Navigation arrays and related methods for use with robotic arms

Abstract

Navigation apparatus guidance systems and related methods are provided that can identify the absolute position of an apparatus received within an apparatus mount of a robotic arm. A navigation array unit of the guidance system can include a master array and a mounting array. The master array can identify the position of the robotic arm and the apparatus mount, while the mounting array can identify the depth position of a distal end of an apparatus received within the apparatus mount. As the apparatus is inserted into the apparatus mount, the apparatus can pass through a lumen of the mounting array. The mounting array can be configured to translate relative to the apparatus mount and the master array as the distal end of the apparatus translates. In this manner, the position of the mounting array can identify the depth position of the apparatus without the need for a mechanical connection between the mounting array and the apparatus.

Description

Technical Field

[0001] This article discloses navigation arrays and related methods, for example, for locating, tracking and / or navigating instruments associated with robotic or robot-assisted surgery. Background Technology

[0002] Many different surgical procedures utilize some form of surgical navigation or tracking to help partially position surgical instruments relative to the patient's anatomy during the procedure. One such type of procedure is robotic or robot-assisted surgical procedures, where surgical navigation can be important for the correct positioning of robot-controlled or robot-assisted surgical instruments relative to the patient.

[0003] In known surgical navigation techniques, navigation arrays or trackers can be mounted on instruments received and / or controlled by a robotic arm to identify the instrument's position. In some cases, the navigation array or tracker can be integrally formed with the instrument itself. However, such solutions can be inconvenient due to the lack of ability to disconnect the array from the instrument or attach the array to other instruments. Additionally, arrangements with navigation arrays integrally formed with instruments may require separate instruments for both standard and navigation purposes, increasing the cost of the equipment. In other cases, the navigation array can be removably attached to the instrument and can be used to track the position of multiple instruments during the course of a surgical procedure. However, this approach requires removing and reinstalling the array relative to each specific instrument each time a different instrument is used. These steps can be time-consuming, increase the risk of damage to surgical components (such as instruments, arrays, robotic arms, etc.) due to the increased manipulation of the equipment, and may interfere with and / or disrupt the flow of the surgical procedure. Furthermore, the risk of incorrect calibration may increase when reinstalling the array onto a new instrument.

[0004] Therefore, there is a need for improved systems, methods, and apparatus for positioning instruments associated with robotic surgical arms in a more accurate, efficient, and less destructive manner during robotic or robot-assisted surgical procedures. Summary of the Invention

[0005] This document discloses a navigation instrument guidance system for accurately and precisely identifying the absolute placement of a robotic arm and an instrument associated with the robotic arm in a manner that does not disrupt surgical procedures or requires excessive manipulation of the instrument. The navigation array unit of the instrument guidance system may include a main array configured to position the distal end of the robotic arm; and a mounting array configured to position the distal end of an instrument received within the instrument guidance system, and more specifically, the depth position of the distal end of the instrument. In some embodiments, positioning the distal end of the robotic arm may include identifying the absolute position of an instrument guidance system (e.g., an instrument mount) that can be known to be coupled to the distal end of the robotic arm. In other embodiments, positioning the distal end of the robotic arm may include identifying the position of a longitudinal axis of the instrument guidance system along which the instrument can be received. The main array may be coupled to the distal end of the robotic arm, and the mounting array may be mounted on the main array such that the mounting array can be translated relative to the main array. The mounting array may include a lumen through which an instrument can be inserted into the instrument mount of the navigation instrument guidance system. The mounting array can incorporate longitudinal movement of the instrument within the instrument mount relative to both the main array and the instrument mount. Therefore, the movement of the mounting array can be tracked, and the depth position of the distal end of the instrument can be identified or located.

[0006] In one aspect, a surgical assembly may include a first array coupled to a surgical robotic arm and configured to position a distal portion of the arm; an instrument mount; and a second array. The instrument mount may be coupled to the robotic arm and may have a proximal end, a distal end, and an inner cavity extending between the proximal and distal ends. The second array may be configured to move relative to the instrument mount and the first array as an instrument passes through the inner cavity of the instrument mount and may be configured to move along a path defined by the first array.

[0007] The apparatus and methods described herein may have various additional features and / or variations, all of which are within the scope of this invention. In some embodiments, for example, a first array may be configured to position the longitudinal axis of a positioning instrument mount. A second array may be configured to travel along a slot formed in the first array. In some such embodiments, the second array may also be configured to translate along the longitudinal axis of the instrument mount. The first array may be stationary relative to the distal portion of the robotic arm, and the second array may be configured to move longitudinally relative to the first array and the instrument mount as the instrument received within the cavity of the instrument mount moves longitudinally.

[0008] The second array may include an array support, an extension, and a tubular body. The tubular body of the second array may have a proximal end, a distal end, and an inner cavity extending between the proximal and distal ends. The inner cavity of the tubular body may be configured to receive a device passing through the inner cavity. In some such embodiments, the inner cavity of the second array may be coaxial with the inner cavity of a device mount. The second array may include multiple tracking elements. In some embodiments, the first array may include a greater number of tracking elements than the second array.

[0009] The surgical assembly may also include a biasing element configured to proximally push a second array relative to the instrument mount. In some embodiments, the biasing element may be disposed within an internal cavity of the instrument mount. In other embodiments, the biasing element may be disposed proximally to the instrument mount.

[0010] In another aspect, a surgical robotic system may include an instrument mount, an instrument, a first array component, and a second array component. The instrument mount may be coupled to a surgical robotic arm and may have a proximal end, a distal end, and an internal cavity extending between the proximal and distal ends. The instrument may have an instrument body, wherein a collar is formed on the instrument body at a proximal position to the distal end of the instrument. The first array component may be configured to position the distal portion of the surgical robotic arm. The second array component may have a tubular body received within the cavity of the instrument mount. The second array may be configured to advance distally with the instrument when the collar of the instrument contacts the proximal portion of the second array component.

[0011] The surgical robot system may also include a spring extending between the second array member and the instrument mount, such that the spring can compress and expand with longitudinal movement of the second array member. In some such embodiments, the spring may be biased away from the instrument mount. The instrument may be any of a drill, tap, needle, stylus, and probe. The distally facing surface of the instrument's collar may be configured to contact the proximal facing surface of the second array member, such that distal movement of the instrument can cause distal movement of the second array member. The distance between the proximal end of the second array member and the distal end of the instrument mount may be substantially equal to the distance between the collar formed on the instrument body and the distal end of the instrument.

