the functions and methods described herein. The control system 60 may include an instrument controller 28, a navigation controller 36, or a combination thereof, and / or may include only one of these controllers, or other controllers. These controllers can be configured via, for example... Figure 7 The wired bus or communication network shown communicates wirelessly or otherwise. The control system 60 may also be referred to as a controller. The control system 60 may include one or more microcontrollers, field-programmable gate arrays, systems-on-a-chip, discrete circuits, sensors, displays, user interfaces, indicators, and / or other suitable hardware, software, or firmware capable of performing the functions described herein.

[0135] instrument

[0136] In one exemplary configuration, device 14 is in Figure 8-19The device 14 is best shown in the diagram. It includes a handheld portion 16 for being held by a user, a tool support 18 movably coupled to the handheld portion 16 to support a tool 20, an actuator assembly 400 having a plurality of actuators 21, 22, 23 that operatively interconnect the tool support 18 and the handheld portion 16 to move the tool support 18 in three degrees of freedom relative to the handheld portion 16, and a constraint assembly 24 having a passive linkage mechanism 26 that operatively interconnects the tool support 18 and the handheld portion 16.

[0137] The handheld portion 16 includes a grip 72 for a user to hold, enabling the user to manually support the device 14. The handheld portion 16 may be configured with ergonomic features, such as a grip for the user's hand to hold, a textured coating or composite material coating to prevent the user's hand from slipping when wet and / or bloodied. The handheld portion 16 may include a taper to accommodate users with different hand sizes, and its profile is designed to match the profile of the user's hand and / or fingers. The handheld portion 16 also includes a base 74 to which the grip 72 is attached by one or more fasteners, adhesives, welds, etc. In the illustrated form, the base 74 includes a sleeve 76 having a generally hollow cylindrical shape. Connector supports 77, 78, 79 extend from the sleeve 76. Actuators 21, 22, 23 may be movably coupled to the base 74 at the connector supports 77, 78, 79 via connectors described further below.

[0138] The tool support 18 includes a tool support body 80 to which a tracker 52 can be detachably mounted via one or more tracker mounts secured to the tool support 18 at one or more mounting positions 82. In the illustrated configuration, the tool 20 is detachably coupled to the tool support 18. Specifically, the tool support 18 includes a tool connector, such as a head 84 to which the tool 20 is mounted, as described in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference. A drive motor M (e.g., in some configurations, for driving the oscillation of a saw blade) for operating the tool 20 is disposed in the tool support body 80. The tool 20 can be attached to and released from the head 84 in a manner disclosed in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference. Figure 12 and 13As shown in the preferred embodiment, the tool support 18 also includes a plurality of actuator mounts 86, 88, 90, at which actuators 21, 22, 23 are movably connected to the tool support 18 via connectors, as further described below. The actuator mounts 86, 88, 90 may include brackets, etc., adapted to mount the actuators 21, 22, 23, enabling the tool support 18 to move relative to the handheld portion 16 in at least three degrees of freedom.

[0139] In the illustrated configuration, actuators 21, 22, and 23 comprise electrically driven linear actuators extending between the base 74 and the tool support body 80. When actuated, the effective lengths of actuators 21, 22, and 23 change to alter the distance between the tool support body 80 and the base 74 along the respective axes of actuators 21, 22, and 23. Therefore, actuators 21, 22, and 23 cooperate to change their effective lengths and allow the tool support 18 to move relative to the handheld portion 16 in at least three degrees of freedom. In the illustrated configuration, three actuators 21, 22, and 23 are provided, and they may be referred to as first, second, and third actuators 21, 22, and 23, or front actuators 21, 22, and rear actuator 23. The effective lengths of the first, second, and third actuators 21, 22, and 23 are along the first axis of motion AA1, the second axis of motion AA2, and the third axis of motion AA3 (see...). Figure 14 The actuators are adjustable. The effective lengths of the first, second, and third actuators 21, 22, and 23 are independently adjustable to adjust one or more of the pitch, yaw, and z-axis translation positions of the tool support 18 relative to the handheld portion 16, as previously described. In some examples, more actuators may be provided. In some examples, the actuators may include rotary actuators. Actuators 21, 22, and 23 may include linkage structures with one or more links of any suitable size or shape. Actuators 21, 22, and 23 may have any configuration suitable for enabling the tool support 18 to move relative to the handheld portion 16 in at least three degrees of freedom. For example, in some forms, there may be one front actuator and two rear actuators, or some other actuator arrangement.

[0140] In this form, actuators 21, 22, and 23 are connected to the base 74 and the tool support body 80 via multiple movable joints. The movable joints include a set of first movable joints 92 that connect actuators 21, 22, and 23 to the tool support body 80 at actuator mounts 86, 88, and 90. In one form, as... Figure 14 and 16As shown, the first movable joint 92 includes a movable U-shaped joint. The U-shaped joint includes a first pivot pin 94 and a joint block 96. The first pivot pin 94 pivotally connects the joint block 96 to the actuator mounts 86, 88, 90 via a through hole 98 in the joint block 96. A retaining screw 100 can fasten the first pivot pin 94 to the actuator mounts 86, 88, 90. The U-shaped joint may also include a second pivot pin 104. The joint block 96 has a transverse hole 102 to receive the second pivot pin 104. The second pivot pin 104 has a through hole 103 to receive the first pivot pin 94, such that the first pivot pin 94, the joint block 96, and the second pivot pin 104 form the intersection of the U-shaped joint. The first pivot pin 94 and the second pivot pin 104 of each U-shaped joint define intersecting pivot axes PA (see Figure 16 The second pivot pin 104 pivotally connects the pivot yoke 106 of actuators 21, 22, and 23 to the connector block 96. Thus, actuators 21, 22, and 23 can move in two degrees of freedom relative to the tool support body 80. Other types of movable connectors are also considered, such as movable spherical connectors 105 including a ball with a groove for receiving a pin (see, for example, see...). Figure 20 and 21 ).

[0141] refer to Figure 14 and 15 The movable joint also includes a set of second movable joints 108 that connect the first two actuators 21, 22 to the base 74 of the handheld portion 16. In the illustrated configuration, the second movable joints 108 are supported at joint supports 77, 78. Each second movable joint 108 includes a swivel yoke 110 arranged to rotate about a rotation axis SA relative to the base 74 of the handheld portion 16. Each swivel yoke 110 has a swivel head 112 and a post 114 extending from the swivel head 112 to pivotally engage the base 74 at one of the joint supports 77, 78. A nut 115 is threaded onto one end of the post 114 to capture the post 114 in the base 74 while allowing the respective swivel yoke 110 to rotate freely within its respective joint support 77, 78.

[0142] Each second movable joint 108 includes a carrier 116 pivotally coupled to one of the swivel yokes 110. The carrier 116 has a threaded through-hole 117 to receive the lead screws 150 of the first two actuators 21, 22, as further described below. Each carrier 116 also includes an opposing trunnion 118, which allows the carrier 116 to pass through a recess 120 located on the swivel yoke 110 about a pivot axis PA (see [link to relevant documentation]). Figure 14 Pivoting. In some forms, for each second movable joint 108, the rotation axis SA intersects the pivot axis PA to define a single vertex around which the actuators 21, 22 move in two degrees of freedom.

[0143] The cover 122 is fastened to the rotating head 112 and defines one of the recesses 120, while the rotating head 112 defines the other recess 120. During assembly, the carrier 116 is first positioned such that one of the trunnions 118 is placed in the recess 120 on the rotating head 112, and then the cover 122 is fastened to the other trunnion 118 such that the carrier 116 is captured between the cover 122 and the rotating head 112 and is pivotable relative to the yoke 110 via the trunnion 118 and the recess 120. Due to the configuration of the yoke 110 and the associated carrier 116, i.e., the carrier 116 is capable of rotating about the axis of rotation SA and pivoting about the axis of pivot PA, the second movable joint 108 allows for two degrees of freedom of movement of the first two actuators 21, 22 relative to the base 74. Other joint arrangements between the first two actuators 21, 22 and the base 74 are also possible.

[0144] The movable joint also includes a third movable joint 124 that connects the rear (third) actuator 23 to the base 74 of the handheld portion 16. In the illustrated configuration, the third movable joint 124 is supported at the joint support 79. The third movable joint 124 includes a pivot housing 126 fixed to the joint support 79 at the base 74.

[0145] The third movable joint 124 includes a carrier 116 pivotally connected to the pivot housing 126 via a trunnion 118. A fastener 130 having a recess 132 is attached to either side of the pivot housing 126 via a through-hole 133 to engage the trunnion 118. The fastener 130 is arranged such that the carrier 116, after assembly, can pivot via the trunnion 118 located in the recess 132. The carrier 116 has a threaded through-hole 117 to receive the lead screw 150 of the rear actuator 23, as further described below. Due to the configuration of the pivot housing 126 and the associated carrier 116, i.e., the ability of the associated carrier 116 to pivot (e.g., rather than rotate) only about the pivot axis PA, the third movable joint 124 allows only one degree of freedom of movement for the rear actuator 23 relative to the base 74. Other joint arrangements between the rear actuator 23 and the base 74 are also possible.

[0146] refer to Figure 16 Each of actuators 21, 22, and 23 includes a housing 134. Housing 134 includes a cylindrical body 136 and a cap 138 threadedly connected to the cylindrical body 136. A pivot yoke 106, forming part of a first movable joint 92, is secured to housing 134 such that housing 134 and pivot yoke 106 are movable together relative to tool support 18 via the first movable joint 92. Cap 138 engages an annular shoulder 140 of pivot yoke 106 to secure pivot yoke 106 to cylindrical body 136.

[0147] In some forms, the pivot yoke 106 and the cylinder 136 include one or more alignment features to align each pivot yoke 106 to its corresponding cylinder 136 in a predefined relative orientation. Such alignment features may include mating portions, keys / keyways, etc. During assembly, the pivot yoke 106 can first be fastened to the cylinder 136 in its predefined relative orientation, and then a cap 138 can be threaded onto the cylinder 136 (e.g., via mating external and internal threads) to capture the pivot yoke 106 to the cylinder 136 in its predefined relative orientation. This predefined relationship can facilitate wiring and / or alignment of flexible circuitry FC, prevent the pivot yoke 106 from wobbling relative to the cylinder 136, and / or be used for other purposes.

[0148] Each of actuators 21, 22, and 23 also includes a motor 142 disposed within each housing 134. The motor 142 has a housing 144 disposed within the housing 134 and a motor winding assembly 146 disposed within the housing 144. The motor winding assembly 146 can also be secured, for example, by a fixing screw SS (see...). Figure 16 Alignment features (such as those described above) or other alignment features are used to align the motor 142 to the housing 136 in a predefined relative orientation. Each motor 142 also has a rotor 148 attached to a lead screw 150. The lead screw 150 is supported by one or more bushings and / or bearings 151 to rotate within the housing 134. The rotor 148 and the associated lead screw 150 are configured to actuate relative to the housing 134 when the motor 142 is selectively energized. The lead screws 150 have a fine pitch and lead angle to prevent reverse drive (i.e., they are self-locking). In this way, the load placed on the tool 20 is less likely to reverse drive the motor 142. In some examples, the lead screw 150 has 8-36 grade 3 threads with a lead from 0.02 to 0.03 inches / revolution. Other thread types / sizes may also be used.

[0149] Each of actuators 21, 22, and 23 can be controlled by a separate motor controller. The motor controller can be connected to each actuator 21, 22, and 23 individually to direct each actuator 21, 22, and 23 to a given target position. In some examples, the motor controller is a proportional-integral-derivative (PID) controller. In some examples, the motor controller can be integrated with or form part of the instrument controller 28. For ease of illustration, the motor controller will be described herein as part of the instrument controller 28.

[0150] A power supply provides a power signal, for example, 32 VDC, to motor 142 via console 33. This 32 VDC signal is applied to motor 142 via instrument controller 28. Instrument controller 28 selectively provides a power signal to each motor 142 to selectively activate it. This selective activation of motor 142 is used to position tool 20. Motor 142 can be any suitable type of motor, including brushless DC servo motors, other forms of DC motors, etc. The power supply also supplies power to instrument controller 28 to power components within instrument controller 28. It should be understood that the power supply can provide other types of power signals, such as 12 VDC, 24 VDC, 40 VDC, etc.

[0151] One or more sensors S (see also) Figure 7 The signals are transmitted back to the instrument controller 28, allowing the instrument controller 28 to determine the current position (i.e., measurement position) of the associated actuators 21, 22, and 23. The levels of these signals can vary in relation to the rotational position of the associated rotor 148. In one embodiment, the sensors S can resolve the rotational position of the rotor 148 within a given revolution at high resolution. These sensors S can be Hall effect sensors, based on a magnet from the rotor 148 or from another magnet placed on the lead screw 150 (e.g., see...). Figure 16 The sensory magnetic field of the 2-pole magnet MG in the rotor 142 is used to output analog and / or digital signals. A low-voltage signal, such as 5 VDC, to excite the Hall effect sensor can be supplied from a motor controller associated with the motor 142 associated with the Hall effect sensor. In some examples, two Hall effect sensors are arranged in the housing 134 and spaced 90 degrees apart from each other around the rotor 148 to sense the rotor position, so that the instrument controller 28 can determine the position of the rotor 148 and calculate the increase in the number of rotor revolutions (one such sensor S and magnet MG in the housing 134). Figure 16(As shown in the diagram). In some forms, the Hall effect sensor outputs a digital signal representing an increasing count. Various types of motor and sensor arrangements are possible. In some examples, motor 142 is a brushless DC servo motor and two or more internal Hall effect sensors may be spaced 90 degrees, 120 degrees, or any other suitable interval around rotor 148. Sensor S may also include an absolute or incremental encoder, which can be used to detect the rotational position of rotor 148 and count the number of revolutions of rotor 148. Other types of encoders may also be used as said one or more sensors. Sensors can be placed at any suitable location on the actuator and surrounding components, suitable for determining the position of each actuator as the actuator is adjusted, such as on a housing, nut, screw, etc. In yet another configuration, sensorless motor control can be used. In this implementation, the position of each rotor can be determined by measuring the back electromotive force and / or inductance of the motor. A suitable example can be found in U.S. Patent No. 7,422,582, which is incorporated herein by reference in its entirety.

[0152] In some examples, the output signal from the Hall effect sensor is sent to the instrument controller 28. The instrument controller 28 monitors changes in the level of the received signals. Based on these signals, the instrument controller 28 determines the rotor position. The rotor position can be considered as the number of degrees of rotation of the rotor 148 from its initial or initial position. The rotor 148 can rotate 360° multiple times. Therefore, the rotor position can exceed 360°. A scalar value called a count represents the rotor position from the initial position. The rotor 148 rotates in both clockwise and counterclockwise directions. Each time the signal level of a plurality of signals (analog or digital) undergoes a defined state change, the instrument controller 28 increments or decrements the count to indicate a change in rotor position. For each complete 360° rotation of the rotor 148, the instrument controller 28 increments or decrements the count value by a fixed count number. In some examples, the count increments or decrements between 100 and 3,000 for every 360 degrees of rotation of the rotor 148. In some examples, each 360-degree rotation of rotor 148 has 1,024 positions (counts), for example, when an incremental encoder is used to monitor rotor position. Internally, the instrument controller 28 contains counters associated with each actuator 21, 22, 23. The counters store values ​​equal to the cumulative number of each count that has been incremented or decremented. Count values ​​can be positive, zero, or negative. In some forms, the count value defines the increment of movement of rotor 148. Thus, rotor 148 of actuators 21, 22, 23 can first move to a known position, referred to as their initial position (described further below), while the count value is used to define the current position of rotor 148.

[0153] As previously described, the carrier 116 has a threaded through-hole 117 to threadedly receive the lead screws 150, such that each lead screw 150 can rotate relative to a corresponding one of the carriers 116 to adjust the effective length of a corresponding actuator among the plurality of actuators 21, 22, 23, thereby changing the count measured by the instrument controller 28. The housing 134 and each of the corresponding carriers 116 are constrained in relative movement in at least one degree of freedom to allow the lead screw 150 to rotate relative to the carrier 116. More specifically, the lead screw 150 is rotatable relative to the carrier 116 because: the pivot yoke 106 cannot rotate about the associated axes of motion AA1, AA2, AA3 (i.e., such rotational movement of the pivot yoke 106 is constrained due to the configuration of the first movable joint 92); and the carrier 116 cannot rotate about the associated axes of motion AA1, AA2, AA3 (i.e., such rotational movement of the carrier 116 is constrained due to the configuration of the second movable joint 108 and the third movable joint 124).

[0154] Stops 152, such as threaded fasteners and shoulders formed on the lead screw 150, are secured to the lead screw 150. The stops 152 are sized to abut against the carrier 116 at the end of the travel of each lead screw 150.

[0155] As previously stated, the effective length of actuators 21, 22, and 23 is actively adjustable to allow the tool support 18 to move relative to the handheld portion 16. An example of this effective length is... Figure 16 The third actuator 23 is marked "EL". Here, the effective length EL is measured from the center of the associated carrier 116 to the center of the associated first movable joint 92. When each actuator 21, 22, 23 is adjusted, the effective length EL changes by changing how far the lead screw 150 is screwed into or out of its associated carrier 116, thereby changing the distance from the center of the associated carrier 116 to the center of the associated first movable joint 92. Actuators 21, 22, 23 are adjustable between a minimum and a maximum value of the effective length EL. The effective length EL of each actuator 21, 22, 23 can be represented / measured in any suitable manner to represent the distance between the tool support 18 and the handheld portion 16 along the active axes AA1, AA2, AA3, which changes to cause various movements of the tool support 18 relative to the handheld portion 16.

[0156] The constraint assembly 24 works in conjunction with actuators 21, 22, and 23 to constrain the movement provided by actuators 21, 22, and 23. Actuators 21, 22, and 23 provide movement in three degrees of freedom, while the constraint assembly 24 constrains the movement in three degrees of freedom. In the illustrated form, the constraint assembly 24 includes a passive linkage 26 and a passive linkage joint 156 that connects the passive linkage 26 to the tool support 18.

[0157] In one form, such as Figure 14 and 16 As shown, the passive linkage joint 156 includes a passive linkage U-shaped joint. The U-shaped joint includes a first pivot pin 158 and a joint block 160. The first pivot pin 158 pivotally connects the joint block 160 to the passive linkage mounting member 162 of the tool support body 80 via a through hole 164 in the joint block 160. A retaining screw 166 secures the first pivot pin 158 to the passive linkage mounting member 162. The U-shaped joint also includes a second pivot pin 170. The joint block 160 has a transverse hole 168 for receiving the second pivot pin 170. The second pivot pin 170 pivotally connects the passive linkage pivot yoke 172 of the passive linkage mechanism 26 to the joint block 160. The second pivot pin 170 has a through hole 171 to receive the first pivot pin 158, such that the first pivot pin 158, the joint block 160, and the second pivot pin 170 form the intersection of the U-shaped joint. The first pivot pin 158 and the second pivot pin 170 define the intersecting pivot axis PA (see...). Figure 16 Thus, the passive linkage 26 can move in two degrees of freedom relative to the tool support body 80. Other types of passive linkage joints are also envisioned, such as a passive linkage ball joint 107 including a ball with a groove for receiving a pin (see, for example, [link to relevant documentation]). Figure 20 and 21 ).

[0158] The passive linkage 26 includes a shaft 174 fixed to the passive linkage pivot yoke 172. The passive linkage 26 also includes a sleeve 76 at a base 74 configured to receive the shaft 174 along the constraint axis CA. The passive linkage 26 is configured to allow axial sliding of the shaft 174 relative to the sleeve 74 along the constraint axis CA and radial movement of the constraint shaft 174 relative to the constraint axis CA during actuation of one or more of the actuators 21, 22, 23.

[0159] The passive linkage 26 also includes a key 176 to constrain the rotation of the shaft 174 relative to the sleeve 76 about the constraint axis CA. Key 176 is best displayed... Figure 16In the middle, key 176 is fitted into opposing keyways 178, 180 on shaft 174 and sleeve 76 to lock shaft 174 to sleeve 76 in a way that prevents relative rotation. Other arrangements for preventing relative rotation of shaft 174 and sleeve 76 are also considered, such as integral key / slot arrangements, etc. Passive linkage 26 operatively interconnects tool support 18 and handheld portion 16 independently of actuators 21, 22, 23. During actuation of one or more of actuators 21, 22, 23, the effective length EL of passive linkage is passively adjustable along constraint axis CA. Sleeve 76, shaft 174, and key 176 represent one linkage combination for passive linkage 26. Other sizes, shapes, and numbers of links connected in any suitable manner can be used for passive linkage 26.

[0160] In the configuration shown, the passive linkage joint 156 is pivotable relative to the tool support 18 about two pivot axes PA. Other configurations are also possible.

[0161] Furthermore, in the form shown, the first active joint 92 and the passive linkage joint 156 define the pivot axis PA arranged on the common plane CP (see...). Figure 9 and 11 Non-parallel pivot axes PA, parallel pivot axes PA arranged in different planes, combinations thereof and / or other configurations are also considered.

[0162] In some forms, the head 84 of the tool support 18 is arranged such that when the tool 20 is attached to the tool support 18, the tool 20 lies on a tool plane TP (e.g., insert plane) parallel to the common plane CP (see [link to relevant documentation]). Figure 9 and 11 In some examples, the tool plane TP is spaced 2.0 inches or less, 1.0 inch or less, 0.8 inches or less, or 0.5 inches or less from the common plane CP.

[0163] refer to Figure 10 , 14 In configurations 21, 22, and 23, the constraint axis CA and the third active axis AA3 can be positioned coplanar along the vertical center plane VCP throughout the entire actuation period. Other configurations are also envisioned, including those in which the constraint axis CA and the third active axis AA3 are not coplanar.

[0164] In the illustrated configuration, actuators 21, 22, and 23 are arranged such that in all positions of actuators 21, 22, and 23 (including in their initial positions), the actuating axes AA1, AA2, and AA3 are in an inclined configuration relative to the constraint axis CA. Inclining axes AA1, AA2, and AA3 generally results in a gradually tapering actuator arrangement, allowing for a thinner and more compact base 74 and associated grip 72. Other configurations are conceivable, including those in which the actuating axes AA1, AA2, and AA3 are not in an inclined configuration relative to the constraint axis CA. Such configurations may include those in which the actuator axes AA1, AA2, and AA3 are parallel to each other in their initial positions.

[0165] Other configurations of the actuator, movable joint, and constraint assembly are possible. In some forms, the constraint assembly may be absent, and the tool support 18 of the instrument 14 may be moved in additional degrees of freedom relative to the handheld portion 16. Furthermore, as described above, the actuator assembly described below may be used.

[0166] Virtual Boundary

[0167] The software used by the control system 60 to control the operation of the device 14 includes a boundary generator 182 (see...). Figure 7 Boundary generator 182 may be implemented on instrument controller 28, navigation controller 36, and / or other components (e.g., on a separate controller). Boundary generator 182 may also be part of a separate system operated remotely from instrument 14. (See reference) Figure 22 Boundary generator 182 is a software program or module that generates one or more virtual boundaries 184 for the movement and / or manipulation of restraint instrument 14. In some examples, boundary generator 182 provides virtual boundaries 184 that define virtual cutting guides (e.g., virtual saw cutting guides). Virtual boundaries 184 can also be provided to depict various operating / control areas as described below. Virtual boundaries 184 can be one-dimensional (1D), two-dimensional (2D), or three-dimensional (3D) and can include points, lines, axes, trajectories, planes (infinite planes or plane segments defined by anatomical structures or other boundaries), volumes, or other shapes, including complex geometries. Virtual boundaries 184 can be represented by pixels, point clouds, voxels, triangular meshes, other 2D or 3D models, combinations thereof, etc. U.S. Patent Publication No. 2018 / 0333207 and U.S. Patent No. 8,898,043 are incorporated herein by reference, and any features thereof can be used to facilitate the planning or execution of surgical procedures.

[0168] The virtual boundary 184 can be used in various ways. For example, the control system 60 can: control certain movements of the tool 20 to remain within the boundary; control certain movements of the tool 20 to remain outside the boundary; control certain movements of the tool 20 to remain on the boundary (e.g., remain on a point, trajectory, and / or plane); control certain movements of the tool 20 to approach the boundary (attract the boundary) or repel the boundary (repel the boundary); and / or control certain operations / functions of the tool 14 based on its relationship to the boundary (e.g., space, speed, etc.). Other uses for the boundary 184 are also envisioned.

