End effector arm used with robotic surgical systems

Abstract

This invention discloses an end effector arm for use with a robotic surgical system, the end effector arm comprising: a base configured to attach to an end effector connector of a surgical robotic arm, and a mechanical link. The mechanical link includes a first end rotatably coupled to the base and a second end opposite the first end, the second end being configured to be removably coupled to a handheld surgical instrument. The end effector arm further includes a spring mechanism configured to impart a variable rotational force to the mechanical link based on a rotational angle of the mechanical link relative to the base.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 212,949, filed June 21, 2021, the contents of which are incorporated herein by reference in their entirety.

[0003] This application relates to U.S. Patent Application No. 16 / 587,203, filed September 30, 2019, and U.S. Patent Application No. 16 / 737,054, filed January 8, 2020, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0004] This invention relates to robotic surgery, and more particularly to an end effector arm for use with a robot-assisted surgical system. Background Technology

[0005] Many surgical interventions require osteotomy, which involves cutting anatomical structures such as bone along a target plane. Total knee arthroplasty typically requires cutting the femoral and tibial epiphyses to remove damaged bone and cartilage and to install a knee prosthesis. Surgeons may use an oscillating surgical saw to perform five or more cuts on the femur and one or more cuts on the tibia.

[0006] During orthopedic surgery (including joint and knee procedures), accurately aligning and stabilizing the saw when cutting the desired location on the bone is crucial. Limited visibility of the surgical site by the surgeon, coupled with the difficulty in controlling the saw's movement, creates a risk of cutting unwanted portions of bone or adjacent tissue. Vibrations generated by the saw during cutting can reduce the accuracy of the cut. During knee surgery, the precision of the bone cut (planar cut) affects the accuracy with which the implant can attach to the exposed bone.

[0007] In some conventional systems, the direct sagittal saw blade guiding structure can utilize passive kinematics positioned in space by the robotic arm, which confines the blade within its cutting plane. Passive structures also designated as end effector arms can comprise a three-link series providing three degrees of freedom (two translational and one rotational) to the blade. The sagittal saw handpiece is rigidly connected to the passive structure via the blade and provides mechanical power to actuate it. To achieve sufficient cutting accuracy, the passive structure must be designed with the highest possible lateral stiffness. Aluminum was chosen as the appropriate material for the structural components of the connector to facilitate encoder integration and reduce manufacturing costs. This affects the weight of these structural components. When the cutting plane is horizontal, the gravity generated by the connector mass is fully supported by the articulated bearings. However, in many cuts, the cutting plane is inclined relative to the horizontal plane or nearly vertical. In such configurations, the weight of the connector is partially or fully supported by the surgeon's hand, which can lead to undesirable strain or stress on the surgeon's hand and may negatively impact surgeon performance.

[0008] Therefore, there is a need for a surgical guidance system that allows saw blades or other handheld surgical tools to move freely without requiring the surgeon to support the weight of additional system components. Summary of the Invention

[0009] This invention relates to robotic surgery, and more particularly to an end effector arm for use with a robot-assisted surgical system.

[0010] According to some embodiments, an end effector arm used with a surgical navigation system includes: a base configured to attach to an end effector connector of a surgical robotic arm, and a mechanical link. The mechanical link includes a first end rotatably coupled to the base and a second end opposite the first end, the second end being configured to be removably coupled to a handheld surgical instrument. The end effector arm also includes a spring mechanism configured to impart a variable rotational force to the mechanical link based on the rotational angle of the mechanical link relative to the base.

[0011] According to some embodiments, a surgical tool guidance system includes a robotic arm configured for positioning by a surgical robot including an end effector connector. The system also includes an end effector arm comprising: a base configured to attach to the end effector connector of the robotic arm; and a mechanical link. The mechanical link includes a first end rotatably coupled to the base and a second end opposite the first end. The end effector arm further includes a spring mechanism configured to impart a variable rotational force to the mechanical link based on a rotational angle of the mechanical link relative to the base. The system also includes a handheld surgical tool configured to be coupled to the second end of the mechanical link.

[0012] According to some embodiments, the surgical system includes a tracking system configured to determine the pose of an anatomical structure to be engaged by a handheld surgical tool and to determine the pose of the surgical tool. The system also includes a surgical robot including a robot base and a robotic arm connected to the robot base, the robotic arm including an end effector connector. The robot also includes at least one motor operatively connected to move the robotic arm relative to the robot base. The system further includes an end effector arm including: a base configured to attach to the end effector connector of the robotic arm; and a mechanical link. The mechanical link includes a first end rotatably coupled to the base and a second end opposite the first end. The end effector arm also includes a spring mechanism configured to impart a variable rotational force to the mechanical link based on a rotational angle of the mechanical link relative to the base. The system also includes a handheld surgical tool coupled to the second end of the mechanical link. Attached Figure Description

[0013] The accompanying drawings, which are included and constitute a part of this application and are intended to further illustrate this disclosure, show certain non-limiting embodiments of the inventive concept. In the drawings:

[0014] Figure 1 These are implementation schemes of a surgical system based on some embodiments of this disclosure;

[0015] Figure 2 Some embodiments according to this disclosure are shown. Figure 1 Surgical robot components of a surgical system;

[0016] Figure 3 Some embodiments according to this disclosure are shown. Figure 1 Camera tracking system components of surgical systems;

[0017] Figure 4An embodiment of a passive end effector capable of being attached to a robotic arm and constructed according to some embodiments of this disclosure is shown;

[0018] Figure 5 The illustration shows a medical procedure in which a surgical robot and camera system are positioned around the patient.

[0019] Figure 6 An embodiment of an end effector coupler for connecting to a passive end effector of a robot arm is shown according to some embodiments of the present disclosure;

[0020] Figure 7 It shows Figure 6 A cross-sectional view of an embodiment of an end effector connector;

[0021] Figure 8 A block diagram of components of a surgical system according to some embodiments of the present disclosure is shown;

[0022] Figure 9 A block diagram of a surgical system computer platform according to some embodiments of the present disclosure is shown. The surgical system computer platform includes a surgical planning computer that can be separate from and operatively connected to the surgical robot or at least partially incorporated into the surgical robot.

[0023] Figure 10 Embodiments of a C-arm imaging device according to some embodiments of the present disclosure are shown, which can be used in combination with a surgical robot and a passive end effector;

[0024] Figure 11 Embodiments of an O-arm imaging device according to some embodiments of the present disclosure are shown, which can be used in combination with a surgical robot and a passive end effector; and

[0025] Figure 12 An embodiment of a passive end effector constructed according to some embodiments of the present disclosure is shown.

[0026] Figure 13 It is a screenshot of the monitor showing the progress of bone cutting during the surgical procedure.

[0027] Figure 14 An embodiment of an end effector arm according to some embodiments of the present disclosure is shown, the end effector arm having a spring mechanism for compensating for gravity on the end effector arm components.

[0028] Figure 15 Some embodiments according to this disclosure are shown. Figure 14An embodiment of an end effector arm with a spring mechanism is shown, illustrating the force applied to the end effector arm component when the end effector arm is in a vertical cutting plane.

[0029] Figure 16A and Figure 16B Some embodiments according to this disclosure are shown. Figure 14 and Figure 15 A portion of the end effector arm, showing the force applied to the first coupling of the end effector arm when the end effector arm is in the docked position and the extended position.

[0030] Figure 17 It is a graph of gravity and compensating force on the end effector arm when the end effector arm is in a vertical cutting plane, according to some embodiments of this disclosure.

[0031] Figure 18 It is a graph of gravity and compensating force on the end effector arm when the end effector arm is in a cut-off plane at approximately 30 degrees relative to the horizontal, according to some embodiments of the present disclosure.

[0032] Figures 19A to 19C A locking mechanism according to some embodiments of the present disclosure is shown, which is configured to selectively fix a surgical instrument relative to the base of an end effector arm. Detailed Implementation

[0033] The inventive concept will now be described more fully below with reference to the accompanying drawings, in which examples of embodiments of the inventive concept are illustrated. However, the inventive concept may be embodied in many different forms and should not be construed as limited to the exemplary embodiments described herein. Rather, these embodiments are provided so that this disclosure will be comprehensive and complete, and will fully convey to those skilled in the art the scope of the various inventive concepts. It should also be noted that these embodiments are not mutually exclusive. A component from one embodiment may be assumed to be present or used in another embodiment.

[0034] The various embodiments disclosed herein relate to improving the operation of surgical systems when performing surgical interventions requiring osteotomy. Passive end effectors capable of attaching to a robotic arm positioned by a surgical robot are disclosed. The passive end effectors have mechanisms that limit the movement of tool attachment mechanisms (such as surgical saws) to a certain range of motion. These mechanisms can be configured to limit the cutting plane of the saw blade to be parallel to the working plane.

[0035] The passive end effector includes a spring mechanism configured to impart a variable rotational force to the mechanical link based on the rotation angle of the mechanical link relative to the base. When the end effector is in an inclined and / or vertical cutting plane, the variable rotational force is sufficient within a certain rotation angle range to overcome the gravity on the distal end of the end effector arm.

[0036] Compared to other robotic and manual solutions used in surgery, these and other related implementations can be operated to improve the accuracy of tool guidance and reduce the effort and fatigue expended by the surgeon's hand due to the weight of the end effector arm. The spring mechanism can also be configured to minimize variations in the compensation effect throughout the entire range of motion of the end effector arm, providing gradual and predictable changes in net force on the end effector.

[0037] Figure 1 This is an embodiment of surgical system 2 according to some embodiments of this disclosure. Prior to performing orthopedic surgical procedures, for example... Figure 10 C-arm imaging device 104 or Figure 11 The O-arm imaging device 106 acquires a three-dimensional (“3D”) image scan of the patient’s planned surgical area from either a computed tomography (CT) image or a Mill image. This scan can be performed preoperatively (e.g., most commonly a few weeks before the procedure) or intraoperatively. However, depending on the various implementations of the surgical system 2, any known 3D or 2D image scan can be used. The image scan is sent to a computer platform communicating with the surgical system 2, such as… Figure 9 A surgical system computer platform 900, which includes a surgical robot 800 (e.g., Figure 1 The surgical system 2 (robot) and surgical planning computer 910. The surgical planning computer 910 ( Figure 9 A surgeon viewing an image scan on a display device generates a surgical plan that defines a target plane for cutting the patient's anatomy. This plane is a function of the patient's anatomical limitations, the selected implant, and its size. In some embodiments, the surgical plan defining the target plane is planned on a 3D image scan displayed on the display device.

[0038] Figure 1The surgical system 2 can assist the surgeon during medical procedures by, for example, holding, aligning, using, guiding, and / or positioning the tools used. In some embodiments, the surgical system 2 includes a surgical robot 4 and a camera tracking system 6. These two systems can be mechanically coupled together by any variety of mechanisms. Suitable mechanisms may include, but are not limited to, mechanical latches, straps, clamps, supports, or magnetic or magnetized surfaces. The ability to mechanically couple the surgical robot 4 and the camera tracking system 6 allows the surgical system 2 to be manipulated and moved as a single unit, allows the surgical system 2 to have a small footprint in the area, allows easier movement through narrow passages and around bends, and allows storage in a small area.

[0039] Orthopedic surgical procedures can begin with the movement of surgical system 2 from the medical storage device to the medical procedure room. Surgical system 2 can be manipulated through doorways, corridors, and elevators to reach the medical procedure room. Within this room, surgical system 2 can be physically separated into two separate and distinct systems: surgical robot 4 and camera tracking system 6. Surgical robot 4 can be positioned in any suitable location adjacent to the patient to appropriately assist medical personnel. Camera tracking system 6 can be positioned at the patient's feet, shoulder, or any other location suitable for tracking the patient's pose and the movement of the tracking portion of surgical robot 4 and the patient. Surgical robot 4 and camera tracking system 6 can be powered by an onboard power supply and / or plugged into an external wall socket.