[0012] In another aspect, a surgical method may include positioning an instrument for insertion into a navigation instrument guide, wherein the navigation instrument guide may have a main array, a mounting array, and an instrument mount. The method may include inserting an instrument into the navigation instrument guide such that the instrument extends through the lumen of the mounting array and the lumen of the instrument mount; moving the instrument distally via the navigation instrument guide such that the instrument contacts the mounting array and the mounting array is moved distally along a path defined by the main array; and tracking the distal end of the instrument based on the position of the mounting array.

[0013] In some embodiments, the device mount can be located a distance away from the patient's body. The device may include a collar formed on the device that contacts the mounting array and drags the mounting array distally as the device is advanced distally through the device mount. As the device is advanced distally through the device mount, the mounting array can move distally relative to the main array and the device mount.

[0014] Additionally, in some implementations, the distal end of the tracking device can be based on the location of the mounting array and a fixed distance between the collar formed on the device and the distal end of the device.

[0015] Any of the above features or variations can be applied in a variety of different combinations to any particular aspect or embodiment of this disclosure. No specific combination is explicitly described merely to avoid redundancy within the scope of this invention. Attached Figure Description

[0016] Figure 1 Implementation schemes of surgical robotic systems are shown, including one embodiment of a navigation instrument guidance system according to the present disclosure;

[0017] Figure 2A Steps are shown in an embodiment of a method for identifying the depth of a device associated with a robotic arm according to the present disclosure;

[0018] Figure 2B Another step is shown in an embodiment of the method for identifying the depth of a device associated with a robotic arm according to this disclosure;

[0019] Figure 2C This illustrates another step in the method for identifying the depth of a device associated with a robotic arm according to the present disclosure;

[0020] Figure 2D This illustrates another step in the method for identifying the depth of a device associated with a robotic arm according to the present disclosure;

[0021] Figure 3A It shows Figure 1 An exploded view of the navigation device guidance system shown.

[0022] Figure 3B An embodiment of an adapter for the navigation device guidance system of this disclosure is shown;

[0023] Figure 4 yes Figure 1 A perspective view of a navigation device guidance system shown, in which the device is received;

[0024] Figure 5 yes Figure 1 The diagram shows a front view of the main array of the navigation device guidance system.

[0025] Figure 6 yes Figure 5 A perspective view of the main array;

[0026] Figure 7 yes Figure 1 A perspective view of the mounting array of the navigation device guidance system shown;

[0027] Figure 8 yes Figure 1 A perspective view of the instrument mounting components of the navigation instrument guidance system shown.

[0028] Figure 9 yes Figure 8 The exploded view of the device mounting assembly shown illustrates the device guide and adapter;

[0029] Figure 10 This is a front view of one embodiment of a device that can be used in conjunction with the navigation device guidance system disclosed herein;

[0030] Figure 11 yes Figure 1 A detailed perspective view of a navigation device guidance system, in which the device is received;

[0031] Figure 12 yes Figure 1 Another perspective view of the navigation device guidance system shown, in which the device is received in the navigation device guidance system;

[0032] Figure 13 yes Figure 1 A side view of the navigation device guidance system shown.

[0033] Figure 14 Another embodiment of the navigation device guidance system according to this disclosure is shown; and

[0034] Figure 15 It shows Figure 14 An exploded view of the navigation device guidance system. Detailed Implementation

[0035] This document discloses navigation instrument systems and related methods, for example, for identifying, visualizing, and / or tracking the absolute placement of a robotic arm and associated instruments (i.e., instruments, devices, tools, etc., received at the distal end of a robotic arm configured to interact with the surrounding environment) during a surgical procedure. The navigation instrument system disclosed herein may include a navigation array unit having a main array (also referred to as a first array) and a mounting array (also referred to as a second array). The navigation array unit can identify the position of multiple instruments during a surgical procedure without mechanical attachment between the navigation array unit and any of the multiple instruments. The main array may be coupled to the surgical robotic arm and may be configured to position the absolute position of the robotic arm in three-dimensional space. The mounting array may be mounted on the main array and may be configured to position instruments received based on the position of the mounting array. More specifically, the mounting array may be configured to receive a portion of an instrument inserted into an instrument mount of the navigation instrument system and may move relative to the main array and the instrument mount as the instrument moves longitudinally. In this way, the mounting array can identify and track the depth positioning of the distal end of the instrument without mechanical connection or fastening between the mounting array and the instrument itself. Therefore, the need to attach the array to every instrument used throughout the surgical procedure can be eliminated. Thus, the navigation array of this disclosure can effectively and efficiently position the robotic arm and associated instruments during the surgical procedure without disrupting the surgical flow or requiring excessive manipulation of the instruments.

[0036] Certain exemplary embodiments will now be described to provide an overall understanding of the structure, function, manufacture, and principles of use of the apparatuses, systems, and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. The apparatuses, systems, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting embodiments. Features shown or described in one embodiment may be combined with features of other embodiments. Such modifications and variations are intended to be included within the scope of this disclosure.

[0037] Furthermore, the use of linear or circular dimensions in the description of the disclosed devices and methods is not intended to limit the types of shapes that can be used in conjunction with such devices and methods. Equivalents to such linear and circular dimensions can be determined for different geometries. Additionally, in this disclosure, components with similar designations in the embodiments generally have similar characteristics. Furthermore, the size and shape of the devices and their components may depend at least on the anatomy of the subjects who will use these devices, the size and shape of the objects to be used with these devices, and the methods and procedures for using these devices.

