Robotic hand-held surgical instrument system and method

Abstract

A system is provided that includes a surgical robotic system for use with a tool. In some versions, a robotic instrument includes a handheld portion to be held by a user and a tool support movably coupled to the handheld portion to support a tool. The robotic system also includes an actuator assembly operatively attached to the tool support and the handheld portion and configured to move the tool support in a plurality of degrees of freedom relative to the handheld portion. The robotic system may include a handle alignment member extending from the handheld portion. At least a portion of the handle alignment member is aligned with a tool plane defined by the tool when the tool support has an optimal range of motion relative to the handheld portion.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and all benefits of U.S. Provisional Patent Application No. 63 / 390,856, filed on July 20, 2022, the entire contents of which are expressly incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to surgical robotic handheld instrument systems and methods of use. Background Art

[0004] Physical cutting guides are used to constrain surgical tools when removing tissue from a patient. In some cases, physical cutting guides constrain such surgical tools for the purpose of preparing a joint to receive a replacement implant. The time required to position and secure the physical cutting guide to the patient can represent a large portion of the total time required to perform a surgical procedure.

[0005] A navigation system (also referred to as a tracking system) can be used to properly align and secure the fixture, as well as track the position and / or orientation of the surgical tool used to remove tissue from the patient. The tracking system typically employs one or more trackers associated with the tool and the tissue being removed. The user can then view a display to determine the current position of the tool relative to the desired cutting path of the tissue to be removed. The display may be arranged in a manner that requires the user to shift their gaze away from the tissue and the surgical site to visualize the progress of the tool. This can distract the user from the surgical site. Moreover, it may be difficult for the user to place the tool in the desired manner.

[0006] Robotic-assisted surgery typically relies on large robots with robotic arms that can move in six degrees of freedom (DOF). These large robots can be cumbersome to operate and maneuver in an operating room.

[0007] Furthermore, robotic handheld surgical instruments that use actuators to align the tool with the desired target object have a limited range of adjustability. Thus, an operator is required to hold these instruments within a certain distance and / or angle from the desired target object to allow the instrument to be aligned with the desired target object. However, it is difficult for the operator to perceive how much adjustability the instrument has at a given moment during surgery.

[0008] Therefore, a need exists for systems and methods to address one or more of these challenges. Summary of the invention

[0009] One aspect of the present disclosure includes a handheld surgical robot system. The handheld surgical robot system includes: a handheld portion; a saw blade support that is movably connected to the handheld portion and includes a saw blade mount that defines a saw blade plane; a saw blade that is detachably connected to the saw blade support and is disposed in the saw blade plane. The saw blade defines a longitudinal axis and a transverse axis. The handheld surgical robot system also includes an actuator assembly that is operatively attached to the saw blade support and the handheld portion. The actuator assembly is configured to move the saw blade support in multiple degrees of freedom relative to the handheld portion. The handheld surgical robot system also includes a handle alignment member extending from the handheld portion. The handle alignment member includes a handle alignment protrusion extending toward the saw blade mount, wherein at least a portion of the handle alignment protrusion is inclined relative to the longitudinal axis and the transverse axis of the saw blade, and when the saw blade support has an optimal range of motion relative to the handheld portion, the portion of the handle alignment protrusion is aligned with the saw blade plane.

[0010] The actuator assembly includes a plurality of actuators, wherein each of the plurality of actuators is configured to move between a first position and a second position to move the saw blade support relative to the handheld portion. The home position may be a midpoint between the first position and the second position of each of the plurality of actuators, and the saw blade support has an optimal range of motion when at least two of the plurality of actuators are in their home positions.

[0011] When the handheld portion is in a position that does not provide an optimal range of motion, the blade plane and the handle alignment tab may be misaligned, thereby providing a visual indication that the handheld portion is in a position that does not provide an optimal range of motion for the blade support.

[0012] The actuator assembly is configured to adjust at least one of the pitch, elevation, and roll of the saw blade support relative to the handheld portion. The first spatial arrangement of the handle alignment protrusion relative to the saw blade plane can provide a visual indication of at least one of a first pitch relationship, a first elevation relationship, and a first roll relationship of the saw blade support relative to the handheld portion. Thus, the first spatial arrangement provides a visual indication that the handle alignment protrusion is aligned with the saw blade plane and the saw blade support has an optimal range of motion relative to the handheld portion. The second spatial arrangement of the handle alignment protrusion relative to the saw blade plane provides a visual indication of at least one of a second pitch relationship, a second elevation relationship, and a second roll relationship of the saw blade support relative to the handheld portion. Thus, the second spatial arrangement provides a visual indication that the handheld portion is in a posture relative to the saw blade support that does not provide an optimal range of motion for the saw blade support.

[0013] The first spatial arrangement can provide a visual indication of a first pitch relationship of the saw blade support relative to the hand-held portion, and the second spatial arrangement can provide a visual indication of a second pitch relationship of the saw blade support relative to the hand-held portion. The second pitch relationship provides a visual indication of the pitch of the saw blade support relative to the hand-held portion when the actuator pitches the saw blade support relative to the hand-held portion, wherein the first portion of the handle alignment tab is further away from the saw blade plane along the longitudinal axis in the direction of the pitch than the second portion of the handle alignment tab.

[0014] The first spatial arrangement may also provide a visual indication of a first elevated relationship of the saw blade support relative to the hand-held portion, and the second spatial arrangement may also provide a visual indication of a second elevated relationship of the saw blade support relative to the hand-held portion. Thus, the second elevated relationship provides a visual indication of elevation of the saw blade support relative to the hand-held portion, wherein the handle alignment tab is at least partially located above or below the plane of the saw blade in the direction of elevation.

[0015] The first spatial arrangement may also provide a visual indication of a first roll relationship of the saw blade support relative to the hand-held portion, and the second spatial arrangement may also provide a visual indication of a second roll relationship of the saw blade support relative to the hand-held portion. Thus, the second roll relationship provides a visual indication of a roll of the saw blade support relative to the hand-held portion, wherein an outer portion of the handle alignment projection is further away from the saw blade plane in the direction of the roll than an inner portion of the handle alignment projection.

[0016] The handheld surgical robotic system may further include a second handle alignment member extending from the handheld portion at a position separated from the first handle alignment member, the second handle alignment member including a second handle alignment protrusion extending toward the saw blade mount, wherein at least a portion of the second handle alignment protrusion is inclined relative to the longitudinal axis and the transverse axis of the saw blade. Similar to the above, when the saw blade support has an optimal range of motion relative to the handheld portion, the first handle alignment protrusion and the second handle alignment protrusion are aligned with the saw blade plane.

[0017] The handheld surgical robotic system may further include a tool alignment member extending from the saw blade support. The tool alignment member includes a tool alignment protrusion extending toward the saw blade mount, wherein at least a portion of the tool alignment protrusion is inclined relative to the longitudinal axis and the transverse axis of the saw blade. The tool alignment protrusion may define a tool alignment edge, and the handle alignment member defines a handle alignment edge inclined relative to the longitudinal axis and the transverse axis of the saw blade. The tool alignment edge may be defined so that when the saw blade support is aligned with the handheld portion, the tool alignment edge is offset relative to and parallel to the handle alignment edge. When the handheld portion is in a posture that does not provide an optimal range of motion, the tool alignment protrusion and the handle alignment protrusion may be misaligned, thereby providing a visual indication that the handheld portion is in a posture that does not provide an optimal range of motion to the saw blade support.

[0018] The handle alignment tab and the tool alignment tab may include a first visual indicia and a second visual indicia, the first visual indicia being visually distinguishable from the second visual indicia. When the tool alignment tab and the handle alignment tab are aligned, the first visual indicia of the handle alignment tab and the first visual indicia of the tool alignment tab may be aligned, thereby providing a visual indication that the saw blade support has an optimal range of motion relative to the handheld portion. When the tool alignment tab and the handle alignment tab are not aligned, the first visual indicia of the handle alignment tab and the first visual indicia of the tool alignment tab may be misaligned, thereby providing a visual indication that the handheld portion is in a posture that does not provide an optimal range of motion for the saw blade support. The first visual indicia may be a first color, and the second visual indicia is a second color.

[0019] Another aspect of the present disclosure includes a handheld surgical robotic system for supporting a saw blade. The handheld surgical robotic system includes a handheld portion, a tool support that is movably connected to the handheld portion and defines a tool support plane, and an actuator assembly that is operatively attached to the tool support and the handheld portion. The actuator assembly is configured to move the tool support in multiple degrees of freedom relative to the handheld portion. The handheld surgical robotic system also includes a handle alignment member extending from the handheld portion, the handle alignment member including a handle hook portion. When the tool support has an optimal range of motion relative to the handheld portion, the handle hook portion is aligned with the tool support plane.

[0020] Another aspect of the present disclosure includes a handheld surgical robot system. The handheld surgical robot system includes a handheld portion, a tool support that is movably connected to the handheld portion and defines a tool support plane, and a tool that is detachably connected to the tool support. The tool defines a longitudinal axis and a transverse axis. The handheld surgical robot system also includes an actuator assembly that is operably attached to the tool support and the handheld portion. The actuator assembly is configured to move the tool support in multiple degrees of freedom relative to the handheld portion. The handheld surgical robot system also includes a handle alignment member extending from the handheld portion, the handle alignment member including a handle alignment protrusion extending toward the tool support, wherein at least a portion of the handle alignment protrusion is arranged at an angle greater than 0 degrees and less than 90 degrees relative to the longitudinal axis; wherein, when the tool support has an optimal range of motion relative to the handheld portion, the portion of the handle alignment protrusion is aligned with the tool support plane.

[0021] Another aspect of the present disclosure includes a handheld surgical robot system for supporting a tool. The handheld surgical robot system includes a handheld portion and a tool support movably connected to the handheld portion. The tool support is configured to support a tool defining a tool plane. The handheld surgical robot system also includes an actuator assembly operatively attached to the tool support and the handheld portion. The actuator assembly is configured to move the tool support relative to the handheld portion in multiple degrees of freedom. The handheld surgical robot system also includes a handle alignment member extending from the handheld portion. The handle alignment member includes a handle support arm extending between a first handle support arm end and a second handle support arm end. The handle support arm includes a handle coupling portion, which is coupled to the first handle support arm end and is detachably coupled to the handheld portion. The handle alignment member also includes a handle alignment member mounting seat coupled to the second handle support arm end and a handle alignment indication member coupled to the handle alignment member mounting seat. The handle coupling portion may include a handle coupling member configured to be coupled to a corresponding coupling member disposed on the handheld portion to couple the handle alignment member to the handheld portion.

[0022] Another aspect of the present disclosure includes a mechanical alignment device configured for use with a handheld surgical robotic system, the mechanical alignment device being used to provide a visual indication of a posture of a handheld portion of the handheld surgical robotic system relative to a tool support of the handheld surgical robotic system. The mechanical alignment device includes a support arm extending between a first support arm end and a second support arm end. The support arm includes a coupling portion that is coupled to the first support arm end and is configured to be removably coupled to one of a handheld portion and a tool support of the handheld surgical robotic system. The mechanical alignment device also includes an alignment member mount coupled to the second support arm end and an alignment indication member coupled to the alignment member mount.

[0023] Additional aspects of the present disclosure include a handheld surgical robotic system for supporting a saw blade. The handheld surgical robotic system also includes a handheld portion. The system also includes a saw blade support movably connected to the handheld portion. The saw blade support is configured to support the saw blade. The system also includes an actuator assembly operatively attached to the saw blade support and the handheld portion. The actuator assembly is configured to move the saw blade support in multiple degrees of freedom relative to the handheld portion. The system also includes a tool alignment member connected to the saw blade support and extending from the saw blade support and a handle alignment member connected to the handheld portion and extending from the handheld portion, wherein at least a portion of the tool alignment member is aligned with at least a portion of the handle alignment member when the saw blade support has a desired range of motion relative to the handheld portion.

[0024] Another aspect of the present disclosure includes a handheld robotic system for supporting a saw blade. The handheld robotic system also includes a handheld portion. The system also includes a saw blade support that is movably connected to the handheld portion to support the saw blade. The system also includes an actuator assembly that is operatively attached to the saw blade support and the handheld portion. The actuator assembly is configured to move the saw blade support in multiple degrees of freedom relative to the handheld portion. The system also includes a first tool alignment member and a second tool alignment member that are connected to the saw blade support and extend from the saw blade support on both sides. The system also includes a first handle alignment member and a second handle alignment member that are connected to the handheld portion and extend from the handheld portion, wherein when the saw blade support has a desired range of motion relative to the handheld portion, the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively.