[0169] In some examples, one of the virtual boundaries 184 is the desired cutting plane, such as Figure 22 As shown. In some forms, the control system 60 is fundamentally used to hold the cutter 20 on the desired cutting plane. The virtual boundary 184 controlling the positioning of the cutter 20 can also be a volume boundary, for example, the thickness of which is slightly greater than the thickness of the blade to constrain the saw blade to remain within the boundary and on the desired cutting plane, such as... Figure 2 As shown in the diagram. Therefore, the desired cutting plane can be defined by a virtual plane boundary, a virtual volume boundary, or other forms of virtual boundary. Virtual boundary 184 can also be referred to as a virtual object. Virtual boundary 184 can be defined relative to an anatomical model AM, such as a 3D skeletal model (see...). Figure 22 The illustration shows the anatomical model AM virtually overlaid on the real femur F due to their registration. In other words, points, lines, axes, trajectories, planes, volumes, etc., associated with the virtual boundary 184 can be defined in a coordinate system fixed relative to the coordinate system of the anatomical model AM, so that the tracking of the anatomical model AM (e.g., by tracking the associated anatomical structures to which it is registered) can also achieve the tracking of the virtual boundary 184.

[0170] The anatomical model AM is registered to the first patient tracker 54, such that a virtual boundary 184 is associated with the anatomical model AM and its associated coordinate system. The virtual boundary 184 can be implant-specific, defined, for example, based on the size, shape, volume, etc., of the implant, and / or patient-specific, defined, for example, based on the patient's anatomy. The virtual boundary 184 can be a boundary created preoperatively, intraoperatively, or in combination thereof. In other words, the virtual boundary 184 can be defined before the start of surgery, during the surgical procedure (including during tissue removal), or in combination thereof. The virtual boundaries 184 can be provided in various ways, such as by creating them via the control system 60, receiving them from other sources / systems, etc. The virtual boundary 184 can be stored in memory for retrieval and / or updating.

[0171] In some cases, such as when preparing the femoral F to receive a total knee implant IM (see...), Figure 1When the virtual boundary 184 is used, it includes multiple planar boundaries that can be used to depict multiple cutting planes (e.g., five cutting planes) for the total knee implant IM and are associated with a 3D model of the distal end of the femur F. These multiple virtual boundaries 184 can be activated one at a time by the control system 60 to constrain the cutting to a plane one at a time.

[0172] The instrument controller 28 and / or navigation controller 36 track the state of the tool 20 relative to the virtual boundary 184. In one example, the state of the TCP coordinate system (e.g., the orientation of the saw blade) relative to the virtual boundary 184 is measured for the purpose of determining the target positions of actuators 21, 22, 23, so that the tool 20 remains in the desired state. In some cases, the control system 60 controls / positions the instrument 14 to simulate how the physical head responds in the presence of physical boundaries / obstacles.

[0173] Return to reference Figure 7 Two additional software programs or modules run on the instrument controller 28 and / or the navigation controller 36. One software module performs behavior control 186. Behavior control 186 is the process of calculating data instructing the next commanded / desired position and / or orientation (e.g., desired posture) of the tool 20. In some cases, only the desired position of the TCP is output from behavior control 186, while in other cases, the commanded posture of the tool 20 is output. The output from the boundary generator 182 (e.g., the current position and / or orientation of a virtual boundary 184 in one or more coordinate systems) can be fed as input into behavior control 186 to determine the next commanded position of actuators 21, 22, 23 and / or the orientation of the tool 20. Behavior control 186 can process this input along with one or more other inputs further described below to determine the commanded posture.

[0174] The instrument controller 28 can control one or more actuators 21, 22, 23 to adjust the tool 20 toward a desired orientation by sending command signals to each actuator 21, 22, 23. The instrument controller 28 knows that the actuators 21, 22, 23 can adjust the entire length of the tool support 18 relative to the handheld portion 16. In some examples, the instrument controller 28 knows the entire adjustable length of the actuators 21, 22, 23 and can send command signals to the actuators 21, 22, 23 to move them a measured distance from one position to another. The measured position can be a known position or the distance between the current position of the actuators 21, 22, 23 and the actuator limits. Each position that the actuators 21, 22, 23 move to can be a measured distance from the positive and negative limits of the actuator's travel (i.e., the position between the two ends of the lead screw). The instrument controller 28 can command the actuators 21, 22, 23 to reach and leave the measured position, as described below.

[0175] The instrument controller 28 can send command signals to each actuator 21, 22, 23 to move the actuators 21, 22, 23 from a first position to a commanded position that places the cutter 20 in a desired orientation. In some examples, this commanded position can be determined by the instrument controller 28 in conjunction with the navigation system 32 to determine the position of the cutter 20 and cutter support 18 relative to the handheld portion 16, patient trackers PT, 54, 56, virtual objects (e.g., desired cutting planes), or combinations thereof, and to send signals to the actuators 21, 22, 23 to adjust a specific distance or commanded position to place the cutter 20 in the desired orientation. The instrument controller can command the actuators 21, 22, 23 to a position to achieve the desired adjustment of the cutter 20. The instrument controller 28 can control the actuators 21, 22, 23 to move linearly a calculated distance to adjust the cutter 20 toward the desired orientation. In other examples, such as when using an absolute encoder, the instrument controller may send signals to actuators 21, 22, 23 based on the known position of the tool support 18 relative to the handpiece determined by the absolute encoder, to place each actuator 21, 22, 23 into a commanded position. The previous commanded position may be a position to which the actuators 21, 22, 23 were adjusted before their current position. In some examples, the previous commanded position may be a position to which the actuators 21, 22, 23 were commanded in order to adjust the tool 20 toward a desired orientation.

[0176] In some examples, when one or more of actuators 21, 22, 23 have reached their limits, the instrument controller 28 may instruct the handpiece 16 to adjust in order to bring the tool 20 back within the range where the actuators can adjust the tool 20 toward the desired orientation. In this case, a simulated command position can be used to instruct the user how to move the handpiece 16 to bring the tool 20 and actuators 21, 22, 23 back to alignment with the desired orientation. The simulated command position can be a position determined by the instrument controller 28 in conjunction with navigation data from the navigation system 32, where the handpiece 16 must be moved to adjust the tool 20 toward the desired orientation without adjusting actuators 21, 22, 23. This simulated command position works in conjunction with the guide array 200, indicators 201, 202, 203, or both, to signal to the user that the handpiece 16 needs to be moved in a specific manner to place the tool 20 in the desired orientation. In some examples, the guide array 200, indicators 201, 202, 203 or both signal the user to move the handheld portion 16 in the same way that the actuators 21, 22, 23 adjust the tool 20, except that the user corrects the orientation of the tool 20 by manipulating the handheld portion 16 while the actuators are in place.

[0177] The second software module executes motion control 188. One aspect of motion control 188 is the control of the instrument 14. Motion control 188 receives data from behavior control 186 defining the next command posture. Based on this data, motion control 188 determines the next rotor position (e.g., by inverse kinematics) of the rotor 148 of each actuator 21, 22, 23 such that instrument 14 can position the tool 20 as commanded by behavior control 186, for example, in the command posture. In other words, motion control 188 processes the command posture, which can be defined in Cartesian space, into actuator positions (e.g., rotor positions) of instrument 14, such that instrument controller 28 can accordingly command motors 142 to move actuators 21, 22, 23 of instrument 14 to the command positions, for example, the command rotor positions corresponding to the command posture of tool 20. In one form, motion control 188 adjusts the rotor position of each motor 142 and continuously adjusts the torque output of each motor 142 to ensure, as far as possible, that motors 142 drive the associated actuators 21, 22, 23 to the command rotor positions.

[0178] In some configurations, for each actuator 21, 22, 23, the instrument controller 28 determines the difference between the measured position and the commanded position of the rotor 148. The instrument controller 28 outputs a target current (proportional to the rotor torque) and changes the voltage to adjust the current at the actuator from the initial current to the target current. The target current causes movement of the actuators 21, 22, 23, moving the tool 20 from the measured position to the commanded position. This may occur after the commanded position has been converted to the joint position. In one example, the measured position of each rotor 148 may be derived from the aforementioned sensor S, such as an encoder.

[0179] Boundary generator 182, behavior control 186, and motion control 188 may be subsets of the software program. Alternatively, each may be a separate and / or independently operating software program in any combination thereof. The term "software program" is used herein to describe computer-executable instructions configured to perform the various capabilities described in the technical solutions. For simplicity, the term "software program" is intended to include at least any one or more of boundary generator 182, behavior control 186, and / or motion control 188. The software program may be implemented on instrument controller 28, navigation controller 36, or any combination thereof, or may be implemented by control system 60 in any suitable manner.

[0180] A clinical application 190 can be provided to handle user interactions. The clinical application 190 handles many aspects of the user interaction and coordinates the surgical workflow, including preoperative planning, implant placement, registration, bone preparation visualization, and postoperative assessment of implant fit. The clinical application 190 is configured to output to a display 38. The clinical application 190 can run on its own separate processor or can run in conjunction with the instrument controller 28 and / or the navigation controller 36. In one example, after the user has set the implant placement, the clinical application 190 interfaces with a boundary generator 182 and then sends the virtual boundary 184 returned by the boundary generator 182 to the instrument controller 28 for execution.

[0181] Return to position

[0182] Before processing anatomical structures (e.g., before cutting the femur F and / or tibia T), and during certain operating modes described below, a homing procedure may be performed, which establishes the initial position of the cutter 20 by placing each actuator 21, 22, 23 in its respective initial position. This procedure is used to provide a reference position from which incremental movement of the rotor 148, measured by the sensor S, is counted, enabling the control system 60 to determine the current position of the rotor 148. In some forms, homing may no longer be necessary when the sensor S is able to measure the absolute position of the rotor 148. In practice, the homing procedure creates the initial rotor position (zero position) of the actuators 21, 22, 23. The initial position is, in effect, the rotor 148 position that provides the maximum possible amount of travel in each direction along the active axes AA1, AA2, AA3. In some examples, the initial position is positioned such that the initial point HP of the lead screw 150 (centered between the stops 152) is centered in the associated carrier 116 (see [reference]). Figure 16 The diagram shows two actuators 22 and 23 in their initial positions. Even without a homing procedure, such as when using an absolute encoder, it is possible to set actuators 21, 22, and 23 to their initial point HP before or after performing other modes (e.g., proximity mode, described further below). The instrument controller 28 can be configured to control actuators 21, 22, and 23 to their initial positions between the minimum and maximum values ​​of the effective length EL of actuators 21, 22, and 23.

[0183] When in their initial positions, the adjustability of actuators 21, 22, and 23 is maximized to hold tool 20 in the desired orientation. Depending on the specific geometry and configuration of instrument 14, various levels of adjustment are possible. In some examples, with all actuators 21, 22, and 23 in their initial positions, assuming zero change in pitch orientation and no z-axis translation, the pitch orientation of tool 20 can be adjusted relative to the initial position by + / -18°. In some examples, with all actuators 21, 22, and 23 in their initial positions, assuming zero change in pitch orientation and no z-axis translation, the pitch orientation of tool 20 can be adjusted relative to the initial position by + / -33°. In some examples, with all actuators 21, 22, and 23 in their initial positions, assuming zero change in both pitch and pitch orientation, the z-axis translation of tool 20 can be adjusted relative to the initial position by + / -0.37°. Of course, during operation, the tool 20 can be adjusted simultaneously, sequentially, or in combination in terms of pitch, yaw, and z-axis translation.

[0184] The homing procedure for each actuator 21, 22, 23 can be performed sequentially, simultaneously, or in any desired order. In some cases, during the homing procedure, the instrument controller 28 actuates each motor 142. The motor 142 is actuated to rotate its associated lead screw 150, resulting in relative axial displacement between the lead screw 150 and the associated carrier 116 along the associated active axes AA1, AA2, AA3 in each axial direction until the stop 152 engages with the carrier 116. This contact can be determined by an additional sensor S, by monitoring the current of the motor 142 (e.g., a current spike exceeding a threshold indicates that the stop 152 has been reached), etc. For example, the motor 142 can actuate the lead screw 150 until one of the stops 152 engages the carrier 116, at which point an accumulated count and associated end rotor position are stored. Alternatively, the counter storing the accumulated count representing the rotor position can be set to zero upon reaching the first stop 152, but this is not necessary. The motor 142 can then actuate the lead screw 150 in the opposite direction until another stop 152 engages the carrier 116. During this time period, the instrument controller 28 monitors signals from the sensor S to count the number of revolutions of the rotor 148 until the other end rotor position is reached. The instrument controller 28 maintains a counter that represents the total number of degrees of rotation of the lead screw 150 (e.g., its shaft) between the stops 152. The initial position is the average of these counts or the average rotor position between the stops 152.

[0185] In some examples, the instrument controller 28 stores as a cumulative count of the rotations of rotor 148 required to shift lead screw 150 between various end rotor positions (e.g., between travel limits). The absolute difference between these two counts is calculated. This difference is divided by two. This value represents the number of counts that rotor 148 must cycle through from its current position to center the initial point HP in carrier 116 to the initial position. For example, in this process, the instrument controller 28 might receive an instruction: at one end rotor position, the count is 2500; at another end rotor position, the count is -1480. The difference between these counts is 3980. Half of this difference is 1990. Therefore, the average count value between the end rotor positions can be calculated as -1480 + 1990 = 510. This number is called the target position. During homing, this target position is either a positive or negative number equal to the cumulative count representing the initial position. The instrument controller 28 then applies an excitation signal to the motor 142 so that the rotor 148 rotates toward the count representing the initial position.

[0186] During the rotation of rotor 148 caused by this, the changing value of sensor S results in a count output, which alters the count value stored in the counter. During this step, instrument controller 28 compares the accumulated count stored in the counter with the count represented by the initial position. When the two values ​​are equal, instrument controller 28 terminates the application of an excitation signal to motor 142. Instrument controller 28 can also set the counter to zero at the initial position. It should be understood that this rotation of rotor 148 and (by extension) lead screw 150 causes lead screw 150 to shift relative to carrier 116 along the active axes AA1, AA2, AA3 to its initial position. Once actuators 21, 22, 23 are in their initial positions, a soft stop can be enabled to prevent stop 152 (e.g., a hard stop) from contacting carrier 116 at the limit end of travel. The soft stop can be a software-enabled stop set just below the count value measured at the limit end of travel in the homing procedure. The soft stop can be a value pre-programmed into the software. The soft stop can be a combination of a count value and a pre-programmed value.

[0187] like Figure 16 As shown, each of actuators 21, 22, and 23 has an effective length EL. The effective length EL at the initial position can be any suitable length. In some examples, the effective length EL at the initial position can be approximately 2.14 inches, and the minimum / maximum effective length EL when engaged with the hard stop 152 can be approximately 1.72 and 2.56 inches, respectively. When using a soft stop, the minimum / maximum effective length EL can be approximately 1.78 and 2.50 inches, respectively. It should be understood that these values ​​are merely examples, and other values ​​are foreseeable.

[0188] In some examples, each incremental count associated with rotation of rotor 148 that causes rotor 148 to shift toward carrier 116 is a positive incremental count, and each incremental count associated with rotation of rotor 148 that causes rotor 148 to shift away from carrier 116 is a negative incremental count. Thus, the instrument controller 28 is able to provide cumulative count data representing rotor position.

[0189] When actuators 21, 22, and 23 are in their initial or other predetermined positions, the initial position of the base coordinate system BCS can be determined based on the known geometric relationship between the tool support coordinate system TCS and the base coordinate system BCS. This relationship changes as actuators 21, 22, and 23 are adjusted, and the associated changes can be determined based on the kinematics of the robot system 10 (e.g., by establishing dynamic transformations between these coordinate systems). Alternatively or additionally, another tracker can be attached and fixed relative to the base coordinate system BCS to directly track the orientation of the base coordinate system BCS relative to the tool support coordinate system TCS. Thus, the robot system 10 knows the position of the tool 20, such as in its initial position, and its orientation relative to the handheld portion 16. Therefore, when the user moves the tool 20 and tracks its orientation using the tool tracker 52, the robot system 10 also tracks the orientation of the handheld portion 16 and its base coordinate system BCS. In some examples, as a result of a previous calibration process, it is assumed that the position of the tool 20 relative to the tool support 18 is known.

[0190] In some forms, this is achieved by first employing a separate tracker fixed to the handheld portion 16 (see...). Figure 60 The initial position is determined by determining the orientation of the handpiece 16 relative to the tool support 18 (e.g., relative to the tool support coordinate system TCS) in a common coordinate system (e.g., the base coordinate system BCS). This spatial relationship between the handpiece 16 and the tool support 18 can also be determined by registration using pointer 57 and known calibration indentations on the handpiece 16 or by other navigation methods. The current rotor position of each of the actuators 21, 22, and 23 can then be derived from this spatial relationship based on the kinematics of the instrument 14. Knowing the current rotor position and measuring the change from the current rotor position using an encoder (and corresponding encoder signals), the instrument controller 28 can then operate each actuator 21, 22, and 23 until they reach their initial positions. The initial positions can be stored in the memory of the instrument controller 28.

[0191] Essentially, the instrument controller 28 uses tracking data obtained by the navigation system 32 from the tracker 52 connected to the tool support 18 and the handheld part 16 on the instrument 14 to determine the position of the actuators 21, 22, 23, so that the incremental encoder can then operate as an absolute encoder.

[0192] Once registration, calibration, and repositioning (if used) are complete, navigation system 32 is able to determine the spatial orientation of the cutter 20 relative to the anatomical structure (e.g., relative to the femur F or other target tissue) and the one or more virtual boundaries 184. Thus, instrument 14 is ready to perform boundary-constrained treatment of the anatomical structure (e.g., instrument 14 is ready to cut a target volume of material from the femur F). Even without using the repositioning procedure as defined above (e.g., an absolute encoder), actuators 21, 22, and 23 can still be set to their initial positions before or after execution, other operating modes (e.g., proximity modes).

[0193] Following the homing process, control is performed based on position and / or orientation data from navigation controller 36 and accumulated count data or other position data from instrument controller 28. Control may also be based on user input, such as from triggers or other input devices, like a foot switch. In some examples, instrument 28 may operate automatically based on the posture of the blade 20 relative to the anatomical structure being treated, as further described below.

[0194] Control of instrument 14 takes into account anatomical structures (e.g., femur F) and the latest position and / or orientation of instrument 14, which are transmitted from navigation controller 36 to instrument controller 28 via a data connection. Using this data, instrument controller 28 determines the location (i.e., position and / or orientation) of virtual boundary 184 in the desired coordinate system. The relative position of tool 20 (e.g., TCP) with respect to virtual boundary 184 is also calculated. Instrument controller 28 updates navigation system 32 (including display 38) with the position and / or orientation of tool 20 relative to the anatomical structure to which tool 20 is to be applied. An indication of the positioning of virtual boundary 184 may also be presented.

[0195] The relative positioning of the cutter 20 with the virtual boundary 184 is evaluated by the instrument controller 28 to determine whether action needs to be taken, such as moving the cutter 20, changing the speed of the cutter 20 (e.g., oscillation speed), or stopping the operation of the cutter 20. For example, instruction packets are sent to motor controllers, such as from the console 33 or other components of the instrument controller 28. These instruction packets include the target position of the rotor 148 of the motor 142 (or the target position of the actuator). Here, each target position can be a positive or negative number representing a target cumulative count of the associated rotor 148. The console 33 or other components of the instrument controller 28 generate these instruction packets at a rate of one packet every 0.05 to 4 milliseconds and send them to each motor controller. In some examples, each motor controller receives instruction packets at least once every 0.125 milliseconds. The instrument controller 28 can also selectively adjust the cutting speed of the instrument 14 based on the relative positioning of the cutter 20 with one or more of the virtual boundaries 184. For example, the drive motor M that controls the oscillation of the tool 20 and the corresponding cutting can be disabled by the instrument controller 28 at any time when the tool 20 is in an undesirable relationship with the virtual boundary 184 (e.g., the tool 20 deviates from the target plane by more than a threshold).

[0196] During use, when the robot system 10 determines the orientation (current orientation) of the tool 20 using the navigation system 32 by means of the tracker 52 positioned on the tool support 18, the instrument controller 28 can also determine the current position of each of the actuators 21, 22, 23 based on the output encoder signals from the one or more encoders located on each of the actuators 21, 22, 23. Once the current position of each actuator 21, 22, 23 is received, the instrument controller 28 can calculate the current orientation of the handheld part 16 (e.g., the current orientation of the base coordinate system BCS relative to a desired coordinate system, such as the TCP coordinate system), and use positive kinematics to convert the actuator position into an orientation (TCP relative to BCS). Once the instrument controller 28 has the current relative orientation of the tool support 18 and the handheld portion 16 in the desired coordinate system, it can then determine the command orientation of the tool 20 based on the current orientation of the tool 20, as determined by the navigation system 32, the current orientation of the handheld portion 16 calculated from the current position of each of the actuators 21, 22, and 23, and the position and / or orientation of the planned virtual object (as the desired cutting plane). The instrument calculates the orientation of the TCP relative to the BCS (command orientation), which causes the TCP to be positioned on the desired plane or aligned with the planned virtual object. The instrument controller 28 can send command instructions to the actuators 21, 22, and 23 to move to the commanded position, thereby changing the orientation of the tool support 18 and the tool 20. In one example, the command orientation of the tool 20 is further based on the target cutting plane, so the instrument controller 28 calculates the current orientation of the tool support 18 and the current position of the actuators 21, 22, and 23 to determine the current orientation of the handheld portion 16. Once the current orientation of the tool support 18, the current positions of actuators 21, 22, and 23, and the current orientation of the handheld portion 16 are known, the instrument controller 28 can send command signals to actuators 21, 22, and 23 to adjust the tool support 18 and the tool 20 based on the desired planar orientation. The controller calculates the commanded orientation, assuming that the orientation of the handheld portion (BCS) is temporarily (during a single iteration) stationary relative to the patient's anatomy. The actual movement of the BCS is adjusted by updating the corresponding orientation each time.

[0197] Turning Figure 64Exemplary control is described regarding various transformations. TCP is determined by tracking tool 20 with tracker 52 in the LCLZ (LCLZ-TT) and by determining the transformation between the TCP of tool tracker 52 and tool 20 (e.g., a saw) using registration data (TT-TCP). Similarly, a patient tracker PT (shown as 54) in the LCLZ (LCLZ-PT) tracks the patient. A transformation (PT-TP) is determined between the patient tracker PT and each planned virtual object 184 (TP) using registration data and planning information. As described above, the transformation between BCS and TCP (BCS-TCP) is calculated based on the current position of each actuator (as described above). The transformation between BCS and TCP is used to correlate various coordinate systems back to the handheld part 16, as the command pose can be determined relative to the BCS. Conceptually, the command pose is an update of the BCS-TCP transformation, which in this example results in the TCP being aligned with the planned virtual object 184 (target plane TP).

[0198] Throughout this specification, unless otherwise stated, any instance of a pose can be a command pose, a current pose, a past pose, or a past command pose. While each of these poses may differ from one another, the differences in position and / or orientation between these poses can be minimized in each control iteration due to the control frequency.

[0199] It should be understood that the combination of an object's position and orientation is referred to as the object's pose. Throughout this disclosure, it is foreseeable that the term pose can be replaced by position and / or orientation, and vice versa, as suitable alternatives for realizing the concepts described herein. In other words, any use of the term pose can be replaced by position, and any use of the term position can be replaced by pose.

[0200] Visual guidance

[0201] like Figure 22 As shown, the guide array 200 can be coupled to the tool support 18. Alternatively or additionally, the guide array 200 can be attached to the handheld portion 16, such as... Figure 65 As shown, or other parts of the device 14. In the illustrated form, the guide array 200 includes at least a first visual indicator 201, a second visual indicator 202, and a third visual indicator 203. Each of the visual indicators 201, 202, and 203 includes one or more illumination sources coupled to the device controller 28. In some forms, the illumination sources include one or more light-emitting diodes (e.g., RGB LEDs) that can operate in different states, such as on, off, flashing / blinking at different frequencies, illuminating with different intensities, different colors, combinations thereof, etc. Figure 22In the form shown, each visual indicator 201, 202, 203 includes an upper portion and a lower portion 204, 206 (upper segment 204; lower segment 206). It is further envisioned that each of the visual indicators 201, 202, 203 can be divided into more than two portions 204, 206, such as three or more, four or more, or even ten or more portions. For example, each of the visual indicators 201, 202, 203 can be divided into three portions, each including one or more LEDs. The visual indicators 201, 202, 203 can have a generally spherical shape, wherein the upper and lower portions 204, 206 include hemispherical, transparent, or translucent domes that can be individually controlled / illuminated as needed. It is envisioned that the visual indicators 201, 202, 203 can have shapes other than spherical, such as cylindrical, annular, square, polygonal, or any other shape capable of conveying visual cues to the user. One or more light-emitting diodes may be associated with each dome. The visual indicators 201, 202, and 203 can be fixed to the tool support 18 or the handheld part 16 via one or more mounting brackets 205.