[0040] Surgical robot 4 can be used to assist surgeons during medical procedures by holding and / or using tools. To properly utilize and hold the tools, surgical robot 4 may rely on multiple motors, computers, and / or actuators for normal operation. For example... Figure 1 As shown, the robot body 8 can serve as a structure that can secure multiple motors, computers, and / or actuators within the surgical robot 4. The robot body 8 can also provide support for the robot's telescopic support arm 16. In some embodiments, the robot body 8 can be made of any suitable material. Suitable materials can be, but are not limited to, metals (such as titanium, aluminum, or stainless steel), carbon fiber, fiberglass, or heavy-duty plastics. The size of the robot body 8 can provide a solid platform to support the attached components and can accommodate, conceal, and protect the multiple motors, computers, and / or actuators that can operate these attached components.

[0041] The robot base 10 can serve as a lower support for the surgical robot 4. In some embodiments, the robot base 10 can support the robot body 8 and can attach the robot body 8 to multiple drive wheels 12. This attachment to the wheels allows the robot body 8 to move efficiently in space. The robot base 10 can have the same length and width as the robot body 8. The robot base 10 can be approximately 2 inches to approximately 10 inches high. The robot base 10 can be made of any suitable material. Suitable materials can be, but are not limited to, metals (such as titanium, aluminum, or stainless steel), carbon fiber, fiberglass, or heavy-duty plastics or resins. The robot base 10 can cover, protect, and support the drive wheels 12.

[0042] In some implementation schemes, such as Figure 1 As shown, at least one drive wheel 12 can be attached to the robot base 10. The drive wheel 12 can be attached to the robot base 10 in any position. Each individual drive wheel 12 can rotate about a vertical axis in any direction. A motor can be positioned above, within, or adjacent to the drive wheel 12. The motor allows the surgical system 2 to be manipulated to any position and stabilized and / or leveled. A lever located within or adjacent to the drive wheel 12 can be pressed into a surface by the motor. The lever (not shown) can be made of any suitable metal to lift the surgical system 2. Suitable metals can be, but are not limited to, stainless steel, aluminum, or titanium. In addition, the lever can include a buffer (not shown) at the contact surface side end, which can prevent the lever from slipping and / or create a suitable contact surface. The material can be any suitable material used to act as a buffer. Suitable materials can be, but are not limited to, plastic, neoprene, rubber, or textured metal. The lever can lift the drive wheel 12 to any height required for leveling or otherwise securing the surgical system 2 relative to the patient's orientation. The weight of the surgical system 2 is supported by the lever on each wheel through small contact areas, preventing movement of the surgical system 2 during medical procedures. This rigid positioning prevents accidental movement of the surgical system 2 by the object and / or personnel.

[0043] The robotic armrest 14 can be used to facilitate the movement of the surgical system 2. The robotic armrest 14 provides personnel with the ability to move the surgical system 2 without gripping the main body of the robot 8. Figure 1As shown, the robot railing 14 may be shorter than the length of the robot body 8, and / or may be longer than the length of the robot body 8. The robot railing 14 may be made of any suitable material. Suitable materials may be, but are not limited to, metals (such as titanium, aluminum, or stainless steel), carbon fiber, fiberglass, or heavy-duty plastics. The robot railing 14 may also provide protection for the robot body 8, preventing objects and / or people from contacting, impacting, or colliding with the robot body 8.

[0044] The robot body 8 can provide support for a selectively compliant articulated robotic arm (hereinafter referred to as "SCARA"). Due to the repeatability and compactness of the robotic arm, SCARA 24 can be beneficial for use within the surgical system 2. The compactness of SCARA can provide additional space during medical procedures, allowing medical professionals to perform procedures without excessive clutter and confinement. SCARA 24 may include a robot telescopic support 16, a robot support arm 18, and / or a robotic arm 20. The robot telescopic support 16 may be positioned along the robot body 8. Figure 1 As shown, the robot telescopic support 16 can provide support for the SCARA 24 and the display 34. In some embodiments, the robot telescopic support 16 can extend and retract in the vertical direction. The robot telescopic support 16 can be made of any suitable material. Suitable materials can be, but are not limited to, metals (such as titanium or stainless steel), carbon fiber, fiberglass, or heavy-duty plastics. The body of the robot telescopic support 16 can have any width and / or height to support the stress and weight placed thereon.

[0045] In some implementations, a medical professional can move the SCARA24 by issuing a command. This command can originate from input received on the display 34 and / or a tablet computer. The command can come from pressing a single switch and / or pressing multiple switches. Figure 4 and Figure 5 As best shown, activation component 60 may include one and / or more switches. Activation component 60 is operable to transmit movement commands to SCARA 24, thereby allowing an operator to manually manipulate SCARA 24. When one or more switches are pressed, a medical personnel may be able to easily move SCARA 24. In addition, when SCARA 24 does not receive a movement command, SCARA 24 may lock in place to prevent accidental movement by personnel and / or other objects. By locking in place, SCARA 24 provides a solid platform on which the passive end effector 1100 and the connected surgical saw 1140 (in...) Figure 4 and Figure 5(As shown in the image) Ready for medical procedures.

[0046] The robot support arm 18 can be mounted on the robot telescopic support 16 via various mechanisms. In some implementations, in Figure 1 and Figure 2 Ideally, the robot support arm 18 can rotate relative to the robot telescopic support 16 in any direction. The robot support arm 18 can rotate 360 ​​degrees around the robot telescopic support 16. The robot arm 20 can be attached to the robot support arm 18 at any suitable location. The robot arm 20 can be attached to the robot support arm 16 via various mechanisms. Suitable mechanisms can be, but are not limited to, nuts and bolts, ball joint fittings, compression fittings, welding, adhesion, screws, rivets, clamps, latches, and / or any combination thereof. The robot arm 20 can rotate relative to the robot support arm 18 in any direction; in this embodiment, the robot arm 20 can rotate 360 ​​degrees relative to the robot support arm 18. This free rotation allows the operator to position the robot arm 20 as planned.

[0047] Figure 4 and Figure 5 The passive end effector 1100 can be attached to the robotic arm 20 at any suitable location. As will be described in further detail below, the passive end effector 1100 includes a base, a first mechanism, and a second mechanism. The base is configured to attach to the end effector connector 22 of the robotic arm 20 positioned by the surgical robot 4. The base can be attached to the end effector connector 22 via various mechanisms, including but not limited to latches, clamps, nuts and bolts, ball joint fittings, press fittings, welds, adhesives, screws, rivets, and / or any combination thereof. The first mechanism extends between a rotatable connector to the base and a rotatable connector to the tool attachment mechanism. The second mechanism extends between the rotatable connector to the base and the rotatable connector to the tool attachment mechanism. The first and second mechanisms pivot about the rotatable connectors and can be configured to limit the movement of the tool attachment mechanism to a range of motion within the working plane. The rotatable connector can be a pivot joint allowing one degree of freedom (DOF) of movement, a universal joint allowing two DOF of movement, or a ball joint allowing three DOF of movement. The tool attachment mechanism is configured to connect directly to a surgical saw 1140 with a saw blade or saw blade. The surgical saw 1140 can be configured to oscillate the saw blade for cutting. The first and second mechanisms can be configured to restrict the cutting plane of the saw blade to be parallel to the working plane. A pivot joint can preferably be used to connect the planar mechanisms when the passive end effector is configured to restrict the movement of the saw blade to the cutting plane.

[0048] The tool attachment mechanism can be connected to the surgical saw 1140 or the saw blade via various mechanisms, including but not limited to screws, nuts and bolts, clamps, latches, bands, pressure fittings, or magnets. In some embodiments, the dynamic reference array 52 is attached to the passive end effector 1100 (e.g., attached to the tool attachment mechanism) and / or to the surgical saw 1140. The dynamic reference array, also referred to herein as “DRA,” is a rigid body that can be positioned on the patient, surgical robot, passive end effector, and / or surgical saw in a navigational surgical procedure. A camera tracking system 6 or other 3D positioning system is configured to track the pose (e.g., position and rotational orientation) of the tracking markers of the DRA in real time. The tracking markers may include spheres or other optical markers arranged as shown. This tracking of the 3D coordinates of the tracking markers allows the surgical system 2 to determine the DRA 52 relative to the target in any space. Figure 5 The pose of the target anatomical structures in patient 50.

[0049] like Figure 1 As shown, the light indicator 28 can be positioned on top of the SCARA 24. The light indicator 28 can be illuminated as any type of light to indicate the "condition" currently in operation of the surgical system 2. For example, illuminating green can indicate that all systems are functioning normally. Illuminating red can indicate that the surgical system 2 is malfunctioning. Pulsating light can signify that the surgical system 2 is performing a function. Combinations of light and pulsation can produce virtually an unlimited number of combinations to convey current operating conditions, status, or other operational indications. In some embodiments, the light can be generated by LED bulbs that can form a ring around the light indicator 28. The light indicator 28 can include a fully translucent material that allows light to pass through the entire light indicator 28.

[0050] The light indicator 28 can be attached to the lower display support 30. For example... Figure 2 As shown, the lower display support 30 allows the operator to manipulate the display 34 to any suitable position. The lower display support 30 can be attached to the light indicator 28 via any suitable mechanism. In one embodiment, the lower display support 30 can rotate about the light indicator 28. In another embodiment, the lower display support 30 can be rigidly attached to the light indicator 28. The light indicator 28 can then rotate 360 ​​degrees about the robot support arm 18. The lower display support 30 can have any suitable length, from approximately eight inches to approximately thirty-four inches. The lower display support 30 can serve as the base of the upper display support 32.

[0051] The upper display support 32 can be attached to the lower display support 30 via any suitable mechanism. The upper display support 32 can have any suitable length, ranging from approximately eight inches to approximately thirty-four inches. In some embodiments, such as... Figure 1 As shown, the upper display support 32 allows the display 34 to rotate 360 ​​degrees relative to the upper display support 32. Similarly, the upper display support 32 can rotate 360 ​​degrees relative to the lower display support 30.

[0052] The display 34 can be any device that can be supported by the upper display support 32. In an embodiment, such as... Figure 2 As shown, display 34 can produce color images and / or black and white images. The width of display 34 can be from approximately eight inches to approximately thirty inches. The height of display 34 can be from approximately six inches to approximately twenty-two inches. The depth of display 34 can be from approximately half an inch to approximately four inches.

[0053] In some embodiments, the tablet computer can be used in conjunction with and / or independently of the display 34. In other embodiments, the tablet computer may replace the display 34 and be mounted on the upper display support 32, and may be removable from the upper display support 32 during medical procedures. Additionally, the tablet computer can communicate with the display 34. The tablet computer may be able to connect to the surgical robot 4 via any suitable wireless and / or wired connection. In some embodiments, the tablet computer may be able to program and / or control the surgical system 2 during medical procedures. When the surgical system 2 is controlled using the tablet computer, all input and output commands can be copied onto the display 34. Using the tablet computer allows the operator to manipulate the surgical robot 4 without having to move around the patient 50 and / or to the surgical robot 4.

[0054] like Figure 5 As shown, the camera tracking system 6 operates in conjunction with the surgical robot 4 via a wired or wireless communication network. (Reference) Figure 1 and Figure 5 The camera tracking system 6 may include some components similar to those in the surgical robot 4. For example, the camera body 36 may provide the functionality present in the robot body 8. The robot body 8 may provide a structure on which the camera 46 is mounted. The structure within the robot body 8 may also provide support for the electronics, communication devices, and power supply used to operate the camera tracking system 6. The camera body 36 may be made of the same material as the robot body 8. The camera tracking system 6 may communicate directly with a tablet computer and / or display 34 via a wireless and / or wired network, enabling the tablet computer and / or display 34 to control the functionality of the camera tracking system 6.

[0055] The camera body 36 is supported by the camera base 38. The camera base 38 can also be used as the robot base 10. Figure 1 In one implementation, the camera base 38 may be wider than the robot base 10. The width of the camera base 38 allows the camera tracking system 6 to be connected to the surgical robot 4. Figure 1 As shown, the width of the camera base 38 can be large enough to accommodate the exterior of the robot base 10. When the camera tracking system 6 and the surgical robot 4 are connected, the additional width of the camera base 38 allows the surgical system 2 to have additional maneuverability and allows for support of the surgical system 2.