[0038] Figure 1An embodiment of a robotic surgical system 100 is shown, including one embodiment of a navigation instrument system 101 of this disclosure coupled to a surgical robotic arm 120. The navigation instrument system 101 may include a navigation array unit 110 and an instrument mount 116. The navigation array unit 110 and the instrument mount 116 may be configured to receive an instrument 130 therein and to identify the positioning of the instrument 130 and the robotic arm 120 in absolute space (i.e., relative to a three-dimensional coordinate system such as...). Figure 1 The coordinate system 102 shown represents all degrees of freedom for identifying or locating the positions of the instrument 130 and the robotic arm 120. The positions of the instrument 130 and the robotic arm 120 may include the depth position of the instrument 130. As used herein, the term "depth" may refer to a position along an axis that extends parallel to the longitudinal axis of the instrument mount 116. Figure 1 In the coordinate system 102 shown, depth position can refer to the position along the z-axis 104. The navigation array unit 110 may include a main array 112 and a mounting array 114. The main array 112 can identify the position of the distal end portion 122 of the robot arm 120. In some embodiments, identifying the position of the distal end portion 122 of the robot arm 120 may include identifying the absolute position of the instrument mount 116, which may be known to be coupled to the distal end portion of the robot arm 120. In other embodiments, identifying the position of the distal end portion 122 of the robot arm 120 may include identifying the position of the longitudinal axis L of the instrument mount 116. For example, as... Figure 1 As shown, the longitudinal axis L extends parallel to the Z-axis. Identifying the position of the longitudinal axis L may include locating the longitudinal axis along the x-axis and y-axis. The mounting array 114 can identify the depth positioning of the instrument 130 received within the instrument mount 116. In this way, the navigation array unit 110 can provide complete positioning information to the user (e.g., surgical robotic systems, surgeons, nurses, practitioners, etc.) by identifying the absolute position of the robotic arm 120 and the depth position of the instrument 130 associated with that robotic arm.

[0039] For this purpose, the main array 112 and the mounting array 114 may each include one or more markers 113 and 115. The navigation system camera 125 can capture the positions of one or more markers 113 and 115. The main array 112 can be coupled to the distal end 122 of the robot arm 120 in a known and precise relationship. In some embodiments, as discussed in detail below, the main array 112 can be coupled to a device mount 116, which in turn can be coupled to the distal end 122 of the robot arm 120. The coupling of the main array 112 to the distal end 122 of the robot arm restricts relative movement between the main array and the distal end of the robot arm. In other words, the main array 112 can be stationary relative to the distal end 122 of the robot arm. Therefore, given the known and precise relationship between the distal end 122 of the robot arm 120 and the main array 112, the positional information captured from the markers 113 of the main array can identify the position of the robot arm in three-dimensional space.

[0040] Mounting array 114 can be configured to locate the depth of the distal end 130d of instrument 130 when instrument 130 is received within instrument mount 116. Mounting array 114 can be configured to identify the depth position of instrument 130 without mechanical connection or fastening to instrument 130. As described in detail below, instrument 130 can pass through the cavity of mounting array 114 and can be dragged or moved distally with distal translation of instrument 130. Mounting array 114 and marker 115 can move absolutely and linearly with translation of instrument 130. Therefore, the position and / or movement of mounting array 114, as captured by marker 115 and navigation system camera 125, can identify and track the depth position of instrument 130.

[0041] Figures 2A to 2D An exemplary method is shown that uses a navigation array unit 110 to identify the absolute placement of an instrument 130 associated with a robotic surgical arm 120. Figure 2A In this configuration, the device 130 can be inserted into the device mount 116. The device 130 may have a device body having a proximal end 130p and a distal end (in...) Figure 2A (Not visible in the image), and a collar 132 formed on the instrument body. An instrument 130 can be inserted such that the distal end of the instrument can be located within the cavity of the instrument guide 116 without extending beyond the distal end 116d of the instrument guide, and the collar 132 of the instrument 130 can be positioned proximally to the mounting array 114. More specifically, the collar 132 can be located proximally to the proximal end 114p of the mounting array 114. A known length C can define the distance between the proximal end 114p of the mounting array 114 and the distal end 116d of the instrument mount 116. Figure 2AThe insertion position (i.e., with the collar 132 of the instrument 130 proximal to the proximal end 114p of the mounting array 114) allows the mounting array 114 to be located at a first proximal position relative to the main array 112. At this proximal position, the mounting array 114 may be located at the proximal end of the slot 124 of the main array 112. The mounting array 114 may be configured to translate longitudinally along the path defined by the slot 124 of the main array 112. In some embodiments, the slot 124 may provide structural integrity to the mounting array 114 through contact or tight tolerances between the mounting array and the main array 112 as the mounting array translates along the path defined by the slot 124. A biasing element 126 may extend in an uncompressed position between the mounting array 114 and the instrument mount 116 and may proximally bias the mounting array relative to the instrument mount.

[0042] like Figure 2B As shown, the instrument 130 can be moved distally to advance the instrument within the instrument mount 116 to a point where the instrument's collar 132 contacts the proximal end 114p of the mount array 114. More specifically, the distally facing surface of the collar 132 can contact the proximal facing surface of the proximal end 114p of the mount array 114. In this configuration (i.e., the point where the collar 132 of the instrument 130 first contacts the proximal end 114p of the mount array 114), the mount array 114 can maintain... Figure 2A The nearest side position. As described below, the distance D between the collar 132 of the instrument 130 and the distal end of the instrument 130 can be substantially equal to the distance C between the proximal end 114p of the mounting array 114 and the distal end 116d of the instrument mount 116. Therefore, in Figure 2B In the illustrated configuration, the distal end of the instrument 130 and the distal end 116d of the instrument mount 116 can be aligned, and distance C can represent the distance between the collar 132 and the distal end of the instrument 130. In other embodiments, an additional known backlash or buffer distance may exist between the distal end 116d of the instrument mount 116 and the distal end of the instrument 130, such that when in… Figure 2B When the instrument is positioned, the distal end of the device is proximal to the distal end 116d by a retraction or buffering amount. Because this retraction or buffering distance is known, it can be taken into account when determining the position of the distal end of the device 130.