[0202] In some examples where a guide array is not used, visual indicators 201, 202, 203 may include separate portions of the display screen (see [link to documentation]). Figure 66 ), for example, a separate area on the LCD or LED display mounted to the tool support 18 or the handheld part 16 (e.g. Figure 66 The display screen can also be included as part of the navigation system, as a supplement to or replacement for a display screen that is mounted on the device.

[0203] In some configurations, there may be one, two, three, or four sections of the display screen, each corresponding to a different visual indicator. Each section of the display screen may correspond to a different visual graphic. As described below, each visual indicator (or section of the display screen) may be based on actuator information. In some cases, a single visual indicator may be based on actuator information from two or more actuators. Furthermore, as described throughout, the visual indicator can be used in a first mode to indicate where the user should position the tool and in a second mode to indicate where the user should position the handheld component.

[0204] For example, visual indicators 201, 202, and 203 can be configured to output a first indication (first visual graphic) based on a first command position of the first actuators 21, 22, and 23, and a second indication (second visual graphic) based on a second command position of the first actuators 21, 22, and 23, wherein the first indication differs from the second indication, and the first command position differs from the second command position. As described above, visual indicators 201, 202, and 203 can be controlled based on any suitable type of actuator information. In other words, the visual graphic displayed on the screen can be based on the command position, previous command position, simulated command position, current measurement position, previous measurement position, available travel distance, actuator limits (e.g., hard or soft stop), the distance required from the current position to the command position, or a combination thereof.

[0205] In some configurations, the instrument controller 28 is configured to control the illumination of the upper and lower parts 204, 206 such that the upper and lower parts 204, 206 operate in different states to indicate the desired direction of movement of the tool 20. Further envisioning, the instrument controller 28 may be configured to control the illumination of multiple parts in different states or using different indications. For example, different states may instruct the user: (1) how the user should move the handheld part 16 to position the tool 20 (e.g., a saw blade) in a desired posture (e.g., on a desired cutting plane); or (2) how the user should move the handheld part 16 to move the actuators 21, 22, 23 in a preferred direction (e.g., closer to their initial positions), while the control system 60 simultaneously operates to hold the tool 20 in the desired posture, as will be further described below.

[0206] During certain operating modes, the instrument controller 28 is configured to automatically control / adjust the guide array 200 (e.g., change its state) to visually indicate to the user desired changes in pitch orientation, yaw orientation, and z-axis translation, so as to achieve the desired orientation of the tool 20 while the user moves the tool 20 via the handheld portion 16. In some forms, the guide array 200 is coupled to the tool support 18 or the handheld portion 16 in a manner that visually represents the plane of the tool 20. For example, since three points define a plane, the three visual indicators 201, 202, and 203 can approximately represent the plane of the tool 20. In some cases, each of the indicators 201, 202, and 203 corresponds to one of the points P1, P2, and P3 with a known position relative to the plane of the tool 20 (e.g., located in the tool plane and defined in the TCP coordinate system, the tool support coordinate system TCS, or any other suitable coordinate system). In some forms, the indicators 201, 202, and 203 correspond to points P4, P5, and P6 of the tool 20, respectively, as... Figures 23A-23DAs shown. The points associated with the visual indicators 201, 202, and 203 can be defined at other suitable locations in the plane of the tool 20 or at locations with a known relationship to the plane of the tool 20.

[0207] In summary, the guide array 200, using one or more visual indicators 201, 202, 203, can be positioned and its state controlled to visually indicate to the user the desired changes in movement (e.g., travel amount) for altering the pitch, yaw, and translation of the tool 20, and (by extension) visually indicate to the user the desired changes in pitch, yaw, and translation of the tool support coordinate system (TCS) to achieve the desired orientation. More specifically, the instrument controller 28 is configured to illuminate the guide array 200 in a manner that allows the user to distinguish between desired changes in pitch orientation, desired changes in yaw orientation, and desired changes in translation. The instrument controller 28 can be configured to illuminate the guide array 200 or a control display screen in a manner that allows the user to indicate the travel amount required to move the tool 20 to the desired plane. The desired plane can be a plane or a segment of a plane. For example, the changes in pitch, yaw, and translation are relative to one or more virtual boundaries.

[0208] In another configuration, the guide array 200, using one or more visual indicators 201, 202, 203, can be positioned and its state controlled to visually indicate to the user desired changes in movement (e.g., travel amount) for altering the pitch, yaw, and translation of the handheld portion 16, and (by extension) visually indicate to the user desired changes in pitch, yaw, and translation of the base coordinate system (BCS) to achieve the desired posture. More specifically, the instrument controller 28 is configured to illuminate the guide array 200 or the display screen in a manner that allows the user to distinguish between desired changes in pitch orientation, desired changes in yaw orientation, and desired changes in translation. The instrument controller 28 is configured to illuminate the guide array 200 in a manner that allows the user to indicate the travel amount required to move the handheld portion 16 to position the tool 20 on the desired plane. For example, the changes in pitch, yaw, and translation are relative to one or more virtual boundaries in virtual boundaries 184.

[0209] Based on the activation of an input signal, such as an input device (e.g., a foot switch, trigger, etc.), the instrument controller 28 can switch the operation of the guide array 200 and / or visual indicators 201, 202, 203 (or display screen) from a mode in which the guide array / visual indicators indicate a desired change in the movement of the cutter 20 to a mode indicating a desired change in the movement of the handheld portion 16. Alternatively, the instrument controller 28 can be configured to switch between these modes based on the position of the cutter 20 in a known coordinate system and the position of a reference location of the bone, such as trackers 54, 56, PT. The reference location can be a point, surface, or volume in that coordinate system used to position the instrument 14 relative to a target object. For example, the reference location can be a surface of bone, a point within bone, an imaginary or virtual point in a known coordinate system, a volume in the coordinate system, or a combination thereof. The position and / or orientation of the reference location relative to the patient tracker is known through registration and appropriate planning steps.

[0210] As described below, the instrument controller 28 can switch modes based on distance parameters. Distance parameters can be distance (e.g., how far apart two objects are), magnitude (distance relative to the direction of an object), or both. In some examples, the instrument controller 28 can switch modes when the distance parameter has a magnitude greater than a first threshold and is directed away from the bone. It should be understood that in a first mode, the instrument controller 28 automatically controls each of the actuators 21, 22, 23 to hold the cutter 20 in a posture relative to the handheld portion 16, and in a second mode, the controller automatically controls each of the actuators 21, 22, 23 such that the cutter 20 actively moves towards the desired plane relative to the handheld portion 16. Automatic switching between modes can provide the user with a guidance type appropriately determined by the proximity to the bone and the cut to be made. In other words, when the instrument 14 is close to the bone, the guide array 200 and / or visual indicators 201, 202, 203 operate to provide precise guidance to ensure that the handheld portion 16 remains positioned in a posture that maximizes the range of motion relative to the desired plane.

[0211] exist Figures 23A-23D In the illustrated configuration, the first and second visual indicators 201 and 202 are located in front of the handheld portion 16 and on opposite sides of the device 14, respectively, and are substantially aligned with actuators 21 and 22. The third visual indicator 203 is located behind the handheld portion 16, substantially aligned with actuator 23, and near the rear of the device 14, i.e., the first and second visual indicators 201 and 202 are located distal to the third visual indicator 203. Figure 2As shown, when viewed from above and in the initial position, the first and second visual indicators 201, 202 are located in front of the y-axis of the tool support coordinate system TCS and the base coordinate system BCS, and on opposite sides of the x-axis of the tool support coordinate system TCS and the base coordinate system BCS. When viewed from above and in the initial position, the third visual indicator 203 is located behind the y-axis and aligned with the x-axis. In some examples, when in the initial position, the tool support 18 defines a vertical center plane VCP passing through the x-axis, wherein the first and second visual indicators 201, 202 are offset from the vertical center plane VCP on opposite sides of the vertical center plane VCP, and the vertical center plane VCP passes through the third visual indicator 203 (see [link to documentation]). Figure 11 Other arrangements of visual indicators 201, 202, and 203 were envisioned.

[0212] In some examples, a reference is returned. Figures 23A-23D The upper and lower parts 204, 206 can be vertically oriented on the direction axis DA parallel to the z-axis of the tool support coordinate system TCS, and different states (e.g., color, frequency, intensity, etc.) can be displayed in each of the upper and lower parts 204, 206 to indicate the desired upward / downward direction of movement of each visual indicator 201, 202, 203. As a result of this arrangement, for example, when all visual indicators 201, 202, 203 are controlled to indicate a desired downward movement, this instructs the user to move their hand downward (see...). Figure 23A (The arrow in the diagram). The instrument controller 28 can control the illumination of the upper part 204 to operate the upper part 204 in a first state and the lower part 206 in a second state different from the first state, to indicate to the user a change in the translational position of the tool 20 and / or the handheld part 16 relative to the virtual boundary 184. In the example shown, the downward direction can be visually indicated by illuminating the upper part 204 in red while the lower part 206 is illuminated in yellow (e.g., yellow above red indicating the downward direction).

[0213] The instrument controller 28 can also be configured to control the illumination of the upper portion 204 of the first visual indicator 201 to operate in a first state and to control the illumination of the upper portion 204 of the second visual indicator 202 to operate in a second state different from the first state, thereby instructing the user to change the yaw orientation of the tool 20. Similarly, the instrument controller 28 can be configured to control the illumination of the upper portion 204 of the third visual indicator 203 to operate in a first state and to control the illumination of the upper portions 204 of the first and second visual indicators 201 and 202 to operate in a second state different from the first state, thereby instructing the user to change the pitch orientation of the tool 20 relative to the virtual boundary 184. For example, as... Figure 23BAs shown, when only slight downward movement and pitch orientation changes are required (see arrows), the first and second visual indicators 201 and 202 can be illuminated to show that they still need to move slightly downward. However, the third visual indicator 203 can be illuminated differently to show that the rear of the device 14 needs to move further downward than the front (i.e., a change in pitch is required). In the example shown, a slightly downward direction can be visually indicated by illuminating the upper portion 204 of the first and second visual indicators 201 and 202 in yellow and the lower portion 206 in green (e.g., yellow above green indicates a slightly downward direction). Meanwhile, the third visual indicator 203 can be illuminated as follows... Figure 23A The device is kept illuminated (e.g., red above yellow) to indicate the need for further downward movement at the rear, and thus visually and intuitively instructs the user that the device 14 will be repositioned in the pitch direction.

[0214] like Figure 23C As shown, the instrument controller 28 can be configured to control the illumination of the upper and lower portions 204, 206 of the first and second visual indicators 201, 202, such that the upper and lower portions 204, 206 operate in the same state to indicate that corresponding points (P1, P2 or P4, P5) in or associated with the plane of the tool 20 are in the desired position (e.g., as indicated by illumination pattern of green above green). In other words, the first and second actuators 21, 22 do not require any further actuation to ultimately place the tool 20 on the desired plane. However, as also... Figure 23C As shown, the upper and lower parts 204 and 206 of the third visual indicator 203 are still in different states, indicating that the rear part of the device 14 (and the corresponding point P3 or P6) still needs to be lowered, although less than Figure 23B The required information (as mentioned above, can be indicated by yellow above green). Figure 23D The result is shown when the user makes a slight movement of the rear of the instrument 14 as instructed (in terms of pitch), so that the cutter 20 is in the desired orientation, as indicated by the upper and lower parts 204, 206 of all visual indicators 201, 202, 203 operating in the same state (e.g., green lighting over green).

[0215] As previously described, each visual indicator 201, 202, 203 (or each portion of the display screen) of the guide array 200 can be associated with one or more actuators of actuators 21, 22, 23. In other words, in some configurations, each visual indicator 201, 202, 203 can be paired with a corresponding actuator of actuators 21, 22, 23, such that the state of a particular visual indicator 201, 202, 203 directly reflects the actuator information associated with its corresponding actuator 21, 22, 23. It is also anticipated that each visual indicator 201, 202, 203 can be paired with two or more actuators of actuators 21, 22, 23. In another example, two or more actuators of actuators 21, 22, 23 can be paired with one or more visual indicators 201, 202, 203. In some cases, the state of specific visual indicators 201, 202, 203 can reflect the amount of movement required for one or more actuators 21, 22, 23 to move their corresponding points (e.g., P1, P2, P3 or P4, P5, P6) to a commanded pose (e.g., the desired plane of the tool 20). For example, as Figure 23A The yellow-over-red lighting scheme displayed on all visual indicators 201, 202, 203 indicates that each actuator 21, 22, 23 needs to travel (e.g., retract) a relatively large distance to move its corresponding point to the desired plane, or it may indicate that the desired plane is beyond the reach of actuators 21, 22, 23. More specifically, in some cases, the yellow-over-red lighting scheme indicates that the distance traveled to reach the desired plane may be greater than 60%, 65%, 70%, 75%, 80% or more of the total available travel of the actuators (e.g., measured from the actuator's initial position to its hard or soft limits). Other ranges are also considered. If the lighting scheme is yellow over red, then actuators 21, 22, 23 need to travel a relatively large distance (e.g., extend) in the opposite direction.

[0216] Similarly, such as Figure 23BThe green-over-yellow lighting scheme displayed on the visual indicators 201 and 202 indicates that the associated actuators 21 and 22 need to move (e.g., retract; extend) a relatively smaller distance to move their corresponding points to the desired plane. More specifically, in some cases, the green-over-yellow lighting scheme indicates that the operating range required to reach the desired plane may be within the following ranges of the actuator's total available travel: 30-80%, 30-75%, 30-70%, 30-65%, 30-60%, 40-80%, 40-75%, 40-70%, 40-65%, 40-60%, 50-80%, 50-75%, 50-70%, 50-65%, or 50-60%. Other ranges are also considered. If the lighting scheme is green over yellow, then actuators 21 and 22 need to travel a relatively small distance (e.g., extend) in the opposite direction.

[0217] like Figure 23D The green-over-green lighting scheme displayed on all visual indicators 201, 202, 203 can indicate that the associated actuators 21, 22, 23 need to travel (e.g., retract or extend) a relatively small distance to move their corresponding points to the desired plane, or it can indicate that the corresponding points are already on the desired plane. More specifically, in some cases, the green-over-green lighting scheme indicates that the distance required to reach the desired plane may be within the range of 0-30%, 0-40%, or 0-50% of the total available travel of the actuators, in either direction. Other ranges are also considered. Figure 23E An example scheme of the states of visual indicators 201, 202, and 203 and the thresholds used to determine when the states change are shown. Figure 23E In this context, a positive (+) percentage of travel required from the initial position indicates a need for extension movement, while a negative (-) percentage indicates a need for retraction movement. Other thresholds and associated state changes are also taken into account. For example, thresholds may be based on the actual distance required to travel (e.g., in millimeters or inches) and / or other suitable parameters.

[0218] Each of the visual indicators 201, 202, and 203 includes at least one illumination source, such as a light-emitting diode (LED). Each LED can operate in different states, such as on, off, flashing / blinking at different frequencies, illuminating at different intensities / colors, or combinations thereof. In most examples, the visual indicators 201, 202, and 203 include multiple LEDs, enabling each of the visual indicators 201, 202, and 203 to produce multiple colors of light, such as green, yellow, and red, in each part of the visual indicator. Each color can represent information associated with one or more actuators 21, 22, and 23. The color, frequency, intensity, and / or state of the visual indicators 201, 202, and 203 can be associated with one or more actuator information, such as command position, previous command position, simulated command position, current position, previously measured position, available travel distance, actuator limits (e.g., hard or soft stop), distance required from the current position to the command position, or combinations thereof.

[0219] In one example, the information associated with at least one of the actuators 21, 22, 23 may be the commanded position and available travel amount of the first actuator 21, 22, 23. The visual indicator may be controlled based on the commanded position and available travel amount of the first actuator for moving the tool 20. For example, a first color may be based on a first travel range within the operating range of the actuator and the commanded position of the actuator 21, 22, 23, and a second color may be based on a second travel range within the operating range of the actuator 21, 22, 23 and the commanded position of the actuator 21, 22, 23, the second travel range being different from the first travel range. A third color may also be included, representing a third travel range of the actuators 21, 22, 23 within the available travel amount, the third travel range being different from the second travel range. For example, the first color is red and is associated with the commanded position of actuators 21, 22, and 23 being closest to the outer limit of the available travel distance; the second color is yellow and is associated with the commanded position of actuators 21, 22, and 23 being farther from the outer limit of the available travel distance; and the third color is green, indicating that the commanded position of actuators 21, 22, and 23 is far from each limit of the available travel distance range. In one example, each visual indicator 201, 202, and 203 represents actuators 21, 22, and 23, displaying visual cues (e.g., one or more colors; one or more patterns; one or more intensities) required to move each actuator to the desired position. In another example, the colors associated with each of the visual indicators 201, 202, 203 represent several actuator parameters, such that the visual indicators 201, 202, 203 convey to the user a first color representing the amount of travel required to bring at least one actuator 21, 22, 23 to a commanded position, and a second color representing the direction of movement of the handheld portion 16 required to bring the tool 20 into the operating range of the actuator. As described above, a third color may correspond to the outermost range of available travel (i.e., the minimum remaining available travel relative to the commanded position), a second color may correspond to the middle range of available travel, and a first color may correspond to the innermost range of available travel (i.e., the maximum remaining available travel relative to the commanded position). In some examples, when visual indicators 201, 202, 203 are configured to have an upper portion 204 and a lower portion 206, each of the visual indicators 201, 202, 203 can illuminate both the upper portion 204 and the lower portion 206 in different states to indicate the desired direction of movement of the handheld portion 16. In some forms, the illumination of the upper and lower portions 204, 206 of the visual indicators 201, 202, 203 can operate in the same state based on the commanded position and available travel of the handheld portion 16.

[0220] The guide array 200 and vision indicators 201, 202, and 203 can be configured to visually indicate changes in pitch orientation, yaw orientation, z-axis translation, or combinations thereof based on actuator information in a first mode in which the guide array and / or vision indicators indicate tool placement and in a second mode in which the guide array 200 and / or vision indicators 201, 202, and 203 indicate handheld portion 16 placement. The guide array 200 and vision indicators 201, 202, and 203 can visually indicate the same visual cues based on actuator information in both modes. Alternatively, the guide array 200 and vision indicators 201, 202, and 203 can visually indicate different visual cues based on actuator information in each mode. For example, the vision indicators 201, 202, and 203 can be controlled based on the available travel and command position of one or more of the actuators 21, 22, and 23. In another configuration, each visual indicator 201, 202, 203 may display the position of the corresponding actuator 21, 22, 23 and indicate corrective movements and / or directions to the user to place the handheld part 16 and / or the tool 20 on a plane. Additionally, and / or alternatively, each visual indicator 201, 202, 203 may display the position of the handheld part 16 and indicate corrective movements and / or directions to the user to place the handheld part 16 and / or the tool 20 on a plane. For example, each of the visual indicators 201, 202, 203 may indicate to the user, based on actuator information, changes in pitch orientation, yaw orientation, z-axis translation, or combinations thereof, to adjust the handheld part 16.

[0221] As described above, the guide array 200 and / or visual indicators 201, 202, 203 (e.g., displays) can be used to guide the user to move the handheld portion 16 and / or the tool 20 to a desired orientation (e.g., a target plane). In cases where actuators 21, 22, 23 may not actively move the tool 20 toward the desired orientation—that is, the orientation change of the tool 20 may only be caused by the user moving the handheld portion 16—a virtual simulation can be used to instruct the user on how to move the handheld portion 16 to achieve the desired orientation of the tool 20. This simulation can operate as if the actuators 21, 22, 23 were actively controlled to achieve the desired orientation; therefore, the instrument controller 28 generates simulated command positions (not executed) for each of the actuators 21, 22, 23, which may exceed the available travel of one or more of the actuators 21, 22, 23. In this case, the visual indicators 201, 202, 203 may still emit red light (e.g., out of range or near range limits) to indicate to the user that the handheld portion 16 needs to be moved. In other words, when actuators 21, 22, and 23 need to be operated to positions close to or beyond their limits, this directly instructs the user to move the handheld portion 16; that is, the handheld portion 16 is thus positioned such that actuators 21, 22, and 23 can be operated to place the tool 20 in the desired posture without exceeding its limits. For example, the instrument controller 28 determines the current position of each of actuators 21, 22, and 23 based on output signals from one or more encoders located on each of the actuators 21, 22, and 23. Once the current position of each actuator 21, 22, and 23 is received, the instrument controller 28 can calculate the current posture of the handheld portion 16. Once the instrument controller 28 has the current postures of the tool support 18 and the handheld portion 16, the instrument controller 28 can then determine the command posture of the tool 20, the handheld portion 16, or both, based on the current posture of the tool 20 calculated from the current positions of each actuator 21, 22, and 23. The instrument controller 28 can then send command instructions to the user via visual indicators 201, 202, 203 (in some cases by using guide array 200), which are also related to how the user will move the handheld part 16 (i.e., move the entire instrument 14 toward the target plane).

[0222] It should be understood that the guide arrays and / or visual indicators 201, 202, 203 described throughout can be used with any actuator configuration of any surgical tool and instrument 14. For example, guide array 200, visual indicators 201, 202, 203, or both can be used with configurations further described below. Furthermore, guide array 200 and / or visual indicators 201, 202, 203 can be understood to include configurations in which: guide array 200 and / or visual indicators 201, 202, 203 enable robot system 10 to indicate the amount of travel required to move tool 20 and / or handheld portion 16 to a desired posture, trajectory, orientation, position, plane, or combination thereof. Any guide array and / or visual indicator can be used with any configuration of instrument 14 to send signals to the user, in any operating mode described throughout this application, on how to position, move, and / or adjust instrument 14. For example, changes in pitch, yaw, and translation are relative to one or more virtual boundaries. The guide array 200 and / or vision indicators 201, 202, 203 can facilitate the positioning of different types of tools, including, but not limited to, drills or reamers, drivers (for placing screws or pins), drills, pins, guides, etc.

[0223] It should be understood that other types of feedback can be used to help guide the user, such as sound, touch (e.g., vibration), etc. For example, a drive motor M can be used to provide feedback. Other types of visual feedback can also be used, such as using augmented reality technology or projecting light onto anatomical structures.

[0224] operate

[0225] During operation, the robotic system 10 is initially powered on and the software application used to operate the system is activated. Trackers 52, 54, 56, and PT are initialized and placed on instrument 14 and the target anatomical structure (e.g., femoral F and tibial T). As trackers 54 and 56 are mounted to the anatomical structure, the anatomical structure and / or associated images / models are registered to trackers 54 and 56 using known registration techniques. This may require the user to touch certain surfaces or landmarks on the anatomical structure with pointer 57. For example, this may require the user to touch several points on the surface of the anatomical structure while pressing a selection button on pointer 57 or pressing a foot switch on navigation system 32. This “draws” these points on the surface in navigation system 32 to match the preoperative and / or intraoperative images / models of the anatomical structure. The preoperative and / or intraoperative images / models of the anatomical structure are loaded into navigation system 32. The tracked portion of the anatomical structure is registered to the preoperative / intraoperative images / models. By extending this, the robotic system 10 can display a graphical representation of the actual position and orientation of the anatomical structure on the display 38 as the anatomical structure moves.

[0226] During the calibration / registration procedure, the orientation and positioning of tracker 52 are calibrated / registered to tool support 18 by referencing a fixed and known positioning of the calibration indentation CD or other reference points. In some examples, one or more trackers 52 may be located on tool support 18, handheld portion 16, or both, such that the position of tool support 18 and / or handheld portion 16 is tracked by navigation system 32. In examples where tracker 52 is integrated into instrument 14, such calibration is unnecessary since the relative positioning of tracker 52 to tool support 18 is known.

[0227] Virtual objects (e.g., virtual boundaries 184) for controlling the operation of instrument 14 are also defined / obtained. Software running on instrument controller 28 (e.g., boundary generator 182) generates / obtains the initial definitions of the virtual objects. Where necessary, the user may have the ability and options to adjust the properties / placement of the virtual objects.