[0025] Yet another aspect of the present disclosure includes a visual indication system for use with a handheld robotic system. The visual indication system includes a guard coupled to and extending between a saw blade support and a handheld portion such that the guard surrounds at least one of a plurality of actuators. The guard defines at least two guard landmarks configured to shift relative to each other when the saw blade support and the handheld portion are misaligned with each other to provide a visual indication of a posture of the saw blade support relative to the handheld portion.

[0026] Another aspect of the present disclosure includes a handheld robotic system for supporting a saw blade. The handheld robotic system includes a handheld portion and a saw blade support that is movably connected to the handheld portion to support the saw blade. The system also includes a plurality of actuators that operatively interconnect the saw blade support and the handheld portion and are configured to move the saw blade support in multiple degrees of freedom relative to the handheld portion. The system also includes a light source located on the saw blade support. The system also includes a first tool alignment member and a second tool alignment member that are connected to the saw blade support and extend from the saw blade support on both sides. The system also includes a first handle alignment member and a second handle alignment member that are connected to the handheld portion and extend from the handheld portion. When the saw blade support has a desired range of motion relative to the handheld portion, the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively. When the saw blade support has a desired range of motion, the light source is illuminated to indicate that the saw blade support and the handheld portion are within a specified alignment range aligned with the cutting plane.

[0027] Another aspect of the present disclosure includes a handheld surgical robotic system for supporting a saw blade. The handheld surgical robotic system includes a handheld portion. The system also includes a saw blade support movably connected to the handheld portion. The saw blade support is configured to support the saw blade. The system also includes a plurality of actuators operatively interconnecting the saw blade support and the handheld portion, which are configured to move the saw blade support in multiple degrees of freedom relative to the handheld portion. The system also includes a tool alignment member connected to the saw blade support and extending from the saw blade support and a handle alignment member connected to the handheld portion and extending from the handheld portion, wherein the handle alignment member is detachably connected to the handheld portion.

[0028] Additional aspects of the present disclosure include a surgical system for processing an anatomical structure according to multiple target planes. The surgical system includes an instrument, the instrument including a saw blade, a handheld portion, an actuator system and a saw blade support, the actuator system may include a plurality of actuators, the saw blade support is used to support the saw blade and move the saw blade. The plurality of actuators extend between the saw blade support and the handheld portion, and the saw blade support may include a saw drive motor connected to a saw mount. The system also includes a navigation system and a tracker for being connected to the saw blade support, the tracker is configured to determine a current tool plane and includes a tracker frame, at least six optical markers connected to the tracker frame. The tracker frame includes at least two faces, the at least two faces are non-planar with respect to each other, wherein at least three of the at least three to six optical markers are connected to each of the at least two faces. The system also includes a control system in communication with the navigation system and the tracker, the control system being configured to control the actuator system to align the current tool plane with at least one of the multiple target planes.

[0029] Another additional aspect of the present disclosure includes a surgical method of controlling a surgical system, the surgical system including a handheld robotic instrument, a saw blade, a handheld portion, an actuator system including a plurality of actuators, and a saw blade support for supporting and moving the saw blade. The surgical method includes determining a current tool plane using a tool tracker and a navigation system, selecting one of a plurality of target planes using an input device on the tracker, and adjusting the tool support using a plurality of actuators to place the current plane in line with the selected target plane. The control also includes selecting a different one of the plurality of target planes using the input device.

[0030] A final aspect of the present disclosure includes a surgical instrument tracker for tracking a surgical saw. The surgical instrument tracker includes a tracker frame defining an instrument engagement aperture for receiving a proximal portion of a saw, the saw tracker frame including a mount. The tracker also includes at least six optical markers coupled to the tracker frame, the tracker frame including at least two faces that are non-planar with respect to each other, wherein at least three of the at least three to six optical markers are coupled to each of the at least two faces. When the mount of the saw tracker is coupled to an accessory mount, the tracker frame at least partially surrounds the accessory mount. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Advantages of the present disclosure will be readily appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings as it becomes more readily understood.

[0032] Figure 1 is a perspective view of the robotic system.

[0033] Figure 2 is a perspective view of the robotic instrument used to cut five planes in the femur to receive a total knee implant.

[0034] Figures 3A-3C is a graphical illustration of multiple pitch orientations of a robotic instrument.

[0035] Figures 4A-4C is a graphical illustration of multiple roll orientations of a robotic instrument.

[0036] Figures 5A-5C is a graphical illustration of multiple z-axis translation positions of a robotic instrument.

[0037] Figure 6 is a front perspective view of the robotic instrument showing one particular posture of the tool support relative to the handheld portion.

[0038] Figure 7 is a block diagram of a control system and also shows various software modules.

[0039] Figure 8 is a rear perspective view of the robotic instrument.

[0040] Fig. 9 is a side elevation view of the robotic device.

[0041] Fig.10 is a schematic diagram of various transformations of the handheld robotic surgical system.

[0042] Fig.11 It is a partial cross-sectional view of the robotic device.

[0043] Fig.12 is a rear perspective view of a robotic instrument including a guide array.

[0044] Fig.13 yes Fig.12 Side view of a robotic instrument including a guidance array.

[0045] Fig.14 yes Fig.12 A top view of a robotic instrument including a guide array.

[0046] Fig.15 yes Fig.12 Another rear perspective view of a robotic instrument including a guide array.

[0047] Fig.16 yes Fig.12 An exploded rear perspective view of a robotic instrument including a guide array.

[0048] Fig.17 It is arranged in the first space configuration Fig.12 Rear perspective view of a robotic instrument including a guide array.

[0049] Fig.18 is a rear perspective view of a robotic instrument including a guidance array arranged in an elevation relationship.

[0050] Fig.19 yes Fig.18 Another rear perspective view of a robotic instrument including a guide array arranged in an elevation relationship.

[0051] Fig. 20 yes Fig.18 A side view of a robotic instrument including a first guide array arranged in a pitch relationship.

[0052] Fig.21 yes Fig.18 A rear view of a robotic instrument including a guide array arranged in a pitch relationship.

[0053] Fig. 22 is a rear perspective view of a robotic instrument including a guide array arranged in a canted relationship.

[0054] Fig.23 yes Fig. 22 Another rear perspective view of a robotic instrument including a guide array arranged in a canted relationship.

[0055] Fig.24 yes Fig. 22 A rear view of a robotic instrument including a guide array arranged in a tilted relationship.

[0056] Fig.25 is a rear perspective view of a robotic instrument including a guide array arranged in an elevated relationship.

[0057] Fig.26 yes Fig.25 Another rear perspective view of a robotic instrument including a guide array arranged in a lifted relationship.

[0058] Fig. 27 yes Fig.25 A side view of a robotic instrument including a guide array arranged in a lifting relationship.

[0059] Fig.28 yes Fig.25 A rear view of a robotic instrument including a guide array arranged in a lifting relationship.

[0060] Fig.29 is a rear perspective view of a robotic instrument including another configuration of a guide array.

[0061] Fig.30 yes Fig.29 A front perspective view of a robotic instrument including a guide array with a handle alignment member removed from the robotic instrument.

[0062] Fig.31 yes Fig.29 A front perspective view of a robotic instrument including a guide array with a handle alignment member attached to the robotic instrument.

[0063] Fig.32 It is arranged in the first space configuration Fig.29 Rear perspective view of a robotic instrument including a guide array.

[0064] Fig.33 is a rear perspective view of a robotic instrument including yet another configuration of a guide array.

[0065] Fig.34 It is arranged in the first space configuration Fig.33 A rear perspective view of yet another configuration of a robotic instrument including a guide array.

[0066] Fig.35is a rear perspective view of a robotic instrument including another configuration of a guide array.

[0067] Fig.36 yes Fig.35 A side view of another configuration of a robotic instrument including a guidance array.

[0068] Fig.37 It is arranged in the first space configuration Fig.35 A rear perspective view of yet another configuration of a robotic instrument including a guide array.

[0069] Fig.38 is a rear perspective view of the robotic instrument including an additional configuration of the guide array.

[0070] Fig.39 It is arranged in the first space configuration Fig.38 A rear perspective view of an additional configuration of the robotic instrument including a guidance array.

[0071] Fig.40 is a rear perspective view of a configuration of the robotic instrument including a first visual marker.

[0072] Fig.41 are in different spatial orientations Fig.40 Another rear perspective view of the configuration of the robotic instrument.

[0073] Fig.42 is a rear perspective view of a configuration of a robotic instrument including a light emitter.

[0074] Fig.43 In different spatial configurations Fig.42 Another rear perspective view of the configuration of the robotic instrument.

[0075] Fig.44 is a front perspective view of a configuration of the robotic instrument including a shield.

[0076] Fig.45 is a partial front perspective view of a configuration of a robotic instrument including a shield and a shield alignment member spaced apart from the robotic instrument.

[0077] Fig.46 is a rear perspective view of a configuration of the robotic instrument including a shield.

[0078] Fig.47 is a rear perspective view of a configuration of the robotic instrument including a shield disposed in a first position.

[0079] Fig.48 is a rear perspective view of a configuration of the robotic instrument including the shroud disposed in a second position.

[0080] Fig.49 is a rear perspective view of a configuration of the robotic instrument including the shroud disposed in an alternate second position.

[0081] Fig.50 is a rear perspective view of a configuration of the robotic instrument including the shroud disposed in an alternate second position.

[0082] Fig.51 is a rear perspective view of a tool tracker for a robotic instrument.

[0083] Fig.52 is a side view of the robotic instrument illustrating the potential range of motion of the tool support relative to the handheld portion.

[0084] Fig.53 is a front view of the robotic instrument illustrating the potential range of motion of the tool support relative to the handheld portion.

[0085] Fig.54 is a rear perspective view of a robotic instrument including yet another embodiment of a guide array.

[0086] Fig.55 yes Fig.54 Side view of a robotic instrument including a guidance array.

[0087] Fig.56 yes Fig.54 A top view of a robotic instrument including a guide array.

[0088] Fig.57 It is arranged in the first space configuration Fig.54 Rear perspective view of a robotic instrument including a guide array.

[0089] Fig.58 yes Fig.54 An exploded rear perspective view of a robotic instrument including a guide array.

[0090] Fig.59 It is arranged in a pitch relationship Fig.54 Rear perspective view of a robotic instrument including a guide array.

[0091] Fig.60 yes Fig.59 Arranged in pitch relationship Fig.54 Another rear perspective view of a robotic instrument including a guide array.

[0092] Fig.61 yes Fig.59 Arranged in pitch relationship Fig.54 Side view of a robotic instrument including a guidance array.

[0093] Fig.62 yes Fig.59 Arranged in pitch relationship Fig.54 Rear view of a robotic instrument including a guidance array.

[0094] Fig.63 It is arranged in a sideways relationship Fig.54 Rear perspective view of a robotic instrument including a guide array.

[0095] Fig.64 yes Fig.63 Arranged in a tilt relationship Fig.54 Another rear perspective view of a robotic instrument including a guide array.

[0096] Fig.65 yes Fig.63 Arranged in a tilt relationship Fig.54 Side view of a robotic instrument including a guidance array.

[0097] Fig.66 yes Fig.63 Arranged in a tilt relationship Fig.54 Rear view of a robotic instrument including a guidance array.

[0098] Fig.67 It is arranged to enhance the relationship Fig.54 Rear perspective view of a robotic instrument including a guide array.

[0099] Fig.68 yes Fig.67 The relationship between the arrangement of Fig.54 Another rear perspective view of a robotic instrument including a guide array.

[0100] Fig.69 yes Fig.67 The relationship between the arrangement of Fig.54 Side view of a robotic instrument including a guidance array.

[0101] Fig.70 yes Fig.67 The relationship between the arrangement of Fig.54 Rear view of a robotic instrument including a guidance array.

[0102] Fig.71 It is arranged in another spatial relationship Fig.54 Side view of a robotic instrument including a guidance array.