[0056] Similar to the robot base 10, multiple drive wheels 12 can be attached to the camera base 38. Similar to the operation of the robot base 10 and drive wheels 12, the drive wheels 12 allow the camera tracking system 6 to be stabilized and leveled or set in a fixed orientation relative to the patient 50. This stabilization prevents the camera tracking system 6 from moving during medical procedures and prevents the camera 46 from losing tracking of one or more DRAs 52 connected to anatomical structures 54 and / or tools 58 within the designated area 56, such as... Figure 5 As shown. This stability and tracking enhance the ability of the surgical robot 4 to operate effectively together with the camera tracking system 6. In addition, the wide camera base 38 provides additional support to the camera tracking system 6. Specifically, the wide camera base 38 prevents the camera tracking system 6 from tilting when the camera 46 is positioned above the patient, such as... Figure 5 As shown. Without the wide camera base 38, the protruding camera 46 may cause the camera tracking system 6 to become unbalanced, which could cause the camera tracking system 6 to fall over.

[0057] A telescopic camera support 40 can support the camera 46. In an embodiment, the telescopic support 40 can move the camera 46 higher or lower in the vertical direction. The telescopic support 40 can be made of any suitable material to support the camera 46. Suitable materials can be, but are not limited to, metals (such as titanium, aluminum, or stainless steel), carbon fiber, fiberglass, or heavy-duty plastics. A camera handle 48 can be attached to the telescopic camera support 40 at any suitable location. The camera handle 48 can be any suitable handle configuration. Suitable configurations can be, but are not limited to, rod-shaped, circular, triangular, square, and / or any combination thereof. Figure 1 As shown, the camera handle 48 may be triangular, allowing the operator to move the camera tracking system 6 into the planned position prior to medical procedures. In an embodiment, the camera handle 48 can be used to lower and raise the camera telescopic support 40. The camera handle 48 can be used to raise and lower the camera telescopic support 40 by pressing buttons, switches, joysticks, and / or any combination thereof.

[0058] The lower camera support arm 42 can be attached to the camera telescopic support 40 at any suitable location, as in the implementation scheme, such as Figure 1 As shown, the lower camera support arm 42 can rotate 360 ​​degrees around the telescopic support 40. This free rotation allows the operator to position the camera 46 in any suitable location. The lower camera support arm 42 can be made of any suitable material to support the camera 46. Suitable materials can be, but are not limited to, metals (such as titanium, aluminum, or stainless steel), carbon fiber, fiberglass, or heavy-duty plastics. The cross-section of the lower camera support arm 42 can be of any suitable shape. Suitable cross-sectional shapes can be, but are not limited to, circular, square, rectangular, hexagonal, octagonal, or I-beam. The length and width of the cross-section can be from about one inch to ten inches. The length of the lower camera support arm can be from about four inches to about thirty-six inches. The lower camera support arm 42 can be connected to the telescopic support 40 by any suitable mechanism. Suitable mechanisms can be, but are not limited to, nuts and bolts, ball joint fittings, compression fittings, welding, adhesion, screws, rivets, clamps, latches, and / or any combination thereof. The lower camera support arm 42 can be used to provide support for the camera 46. The camera 46 can be attached to the lower camera support arm 42 by any suitable mechanism. Suitable mechanisms may be, but are not limited to, nuts and bolts, ball joint fittings, compression fittings, welding, adhesion, screws, rivets, and / or any combination thereof. Camera 46 may pivot in any direction at the attachment area between camera 46 and lower camera support arm 42. In an embodiment, a bending crossbar 44 may be provided on the lower camera support arm 42.

[0059] The curved crossbar 44 can be positioned at any suitable location on the lower camera support arm 42. For example... Figure 3 As shown, the curved crossbar 44 can be attached to the lower camera support arm 42 by any suitable mechanism. Suitable mechanisms can be, but are not limited to, nuts and bolts, ball joint fittings, compression fittings, welding, adhesion, screws, rivets, clamps, latches, and / or any combination thereof. The curved crossbar 44 can have any suitable shape, including crescent, circular, oval, elliptical, and / or any combination thereof. In embodiments, the curved crossbar 44 can have any suitable length. A suitable length can be from about one foot to about six feet. The camera 46 can be movably positioned along the curved crossbar 44. The camera 46 can be attached to the curved crossbar 44 by any suitable mechanism. Suitable mechanisms can be, but are not limited to, rollers, brackets, supports, motors, and / or any combination thereof. Motors and rollers, not shown, can be used to move the camera 46 along the curved crossbar 44. Figure 3As shown, during medical procedures, if an object obstructs camera 46's view of one or more DRAs 52, a motor can use rollers to move camera 46 along a curved crossbar 44. This maneuvering movement allows camera 46 to move to a new position where it is no longer obstructed by the object, without moving camera tracking system 6. When camera 46 is obstructed and cannot view DRAs 52, camera tracking system 6 can send a stop signal to surgical robot 4, display 34, and / or tablet. The stop signal can prevent SCARA 24 from moving until camera 46 regains access to DRAs 52. This stop can prevent SCARA 24 and / or end effector coupler 22 from moving and / or using medical instruments without being tracked by surgical system 2.

[0060] like Figure 6 As shown, the end effector connector 22 is configured to connect various types of passive end effectors to the surgical robot 4. The end effector connector 22 may include a saddle joint 62, an activation component 60, and a force sensor 64. Figure 7 The saddle connector 62 attaches the end effector connector 22 to the SCARA 24. The saddle connector 62 can be made of any suitable material. Suitable materials can be, but are not limited to, metals (such as titanium, aluminum, or stainless steel), carbon fiber, fiberglass, or heavy-duty plastics. The saddle connector 62 can be made of a single metal piece that provides additional strength and durability to the end effector. The saddle connector 62 can be attached to the SCARA 24 via attachment points 68. Multiple attachment points 68 can be present around the saddle connector 62. Attachment points 68 can be recessed, flush, and / or located on the saddle connector 62. In some examples, screws, nuts, and bolts and / or any combination thereof can pass through the attachment points 68 and secure the saddle connector 62 to the SCARA 24. Nuts and bolts can connect the saddle connector 62 to a motor (not shown) within the SCARA 24. The motor can move the saddle connector 62 in any direction. The motor can be further prevented from moving due to accidental collision and / or accidental contact by actively servoing at the current position or by passively applying a spring-actuated brake.

[0061] The end effector connector 22 may include a force sensor 64 inserted between the saddle connector 62 and the connected passive end effector. For example... Figure 7 As shown, the force sensor 64 can be attached to the saddle joint 62 by any suitable mechanism. Suitable mechanisms can be, but are not limited to, screws, nuts and bolts, threads, compression fittings and / or any combination thereof.

[0062] Figure 8A block diagram of the components of a surgical system 800 according to some embodiments of the present disclosure is shown. Reference Figure 7 and Figure 8 The force sensor 64 can be any suitable instrument for detecting and measuring force. In some examples, the force sensor 64 can be a six-axis force sensor, a three-axis force sensor, or a single-axis force sensor. The force sensor 64 can be used to track the force applied to the end effector connector 22. In some embodiments, the force sensor 64 can communicate with multiple motors 850, 851, 852, 853, and / or 854. When the force sensor 64 senses a force, information about the amount of the applied force can be distributed from one and / or multiple switch arrays to the controller 846. The controller 846 can take the force information from the force sensor 64 and process the force information using a switching algorithm. The controller 846 uses the switching algorithm to control the motor driver 842. The motor driver 842 controls the operation of one or more motors. The motor driver 842 can instruct a particular motor to produce a force equal to, for example, the amount measured on that motor by the force sensor 64. In some implementations, the generated force may originate from multiple motors, such as 850-854, as indicated by controller 846. Additionally, motor drivers 842 may receive input from controller 846. Controller 846 may receive information about the direction of the force sensed by force sensor 64. Controller 846 may process this information using a motion controller algorithm. The algorithm may be used to provide information to a specific motor driver 842. To parallel determine the direction of the force, controller 846 may activate and / or deactivate certain motor drivers 842. Controller 846 may control one or more motors (e.g., one or more of 850-854) to cause the passive end effector 1100 to move in the direction of the force sensed by force sensor 64. This force-controlled motion allows the operator to move the SCARA 24 and the passive end effector 1100 effortlessly and / or with very little resistance. The passive end effector 1100 can be moved to position it in any suitable pose (i.e., position and angular orientation relative to a defined three-dimensional (3D) orthogonal reference axis) for use by medical personnel.

[0063] Connector 66 is configured to connect to the base of the passive end effector 1100 and to the force sensor 64. Connector 66 may include attachment point 68, a feel button 70, a tool guide 72, and / or a tool connector / attachment point 74. Figure 6 and Figure 8As best shown, multiple attachment points 68 may be present. Attachment points 68 can connect connector 66 to force sensor 64. Attachment points 68 may be recessed, flush, and / or located on connector 66. Attachment points 68 and 76 can be used to attach connector 66 to force sensor 64 and / or passive end effector 1100. In some examples, attachment points 68 and 76 may include screws, nuts and bolts, compression fittings, magnetic attachments, and / or any combination thereof.

[0064] like Figure 6 As shown, the sensor button 70 can be positioned around the center of the connector 66. The sensor button 70 can be pressed when the passive end effector 1100 is connected to the SCARA 24. Pressing the sensor button 70 alerts the surgical robot 4 and, consequently, the medical personnel that the passive end effector 1100 has been attached to the SCARA 24. Figure 6 As shown, guide 72 can be used to facilitate proper attachment of the passive end effector 1100 to the SCARA 24. Guide 72 can be recessed, flush, and / or disposed on connector 66. In some examples, multiple guides 72 may be present, which can have any suitable pattern and can be oriented in any suitable direction. Guide 72 can be any suitable shape to facilitate attachment of the passive end effector 1100 to the SCARA 24. Suitable shapes can be, but are not limited to, circular, elliptical, square, polyhedral, and / or any combination thereof. In addition, guide 72 can be cut into bevels, straight faces, and / or any combination thereof.

[0065] Connector 66 may have attachment point 74. For example... Figure 6 As shown, attachment point 74 may form one flange and / or multiple flanges. Attachment point 74 may provide a surface for connector 66 on which passive end effector 1100 may clamp. In some embodiments, attachment point 74 is disposed around any surface of connector 66 and oriented in any suitable manner relative to connector 66.

[0066] exist Figure 6 and Figure 7As best shown, activation component 60 may surround connector 66. In some embodiments, activation component 60 may take the form of a bracelet surrounding connector 66. In some embodiments, activation component 60 may be located in any suitable area within surgical system 2. In some examples, activation component 60 may be located on any part of SCARA 24, any part of end effector connector 22, may be worn by a medical personnel (and communicate wirelessly), and / or any combination thereof. Activation component 60 may be made of any suitable material. Suitable materials may be, but are not limited to, neoprene, plastic, rubber, gel, carbon fiber, fabric, and / or any combination thereof. Activation component 60 may include a main button 78 and an auxiliary button 80. Main button 78 and auxiliary button 80 may surround the entire connector 66.

[0067] The main button 78 can be a single raised portion that can surround the connector 66, such as Figure 6 As shown. In some examples, the main button 78 may be positioned on the activation component 60 along the end furthest from the saddle connector 62. The main button 78 may also be positioned on the main activation switch 82, which is... Figure 7 The main activation switch 82 may be positioned between the connector 66 and the activation component 60. In some examples, multiple main activation switches 82 may be present, positioned adjacent to and below the main button 78 along its entire length. Pressing the main button 78 on the main activation switch 82 allows the operator to move the SCARA 24 and the end effector connector 22. As discussed above, once positioned, the SCARA 24 and the end effector connector 22 may not move until the operator programs the surgical robot 4 to move them, or uses the main button 78 and the main activation switch 82 to move them. In some examples, it may be necessary to press at least two non-adjacent main activation switches 82 before the SCARA 24 and the end effector connector 22 will respond to operator commands. Pressing at least two main activation switches 82 can prevent the SCARA 24 and end effector connector 22 from moving accidentally during medical procedures.