[0228] like Figure 22 As shown, in one exemplary configuration, the control system 60 defines various regions at predefined distances and / or locations from the target site and / or anatomical structure. These are shown as regions I, II, and III. Each of these regions can be defined in a coordinate system associated with the anatomical structure and / or virtual boundary 184. In some cases, these regions are defined as spheres or other geometric primitives surrounding the target site and / or anatomical structure. In other examples, the regions (and other regions described below) can be defined relative to the instrument 14, the tool support 18, the handheld portion 16, the tool 20, the target site / anatomical structure, or combinations thereof. The control system 60 can control the instrument 14 as the regions defined by the handheld portion 16, the tool support 18, the tool 20, the target site / anatomical structure, or combinations thereof approach a specific virtual boundary / virtual cutting guide feature.

[0229] In some examples, the instrument controller 28 is coupled to a plurality of actuators 21, 22, 23 and visual indicators 201, 202, 203 to control their operation in a variety of modes including: an initial mode in which the instrument controller 28 automatically adjusts each of the plurality of actuators 21, 22, 23 to their initial position; a proximity mode in which the instrument controller 28 instructs the desired movement of the tool 20 to place the tool 20 in a desired orientation (e.g., on a desired trajectory or plane) while the plurality of actuators 21, 22, 23 remain in their initial positions; and an on-target mode in which the tool 20 is approximately in the desired orientation and the instrument controller 28 uses the guide array 200 and its associated visual indicators 201, 202, 203 to instruct the desired movement of the handheld portion 16 to hold the plurality of actuators 21, 22, 23 within a threshold of their initial positions.

[0230] Additionally and / or alternatively, the instrument controller 28 may place the instrument 14 in modes other than homing mode, proximity mode, and aiming mode, and control the visual guidance array, visual indicators 201, 202, 203, actuators 21, 22, 23, or combinations thereof for actuation and adjustment based on multiple inputs.

[0231] In another configuration, the instrument controller 28 can operate in a mode to control the guide array and / or visual indicators based on the attitude of the instrument 14 in a region to indicate the desired movement of the handheld part 16 so as to place the tool 20 in a desired attitude (e.g., on a desired trajectory or plane), while the plurality of actuators 21, 22, 23 remain in a position.

[0232] In another example, the instrument controller 28 can operate in a mode to control the guide array and / or visual indicators based on the attitude of the instrument 14 in a region to indicate the desired movement of the handheld part 16 to place the tool 20 in a desired attitude (e.g., on a desired trajectory or plane), while multiple actuators 21, 22, 23 actively adjust the tool support 18 and the tool 20 relative to the target plane and the handheld part 16.

[0233] In some examples, the instrument controller 28 can operate in a first mode, which automatically controls each of the actuators 21, 22, 23 based on the posture of the instrument 14 to actively move the tool support 18 and the tool 20 relative to the handheld portion 16 toward a desired plane, and automatically switches to a second mode, which, based on the posture of the instrument 14, uses the guide array 200, visual indicators 201, 202, 203, or both to indicate the desired movement of the handheld portion 16 to place the tool 20 in the desired posture, while the multiple actuators 21, 22, 23 are held in one position. Other operating modes are also possible.

[0234] Furthermore, in one example, the controller can be configured to control a vision indicator in a first mode based on actuator information from multiple actuators, for visually indicating changes in the pitch, yaw, and translational positions of the saw blade while the user moves the instrument. The controller is also configured to control the vision indicator in a second mode based on actuator information from multiple actuators, for visually indicating changes in the pitch, yaw, and translational positions of the handheld part while the user moves the instrument. The controller is configured to switch between the first and second modes based on the position of the tool 20 and the reference positioning position or based on input signals received from the input device.

[0235] The robot system 10 can activate an initial mode to place the device 14 in its initial position upon startup, for example, when the robot system 10 is initially powered on, actuators 21, 22, and 23 are placed in their initial positions. Even without completing the fully defined initial mode, actuators 21, 22, and 23 can be set in their respective initial positions before movement.

[0236] like Figure 24A As shown, when the TCP of instrument 14 is located in zone III and outside zone II, the scalpel 20 is spaced apart from the anatomical structure. Zone III can also be referred to as a “remote” or “remote” zone. Thus, the control system 60 may not yet need to guide the user to place the scalpel 20 in the desired position (however, in some forms, guidance may begin in zone III). In zone III, the instrument controller 28 holds instrument 14 in its initial position, for example, the instrument controller 28 holds the target positions of actuators 21, 22, and 23 in their initial positions. Typically, operation of the scalpel 20 is disabled in zone III; for example, the user cannot activate the drive motor M via a trigger, foot switch, or other input device. In some forms, the user may be able to override this disabling function to allow the user to perform certain treatments while in zone III.

[0237] It should be understood that the phrase "the TCP of the instrument" is used interchangeably with the phrase "the position of the saw blade." Therefore, in any case where the TCP of the instrument / tool ​​is used, it can be replaced by the position of the saw blade, and vice versa. Of course, it is also conceivable that the position of the "saw blade" can be replaced by the position of any suitably configured tool, such as a drill bit, drill, pipe, pin, etc.

[0238] In an alternative configuration, based on actuator information, such as the operating range of one or more actuator parameters, the instrument controller 28 can automatically disable input devices, such as foot switches or triggers, when the instrument 14 is in any area.

[0239] refer to Figure 24B The user advances tool 20 from region III to region II (e.g., as indicated by TCP positioning). Region II may also be referred to as the “intermediate” region. In some forms, when the user advances tool 20 from region III to region II, the instrument controller 28 automatically activates a proximity mode. In proximity mode, the instrument controller 28 controls the guide array 200 and its associated visual indicators 201, 202, 203 to guide the user to position tool support 18 and tool 20 in the desired orientation (e.g., desired trajectory, plane, etc.), as previously described. An image may also be presented on the navigation display 38 to indicate the relative positioning of instrument 14 to the desired orientation. Once tool 20 is within a threshold distance of the desired orientation, which can be indicated when all current accumulated count values ​​are within the corresponding threshold count values ​​of each actuator 21, 22, 23, the instrument controller 28 then latches tool 20 into the desired orientation, as... Figure 24C As shown.

[0240] Locking refers to the process where behavior control 186 transmits the desired orientation of tool 20 to motion control 188, which then generates target rotor positions for actuators 21, 22, and 23 to position tool 20 in the desired orientation. In some forms, locking occurs when the available travel amount for each actuator 21, 22, and 23 to position tool 20 in the desired orientation is within a threshold, such as a threshold percentage of available travel amount, a threshold distance of available travel amount, etc. In some cases, these thresholds are the same as those associated with changes in the state of visual indicators 201, 202, and 203. For example, once all visual indicators 201, 202, and 203 show green, the instrument controller 28 locks tool 20 in the desired orientation by activating each actuator 21, 22, and 23 to move as needed, thereby positioning its corresponding points (e.g., P1, P2, P3 or P4, P5, P6) in their desired positions (e.g., on the tool plane). The speed (velocity) and / or acceleration at which actuators 21, 22, and 23 are operated to perform the locking operation can be controlled / limited by the control system 60. In some cases, since the associated force is transmitted to the user's hand through the handheld part 16, a faster acceleration may be desired to provide the user with clear tactile feedback when locking into the desired posture. Because all actuators 21, 22, and 23 operate simultaneously, audible and visual feedback is also provided when actuators 21, 22, and 23 lock into the desired posture.

[0241] In other configurations, the cutter 20 can be moved to a desired posture, and then, while the cutter 20 is held in its desired position, the user can adjust the handheld portion 16 to a more comfortable position within the threshold of the available travel of the actuators 21, 22, and 23 to perform the cut. The user can then select to move to a free-hand mode by activating an input device such as a button and / or foot switch or by making a selection on a touchscreen. In this mode, the posture of the handheld portion 16 is held or frozen in its current spatial relationship relative to the posture of the cutter 20. It is foreseeable that the virtual thresholds of the actuators 21, 22, and 23, which are held relative to the posture of the cutter 20, will prevent the actuators from moving to maintain the held posture once the user selects the free-hand mode. Alternatively, when the free-hand mode is activated, the plurality of actuators 21, 22, and 23 can be reset to their initial positions.

[0242] Once the instrument controller 28 locks the tool 20 into the desired position, the aiming mode is activated, such as... Figures 25A-25CAs shown. Specifically, the instrument controller 28 generates a set of target rotor positions, to which the rotor 148, integrated with the motor 142, must rotate to maintain the tool 20 in the desired posture. In other words, if the user moves the handheld part 16 in a manner that causes the tool 20 to move away from its desired posture, this will be detected by the navigation system 32. In response to this movement, the instrument controller 28 determines, based on data from the navigation system 32, how far the tool 20 has moved from the desired posture, and compensates for this movement as needed by driving actuators 21, 22, 23 to return the tool 20 to the desired posture. It should be understood that such deviations from the desired posture are typically small because the instrument controller 28 operates at a high frequency (e.g., frame rate) to continuously respond to such deviations in essentially real-time.

[0243] The target rotor position is determined based on the relationship between the actuation of actuators 21, 22, and 23 and the resulting movement (e.g., kinematics). For example, if the desired posture described above requires translation relative to the z-axis of the handheld portion 16, the degree to which the tool 20 will move along the z-axis has a first-order relationship with the amount of rotation of each rotor 148 (e.g., how many counts are associated with such z-axis movement). There is also a relationship between the degree to which the tool 20 changes its pitch orientation in response to actuation of the third actuator 23 alone, or in response to a combination of actuation of the former and actuation of one or both of the first and second actuators 21, 22. Finally, the degree to which the tool 20 changes its pitch orientation in response to actuation of one or both of the first and second actuators 21, 22 (with or without actuation of the third actuator 23)...

[0244] The instrument controller 28 can utilize the relationship between the degree of yaw orientation from the navigation system 32. Based on these relationships, the instrument controller 28 determines the target rotor position required for each rotor 148 to maintain the desired orientation of the tool 20. The instrument controller 28 operates the motor 142 based on these target rotor positions. For example, the console 33 can transmit a data packet containing these target rotor positions to the motor controller, and each motor controller can apply an appropriate excitation signal to the associated motor 142. These excitation signals cause the rotor 148 to rotate, which leads to the repositioning of the lead screw 150, which moves the tool support 18 / tool ​​20 as needed to hold the tool 20 in the desired orientation. The tracking data is used to operate the motor 142 based on the positioning of the handheld part 16 relative to the tool support 18, adjusting the actuators 21, 22, 23 to hold the tool 20 in the desired orientation.

[0245] Figure 25B and 25C This indicates that the user is moving the handheld part 16. If the actuators 21, 22, and 23 were not to compensate for this error to keep the tool 20 in the desired position, this movement would cause the tool 20 to move away from the desired position (as shown in the image). Figure 25A (Compared to). The time period (e.g., frame rate) for performing this detection and compensation can be milliseconds or sub-milliseconds, such as 0.5 to 4 milliseconds, or even faster. Faster or slower frame rates are also envisioned. Thus, the robot system 10 responds quickly to the tool 20 moving away from its desired posture, such that the tool 20 deviates only slightly from the desired posture within any given time period.

[0246] In area II, when the handheld part 16 has been moved by the user to a position where the instrument 14 cannot hold the cutter 20 in the desired posture by operating the actuators 21, 22, and 23, such as... Figure 26A As shown, the tool 20 unlocks from the desired position. More specifically, unlocking occurs when one or more of the actuators 21, 22, and 23 exceed their available travel and can no longer be adjusted as needed to remain in the desired position. Upon unlocking, the instrument controller 28 exits the aiming mode. The instrument controller 28 then immediately operates in the initial mode to return the actuators 21, 22, and 23 to their original positions. The return of the actuators 21, 22, and 23 can be considered part of the unlocking process. Therefore, by returning each of the actuators 21, 22, and 23 to their original positions, force is transmitted to the user's hand via the handheld portion 16, providing tactile feedback to the user. Audible and visual feedback is also provided in association with the return of the actuators 21, 22, and 23. Once return is complete, the instrument controller 28 again operates the guide array 200 in proximity mode, as previously described, to guide the user on how to move the handheld portion 16 to place the tool 20 in the desired position. Figure 26B Once the required travel distance of all actuators 21, 22, and 23 is again within the predefined threshold, the instrument controller 28 relocks the tool 20 to the desired posture and re-enters the aiming mode.

[0247] The instrument controller 28 also controls the operation of the guide array 200 in aiming mode, but its function differs slightly from that in proximity mode. In both aiming and proximity modes, the guide array 200 is controlled to control the state of the visual indicators 201, 202, 203 to indicate the user's desired movement of the handheld portion 16 of the instrument 14. As previously described, when the user positions the handheld portion 16 toward the desired plane under the guidance of the visual indicators 201, 202, 203, the actuators 21, 22, 23 are held in their initial or other predetermined positions. By holding the actuators 21, 22, 23 in their initial or other predetermined positions, the user finds it easier to adjust the tool 20 and align it with the desired plane and instrument posture relative to the target. However, in aiming mode, the tool 20 is already roughly in the desired posture, so the visual guidance is not intended to help position the tool 20 in the desired posture, but rather to guide the user on how to move the handheld portion 16 to provide sufficient adjustability to the instrument 14 by keeping the actuators 21, 22, 23 near their initial positions or other predetermined positions. For example, when in aiming mode in Zone II, the user might need to move the handheld portion 16 upwards in the z-axis direction to move all actuators 21, 22, 23 closer to their initial positions while keeping the tool 20 in the desired posture. In other words, the actuators 21, 22, 23 can be almost fully extended. To achieve this, the directional indication from the guide array 200 is upwards. In this case, the guide array 200 is actually guiding the user to move the handheld portion 16 upwards, causing the actuators 21, 22, 23 to operate toward their initial positions to maximize the adjustability of the actuators 21, 22, 23. As the user moves the handheld portion 16 upward, actuators 21, 22, and 23 continue to operate to hold the cutter 20 in the desired posture (e.g., on virtual boundary 184). Thus, actuators 21, 22, and 23 retract, for example, toward their initial positions. Ideally, each actuator 21, 22, and 23 has a maximum travel value available in either direction when the user reaches region I and begins cutting the bone. Otherwise, if one or more of actuators 21, 22, and 23 have nearly reached their available travel in either direction, even slight movement of the handheld portion 16 may cause the instrument controller 28 to fail to hold the cutter 20 in the desired posture, potentially resulting in inaccurate cuts. In some cases, as further described below, when this occurs (e.g., when one or more of actuators 21, 22, and 23 have reached their travel limits or thresholds), the instrument controller 28 may deactivate / disable the drive motor M regardless of whether an input device (e.g., a trigger or foot switch) is actuated.Based on the orientation of the tool 20 in a known coordinate system, the orientation of the handheld portion 16, and the command orientation of the tool 20, the instrument controller 28 can automatically switch the instrument 14 between an operating state where the drive motor M can be actuated (e.g., via an input device) and a disabled state where an input signal sent from the input device prevents the drive motor M from activating. The orientation of the handheld portion 16 can be based on actuator information, such as the measured position of each actuator 21, 22, 23. By controlling the instrument 14 in this way, the instrument controller 28 is configured to automatically switch between modes when the orientation of the tool 20, the orientation of the handheld portion 16, and the command orientation of the tool 20 indicate that the command orientation of the tool 20 exceeds the range achievable by the actuators 21, 22, 23. In other words, when this situation exists, the actuators 21, 22, 23 cannot effectively hold the tool 20 on the desired plane.

[0248] In aiming mode, the visual indicators 201, 202, and 203 collectively indicate the desired movement of the handpiece 16 and the corresponding movement of the actuators 21, 22, and 23 to hold the tool 20 in the desired orientation. For example, when the first visual indicator 201 is activated to indicate that the handpiece 16 needs to be moved, the visual indicators 201, 202, and 203 represent that one or more of the actuators 21, 22, and 23 are too far from their initial positions and the handpiece 16 needs to be moved. As another example, if the tool 20 is in the desired orientation, but all three actuators 21, 22, and 23 are almost completely retracted—that is, they have reached their maximum available travel in one direction—the instrument controller 28 will operate the guide array 200 and / or the display to instruct the user that the handpiece 16 needs to be lowered approximately in the z-axis direction so that all actuators 21, 22, and 23 extend toward their initial positions.

[0249] Alternatively, in some example modes, when the first visual indicator 201 is activated to indicate that the handheld portion 16 needs to be moved, the visual indicator 201 indicates that one or more of the actuators 21, 22, 23 are outside the operating range of each actuator 21, 22, 23 relative to the commanded position and that the handheld portion 16 needs to be moved. As another example, if the tool 20 is in the desired posture, but all three actuators 21, 22, 23 are almost completely retracted, i.e., they have reached the limit of the actuators in one direction or are within a specific range of motion within the total available travel, then the instrument controller 28 will activate the visual indicators 201, 202, 203 to instruct the user that the handheld portion 16 needs to be lowered or raised approximately in the z-axis direction so that all actuators 21, 22, 23 are within their operating range relative to the commanded position.

[0250] In some configurations, when the user moves the instrument 14, the instrument controller 28 can change the operating mode of the instrument 14, actively controlling at least one motion parameter of the cutter 20 relative to the handheld portion 16 using a specific control configuration. The motion parameter can be a controlled variable related to the movement of the cutter support relative to the handheld portion. For example, the motion parameter can be velocity, acceleration, torque, or a combination thereof related to the movement behavior of the cutter support. In some examples, the instrument controller 28 can change the value of the motion parameter related to velocity, acceleration, or both, causing the instrument 14 to adjust the cutter support 18 faster or slower to maintain each desired posture of the instrument 14. Velocity can be related to the rate at which the cutter support adjusts its position in a particular direction. Actuator acceleration can be related to the rate of change of velocity of the cutter support 18 adjusted relative to the handheld portion 16 between positions. This change may depend on: (i) the area where the TCP is located; (ii) the positioning of the instrument 14 (e.g., the TCP) relative to a reference position associated with the skeleton in a known coordinate system; (iii) a distance parameter; (iv) the posture of the cutter support 18 relative to the handheld portion 16; (v) or a combination thereof. Controlling the acceleration of the tool support can affect the force and / or torque used to attract the tool support to the desired plane. The motor current and / or voltage of each actuator can be controlled to adjust the motion parameters of the tool support relative to the handheld part.

[0251] The distance parameter can be determined by using the navigation system 32 to set one or more trackers 52 associated with the cutter 20, cutter support 18, handheld part 16, or a combination thereof relative to a reference position associated with the skeleton (e.g., one or more trackers 54, 56), and using the instrument controller 28 to determine the orientation, distance, or both of the cutter 20, cutter support 18, handheld part 16, or the combination thereof. The distance parameter can be a magnitude, a distance, or both.

[0252] The instrument controller 28 can control actuators 21, 22, and 23 to move the tool 20 toward a desired plane with a first value of motion parameters between the tool 20 and the handheld part 16. The instrument controller 28 can then move the tool 20 toward the desired plane with a second value of motion parameters, such that the velocity, acceleration, or both differ between the first and second values. For example, as... Figure 61A and 61B As shown, when the user moves the instrument 14 closer to the reference position associated with the skeleton, the instrument controller 28 uses distance parameters provided by the navigation system 32 to adjust one or more motion parameters (e.g., velocity; acceleration) to move the cutter 20 relative to the handheld part 16 toward the desired plane with changed motion parameter values ​​(i.e., a first value and a second value of the motion parameters).

[0253] By controlling the speed, acceleration, or both of the tool support relative to the handheld part, the speed can be adjusted so that before the tool 20 is within range capable of cutting the bone ( Figure 61A The relatively low speed and / or acceleration mean the movement may be less reckless and result in a smaller force / torque to be applied. This can reduce the potential disorientation of the actuators 21, 22, 23 as they move to compensate for the posture of the handheld part 16 and / or reduce the force acting on the user's hand. Then, when the blade is within range of cutting bone ( Figure 61B The controller functions to control the speed, acceleration, or both of the tool support relative to the handheld part, so that the speed and / or acceleration are relatively high to ensure precise cutting.

[0254] refer to Figure 61A When the TCP position is spaced from the reference position (RL) associated with the bone by a first distance parameter (DPI), the instrument is controlled to move the tool support relative to the handpiece, for example, by a motion parameter having a first value. This is because the TCP is still far from the bone surface.

[0255] refer to Figure 61B When the TCP position is spaced apart from the reference positioning (RL) associated with the skeleton by a second distance parameter (DP2), the device 14 is controlled to utilize a motion parameter having a second value. The first value is lower than the second value. For example, when the motion parameter is acceleration, the acceleration of the first value is lower than the acceleration of the second value.

[0256] By controlling the acceleration of actuators 21, 22, and 23, the instrument controller 28 can indicate to the user that a mode transition is in progress. This is because significant changes in the acceleration of actuators 21, 22, and 23 can alter the center of gravity of instrument 14 and result in the user experiencing a sense of force. In one example, by altering the acceleration of actuators 21, 22, and 23 based on a distance parameter or orientation of the tool 20 relative to a reference position on the bone, instrument 14 can provide the user with a sense of force, indicating that actuators 21, 22, and 23 behave differently as instrument 14 moves closer to the reference position (i.e., the distance parameter has a smaller value).

[0257] When the device changes between modes, states, or modes and states, any part of the guide array 200, visual indicators 201, 202, 203, device 14, or robot system 10 may include an indicator that signals a transition between modes, states, or modes and states. This indicator may be a tactile indicator, a visual indicator, an audio indicator, or a combination thereof to notify the user of the transition. For example, a tactile guide indicator, such as that described in U.S. Patent No. 10,231,790 to Quaid et al., may be used. In another example, an audio indicator similar to that described in U.S. Patent No. 9,707,043 to Bozung may be introduced, for example, for a change in the operation of the drive motor M. Other indicators are also considered.

[0258] In some configurations, the robot system 10 is understood to have two main operating areas—area IV and area V. When the tool enters area IV, the instrument 14 can be controlled and responds similarly to the aiming mode in area I. In area V, the instrument controller 28 can hold actuators 21, 22, 23 in specific positions while guiding the user to move the handheld portion 16 of the instrument 14 via the guide array 200, so that the tool 20 moves toward the target plane when the motor M is disabled. Any features described with reference to area I can be used with area IV, and vice versa.

[0259] In some configurations, the instrument controller 28 can control the velocity, acceleration, or both of the tool support 18 and the tool 20 relative to the handheld portion 16, and can change the values ​​of these motion parameters as the device moves from region V to region IV. This can be achieved by changing the values ​​of one or more motion parameters of actuators 21, 22, and 23 as the device moves from region V to region IV. Region IV is adjacent to and contains a reference position associated with the skeleton, and region V is the space outside region IV. In this example, one or more values ​​of the motion parameters are adjusted such that as the tool 20 enters region IV, the velocity, acceleration, or both of the tool 20 relative to the handheld portion 16 toward the desired plane are progressively adjusted, while the guide array 200 instructs the user to adjust the handheld portion 16 to remain in aiming mode. In other words, as the device approaches region IV, actuators 21, 22, and 23 are controlled such that the acceleration of the tool support 18 relative to the handheld portion 16 is greater than the acceleration of the device 14 when it initially entered region V (based on the position of the tool 20 relative to the reference position of the skeleton or determined based on calculated distance parameters).

[0260] When in aiming mode in Zone II, the instrument controller 28 can enable operation of the tool 20. For example, a trigger or foot switch of the instrument 14's user interface (UI) can be operated to allow the user to start / stop the operation of the drive motor M. In some cases, the input device only allows on / off functionality, while the instrument controller 28 automatically controls the speed of the drive motor M. In other forms, user input can be used to control the speed of the drive motor M. In some examples, the drive motor M is operational in aiming mode but is disabled if the tool 20 is unlocked from the desired posture.

[0261] In some forms, the drive motor M may be disabled before TCP reaches region I or IV. In some examples, the instrument controller 28 controls actuators 21, 22, 23 to move the tool 20 toward a desired plane and further controls the motor parameters of the drive motor M to a first value and a second value, such that the first value differs from the second value. The motor parameters can be controlled variables of the drive motor M that affect the behavior of the tool 20 during different modes. For example, the motor parameters can be speed (e.g., revolutions per minute (RPM)), torque, operation time, current, acceleration, or a combination thereof. The instrument controller 28 changes the operation from the first value to the second value based on the position of the tool 20 and the position of the reference positioning associated with the bone. In another example, the instrument controller 28 controls actuators 21, 22, 23 to move the tool 20 toward a desired plane and further controls the motor parameters of the drive motor M to a first value and a second value, such that the first value differs from the second value. The instrument controller 28 is configured to change the operation from the first value to the second value based on a distance parameter. The motor parameter can be motor speed or motor torque.