[0043] like Figure 2CAs shown, when the collar 132 of the instrument 130 contacts the proximal end 114p of the mounting array 114, the instrument can be further advanced distally within the instrument mount 116, such that the distal end 130d of the instrument can extend distally beyond the distal end 116d of the instrument mount 116. When the instrument 130 moves distally beyond the position where the collar 132 can contact the proximal end 114p of the mounting array 114 (i.e., Figure 2B When the instrument 130 is in its distal position, distal movement of the collar 132 can drag or move the mounting array 114 distally. When the mounting array 114 is dragged distally, the mounting array can be translated distally along the path defined by the slot 124 of the main array 112. Thus, the mounting array 114 can move linearly with distal movement of the instrument 130. As the instrument 130 moves distally, the biasing element 126 can be compressed distally toward the instrument mount 116 by the distal force of the collar 132. The biasing element 126 can apply a desired dragging force that can semi-rigidly maintain the position of the mounting array 114 in the nearest-side position relative to the instrument mount 116 and the main array 112, while allowing longitudinal movement of the mounting array to continue if, for example, a user (i.e., a robot or a human) overcomes the dragging force by distal translation of the instrument 130 when the collar 132 of the instrument contacts the mounting array. In some implementations, the desired drag force applied by the biasing element 126 can help position the drill or other instrument 130 against the instrument mount 116.

[0044] The distal end 130d of the instrument may extend beyond the distal end 116d of the instrument mount 116 by a distance D1. Distance D1 may be equal to the distance D1' traveled by the mounting array 114 when the instrument 130 drags it along the axis (i.e., z-axis 104) of the mounting array 114. The distance D1' traveled by the mounting array 114 can be tracked by one or more markers 115 of the mounting array (see...). Figure 1 ) to determine. For example, navigation system camera 124 (see Figure 1 The marker 115 can be tracked and the distance D1' traveled by the mounting array 114 can be calculated. Since the distance between the proximal end 114p of the mounting array and the distal end 130d of the instrument remains constant once the collar 132 contacts the proximal end of the mounting array 114, the distance D1' traveled by the mounting array 114 can be used to identify the depth position of the distal end of the instrument 130. Alternatively, in embodiments employing known retraction or buffering, the distance D1' traveled by the mounting array can be equal to the distance D1 extending from the distal end of the instrument 130 from the instrument mount 116 by subtracting the known retraction or buffering from the distance D1' traveled by the mounting array 114.

[0045] Figure 2DThe device 130 is shown in its fully inserted position within the device mount 116. In this position, the biasing member 126 can be fully compressed, making further distal translation of the device 130 relative to the device mount 116 impossible. The distance D1 by which the distal end 130d of the device 130 extends beyond the distal end 116d of the device mount 116 can be greater than [a certain value]. Figure 2C The distance shown. The mounting array 114 can continue to be dragged distally as the collar 132 of the instrument 130 moves distally, such that the distance D1' in the fully inserted position, and thus the depth position of the distal end 130d of the instrument, can be determined by the mounting array 114. When the instrument 130 is fully inserted into the instrument mount 116, the mounting array 114 can be at its distalst position within the slot 124 of the main array 112. In some embodiments, the depth of the instrument 130 can be identified when the distal end 130d of the instrument 130 is at a distance away from the working surface or surgical site (i.e., not in contact).

[0046] Now refer to Figure 3A , Figure 3B and Figure 4 A more detailed description, such as Figure 1 The navigation device system 101 shown. Figure 3A An exploded view of a navigation device system 101 and a device 130 configured to be received within the navigation device system is shown. The main array 112, mounting array 114, biasing element 126, device mount 116, and device 130 are visible in this figure. In some embodiments, device mount 116 may include a device guide 117 and an adapter 119. Device guide 117 may be configured to be received within the cavity of adapter 119 such that the distal end 117d of device guide extends beyond the distal end 119d of adapter 119. In other embodiments, device mount 116 may be a single tubular member.

[0047] The instrument mount 116 can be configured to be securely attached to the robot arm 120 (see...). Figure 1 It can be configured to receive a device passing through the device mount. More specifically, in some embodiments, the adapter 119 can be securely attached to the robotic arm 120. As a non-limiting example, Figure 3BAn embodiment of adapter 119 is shown, which can be attached to the distal end of robotic arm 120 using connection feature 121. Other configurations of adapter 119 are within the scope of this disclosure, as long as adapter 119 can be configured to receive surgical instruments and maintain a secure and precise connection with robotic arm 120. In some embodiments, instrument mount 116 can be slidably received within adapter 119, such that instrument mount can slide or translate relative to the longitudinal axis L of adapter 119. In such embodiments, instrument mount can be adjusted to a desired position along longitudinal axis L and can be securely locked so that instrument mount can be maintained in a secure and known position relative to robotic arm 120.

[0048] The main array 112 can be coupled to the instrument mount 116 in a known and precise manner, such that the main array 112 can be used to identify and track the position of the instrument mount 116 and thus the distal end of the robotic arm 120. The mounting array 114 can be configured such that a portion 312 of the mounting array can be slidably received within a slot 124 of the main array 112, while another portion 310 of the mounting array can be slidably received within the lumen of the instrument mount 116. In an illustrated embodiment, a portion 310 of the mounting array 114 can be slidably received within the lumen of the instrument guide 117. As described in detail below, the mounting array 114 can be slidably received within the main array 112 such that the support of the mounting array can be positioned in a plane parallel to the plane of the support of the main array. In use, the main array 112 and the mounting array 114 can be positioned such that both arrays face the navigation camera 125 and do not obstruct the surgeon's access to the work area.

[0049] The biasing element 126, which may be, for example, a coil or other compression spring, may have a proximal end 126p configured to abut a surface adjacent to the mounting array 114 and a distal end 126d configured to abut a surface adjacent to the instrument mount 116. As described above, the biasing element 126 can apply a desired drag force that can semi-rigidly maintain the position of the mounting array 114 in a proximal position relative to the instrument mount 116 and the main array 112, while allowing longitudinal movement of the array to continue if, for example, a user (i.e., a robot or human) overcomes the drag force by distal translation of the instrument 130 when the instrument's collar 132 contacts the mounting array. In the illustrated embodiment, the distal end 126d of the biasing element 126 may be configured to abut a surface adjacent to the instrument guide 117.

[0050] exist Figure 3AAlso visible is instrument 130, which is configured to be received within instrument mount 116 during surgical procedures. Instrument 130 can be inserted into the lumen of mount array 114 and can extend distally through the lumen of instrument guide 117, such that the distal end 130d of the instrument can extend beyond the distal end of instrument mount 116. From the following... Figure 4 As will be apparent from the detailed description of the assembly navigation device system 101, in some embodiments, the distal end 116d of the device mount 116 may be the distal end 117d of the device guide 117.