[0068] Activated via the main button 78 and main activation switch 82, force sensor 64 measures the magnitude and / or direction of the force applied to end effector connector 22 by the operator (i.e., medical personnel). This information can be transmitted to motors within the SCARA 24, which can then be used to move the SCARA 24 and end effector connector 22. Information about the magnitude and direction of the force measured by force sensor 64 can cause the motors to move the SCARA 24 and end effector connector 22 in the same direction as sensed by force sensor 64. Because the motors are moving the SCARA 24 and end effector connector 22 simultaneously with the operator moving them, this force-controlled movement allows the operator to easily move the SCARA 24 and end effector connector 22 without expending significant force.

[0069] like Figure 6 As shown, the auxiliary button 80 can be located on the end of the activation component 60 closest to the saddle connector 62. In some examples, the auxiliary button 80 may include multiple raised portions. These multiple raised portions may be arranged adjacent to each other and may surround the connector 66. Alternatively, the auxiliary button 80 may be located on the auxiliary activation switch 84. Figure 7 As shown, an auxiliary activation switch 84 may be positioned between the auxiliary button 80 and the connector 66. In some examples, the operator may use the auxiliary button 80 as a "selection" device. During medical procedures, the surgical robot 4 may notify the medical personnel of certain conditions via the display 34 and / or the light indicator 28. The surgical robot 4 may prompt the medical personnel to select functions, modes, and / or assess the conditions of the surgical system 2. Pressing the auxiliary button 80 once on the auxiliary activation switch 84 activates certain functions, modes, and / or confirmation information communicated to the medical personnel via the display 34 and / or the light indicator 28. Furthermore, consecutive presses of the auxiliary button 80 on the auxiliary activation switch 84 activate additional functions, modes, and / or selection information communicated to the medical personnel via the display 34 and / or the light indicator 28. In some examples, at least two non-adjacent auxiliary activation switches 84 may be pressed before the auxiliary button 80 can function properly. This requirement prevents accidental use of the auxiliary button 80 due to accidental bumping of the activation component 60 by the medical personnel. The main button 78 and auxiliary button 80 can use the software architecture 86 to transmit commands from medical personnel to the surgical system 2.

[0070] Figure 8A block diagram of components of a surgical system 800 configured according to some embodiments of the present disclosure is shown, and this surgical system may correspond to the surgical system 2 described above. The surgical system 800 includes a platform subsystem 802, a computer subsystem 820, a motion control subsystem 840, and a tracking subsystem 830. The platform subsystem 802 includes a battery 806, a power distribution module 804, a connector panel 808, and a charging station 810. The computer subsystem 820 includes a computer 822, a display 824, and a speaker 826. The motion control subsystem 840 includes a drive circuit 842, motors 850, 851, 852, 853, and 854, stabilizers 855, 856, 857, and 858, an end effector connector 844, and a controller 846. The tracking subsystem 830 includes a position sensor 832 and a camera converter 834. The surgical system 800 may also include a removable foot switch 880 and a removable tablet computer 890.

[0071] Input power is provided to the surgical system 800 via a power supply, which can be supplied to a power distribution module 804. The power distribution module 804 receives the input power and is configured to generate different power supply voltages for other modules, components, and subsystems of the surgical system 800. The power distribution module 804 can be configured to provide different voltage supplies to a connector panel 808, which can be supplied to other components such as a computer 822, a display 824, a speaker 826, a driver 842 to power motors 850-854 and an end effector connector 844, and to a camera converter 834 and other components of the surgical system 800. The power distribution module 804 can also be connected to a battery 806, which acts as a temporary power source when the power distribution module 804 is not receiving power from the input power. At other times, the power distribution module 804 can be used to charge the battery 806.

[0072] Connector panel 808 can be used to connect different devices and components to surgical system 800 and / or associated components and modules. Connector panel 808 may include one or more ports for accommodating wires or connectors from different components. For example, connector panel 808 may have: a grounding terminal port for grounding surgical system 800 to other equipment, a port for connecting foot switch 880, and a port for connecting tracking subsystem 830, which may include position sensor 832, camera converter 834, and marker tracking camera 870. Connector panel 808 may also include other ports to allow communication with other components such as computer 822 via USB, Ethernet, or HDMI.

[0073] Control panel 816 may provide various buttons or indicators for controlling the operation of surgical system 800 and / or provide information from surgical system 800 for operator observation. For example, control panel 816 may include buttons for turning surgical system 800 on or off, raising or lowering the vertical column of support arm 16, and raising or lowering stabilizers 855-858, which may be designed to engage casters (e.g., drive wheels 12) to lock surgical system 800 in place, preventing physical movement. Other buttons may stop surgical system 800 in an emergency, potentially by cutting off all motor power and applying mechanical brakes to stop all movement. Control panel 816 may also have indicators that notify the operator of certain system conditions, such as line power indicators or the charging status of battery 806.

[0074] The computer 822 of the computer subsystem 820 includes an operating system and software to operate designated functions of the surgical system 800. The computer 822 can receive and process information from other components (e.g., the tracking subsystem 830, the platform subsystem 802, and / or the motion control subsystem 840) to display information to the operator. Furthermore, the computer subsystem 820 can provide output to the operator via a speaker 826. The speaker may be part of the surgical robot, part of a head-mounted display unit, or within another component of the surgical system 800. A display 824 may correspond to... Figure 1 and Figure 2 The display 34 shown may be a head-mounted display that projects images onto a perspective display screen, which forms an augmented reality (AR) image superimposed on a real-world object visible through the perspective display screen.

[0075] The tracking subsystem 830 may include a position sensor 832 and a camera converter 834. The tracking subsystem 830 may correspond to... Figure 3 The camera tracking system 6. A marker tracking camera 870 operates in conjunction with a position sensor 832 to determine the pose of the DRA 52. This tracking can be performed in a manner consistent with this disclosure, including using infrared or visible light techniques to track the position of active or passive elements such as LEDs or reflective markers, respectively, of the DRA 52. The position, orientation, and orientation of structures having these types of markers (such as the DRA 52) can be provided to a computer 822, and this information can be displayed to an operator on a display 824. For example, as... Figure 4 and Figure 5 As shown, a surgical saw 1240 having a DRA 52 or an end effector connector 22 having a DRA 52 that tracks in this way (which may be referred to as a navigation space) can be displayed to the operator as a three-dimensional image of the patient's anatomy.

[0076] The motion control subsystem 840 can be configured to physically move the vertical column 16, upper arm 18, lower arm 20, or rotary end effector connector 22. Physical movement can be achieved using one or more motors 850-854. For example, motor 850 can be configured to vertically raise or lower the vertical column 16. Figure 2 As shown, motor 851 can be configured to laterally move upper arm 18 about the engagement point with the vertical column. (As indicated...) Figure 2 As shown, motor 852 can be configured to laterally move lower arm 20 about the engagement point with upper arm 18. Motors 853 and 854 can be configured to move end effector coupler 22 to provide translational and rotational movement along approximately three-dimensional axes. Figure 9 The surgical planning computer 910 shown can provide control input to a controller 846, which guides the movement of the end effector connector 22 to position the passive end effector connected to the connector in a planned pose (i.e., position and angular orientation relative to a defined 3D orthogonal reference axis) relative to the anatomical structure to be cut during the surgical procedure. The motion control subsystem 840 can be configured to measure the position of the passive end effector structure using an integrated position sensor (e.g., an encoder). In one embodiment, the position sensor is directly connected to at least one connector of the passive end effector structure, but it can also be positioned in another location within the structure and the connector position can be measured remotely via an interconnection of a timing belt, wire, or any other synchronous transmission interconnect.

[0077] Figure 9 A block diagram of a surgical system computer platform 900 according to some embodiments of the present disclosure is shown. The surgical system computer platform includes a surgical planning computer 910, which may be separate from and operatively connected to or at least partially incorporated into a surgical robot 800. Alternatively, at least a portion of the operation of the surgical planning computer 910 disclosed herein may be performed by components of the surgical robot 800, such as a computer subsystem 820.

[0078] refer to Figure 9 The surgical planning computer 910 includes: a display 912, at least one processor circuitry 914 (also referred to as a processor for simplicity), at least one memory circuitry 916 (also referred to as memory for simplicity) containing computer-readable program code 918, and at least one network interface 920 (also referred to as a network interface for simplicity). The network interface 920 can be configured to connect to... Figure 10 C-arm imaging device 104 in Figure 11 The O-arm imaging device 106, another medical imaging device, a medical image database 950, components of a surgical robot 800, and / or other electronic equipment.

[0079] When the surgical planning computer 910 is at least partially integrated within the surgical robot 800, the display 912 can correspond to... Figure 2 The monitor 34 and / or Figure 8 The tablet 890 and / or head-mounted display, network interface 920 can correspond to Figure 8 The platform network interface 812, and the processor 914 can correspond to Figure 8 Computer 822.

[0080] Processor 914 may include one or more data processing circuitry, such as general-purpose and / or special-purpose processors, like microprocessors and / or digital signal processors. Processor 914 is configured to execute computer-readable program code 918 in memory 916 to perform operations, which may include some or all of the operations described herein as being performed by a surgical planning computer.

[0081] Processor 914 is operable to display images of bones received from one of imaging devices 104 and 106 and / or from image database 950 via network interface 920 on display device 912. Processor 914 receives operator specifications for the location to be cut of anatomical structures (i.e., one or more bones) shown in one or more images, such as by operator touch to select the location for planned surgical cut on display 912 or by using a mouse-based cursor to specify the location for planned surgical cut.

[0082] The surgical planning computer 910 enables anatomical measurements to be applied to knee surgery, such as measurements of various angles for determining the center of the hip joint, the center of angles, natural landmarks (e.g., via the femoral epicondyle line, Whiteside line, posterior condyle line, etc.). Some measurements can be automated, while others involve user input or assistance. The surgical planning computer 910 allows the operator to select the correct implant for the patient, including selecting size and alignment. The surgical planning computer 910 enables automatic or semi-automatic (involving human input) segmentation (image processing) of CT images or other medical images. The patient's surgical plan can be stored in a cloud-based server for retrieval by the surgical robot 800. During surgery, the surgeon will use a computer screen (e.g., a touchscreen) or augmented reality interaction via, for example, a head-mounted display, to select the cuts to be made (e.g., posterior femur, proximal tibia, etc.). The surgical robot 4 can automatically move the surgical saw blade to the planned position, such that the target plane of the planned cut is optimally positioned within the workspace of the passive end effector that interconnects the surgical saw blade and the robotic arm 20. Users can use various modalities, such as a foot switch, to give commands to enable movement.

[0083] In some implementations, the surgical system computer platform 900 may use two DRAs to track the location of patient anatomy: one DRA on the patient's tibia and another on the patient's femur. Platform 900 may use standard navigation instruments (e.g., pointers similar to those used in the Globus Excelsius GPS system for spinal surgery) for registration and inspection. Alternatively, tracking markers that allow for reference tracking of anatomical structures may be used to detect DRA movement.

[0084] A major challenge in knee surgery is planning the placement of implants within the knee joint, and many surgeons struggle with this on a computer screen displaying a 2D representation of the 3D anatomy. Platform 900 addresses this by generating an implant overlay around the actual patient's knee joint using an augmented reality (AR) head-mounted display. For example, the surgeon can operatively display a virtual handle to grasp the implant and move it into the desired pose, adjusting the planned implant placement. Subsequently, during surgery, Platform 900 can render navigation through the AR head-mounted display to show the surgeon objects that are not directly visible. Furthermore, the progress of bone removal (e.g., depth or incision) can be displayed in real time. Other features that can be displayed via AR include, but are not limited to, gaps or ligament balance along the joint's range of motion, contact lines on the implant along the joint's range of motion, ligament tension and / or laxity through color or other graphic overlays.

[0085] In some implementations, the surgical planning computer 910 may allow the planning of corrective systems for surgeries involving, for example, total or partial knee and / or hip replacements and / or trauma, using standard implants (e.g., posterior stabilizing implants and cruciate retention implants, cemented and uncemented implants).