[0262] In one embodiment, the motor parameter can be a motor speed, and the instrument controller 28 can be operated such that the motor speed is controlled at a first speed when the distance parameter has a first value and direction, and at a second speed when the distance parameter has a second value and direction different from the first value. This can be implemented as follows: the first value is 10 cm and the second value is 2 cm, the first motor speed is 0 rpm, the second motor speed is 16000 rpm, and the direction is away from the bone. This can also be implemented when the instrument 14 is at a given position relative to a predetermined coordinate system. This may only cause the drive motor M to be activated when the instrument 14 is relatively close to the bone to be cut. The first motor speed can be the speed at which the motor stops, while the second motor speed can be the desired operating speed of a given tool.

[0263] As the user continues to move the TCP into region I, the instrument controller 28 continues to operate the instrument 14 in aiming mode, ultimately causing the distal end of the blade 20 to penetrate the surface of the anatomical structure at the site to be treated, such as... Figure 27As shown. Region I can also be referred to as the "treatment" or "resection" region. In some forms, the drive motor M becomes operational upon entering Region I, allowing the user to depress a trigger, foot switch, or other input device to drive the blade 20 to treat (e.g., cut) tissue. Specifically, the instrument controller 28 enables the operation of the drive motor M (e.g., the console 33 sends an associated instruction packet to the drive motor controller indicating that the drive motor M can be actuated). The user then depresses the trigger, foot switch, or actuates another input device to actuate the drive motor M. The blade 20 is thus energized, for example, to remove tissue from the target site. In some forms, the drive motor M can be directly controlled by the instrument controller 28 without any input from the user; for example, the blade 20 can be automatically actuated based on its position within Region I.

[0264] In region I, when in aiming mode, the instrument controller 28 can monitor the rotor position of each of actuators 21, 22, and 23 and disable the drive motor M when any of actuators 21, 22, and 23 reaches one of the following: soft stop, hard stop, or any other predefined threshold, such as 90% of the travel distance to a soft stop. This threshold can be configurable. As described above, the instrument controller 28 can automatically switch the instrument 14 between an operating state and a disabled state based on the orientation of the tool 20 in a known coordinate system, the orientation of the handheld portion 16, and the commanded orientation of the tool 20. In the operating state, the drive motor M can be actuated (e.g., via an input device), while in the disabled state, input signals sent by the input device prevent the activation of the drive motor M. The orientation of the handheld portion 16 can be based on actuator information, such as the measured position of each actuator 21, 22, and 23. By controlling the instrument 14 in this way, the instrument controller 28 is configured to automatically switch between modes when the posture of the tool 20, the posture of the handheld part 16, and the command posture of the tool 20 indicate that the command posture of the tool 20 exceeds the range achievable by the actuators 21, 22, and 23. In other words, when this situation occurs, the actuators 21, 22, and 23 cannot effectively hold the tool 20 on the desired plane. Even if the drive motor M may be disabled, the actuators 21, 22, and 23 can still operate to maintain the desired posture of the tool 20 as much as possible.

[0265] If the TCP of tool 20 is in zone II when this occurs, the instrument controller 28 will respond to the fact that one of the actuators has reached its limit or threshold by unlocking and repositioning tool 20 from the desired position. However, unlocking tool 20 from the desired position in zone I may be undesirable, especially if tool 20 has engaged tissue. Instead, in zone I, visual indicators 201, 202, 203 may be placed in a state that signals to the user which of actuators 21, 22, 23 is outside its acceptable limit / threshold for operation of drive motor M (e.g., visual indicators 201, 202, 203 may begin to flash / blink, change color, intensity, etc.). Once the user has moved the handpiece 16 so that all actuators 21, 22, 23 can again reach the desired position (e.g., the threshold amount of travel is available), visual indicators 201, 202, 203 can resume operation as usual. Of course, in some forms and / or under certain specific circumstances, unlocking may still occur in Zone I.

[0266] In some forms, once processing begins (e.g., tissue is being cut), the drive motor M can continue operating even if one or more of the actuators 21, 22, 23 have reached their operating limits. This may occur, for example, when cutting into bone and the bone itself provides suitable cutting guidance to continue cutting substantially in the desired plane. In this case, actuators 21, 22, 23 may be held in their current positions and / or the virtual boundary 184 may be disabled, so that the control system 60 ceases operation to hold the cutter 20 in the desired posture. As described above, another potential implementation of this feature is to determine distance parameters, such as the direction of entry into the bone relative to a reference position and the magnitude of the cutter 20 relative to the reference position on the bone (i.e., 2 cm, 3 cm, 4 cm into the bone). Based on this determination, the instrument controller 28 can control actuators 21, 22, 23 such that the cutter 20 moves relative to the handpiece 16 toward the desired plane with a first value of the motion parameter based on the distance parameter and a second value of the motion parameter based on the distance parameter. The motion parameter can be velocity. When the distance parameter is less than 3 cm, it can have a first value greater than 0 (or 1-5 m / s). When the distance parameter is greater than 3 cm, it can have a second value of 0. The direction is entering the bone.

[0267] refer to Figure 63A and 63BOnce a notch is established, the instrument controller 28 can automatically adjust the values ​​of one or more motion parameters of the cutter 20 relative to the handpiece 16 as the user cuts towards the target cutting plane associated with the patient's anatomy (e.g., the bone to be cut). In one example, the motion parameter is the acceleration of the cutter 20 relative to the handpiece 16 as it moves toward the desired plane. The instrument controller 28 can automatically change the adjustment rate of the actuators 21, 22, 23 based on distance parameters (e.g., orientation, magnitude) relative to a reference position associated with the bone, determined by the orientation of the cutter 20 (e.g., by TCP). The orientation of the cutter 20 can be maintained while the guide array 200 guides the user to move the handpiece 16 to maintain or correct it toward the desired plane.

[0268] refer to Figure 63A When the saw blade (TCP) is positioned at a distance from the reference position (RL) associated with the bone by a first distance parameter (DP1), the instrument is controlled to move the cutter support relative to the handpiece, for example, using a motion parameter with a magnitude greater than zero. This is because the notch has not yet been fully established.

[0269] refer to Figure 63B When the saw blade (TCP) is positioned at a distance from the reference position (RL) associated with the bone by a second distance parameter (DP2), the instrument is controlled to either reduce the amount of motion to zero or otherwise stop the movement of the tool support relative to the handpiece. This is because the notch has been adequately established.

[0270] Once the cutter 20 has established a notch, the instrument controller 28 can set the motion parameters to zero, stopping the actuators 21, 22, and 23 from adjusting the cutter support 18 relative to the handpiece 16. Once the cutter 20 has established a cutting path within the bone, it may bend and attempt to deviate from its path, pushing back against the handpiece 16. This force is perceptible to the user. When the cutter 20 is in the cutting notch 290, the actuators 21, 22, and 23 are controlled by the instrument controller 28 to create a feeling of "pushing back" or "resisting" the handpiece. Therefore, the only movement caused by controlling the actuators to move toward the desired plane is the movement of the handpiece 16. This means that the instrument controller 28 can apply force to the handpiece 16 and then transmit it to the user's hand. These forces can cause fatigue and / or discomfort during cutting. By changing the motion parameters, the cutter 20 can provide further reduced resistance during cutting. Users may find that when the tool 20 is within the cutting groove 290, cutting can be completed without resistance to the handheld part 16 by setting the motion parameter value to 0 or by otherwise stopping the movement of the handheld part relative to the tool support. The cutting groove 290 acts as a natural cutting guide (see...). Figures 63A-63BMore specifically, the instrument controller 28 can actively change the values ​​of motion parameters related to velocity, acceleration, or both, such that the further the cutter 20 enters the target anatomical structure, the lower the velocity and / or acceleration of the actuators 21, 22, 23 toward the target plane compared to the initial velocity and / or acceleration at the start of the cut, ultimately stopping actuator movement when the cutter 20 has made an intermediate cut, using the path cut into the bone as guidance. In other words, the velocity and / or acceleration of the cutter support 18 at the start of the cut can be greater than the velocity and / or acceleration after advancing a threshold distance into the bone relative to a reference position. While stopping the adjustment of the cutter support 18 by the actuators 21, 22, 23 is described with respect to setting the motion parameters to zero, it should be understood that other suitable control logic can be used to stop the actuators 21, 22, 23, for example, by stopping the motion control aspects of the algorithm or otherwise freezing the positions of multiple actuators 21, 22, 23.

[0271] In some forms, once treatment begins, the instrument controller 28 can limit the user's ability to move the blade 20 away from the desired orientation (e.g., outside or off the virtual boundary 184). For example, in some embodiments, once the navigation system 32 provides any indication that the blade 20 is moving away from the desired cutting plane, the instrument controller 28 immediately terminates the application of excitation signals to the drive motor M to prevent the blade 20 from striking the bone and to minimize soft tissue damage. In some embodiments of this feature, the acceptable misalignment of the blade 20 from the desired orientation can vary inversely with increasing resection depth.

[0272] The navigation system 32 can also monitor the cutting depth. In some forms, the instrument controller 28 can stop the operation of the drive motor M when the cutting depth is determined to be between 0.1 and 2.0 mm of the target depth. In some examples, the instrument controller 28 may not stop the operation of the drive motor M, but instead rely on user-controlled start, stop, and / or speed control of the drive motor M. In some configurations, the surface of the anatomical feature to be cut (e.g., a bone surface) can be used as a reference point, virtual boundary, or both, causing the instrument controller 28 to change the operating mode or behavior of: (i) the instrument 14; (ii) one or more actuators 21, 22, 23; (iii) the guide array 200; (iv) one or more visual indicators 201, 202, 203; (v) or a combination thereof. In some examples, the instrument controller 28 controls the motor parameters of the drive motor M to a first value and a second value, such that the first value differs from the second value. The instrument controller 28 changes the operation from the first value to the second value based on the position of the cutter 20 and the position of the reference positioning associated with the bone, or based on calculated distance parameters. As the blade 20 enters the bone incision, the instrument controller 28 can activate the drive motor M using navigation data of the blade 20's positioning relative to a reference point associated with the bone. Furthermore, the instrument controller 28 can cut off the drive motor M based on specific distance parameter values ​​or positions that the blade 20 has reached and are associated with the bone-associated reference point. In some cases, the user may lose sensation to the blade 20 during surgical procedures. By controlling the drive motor M based on the depth of the blade 20, the user may be able to more accurately control how deep the cut should be made, preventing interference with ligaments and arteries located around the cutting area.

[0273] In some examples, when the instrument controller 28 changes the operating mode by altering the parameters of the drive motor M, the instrument 14, input device, navigation system 32, instrument controller 28, or a combination thereof, can provide audible, tactile, or both indications that the mode has changed. In one case, the input device may be a foot switch that controls the speed of the drive motor M when the instrument's mode changes; the foot switch may vibrate. In another example, when the mode changes to accelerate or decelerate the drive motor M, the user can perceive audible indications such as changes in the volume, tone, vibration, or a combination thereof of the motor speed of the drive motor M, indicating that the instrument's mode has changed, as described in Bozung's U.S. Patent No. 9,707,043.

[0274] If at any time the user deems it difficult to maintain the blade 20 in the desired orientation in aiming mode based on the current treatment process (e.g., the cut appears to be off-plane), the user can pull the blade 20 back to Zone II and away from the desired orientation to cause the blade 20 to unlock and return to its original position, and then restart in approach mode. The user can also manipulate the blade 20 by repeatedly inserting and withdrawing it into the anatomical structure with small reciprocating movements to ensure that the blade 20 remains in the desired orientation during treatment, for example, to prevent the blade 20 from becoming trapped in the trajectory that would eventually pull it off the desired orientation if the cut continues to penetrate the bone. In other words, these reciprocating movements of the blade 20 correct any slight deviation from the desired orientation to prevent the blade 20 from becoming trapped in the bone, for example, on a cutting plane that is off-plane from the desired cutting plane.

[0275] In some examples, when the blade 20 is retracted from the current treatment procedure (e.g., cutting), the instrument controller 28 can control each of a plurality of actuators 21, 22, 23 to hold the blade 20 in its current position relative to the handheld portion 16, thus preventing unlocking and repositioning. In other words, even as the user moves from one area to another, the user can retract the blade 20 from the incision and the actuators 21, 22, 23 maintain the position of the blade 20 relative to the handheld portion 16, allowing the user to return to the initial incision with the same grip and orientation in their hand (see [link to original text]). Figures 62A-62C ). Figure 62A The device 14 is shown in an orientation within region IV, and Figure 62B This shows that when the device 14 moves into region V, the device 14 remains in the same posture. Figure 62C Device 14 is shown to be used with Figure 62A The same pose is returned to region IV. However, regarding Figure 62B When placed in region V, it can be in any suitable posture, as long as it is in the same posture as when it was initially removed from region IV when it re-enters region IV.

[0276] It is foreseeable that the current posture is a position other than the initial position, that is, the controller is able to maintain the positions of actuators 21, 22, and 23 in a position other than the initial position. The user can hold the actuators in this position to prevent unnecessary actuation and movement, and to prevent the actuators from generating excessive heat due to movement, for example, when the instrument 14 is a considerable distance away from the target bone. In some forms, the user can select the tool behavior by actuating the input device and selecting a freehand mode in which the instrument controller 28 commands the tool posture to be held or frozen in place. Alternatively, in some examples, the instrument controller 28 controls the operation of the instrument 14 in at least a first mode and a second mode. In the first mode, the instrument controller 28 automatically controls each of the actuators 21, 22, and 23 to maintain the current posture of the tool 20 relative to the handheld portion 16. In the second mode, the controller automatically controls each of the actuators 21, 22, and 23 such that the tool 20 actively moves towards the desired plane relative to the posture of the handheld portion 16. The instrument controller 28 automatically switches from the first mode to the second mode based on the position of the tool in a known coordinate system and the reference positioning associated with the bone. It is also anticipated that the instrument controller 28 can control the drive motor M of the instrument 14 based on the position of the reference positioning associated with the bone and the posture of the blade 20, automatically switching from a first state in which the motor M can be actuated and a second state in which the motor M is prevented from being actuated. When the blade 20 is removed from the incision, the instrument controller 28 can automatically switch the instrument 14 from movement of the active control actuators 21, 22, 23 to a freehand mode based on the posture of the blade 20 determined by the navigation system 32 and the reference positioning associated with the bone, so that the user can resume the process with the same grip around the handheld part 16 relative to the blade 20 in order to maintain a comfortable grip, control, convenience, familiarity with the anatomy, unexpected anatomy, or a combination thereof. Alternatively, the instrument controller 28 can be configured to switch between a first mode and a second mode based on a distance parameter (e.g., distance; magnitude) determined according to the position of the blade 20 and the reference positioning associated with the bone. The distance parameter can be direction, magnitude, or both. In some cases, when the distance parameter has a direction away from the bone and the value is greater than the first threshold, such as 12 cm, the controller can switch to the second mode.

[0277] In some forms, the instrument controller 28 can switch between a mode in which the instrument controller 28 automatically controls the actuators 21, 22, 23 to actively move the blade 20 toward a desired plane relative to the handheld portion 16, and a mode in which the instrument controller 28 automatically controls the blade 20 to remain in its current position relative to the handheld portion 16. The user may be able to freeze the movement of the actuators 21, 22, 23 in freehand mode (in any area) to allow the user to perform certain treatments (e.g., cutting the patella or other parts of the anatomy). When the actuators 21, 22, 23 are prevented from further movement in freehand mode, the instrument 14 behaves much like a conventional cutting instrument, with no movement of the blade support 18 relative to the handheld portion 16. The virtual boundary 184 is also deactivated in freehand mode. Freehand mode can be enabled by any suitable user input device (e.g., a button, foot switch, etc.).

[0278] Furthermore, it is foreseeable that the instrument controller 28, the user, or both can manually switch between modes and behaviors of the instrument 14 via input devices based on navigation data, actuator data, drive motor data, or a combination thereof. In some cases, the user can determine that the instrument should be held in a specific position (tool support relative to the handheld part) and control the instrument controller via input devices.

[0279] In some examples, the instrument controller 28 may utilize one or more inputs to determine one or more outputs. The one or more inputs may include skeletal position determined by patient trackers 54, 56, such as reference positioning; the tool center point TCP of the tool 20 determined by tracker 52 on the tool support 18; the posture of the handheld portion 16; the command posture of the tool 20; distance parameters; actuator information (e.g., command position, current position, past position, etc.); input signals from a foot switch or touchscreen; or combinations thereof. The one or more outputs of the instrument controller 28 may include changing motor parameters of the drive motor M; adjusting motion parameters of the tool support, including changing acceleration or velocity; disengaging boundary control; holding or freezing the tool 20 and tool support 18 relative to the handheld portion 16; activating a homing mode; or combinations thereof. Any suitable combination of inputs may be used with any suitable output.

[0280] It is understood that each of the operating modes can be used in combination with any other operating mode. An operating mode can be any controlled movement determined by the instrument controller 28 and implemented by the instrument 14, including no movement. For example, the instrument controller 28 can control the tool support 18 to adjust the speed, acceleration, or both of the tool 20, and guide the user to, as per... Figures 24A-24C , Figures 25A-25C , Figures 26A-26B , Figures 61A-61B, Figures 62A-62C , Figures 63A-63B The desired posture described by one or more of these, or a combination thereof. In one example... Figures 24A-24C The control modes described in Figures 63A-63B The combination of control modes allows the instrument 14 to operate in zones III, II, and I according to... Figures 24A-24C The equipment is controlled by the instrument, and once inside the slot, it behaves as described above. Figures 63A-63B Controlled as described. Furthermore, any pattern or behavior described (e.g., device behavior, actuator behavior, drive motor behavior, or a combination thereof) may be combined with any area or position of the device 14 relative to itself, the patient, the coordinate system, virtual positioning, or a combination thereof.

[0281] It should be understood that the guide arrays and / or visual indicators 201, 202, 203 described throughout can be used with any actuator configuration of any surgical instrument 14, having any control mode or behavior control. For example, guide array 200, visual indicators 201, 202, 203, or both can be used with any control mode and instrument behavior having any configuration currently described. In one example, guide array 200, visual indicators 201, 202, 203, or both can be used with at least Figure 35 , Figure 45A -B、 Figure 57 , Figure 59 , Figure 60 , Figure 65 , Figure 66 The device 14 described in the illustrated configuration, or any configuration of device 14, may be used in conjunction with it. Furthermore, the guide array 200 and / or vision indicators 201, 202, 203 can be understood to include a configuration in which the guide array 200 and / or vision indicators 201, 202, 203 enable the robot system 10 to indicate the amount of travel required to move the tool 20 and / or the handheld portion 16 to a desired posture, trajectory, orientation, position, plane, or combination thereof. Throughout any mode described in this application, any guide array 200 and / or vision indicators 201, 202, 203 can be used with any configuration of the device to send signals to the user on how to position, move, and / or adjust the device 14. For example, changes in pitch, yaw, and translation are relative to one or more virtual boundaries. The guide array 200 and / or vision indicators 201, 202, 203 can facilitate the positioning of different types of tools, including but not limited to drills or reamers, actuators (for placing screws or pins), drills, pins, guides, etc.

[0282] refer to Figure 28 and 29Another form of the robotic device 14 is shown. This form is largely the same as that described previously. In this form: (1) the wiring of the flexible circuit FC has been slightly modified to take into account the range of movement of the actuators 21, 22, 23 about their respective pivots; (2) a weighted end cap 208 has been added to the base 74; and (3) the grip 72 has been modified to take into account the alternative wiring of the flexible circuit FC and the presence of the weighted end cap 208.

[0283] The wiring of flexible circuit FC in Figure 29 The best example shown is in the middle. Figure 30 and 31 The flexible circuit FC and control housing 29 are shown to be isolated from the rest of the device 14. Figure 30 and 31 As shown, the flexible circuit FC forms part of the flexible circuit assembly 210. The flexible circuit assembly 210 may include a plurality of integrally formed flexible elongated portions (or legs), or these portions may be formed separately and attached together. The flexible elongated portions may include one or more flexible plastic substrates, such as polyimide, transparent conductive polyester film, etc.

[0284] The flexible circuit assembly 210 includes electronic circuitry mounted and / or embedded in a flexible plastic substrate. The electronic circuitry may include one or more circuits for transmitting data and / or power between the visual indicators 201, 202, 203 and one or more circuit boards 31 in the control housing 29. The electronic circuitry may also include one or more circuits for transmitting data and / or power between the actuators 21, 22, 23 and one or more circuit boards 31. The electronic circuitry may also include one or more circuits for transmitting data and / or power between the sensor S and one or more circuit boards 31 (or the sensor S may be considered part of the actuators 21, 22, 23).

[0285] refer to Figure 29 and 32 The flexible circuit support 212 is mounted to the tool support 18 via one or more fasteners to anchor two flexible elongated portions of the flexible circuit assembly 210 that extend into the actuators 21, 22. Specifically, these two flexible elongated portions are anchored to the flexible circuit support 212 via anchor 214. Anchor 214 is used to capture and abut the flexible elongated portions against the surface of the flexible circuit support 212. Anchor 214 may include fasteners, such as screws, or any other suitable form of anchor to hold the flexible elongated portions in the indicated position.

[0286] For details, please refer to the following: Figure 32The flexible circuit support 212 includes a body defining one or more anchor mounting positions 216 for receiving anchors 214. The flexible elongated portion captured by the anchor 214 includes an opening 220 through which the anchor 214 secures the flexible elongated portion to the body (see [link to documentation]). Figure 30 (Opening 220 shown). The body also defines a pair of notches 218, which are sized to receive flexible elongated portions of the flexible circuit assembly 210 to guide those flexible elongated portions, thereby reducing stress on the flexible elongated portions when the actuators 21, 22 move during operation.

[0287] like Figure 28 , 29 As shown in Figure 33, the weight cap 208 may be formed of one or more materials, such as plastic, metal, ceramic, combinations thereof, etc. The size and / or shape of the weight cap 208 may be designed and have a mass capable of altering the weight distribution of the instrument 14 to provide suitable balance in the user's hand. The weight cap 208 may also be designed to address / improve the reaction load on the user's hand caused by operating the instrument 14.

[0288] In addition to the top 222 of the grip 72 having an angled, inclined portion 224 extending rearward, Figure 34 The grip 72 shown is substantially the same as the grip 72 previously shown and described. When the tool support 18 is in certain extreme positions relative to the handheld portion 16, the angled inclined portion 224 causes the grip 72 to open at the rear to accommodate the flexible circuit FC.

[0289] Figure 69 The grip 72 shown is substantially similar to the grip 72 / handheld portion 16 previously shown and described, except that it includes an input device 298, which is configured as a trigger in this depiction. The input device in this configuration is located on the grip 72 to allow the user to selectively send actuation signals to the instrument controller 28.

[0290] Alternative configuration

[0291] Figure 67 and 68 An alternative configuration for mounting the actuator in the handheld portion 16 with base 74 is shown. Figure 67 and 68An alternative configuration of the movable joint is provided. The movable joint may include a set of second movable joints 108 that connect the first two actuators 21, 22 to the base 74 of the handheld portion 16. In the illustrated form, the second movable joints 108 are supported at a joint support 288. Each second movable joint 108 includes a swivel yoke 110 arranged to rotate relative to the base 74 of the handheld portion 16. Each swivel yoke 110 has a rotating head 286 and a post 114 extending from the rotating head 286 to pivotally engage the base 74 at the joint support 286. A nut 115 is threadedly connected to one end of the post 114 to capture the post 114 in the base 74 while allowing the respective swivel yoke 110 to rotate freely within its respective joint support 286.

[0292] Each second movable joint 108 includes a carrier 116 pivotally coupled to one of the swivel yokes 110. Each carrier 116 includes opposing trunnions 118, allowing the carrier 116 to revolve around a pivot axis PA (see [link to relevant documentation]) by placing the trunnions in recesses 290 in the swivel yoke 110. Figure 14 ) pivot relative to the rotation yoke 110.

[0293] The rotating head 286 defines a recess 290 configured to receive the trunnion 118. The trunnion 118 of the carrier 116 slides into the recess 290, such that the trunnion 118 and the carrier 116 are positioned within the rotating head 286. A collar 294 is pressed into either side of the pivot housing 292, engaging the trunnion 118. The carrier 116 is pivotable relative to the yoke 110 via the trunnion 118 and the recess 290. Due to the configuration of the yoke 110 and the associated carrier 116, i.e., the carrier 116 is rotatable about the rotation axis SA and pivotable about the pivot axis PA, the second movable joint 108 allows two degrees of freedom of movement of the first two actuators 21, 22 relative to the base 74.