[0103] Fig.72 So Fig.71 Configuration layout Fig.54 Rear view of a robotic instrument including a guidance array.

[0104] Fig.73 So Fig.71 Configuration layout Fig.54 A first rear perspective view of a robotic instrument including a guide array.

[0105] Fig.74 So Fig.71 Configuration layout Fig.54 A front perspective view of a robotic instrument including a guide array.

[0106] Fig.75 So Fig.71 Configuration layout Fig.54 A second rear perspective view of the robotic instrument including a guide array.

[0107] Fig.76 are arranged in a first spatial relationship and include a visual marker Fig.54 Rear perspective view of a robotic instrument including a guide array.

[0108] Fig.77 is arranged in a second spatial relationship and includes a visual marker Fig.54 Rear perspective view of a robotic instrument including a guide array.

[0109] Fig.78 is a front perspective view of another configuration of a robotic instrument including one configuration of a tracker and guidance array.

[0110] Fig.79 yes Fig.78 Rear perspective view of the robotic instrument.

[0111] Fig.80 is an exploded view of one configuration of a guide array.

[0112] Fig.81 is an exploded view of one configuration of a handle alignment member.

[0113] Fig.82 yes Fig.81 A partial perspective cross-sectional view of a handle alignment member.

[0114] Fig.83 yes Fig.81 Another partial perspective cross-sectional view of the handle alignment member.

[0115] Fig.84 is a rear perspective view of yet another configuration of a robotic instrument including another configuration of a guidance array.

[0116] Fig.85 is a rear perspective view of another configuration of a robotic instrument including yet another configuration of a guidance array.

[0117] Fig.86is a schematic depiction of a tracker in communication with a control system.

[0118] Fig.87 is a perspective view of an example of a handheld surgical robotic instrument.

[0119] Fig.88 is a perspective view of an example of a handheld surgical robotic instrument.

[0120] Fig.89 and Fig.90 An obstruction between the handle alignment member and the tool alignment member is shown.

[0121] Figures 91-92 is a perspective view of another example of a handheld surgical robotic instrument.

[0122] Fig.93 and Fig.94 The handle alignment member is shown in a disengaged state.

[0123] Fig.95 is a perspective view of the handle alignment member in a disengaged state.

[0124] Fig.96 is a perspective view of one example of a handle alignment member.

[0125] Fig.97 and Fig.98 is a perspective view of a handheld surgical robotic instrument.

[0126] Fig.99 and Fig.100 is an alternative example of a handle alignment member.

[0127] Fig.101 is another alternative example of a handle alignment member.

[0128] Fig.102 Another example of a handheld surgical robotic instrument is shown. DETAILED DESCRIPTION

[0129] Overview

[0130] refer to Figure 1, a robotic system 10 is shown. The robotic system 10 is shown as performing total knee surgery on a patient 12 to remove multiple parts of the femur F and tibia T of the patient 12 so that the patient 12 can receive a total knee implant IM. The robotic system 10 can be used to perform other types of surgical procedures, including procedures involving hard / soft tissue removal or other forms of treatment. For example, treatment may include cutting tissue, coagulating tissue, ablating tissue, stapling tissue, suturing tissue, etc. In some examples, the surgical procedure involves knee surgery, hip surgery, shoulder surgery, spinal surgery and / or ankle surgery, and may involve removing tissue to be replaced by a surgical implant (e.g., a knee implant, a hip implant, a shoulder implant, a spinal implant and / or an ankle implant). The technology and robotic system 10 disclosed herein can be used to perform other surgeries (surgical or non-surgical), and can be used for industrial applications or other applications utilizing a robotic system.

[0131] refer to Figure 1 and Figure 2 , the robotic system 10 includes an instrument 14. In some examples, a user manually holds and supports the instrument 14 (e.g., Figure 1 In some examples, the user may manually hold the apparatus 14 while the apparatus is being at least partially or completely supported by an auxiliary device, such as a passive arm (e.g., a linkage arm with a locking joint, a counterweight arm), an active arm, etc. Figure 1 and Figure 2 As best shown in FIG. 1 , the instrument 14 includes a handheld portion 16 for manual holding and / or support by a user and / or an auxiliary device.

[0132] The instrument 14 can be moved and supported by the user at will without the help of the guide arm, for example, configured to be held by a human user while achieving physical removal of material, so that the weight of the tool is supported only by the user's hand during surgery. In other words, the instrument 14 can be configured to be held so that the user's hand supports the instrument 14 against gravity. The instrument 14 can weigh 8 pounds or less, 6 pounds or less, 5 pounds or less, or even 3 pounds or less. The instrument 14 can have a weight corresponding to ANSI / AAMI HE75:2009. The instrument 14 also includes a tool support 18 for receiving the tool 20. In some examples, when the tool 20 is a saw blade 380, the tool support 18 can be referred to as a saw blade support. The method for operating the instrument 14 can include the user suspending the weight of the instrument 14 without any assistance from a passive arm or a robotic arm. Alternatively, the weight of the instrument 14 can be supported by using a counterweighted passive arm, an auxiliary device, or an active robotic arm, so that the user does not have to support the entire weight of the instrument. In this case, the user can still hold the handheld portion 16 to interact with and / or guide the instrument 14. The contents of U.S. Patent No. 9,060,794 to Kang et al. and the passive arm are incorporated herein by reference. In addition, in some examples, the robotic system 10 may not have a robotic arm with more than one joint in series.

[0133] The tool 20 is coupled to the tool support 18 to interact with the anatomical structure during certain operations of the robotic system 10 described further below. The tool 20 may also be referred to as an end effector. The tool 20 may be removable from the tool support 18 so that a new / different tool 20 may be attached when needed. The tool 20 may also be permanently fixed to the tool support 18. The tool 20 may include an energy applicator designed to contact tissue of the patient 12. In some examples, the tool 20 may be a saw blade (e.g., Figure 1 and Figure 2) or other types of cutting accessories. In this case, the tool support 18 may be referred to as a saw blade support. It should be understood that in any case where a saw blade support is mentioned, the term "tool support" may be used instead, and vice versa. However, other tools are contemplated, such as the contents of U.S. Patent No. 9,707,043 to Bozung, which is hereby incorporated by reference herein. In some examples, the tool 20 may be a drill, an ultrasonic vibrating tip, a drill bit, a stapler, etc. The tool 20 may include a saw blade assembly and a drive motor to cause an oscillating motion of the saw blade, as shown in U.S. Patent No. 9,820,753 or U.S. Patent No. 10,687,823 to Walen et al., which are incorporated herein by reference. Such a drive component may include a transmission TM coupled to the drive motor M to convert the rotational motion from the drive motor M into an oscillating motion of the tool 20.

[0134] The systems and methods described in PCT / US2020 / 042128, entitled “Robotic Handheld Surgical Instrument Systems and Methods,” filed on July 15, 2020, are also incorporated herein by reference.

[0135] The actuator assembly 400, including one or more actuators 21, 22, 23, moves the tool support 18 relative to the handheld portion 16 in three degrees of freedom to provide robotic motion that helps place the tool 20 in a desired position and / or orientation (e.g., in a desired posture relative to the femur F and / or tibia T during resection) while the user holds the handheld portion 16. The actuator assembly 400 may include the actuators 21, 22, 23 arranged in parallel, in series, or a combination thereof. In some examples, the actuators 21, 22, 23 move the tool support 18 relative to the handheld portion 16 in three or more degrees of freedom. In some examples, the actuator assembly 400 is configured to move the tool support 18 relative to the handheld portion 16 in at least two degrees of freedom (e.g., pitch and z-axis translation). In some examples, such as those shown herein, the actuators 21, 22, 23 move the tool support 18 and its associated tool support coordinate system TCS relative to the handheld portion 16 and its associated base coordinate system BCS in only three degrees of freedom. For example, the tool support 18 and its tool support coordinate system TCS can: rotate about its y-axis to provide pitch motion; rotate about its x-axis to provide roll motion; and translate along an axis Z that coincides with the z-axis of the base coordinate system BCS to provide z-axis translation motion. Figure 2 By arrows and in Figures 3A-3C , Figures 4A-4Cand Figures 5A-5C The schematic diagram of FIG. 1 shows the allowed pitch motion, roll motion and z-axis translation motion respectively. Figure 6 One example is provided of the pose of the tool support 18 and the pose of the hand portion 16 within the range of motion of the instrument 14. In some examples not shown in the figures, the actuators may move the tool support 18 relative to the hand portion 16 in four or more degrees of freedom.

[0136] Return to reference Figure 2 , a constraint assembly 24 having a passive linkage 26 may be used to constrain movement of the tool support 18 relative to the handheld portion 16 in the remaining three degrees of freedom. The constraint assembly 24 may include any suitable linkage (e.g., one or more links having any suitable shape or configuration) to constrain motion as described herein. Figure 2 In the example shown, the constraint assembly 24 operates to limit the motion of the tool support coordinate system TCS by: constraining rotation about the z-axis of the base coordinate system BCS to constrain yaw motion; constraining translation along the x-axis direction of the base coordinate system BCS to constrain x-axis translation; and constraining translation along the y-axis direction of the base coordinate system BCS to constrain y-axis translation. In certain cases, described further below, the actuators 21, 22, 23 and the constraint assembly 24 are controlled to effectively simulate the function of a physical cutting guide (e.g., a physical sawing guide).

[0137] refer to Figure 7 , an instrument controller 28 or other type of control unit is provided to control the instrument 14. The instrument controller 28 may include one or more computers, or any other suitable form of controller that guides the operation of the instrument 14 and the movement of the tool support 18 (and the tool 20) relative to the handheld portion 16. The instrument controller 28 may have a central processing unit (CPU) and / or other processors, memory and storage devices (not shown). The instrument controller 28 is loaded with software as described below. The processor may include one or more processors to control the operation of the instrument 14. The processor may be any type of microprocessor, multiprocessor and / or multi-core processing system. The instrument controller 28 may additionally or alternatively include one or more microcontrollers, field programmable gate arrays, systems on chips, discrete circuits and / or other applicable hardware, software or firmware capable of performing the functions described herein. The term processor is not intended to limit any embodiment to a single processor. The instrument 14 may also include a user interface UI with one or more displays and / or an input device (e.g., a trigger, a button, a foot switch, a keyboard, a mouse, a microphone (voice activation), a gesture control device, a touch screen, etc.).

[0138] The control system 60 also includes one or more software programs and software modules. The software module can be part of one or more programs that operate on the navigation controller 36, the instrument controller 28, or both to process data to assist the control of the robot system 10. The software program and / or module includes computer-readable instructions that are stored in a non-transitory memory 64 on the navigation controller 36, the instrument controller 28, or both to be executed by one or more processors 70 of the controller 28, 36. The memory 64 can be any applicable memory configuration (e.g., RAM, non-volatile memory, etc.) and can be implemented locally or from a remote database. In addition, software modules for prompting users and / or communicating with users can form part of one or more programs and can include instructions stored in the memory 64 on the navigation controller 36, the instrument controller 28, or both. The user can interact with any of the input devices of the navigation user interface UI or other user interfaces UI to communicate with the software module. The user interface software can run on a device separate from the navigation controller 36 and / or the instrument controller 28.

[0139] The instrument controller 28 controls the operation of the tool 20, for example, by controlling the power provided to the tool 20 (e.g., to the drive motor M of the tool 20 that controls the cutting motion) and controlling the movement of the tool support 18 relative to the handheld portion 16 (e.g., by controlling the actuators 21, 22, 23). The instrument controller 28 controls the state (e.g., position and / or orientation) of the tool support 18 and the tool 20 relative to the handheld portion 16. The instrument controller 28 can control the speed (linear or angular velocity), acceleration, or other derivatives of the motion of the tool 20 caused by the actuators 21, 22, 23 relative to the handheld portion 16 and / or relative to the anatomical structure.