[0086] The processor 914 can graphically display one or more cutting planes on the display 912, which intersect the displayed anatomical structure at a location selected by the operator for cutting the anatomical structure. The processor 914 also determines one or more sets of angular orientations and positions, wherein the end effector connector 22 must be positioned such that the cutting plane of the surgical saw blade will align with the target plane to perform the operator-defined cut, and the processor stores the sets of angular orientations and positions as data in a surgical planning data structure. The processor 914 uses the known range of motion of the passive end effector's tool attachment mechanism to determine where the end effector connector 22, attached to the robotic arm 20, needs to be positioned.

[0087] The computer subsystem 820 of the surgical robot 800 receives data from a surgical planning data structure and information from a camera tracking system 6, indicating the current pose of the anatomical structure to be cut and the current pose of the passive end effector and / or surgical saw tracked by DRA. The computer subsystem 820 determines the pose of the target plane based on the surgical plan defining the location where the anatomical structure will be cut and based on the pose of the anatomical structure. The computer subsystem 820 generates steering information based on a comparison of the pose of the target plane and the pose of the surgical saw. This steering information indicates the position to which the passive end effector needs to move, such that the cutting plane of the saw blade is aligned with the target plane, and the saw blade is positioned at a distance from the anatomical structure to be cut, within the range of motion of the tool attachment mechanism of the passive end effector.

[0088] As described above, the surgical robot includes a robot base, a robotic arm connected to the robot base, and at least one motor operatively connected to move the robotic arm relative to the robot base. The surgical robot also includes at least one controller, such as a computer subsystem 820 and a motion control subsystem 840, connected to the at least one motor and configured to perform operations.

[0089] As will be referred to below Figures 12 to 19. Further detailed description: The passive end effector includes a base configured to attach to an activation component of a robotic arm, a first mechanism, and a second mechanism. The first mechanism extends between a rotatable connector to the base and a rotatable connector to a tool attachment mechanism. The second mechanism extends between the rotatable connector to the base and the rotatable connector to the tool attachment mechanism. The first and second mechanisms pivot about the rotatable connector and can be configured to limit movement of the tool attachment mechanism to a range of motion within a working plane. The rotatable connector can be a pivot joint allowing one degree of freedom (DOF) of movement, a universal joint allowing two DOF of movement, or a ball joint allowing three DOF of movement. The tool attachment mechanism is configured to connect to a surgical saw including a saw blade for cutting. The first and second mechanisms can be configured to limit the cutting plane of the saw blade to parallel to the working plane.

[0090] In some embodiments, the operation performed by the at least one controller of the surgical robot further includes: controlling the movement of the at least one motor based on steering information to reposition the passive end effector such that the cutting plane of the saw blade is aligned with the target plane and the saw blade is positioned at a distance from the anatomical structure to be cut, the distance being within the range of movement of the tool attachment mechanism of the passive end effector. The steering information may be displayed to guide the operator in moving the surgical saw, and / or the at least one controller may use the steering information to automatically move the surgical saw.

[0091] In one embodiment, the operation performed by the at least one controller of the surgical robot further includes: providing steering information to a display device for display, thereby guiding the operator to move the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade becomes positioned at a distance from the anatomical structure to be cut, the distance being within the range of movement of the tool attachment mechanism of the passive end effector. The display device may correspond to a display 824 ( Figure 8 ), Figure 1 The display 34 and / or head-mounted display.

[0092] For example, steering information can be displayed on a head-mounted display that projects images onto a fluoroscopic display screen, forming an augmented reality image superimposed on a real-world object visible through the fluoroscopic display screen. These operations can display a graphical representation of a target plane, the pose of which is superimposed on the bone, and the relative orientation between the target plane and the bone corresponding to a surgical plan regarding the planned manner of bone cutting. These operations can optionally or additionally display a graphical representation of the saw blade's cutting plane, making it easier for the operator to align the cutting plane with the planned target plane to cut the bone. Thus, the operator can visually observe and perform movements to align the saw blade's cutting plane with the target plane, positioning the saw blade relative to the bone and within the range of motion of the passive end effector's tool attachment mechanism.

[0093] The automated imaging system can be used in conjunction with the surgical planning computer 910 and / or the surgical system 2 to obtain preoperative, intraoperative, postoperative and / or real-time image data of the patient. Figure 10 and Figure 11 An exemplary automated imaging system is illustrated. In some embodiments, the automated imaging system is a C-arm 104 ( Figure 10 Imaging device or 106 ( Figure 11 ). ( Copyright owned by Medtronic Navigation, Inc., which has a business location in Louisville, Colorado, USA. What might be desired is the ability to acquire X-ray images of a patient from many different locations without the need for frequent manual repositioning of the patient (a requirement common in X-ray systems). The C-arm 104 X-ray diagnostic equipment solves the problem of frequent manual repositioning and is likely well-known in the medical field for surgical and other interventional procedures. Figure 10 As shown, the C-arm includes an elongated C-shaped member terminating at a relatively distal end 112 of the “C” shape. The C-shaped member is attached to an X-ray source 114 and an image receiver 116. The space within the C-arm 104 of the arm provides a physician with space to care for the patient, largely unaffected by the X-ray support structure.

[0094] The C-arm is mounted such that it can rotate in two degrees of freedom (i.e., about two vertical axes in spherical motion). The C-arm is slidably mounted to the X-ray support structure, allowing it to rotate about its center of curvature, which permits selective vertical and / or horizontal orientation of the X-ray source 114 and image receiver 116. The C-arm can also be laterally rotatable (i.e., rotatable in a direction perpendicular to the rotational direction, allowing selective adjustment of the positioning of the X-ray source 114 and image receiver 116 relative to the width and length of the patient). The spherical rotation aspect of the C-arm device allows the physician to acquire X-ray images of the patient at an optimal angle determined relative to the specific anatomical conditions being imaged.

[0095] Figure 11 shown 106 includes a rack housing 124 that can enclose an image capture section (not shown). The image capture section includes an X-ray source and / or emitting section and an X-ray receiving and / or image receiving section, which can be positioned approximately 180 degrees apart from each other and mounted on a rotor (not shown) relative to the trajectory of the image capture section. The image capture section may be operable to rotate 360 ​​degrees during image acquisition. The image capture section can rotate about a center point and / or axis, thereby allowing the acquisition of patient image data from multiple directions or multiple planes.

[0096] With rack housing 124 106 has a radiation source rotatable about the interior of the frame housing 124, with a central opening for positioning around the object to be imaged. This radiation source is adapted to project radiation from multiple different projection angles. A detector system is adapted to detect the radiation at each projection angle to acquire object images from multiple projection planes in a quasi-simultaneous manner. The frame can be cantilevered to a supporting structure. Support structures, such as wheeled mobile carts with wheels, are used. The positioning unit preferably translates and / or tilts the frame to a planned position and orientation under the control of a computerized motion control system. The frame may include sources and detectors disposed opposite to each other on the frame. The sources and detectors may be fixed to a motorized rotor that allows the sources and detectors to rotate in a coordinated manner about the interior of the frame. Pulse sources can be used at multiple positions and orientations with partial and / or full 360-degree rotation for multi-planar imaging of a target object located inside the frame. The frame may also include a track and bearing system for guiding the rotor during its rotation, which can carry the sources and detectors. Both and / or either of 106 and C-arm 104 can be used as an automated imaging system to scan the patient and send information to the surgical system 2.

[0097] Images captured by the automated imaging system can be displayed on the display device of the surgical planning computer 910, the surgical robot 800, and / or another component of the surgical system 2.

[0098] Now Figures 12 to 19C In the context of this, various implementations of passive end effectors configured for use with surgical systems are described.

[0099] As will be explained in further detail below, Figures 12 to 19C The various passive end effectors shown may each include a base, a first planar mechanism, and a second planar mechanism. The base is configured to attach to a robotic arm positioned by a surgical robot (e.g., Figure 1 and Figure 2 The end effector connector (e.g., of the robot arm 20) in the robot arm 20 Figure 4 and Figure 5 The end effector connector 22 in the example is used. Various clamping mechanisms can be used to securely attach the base to the end effector connector, thereby removing recoil and ensuring appropriate stiffness. Irreversible clamping mechanisms that can be used to attach the base to the end effector connector may include, but are not limited to, switching joint mechanisms or irreversible locking screws. The user can use additional tools (such as, but not limited to, screwdrivers, torque wrenches, or drivers) to activate or tighten the clamping mechanism. A first mechanism extends between a rotatable connector to the base and a rotatable connector to the tool attachment mechanism. A second mechanism extends between a rotatable connector to the base and a rotatable connector to the tool attachment mechanism. The first and second mechanisms pivot about the rotatable connector. The rotatable connector may be a pivot joint allowing one degree of freedom (DOF) of movement, a universal joint allowing two DOF of movement, or a ball joint allowing three DOF of movement. When using a pivot joint, the first and second mechanisms can be configured to limit the movement of the tool attachment mechanism to a range of motion within the working plane. The tool attachment mechanism is configured to connect to a surgical saw with a saw blade configured to oscillate for cutting. A first and a second mechanism can be configured to constrain the cutting plane of the saw blade to be parallel to the working plane via a pivot joint having one DOF motion. The tool attachment mechanism can be connected to the surgical saw or saw blade via various mechanisms, including but not limited to screws, nuts and bolts, clamps, latches, bands, pressure fittings, or magnets. A DRA can be connected to the tool attachment mechanism or the surgical saw to enable tracking via a camera tracking system 6 ( Figure 3 Track the position of the saw blade.

[0100] As described above, surgical systems (e.g., Figure 1 and Figure 2 Surgical systems 2) include surgical robots (e.g., Figure 1 and Figure 2 Surgical robots (4) and tracking systems (e.g., Figure 1 and Figure 3 The camera tracking system 6 is configured to determine the pose of the anatomical structure to be cut by the saw blade and to determine the pose of the saw blade. The surgical robot includes a robot base, a robotic arm rotatably connected to the robot base and configured to position a passive end effector. At least one motor is operatively connected to move the robotic arm relative to the robot base. At least one controller is connected to the at least one motor and configured to perform operations including a surgical plan based on defining the location where the anatomical structure is to be cut and determining the pose of a target plane based on the pose of the anatomical structure, wherein the surgical plan can be determined by… Figure 9 The surgical planning computer 910 generates commands based on input from the operator (e.g., a surgeon or other surgical personnel). These commands also include generating steering information based on a comparison of the pose of the target plane with the pose of the surgical saw. This steering information indicates the location where the passive end effector needs to move to, and that position is used to position the passive end effector's working plane so that the saw blade's cutting plane is aligned with the target plane.

[0101] In some other embodiments, the operation performed by the at least one controller further includes: controlling the movement of the at least one motor based on steering information to reposition the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade becomes positioned at a distance from the anatomical structure to be cut, the distance being within the range of movement of the tool attachment mechanism of the passive end effector.

[0102] These operations may include: providing steering information to a display device for display, thereby guiding the operator to move the passive end effector so that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade becomes positioned at a distance from the anatomical structure to be cut, the distance being within the range of movement of the tool attachment mechanism of the passive end effector.

[0103] As described above, some surgical systems may include a head-mounted display device that can be worn by a surgeon, nurse practitioner, and / or other personnel assisting in the surgical procedure. The surgical system may display information that allows the wearer to more accurately position the passive end effector and / or confirm that the passive end effector has been accurately positioned, with the saw blade aligned with the target plane for planned cutting of the anatomical structure. Providing steering information to the display device may include configuring that steering information for display on a head-mounted display device with a fluoroscopic display showing the steering information as an overlay on the anatomical structure to be cut, guiding the operator to move the passive end effector such that the cutting plane of the saw blade becomes aligned with the target plane and the saw blade becomes positioned at a distance from the anatomical structure, within the range of movement of the tool attachment mechanism of the passive end effector.

[0104] Configuring steering information for display on a head-mounted display can include: generating a graphical representation of the target plane, displayed as an overlay anchored to and aligned with the anatomical structure to be cut; and generating another graphical representation of the cutting plane of the saw blade, displayed as an overlay anchored to and aligned with the saw blade. Thus, the wearer can move the surgical saw to provide a visually apparent alignment between the graphically rendered target plane and the graphically rendered cutting plane.