[0294] The movable joint also includes a third movable joint 124 that connects the rear (third) actuator 23 to the base 74 of the handheld portion 16. In the illustrated configuration, the third movable joint 124 is supported at the joint support 79. The third movable joint 124 includes a pivot housing 292 fixed to the joint support 288 of the base 74.

[0295] The third movable joint 124 includes a carrier 116 pivotally connected to the pivot housing 292 via a trunnion 118 engaging within a recess 290. A collar 294 is pushed into both sides of the pivot housing 292 and engages with the trunnion 118. The collar 294 is arranged such that, after assembly, the carrier 116 can pivot via the trunnion 118 positioned in the recess 290 of the pivot housing 292. Due to the configuration of the pivot housing 292 and the associated carrier 116, i.e., the associated carrier 116 can only pivot (e.g., not rotate) about the pivot axis PA, the third movable joint 124 allows only one degree of freedom of movement for the rear actuator 23 relative to the base 74.

[0296] Turning Figure 35-45B This illustrates an alternative configuration of instrument 14, which uses an actuator assembly 400 including actuators 21, 22 and a rotary actuator 228, and a constraint assembly 24 for connecting the handheld portion 16 to the tool support 18. Actuators 21, 22 are configured to control the height and pitch of the tool body 80 of the tool support 18 relative to the handheld portion 16. The rotary actuator assembly 228 is coupled to the tool support 18 to control the oscillating movement of the tool head 84 connected to the tool 20, thereby adjusting the cutting plane of the tool 20 while the tool body 80 of the tool support 18 and the handheld portion 16 are constrained to oscillate relative to each other.

[0297] like Figures 35-37 As seen in the image, the device 14 includes a handheld portion 16 for user holding. The handheld portion 16 may be interchangeably referred to as a hand-held body. The hand-held body 16 is part of the device, held and manually supported by the user by gripping it. The hand-held body 16 allows the user to move and manipulate the device without restriction. A tool support 18 is movably coupled to the hand-held body 16 to support a tool 20. A first actuator 21 and a second actuator 22 are located between the tool support 18 and the hand-held body 16, operatively interconnecting them. The actuators 21 and 22 are aligned along a longitudinal plane that bisects the hand-held body. The actuators 21 and 22 are configured to move the tool support 18 in two degrees of freedom, altering z-axis translation (height relative to the handheld portion 16) and pitch relative to the hand-held body 16. A constraint assembly 24, including a passive linkage 26, is located between the handheld body 16 and the tool support 18, further interconnecting the tool support 18 and the handheld body 16. The constraint assembly 24 is configured to constrain the movement of the tool support 18 to three degrees of freedom relative to the handheld body 16.

[0298] The tool support 18 includes a rotary actuator assembly 228 configured to control the swinging movement of the tool 20 relative to the hand-held body 16. Figure 38A and 38BA rotary actuator assembly 228 is depicted, including a rotary actuator motor 230, a drive member 232, and a ring gear 234. The rotary actuator motor 230 is connected to the tool support 18 and may be an electric motor. The drive member 232 is connected to the rotary actuator motor 230 and configured to be rotated by the rotary actuator motor 230. The drive member 232 may be a gear. The drive member 232 in... Figure 38A and 38B The gear is specifically shown as a spur gear. The rotary actuator assembly 228 can be configured such that when the rotary actuator motor 230 is actuated, the drive gear 232 directly contacts the ring gear 234 and rotates it relative to the tool support 18 and the handheld body 16. The ring gear 234 can be configured as a worm gear connected to the drive member 232, which can be configured as a worm to prevent the tool 20 from being driven backward during operation. Figure 38B As seen, the rotary actuator assembly 228 may include one or more intermediate gears 236. The one or more intermediate gears 236 can be used to change the gear ratio between the drive gear 232 and the ring gear 234. The one or more intermediate gears 236 may be idler gears. For example, the one or more intermediate gears 236 can increase the speed ratio between the drive gear 232 and the ring gear 234. The drive gear 232 may be directly connected to the intermediate gear 236 to rotate the intermediate gear 236. Figure 38B The intermediate gear can be directly connected to the ring gear 234, so that the ring gear 234 rotates when the rotary actuator motor 230 is actuated.

[0299] exist Figure 39A and 39B In the example configuration seen, the ring gear 234 is integrated with the head 84 of the cutter support 18. The cutter head 84 can rotate with the ring gear 234, thereby adjusting and controlling the rotational position of the cutter 20 (e.g., a saw blade). The cutter head 84 can rotate about an axis defined by the drive motor M. Figure 39A The tool support 18, depicted in partial exploded form with a body 80 and a head 84, shows a ring gear 234 on the head 84 and a rotary actuator motor 230, drive gear 232, and intermediate gear 236 connected to the body 80 of the tool support 18. The head 84 can be configured to engage with a tool 20 such that when the ring gear 234 is rotated by the rotary actuator motor 230, the head 84 and the tool 20 also rotate, thereby adjusting the rocking position of the tool 20 relative to the handheld body 16 and the tool support 18 (e.g., ...). Figure 45A and 45BThe head 84 is configured to rotate 360 ​​degrees relative to the handheld body 16 and the tool support 18 to position the tool 20. The tool head 84 can be connected to the tool support body 80 via an axial retaining nut configured to hold the tool head 84 in place. In other configurations, the head 84 can swing 360 degrees or less, 270 degrees or less, 180 degrees or less, 90 degrees or less, or even 50 degrees or less. In further configurations, the tool head 84 can swing 30 degrees or more, 90 degrees or more, 180 degrees or more, 270 degrees or more, or even 360 degrees or more. In some examples, the tool head 84 may have a hard stop that prevents rotation of the tool head 84, limiting the range of rotation of the tool head 84 relative to the tool support 18 and the handheld portion 16.

[0300] like Figures 38A-38C As shown in 40A-40B, a rotary actuator motor 230 is located below the tool support body 80. The rotary actuator motor 230 is attached to the tool support body 80 and configured to move with the tool support body 80 as the actuators 21, 22 adjust the height and pitch of the tool support body 80 relative to the handheld body 16. The rotary actuator motor is configured to rotate a drive gear 232, which is rotatably connected to a ring gear 234 relative to the tool support body 80. The rotary actuator motor rotates the drive gear, which in turn rotates the ring gear 234 connected to the tool head 84, causing the ring gear 234 and the tool head 84 to rotate relative to the tool support body 80. In some configurations, the rotary actuator motor 230 may be integrated into the tool support body 80. In some configurations, the rotary actuator may include an absolute encoder. In another example, for example in… Figure 38C In this configuration, the rotary actuator motor 230 is a separate unit attached to the tool support body 80. For example, Figure 38C A partially exploded view of the tool support body 80 and the rotary actuator motor 230 is shown. The rotary actuator motor 230 includes a housing 250. The rotary actuator motor 230 is attached to the tool support body 80 by fasteners 272 disposed through the rotary actuator motor housing 250 and received within the tool support body 80; however, other attachment methods (e.g., adhesives, welding, etc.) are also considered. Figure 38CFasteners 272 are shown at opposite corners of the rotary actuator motor 230 for attaching the rotary actuator motor to the tool support. Alignment pins 280 corresponding to the opposite corners of the rotary actuator motor 230 are provided in the tool support body 80 to facilitate attachment of the rotary actuator motor 230 to the tool support body 80 and alignment with the ring gear 234. The rotary actuator motor 230 includes a housing 250. The housing 250 of the rotary actuator motor 230 can serve to provide a passive linkage mounting 254 for the passive linkage mechanism 26, which will be further described below.

[0301] Prior to treating anatomical structures (e.g., before cutting the femur F and / or tibia T), during certain operating modes described below, a homing procedure may be performed to establish an initial position for the rotary actuator 228. This may include a homing process similar to that of actuators 21, 22 (as described above) to position the cutter head 84 and the cutter 20. This process provides a reference position from which incremental movements of the drive gear 232, ring gear 234, or both, as measured by sensors, are counted, enabling the control system 60 to determine the current position of the cutter head 84 and the cutter 20. In some forms, homing may not be necessary when sensors are capable of measuring the absolute position of the drive gear 232, ring gear 234, or both. In some other configurations, the initial position of the cutter head 84 may be determined by other methods. For example, pointer 57 can be used with calibration indentation CD in tool head 84 and / or tool 20 to determine the position of tool head 84 and tool 20 relative to tool support 18, handheld body 16, tool tracker 52, patient tracker 54, 56, PT or a combination thereof.

[0302] Figures 35-37 A tool support body 80, comprising a handheld body 16 connected to a tool support 18 via actuators 21, 22 and a passive linkage mechanism 26, is depicted. The handheld body 16 includes a grip 72 for user gripping, enabling manual support of the instrument 14. The handheld body 16 also includes a base 74 to which the grip 72 is attached by one or more fasteners, adhesives, welds, etc. In the illustrated form, the base 74 includes a sleeve 76 having a generally hollow cylindrical shape. Pivoting housings 126, 226 extend from the sleeve 76. Figure 42 and 43 Actuators 21 and 22 are movably coupled to base 74 at pivot housings 126 and 226, which are further described below.

[0303] exist Figure 35-45BIn the configuration shown, the tool 20 is detachably coupled to the tool support 18. Specifically, as described in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference, the head 84 can be detachably coupled to the tool 20.

[0304] The drive motor M that drives the operation of the cutting tool 20 is located in the tool support body 80 (for example, in some forms, it is used to drive the swing of the saw blade). Figure 39A and 39B The image shows a tool support 18 and a head 84 with a ring gear 234. The tool support 18 may include a drive motor M and other drive components shown in U.S. Patent No. 9,820,753, by Walen et al., to drive the oscillating motion of the cutting tool assembly. The drive motor M includes a drive member 248 extending therefrom, configured to rotate with the output of the motor M. A driven member 248 extends distally from the motor M. The driven member 248 includes a slot 282 configured to receive a driven shaft 252 of the head 84, such that the driven member 248 receives the driven shaft 252. When the driven member 248 receives the driven shaft 252 in the slot 282 of the driven member 248 and when the motor M is activated, the driven member 248 and the driven shaft 252 rotate together. The rotational motion of the drive motor M causes the driven member 248 to rotate, which in turn rotates the driven shaft 252, thereby powering the tool 20. When the rotary actuator 228 is actuated, the head 84 rotates together with the ring gear 234 to adjust the rotational position of the head 84 and the tool 20, independent of the activation of the drive motor M. The drive motor M can be configured to remain stationary when the tool 20 and the head 84 are rotated by the ring gear 234 of the rotary actuator assembly 228. In another configuration, the drive motor M can be configured to rotate together with the ring gear 234 of the rotary actuator assembly 228. The tool 20 can be attached to and released from the head 84 in a manner disclosed in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference.

[0305] like Figure 40A and 40B As best shown, the tool support 18 also includes a plurality of actuator mounts 86, 88, at which actuators 21, 22 are movably coupled to the tool support 18 via pivot mounts, as further described below. The actuator mounts 86, 88 may include brackets or the like adapted to mount the actuators 21, 22, allowing the tool support 18 to move relative to the handheld portion 16 in two degrees of freedom (i.e., z-axis translation and pitch).

[0306] like Figure 36 and 37As can be seen, actuators 21 and 22 include electrically driven linear actuators extending between the base 74 and the tool support body 80. When actuated, the effective length of actuators 21 and 22 (previously regarding) Figure 16 The description describes a change in the distance between the tool support body 80 and the base 74 along the corresponding axes of the actuators 21, 22. Therefore, the actuators 21, 22 work together to change their effective length and allow the tool support 18 to move relative to the handheld body 16 in at least two degrees of freedom (pitch and z-axis translation). In the illustrated form, two actuators 21, 22 are provided and may be referred to as first and second linear actuators 21, 22 or front actuator 21 and rear actuator 22. The effective lengths of the first and second actuators 21, 22 are along the first active axis AA1 and the second active axis AA2 (see...). Figure 41 Adjustable. The effective lengths of the first and second actuators 21, 22 are independently adjustable to adjust the pitch orientation, z-axis translation position, or one or more of both of the tool support 18 relative to the handheld body 16, as previously described. Actuators 21, 22, in conjunction with rotary actuator assembly 228, are configured to adjust the tool 20 in at least three degrees of freedom relative to the handheld body 16, including oscillation about the longitudinal axis of the tool support 18. More actuators may be provided in some examples. Actuators 21, 22 may include linkage mechanisms with one or more links having any suitable size or shape. The actuator assembly 400 having actuators 21, 22 and rotary actuator assembly 228 can have any configuration suitable for enabling the tool 20 to move in at least three degrees of freedom relative to the handheld body 16.

[0307] Figure 36 , 37 Figure 38A shows actuators 21, 22 connected to base 74 and tool support body 80 via multiple movable joints. The movable joints include a set of first movable joints 92 that connect actuators 21, 22 to tool support body 80 at actuator mounts 86, 88. In one form, such as... Figure 41 and 42 As shown, the first movable joint 92 includes a movable pivot joint. The pivot joint includes a pivot pin 94. The pivot pin 94 passes through actuator mounts 86, 88 and a pivot yoke 106 located on actuators 21, 22, pivotally connecting actuators 21, 22 to actuator mounts 86, 88. A retaining screw 100 can secure a locking pin 240, which passes laterally through the first pivot pin 94, to actuator mounts 86, 88.

[0308] exist Figure 41In the configuration shown, actuators 21 and 22 (along with the passive linkage 26) are constrained to pivot in one direction, preventing the tool support 18 and the handheld body 16 from rotating and swaying relative to each other, while allowing the tool support 18 to translate and pitch vertically. Actuator mounts 86 and 88 have through holes 242 to receive locking pins 240. A first pivot pin 94 has a transverse hole 244 to receive the locking pin 240, such that the first pivot pin 94 and the locking pin 240 intersect, causing the first pivot pin 94 to be clocked relative to actuator mounts 86 and 88. Thus, actuators 21 and 22 are capable of lifting, lowering, and pivoting relative to the tool support body 80.

[0309] Actuators 21 and 22 are movably coupled to base 74 at pivot housings 126 and 226, forming lower movable joints 246 and 270 that connect the front actuator 21 and the rear actuator 22 to base 74 of handheld body 16. Lower movable joints 246 and 270 are supported at joint support 79. Lower movable joints 246 and 270 include pivot housings 126 and 226 that are fixed to joint support 79 at base 74.

[0310] Lower movable joints 246 and 270 each include a carrier 116 pivotally connected to pivot housings 126 and 226 via trunnion 118. A fastener 130 having a recess 132 is attached to either side of pivot housings 126 and 226 via a through-hole 133 to engage the trunnion 118. The fastener 130 is arranged such that the carrier 116 can pivot via the trunnion 118 located in the recess 132 after assembly. The carrier 116 has a threaded through-hole 117 to receive the lead screw 150 of actuators 21 and 22, as further described below. Due to the configuration of pivot housings 126 and 226 and the associated carrier 116, i.e., the associated carrier 116 can only pivot (e.g., not rotate) about the pivot axis PA, the lower movable joints 246 and 270 allow only one degree of freedom of movement for actuators 21 and 22 relative to base 74. Other joint arrangements between actuators 21, 22 and base 74 are also possible. Furthermore, in Figure 35-45B The design and function of actuators 21 and 22 presented in the previous version are similar to those in the previous version. Figure 1-34 The actuators 21 and 22 shown are identical. Furthermore, except for the rotary actuator assembly 228, actuators 21 and 22 are identical to... Figure 1-34 It is controlled, powered, and sensed in a similar manner as described in the text.

[0311] As previously described, the carrier 116 has a threaded through-hole 117 to threadedly receive the lead screw 150, such that each lead screw 150 can be rotated relative to a corresponding one in the carrier 116 to adjust the effective length of a corresponding actuator among the plurality of actuators 21, 22, and thus change the count measured by the instrument controller 28. Each housing 134 and the corresponding carrier 116 are constrained in relative movement in at least one degree of freedom to allow the lead screw 150 to rotate relative to the carrier 116 (see [link to documentation]). Figure 16 More specifically, the lead screw 150 is rotatable relative to the carrier 116 because: the pivot yoke 106 cannot rotate about the associated axes of motion AA1, AA2 (i.e., the pivot yoke 106 is restricted to such rotational movement by means of the configuration of the first movable joint 92); and the carrier 116 cannot rotate about the associated axes of motion AA1, AA2 (i.e., the carrier 116 is restricted to such rotational movement by means of the configuration of the second movable joints 246, 270).

[0312] Stops 152, such as threaded fasteners and shoulders formed on the lead screws 150, are secured to the lead screws 150. The stops 152 are sized to abut against the carrier 116 at the end of the travel of each lead screw 150.

[0313] As described above, the effective lengths of actuators 21 and 22 are actively adjustable (at least in the above text). Figure 16 (As described above) to enable the tool support 18 to move relative to the handheld portion 16. Each actuator 21, 22 is adjusted by changing how far the lead screw 150 is screwed into or out of its associated carrier 116 and thus changing the distance from the center of the associated carrier 116 to the center of the associated first movable joint 92. Actuators 21, 22 can be adjusted between a minimum and a maximum effective length. The effective length of each actuator 21, 22 can be represented / measured in any suitable manner to represent the distance between the tool support 18 and the handheld portion 16 along the active axes AA1, AA2, which changes to cause various movements of the tool support 18 relative to the handheld portion 16.

[0314] The constraint assembly 24 works in conjunction with actuators 21 and 22 to constrain the movement provided by actuators 21 and 22. Actuators 21 and 22 provide movement in two degrees of freedom, while the constraint assembly 24 constrains movement in three degrees of freedom. In the illustrated form, the constraint assembly 24 includes a passive linkage 26 and a passive linkage joint 156 that connects the passive linkage 26 to the tool support 18.

[0315] exist Figure 41 and 42In the configuration shown, the constraint assembly is connected to the tool support 18 via a passive linkage joint 156. The passive linkage joint 156 includes a passive linkage mount 254 on the tool support 18 and a passive linkage pivot yoke 172. A pair of pivot pins 256 pivotally connect the passive linkage pivot yoke 172 of the passive linkage 26 to the passive linkage mount 254 of the tool support 18, which is located on the housing 250 of the rotary actuator motor 230. Figure 38C and 40A As seen in -42, the housing 250 of the rotary actuator motor 230 of the rotary actuator assembly 228 is attached to the tool support body 80. The passive linkage mechanism 26 is mounted to the housing 250 of the rotary motor 230 via a pair of pivot pins 256 through a passive linkage yoke 172. These pivot pins 256 are held in place by pins 274, which pass through holes 276 and 278 in the passive linkage yoke 172 and the pivot pins 256, respectively, and are secured by screws 258, thereby maintaining the axial alignment of the pivot pins 256 with the passive linkage yoke 172. As a result of its connection to the tool support 18, the passive linkage mechanism 26 is capable of raising and lowering when the actuators 21 and 22 are actuated, and of pivoting to accommodate different pitch angles relative to the tool support body 80.

[0316] The passive linkage 26 includes a shaft 174 fixed to a passive linkage pivot yoke 172. The passive linkage 26 also includes a sleeve 76 at a base 74 configured to receive the shaft 174 along a constraint axis CA. The passive linkage 26 is configured to allow the shaft 174 to slide axially relative to the sleeve 74 along the constraint axis CA and to allow radial movement of the constraint shaft 174 relative to the constraint axis CA during actuation of one or more of the actuators 21, 22.

[0317] The passive linkage 26 also includes a key 176 to constrain the rotation of the shaft 174 relative to the sleeve 76 about the constraint axis CA. Key 176 is best shown in... Figure 44In the middle, key 176 is fitted into opposing keyways 178, 180 on shaft 174 and sleeve 76 to lock shaft 174 to sleeve 76 in a way that prevents relative rotation. Other arrangements for preventing relative rotation of shaft 174 and sleeve 76 are also considered, such as an integral key / slot arrangement. Passive linkage 26 operatively interconnects tool support 18 and handheld body 16 independently of actuators 21, 22. During actuation of one or more of actuators 21, 22, the effective length of passive linkage is passively adjustable along constraint axis CA. Sleeve 76, shaft 174, and key 176 represent one linkage combination for passive linkage 26. Other sizes, shapes, and numbers of linkages connected in any suitable manner can be used for passive linkage 26. Passive linkage joint 156 is pivotable relative to tool support 18 about a single pivot axis PA. The first active joint 92 and the passive linkage joint 156 define the pivot axis PA (see) which is set on the common plane CP. Figure 41 and 42 Non-parallel pivot axes PA, parallel pivot axes PA arranged in different planes, combinations thereof and / or other configurations are also considered.

[0318] As in Figure 36 As can be seen, the head 84 of the tool support 18 is arranged such that when the tool 20 is attached to the tool support 18, the tool 20 lies on a tool plane TP (e.g., the insert plane) parallel to the common plane CP. In some examples, the tool plane TP is spaced from the common plane CP by 2.0 inches or less, 1.0 inch or less, 0.8 inches or less, or 0.5 inches or less.

[0319] In the illustrated configuration, actuators 21 and 22 are arranged such that the actuating axes AA1 and AA2 are tilted relative to the constraint axis CA in all positions of actuators 21 and 22 (including in their initial positions). Tiltping axes AA1 and AA2 typically results in a gradually tapering actuator arrangement, allowing for a thinner and more compact base 74 and associated grip 72. Other configurations are conceivable, including those in which the actuating axes AA1 and AA2 are not tilted relative to the constraint axis CA. Such configurations may include those in which the actuator axes AA1 and AA2 are parallel to each other in their initial positions.

[0320] Figure 45A and 45B The surgical instruments in different actuation states are depicted. Figure 45AA surgical instrument is shown, with the lead screw 150 of its distal actuator 21 fully screwed into the carrier 116. The proximal actuator 22 is shown with an extended lead screw 150, vertically pushing the proximal end of the tool support 18, causing the distal end of the tool support 18 to tilt downwards. The tool tip 84, which holds the tool 20 in the figure, is rotated about the longitudinal axis of the tool support 18. Similarly, Figure 45B The lead screw 150 of the proximal actuator 22 is shown fully screwed into the carrier 116. The distal actuator 21 is shown with an extended lead screw 150 that vertically pushes the distal end of the tool support 18, causing the distal end of the tool support 18 to tilt upward. The tool head 84 and the tool are shown in relation to... Figure 45A It rotates in the opposite direction around the longitudinal axis of the tool support 18.

[0321] Figure 46-56C An alternative configuration of device 14 is best illustrated in the diagram. Device 14 includes a handheld body 16 for user holding, a tool support 18 movably coupled to the handheld body 16 to support a tool 20, and an actuator assembly 400 including a plurality of actuators 21, 22, 260 that operatively interconnects the tool support 18 and the handheld body 16 to move the tool support 18 in three degrees of freedom relative to the handheld body 16. Actuator 260 is a primary lifting actuator controlling z-axis translation and is configured to support and carry auxiliary actuators 21 and 22. Actuator 260 translates in the z-axis direction, causing the tool support 18 and the auxiliary actuators to move relative to the handheld body 16. Auxiliary actuators 21 and 22 are configured to adjust the pitch and yaw of the tool support 18 relative to the lifting actuator 260 and the handheld body 16. When the lifting actuator 260 moves the tool support 18 and auxiliary actuators 21, 22 away from the hand-held body, the auxiliary actuators have a greater range of motion.

[0322] Turning Figures 46-48 The handheld body 16 includes a handle 72 for a user to grip, allowing the user to manually support and freely move the device 14. The handheld body 16 can be configured as a pistol grip. The handheld body 16 also includes a base 74 to which the handle 72 is attached by one or more fasteners, adhesives, welds, etc.

[0323] Figures 46-48 A front, side, and rear perspective view of a surgical instrument 14 are depicted, in which a lifting actuator assembly 260 is coupled to a tool support. The lifting actuator assembly is operatively coupled to the tool support 18 and auxiliary actuators 21, 22 such that when the lifting actuator assembly 260 is actuated and moves vertically, the tool support 18 and auxiliary actuators 21, 22 also move vertically.

[0324] Turning Figure 49The base 74 includes a lifting actuator 260 connecting the handheld body 16 to the tool support 18. The tool support 18 is connected to the handheld body 16 via the lifting actuator 260 and auxiliary actuators 21, 22. The tool support 18 includes a tool support body 80, to which the tracker 52 can be detachably mounted via one or more tracker mounts fixed to the tool support 18. In the illustrated form, the tool 20 is detachably coupled to the tool support 18. In particular, the tool support 18 includes a tool connector, such as a head 84 to which the tool 20 is mounted, as disclosed in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference. A drive motor M for operating the tool 20 is disposed in the tool support body 80 (e.g., in some forms for driving the oscillation of the saw blade). The cutter 20 can be attached to and released from the head 84 in the manner disclosed in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference.