[0140] like Figure 2As shown, the instrument controller 28 may include a control housing 29 mounted to the tool support 18 and / or the handheld portion 16 or a combination thereof, wherein one or more control boards 31 (e.g., one or more printed circuit boards and associated electronic components) are positioned inside the control housing 29. The control board 31 may include a microcontroller, a field programmable gate array (FPGA), a driver, a memory, a sensor, or other electronic components for controlling the actuators 21, 22, 23 and (e.g., via a motor controller) the drive motor M. The instrument controller 28 may also include an off-board console 33 in data and power communication with the control board 31. The sensors S, actuators 21, 22, 23, and / or drive motor M described herein may feed signals to the control board 31, which transmits the data signals to the console 33 for processing, and the console 33 may feed control commands (e.g., current commands, torque commands, speed commands, angle commands, position commands, or combinations thereof and a variety of control and configuration parameters) back to the control board 31 to power and control the actuators 21, 22, 23 and / or drive motor M. It is contemplated that the processing may also be performed on a control board in a control housing. In some examples, the processing of the control algorithm may be distributed between the control console and the control housing. In one example, the position control calculations and the velocity control calculations may be in the control console, and the current control may be in a field programmable gate array located in the control housing. Of course, it is contemplated that a separate control housing is not required, and / or that the processing may be performed in any number of different locations.

[0141] In some versions, the console 33 may include a single console for powering and controlling the actuators 21, 22, 23 and the drive motor M. In some versions, the console 33 may include one console for powering and controlling the actuators 21, 22, 23 and a separate console for powering and controlling the drive motor M. Such a console for powering and controlling the drive motor M may be similar to the console described in U.S. Patent No. 7,422,582, entitled "Control Console which powered Surgical Handpiece is Connected, the Console Configured to Simultaneously Energize more one and less than all of the Handpiece", filed on September 30, 2004, which is hereby incorporated by reference herein. A flexible circuit FC (also referred to as a soft board) may interconnect the actuators 21, 22, 23 and / or other components with the instrument controller 28. For example, a flexible circuit FC may be provided between the actuators 21, 22, 23 and the control board 31. Other forms of connection (wired or wireless) may additionally or alternatively exist between the components.

[0142] Briefly return to reference Figure 1 , the robotic system 10 also includes a navigation system 32. An example of the navigation system 32 is described in U.S. Patent No. 9,008,757, filed on September 24, 2013, entitled "Navigation System Including Optical and Non-Optical Sensors", which is incorporated herein by reference. The navigation system 32 tracks the movement of multiple objects. For example, such objects include instruments 14, tools 20, and anatomical structures (e.g., femur F and tibia T). The navigation system 32 tracks these objects to collect state information of each object relative to the (navigation) locator coordinate system LCLZ. As used herein, the state of an object includes, but is not limited to, data defining the position and / or orientation (e.g., its coordinate system) or equivalents / derivatives of the position and / or orientation of the tracked object. For example, the state can be the posture of the object, and / or can include linear velocity data, angular velocity data, etc.

[0143] The navigation system 32 may include a cart assembly 34 that houses a navigation controller 36 and / or other types of control units. A navigation user interface UI is in operative communication with the navigation controller 36. The navigation user interface UI includes one or more displays 38. The navigation system 32 is capable of displaying a graphical representation of the relative state of the tracked object to the user using the one or more displays 38. The navigation user interface UI also includes one or more input devices to input information into the navigation controller 36 or otherwise select / control certain aspects of the navigation controller 36. Such input devices include interactive touch screen displays. However, the input devices may include any one or more of buttons, indicators, foot switches, keyboards, mice, microphones (voice activated), gesture control devices, etc. In some examples, the user can use buttons located on the indicators to navigate through icons and menus of the user interface UI to make selections, thereby configuring the robotic surgery system 10 and / or advancing through the workflow.

[0144] The navigation system 32 also includes a localizer 44 coupled to the navigation controller 36. In one example, the localizer 44 is an optical localizer and includes a camera unit 46. The camera unit 46 has an outer housing 48 housing one or more optical sensors 50. The localizer 44 may include its own localizer controller 49 and may also include a camera VC.

[0145] The navigation system 32 includes one or more trackers. In some examples, the trackers include a pointer tracker PT, a tool tracker 52, a first patient tracker 54, and a second patient tracker 56. Figure 1In the example shown, the tool tracker 52 is securely attached to the instrument 14, the first patient tracker 54 is securely attached to the femur F of the patient 12, and the second patient tracker 56 is securely attached to the tibia T of the patient 12. In this example, the patient trackers 54, 56 are securely attached to multiple bone segments. The trackers 52, 54, 56 and the indicator trackers are manually, automatically, or a combination thereof, registered to their respective objects (e.g., bones, tools) and the navigation system 32. In some examples, the indicator tracker PT is securely attached to the indicator 57 and is used to register the anatomical structure to one or more coordinate systems (including the localizer coordinate system LCLZ) and / or is used for other calibration and / or registration functions. In one example, the indicator 57 can be used to register the patient trackers 54, 56 to the bones to which the trackers 54, 56 are attached, respectively, and to register the tool tracker 52 (and optionally 53) to the tool support 18, the tool 20, the handheld portion 16, or a combination thereof. In some examples, the indicator tracker PT can be used to register the TCP of the instrument 14 to the tracker 52 relative to the tracker coordinate system. In this way, if the positioner 44 is moved from one position to another, the registration of the instrument 14 is located relative to the tool tracker 52. However, other means of registration of the trackers 52, 54, 56 are contemplated and can be implemented together with or separately from the indicator tracker PT. Other tracker positions are also contemplated.

[0146] Throughout the specification, various transformations are described, such as 'bone to tracker' or 'instrument TCP to tracker', i.e., described relative to the 'tracker coordinate system' rather than the LCTZ coordinate system. The localizer coordinate system can be used as an intermediate coordinate system during registration and bone preparation, since all tracked objects are measured relative to the LCTZ. During registration, the poses of the various reference localizers are ultimately combined mathematically, and the registration results are stored 'with respect to the tracker', so that if the camera (i.e., the LCTZ) moves, the registration remains valid.

[0147] The tool tracker 52 may be attached to any applicable component of the instrument 14, and in some versions may be attached to the handheld portion 16, the tool support 18, directly to the tool 20, or a combination thereof. The trackers 52, 54, 56, PT may be fixed to their respective components in any applicable manner (e.g., by fasteners, clamps, etc.). For example, the trackers 52, 54, 56, PT may be rigidly fixed, flexibly connected (fiber optics), or not physically connected at all (ultrasound), as long as there is an applicable (supplementary) way to determine the relationship (measurement) of the respective tracker to the associated object. Any one or more of the trackers 52, 54, 56, PT may include an active marker 58. The active marker 58 may include a light emitting diode (LED). Alternatively, the trackers 52, 54, 56, PT may have a passive marker (e.g., a reflector) that reflects light emitted from the camera unit 46. Printed markers or other applicable markers not specifically described herein may also be used.

[0148] For the purpose of tracking the object, a variety of coordinate systems can be used. For example, the coordinate system may include a locator coordinate system LCLZ, a tool support coordinate system TCS, a base coordinate system BCS, a coordinate system associated with each of the trackers 52, 54, 56, PT, one or more coordinate systems associated with the anatomical structure, one or more coordinate systems associated with the preoperative and / or intraoperative images (e.g., CT images, MRI images, etc.) and / or models (e.g., 2D or 3D models) of the anatomical structure (e.g., implant coordinate system) and a TCP (tool center point) coordinate system. In some examples, the robotic system 10 does not rely on preoperative and / or intraoperative imaging to create a 2D or 3D model of the target bone. On the contrary, the robotic system can be used in an image-free system that uses an indicator tracker PT to register the target anatomical structure, thereby capturing a variety of anatomical landmarks, which are then processed by the control system 60 to deform the nominal bone model to match the captured data. In other examples, preoperative and intraoperative imaging is used to image the target area of ​​the patient, and then the 2D and / or 3D images are transformed into a 3D model of the target bone. It is also contemplated that the robotic surgery system 10 can use a combination of imaging and image-free procedures to create a 3D model of the target surgical area. An exemplary system is described in U.S. Patent No. 8,617,174, which is incorporated herein by reference. Once a relationship is established between coordinate systems (e.g., via registration, calibration, geometric relationships, measurements, etc.), coordinates in a variety of coordinate systems can be transformed to other coordinate systems using transformations.

[0149] like Figure 2As shown, in some examples, TCP is a predetermined reference point or origin of a TCP coordinate system defined at the distal end of the tool 20. The geometry of the tool 20 may be defined relative to the TCP coordinate system and / or relative to a tool support coordinate system TCS. The tool 20 may include one or more geometric features (e.g., circumference, circumference, radius, diameter, width, length, height, volume, area, surface / plane, range of motion envelope (along any one or more axes), etc.) that are defined relative to the TCP coordinate system and / or relative to the tool support coordinate system TCS and stored in a non-volatile memory of the control board 31, the navigation system 32, the instrument controller 28, or a combination thereof, in the control housing 29 of the instrument 14. For example, the tool 20 may define a longitudinal axis 910 extending the length of the tool (see Fig.68 ), and can define a lateral axis 912 extending across the width of the tool. In another example, a tool center point (TCP) is a predetermined reference point and corresponding coordinate system defined at the tool 20. The TCP has a known or calculated (i.e., not necessarily static) pose relative to other coordinate systems. The TCP coordinate system includes an origin and a set of axes (e.g., x-axis, y-axis, z-axis) that define the pose of the TCP. By tracking the TCP (or knowing the pose of the TCP), the system 10 can calculate the position and orientation of the instrument 14 based on the pose of the TCP and the known positional relationship between the TCP and features of the instrument 14. In some examples, the tool 20 has a tool plane (e.g., for a saw blade), which will be described for convenience and ease of illustration, but is not intended to limit the tool 20 to any particular form. For example, the tool support 18 may include a tool mount 18a that defines a saw blade plane BP. Points, other primitives, meshes, other 3D models, etc. may be used to virtually represent the tool 20. The origin of the TCP coordinate system may be located at the center of the drill bit of the tool 20 or at the distal end of the saw blade 27, so that the TCP coordinate system is tracked relative to the origin on the distal end of the tool 20. Alternatively, multiple tracked points can be used to track the TCP. The TCP can be defined in a variety of ways depending on the configuration of the tool 20. The instrument can use joint / motor encoders or any other non-encoder position sensing method, so the control system 60 can determine the posture and / or position of the TCP relative to the handheld portion 16 and the BCS. The tool support 18 can use joint measurements to determine the TCP posture and / or can use technology to directly measure the TCP posture. Control of the tool 20 is not limited to the center point. For example, any applicable primitives, grids, etc. can be used to represent the tool 20. It should be understood that, as an option, the TCP can be defined as a point rather than a coordinate system. Once the posture of the saw blade or other tool is determined, the TCP coordinate system allows any desired reference point or geometric aspect of the tool to be calculated.

[0150] The TCP coordinate system, the tool support coordinate system TCS, and the coordinate system of the tool tracker 52 may be defined in a variety of ways, depending on the configuration of the tool 20. For example, the indicator 57 may be used together with the calibration dimple CD in the tool support 18 and / or in the tool 20 to: register (calibrate) the pose of the tool support coordinate system TCS relative to the coordinate system of the tool tracker 52; determine the pose of the TCP coordinate system relative to the coordinate system of the tool tracker 52; and / or determine the pose of the TCP coordinate system relative to the tool support coordinate system TCS. Other techniques may be used to directly measure the pose of the TCP coordinate system, such as by attaching and fixing one or more additional trackers / markers directly to the tool 20. In some versions, the trackers / markers may also be attached and fixed to the handheld portion 16, the tool support 18, or both. In the case where the handheld portion includes a tracker, the pose of the handheld portion relative to the locator coordinate system LCTZ may be measured directly. In other alternatives, the TCP may be defined relative to the tool tracker using an intermediate tool support coordinate system TCS.

[0151] Since the tool support 18 can be moved in multiple degrees of freedom relative to the handheld portion 16 via the actuators 21, 22, 23, the instrument 14 can use encoders, Hall effect sensors (with analog or digital outputs) and / or any other position sensing method to measure the attitude of the TCP coordinate system and / or the tool support coordinate system TCS relative to the base coordinate system BCS. In one example, the instrument 14 can use measurements from sensors that measure actuation of the actuators 21, 22, 23 to determine the attitude of the TCP coordinate system and / or the tool support coordinate system TCS relative to the base coordinate system BCS, as further described below.