[0105] Configuring steering information for display on a head-mounted display can include generating a graphical representation of the cutting depth produced by the saw blade cutting into the anatomical structure being cut. Therefore, even though direct observation of the cut is obscured by tissue or other structures, the wearer can use the graphical representation of the cutting depth to better monitor how the saw blade cuts through bone.

[0106] The tracking system can be configured to determine the pose of the anatomical structure to be cut by the saw blade based on the pose of a tracking marker (e.g., DRA) attached to the anatomical structure, and can be configured to determine the pose of the surgical saw based on the pose of a tracking marker attached to at least one of the surgical saw and the passive end effector. The tracking system can be configured to determine the pose of the surgical saw based on a rotary position sensor configured to measure the rotational positions of a first and a second mechanism during movement of the tool attachment mechanism within the working plane. As described above, the position sensor can be directly connected to at least one joint of the passive end effector structure, but can also be located in another location within the structure and the joint position can be measured remotely via an interconnection of a timing belt, wire, or any other synchronous transmission interconnect. Furthermore, the pose of the saw blade can be determined based on the tracking marker attached to the base of the structure, the position sensor in the passive structure, and the motion model of the structure.

[0107] The various passive end effectors disclosed herein can be sterile or non-sterilized (covered by sterile drapes) passive 3DOF (degrees of freedom) mechanical structures, thereby allowing mechanical guidance of a surgical saw or saw blade (such as a sagittal saw) along two translations in a plane parallel to the saw blade (defining the cutting plane) and one rotation perpendicular to that cutting plane (instrument orientation). During surgery, the surgical robot 4 automatically moves the end effector connector 22, the passive end effector, and the surgical saw attached thereto to a position close to the knee joint or other anatomical structures, such that all bone to be cut is within the workspace of the passive end effector. This position depends on the cut to be performed, the surgical plan, and the implant construction. The passive end effector can have 3 DOFs to guide the sagittal saw or saw blade in the cutting plane, providing two translations (X and Y directions) and one rotation (about the Z axis), such as... Figure 12 As shown.

[0108] Once the surgical robot 4 reaches the planned position, it maintains that position (controlled by braking or an active motor) and does not move during specific bone cuts. A passive end effector allows the surgical saw blade to move along the planned target plane. This planar cutting is particularly useful for classic total knee arthroplasty, where all bone cuts are planar. In partial knee arthroplasty, special types of implants (called "on-lays") are available that can be used in conjunction with the bone surface prepared by the saw. Various passive end effectors have mechanical structures that ensure guidance accuracy during cutting (higher than classic jigs) and provide sufficient workspace to cut all planned bone while providing adequate lateral stiffness (corresponding to locking DOF), although there is a significant amount of vibration from the surgical saw in addition to the forces applied by the surgeon and bone reaction forces.

[0109] Simultaneously, it is preferable to measure the position of the passive end effector, as this allows the surgical robot 4 to inform the surgeon how much bone has been removed (procedure progress). One way to provide real-time information about bone removal is for the surgical robot 4 to measure the saw blade position based on where the bone has passed, since the blade can only pass through where the bone has been cut. To measure the saw blade position, a DRA can be mounted to the surgical saw and / or the passive end effector. This allows for direct or indirect measurement of the saw position in 3D space. An alternative method for measuring the saw blade position is to integrate a position (rotational or translational) sensor (e.g., encoder, resolver) into the position information of the passive end effector so that the saw blade position can be calculated using a mathematical model of the defined relationship between the position of the passive end effector geometry and the tip of the saw blade.

[0110] In one implementation, a conventional sagittal saw mechanism can be used with the surgical system computer platform 900 with minimal changes. Possible variations would involve adjusting the external shield to allow the surgical saw to be easily attached to the passive end effector, but not necessarily involving changes to the internal mechanisms. The passive end effector can be configured to connect to a conventional sagittal saw, such as those supplied by DeSoutter. Alternatively, the saw blade can be attached directly to the passive end effector without a saw handle.

[0111] To prevent accidental passive end effector movement of the saw during positioning of the passive end effector in the surgical robot 4, for example, to prevent the surgical saw from falling onto the patient due to gravity, the passive end effector may include a locking mechanism that transitions between engagement and disengagement. When engaged, the locking mechanism can prevent movement of the saw blade relative to the robot end effector connector directly by locking the degrees of freedom (DOF) of the surgical saw, or indirectly by braking or locking a specific joint of the passive end effector. When disengaged, the first and second mechanisms of the passive end effector can move relative to the base without interference from the locking mechanism. (The following refers to...) Figures 19A to 19C The locking mechanism, described in more detail, can also be used when a surgeon holds a surgical saw and controls the movement of the surgical robot 4 by applying force and torque to the surgical saw. This is achieved using the locking mechanism integrated into the distal end of the robotic arm 20. Figure 6 and Figure 7 The force sensor 64 of the surgical robot 4 measures the applied force and torque and generates responsive force and torque on the robotic arm 20, making it easier for surgeons to move the passive end effector back and forth and left and right to apply rotation about various axes.

[0112] Figure 12 An embodiment of a passive end effector is shown. The passive end effector 1200 includes a base 1202 configured to attach to a robotic arm positioned by a surgical robot (e.g., Figure 1 and Figure 2 The end effector connector of the robot arm 18) (e.g., Figure 4(And the end effector connector 22 in Figure 5). The passive end effector 1200 also includes a first connector section 1210 and a second connector section 1220. The first connector section 1210 extends between a rotatable connector to the base 1202 and a rotatable connector to one end of the second connector section 1220. The other end of the second connector section 1220 is rotatably connected to a tool attachment mechanism. Rotation axes q1, q2, and q3 are parallel to each other to provide a planar cutting plane for the blade 1242. Therefore, the three DOF movements of the saw 1240 include the x-direction Tx, the y-direction Ty, and the rotational direction about the z-axis Rz. One or more of the rotatable connectors disclosed for this embodiment may be a pivot joint allowing one DOF movement, a universal joint allowing two DOF movements, or a ball joint allowing three DOF movements.

[0113] Tracking markers (e.g., DRA 52) attached to the end effector base 1202 and saw 1240, together with tracking markers on the bone (e.g., tibia and femur), can be used to accurately and continuously monitor the real-time position of the blade 1242 and blade tip relative to the patient bone being cut. Although not explicitly shown in other figures, in all embodiments, tracking markers may be attached to saw 1240 and all end effectors (e.g., end effector 1200, end effector arm 1400, etc.) to track the position of the blade relative to the patient bone being cut. Although not shown, alternatively, or in addition to tracking markers, encoders may be positioned in each of the connecting sections 1210 and 1220 to accurately determine where the saw blade tip is always located.

[0114] Exemplary surgical procedure

[0115] An exemplary surgical procedure using surgical robot 4 in the operating room (OR) may include:

[0116] Optional step: Preoperative planning of surgery based on medical images

[0117] The Surgical Robot 4 system is located outside the operating room (OR). The nurse takes the system to the OR when the patient is ready for surgery.

[0118] The nurse turns on the robot and deploys its arm. The nurse then verifies the accuracy of the robot and the tracking system.

[0119] For sterilized passive end effectors, the scrubbing nurse places a sterile drape on the robotic arm and mounts the passive end effector with a sagittal saw onto the robotic arm. The scrubbing nurse locks the passive end effector using a locking mechanism. The scrubbing nurse attaches the DRA to the passive structure (if necessary) through the drape. For unsterilized passive end effectors, after the passive end effector is attached to the robotic arm, a drape is placed, and the DRA is attached to the passive end effector using the drape centered therein. A sterile saw or saw blade is also attached to the passive end effector using the drape centered therein. The locking mechanism is engaged to secure the position of the saw blade relative to the end effector connector.

[0120] The surgeon attaches navigation markers to the patient's bones, such as the tibia and femur. The bones are registered with the camera tracking system using algorithms such as Horn point-to-point algorithms, surface matching, or others. Soft tissue balance assessments can be performed, allowing the system to enable the surgeon to evaluate the balance of soft tissues in the operating room, for example, by tracking the relative movement of the femur and tibia as the surgeon applies forces in different directions (e.g., varus / valgus stress). Soft tissue balance information can be used to modify surgical planning (e.g., moving implant portions, changing implant type, etc.).

[0121] Once the surgeon is ready to cut the bone, the scrubbing nurse brings the surgical robot 4 to the operating table near the knee joint to be operated on and stabilizes it on the floor. The system can be operated to guide the nurse to position the robot 4 so that all cutting planes are within the workspace of the robot and the passive structure.

[0122] The surgeon selects different parameters on the screen of the surgical robot 4 based on the surgical plan for the first cut (the bone to be cut, the desired cutting plan, etc.).

[0123] The surgical robot 4 uses an automated mobile robotic arm 20 to reposition the passive end effector so that the cutting plane of the saw blade is aligned with the target plane, and the saw blade is positioned at a distance from the anatomical structure to be cut, which is within the range of movement of the tool attachment mechanism of the passive end effector.

[0124] The surgeon unlocks the passive end effector.

[0125] The surgeon performs cuts limited to the cutting plane provided by the passive end effector. The surgical robot 4 can provide a real-time display of the saw blade's tracking position relative to the bone, allowing the surgeon to monitor the progress of bone removal. In one manner, the tracking subsystem processes the saw's position relative to the bone in real time based on camera images and various tracking markers attached to the saw, robotic arm, end effector, femur, and tibia. Then, upon completion of the cut, the surgeon can use a locking mechanism to lock the passive end effector.

[0126] The surgeon selects the next cut to perform on the screen and proceeds as described above.

[0127] Surgeons can perform trial implant placements and assessments of intermediate soft tissue balance, and based on these two points, can modify the implant plan and associated incisions.

[0128] After all the cutting was completed, the nurse removed the surgical robot 4 from the operating table and detached the passive end effector from the robotic arm.

[0129] The surgeon places the implant and performs the surgery.

[0130] In step 9 above, the surgeon may have difficulty visually confirming the progress of the cut due to the surrounding tissues and ligaments, debris generated from the cutting, and other surgical instruments near the bone. Even if visual confirmation may be acceptable, there are areas of bone that the surgeon cannot see, such as the posterior portion of the cut bone.

[0131] Advantageously, one embodiment of the robotic system of the present invention provides a method for a physician to confirm the progress of bone removal in multiple dimensions. A camera tracking system 6, together with tracking markers attached to the end effector base 1202, the robotic arm 20, and the saw 1240, allows the tracking subsystem 830 and the computer subsystem 820 to calculate the precise position of the saw blade relative to the bone in real time, enabling the surgeon to monitor the progress of bone removal. In this and other embodiments, the saw 1240 serves as an example of a handheld surgical device attached to and guided by a passive end effector arm. However, it should be understood that other handheld surgical devices such as drills, scalpels, actuators, etc., may also be used with the embodiments described herein, as needed.

[0132] Figure 13 It is a screenshot of the monitor showing the progress of bone cutting during the surgical procedure. Figure 13Subsystems 830 and 820 are shown displaying three types of images: a side view, an AP view, and a top view. In each image, the real-time position of the saw blade 1242 relative to the bone (e.g., the tibia 1300) is displayed on monitor 34. The side and top views are particularly useful to physicians as they show the position of the saw blade, which is not easily visible. At the top portion of the monitor, computer subsystems 830 and 820 display the number of cutting procedures and the currently running procedure. For example, as shown in the screenshot, the physician may have programmed six planar cuts, and the current cutting procedure is the first. Furthermore, because subsystems 830 and 820 can utilize tracking markers to track the position the blade may have traveled to, these subsystems can determine how much bone cutting (the area cut) of a particular cutting procedure has been completed, and the percentage of progress is displayed on monitor 34. The bone images themselves are preferably derived from actual images of the patient's body for a more accurate representation. Subsystem 820 enhances the bone images using contour lines that show the cortical bone 1304 and cancellous bone 1302. This can be important for physicians because the amount of resistance to cutting differs greatly between the two types of bone.