[0325] As in Figure 54A and 54B As best viewed, the lifting actuator 260 includes a base motor 262, a drive screw 264, and a carriage 266 having a generally hollow cylindrical shape. The carriage 266 is threaded to receive the drive screw 264, which is driven by the base motor 262. The carriage 266 is keyed and / or guided to the handheld body 16, thereby allowing the carriage 266 to translate along the drive screw 264 without rotating the carriage 266 relative to the handheld body 16 and the tool support 18. The carriage 266 includes connector supports 77 and 78 for connecting auxiliary actuators 21 and 22 to the carriage.

[0326] The lifting actuator assembly 260 is movable between a retracted position where the tool support 18 is adjacent to the handheld body 16 and an extended position where the tool support 18 is spaced away from the handheld body 16 (e.g., in...). Figures 55A-55B (As can be seen in the image). The lifting actuator 260 is arranged to allow the tool support 18 and auxiliary actuators 21, 22 to move relative to the handheld body 16 in one degree of freedom. The auxiliary actuators 21, 22, together with the lifting actuator 260, are configured to allow the tool support 18 to move relative to the handheld body 16 in three degrees of freedom. In some examples, more actuators may be provided. When the lifting actuator is in a fully extended position, spaced away from the handheld body 16, the auxiliary actuators 21, 22 have a greater translational length (…). Figure 55CIn some examples, auxiliary actuators 21, 22 may include rotary actuators. Auxiliary actuators 21, 22 may include linkage mechanisms with one or more links having any suitable size or shape. Auxiliary actuators 21, 22 may have any configuration suitable for enabling the tool support 18 to move relative to the hand-held body 16 and the carriage 266 in at least two degrees of freedom. For example, in some forms, there may be two rear auxiliary actuators, or some other actuator arrangement.

[0327] like Figure 52 and 53A As shown in -53B, the tool support 18 includes a plurality of actuator mounts 86, 88, and 90, at which actuators 21, 22, and 260 are movably connected to the tool support 18 via connectors, as further described below. The actuator mounts 86, 88, and 90 may include brackets or the like suitable for mounting the actuators 21, 22, and 260, allowing the tool support 18 to move in three degrees of freedom relative to the handheld body 16.

[0328] Figure 53A and 53B Auxiliary actuators 21 and 22 are depicted as electrically driven, linear actuators extending between the carriage 266 and the tool support body 80. When actuated, the effective lengths of actuators 21 and 22 change to alter the distance between the tool support body 80 and the carriage 266 along their respective axes. Thus, auxiliary actuators 21 and 22 cooperate to change their effective lengths and allow the tool support 18 to move relative to the handheld body 16 and the carriage 266 in at least two degrees of freedom (e.g., yaw, pitch, or both). Actuators 21 and 22 are provided and may be referred to as auxiliary actuators 21 and 22 or pitch / yaw actuators 21 and 22. Each of the auxiliary actuators 21 and 22 has a stroke length less than the stroke length of the lifting actuator 260. The effective lengths of the auxiliary actuators 21 and 22 are adjustable along a first movable axis AA1 and a second movable axis AA2, respectively (see...). Figure 53A , 54A The effective length of the lifting actuator 260 is adjustable along the third movable axis AA3, and the carriage 266 translates along the drive screw 264 when the base motor 262 is actuated. The effective lengths of the auxiliary actuators 21 and 22 are independently adjustable to adjust the pitch orientation, yaw orientation, or one or more of both of the tool support 18 relative to the handheld body 16 and the carriage 266, as previously described.

[0329] The carriage 266 of the lifting actuator 260 and the auxiliary actuators 21, 22 are connected to the tool support body 80 via a plurality of movable joints. The movable joints include a set of first movable joints 92 that connect the carriage 266 and the auxiliary actuators 21, 22 to the tool support body 80 at actuator mounts 86, 88, 90. In one form, such as Figure 52 As shown, the first movable joint 92 includes a movable U-shaped joint. The U-shaped joint includes a first pivot pin 94 and a joint block 96. The first pivot pin 94 pivotally connects the joint block 96 to actuator mounts 86, 88, 90 via a through hole 98 in the joint block 96. A retaining screw 100 secures the first pivot pin 94 to the actuator mounts 86, 88, 90. The U-shaped joint may also include a second pivot pin 104. The joint block 96 has a transverse hole 102 to receive the second pivot pin 104. The second pivot pin 104 has a through hole 103 to receive the first pivot pin 94, such that the first pivot pin 94, the joint block 96, and the second pivot pin 104 form the intersection of the U-shaped joint. The first pivot pin 94 and the second pivot pin 104 of each U-shaped joint define intersecting pivot axes. The second pivot pin 104 pivotally connects pivot yokes 106, 268 to the joint block 96. In this way, the carriage 266 and auxiliary actuators 21 and 22 can move in three degrees of freedom relative to the tool support body 80. Other types of movable joints can also be considered.

[0330] Now for reference Figure 53B Each movable joint also includes a set of second movable joints 108 for connecting auxiliary actuators 21, 22 to carriage 266. Figure 53B In this configuration, a second movable joint 108 is supported at joint supports 77, 78. Each second movable joint 108 includes a swivel yoke 110 arranged to rotate about a rotation axis SA relative to the carriage 266 and the handheld body 16. Each swivel yoke 110 has a swivel head 112 and a post 114 extending from the swivel head 112 to pivotally engage the carriage 266 at one of the joint supports 77, 78. A nut 115 is threaded onto one end of the post 114 to capture the post 114 within the carriage 266 while allowing the corresponding swivel yoke 110 to rotate freely within its respective joint support 77, 78.

[0331] like Figure 53BAs seen, each of the second movable joints 108 includes a carrier 116 pivotally coupled to one of the swivel yokes 110. The carrier 116 has a threaded through-hole 117 to receive the lead screws 150 of the first two actuators 21, 22, as further described below. Each carrier 116 also includes an opposing trunnion 118, which, by means of a recess 120 disposed on the swivel yoke 110, allows the carrier 116 to pivot about a pivot axis PA relative to the swivel yoke 110. In some forms, for each of the second movable joints 108, the axis of rotation SA intersects the pivot axis PA to define a single vertex about which the actuators 21, 22 move in two degrees of freedom.

[0332] The cover 122 is fastened to the rotating head 112 and defines one of the recesses 120, while the rotating head 112 defines the other recess 120. During assembly, the carrier 116 is first positioned such that one of the trunnions 118 is placed in the recess 120 in the rotating head 112, and then the cover 122 is fastened to the other trunnion 118 such that the carrier 116 is captured between the cover 122 and the rotating head 112 and is pivotable relative to the yoke 110 via the trunnion 118 and the recess 120. Due to the configuration of the yoke 110 and the associated carrier 116, i.e., the carrier 116 is capable of rotating about the axis of rotation SA and pivoting about the axis of pivot PA, the second movable joint 108 allows the first two actuators 21, 22 to move in two degrees of freedom relative to the base 74. Other joint arrangements between the first two actuators 21, 22 and the carriage 266 are also possible.

[0333] Stops 152, such as threaded fasteners and shoulders formed on the lead screw 150, are secured to the lead screw 150. The stops 152 are sized to abut against the carrier 116 at the end of the travel of each lead screw 150.

[0334] Actuators 21 and 22 are basically similar to those mentioned above. Figure 16 The actuators described herein. Each of actuators 21, 22, and 260 can be controlled by a separate motor controller. The motor controllers can be individually connected to actuators 21, 22, and 260 to individually guide each actuator 21, 22, and 260 to a given target position. In some examples, the motor controller is a proportional-integral-derivative (PID) controller. In some examples, the motor controller can be integrated with or form part of a device controller. For ease of illustration, the motor controller will be described herein as device controller 28 (…). Figure 7 Part of ). Lifting actuator 260 and auxiliary actuator to work with the above and Figure 1-34 The configurations described and displayed are essentially similar in their control, sensing, and power supply methods.

[0335] As previously described, the carrier 116 has a threaded through-hole 117 to threadedly receive the lead screws 150, such that each lead screw 150 can be rotated relative to a corresponding one of the carriers 116 to adjust the effective length of a corresponding actuator of the auxiliary actuators 21, 22, and thus change the count measured by the instrument controller 28. Each of the housings 134 and the corresponding carrier 116 is constrained in relative movement in at least one degree of freedom to allow the lead screw 150 to rotate relative to the carrier 116. More specifically, the lead screw 150 is able to rotate relative to the carrier 116 because: the pivot yoke 106 cannot rotate about the associated axes of motion AA1, AA2 (i.e., the pivot yoke 106 is restricted to this rotational movement due to the configuration of the first movable joint 92); and the carrier 116 cannot rotate about the associated axes of motion AA1, AA2 (i.e., the carrier 116 is restricted to this rotational movement due to the configuration of the second movable joint 108).

[0336] As mentioned earlier, the effective length of actuators 21, 22, and 260 is actively adjustable (as previously stated regarding...). Figure 16 (As described above) to enable the tool support 18 to move relative to the handheld body 16. As each actuator 21, 22, 260 is adjusted, the effective length changes by varying how far the lead screws 150, 264 are screwed into or out of their associated carriers 116, 266, and thus the distance from the center of the associated carrier 116, 266 to the center of the associated movable joint 92. The actuators 21, 22, 260 can be adjusted between a minimum and a maximum effective length. The effective length of each actuator 21, 22, 260 can be represented / measured in any suitable manner to represent the distance between the tool support 18 and the handheld body 16 along the active axes AA1, AA2, AA3, which changes to cause various movements of the tool support 18 relative to the handheld body 16.

[0337] Continue to refer to Figure 49 The head 84 of the tool support 18 is arranged such that when the tool 20 is attached to the tool support 18, the tool 20 lies on a tool plane TP (e.g., the insert plane) parallel to the common plane CP. In some examples, the tool plane TP is spaced from the common plane CP by 2.0 inches or less, 1.0 inch or less, 0.8 inches or less, or 0.5 inches or less.

[0338] exist Figure 52 , 53AIn 53B, actuators 21, 22, and 260 are arranged such that in all positions of the auxiliary actuators 21 and 22 (including when they are in their initial positions), the actuating axes AA1 and AA2 are in an inclined configuration relative to the actuating axis AA3. Inclining axes AA1 and AA2 generally allows the actuator assembly to taper gradually, enabling the carriage 266 and associated grip 72 to be thinner and more compact. Other configurations are conceivable, including those in which the actuating axes AA1 and AA2 are not in an inclined configuration relative to the third actuating axis AA3. Such configurations may include those in which the actuator axes AA1, AA2, and AA3 are parallel to each other in their initial positions.

[0339] Figure 49 and 55A -C shows that the auxiliary actuators 21, 22 are positioned distally toward the tool support 18, away from the user's hand gripping the handheld body 16, essentially eliminating the risk of the user's hand (especially the joint between the thumb and forefinger) coming into contact with the actuators 21, 22 during operation. Furthermore, with the base motor 262 located in the base of the handheld body 16 and the auxiliary actuators 21, 22 positioned distally, the instrument 14 provides thermal management by placing the actuators in different positions.

[0340] Figures 55A-55C A schematic diagram of the device 14 is shown, in which the tool support 18 is movable relative to the hand-held body 16 via a lifting actuator 260 and auxiliary actuators 21, 22. Figure 55A The lifting actuator 260 is shown in the retracted position, keeping the tool support 18 adjacent to the handheld body 16. Figure 55B A lifting actuator in the extended position is depicted, which moves the tool support 18 away from the hand-held body 16. Figure 55C The auxiliary actuators 21 and 22 are shown adjusting the tool support 18, which is in a tilt orientation. In this example, the auxiliary actuators 21 and 22 are retracted, causing the tool support 18 and the tool 20 to tilt downwards.

[0341] Figures 56A-56C The auxiliary actuators 21 and 22 are shown in different actuation states. Figure 56A In the middle, the auxiliary actuators 21 and 22 are in the initial position, keeping the tool 20 on the horizontal plane. Figure 56B The diagram shows auxiliary actuator 22 in the retracted position and auxiliary actuator 21 in the extended position, altering the oscillation of the tool support 18 and the tool 20. Similarly, Figure 56C This shows that auxiliary actuator 21 is retracted and auxiliary actuator 22 is in the extended position, in relation to... Figure 56B The tool support 18 and the tool 20 swing in opposite directions.

[0342] Figure 57 A perspective view is shown of an alternative configuration of the robotic instrument 14, which is configured to be used as a modular tooling system 300. Figure 57 The instrument described above is substantially similar in configuration to that discussed above, having an actuator assembly 400 comprising multiple actuators 21, 22, 23 and a constraint assembly 24. The instrument 14 is configured to move in at least three degrees of freedom (e.g., pitch, yaw, and sag). The instrument 14 is configured as a modular cutting tool system for use with multiple modular cutting tool heads. The modular cutting tool system 300 is configured to detachably attach and replace different modular cutting tool heads (302, 304, 306, 308) into the instrument 14 to perform different functions during surgery. The cutting tool support body 80 includes a receiving portion 332 (e.g., a chuck) for receiving the multiple modular cutting tool heads 302, 304, 306, 308, as discussed further below. The receiving portion 332 includes a locking feature 316 for receiving and securing the multiple modular heads 302, 304, 306, 308. The receiving section 332 includes a drive receiver 318 connected to the output of the motor M, which is configured to provide rotational power to one or more of the modular tool heads 302, 308 when necessary.

[0343] Figures 58A-58D Describing the use of with Figure 57 A perspective view of multiple modular tool attachments used together with the robotic instrument 14. Figures 58A-58D Each of the modular tool heads 302, 304, 306, and 308 shown includes a connection and insertion mechanism. Figure 57 The instrument 14 shown includes a connecting portion 326 within its receiving portion. Each connecting portion 326 includes a lock 314 configured to engage a locking feature 316 of the receiving portion 332. The connecting portion 326 of each of the modular cutter heads 302, 304, 306, and 308 can be configured to align and insert into the receiving portion 332 of the instrument 14. Each of the cutter heads 302, 304, 306, and 308 can be locked into the receiving portion 332 of the instrument 14. Those skilled in the art will understand that any suitable locking configuration and / or method can be contemplated.

[0344] Figure 58A A modular saw head 302 is depicted, which is configured to consist of Figure 57 The instrument 14 is received. The modular saw head 302 includes a shaft 310, which is configured to be located by... Figure 57The shaft receiver 318 in the instrument 14 receives the shaft. The shaft receiver 318 is connected to the motor M to provide rotational force to the shaft 310, thereby powering the modular saw head 302. The modular saw head 302 includes a transmission 312 for converting the rotational motion of the shaft 310 into another type of motion (e.g., oscillation; orbital motion, etc.) at the tool mount 320. The tool mount 320 is configured to receive a cutting tool for performing surgical procedures.

[0345] Similar to Figure 58A , Figure 58B Modular probe 304 is depicted. Modular probe 304 is configured to consist of... Figure 57 The instrument 14 receives the device. The modular probe 304 includes a longitudinally extending rod 324 having a rounded tip 325. The modular probe 304 is configured for use with the navigation system 32 to determine surfaces and / or areas of interest to the surgeon. The modular probe 304 can be used to register a surgical device, a patient, or both to the navigation system 32. The modular probe 304 is configured to be detachably connected to the instrument 14.

[0346] Figure 58C Depicting and Figure 57 A modular bone chisel 306 is used in conjunction with the instrument 14. The modular bone chisel 306 includes a connection portion 326 for attachment to the instrument 14 and a chisel portion 328 extending from the connection portion 326. The modular bone chisel 306 is shown as having a curved chisel portion 328; however, other shapes, curves, and lengths are also considered.

[0347] Figure 58D It shows the relationship with Figure 57 The modular drill bit 308 is used in conjunction with the instrument 14. The modular drill bit 308 includes a shaft 310, which is configured to be located by means of a... Figure 57 The shaft receiver 318 in the device 14 receives the load. The shaft receiver 318 is connected to the motor M to provide rotational force to the shaft 310, thereby powering the modular drill bit 308. The modular drill bit 308 includes a transmission device 312 in the connection portion 326, which includes a system for increasing or decreasing the rotational speed and torque provided by the motor M to change the rotational speed and torque of the drill bit 330. Any of the aforementioned tools can be directly fixed to the tool support 18 and / or detachably connected to the tool support.

[0348] Figure 59This is a perspective view of a robotic instrument 14 configured as a cutting guide 340. In this configuration, a tool support body is configured as the cutting guide 340, which is adjustable in at least three degrees of freedom (e.g., pitch, yaw, and rise) via actuators 21, 22, and 23. The cutting guide 340 is configured for use with surgical instruments, such as a saw, during surgical procedures. The robotic instrument communicates with a control system and a navigation system to guide the user in positioning the cutting guide 340 for selective surgical cuts without attaching the guide to the anatomical object being operated on. The cutting guide 340 includes a body 342 connected to the actuators 21, 22, and 23 and a constraint assembly 24, and a gripper 344 extending from the body 342. The gripper 344 includes a saw blade opening 346 configured to constrain the saw blade to a selected cutting plane, preventing the saw from deviating from the desired cutting area.

[0349] In this application, the term "controller" is replaced by the term "circuit" as defined below. The term "controller" may refer to, be part of, or include the following: application-specific integrated circuit (ASIC); digital, analog, or mixed-signal analog / digital discrete circuit; digital, analog, or mixed-signal analog / digital integrated circuit; combinational logic circuit; field-programmable gate array (FPGA); processor circuitry (shared, dedicated, or grouped) that executes code; memory circuitry (shared, dedicated, or grouped) that stores code executed by the processor circuitry; other suitable hardware components that provide the described functionality; or combinations of some or all of the above, such as in a system-on-a-chip.

[0350] The controller may include one or more interface circuits. In some examples, the interface circuits may implement wired or wireless interfaces for connection to a local area network (LAN) or a wireless personal area network (WPAN). Examples of LANs are Institute of Electrical and Electronics Engineers (IEEE) Standard 802.11-2016 (also known as the Wi-Fi wireless network standard) and IEEE Standard 802.3-2015 (also known as the Ethereum wired network standard). An example of a WPAN is the BLUETOOTH wireless network standard from the Bluetooth Special Interest Group and IEEE Standard 802.15.4.

[0351] The controller can communicate with other controllers using interface circuitry. Although the controller may be described in this disclosure as communicating logically directly with other controllers, in various configurations, the controller may actually communicate via a communication system. Communication systems include physical and / or virtual network devices such as hubs, switches, routers, and gateways. In some configurations, the communication system is connected to or spans a wide area network (WAN), such as the Internet. For example, the communication system may include multiple LANs interconnected via the Internet or peer-to-peer leased lines using technologies including Multiprotocol Label Switching (MPLS) and Virtual Private Networks (VPNs).

[0352] In various configurations, the functionality of a controller can be distributed among multiple controllers connected via a communication system. For example, multiple controllers can perform the same functionality distributed by a load balancing system. In another example, the functionality of a controller can be distributed between a server (also known as a remote or cloud) controller and a client (or user) controller.

[0353] Some or all of the controller's hardware characteristics can be defined using a hardware description language, such as IEEE Standard 1364-2005 (commonly referred to as "Verilog") and IEEE Standard 10182-2008 (commonly referred to as "VHDL"). Hardware description languages ​​can be used to manufacture and / or program hardware circuits. In some configurations, some or all of the controller's characteristics can be defined by a language such as IEEE 1666-2005 (commonly referred to as "SystemC"), which includes both code and hardware description as described below.

[0354] Various controller programs can be stored on memory circuitry. The term memory circuitry is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not include transient electrical or electromagnetic signals propagating through a medium (e.g., on a carrier wave); therefore, the term computer-readable medium can be considered tangible and non-transitory. Non-limiting examples of non-transitory computer-readable media are non-volatile memory circuitry (e.g., flash memory circuitry, erasable programmable read-only memory circuitry, or mask read-only memory circuitry), volatile memory circuitry (e.g., static random access memory circuitry or dynamic random access memory circuitry), magnetic storage media (such as analog or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray Discs).

[0355] The apparatus and methods described in this application can be implemented, partially or entirely, by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The aforementioned function blocks and flowchart elements, as software specifications, can be translated into computer programs through the routine work of skilled technicians or programmers.

[0356] A computer program includes processor-executable instructions stored on at least one non-transitory computer-readable medium. A computer program may also include or depend on stored data. A computer program may include a basic input / output system (BIOS) for interacting with the hardware of a special-purpose computer, device drivers for interacting with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0357] Computer programs may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated from source code by a compiler; (iv) source code executed by an interpreter; and (v) source code compiled and executed by a just-in-time (JIT) compiler, etc. As an example only, source code may be written using syntax rules from languages ​​including: C, C++, C#, Objective C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, JavaScript®, HTML5 (Hypertext Markup Language Version 5), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SENSORLINK, and Python®.

[0358] Terms and Conditions

[0359] i. A handheld robot system for use with a cutting tool, the system comprising: an apparatus including a handheld portion for being held by a user and a cutting tool support coupled to the handheld portion to support the cutting tool; a guide array coupled to the apparatus and controllable to visually indicate to the user desired changes in the pitch, yaw, and translational aspects of the cutting tool to achieve a desired posture; and a controller coupled to the guide array and configured to automatically adjust the guide array to visually indicate desired changes in pitch, yaw, and translational aspects as the user moves the cutting tool.

[0360] ii. A handheld robot system for use with a cutting tool, the system comprising: an apparatus including a handheld portion for being held by a user and a cutting tool support coupled to the handheld portion to support the cutting tool; a guide array coupled to the apparatus and arranged to represent a plane of the cutting tool, the guide array being controllable to visually indicate to the user desired changes in the pitch orientation, yaw orientation, and translation of the cutting tool in order to achieve a desired posture; and a controller coupled to the guide array to control the operation of the guide array.

[0361] iii. A handheld robot system according to clause ii, wherein the controller is configured to enable the user to operate the guide array in a manner that distinguishes between desired changes in pitch orientation, desired changes in yaw orientation, and desired changes in translation.

[0362] iv. The handheld robot system of Clause ii, wherein the guide array includes a first visual indicator, a second visual indicator and a third visual indicator, each of which includes one or more illumination sources coupled to the controller.

[0363] v. Clause iv. A handheld robot system, wherein each visual indicator comprises an upper and a lower portion, and the controller is configured to control the illumination of the upper and lower portions, causing the upper and lower portions to operate in different states to indicate the desired direction of movement of the plane of the tool.

[0364] vi. A handheld robot system of clause v, wherein a controller is configured to control the lighting of the upper and lower parts, so that the upper and lower parts operate in the same state to indicate that the corresponding point is in the desired position.

[0365] vii. Clause v. Handheld robot system in which each visual indicator is arranged in a plane representing a cutting tool.

[0366] viii. Clause vii's handheld robot system, wherein a tool support defines a central plane, wherein first and second vision indicators are offset from the central plane on opposite sides of the central plane and the central plane passes through a third vision indicator.

[0367] ix. Clause viii's handheld robot system, wherein the controller is configured to control the upper and lower lighting to indicate to the user the desired changes in one or more aspects of the tool's pitch orientation, yaw orientation, and translation position relative to the desired orientation.

[0368] x. Clause viii's handheld robot system, wherein the controller is configured to control the upper lighting to operate in a first state and to control the lower lighting to operate in a second state different from the first state, so as to instruct the user to change the translation position of the tool.

[0369] The handheld robot system of clause xi.viii, wherein the controller is configured to control the illumination of the upper part of the third vision indicator to operate in a first state and to control the illumination of the upper parts of the first and second vision indicators to operate in a second state different from the first state, so as to instruct the user to change the pitch orientation of the tool.

[0370] xii. Clause viii's handheld robot system, wherein a controller is configured to control the illumination of the upper part of a first vision indicator to operate in a first state and to control the illumination of the upper part of a second vision indicator to operate in a second state different from the first state, so as to instruct the user to change the yaw orientation of the tool.

[0371] xiii. Clause iv's handheld robot system, wherein each vision indicator is arranged along a tool support such that the first and second vision indicators are located far from the third vision indicator.

[0372] Article xiv. Handheld robot system, wherein each visual indicator has a spherical shape, having an upper hemisphere and a lower hemisphere capable of operating in different states.