[0051] Turn now Figure 4 The navigation instrument end effector 101 is shown in its assembled configuration, in which the instrument 130 is received. The main array 112 can be securely coupled to the instrument mount 116. The mounting array 114 can be received within the slot 124 of the main array 112 and the instrument mount 116, such that the mounting array 114 can be longitudinally translated relative to the main array and the instrument mount as the instrument 130 translates. Figure 4 As shown, the biasing element 126 can be in a state of at least partial compression between the proximal end 114p of the mounting array 114 and the proximal-facing surface of the instrument mount 116. The instrument 130 can be received within the instrument mount 116 such that the collar 132 abuts the proximal end 114p of the mounting array and can be configured to drag or move the mounting array 114 distally.

[0052] Now refer to Figures 5 to 9 Components of the navigation instrument system 101 are described. The main array 112 is... Figure 5 and Figure 6 As shown in the diagram. As described above, the main array 112 can be coupled to the robotic arm 120 and configured to position the robotic arm. In this way, positional information from one or more markers on the main array 112 can be used to identify the position of the robotic arm 120 in three-dimensional space. Since the main array 112 can be coupled to the robotic arm 120, the main array can be initially in the potential positioning error chain relative to the robotic arm 120 and its associated components. Therefore, the main array 112 can be a large array, i.e., larger than the mounting array 114, which can improve the accuracy and precision of the positioning information obtained from the main array. However, the size setting of the main array 112 can be balanced with the operability of the main array in the surgical space and operating room, so that the main array does not obstruct the surgeon, nurse and / or robotic components, and can be positioned so that the navigation camera 125 can capture a view of the main array without tilt or distortion.

[0053] The main array 112 may include a bracket 202 having one or more branches 204. A slot 124 may be formed by the bracket 202. The slot 124 may extend along the longitudinal axis of the main array 112 from a proximal end 124p to a distal end 124d and may be configured to receive a mounting array 114 such that the mounting array can be longitudinally translated within the slot 124. Each branch 204 of the main array 112 may have an attachment feature 206 that may receive a spherical reference point or other mark 113 for use with a navigation system. The attachment features 206 may be arranged in predetermined positions and orientations relative to each other and / or the bracket 202. The attachment features 206 may be positioned such that, in use, one or more marks 113 attached to the attachment features may be placed within the field of view of the navigation system and may be identifiable in images captured by the navigation system (e.g., by the navigation system camera 124). As a non-limiting example, one or more marks 113 may include an infrared reflector, an LED, etc. Branches 204 and / or attachment features 206 may be arranged on the main array 112, having a different position and / or orientation than the branches and / or attachment features of the illustrated main array. For example, while the main array 112 has four branches 204, each with a single attachment feature 206, the main array may have more or fewer branches and / or attachment features. The design of the main array 112 (including the number, location, and orientation of branches 204 and / or markers 206) may take into account factors such as manufacturing constraints and cost, array stability, array weighting, etc. The main array 112 may include an inertial measurement unit (IMU), accelerometer, gyroscope, magnetometer, other sensors, or combinations thereof. In some embodiments, the sensors may transmit position and / or orientation information to a navigation system, such as a processing unit of a navigation system and / or a processing unit of a robotic surgical system. One or more markers 113 of the main array 112 can transmit position information across all degrees of freedom (i.e., along the x, y, and z axes of coordinate system 102) of components to which the main array is coupled or to which it has a known positional relationship. In other words, the position information captured by the navigation system from one or more markers 113 of the main array can identify the position of the distal end of the robot arm 120 and / or the instrument mount 116 in the x, y, and z directions.

[0054] The main array 112 may include a coupling ring 208 configured to securely attach the main array 112 to the robotic arm 120 at a known and precise position and orientation. In some embodiments, the coupling ring 208 may clamp or otherwise attach the main array 112 to an instrument mount 116, which in turn securely attaches to the robotic arm 120. In other embodiments, the main array 112 may be mounted directly along the robotic arm 120. The coupling ring 208 may include a release mechanism, such as a tab 210, which may be actuated by a robot and / or human user and may release the clamping force of the coupling ring 208 or other coupling mechanisms. Additional details of non-limiting embodiments of the coupling ring 208 can be found in U.S. Patent Application Publication 2018 / 0344301, filed May 31, 2017, entitled “Coupling Devices for Surgical Instruments and Related Methods,” which is incorporated herein by reference in its entirety. In some embodiments, the coupling ring 208 may be integrally formed with the main array 112. For example, a post 212 may extend from the rear-facing side of the main array 112 to the coupling ring 208. In other embodiments, the main array 112 may be attached to the coupling ring 208 by a robust coupling assembly, such as the coupling assembly disclosed, for example, in U.S. Patent Application 16 / 696,126, filed November 26, 2019, entitled “Instrument Coupling Interfaces and Related Methods” and subject to common ownership and assignment of this application, which is incorporated herein by reference in its entirety.

[0055] Figure 7A perspective view of mounting bracket 114 is shown. As described above, mounting array 114 can be configured to identify and track the depth position of a device (e.g., device 130) received within the navigation instrumentation system 101 of robotic arm 120. Mounting array 114 may include array bracket 302 having one or more branches 304. Each branch 304 of mounting array 114 may have an attachment feature 306 that can receive a spherical reference point or other mark 115, as described above with respect to main array 112. The reference point or other mark 115 of mounting array 114 may function in the manner described above with respect to main array 112. Therefore, for the sake of brevity, a description of such functionality is omitted here. As described in further detail below, mounting array bracket 302 may be smaller, and in some cases significantly smaller than mounting array bracket 202, such that mounting array bracket 302 and any associated reference point / mark 115 can be fully received within the area or perimeter defined by the mark 113 of main array 112.

[0056] Extension 308 can extend from bracket 302 to the tubular body 310 of mounting array 114. In some embodiments, connecting portion 312 can extend between bracket 302 and extension 308. More specifically, connecting portion 312 can extend from the rear-facing side 302b of bracket 302, where the rear-facing side of bracket is opposite the front-facing side 302f. Connecting portion 312 can be configured to be received within slot 124 of main array 112. For this purpose, connecting portion 312 may have a size and dimensions complementary to the size and dimensions of slot 124, such that connecting portion can be longitudinally translated within slot 124. In some embodiments, connecting portion 312 may have a generally rectangular cross-section to match the cross-section of slot 124. Other geometries of connecting portion 312 and slot 124 are within the scope of this disclosure, as long as connecting portion 312 can be received within slot 124 and allows mounting array 114 to be translated relative to main array 112 along the longitudinal axis of slot. The extension member 308 can extend from the first end 307 at the connecting portion 312 to the second end 309 at the tubular body 310. The extension may have a proximal surface 308p and a distal surface 308d. The proximal end 114p of the mounting array 114 may be defined by the proximal surface 308p of the extension 308 at the second end 309, which may form the outer circumferential surface of the proximal end 310p of the tubular body 310.