[0152] The localizer 44 monitors the trackers 52, 54, 56, PT (e.g., their coordinate systems) to determine the state of each of the trackers 52, 54, 56, PT, which corresponds to the state of the objects respectively attached thereto. The localizer 44 may perform known techniques to determine the state of the trackers 52, 54, 56, PT and associated objects (e.g., tools, patients, tool supports, and handheld portions). The localizer 44 provides the states of the trackers 52, 54, 56, PT to the navigation controller 36. In some examples, the navigation controller 36 determines the states of the trackers 52, 54, 56, PT and transmits them to the instrument controller 28.

[0153] The navigation controller 36 may include one or more computers or any other applicable form of controller. The navigation controller 36 has a central processing unit (CPU) and / or other processors, memory and storage devices (not shown). The processor can be any type of processor, microprocessor or multi-processor system. The navigation controller 36 is loaded with software. For example, the software converts the signal received from the locator 44 into data representing the position and / or orientation of the object being tracked. Additionally or alternatively, the navigation controller 36 may include one or more microcontrollers, field programmable gate arrays, systems on chips, discrete circuits and / or other applicable hardware, software or firmware capable of performing the functions described herein. The term processor is not intended to limit any embodiment to a single processor.

[0154] Although one example of a navigation system 32 is shown for determining an object state, the navigation system 32 may have any other applicable configuration for tracking the instrument 14, tool 20, and / or patient 12. In another example, the navigation system 32 and / or the locator 44 are ultrasound-based. For example, the navigation system 32 may include an ultrasound imaging device connected to a navigation controller 36. The ultrasound imaging device images any of the aforementioned objects (e.g., the instrument 14, tool 20, and / or patient 12) and generates a status signal to the navigation controller 36 based on the ultrasound image. The ultrasound image may be 2D, 3D, or a combination of both. The navigation controller 36 may process the image in near real time to determine the state of the object. The ultrasound imaging device may have any applicable configuration and may be different from, for example, Figure 1 A camera unit 46 is shown.

[0155] In another example, the navigation system 32 and / or the locator 44 are radio frequency (RF) based. For example, the navigation system 32 may include an RF transceiver coupled to the navigation controller 36. The instrument 14, tool 20, and / or patient 12 may include an RF transmitter or transponder attached thereto. The RF transmitter or transponder may be passive or actively powered. The RF transceiver transmits RF tracking signals and generates a status signal to the navigation controller 36 based on the RF signals received from the RF transmitter. The navigation controller 36 may analyze the received RF signals to associate a relative status therewith. The RF signals may have any applicable frequency. The RF transceiver may be positioned at any applicable location to effectively use the RF signals to track the object. In addition, the RF transmitter or transponder may have a frequency that can be coupled to the navigation controller 36. Figure 1 The trackers 52, 54, 56, PT shown may be configured in any suitable manner.

[0156] In yet another example, the navigation system 32 and / or the locator 44 are electromagnetic based. For example, the navigation system 32 may include an electromagnetic (EM) transceiver coupled to the navigation controller 36. The instrument 14, tool 20, and / or patient 12 may include EM components attached thereto, such as any applicable magnetic tracker, electromagnetic tracker, inductive tracker, etc. The tracker may be passive or actively powered. The EM transceiver generates an EM field and generates a status signal to the navigation controller 36 based on the EM signal received from the tracker. The navigation controller 36 may analyze the received EM signal to associate a relative state therewith. Likewise, this example of the navigation system 32 may have an EM field coupled thereto. Figure 1 The navigation system 32 is shown in different configurations.

[0157] The navigation system 32 may have any other applicable components or structures not specifically described herein. In addition, any of the techniques, methods, and / or components described above with respect to the illustrated navigation system 32 may be implemented or provided for any other example of the navigation system 32 described herein. For example, the navigation system 32 may utilize only inertial tracking or any combination of multiple tracking technologies, and may additionally or alternatively include fiber-based tracking, machine vision tracking, and the like.

[0158] refer to Figure 7 , the robotic system 10 includes a control system 60, which includes, among other components, an instrument controller 28 and a navigation controller 36. The control system 60 also includes one or more software programs and software modules. The software module may be part of one or more programs running on the instrument controller 28, the navigation controller 36, or a combination thereof, to process data to assist in the control of the robotic system 10. The software program and / or module includes computer-readable instructions stored in a memory 64 on the instrument controller 28, the navigation controller 36, or a combination thereof, to be executed by one or more processors 70 of the controller 28. The memory 64 may be any suitable memory configuration, such as non-transitory memory, RAM, non-volatile memory, etc., and may be implemented locally or from a remote database. In addition, software modules for prompting and / or communicating with a user may form part of one or more programs and may include instructions stored in a memory 64 on the instrument controller 28, the navigation controller 36, or a combination thereof. The user may interact with any of the input devices of the navigation user interface UI or other user interface UI to communicate with the software module. The user interface software may run on a device separate from the instrument controller 28 and / or the navigation controller 36. The instrument 14 may communicate with the instrument controller 28 via a power / data connection. The power / data connection may provide a path for inputs and outputs for controlling the instrument 14 based on position and orientation data generated by the navigation system 32 and transmitted to the instrument controller 28, such as in Figure 7Shown here as bus / communication connection 37 .

[0159] The control system 60 may include any suitable configuration of input, output, and processing devices suitable for performing the functions and methods described herein. The control system 60 may include the instrument controller 28, the navigation controller 36, or a combination thereof, and / or may include only one of these controllers or additional controllers. The controllers may be connected via a wired bus or communication network (e.g., Figure 7 The control system 60 may also be referred to as a controller. The control system 60 may include one or more microcontrollers, field programmable gate arrays, systems on a chip, discrete circuits, sensors, displays, user interfaces, indicators, and / or other suitable hardware, software, or firmware capable of performing the functions described herein.

[0160] instrument

[0161] In one exemplary configuration, the instrument 14 is Figure 8 and Fig. 9 The instrument 14 includes a handheld portion 16 to be held by a user, a tool support 18 movably coupled to the handheld portion 16 to support a tool 20, an actuator assembly 400 having a plurality of actuators 21, 22, 23 operatively interconnecting the tool support 18 and the handheld portion 16 to move the tool support 18 relative to the handheld portion 16 in at least three degrees of freedom, and a constraint assembly 24 having a passive linkage 26 operatively interconnecting the tool support 18 and the handheld portion 16.

[0162] The handheld portion 16 includes a grip 72 for being held by a user so that the user can manipulate, guide and / or hold the instrument 14. The handheld portion 16 may be configured with ergonomic features, such as a grip for being held by a user's hand, a textured or mixed material coating for preventing the user's hand from sliding when wet and / or bleeding. The handheld portion 16 may include a tapered portion to accommodate multiple users with different hand sizes, the profile of the tapered portion being designed to match the profile of the user's hand and / or fingers. The handheld portion 16 also includes a base 74, to which the grip 72 is attached by one or more fasteners, adhesives, welding, etc. In the illustrated embodiment, the base 74 includes a sleeve 76 having a generally hollow cylindrical shape. Joint supports 77, 78, 79 extend from the sleeve 76. The actuators 21, 22, 23 may be movably coupled to the base 74 at the joint supports 77, 78, 79 via the joints further described below.

[0163] The tool support 18 includes a tool support body 80 to which the tool tracker 52 may be fixed at one or more mounting locations 82 or removably mounted via one or more tracker mounts fixed to the tool support 18. In one example, the tool tracker 52 is integral with the tool support 18. In another example, the tool tracker 52 is removably mounted at one or more mounting locations 82. In the illustrated version, the tool 20 is removably coupled to the tool support 18. Specifically, the tool support 18 includes a tool coupler, such as a head 84 to which the tool 20 is mounted, as described in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference. The head 84 may be configured for use with an oscillating saw blade and a sagittal saw blade. A drive motor M that drives the operation of the tool 20 is disposed in the tool support body 80 (e.g., in some versions to drive the oscillation of the saw blade). The tool 20 may be attached to and released from the head 84 in the manner disclosed in U.S. Pat. No. 9,820,753 to Walen et al., which is incorporated herein by reference. Fig. 9 As best shown in FIG. 1 , the tool support 18 also includes a plurality of actuator mounts 86, 88, 90 at which the actuators 21, 22, 23 are movably coupled to the tool support 18 via joints, as further described below. The actuator mounts 86, 88, 90 may include brackets or the like adapted to mount the actuators 21, 22, 23 such that the tool support 18 is movable relative to the handheld portion 16 in at least three degrees of freedom.

[0164] In the illustrated version, the actuators 21, 22, 23 include electric linear actuators extending between the base 74 and the tool support body 80. When actuated, the effective lengths of the actuators 21, 22, 23 change to change the distance between the tool support body 80 and the base 74 along the corresponding axes of the actuators 21, 22, 23. Thus, the control system 60 commands the actuators 21, 22, 23 to work in a coordinated manner, thereby changing their effective lengths and moving the tool support 18 to a target posture in at least three degrees of freedom relative to the handheld portion 16 in response to individual inputs given to each actuator 21, 22, 23 by the control system 60. In the illustrated version, three actuators 21, 22, 23 are provided, and these three actuators may be referred to as the first actuator 21, the second actuator 22, and the third actuator 23 or the front actuator 21, 22 and the rear actuator 23. The effective lengths of the first actuator 21, the second actuator 22 and the third actuator 23 are all adjustable along the first active axis AA1, the second active axis AA2 and the third active axis AA3 (see Fig. 9). As previously described, the effective lengths of the first actuator 21, the second actuator 22, and the third actuator 23 are individually adjustable to adjust one or more of the pitch orientation, the roll orientation, and the z-axis translation position of the tool support 18 relative to the handheld portion 16. In some examples, more actuators may be provided. In some examples, the actuators may include rotary actuators. The actuators 21, 22, 23 may include one or more linkage mechanisms having linkages of any suitable size or shape. The actuators 21, 22, 23 may have any configuration suitable for enabling the tool support 18 to move in at least three degrees of freedom relative to the handheld portion 16. For example, in some versions, there may be one front actuator and two rear actuators, or some other arrangement of actuators.

[0165] In this version, the actuators 21, 22, 23 are coupled to the base 74 and the tool support body 80 via a plurality of movable joints. The movable joints include a set of first movable joints 92 that couple the actuators 21, 22, 23 to the tool support body 80 at the actuator mounts 86, 88, 90. In one version, as Fig. 9 As shown, the first movable joint 92 includes a movable U-shaped joint. The U-shaped joint includes a first pivot pin 94 and a joint block 96. The first pivot pin 94 pivotally connects the joint block 96 to the actuator mounting seat 86, 88, 90 via a through hole 98 in the joint block 96. A fixing screw 100 can fix the first pivot pin 94 to the actuator mounting seat 86, 88, 90. The U-shaped joint can also include a second pivot pin 104. The joint block 96 has a cross hole 102 to receive the second pivot pin 104. The second pivot pin 104 has a through hole 103 to receive the first pivot pin 94, so that the first pivot pin 94, the joint block 96 and the second pivot pin 104 form a cross section of the U-shaped joint. The first pivot pin 94 and the second pivot pin 104 of each U-shaped joint define intersecting pivot axes PA. The second pivot pin 104 pivotally connects the pivot yoke 106 of the actuator 21, 22, 23 to the joint block 96. As a result, the actuators 21, 22, 23 are movable in two degrees of freedom relative to the tool support body 80. Other types of movable joints are also envisaged, such as a movable spherical joint comprising a ball with a notch for receiving a pin.

[0166] refer to Fig. 9, the movable joint also includes a set of second movable joints 108 that connect the two front actuators 21, 22 to the base 74 of the handheld portion 16. In the illustrated version, the second movable joints 108 are supported at the joint supports 77, 78. Each of the second movable joints 108 includes a swivel yoke 110 that is arranged to swivel about the swivel axis SA relative to the base 74 of the handheld portion 16. Each swivel yoke 110 has a swivel head 112 and a column 114 extending from the swivel head 112 to pivotally engage the base 74 at one of the joint supports 77, 78. A nut 115 is threadedly connected to one end of the column 114 to capture the column 114 in the base 74 while allowing the corresponding swivel yoke 110 to rotate freely within its corresponding joint support 77, 78.