[0133] If an augmented reality (AR) head-mounted display is used, the computer subsystem 820 can generate the same outline showing the cortical and cancellous bone, and continuously overlay this outline onto the actual leg as the physician moves his / her head. Areas that have been cut can be overlaid with black shadows onto the actual bone. Furthermore, implants to be inserted above the cut area can also be overlaid on the bone to show the physician that the cut was correctly completed along the plane of the implant. All of this is possible because subsystems 830 and 820 can track the position of the blade and the history of its movement relative to the bone and camera subsystems with tracking markers.

[0134] As discussed relative to the examples above, knee surgery may require the removal of planar surfaces on the femur and tibia, based on the location and orientation provided by the implant, which will then be further placed on these removed surfaces. To perform these removals, cutting elements such as… Figure 12 The power handheld component of the 1240 saw's oscillating sagittal saw blade can be held by a surgeon, wherein the passive end effector arm, such as... Figure 12 The passive end effector 1200 keeps the saw within a fixed cutting plane while allowing the blade to have three degrees of freedom within that plane: the x and y directions parallel to the cutting plane, and the direction of rotation about a rotation axis perpendicular to the cutting plane.

[0135] To achieve sufficient cutting accuracy, it is desirable to provide a passive end effector 1200 with a high level of lateral stiffness. For example, aluminum is a suitable material for the passive end effector 1200 due to its high stiffness and other factors such as manufacturing cost. However, the use of aluminum and / or other high-stiffness materials may affect the weight of these structural components.

[0136] During knee surgery, both the saw 1240 and the end effector 1200 are positioned relative to the patient's anatomy within the planned resection plane. When the resection plane is horizontal, the weight of the end effector 1200 is entirely supported by the joint bearings of the end effector 1200 (e.g., bearings of joints 1403, 1443, 1445). However, many resection procedures typically employ a resection plane tilted up to and including 90 degrees (i.e., vertical) relative to the horizontal plane. In such configurations, the weight of the connecting sections 1210, 1220 of the end effector 1200 may be partially or fully supported by the surgeon's hand. Therefore, to maintain the saw 1240 in the correct position, in addition to supporting the weight of the saw 1240, the surgeon applies a reaction force in the direction of the end effector 1200 sufficient to compensate for the vertical gravity on the end effector 1200. This can result in a significant increase in the perceived weight of the saw 1240, which negatively impacts usability.

[0137] The motion behavior of the end effector 1200 can also lead to unacceptable risks, especially when the cutting plane is nearly vertical. For example, when a surgeon unlocks the saw 1240 to allow it to move relative to the robotic arm to perform a resection, the gravitational force applied to the center of gravity of the components of the end effector 1200 (e.g., connector segments 1210, 1220) can cause unintended acceleration, which could lead to unexpected behavior of the end effector 1200 structure. In addition to the risk of unintentional contact between the saw 1240 and the patient, acceleration may also tend to exert lateral forces on the surgeon's hand depending on the orientation of the connector segments 1210, 1220. For example, the configuration of the end effector 1200 may change abruptly without proper support, especially when the connector segments 1210, 1220 are substantially collinear (i.e., approaching a singular configuration).

[0138] Therefore, it is desirable to compensate for these undesirable forces generated on the end effector 1200 due to gravity when the end effector 1200 is in the inclined cutting plane. In this respect, Figure 14An embodiment of an end effector arm 1400 according to some embodiments of the present disclosure is shown, the end effector arm having a spring mechanism 1412 for compensating for gravity on the end effector arm components. In this example, the end effector arm 1400 includes a base 1402 configured to attach to an end effector connector of a surgical robot arm, such as, for example... Figure 4 and Figure 5 The end effector connector 22. The end effector arm 1400 includes a mechanical link 1404 comprising a first end 1406 rotatably connected to a base 1402 at a base joint 1403 and a second end 1408 opposite to the first end 1406. For example, the second end 1408 is configured to be removably connected to a handheld surgical instrument, such as... Figure 12 The saw 1240. The end effector arm 1400 includes a spring mechanism 1412, which is configured to impart a variable rotational force to the mechanical link 1404 based on the rotation angle of the mechanical link 1404 relative to the base 1402.

[0139] As will be discussed below, this and other embodiments can compensate for the weight of the components of the end effector arm 1400 to prevent unintended acceleration of these components when subjected to gravity (e.g., when the end effector arm 1400 is unlocked). These and other embodiments can also reduce the effort and fatigue expended by the surgeon's hand due to the weight of the end effector arm 1400.

[0140] For example, Figure 14 An example implementation can be configured to fully compensate for the weight of the first coupling 1436 and partially compensate for the weight of the second coupling 1440 when the end effector arm 1400 is in the vertical cutting plane. The end effector arm can also be configured to minimize the variation of the compensation effect throughout the entire range of motion of the end effector arm 1400.

[0141] To achieve this and other advantages, the spring mechanism 1412 is integrated into the structure of the end effector arm 1400 and is configured to compensate for the weight of the end effector arm 1400 components without any electrical energy. For example, in this embodiment, when the cutting plane is vertical, the spring mechanism 1412 provides elastic potential energy to compensate for all the potential energy loss associated with the first coupling 1436 and part of the potential energy loss associated with the second coupling 1440.

[0142] In this example, spring 1414 has a first end 1416 and a second end 1418, wherein the first end 1416 of spring 1414 is coupled to the base 1402 of end effector arm 1400. Cable 1420 has a first end 1421 and a second end 1423, wherein the first end 1421 is coupled to the first end 1416 of spring 1414. In this example, spring 1414 is a compression coil spring disposed within a channel 1422 in the base 1402, wherein the first end 1416 of spring 1414 abuts a stop 1428 in the channel and a boss 1426 is disposed at the second end 1418 of spring 1414. The guide rod 1424 is attached to the boss 1426, extends through the spring toward the first connector 1436, and is attached to the first end 1421 of the cable 1420, such that the tension in the cable 1420 is transmitted to the second end 1418 of the spring 1414 to compress the spring 1414, and a reaction force is applied to the cable 1420 based on the amount of compression of the spring 1414.

[0143] However, it should be understood that other types of spring mechanisms and / or configurations may be used as needed. For example, suitable spring mechanisms may use tension coil springs, hydraulic and / or pneumatic springs, elastomers, medical-grade rubber bands, and / or any other suitable mechanism or component for applying an elastic reaction force in response to an applied force.

[0144] Return to reference Figure 14 The cam 1430 is connected to the first end 1406 of the mechanical link via a shaft 1431 at a joint between the first connector 1436 and the base 1402, such that the cam 1430 rotates together with the first connector 1436 relative to the base 1402. The second end 1423 of the cable 1420 is connected to the cam 1430, wherein the second end 1423 of the cable 1420 is received in and guided into the cam guide 1432 of the cam 1430 during rotation of the mechanical link 1404 relative to the base 1402.

[0145] However, it should be understood that other arrangements may be used as needed. For example, in some embodiments, the spring may be disposed in the first coupling 1436, and the cam may be coupled to the base such that the first coupling 1436 and the spring rotate relative to the base 1402 and the cam.

[0146] In this embodiment, the cam 1430 has a variable radius relative to the shaft 1431, which causes the mechanical link 1404 to rotate relative to the base 1402 at a linear rate, causing the spring 1414 to deform at a non-linear rate. The cam 1430 can be configured such that a compensating torque M is applied about the shaft 1431 for each angular position of the first coupling 1436 relative to the base 1402. 补偿This compensating torque corresponds to a roughly estimated torque generated by the force of gravity applied to the center of gravity 1437 of the end effector arm 1400. Compensating torque M 补偿 This can correspond to the sum of one or more components. For example, as shown in Figure 15, one component could be the magnitude of the torque generated around the base joint 1403 by the gravity PL1 applied to the center of gravity 1437 of the first connector 1436, where the torque M1 is equal to PL1 multiplied by the horizontal distance RL1 between the center of gravity 1437 of the first connector 1436 and the base joint 1403. Another component could be the magnitude of the torque generated by gravity PL2, which corresponds to the defined portion of the mass of the second connector 1440 at the joint 1443 between the first end 1442 and the second end 1438 of the first connector 1436, where the torque M2 is equal to PL2 multiplied by the horizontal distance RL2 between the joint 1443 and the base joint 1403. This is because the effective magnitude of the downward force PL2 can vary based on the vertical angle of the second connector 1440, which in turn causes the actual distance of the center of gravity 1441 of the second connector 1440 to also vary. Therefore, in this example, PL2 can be roughly estimated as needed based on any number of factors, such as the average amplitude, maximum amplitude, etc. of the actual gravity on the second connector 240.

[0147] In some embodiments, the variable rotational force imparted by the spring mechanism 1412 is sufficient to overcome the gravity on the second end 1408 of the end effector arm 1400 within the range of rotation angles of the mechanical link 1404 relative to the base 1402. For example, the cam 1430 may be configured such that the variable rotational force within this range of rotation angles is substantially equal to the gravity, average gravity, and / or a roughly estimated gravity on the second end 1408 of the end effector arm 1400.

[0148] It should also be understood that in some implementation schemes, multiple spring mechanisms may be employed. For example, in the above... Figure 14 and Figure 15 In the example, a second spring mechanism can be added between the first coupling 1436 and the second coupling 1440, for example, to provide gravity compensation for the second coupling 1440 relative to the first coupling 1436. This allows a reduction in the spring force of the main spring mechanism 1412, since the total compensation torque is provided by both mechanisms simultaneously. In some embodiments, in addition to or instead of the spring mechanism 1412, a spring mechanism can be used between the first coupling 1436 and the second coupling 1440 or between two other couplings, as needed.

[0149] In this respect, Figure 16A and Figure 16B Some embodiments according to this disclosure are shown. Figure 14 and Figure 15 A portion of the end effector arm 1400 is shown, illustrating the force applied to the first coupling 1436 of the end effector arm 1400. (As shown) Figure 16A As shown, when the end effector arm 1400 is in the docking position, due to the shape of the first coupling 1436, the center of gravity 1437 of the first coupling 1436 is offset horizontally from the vertical direction. In this example, the spring 1414 is configured to apply tension F to the cable 1420. s1 This tension imparts a compensating torque M 补偿1 The compensating torque is equal to the tension F. s1 Multiply by the radius R1 of cam 1430 at the mating position angle. In this example, the compensating torque M is calculated as needed. 补偿1 The torque is set to be higher than that generated by gravity on mechanical link 1404, such that mechanical link 1404 is biased toward the docking position for safety, ergonomic and / or other reasons.

[0150] like Figure 16B As shown, the first connecting member 1436 is at an angle of 142 degrees relative to the mating position. The rotation of the cam 1430 causes the spring 1414 to be compressed by the 142-degree rotation of the cam 1430, equal to the additional length of the cable disposed in the cam guide 1432. This compression of the spring 1414 proportionally increases the tension F. s2 Simultaneously, due to the changes in the center of gravity of the mechanical link, and the center of gravity 1437 of the first connecting member 1436 and / or the horizontal distance of the mechanical link 1404 relative to the base joint 1403, the rotation of the mechanical link 1404 also changes the amount of torque required to compensate for the gravity on the mechanical link 1404. In this example, the radius R2 of the cam 1430 at this angle is configured to generate the compensating torque M. 补偿2 The compensating torque is equal to the tension F. s2 Multiplying by the radius R2, this is sufficient to overcome the gravity on the second end 1408 of the end effector arm 1400 at that angle. The compensating torque M can be customized by customizing the profiles of the cam 1430 and the spring 1414. 补偿 To compensate for the weight on the mechanical link 1404, so as to minimize and / or eliminate the perceived weight of the mechanical link 1404 on the surgeon's hand when the mechanical link 1404 is fixed in an angled resection plane.