[0057] The tubular body 310 may have an inner cavity 314 extending from the proximal end 310p of the tubular body to the distal end 310d of the tubular body. The inner cavity 314 may be configured to receive an instrument (e.g., instrument 130) when the instrument is inserted and received within the instrument mount 116. As described in detail below, the tubular body 310 may be configured to be slidably received within the instrument mount 116. More specifically, the distal end 310d of the tubular body 310 may be received within the inner cavity of the instrument mount 116. The tubular body 310 may be configured to translate relative to the instrument mount 116 along the longitudinal axis of the inner cavity. A second end 309 of the extension may form a stop such that the tubular body 310 cannot be translated distally within the inner cavity of the instrument mount 116 beyond the proximal end 310p of the tubular body. The distal surface 308d of the second end portion 309 of the extension 308 may abut the proximal surface of the instrument mount 116 and may prevent distal translation of the tubular body 310. The distal surface 308d of the second end portion 309 of the extension 308 may also serve as a proximal contact point for the biasing element 126.

[0058] Now about Figure 8 and Figure 9 The instrument mount 116 is described, and the figures show an assembly view and an exploded view of the instrument mount. The instrument mount 116 can be attached to a robotic arm 120 and can be configured to receive an instrument 130 and a tubular body 310 of a mounting array 114 within the instrument mount. Multiple instruments can be received within the instrument mount 116 during a surgical procedure. For example, during a single surgical procedure, a first instrument can be inserted into the instrument mount 116, then removed, and a second instrument can be inserted. As described above, the instrument mount 116 may include an instrument guide 117 received within the lumen of an adapter 119. More specifically, the adapter 119 may be a tubular body having a proximal end 119p and a distal end 119d, wherein a lumen 402 extends between the proximal and distal ends. The proximal end 119p can be configured to be coupled to the main array 112 in a known, robust, and precise manner. The proximal end portion 119p may have one or more outer surface features complementary to the features of the coupling ring 208 of the main array 112. In some embodiments, the proximal end portion 119p may include a flange 404. The proximal-facing surface 404p of the flange 404 may be configured to abut the distal-facing surface of the coupling ring 208. Such a configuration helps ensure that the main array 112 can be coupled to the robot arm 120 at a intended known location via the instrument mount 116. The cavity 402 of the adapter 119 may be configured to receive the instrument guide 117 within the cavity.

[0059] The instrument guide 117 may be a tubular body having a proximal end 117p and a distal end 117d, wherein a lumen 406 extends between the proximal and distal ends. In some cases, the instrument guide 117 may be configured for use with a specific instrument and may be replaced with another instrument guide during the course of a surgical procedure depending on the specific instrument in use. For example, a specific instrument guide 117 may be selected based on the inner diameter of the lumen 406, such that the lumen 406 can accommodate the outer diameter of the instrument to be used in the surgical procedure. The lumen 406 may be configured to receive the tubular body 310 and instrument 130 of the mounting array 114. The proximal end 117p of the instrument guide 117 may include a flange 408. The proximal-facing surface 408p of the flange 408 may serve as a stop for the distal end 126d of the biasing element 126. Flange 408 may include features such as ridge 410 that may facilitate a user's gripping or other manipulation (e.g., rotation or turning) of instrument guide 117. An expansion portion 412 of instrument guide 117 may be configured to form a frictional engagement between instrument guide 117 and adapter 119 when the expansion portion 412 is received within the cavity 402 of adapter 119. This frictional engagement may secure the connection between instrument guide 117 and adapter 119. In this manner, instrument 130 and mounting array 114 may be received within the cavity 406 of instrument guide 117 in a known orientation. In some embodiments, expansion portion 412 may include external threads that may be complementary to internal threads formed on the inner surface of the proximal portion 119p of adapter 119. The external threads of expansion portion 412 may engage with the internal threads of the proximal portion 119p of adapter 119 to form a threaded connection between instrument guide 117 and adapter. In some embodiments, the distal end 117d of instrument guide 117 may be tapered. The tapered distal end 117d improves the ease of insertion of the instrument guide 117 through the lumen 404 of the adapter 119 and helps to expand soft tissue when the distal end 117d of the instrument guide 117 is inserted into the patient.

[0060] Figure 10An embodiment of an instrument that can be used with the navigation instrument system of this disclosure is shown. In some embodiments, the instrument 130 may be a drill. The instrument 130 may have a generally tubular body 502 having a tapered portion 504 that transitions from the tubular body 502 to a drill bit 506. A drive feature 508 may be located at the distal end 130d of the instrument 130. A collar 132 may be integrally formed on the tubular body 502. The collar 132 may extend radially from the tubular body 502 and may be sized such that the collar may abut the proximal end 114p of the mounting array. In some embodiments, the collar 132 may be manufactured separately from the instrument 130 and securely and precisely attached to the instrument, while in other embodiments, the collar 132 may be integrally formed with the instrument 130. The collar 132 may be positioned at a fixed distance D from the distal end 130d of the instrument. More specifically, the fixed distance D can be measured from the distal surface 132d of the collar 132 to the distal surface 130d of the instrument 130. Figure 10 In the illustrated embodiment, the distal end 130d of the instrument 130 facing distally may be the distal end surface of the drive feature 508. The distance D between the collar 132 and the distal end 130d of the instrument 130 may be substantially equal to the distance C between the proximal end 114p of the mounting array 114 and the distal end 116d of the instrument mount 116, as described above. In embodiments employing retraction or buffering, distance C may be substantially equal to distance D plus the retraction or buffering distance. The instrument 130 may be manufactured such that the distance D from the collar 132 to the distal end 130d of the instrument can be known precisely and accurately. In some embodiments, the instrument 130 may be manufactured such that distance D can be known precisely and accurately to the sub-decimal millimeter. The precision and accuracy of the known distance D may be crucial for the precision and accuracy of identifying the depth position of the distal end 130d of the instrument 130 via the mounting array 114. While the description of the instrument 130 provided herein refers to the drill shown in the figures, this disclosure is also contemplated for use with other surgical tools or instruments configured to be received within the instrument mount 116, such as, for example, taps, actuators, needles, styluses, probes, etc.