[0167] Each of the second movable joints 108 includes a bracket 116 that is pivotally coupled to one of the slewing yokes 110. The bracket 116 has an internally threaded through hole 117 to receive the lead screws 150 of the two front actuators 21, 22, as described further below. Each of the brackets 116 also includes opposing trunnions 118 that allow the bracket 116 to be rotated relative to the slewing yoke 110 about the pivot axis PA (see Fig. 9 In some versions, for each of second active joints 108, axis of revolution SA intersects pivot axis PA to define a single vertex about which actuators 21, 22 move in two degrees of freedom.

[0168] The cover is secured to the swivel head 112 and defines one of the recesses, while the swivel head 112 defines the other recess. During assembly, the bracket is first positioned to place one of the trunnions in the recess in the swivel head 112, and the cover is then secured over the other trunnion so that the bracket is captured between the cover and the swivel head 112 and is able to pivot relative to the swivel yoke 110 via the trunnions and the recesses. Due to the configuration of the swivel yoke 110 and the associated bracket, i.e., the ability of the bracket to swivel about the swivel axis SA and to pivot about the pivot axis PA, the second active joint 108 allows the two front actuators 21, 22 to move in two degrees of freedom relative to the base 74. Other joint arrangements between the two front actuators 21, 22 and the base 74 are also possible.

[0169] The movable joints also include a third movable joint 124 that couples the rear (third) actuator 23 to the base 74 of the handheld portion 16. In the illustrated version, the third movable joint 124 is supported at the joint support 79. The third movable joint 124 includes a pivot housing 126 fixed to the joint support 79 of the base 74.

[0170] The third movable joint 124 includes a bracket pivotally connected to the pivot housing 126 via an ear shaft. A fastener having a recess is attached to either side of the pivot housing 126 via a through hole to engage the ear shaft. The fastener is arranged so that the bracket can be pivoted via the ear shaft positioned in the recess after assembly. The bracket has an internal threaded through hole to receive the lead screw 150 of the rear actuator 23, as further described below. Due to the configuration of the pivot housing 126 and the associated bracket (i.e., the ability of the associated bracket to pivot only around the pivot axis PA (e.g., and not swivel)), the third movable joint 124 allows the rear actuator 23 to move in only one degree of freedom relative to the base 74. Other joint arrangements between the rear actuator 23 and the base 74 are also possible.

[0171] Each of the actuators 21, 22, 23 includes a housing. The housing includes a can and a cap that is threadedly connected to the can. A pivot yoke 106 that forms part of the first movable joint 92 is fixed to the housing so that the housing and the pivot yoke 106 can move together relative to the tool support 18 via the first movable joint 92. The cap captures an annular shoulder of the pivot yoke 106 to fix the pivot yoke 106 to the can.

[0172] In some versions, pivot yoke 106 and the can include one or more alignment features to align each pivot yoke 106 with its corresponding can in a predetermined relative orientation. Such alignment features may include mating portions, keys / keyways, etc. During assembly, pivot yoke 106 may first be secured to the can in its predetermined relative orientation, and then the cap may be threaded onto the can (e.g., via mating external and internal threads) to capture pivot yoke 106 to the can in the predetermined relative orientation. This predetermined relationship may facilitate routing and / or alignment of flexible circuit FC, thereby preventing pivot yoke 106 from tipping relative to the can, and / or for other purposes.

[0173] Each of the actuators 21, 22, 23 also includes a motor disposed in each housing. The motor has a housing disposed in the housing and a motor winding assembly disposed in the housing. The motor winding assembly can also be aligned with the tank in a predetermined relative orientation, for example, via a set screw or other alignment features (such as those described above). Each motor also has a rotor fixed to a lead screw 150. The lead screw 150 is supported by one or more bushings and / or bearings to rotate in the housing. The rotor and the associated lead screw 150 are configured to rotate relative to the housing once the motor is selectively energized. The lead screw 150 has a fine pitch and lead angle to prevent backdrive (i.e., they are self-locking). As a result, the load placed on the tool 20 is not prone to backdrive the motor. In some examples, the lead screw 150 has an 8-36 grade 3 thread, which results in a lead of 0.02 to 0.03 inches / turn. Other thread types / sizes may also be used.

[0174] Each of the actuators 21, 22, 23 can be controlled by a separate motor controller. The motor controller can be connected to the actuators 21, 22, 23 by wires, respectively, to guide each actuator 21, 22, 23 to a given target position. In some examples, the motor controller is a proportional integral derivative (PID) controller. In some examples, the motor controller may include a cascade control loop associated with position, speed and torque (current). Additionally and / or alternatively, the motor controller may include only a torque (current) control loop. In another example, the position control loop may directly feed the torque (current) control loop. Each of these control levels can be implemented as a PID controller, a state space controller and / or utilize alternative or additional control techniques (e.g., speed feedforward, torque feedforward, etc.). In some cases, the torque (current) control loop is implemented using field oriented control and space vector modulation. The levels of the control loop can be distributed between various components of the system. In some examples, the position loop and the speed loop are implemented in the instrument controller, and the torque control loop is implemented directly in the control board 31 as part of the control housing 29 on the instrument 14, thereby mitigating the effects of data communication delays from the instrument 14 through the connection to the console 33, because the current control loop does not require any data feedback via the console 33. The position control loop and the speed control loop are not as sensitive to communication delays and can be implemented in the console 33. In some examples, the motor controller can be integrated with or form part of the instrument controller 28. For ease of explanation, the motor controller is described herein as part of the instrument controller 28.

[0175] For example, the power supply provides a 32V DC power signal to the motor via the console 33. The 32V DC signal is applied to the motor through the instrument controller 28. The instrument controller 28 selectively provides a power signal to each motor to selectively start the motor. This selective start of the motor is the case of the positioning tool 20. The motor can be any applicable type of motor, including a brushless DC servo motor, a permanent magnet synchronous motor, other forms of DC motors, etc. The power supply also supplies power to the instrument controller 28 to energize the components located inside the instrument controller 28. In some examples, the actuator motor can be a three-phase brushless motor. The actuator motor can be a DC motor. The actuator motor can be a permanent magnet synchronous motor. Each of the actuator motors can be configured with a sinusoidal back electromotive force, which is configured to achieve limited mechanical cogging, thereby allowing smooth and specific movement to limit torque fluctuations. However, other motor types can be conceived. It should be understood that the power supply can provide other types of power signals, for example, a 12V DC signal, a 24V DC signal, a 40V DC signal, etc. The instrument may use electronic switches (eg, MOSFETs or GaN FETs) to pulse width modulate (PWM) a voltage signal to a three-phase motor on / off at a high frequency (eg, typically at a rate of at least 16 kHz, up to 256 kHz or higher).

[0176] In one possible embodiment, one or more sensors S (see also Figure 7) transmits a signal back to the instrument controller 28 so that the instrument controller 28 can determine the current position and / or angle (i.e., measured position) of the associated actuators 21, 22, 23. The levels of these signals may vary depending on the rotational position of the associated rotor. In one embodiment, the sensor S can resolve the rotational position of the rotor within a given revolution with high resolution. These sensors S can be Hall effect sensors that output analog and / or digital signals based on a sensed magnetic field from the rotor or from other magnets (e.g., 2-pole magnets) placed on the lead screw 150. A low voltage signal (e.g., a 5V DC signal) for stimulating the Hall effect sensor can be supplied from a motor controller associated with the motor, wherein the Hall effect sensor is associated with the motor. In some examples, two Hall effect sensors are disposed in a housing and spaced 90 degrees apart from each other around the rotor to sense the joint position, so that the instrument controller 28 can determine the position of the rotor and count the incremental rotation of the rotor. In some versions, the Hall effect sensor outputs a digital signal representing an incremental count. Various types of motors and sensor arrangements are possible. In some examples, the motor is a brushless DC servo motor, and two or more internal Hall effect sensors can be spaced 90 degrees, 120 degrees or any other applicable spacing around the rotor. The sensor S may also include an absolute or incremental encoder, which can be used to sense the rotational position of the rotor and count the rotation of the rotor. Other types of encoders may also be used as one or more sensors. The sensor may be placed at any applicable position on the actuator and its surrounding components, and these sensors are suitable for determining the position of each actuator when adjusting each actuator (e.g., on a housing, nut, screw, etc.). In another configuration, sensorless motor control may be used. In this embodiment, the position of each rotor may be determined by measuring the back electromotive force and / or inductance of the motor. An applicable example is found in U.S. Patent No. 7,422,582, the entire contents of which are incorporated herein by reference.

[0177] In some examples, when used in conjunction with a kinematic model of the instrument 14, sensors and / or encoders can measure position feedback for joint position control and / or determine the position of the tool support 18 relative to the handheld portion 16. In some examples, the sensors and / or encoders rely on multi-turn measurements that are accumulated from one revolution to the next to determine the absolute position of the actuators 21, 22, 23 along their axes and are used in conjunction with a known pitch (i.e., the number of revolutions per inch of the lead screw). Additionally or alternatively, the sensors and / or encoders can be used to determine the "electrical angle of the rotor" for use in the electronic commutation of the motor. For example, the sensors and / or encoders can be used to determine the rotor position and apply appropriate excitation signals to achieve optimal (efficient) torque generation. In this example, the sensors and / or encoders can utilize single-turn or single-sub-turn (within one electrical revolution) measurements that roll on each electrical revolution. The number of electrical revolutions is equal to the number of mechanical revolutions divided by the number of magnetic poles (e.g., number of pole pairs) of the motor. However, it is conceivable that a sensorless approach is implemented.

[0178] In some examples, the output signals from the Hall effect sensors are sent to the instrument controller 28. The instrument controller 28 monitors the level changes of the received signals. Based on these signals, the instrument controller 28 determines the joint position. The joint position can be considered as the angle of rotation of the rotor from the initial or original position. The rotor can undergo multiple 360° rotations. Therefore, the joint position can exceed 360°. The scalar value called count represents the joint position relative to the original position. The rotor rotates both in the clockwise direction and in the counterclockwise direction. Whenever the signal level of multiple signals (analog or digital) undergoes a defined state change, the instrument controller 28 increments or decrements the count to indicate the change in the joint position. For each complete 360° rotation of the rotor, the instrument controller 28 increments or decrements the value of the count by a fixed number of counts. In some examples, the count is incremented or decremented by 100 to 3,000 for each 360-degree rotation of the rotor. In some examples, for example, when an incremental encoder is used to monitor the joint position, there are 1,024 positions (counts) for each 360-degree rotation of the rotor. Located inside the instrument controller 28 is a counter associated with each actuator 21, 22, 23. The counter stores a value equal to the cumulative number count that is incremented or decremented. The count value may be positive, zero, or negative. In some versions, the count value defines the incremental movement of the rotor. Thus, the rotors of the actuators 21, 22, 23 may first be moved to a known position, referred to as their home position (described further below), and the count value is thereafter used to define the current position of the rotor.

[0179] As previously described, the bracket has an internally threaded through hole to threadably receive the lead screw 150, so that each of the lead screws 150 can be rotated relative to a corresponding one of the brackets to adjust the effective length of a corresponding one of the plurality of actuators 21, 22, 23 and thereby change the count measured by the instrument controller 28. Each of the housings and the corresponding bracket are constrained from relative movement in at least one degree of freedom to allow the lead screw 150 to rotate relative to the bracket. More specifically, the lead screw 150 is able to rotate relative to the bracket because: the pivot yoke 106 cannot rotate about the associated active axis AA1, AA2, AA3 (i.e., the pivot yoke 106 is restricted from such rotational movement due to the configuration of the first active joint 92); and the bracket cannot rotate about the associated active axis AA1, AA2, AA3 (i.e., the bracket is restricted from such rotational movement due to the configuration of the second active joint 108 and the third active joint 124).

[0180] A stop 152 (eg, a threaded fastener and a shoulder formed on the lead screw 150) is secured to the lead screw 150. The stop 152 is sized to abut against the bracket 116 at the end of travel of each lead screw 150.

[0181] As previously described, the effective length of the actuators 21, 22, 23 is actively adjustable to enable movement of the tool support 18 relative to the hand portion 16. An example of this effective length is labeled "EL" on the third actuator 23. Here, the effective length EL is measured from the pivot axis PA to the center of the associated first active joint 92. When each actuator 21, 22, 23 is adjusted, the effective length EL changes by changing the distance that the lead screw 150 has been screwed into or out of its associated bracket and thereby changing the distance from the center of the associated bracket to the center of the associated first active joint 92. The actuators 21, 22, 23 are adjustable between a minimum and a maximum value of the effective length EL. The effective length EL of each actuator 21, 22, 23 can be represented / measured in any suitable manner to represent the distance between the tool support 18 and the hand portion 16 along the active axis AA1, AA2, AA3 that changes to cause various movements of the tool support 18 relative to the hand portion 16.