[0151] Now for reference Figure 17 Figure 1700 illustrates the gravitational torque Mg1702 and the compensation torque M on the end effector arm when the end effector arm is in a vertical cutting plane, according to some embodiments of the present disclosure. 补偿 1704 and net torque M 净 1706. In this example, the gravitational torque Mg The drawing in 1702 illustrates the torque exerted at the base joint of the end effector arm due to gravity on the end effector arm between a 0-degree extension angle (i.e., in the vertical docking position) and a 180-degree extension angle (i.e., in the fully extended position). In this example, the maximum torque due to gravity is 90 degrees when the horizontal distance between the center of gravity of the mechanical link and the base joint is at its maximum. In this example, the gravitational torque M... g 1702 can be represented as:

[0152] M g =-M 连杆 *L 连杆 *(sinθ)*G

[0153] Where M 连杆 It is the mass of the mechanical connecting rod, L 连杆 θ is the distance between the center of mass of the mechanical link and the base joint, θ is the vertical angle of the line between the center of mass of the mechanical link and the base joint, and G is the gravitational constant.

[0154] Compensating torque M 补偿 1704 can be similarly represented as:

[0155] M 补偿 =-M 连杆 *L 连杆 *(sinθ)*G

[0156] This compensating torque M is generated by constructing a cam within the same angular range. 补偿 The profile can determine the net torque M 净 The 1706 is custom-designed to maintain zero or near-zero angles across the entire angular range. For example, in Figure 16A In the docking configuration (i.e., θ = 0), M 补偿1 Due to the near-zero angle of mechanical link 1404, it is relatively low, and F s1 Also relatively low due to the restricted compression of spring 1414, wherein cam 1430 is configured with a radius R1 to produce the desired M. 补偿1 When the mechanical linkage rotates, M 补偿 The force is increased to its maximum at 90 degrees relative to the vertical direction, where the profile of cam 1430 is configured to take into account the cable interface point and radius R of cam 1430, based on the increased spring force F. s To generate appropriate compensating torque. For example... Figure 16B As shown, when the mechanical linkage 1404 approaches its full stroke (i.e., 180 degrees), the compensating torque M... 补偿 Decrease, but spring force F s2Continue to increase. By constructing the profile of cam 1430 to reduce the radius R2 as cam 1430 rotates, the compensating torque M is reduced in two ways. 补偿2 First, in the compensation torque equation, the reduced radius offsets the increased spring force. Second, as the cam 1430 rotates, the reduced radius decreases the rate of increase in the spring force, thereby increasing the contribution of the reduced radius when the cam is at these larger angles in the compensation torque equation.

[0157] Figure 18 According to some embodiments of this disclosure, when the end effector arm is in a cutting plane at approximately 30 degrees relative to the horizontal direction, the gravitational torque M on the end effector arm... g 1802, Compensating Torque M 补偿 1804 and net torque M 净 The curve of 1806 is the same as that of 1800.

[0158] In this example, the gravitational torque M g 1802 can be represented as:

[0159] M g = -sinθ r *M 连杆 *L 连杆 (sinθ 连杆 )G

[0160] Where M 连杆 It is the mass of the mechanical connecting rod, L 连杆 G is the distance between the center of mass of the mechanical link and the base joint, θ is the vertical angle of the line between the center of mass of the mechanical link and the base joint, G is the gravitational constant, and θ r It is the angle of the cutting plane relative to the horizontal direction. Therefore, in this embodiment, the gravitational torque on the mechanical link in the 30-degree cutting plane is approximately half of the corresponding gravitational torque in the vertical cutting plane.

[0161] In this example, the compensating torque M 补偿 The equation remains the same in 1804:

[0162] M 补偿 =-M 连杆 *L 连杆 *(sinθ)*G

[0163] Therefore, in this example, the net torque M 净 1706 can be represented as:

[0164] M 净 =Mg+M 补偿 =(1-sinθ) r )*M 连杆*L-link*(sinθ) 连杆 )*G

[0165] Therefore, in this example, gravity is not entirely compensated for by the spring mechanism of the end effector arm. In some examples, it might be preferable that the spring mechanism pulls the end effector arm away from the patient, rather than allowing gravity to push the end effector arm downward toward the patient. The resulting net torque M 净 It may still be less than the corresponding gravitational torque, and surgeons may find that, during operation, pulling the net torque to engage the surgical instrument may be more preferable than pushing it upward against gravity.

[0166] As discussed above, Figures 19A to 19C A locking mechanism 1906 is shown, which is configured to selectively secure the surgical instrument 1904 relative to the base 1902 of the end effector arm 1900. (See diagram) Figure 19A As shown, tool 1904 includes a locking mechanism 1906 having a base 1908 fixed to tool 1904. Base 1908 includes a channel 1910 for receiving a protrusion 1924 of base 1902 attached to end effector 1900 (see [link]). Figure 19C The locking mechanism 1906 also includes spring-loaded locking blocks 1912 coupled to a pair of locking flanges 1914, each locking flange having a tapered engagement surface 1916. A manual actuator 1918 has a handle 1920 on either side of the actuator 1918.

[0167] like Figure 19B As shown, the surgeon can press the handle 1920 to move the actuator away from the base 1908, which causes the tapered engagement surface 1916 of the locking flange 1914 to move away from the opposing inner wall 1922 of the channel 1910, thereby increasing the effective diameter of the channel 1910. Figure 19C As shown, a protrusion 1924 (e.g., a pin or other rigid structure) of the end effector base 1902, which is attached to the end effector arm 1900, is inserted into the channel 1910, and the handle 1920 is released. This allows a spring-loaded locking block to move the engagement surface 1916 of the locking flange 1914 back toward the protrusion 1924 to clamp the protrusion 1924 between the tapered engagement surface 1916 of the flange 1914 and the opposing inner wall 1922 of the channel 1910, thereby selectively securing the surgical instrument 1904 relative to the end effector base 1902. The surgical instrument 1904 can be selectively released from the end effector base 1902 by re-engaging the actuator 1918 to release the protrusion 1924, thereby allowing the surgical instrument 1904 to be moved to remove the protrusion 1924 before re-releasing the actuator 1918.

[0168] Further definitions and implementation plans:

[0169] In the above description of various embodiments of the inventive concept, it should be understood that the terminology used herein is for describing particular embodiments only and is not intended to limit the inventive concept. Unless otherwise specified, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which the inventive concept pertains. It should also be understood that terms such as those defined in common dictionaries should be interpreted as having the meaning consistent with their meaning in the context of this specification and the relevant field, and should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0170] When an element is referred to as “connection,” “link,” “response,” or a variation thereof to another element, the element may be directly connected, linked, or responsive to the other element, or an intermediary element may be present. Conversely, when an element is referred to as “direct connection,” “direct link,” “direct response,” or a variation thereof to another element, no intermediary element is present. Throughout this document, the same numbers refer to the same elements. Furthermore, as used herein, “connection,” “link,” “response,” or a variation thereof may include wireless connections, links, or responses. As used herein, the singular forms “a,” “an,” and “the” are intended to also include the plural forms unless the context clearly indicates otherwise. For the sake of brevity and / or clarity, well-known functions or constructions may not be described in detail. The term “and / or” includes any and all combinations of one or more of the associated listed items.

[0171] It should be understood that although the terms "first," "second," "third," etc., may be used herein to describe various elements / operations, these elements / operations should not be limited by these terms. These terms are only used to distinguish one element / operation from another. Therefore, without departing from the teachings of the inventive concept, a first element / operation in some embodiments may be referred to as a second element / operation in other embodiments. Throughout the specification, the same reference numerals or the same reference indicators denote the same or similar elements.

[0172] As used herein, the terms “comprising,” “having,” or variations thereof are open-ended and include one or more of the stated features, integers, elements, steps, components, or functions, but do not exclude the presence or addition of one or more other features, integers, elements, steps, components, functions, or groups thereof. Furthermore, as used herein, the common abbreviation “eg,” derived from the Latin phrase “exempligratia,” may be used to introduce or specify one or more general examples of previously mentioned items and is not intended to limit such items. The common abbreviation “ie,” derived from the Latin phrase “id est,” may be used to specify a particular item from a more general description.

[0173] This document describes exemplary embodiments with reference to block diagrams and / or flowcharts illustrating computer-implemented methods, apparatus (systems and / or devices), and / or computer program products. It should be understood that the blocks in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can be implemented by computer program instructions executable by one or more computer circuits. These computer program instructions can be provided to processor circuits of general-purpose computer circuits, special-purpose computer circuits, and / or other programmable data processing circuits to produce a machine such that instructions executed via a computer and / or other programmable data processing apparatus transform and control transistors, values ​​stored in memory locations, and other hardware components within such circuits to implement the functions / actions specified in the block diagrams and / or one or more flowchart blocks, thereby creating means (functions) and / or structures for implementing the functions / actions specified in the block diagrams and / or flowchart blocks.

[0174] These computer program instructions can also be stored in a tangible computer-readable medium, which can instruct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of writing including instructions that implement the functions / actions specified in block diagrams and / or one or more flowchart blocks. Therefore, embodiments of the inventive concept can be embodied in hardware and / or software (including firmware, resident software, microcode, etc.) that runs on a processor such as a digital signal processor, which can be collectively referred to as a "circuit," a "module," or variations thereof.

[0175] It should also be noted that in some alternative embodiments, the functions / actions indicated in the boxes may not occur in the order shown in the flowchart. For example, two boxes shown consecutively may actually be executed substantially simultaneously, or these boxes may sometimes be executed in reverse order, depending on the functions / actions involved. Furthermore, the function of a given box in the flowchart and / or block diagram may be divided into multiple boxes, and / or the functions of two or more boxes in the flowchart and / or block diagram may be at least partially integrated. Finally, without departing from the scope of the inventive concept, other boxes may be added / inserted between the shown boxes, and / or boxes / actions may be omitted. Moreover, although some illustrations include arrows on communication paths to indicate the main communication direction, it should be understood that communication may occur in the direction opposite to the depicted arrows.

[0176] Many variations and modifications may be made to the embodiments without substantially departing from the principles of the inventive concept. All such variations and modifications are intended to be included within the scope of the inventive concept herein. Therefore, the subject matter disclosed above should be considered illustrative rather than restrictive, and the appended examples of embodiments are intended to cover all such modifications, enhancements, and other embodiments that fall within the spirit and scope of the inventive concept. Thus, to the fullest extent permitted by law, the scope of the inventive concept will be determined by the broadest permissible interpretation of this disclosure, including the following examples of embodiments and their equivalents, and should not be limited or restricted by the foregoing detailed description.

Claims

1. An end effector arm for use with a robotic surgical system, the end effector arm comprising: The base is configured to be attached to an end effector connector of a surgical robot arm; A mechanical link comprising a first end rotatably connected to the base and a second end opposite the first end, the second end being configured to be removably connected to a handheld surgical instrument; and A spring mechanism configured to impart a variable rotational force to the mechanical link based on its rotation angle. The mechanical linkage mentioned above includes: A first connecting member, comprising a first end and a second end of the mechanical link; and The second connecting member includes the second end of the mechanical link and a first end rotatably connected to the second end of the first connecting member; The spring mechanism includes: A spring, the spring including a first end and a second end, the first end of the spring being connected to the base; A cable, comprising a first end and a second end, wherein the first end of the cable is connected to the first end of the spring; and A cam is coupled to the first end of the mechanical link such that the cam is configured to rotate relative to the base together with the first coupling, and the cam has a variable radius relative to the axis of the joint between the first coupling and the base. The second end of the cable is coupled to the cam. The cam includes a cam guide configured to receive and hold the second end of the cable within the cam guide during rotation of the mechanical link relative to the base.

2. The end effector arm of claim 1, wherein the mechanical link rotates at a linear rate relative to the base in a first rotational direction, causing the spring to deform at a non-linear rate.

3. The end effector arm according to claim 1, wherein the spring comprises a compression coil spring.

4. The end effector arm according to claim 1, wherein the spring comprises a tension coil spring.

5. The end effector arm according to claim 1, wherein the spring comprises a hydraulic spring.

6. The end effector arm according to claim 1, wherein the spring comprises a pneumatic spring.

7. The end effector arm of claim 1, wherein the variable rotational force is sufficient to overcome the gravity at the second end of the end effector arm within the range of rotation angles of the mechanical link relative to the base.

8. The end effector arm of claim 1, wherein the variable rotational force is substantially equal to the gravity at the second end of the end effector arm within the range of rotation angles of the mechanical link relative to the base.

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