[0061] In the case of describing the components of the navigation device system 101 now, Figures 11 to 13 An additional view of the navigation device system is shown. Figure 11 A partial perspective view of the navigation instrument system 101 and the instrument 130 is shown, and more specifically, the assembly and configuration of the proximal ends of the navigation array unit 110 and the instrument mount 116 are shown, wherein the mounting array 114 is dragged distally by the instrument 130. Figure 12 Another perspective view of the rear of the navigation instrument system 101 with instrument 130 is shown. Figure 13 The navigation device system 101 is shown in the side view.

[0062] like Figures 11 to 13 As shown, the mounting array 114 can be located entirely within the periphery or area occupied by the main array 112. In other words, one or more markers 115 of the mounting array 114 can always be located within the periphery formed by one or more markers 113 of the main array 112. This arrangement can be used to significantly reduce the risk of cross-signals between the markers 113 of the main array 112 and the markers 115 of the navigation array 114. Optical navigation systems may confuse markers, especially when one marker passes by or approaches another, and may misidentify which array a particular marker is associated with. By isolating the markers 113 of the main array 112 from the markers 115 of the mounting array 114, the navigation array unit 110 of this disclosure can significantly reduce the risk of improper navigation marker association, even if the markers 115 can move relative to the main array 112. As shown, the mounting array 114 may include three markers 115. Each of these three markers 115 can maintain a constant distance and position relative to each other and the mounting array 114. Using this type of three-star array, the navigation system can clearly identify the marker 115 associated with the mounting array 114 and correspondingly identify the z-axis or depth axis of the instrument 130. Compared to arrays with fewer than three markers, an array with three markers can significantly reduce the navigation system's misidentification of marker 115. In other embodiments, the mounting array 114 may have more or fewer markers 115.

[0063] Figure 14 and Figure 15 The diagram illustrates an alternative embodiment of the navigation device system 1000 according to this disclosure. The navigation device system 1000 in... Figure 14 The assembly configuration is shown in the diagram, and... Figure 15 The diagram is shown in an exploded view. Except as shown below, the structure, operation, and use of this embodiment are similar to or the same as those of the navigation instrument system 101 described above. Therefore, for the sake of brevity, a detailed description of the structure, operation, and use is omitted here. The navigation instrument system 1000 may include a mounting array 1002, an instrument mount 1004, and a biasing element 1006 disposed within the instrument mount. Similar to the navigation instrument system 101 described above, the instrument mount 1004 may be configured to be securely attached to the distal end (not shown) of the robot arm. As a non-limiting example, the instrument mount 1004 may utilize an adapter (such as...) Figure 3BThe adapter 119 shown is securely attached or coupled to the robot arm. Additionally, as described above, the main array (not shown) can be securely attached to the instrument mount 1004 and can be configured to identify the positions of the robot arm and the end effector 1000. The mount array 1002 can be received within a slot of the main array and can be configured to translate longitudinally along the slot as the instrument received within the instrument mount 1004 translates longitudinally. Therefore, the mount array 1002 can be configured to determine the depth position of the instrument received within the instrument mount 1004 in a manner similar to that described above.

[0064] Mounting array 1002 may include an array support (not shown), a connecting member 1008, an extension member 1010, and a tubular body 1012. The connecting member 1008 may extend from the array support and may be configured to translate longitudinally within a slot of the main array. The tubular body 1012 may have a proximal end 1012p and a distal end 1012d, with an inner cavity extending through the tubular body. The inner cavity of the tubular body 1012 may be configured to receive an instrument (e.g., instrument 130), as described above with respect to navigation instrument system 101. At least a portion of the tubular body 1012 may be received within the inner cavity of the instrument mount 1004. More specifically, the distal end 1012d of the tubular body may be received within the inner cavity of the instrument mount, such that the tubular body 1012 is translatable along the longitudinal axis of the instrument mount. As described above, the collar of the instrument received within the cavity of the mounting array 1002 can be configured to drag the mounting array distally relative to the instrument mount 1004 and the main array.

[0065] In some embodiments, biasing element 1006 may be adjacent to the distal end 1012d of tubular body 1012. Biasing element 1006 may bias tubular body 1012 toward proximal end 1006p of instrument mount 1006. Biasing element 1006 may apply a desired drag force that can semi-rigidly maintain the position of mount array 1002 in a proximal biased position relative to instrument mount 1004 and main array, while allowing longitudinal movement of mount array to continue if, for example, a user (i.e., robot or human) overcomes the drag force through distal translation of instrument (e.g., instrument 130) when the instrument's collar contacts the proximal portion 1012p of mount array.

[0066] Similar to the previously described embodiments, the distance C' between the proximal end 1012p of the tubular body 1012 facing the proximal side and the distal end 1116d of the instrument mount 1116 can be known for accurate and precise measurement. Furthermore, in some embodiments, as referenced above… Figure 10The distance C' and the distance D between the collar of the instrument and the distal end of the instrument can be substantially equal. Therefore, as described above, when the instrument is translated distally within the instrument mount 1004, the mount array 1002 can be translated a known distance (i.e., the distance tracked by the markers on the mount array) by applying a distal drag force from the collar of the instrument. One or more trackers of the mount array 1002 can be used to track and measure the distance the mount array has translated distally. The tracking distance traveled by the mount array 1002 can be used to identify the depth position of the distal end of the instrument. In some embodiments, the tubular body 1012 may also include one or more visual depth indicators 1014 along the outer surface of the tubular body, allowing a user to visually confirm or estimate the distance the mount array 1002 has translated within the cavity of the instrument mount 1004.