[0182] The constraint assembly 24 cooperates with the actuators 21, 22, 23 to constrain the movement provided by the actuators 21, 22, 23. The actuators 21, 22, 23 provide movement in three degrees of freedom, and the constraint assembly 24 constrains the movement in three degrees of freedom. In the illustrated version, the constraint assembly 24 includes a passive linkage 26 and a passive linkage joint 156 that couples the passive linkage 26 to the tool support 18.

[0183] In one form, Fig. 9 As shown, the passive linkage joint 156 includes a passive linkage U-shaped joint. The U-shaped joint includes a first pivot pin 158 and a joint block 160. The first pivot pin 158 pivotally connects the joint block 160 to the passive linkage mounting seat 162 of the tool support body 80 via a through hole 164 in the joint block 160. A fixing screw 166 can fix the first pivot pin 158 to the passive linkage mounting seat 162. The U-shaped joint also includes a second pivot pin 170. The joint block 160 has a transverse hole 168 to receive the second pivot pin 170. The second pivot pin 170 pivotally connects the passive linkage pivot yoke 172 of the passive linkage 26 to the joint block 160. The second pivot pin 170 has a through hole 171 to receive the first pivot pin 158, so that the first pivot pin 158, the joint block 160 and the second pivot pin 170 form a cross portion of the U-shaped joint. The first pivot pin 158 and the second pivot pin 170 define an intersecting pivot axis PA. As a result, the passive linkage 26 is movable in two degrees of freedom relative to the tool support body 80. Other types of passive linkage joints are also contemplated, such as a passive linkage spherical joint including a ball having a notch that receives a pin.

[0184] The passive linkage 26 includes a shaft 174 fixed to the passive linkage pivot yoke 172. The passive linkage 26 also includes a sleeve 76 of the base 74, which is configured to receive the shaft 174 along the constraint axis CA. The passive linkage 26 is configured to allow the shaft 174 to slide axially along the constraint axis CA relative to the sleeve 76 and to constrain radial movement of the shaft 174 relative to the constraint axis CA during actuation of one or more of the actuators 21, 22, 23.

[0185] The passive linkage 26 also includes a key to constrain the shaft 174 from rotating relative to the sleeve 76 about the constraint axis CA. The key is assembled in the relative keyways in the shaft 174 and the sleeve 76 to lock the shaft 174 to the sleeve 76 in a rotatable manner. Other arrangements for preventing relative rotation of the shaft 174 and the sleeve 76 are also contemplated, such as an integrated key / slot arrangement, etc. The passive linkage 26 operatively interconnects the tool support 18 and the handheld portion 16 in a manner independent of the actuators 21, 22, 23. During actuation of one or more of the actuators 21, 22, 23, the passive linkage is passively adjustable along the constraint axis CA. The sleeve 76, the shaft 174, and the key 176 represent a combination of links for the passive linkage 26. Links of other sizes, shapes, and numbers connected in any suitable manner may be used for the passive linkage 26.

[0186] In the version shown, the passive linkage joint 156 is pivotable about two pivot axes PA relative to the tool support 18. Other configurations are possible.

[0187] Furthermore, in the illustrated version, first active joint 92 and passive linkage joint 156 define pivot axes PA disposed on a common plane. Non-parallel pivot axes PA, parallel pivot axes PA disposed on different planes, combinations thereof, and / or other configurations are also contemplated.

[0188] In some versions, head 84 of tool support 18 is arranged so that tool 20 is positioned on a tool plane BP (e.g., a saw blade plane) that is parallel to a common plane when tool 20 is coupled to tool support 18. In some examples, tool plane BP is spaced apart from common plane CP by 2.0 inches or less, 1.0 inches or less, 0.8 inches or less, or 0.5 inches or less.

[0189] In the illustrated version, the actuators 21, 22, 23 are arranged so that the active axes AA1, AA2, AA3 are in an inclined configuration relative to the constraint axis CA in all positions of the actuators 21, 22, 23, including when in their home positions. Inclining the axes AA1, AA2, AA3 generally tapers the actuator arrangement in a manner that allows for a thinner and more compact base 74 and associated grip 72. Other configurations are contemplated, including configurations in which the active axes AA1, AA2, AA3 are not in an inclined configuration relative to the constraint axis CA. Such configurations may include configurations in which the actuator axes AA1, AA2, AA3 are parallel to each other in their home positions.

[0190] Other configurations of actuators, movable joints, and constraint assemblies are possible. It is contemplated that the control techniques described may be applied to other mechanical configurations not mentioned, particularly mechanical configurations for controlling a tool or saw blade relative to a handheld portion in one or more degrees of freedom. In some versions, there may be no constraint assembly, and the tool support 18 of the instrument 14 may be movable in additional degrees of freedom relative to the handheld portion 16. For example, the instrument may include a linear actuator, a rotary actuator, or a combination thereof. The instrument may include 2, 3, 4, 5, 6 or more different actuators arranged in parallel or in series.

[0191] Virtual Boundary

[0192] The software used by the control system 60 to control the operation of the instrument 14 includes a boundary generator 182 (see Figure 7). The boundary generator 182 may be implemented on the instrument controller 28, the navigation controller 36, and / or other components (e.g., a separate controller). The boundary generator 182 may also be part of a separate system that operates remotely from the instrument 14. Figure 7 , the boundary generator 182 is a software program or module that generates one or more virtual boundaries 184 for constraining the movement and / or operation of the instrument 14. In some examples, the boundary generator 182 provides a virtual boundary 184 that defines a virtual cutting guide (e.g., a virtual sawing guide). A virtual boundary 184 may also be provided to depict a variety of operation / control areas as described below. The virtual boundary 184 may be one-dimensional (1D), two-dimensional (2D), three-dimensional (3D), and may include points, lines, axes, trajectories, planes (infinite planes or plane segments defined by anatomical structures or other boundaries), volumes, or other shapes (including complex geometric shapes). The virtual boundary 184 may be represented by pixels, point clouds, voxels, triangular meshes, other 2D or 3D models, combinations thereof, and the like. U.S. Patent Publication No. 2018 / 0333207 and U.S. Patent No. 8,898,043 are incorporated by reference, and any of their features may be used to facilitate planning or performing the surgical procedure.

[0193] The virtual boundary 184 can be used in a variety of ways. For example, the control system 60 can: control certain movements of the tool 20 to stay within the boundary; control certain movements of the tool 20 to stay outside the boundary; control certain movements of the tool 20 to stay on the boundary (e.g., stay on a point, track, and / or plane); control certain movements of the tool 20 to approach the boundary (attract boundary) or be expelled from the boundary (repel boundary); and / or control certain operations / functions of the instrument 14 based on the relationship of the instrument 14 to the boundary (e.g., space, velocity, etc.). Other uses of the boundary 184 are also contemplated.

[0194] In some examples, one of the virtual boundaries 184 is a desired cutting plane, such as Figure 2 In some versions, control system 60 will ultimately be used to keep tool 20 on the desired cutting plane. Virtual boundary 184 that controls the positioning of tool 20 may also be a volume boundary (e.g., a volume boundary having a thickness slightly greater than the thickness of the saw blade) to constrain the saw blade to stay within the boundary and on the desired cutting plane, such as Figure 2 Thus, the desired cutting plane may be defined by a virtual plane boundary, a virtual volume boundary, or other forms of virtual boundaries. The virtual boundary 184 may also be referred to as a virtual object. The virtual boundary 184 may be defined relative to an anatomical model AM such as a 3D bone model (see Figure 2, which shows that the anatomical model AM is virtually superimposed on the actual femur F due to its alignment). In other words, points, lines, axes, trajectories, planes, volumes, etc. associated with the virtual boundary 184 can be defined in a coordinate system that is fixed relative to the coordinate system of the anatomical model AM, so that tracking the anatomical model AM (e.g., via tracking associated anatomical structures aligned thereto) also enables tracking of the virtual boundary 184.

[0195] The anatomical model AM is registered to the first patient tracker 54 so that the virtual boundary 184 becomes associated with the anatomical model AM and the associated coordinate system. The virtual boundary 184 can be implant-specific (e.g., defined based on the size, shape, volume, etc. of the implant), and / or patient-specific (e.g., defined based on the patient's anatomical structure). The virtual boundary 184 can be a boundary created before surgery, during surgery, or a combination thereof. In other words, the virtual boundary 184 can be defined before the start of the surgical procedure, during the surgical procedure (including during tissue removal), or a combination thereof. The virtual boundary 184 can be provided in a variety of ways, such as by creating them through the control system 60, receiving them from other sources / systems, etc. The virtual boundary 184 can be stored in a memory for retrieval and / or updating.

[0196] In some cases, such as when preparing the femur F for receiving a total knee implant IM (see Figure 1 ), the virtual boundary 184 includes a plurality of planar boundaries, which can be used to depict a plurality of cutting planes (e.g., five cutting planes) for the total knee implant IM and are associated with the 3D model of the distal end of the femur F. These multiple virtual boundaries 184 can be activated one at a time by the control system 60 to constrain the cutting to one plane each time.

[0197] The instrument controller 28 and / or navigation controller 36 tracks the state of the tool 20 relative to the virtual boundary 184. In one example, the state of the TCP coordinate system (e.g., the pose of the saw blade) is measured relative to the virtual boundary 184 for the purpose of determining the target position of the actuators 21, 22, 23 so that the tool 20 remains in a desired state. In some cases, the control system 60 controls / positions the instrument 14 in a manner that simulates the way a physical head would respond in the presence of a physical boundary / barrier.

[0198] Return to reference Figure 7, two additional software programs or modules run on the instrument controller 28 and / or navigation controller 36. One software module executes behavior control 186. Behavior control 186 is the process of calculating data indicating the next commanded / desired position and / or orientation (e.g., desired pose) of the tool 20. In some cases, only the desired position of the TCP is output from the behavior control 186, while in some cases, the commanded pose of the tool 20 is output. The output from the boundary generator 182 (e.g., the current position and / or orientation of the virtual boundary 184 in one or more coordinate systems) can be fed into the behavior control 186 as an input to determine the next commanded position of the actuators 21, 22, 23 and / or the orientation of the tool 20. The behavior control 186 can process this input and one or more other inputs described further below to determine the commanded pose.

[0199] The instrument controller 28 can control one or more actuators 21, 22, 23 by sending command signals to each actuator 21, 22, 23 to adjust the tool 20 toward the desired posture. The instrument controller 28 can know the entire length of the tool support 18 that the actuator 21, 22, 23 can adjust relative to the handheld portion 16. In some examples, the instrument controller 28 knows the entire length that the actuator 21, 22, 23 can adjust, and can send command signals to the actuator 21, 22, 23 to move a measured distance from one position to another position. The measured position can be a known position, or the distance between the current position of the actuator 21, 22, 23 and the actuator limit. Each position to which the actuator 21, 22, 23 moves can be a distance measured relative to the positive and negative limits of the actuator travel (i.e., the position between the two ends of the lead screw). The instrument controller 28 can command the actuator 21, 22, 23 to and from the measured position as described below.

[0200] The instrument controller 28 may send a command signal to each actuator 21, 22, 23 to move the actuator 21, 22, 23 from a first position to a command position that will place the tool 20 in a desired pose. In some examples, the command position may be determined by the instrument controller 28 in conjunction with the navigation system 32 to determine the position of the tool 20 and the tool support 18 relative to the handheld portion 16, the patient tracker PT, 54, 56, a virtual object (e.g., a desired cutting plane), or a combination thereof, and send a signal to the actuator 21, 22, 23 to adjust a specific distance or command position to place the tool 20 in the desired pose. The instrument controller may command the actuator 21, 22, 23 to a position to achieve the desired adjustment of the tool 20. The instrument controller 28 may control the actuator 21, 22, 23 to move the calculated distance linearly to adjust the tool 20 toward the desired pose. In other examples, such as when absolute encoders are used, the instrument controller may send signals to the actuators 21, 22, 23 to place each actuator 21, 22, 23 into a commanded position based on the known position of the tool support 18 relative to the handpiece as determined by the absolute encoders.