[0373] A handheld robot system according to Clause ii of XV includes a tracker mount that is fixed to the tool support to detachably receive a navigation tracker separated from the guide array.

[0374] xvi. A handheld robotic system for use with a cutting tool, the robotic system comprising: a handheld portion for being held and supported by a user; a tool support movably coupled to the handheld portion to support the cutting tool; a plurality of actuators operatively interconnecting the tool support and the handheld portion to move the tool support in three degrees of freedom relative to the handheld portion to position the cutting tool on a desired trajectory or plane, each of the plurality of actuators being adjustable between a maximum position and a minimum position and having an initial position between the maximum position and the minimum position; and a vision indicator associated with the plurality of actuators to indicate the desired movement of the handheld portion; and a controller coupled to the vision indicator to control the operation of the vision indicator to indicate the desired movement of the handheld portion.

[0375] xvii. A handheld robot system comprising: a handheld portion for being held by a user; a tool support movably coupled to the handheld portion to support a tool; a plurality of actuators operatively interconnected to move the tool support in three degrees of freedom relative to the handheld portion, thereby positioning the tool on a desired trajectory or plane, each of the plurality of actuators being adjustable between a maximum position and a minimum position and having an initial position between the maximum and minimum positions; a vision indicator associated with the plurality of actuators to indicate a desired movement of the handheld portion; and a controller coupled to the plurality of actuators and the vision indicator to control operation in a plurality of modes including: an initial mode in which the controller automatically adjusts each of the plurality of actuators to their initial positions; a proximity mode in which the controller indicates a desired movement of the tool to position the tool on a desired trajectory or plane while the plurality of actuators are in their initial positions; and an aiming mode in which the tool is substantially on the desired trajectory or plane, and the controller indicates a desired movement of the handheld portion to hold the tool on the desired trajectory or plane.

[0376] xviii. A method for initializing a handheld robot system for use, the method comprising: providing an apparatus including a handheld portion for being held by a user and a blade support coupled to the handheld portion to support a saw blade, a plurality of actuators operatively interconnecting the blade support and the handheld portion to move the blade support in three degrees of freedom relative to the handheld portion, wherein each of the plurality of actuators includes an encoder configured to output an encoder output signal; determining the orientation of the handheld portion in a known coordinate system at a first moment; acquiring the encoder signal of each of the plurality of actuators at a first moment; and determining an initial position based on the orientation of the handheld portion and the encoder signal.

[0377] xix. A method for moving a guiding device having a handheld portion for being held by a user and a tool support attached to the handheld portion to support a tool, wherein a guiding array is attached to the device and arranged in a plane representing the tool, the method comprising the steps of: visually indicating to the user desired changes in the pitch orientation, yaw orientation and translation of the tool in order to achieve a desired posture.

[0378] xx. A method for guiding the movement of a robotic instrument having a handheld portion for being held by a user, a tool support movably coupled to the handheld portion to support a tool, a plurality of actuators operatively interconnected with the tool support and the handheld portion to move the tool support in three degrees of freedom relative to the handheld portion to place the tool on a desired trajectory or plane, and a visual indicator associated with the plurality of actuators, the method comprising the steps of: controlling the operation of the robotic instrument in a plurality of modes including: an initial mode in which the controller automatically adjusts each of the plurality of actuators to an initial position between a maximum position and a minimum position; and a proximity mode in which the controller instructs a desired movement of the tool to place the tool on a desired trajectory or plane while the plurality of actuators are in their initial positions; and an aiming mode in which the tool is approximately on the desired trajectory or plane, and the controller instructs a desired movement of the handheld portion to hold the tool on the desired trajectory or plane.

[0379] xxi. A robotic surgical instrument comprising: a handheld body for user-held use; a tool support movably coupled to the handheld body; a tool connector supported by the tool support; and a plurality of actuators for moving the tool support relative to the handheld body in multiple degrees of freedom, the plurality of actuators including: a pair of linear actuators operatively interconnecting the tool support and the handheld body, each of the pair of linear actuators having a first portion connected to the handheld body and a second portion connected to the tool support, the pair of linear actuators being arranged for controlling the lifting and pitching of the tool support relative to the handheld body; and a rotary actuator arranged for controlling the oscillating movement of the tool connector relative to the tool support and the handheld body.

[0380] The surgical instruments of xxii. Clause xxi also include a restraint assembly having a passive linkage mechanism that operatively interconnects a tool support and a handheld body, the passive linkage mechanism being coupled to the tool support and the handheld body in a manner configured to restrain the movement of the tool support relative to the handheld body in three degrees of freedom.

[0381] xxiii. A surgical instrument of clause xxii, wherein the pair of linear actuators includes a first actuator whose effective length is adjustable along a first axis and a second actuator whose effective length is adjustable along a second axis.

[0382] xxiv. Clause xxiii of the surgical instruments wherein the effective length of the passive linkage is adjustable along a constraint axis, the constraint axis being coplanar along a central plane throughout the actuation of the plurality of actuators.

[0383] Surgical instruments according to Article xxv.xxiv, wherein a linear actuator is pivotally coupled to a tool support and pivotally coupled to a hand-held body, such that the linear actuator is pivotable relative to the tool support and the hand-held body during actuation.

[0384] Surgical instruments of xxvi. xxiv, wherein the effective lengths of the first actuator and the second actuator of the pair of linear actuators are independently adjustable to adjust the pitch and vertical orientation of the tool support relative to the hand-held body.

[0385] Surgical instruments of xxvii. xxiii, wherein the rotary actuator comprises a motor and a housing.

[0386] xxviii. Clause xxvii. Surgical instruments in which a restraint assembly is pivotally coupled to the housing of a rotary actuator, thereby connecting the restraint assembly to a tool support.

[0387] xxix. Clause xxii. Surgical instruments wherein a rotary actuator is connected to a tool support and a tool connector, the rotary actuator being configured to rotate the tool connector 360 degrees relative to both the tool support and the hand-held body.

[0388] Surgical instruments of clause xxii, wherein the pair of linear actuators are aligned along a longitudinal plane that divides the hand-held body in two.

[0389] Surgical instruments of xxxi. xxix, wherein the rotary actuator comprises a motor having a drive member rotatably connected to a ring gear.

[0390] xxxii. Surgical instruments of clause xxxi, wherein the drive component of the motor is a worm and the ring gear is configured as a worm wheel.

[0391] xxxiii. Surgical instruments of clause xxxi, wherein the driving component of the motor is a spur gear.

[0392] Surgical instruments of xxxiv. Clause xxiii, wherein a spur gear is rotatably connected to an idler gear, and the idler gear is rotatably connected to a ring gear.

[0393] Surgical instruments of xxxv., xxxi, wherein a ring gear and a cutter connector are arranged such that the ring gear and the cutter connector rotate together when a rotary actuator is activated.

[0394] Surgical instruments of clause xxxvi.xxxv, wherein the cutter support includes an auxiliary motor for driving the movement of the cutter connector.

[0395] xxxvii. Clause xxxvi's surgical instruments, wherein the tool connector includes a working end and the auxiliary motor is configured to actuate the working end of the tool connector, wherein the rotary actuator is configured to rotate the tool connector independently of the auxiliary motor.

[0396] Surgical instruments of clause xxxviii.xxxvi, wherein the cutter connector includes a transmission device coupled to the auxiliary motor for converting rotational motion from the auxiliary motor into oscillating motion of the cutter.

[0397] xxxix. Clause xxxvii Surgical instruments in which the working end of a cutter connector is attached to a saw blade so that the saw blade oscillates when an auxiliary motor is activated.

[0398] XL. XXXIX surgical instruments, wherein a cutter connector is configured to rotate the cutter connector and the saw blade while the saw blade oscillates when an auxiliary motor is activated, thereby changing the cutting plane of the saw blade.

[0399] xli. Clause xxxi Surgical instruments, wherein the motor of the rotary actuator is arranged along the plane of the tool support.

[0400] A surgical instrument of xlii. xxxvi, wherein the tool connector includes a working end and the auxiliary motor is configured to rotate the working end of the tool connector, wherein the rotary actuator is configured to rotate the tool connector and the auxiliary motor together.

[0401] xliii. A robotic surgical instrument for use with a surgical instrument, the surgical instrument comprising: a handheld body for being held by a user; a tool support movably coupled to the handheld body to support the tool; a plurality of actuators for moving the tool support relative to the handheld body in multiple degrees of freedom, the plurality of actuators comprising: a lifting actuator having a first portion connected to the handheld body and a second portion connected to the tool support; and a pair of auxiliary actuators, each of the pair of auxiliary actuators comprising an actuator portion operatively connected to the lifting actuator and a support portion operatively connected to the tool support, such that each of the pair of auxiliary actuators is arranged to effectively operate between the lifting actuator and the tool support to move the tool support relative to the lifting actuator; wherein the lifting actuator is arranged to move both the tool support and the auxiliary actuator relative to the handheld body in one degree of freedom.

[0402] The surgical instruments of the xliv. clause xliii, wherein the effective length of each of the plurality of actuators is actively adjustable.

[0403] XLV. Clause XLIII surgical instruments, wherein an auxiliary actuator can operate independently of a lifting actuator to control the pitch and yaw of a tool support.

[0404] According to clause xliv, a surgical instrument wherein the lifting actuator is movable between a retracted position where the tool support is adjacent to the hand-held body and an extended position where the tool support is spaced away from the hand-held body; wherein, since the distance between the hand-held body and the tool support is greater in the extended position, the auxiliary actuator has a greater translational length in the extended position relative to the retracted position.

[0405] The surgical instruments of the xlvii. clause xliii, wherein the lifting actuator has a first stroke length, and each of the auxiliary actuators has a second stroke length less than the first stroke length.

[0406] A surgical instrument of clause xlviii.xliii, wherein a handheld portion comprises a proximal end and a distal end, a lifting actuator is located between the proximal and distal ends of the handheld portion, and an auxiliary actuator is located distal to the lifting actuator.

[0407] The surgical instruments of xlix. Clause xliii, wherein the pair of auxiliary actuators includes a first actuator with an effective length adjustable along a first active axis, a second actuator with an effective length adjustable along a second active axis; and wherein the effective length of the lifting actuator is adjustable along a third active axis.

[0408] 1. Clause xliv's surgical instruments, including a controller coupled to multiple actuators to control the adjustment of the multiple actuators to define a virtual saw cutting guide.

[0409] The surgical instruments of clause 1, wherein a controller is configured to control multiple actuators to return to an initial position between the minimum and maximum effective lengths of the actuators.

[0410] lii. Clause li's surgical instruments, wherein a controller is configured to control the pitch orientation, yaw orientation, and translational position of a tool support relative to a handheld body to define a virtual saw cutting guide.

[0411] liii. Clause 1 Surgical instruments, wherein the controller comprises a control housing mounted to the tool support and a control plate located inside the control housing.

[0412] A surgical instrument of clause 1, wherein a motor for driving the movement of a cutting tool is connected to a tool support.

[0413] lv. A handheld robotic system for use with surgical instruments, the system comprising: an instrument including a handheld portion for being held and supported by a user; a blade support movably coupled to the handheld portion to support the surgical instrument; a plurality of actuators operatively interconnected to move the blade support in three degrees of freedom relative to the handheld portion, thereby positioning the surgical instrument in a desired position, orientation, or orientation; and a vision indicator for indicating the desired movement of the handheld portion; and a controller coupled to the plurality of actuators to control the adjustment of the plurality of actuators to hold the surgical instrument in the desired position, orienta...

Claims

1. A handheld robotic instrument for use with a scalpel to perform surgery, the robotic instrument comprising: For the handheld portion held by the user; A tool support is movably connected to the handheld portion to support the tool; Multiple actuators operatively interconnect the tool support and the handheld portion to allow the tool support to move in three degrees of freedom relative to the handheld portion, wherein the effective length of each of the multiple actuators is actively adjustable. and A constraint assembly having a passive linkage mechanism that operatively interconnects the tool support and the handheld portion independently of the plurality of actuators, the passive linkage mechanism being coupled to the tool support and the handheld portion in a manner configured to constrain the movement of the tool support relative to the handheld portion in three degrees of freedom, the effective length of the passive linkage mechanism being passively adjustable.

2. The robotic device according to claim 1, wherein, The constraint assembly includes a passive linkage joint that connects the passive linkage to the tool support.

3. The robotic device according to claim 2, wherein, The passive linkage mechanism connector includes a passive linkage mechanism U-shaped connector or a passive linkage mechanism ball connector.

4. The robotic device according to claim 2, wherein, The passive linkage includes a shaft and a sleeve configured to receive the shaft along a constraint axis. The passive linkage is configured to allow the shaft to slide axially relative to the sleeve along the constraint axis and is configured to constrain radial movement of the shaft relative to the constraint axis during actuation of one or more of the plurality of actuators.

5. The robotic device according to claim 4, wherein, The passive linkage includes a key for constraining the rotation of the shaft relative to the sleeve about a constraint axis.

6. The robotic device according to claim 4, wherein, Each of the plurality of actuators is arranged along a movable axis, which is configured to be arranged at an angle relative to a constraint axis.

7. The robotic instrument according to any one of claims 3-6, comprising a plurality of first movable joints connecting the plurality of actuators to a tool support.

8. The robotic device according to claim 7, wherein, Each of the plurality of first movable joints includes a movable U-shaped joint or a movable ball joint.

9. The robotic device according to claim 8, wherein, The first movable joint and the passive linkage joint define parallel pivot axes disposed on a common plane.

10. The robotic device according to claim 9, wherein, The tool support includes a tool connector arranged such that when the tool is detachably connected to the tool support, the tool lies on a tool plane parallel to a common plane.

11. The robotic device according to claim 10, wherein, The cutting plane is spaced 1.0 inch or less from the common plane.

12. The robotic device of claim 8, comprising a second movable joint for connecting two of the plurality of actuators to a handheld portion and a third movable joint for connecting one of the plurality of actuators to the handheld portion.

13. The robotic device according to claim 12, wherein, Each of the second movable joints includes a rotational yoke arranged to rotate about a rotation axis relative to the hand-held portion, and the third movable joint includes a pivot housing fixed to the hand-held portion.

14. The robotic device according to claim 13, wherein, Each of the second movable joints includes a carrier pivotally connected to one of the rotating yokes, and the third movable joint includes a carrier pivotally connected to the pivot housing.

15. The robotic device according to claim 14, wherein, Each of the carriers includes a trunnion.

16. The robotic device according to claim 14, wherein, Each of the plurality of actuators includes a lead screw, and the carrier is configured to threadably receive the lead screw such that each lead screw is rotatable relative to a corresponding carrier to adjust the effective length of the corresponding actuator.

17. The robotic device according to claim 16, wherein, Each of the plurality of actuators includes a motor having a rotor that is fixed to one of the lead screws, and each of the plurality of actuators includes a housing, the rotor being configured to rotate relative to the housing.

18. The robotic device of claim 16, further comprising a stop fixed to the lead screw, the stop being sized to abut against the carrier at the end of the lead screw's travel.

19. The robotic device according to claim 17, wherein, Each of the housings and its corresponding carrier is constrained to relative movement in a first degree of freedom to allow the lead screw to rotate relative to the carrier.

20. The robotic device according to claim 17, wherein, Each of the first movable joints includes a pivot yoke extending from a corresponding housing in the housing.

21. The robotic device according to claim 1, wherein, The plurality of actuators includes a first actuator whose effective length is adjustable along a first movable axis, a second actuator whose effective length is adjustable along a second movable axis, and a third actuator whose effective length is adjustable along a third movable axis.

22. The robotic device according to claim 21, wherein, The effective length of the passive linkage mechanism is adjustable along the constraint axis, and the constraint axis and the third active axis are coplanar along the central plane throughout the actuation process of the plurality of actuators.

23. The robotic device according to claim 21, wherein, The first, second, and third actuators are pivotally coupled to the tool support and the handheld part, such that the first, second, and third actuators can pivot relative to the tool support and the handheld part during actuation.

24. The robotic device according to claim 21, wherein, The effective lengths of the first, second, and third actuators are independently adjustable to adjust one or more of the rocking, pitching, and translational positions of the tool support relative to the handheld portion.

25. The robotic device according to claim 1, wherein, The tool support includes a motor for driving the movement of the tool.

26. The robotic device according to claim 25, wherein, The tool support includes a transmission device connected to a motor for converting the rotational motion from the motor into the oscillating motion of the tool.

27. The robotic device according to claim 1, wherein, The robotic device weighs less than 6 pounds.

28. The robotic device according to claim 27, wherein, The handheld portion is configured for user gripping and manual support.

29. A handheld robotic instrument for use with a saw blade to perform surgery, the robotic instrument comprising: For the handheld portion held by the user; A blade support is movably connected to the handheld portion to support the saw blade; Multiple actuators operatively interconnect the blade support and the handheld portion to allow the blade support to move relative to the handheld portion in three degrees of freedom; A constraint assembly having a passive linkage mechanism that, independently of the plurality of actuators, operatively interconnects the blade support and the handheld portion to constrain the movement of the blade support relative to the handheld portion in three degrees of freedom, the effective length of the passive linkage mechanism being passively adjustable. and A controller is coupled to the plurality of actuators to control the adjustment of the plurality of actuators to hold the saw blade along a plane.

30. The robotic device according to claim 29, wherein, The plurality of actuators includes a first actuator whose effective length is adjustable along a first movable axis, a second actuator whose effective length is adjustable along a second movable axis, and a third actuator whose effective length is adjustable along a third movable axis. The effective length of the passive linkage mechanism is adjustable along a constraint axis.

31. The robotic device according to claim 30, wherein, The effective lengths of the first, second, and third actuators are independently adjustable to adjust one or more of the swing orientation, pitch orientation, and translation position of the blade support relative to the handheld part.

32. The robotic device according to claim 30, wherein, The controller is configured to control the actuator to return it to an initial position between the minimum and maximum effective length of the actuator.

33. The robotic device according to claim 29, wherein, The controller is configured to control the pitch orientation, yaw orientation, and translation position of the blade support relative to the handheld part.

34. The robotic device according to claim 29, wherein, The controller includes a control housing mounted to the blade support and a control board located inside the control housing.

35. The robotic device according to claim 34, wherein, The controller includes a remote console that communicates data and power with the control board.

36. The robotic device according to claim 29, wherein, The blade support includes a motor for driving the movement of the saw.

37. The robotic device according to claim 36, wherein, The blade support includes a transmission device connected to a motor for converting the rotational motion from the motor into the oscillating motion of the saw.

38. The robotic device according to claim 29, wherein, The handheld portion includes a grip for the user to hold.

39. The robotic device according to claim 38, wherein, The handheld portion is configured for user gripping and manual support.

40. The robotic device of claim 29 further includes a tracker mount attached to the blade support for detachably receiving the navigation tracker.

41. The robotic device according to any one of claims 29-40, further comprising a guide array coupled to the device and controllable to visually indicate to the user one or more desired changes in pitch orientation, yaw orientation, and translation of the handheld portion in order to achieve a desired posture.

42. The robotic device according to claim 29, wherein, The robotic device weighs less than 6 pounds.

43. A method for using a robotic instrument with a cutting tool, the robotic instrument comprising a handheld portion for being held by a user, a cutting tool support movably coupled to the handheld portion to support the cutting tool, a plurality of actuators operatively interconnecting the cutting tool support and the handheld portion, and a constraint assembly having a passive linkage mechanism operatively interconnecting the cutting tool support and the handheld portion independently of the plurality of actuators, the effective length of the passive linkage mechanism being passively adjustable, the method comprising the steps of: By actively adjusting one or more effective lengths of the plurality of actuators, the tool support can move in three degrees of freedom relative to the handheld part; and The movement of the tool support relative to the handheld part is constrained in three degrees of freedom.

44. A robotic surgical instrument, comprising: For use as a handheld object to be held by a user; a tool support that is movably connected to the handheld object; A tool connector supported by a tool support member; A plurality of actuators that move a tool support relative to a handheld body in multiple degrees of freedom, the plurality of actuators including: a pair of linear actuators operatively interconnecting the tool support and the handheld body, each of the pair of linear actuators having a first portion connected to the handheld body and a second portion connected to the tool support, the pair of linear actuators being arranged to control the lifting and pitching of the tool support relative to the handheld body. A rotary actuator is arranged to control the swinging movement of the tool connector relative to the tool support and the handheld body. The surgical instrument also includes a restraint assembly having a passive linkage mechanism that operatively interconnects the tool support and the handheld body independently of the plurality of actuators. The passive linkage mechanism is coupled to the tool support and the handheld body in a manner configured to restrain the movement of the tool support relative to the handheld body in three degrees of freedom, and the effective length of the passive linkage mechanism is passively adjustable.

45. The surgical instrument according to claim 44, wherein, The pair of linear actuators includes a first actuator whose effective length is adjustable along a first axis and a second actuator whose effective length is adjustable along a second axis.

46. ​​The surgical instrument according to claim 44, wherein, The effective length of the passive linkage is adjustable along the constraint axis, which is coplanar along the central plane throughout the actuation process of the plurality of actuators.

47. The surgical instrument according to claim 46, wherein, The linear actuator is pivotally coupled to a tool support and pivotally coupled to a handheld body, such that the linear actuator can pivot relative to the tool support and the handheld body during actuation.

48. The surgical instrument according to claim 46, wherein, The effective lengths of the first actuator and the second actuator of the pair of linear actuators are independently adjustable to adjust the pitch and vertical orientation of the tool support relative to the handheld body.

49. The surgical instrument according to claim 45, wherein, The rotary actuator includes a motor and a housing.

50. The surgical instrument according to claim 49, wherein, The constraint assembly is pivotally coupled to the housing of the rotary actuator, thereby connecting the constraint assembly to the tool support.

51. The surgical instrument according to claim 44, wherein, The rotary actuator is connected to the tool support and the tool connector, and the rotary actuator is configured to rotate the tool connector 360 degrees relative to both the tool support and the handheld body.

52. The surgical instrument according to claim 44, wherein, The pair of linear actuators are aligned along the longitudinal plane that divides the handheld body in two.

53. The surgical instrument according to claim 51, wherein, The rotary actuator includes a motor with a drive member rotatably connected to a ring gear.

54. The surgical instrument according to claim 53, wherein, The driving component of the motor is a worm gear and the ring gear is configured as a worm wheel.

55. The surgical instrument according to claim 53, wherein, The driving component of the motor is a spur gear.

56. The surgical instrument according to claim 55, wherein, The spur gear is rotatably connected to the idler gear, which is rotatably connected to the ring gear.

57. The surgical instrument according to claim 53, wherein, The ring gear and the tool connector are arranged such that the ring gear and the tool connector rotate together when the rotary actuator is activated.

58. The surgical instrument according to claim 57, wherein, The tool support includes an auxiliary motor for driving the movement of the tool connector.

59. The surgical instrument according to claim 58, wherein, The tool connector includes a working end and the auxiliary motor is configured to actuate the working end of the tool connector, wherein the rotary actuator is configured to rotate the tool connector independently of the auxiliary motor.

60. The surgical instrument according to claim 58, wherein, The tool connector includes a transmission device connected to the auxiliary motor for converting the rotational motion from the auxiliary motor into the oscillating motion of the tool.

61. The surgical instrument according to claim 59, wherein, The working end of the tool connector is attached to the saw blade, so that the saw blade swings when the auxiliary motor is activated.

62. The surgical instrument according to claim 61, wherein, The cutter connector is configured to rotate both the cutter connector and the saw blade while the saw blade oscillates when the auxiliary motor is activated, thereby changing the cutting plane of the saw blade.

63. The surgical instrument according to claim 53, wherein, The motor of the rotary actuator is arranged along the plane of the tool support.

64. The surgical instrument according to claim 58, wherein, The tool connector includes a working end and the auxiliary motor is configured to rotate the working end of the tool connector, wherein the rotary actuator is configured to rotate the tool connector and the auxiliary motor together.

65. A handheld robotic instrument for use with a scalpel to perform surgery, the robotic instrument comprising: For the handheld portion held by the user; A tool support is movably connected to the handheld portion to support the tool; Multiple actuators operatively interconnect the tool support and the handheld portion to allow the tool support to move relative to the handheld portion in at least three degrees of freedom; A constraint assembly having a linkage mechanism that operatively interconnects a tool support and a handheld portion, the linkage mechanism being coupled to the tool support and the handheld portion in a manner configured to constrain the movement of the tool support relative to the handheld portion in at least two degrees of freedom, wherein the linkage mechanism operatively interconnects the tool support and the handheld portion independently of the plurality of actuators, and the effective length of the linkage mechanism is passively adjustable.

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