[0067] The device mount 1004 may have a generally tubular body 1016, wherein the lumen of the device mount extends from a proximal end 1004p of the tubular body to a distal end 1004d. The lumen of the device mount 1004 may extend through the distal end 1004d of the device mount at a distal opening 1018. In some embodiments, the distal end 1004d of the tubular body 1012 may taper to the distal opening 1018. As described above, the tubular body 1012 of the mounting array 1002 may be inserted into the proximal end of the lumen of the device mount 1004. A stop feature 1020 may be formed at the proximal end 1004p of the device mount 1004. The geometry of the stop feature 1020 (i.e., the cross-section of the stop feature) may be complementary to the geometry of the extension 1010 of the mounting array 1002. The stop feature 1020 can be configured to receive the extension 1010 as the tubular body 1012 moves distally within the cavity of the instrument mount 1004. Therefore, distal movement of the mount array 1002 can be prevented when the extension 1010 is fully received within the stop feature 1020. One or more grip enhancement features 1022 can be formed on the outer surface of the proximal portion 1004p of the instrument mount 1004. In some embodiments, the grip enhancement features 1022 can secure the connection between the main array (not shown) and the instrument mount 1004. As a non-limiting example, the grip enhancement features 1022 may include one or more bellows formed on the outer surface of the instrument mount 1004, which can engage with complementary features of the coupling ring of the main array.

[0068] Alignment between the instrument mount 1004 and the mounting array 1002 can be maintained by one or more alignment features. More specifically, the instrument mount 1004 may have one or more alignment holes 1024 that extend through the tubular body of the instrument mount. Each alignment hole 1024 of the instrument mount 1004 can be aligned with an alignment recess 1026 of the tubular body 1012 of the mounting array 1002. Each alignment recess 1026 may extend longitudinally along at least a portion of the tubular body 1012. In some embodiments, the alignment recess 1026 may extend from the outer surface of the tubular body 1012 toward the inner cavity of the tubular body without extending into the inner cavity. Alignment members (not shown), such as pins, may be inserted through the alignment holes 1024 and into the alignment recesses 1026. In this way, rotation of the tubular body 1012 relative to the instrument mount 1004 can be prevented. The alignment member can also be used to capture the biasing element 1006 and prevent its unintentional removal from the instrument mount 1016, if, for example, the tubular body 1012 is removed during procedure. Although Figure 14 and Figure 15 A single alignment hole 1024 and alignment groove 1026 are shown, but additional alignment holes and grooves can be formed in the tubular body 1012 of the instrument mount 1004 and the mounting array 1002, respectively. Maintaining a known and precise alignment between the instrument mount 1004 and the tubular body 1012 of the mounting array 1002 helps to transmit accurate and precise positional information from the markings on the mounting array 1002 to a robotic or navigation system.

[0069] While specific embodiments have been described above, various variations are possible within the spirit and scope of the described concept. For example, the navigation array unit 110 may include two or more mounting arrays 114, enabling the monitoring of the depth or advance of two or more instruments 130. In some such embodiments, the main array 112 may have two or more slots 124, allowing each mounting array 114 to travel along a corresponding slot 124. In other embodiments, two or more mounting arrays 114 may be received within and travel along a single slot 124, but may be positioned such that the two or more mounting arrays 114 do not contact each other. Therefore, this disclosure is not intended to be limited to the described embodiments, but has the full scope defined by the language of the claims. The above embodiments describe the coupling of a navigation array to an instrument or instrument adapter. While this is one intended use, the methods and apparatus of this disclosure are equally adaptable for use with other objects. Thus, the apparatuses and components described herein can be formed in a variety of sizes and materials suitable for a wide range of applications. All publications and references cited herein are expressly incorporated herein by reference in their entirety.

Claims

1. A surgical component comprising: A first array is coupled to the surgical robotic arm and configured to position the distal portion of the arm. A device mount is coupled to the robot arm, the device mount having a proximal end, a distal end, and an inner cavity extending between the proximal end and the distal end; and A second array is configured to move relative to the instrument mount and the first array as the instrument passes through the cavity of the instrument mount; The second array is configured to move along a slot defined by the first array.

2. The component according to claim 1, wherein, The first array, configured to position the distal portion of the arm, is configured to position the longitudinal axis of the instrument mount.

3. The component according to claim 1, wherein, The second array is configured to translate along the longitudinal axis of the instrument mount.

4. The component according to claim 1, wherein, The first array is stationary relative to the distal portion of the robotic arm, and the second array is configured to move longitudinally relative to the first array and the instrument mount as the instrument received within the cavity of the instrument mount moves longitudinally.

5. The component according to claim 1, wherein, The second array includes an array support, an extension, and a tubular body having a proximal end, a distal end, and an inner cavity extending between the proximal end and the distal end, wherein the inner cavity is configured to receive an instrument passing through the inner cavity.

6. The component according to claim 5, wherein, The inner cavity of the second array is coaxial with the inner cavity of the instrument mounting component.

7. The assembly of claim 1, further comprising a biasing element configured to push the second array proximally relative to the instrument mount.

8. The component according to claim 7, wherein, The biasing element is disposed within the internal cavity of the instrument mounting component.

9. The component according to claim 7, wherein, The biasing element is located on the proximal side of the instrument mounting.

10. The component of claim 1, wherein, The second array includes multiple tracking elements.

11. The component of claim 10, wherein, The first array includes a greater number of tracking elements than the second array.

12. A surgical robotic system, comprising: An instrument mount, which is coupled to a surgical robot arm, has a proximal end, a distal end, and an inner cavity extending between the proximal end and the distal end; An instrument having an instrument body and a collar formed on the instrument body at a position proximal to the distal end of the instrument; A first array component is configured to position the distal portion of the surgical robotic arm. and A second array component having a tubular body received within the lumen of the instrument mount, wherein the second array component is configured to advance distally together with the instrument when the collar of the instrument contacts a proximal portion of the second array component, and A biasing element configured to push the second array proximally relative to the instrument mount.

13. The system according to claim 12, wherein, The biasing element is a spring that extends between the second array component and the instrument mounting, such that the spring compresses and expands as the second array component moves longitudinally.

14. The system according to claim 13, wherein, The spring is biased away from the device mounting.

15. The system according to claim 12, wherein, The instrument is any one of a drill, tap, injection needle, stylus, and probe.

16. The system according to claim 12, wherein, The distance between the proximal end of the second array component and the distal end of the instrument mount is substantially equal to the distance between the collar formed on the instrument body and the distal end of the instrument.

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