[0201] The instrument controller 28 may know the entire length that the actuator 21, 22, 23 can adjust the tool support 18 relative to the handheld portion 16. In some examples, the instrument controller 28 knows the entire length that the actuator 21, 22, 23 can adjust, and may send a command signal to the actuator 21, 22, 23 to move a measured distance from one position to another position (e.g., by commanding a desired amount of linear travel via a commanded rotation). The measured position may be a known position, or the distance between the current position of the actuator 21, 22, 23 and the actuator limit. Each position to which the actuator 21, 22, 23 moves may be a distance measured relative to the positive and negative limits of the actuator travel (i.e., the position between the two ends of the lead screw). The instrument controller 28 may command the actuator 21, 22, 23 to and from the positions described below. The instrument controller may command the actuator 21, 22, 23 to a position so as to achieve the desired adjustment of the tool 20. The instrument controller 28 can control the actuators 21, 22, 23 to move the calculated distance linearly to adjust the tool 20 toward the desired posture. In other examples, such as when an absolute encoder is used, the instrument controller can send a signal to the actuators 21, 22, 23 to place each actuator 21, 22, 23 in a command position based on the known position of the actuators 21, 22, 23 between the respective actuator travel limits determined by the absolute encoder. Alternatively, in one example, the incremental encoder can be used in conjunction with a homing process performed during system setup, as described in U.S. Patent Publication No. 2017 / 0156799, which is hereby incorporated by reference. The homing process can be used to place the actuators 21, 22, 23 and the joints in their center positions, and then determine the absolute offset of the incremental encoder. By determining the offset of the incremental encoder, the incremental encoder can be performed as an absolute encoder for advancement.

[0202] In some examples, when the home position is used, the homing process establishes the initial rotor position (zero position) of the actuator 21, 22, 23. The home position is actually the position of the rotor 148 that provides the maximum possible travel in each direction along the active axis AA1, AA2, AA3. In some examples, the home position is generally positioned so that the home point HP of the lead screw 150, which is centered in the middle of the stop 152, is centered in the associated bracket 116 (see Fig.12, which shows two actuators 22, 23 in their home positions). Even when a homing procedure is not used, for example with an absolute encoder, it may also include placing the actuators 21, 22, 23 at the home point HP before or after executing other modes (e.g., approach mode, described further below). The instrument controller 28 may be configured to control the actuators 21, 22, 23 to their home positions between the minimum and maximum values ​​of the effective length EL of the actuators 21, 22, 23.

[0203] When in the home position, the adjustable amount of the actuators 21, 22, 23 is maximized to maintain the tool 20 in the desired posture. Depending on the specific geometry and configuration of the instrument 14, various degrees of adjustment are possible. In some examples, when all actuators 21, 22, 23 are in their home positions, the tool 20 can be adjusted in a pitch orientation of about + / -18° relative to the home position, assuming that the change in the roll orientation is zero and there is no z-axis translation. In some examples, when all actuators 21, 22, 23 are in their home positions, the tool 20 can be adjusted in a roll orientation of about + / -33° relative to the home position, assuming that the change in the pitch orientation is zero and there is no z-axis translation. In some examples, when all actuators 21, 22, 23 are in their home positions, the tool 20 may be adjusted in a z-axis translation of approximately + / - 0.37 inches from the home position, assuming zero changes in pitch and roll orientations. Of course, the tool 20 may be adjusted in pitch orientation, roll orientation, and z-axis translation simultaneously, sequentially, or in combination thereof during operation.

[0204] In some examples, when one or more of the actuators 21, 22, 23 have reached their limits, the instrument controller 28 may require adjustment of the hand-held portion 16 to return the tool 20 to a range in which the actuators can adjust the tool 20 toward the desired pose. In this case, a simulated command position may be used to indicate to the user how to move the hand-held portion 16 to return the tool 20 and the actuators 21, 22, 23 to alignment with the desired pose. The simulated command position may be a position determined by the instrument controller 28 in conjunction with navigation data from the navigation system 32, where the hand-held portion 16 must be moved to adjust the tool 20 toward the desired pose without adjusting the actuators 21, 22, 23. The simulated command position works in conjunction with one or more displays 38 to signal to the user that the hand-held portion 16 needs to be moved in a particular manner to place the tool 20 in the desired pose. In some examples, guidance array 500 signals the user to move handheld portion 16 in the same manner as actuators 21, 22, 23 are adjusting tool 20, but relies on the user to correct the posture of tool 20 by manipulating handheld portion 16 while the actuators remain in place.

[0205] The second software module performs motion control 188. One aspect of motion control 188 is to control the instrument 14. Motion control 188 receives data defining a next command pose from behavior control 186. Based on this data, motion control 188 determines (e.g., via inverse kinematics) the next rotor position of the rotor 148 of each actuator 21, 22, 23 so that the instrument 14 can position the tool 20 according to the command of behavior control 186, such as positioning it in the command pose. In other words, motion control 188 processes the command pose, which can be defined in Cartesian space, into the actuator position (e.g., rotor position) of the instrument 14 so that the instrument controller 28 can accordingly command the motor 142 to move the actuator 21, 22, 23 of the instrument 14 to the command position, such as the command rotor position corresponding to the command pose of the tool 20. In one version, motion control 188 regulates the rotor position of each motor 142 and continuously regulates the torque output by each motor 142 as closely as possible to ensure that motor 142 drives the associated actuator 21 , 22 , 23 to the commanded rotor position.

[0206] In some versions, for each actuator 21, 22, 23, the instrument controller 28 determines the difference between the measured position and the command position of the rotor 148. The instrument controller 28 outputs a target current (proportional to the torque of the rotor), thereby changing the voltage to adjust the current at the actuator from the initial current to the target current. The target current enables the movement of the actuator 21, 22, 23, thereby moving the tool 20 from the measured posture to the command posture. This can occur after the command posture is converted into a joint position. In one example, the measured position of each rotor 148 can be derived from the above-mentioned sensor S (e.g., an encoder).

[0207] The boundary generator 182, the behavior control 186, and the motion control 188 can be a subset of software programs. Alternatively, each software program can be a software program that operates separately and / or independently in any combination thereof. The term "software program" is used herein to describe computer executable instructions that are configured to perform a variety of capabilities of the described technical solutions. For simplicity, the term "software program" is intended to cover at least any one or more of the boundary generator 182, the behavior control 186, and / or the motion control 188. The software program can be implemented on the instrument controller 28, the navigation controller 36, or any combination thereof, or can be implemented by the control system 60 in any applicable manner.

[0208] A clinical application 190 may be provided to handle user interactions. The clinical application 190 handles many aspects of user interaction and coordinates the surgical workflow, including preoperative planning, implant placement, registration, visualization of bone preparation, and postoperative assessment of implant fit, among others. The clinical application 190 is configured for output to the display 38. The clinical application 190 may run on its own separate processor, or may run in conjunction with the instrument controller 28 and / or navigation controller 36. In one example, after implant placement is set by the user, the clinical application 190 interacts with the boundary generator 182, and then sends the virtual boundary 184 returned by the boundary generator 182 to the instrument controller 28 for execution.

[0209] When the actuators 21, 22, 23 are in their home positions or other predetermined positions, the initial position of the base coordinate system BCS can be determined based on the known geometric relationship between the tool support coordinate system TCS and the base coordinate system BCS. When the actuators 21, 22, 23 are adjusted, the relationship changes, and the associated changes can be determined based on the kinematics of the robot system 10 (for example, it establishes a dynamic transformation between these coordinate systems). As an alternative or in addition, another tracker can be attached and fixed with respect to the base coordinate system BCS to directly track the posture of the base coordinate system BCS relative to the tool support coordinate system TCS. Therefore, the robot system 10 knows the position of the tool 20 (for example, in the home position) and its relationship with the posture of the handheld part 16. Therefore, when the user moves the tool 20 and tracks its posture using the tool tracker 52, the robot system 10 also tracks the posture of the handheld part 16 and its base coordinate system BCS. In some examples, the position of the tool 20 relative to the tool support 18 is assumed to be known due to a previous calibration process.

[0210] In some versions, the home position is determined by first determining the pose of the handheld portion 16 (e.g., base coordinate system BCS) in a common coordinate system relative to the tool support 18 (e.g., relative to the tool support coordinate system TCS) using a separate tracker fixed to the handheld portion 16. This spatial relationship between the handheld portion 16 and the tool support 18 can also be determined by using the registration of the indicator 57 and the known calibration pits on the handheld portion 16 or via other navigation methods. The current rotor position of each actuator 21, 22, 23 can then be derived from this spatial relationship based on the kinematics of the instrument 14. After knowing the current rotor position and measuring the change relative to the current rotor position using the encoder (and corresponding encoder signal), the instrument controller 28 can then operate each actuator 21, 22, 23 until they reach their home position. The home position can be stored in the memory of the instrument controller 28.

[0211] Essentially, the instrument controller 28 determines the position of the actuators 21, 22, 23 using tracking data obtained by the navigation system 32 from a tracker 52 coupled to the tool support 18 and the hand portion 16 of the instrument 14 so that the incremental encoders can then operate as absolute encoders.

[0212] The command packets are sent, for example, to the motor controllers, such as from the console 33 or another component of the instrument controller 28. These command packets include the target position of the rotor 148 of the motor 142 (or the target position of the actuator). Here, each target position can be a positive or negative number representing a target cumulative count for the associated rotor 148. The console 33 or other component of the instrument controller 28 generates these command packets and sends them to each motor controller at a rate of one packet every 0.05 to 4 milliseconds. In some examples, each motor controller receives a command packet at least once every 0.125 milliseconds.

[0213] During use, when the robotic system 10 determines the pose (current pose) of the tool 20 using the navigation system 32 with the aid of the tracker 52 located on the tool support 18, the instrument controller 28 can also determine the current position of each actuator 21, 22, 23 based on the output encoder signals from one or more encoders located on each actuator 21, 22, 23. Once the current position of each of the actuators 21, 22, 23 is received, the instrument controller 28 can calculate the current pose of the handheld portion 16 (e.g., the current pose of the base coordinate system BCS relative to the desired coordinate system (e.g., the TCP coordinate system (TCP relative to BCS) converted from the actuator position to the pose using forward kinematics)). Once the instrument controller 28 has the current relative pose of the tool support 18 and the hand-held portion 16 in the desired coordinate system, the instrument controller 28 can then determine the command pose of the tool 20 based on the current pose of the tool 20 determined by the navigation system 32, the current pose of the hand-held portion 16 calculated by the current position of each actuator 21, 22, 23, and the position and / or orientation of the subject, the planned virtual object as the desired cutting plane. The instrument calculates the pose (command pose) of the TCP relative to the BCS, which causes the TCP to be located on the desired plane or aligned with the planned virtual object. The instrument controller 28 can send command instructions to the actuators 21, 22, 23 to move to the command position, thereby changing the pose of the tool support 18 and the tool 20. In one example, the command pose of the tool 20 is also based on the target cutting plane, so the instrument controller 28 calculates the current pose of the tool support 18 and the current position of the actuators 21, 22, 23 in order to determine the current pose of the hand-held portion 16. Once the current pose of the tool support 18, the current positions of the actuators 21, 22, 23, and the current pose of the hand-held portion 16 are known, the instrument controller 28 can send command signals to the actuators 21, 22, 23 to adjust the tool support 18 and the tool 20 based on the desired plane. The controller calculates the command pose under the assumption (during a single iteration) that the pose of the hand-held portion (BCS) relative to the patient's anatomy is temporarily stationary. The actual movement of the BCS is adjusted by each update of the corresponding pose.

[0214] Go to Fig.11 , an exemplary control is described in conjunction with a variety of transformations. The TCP is determined by using a tracker 52 in the LCLZ to track the tool 20 (LCLZ-TT) and using the registration data to determine the transformation (TT-TCP) between the tool tracker 52 and the TCP of the tool 20 (e.g., a saw). Similarly, the patient is tracked using a patient tracker PT (shown as 54) (LCLZ-PT) in the LCLZ. The transformation (PT-TP) between the patient tracker PT and each planned virtual object 184 (TP) is determined using the registration data and planning information. As described above, the transformation (BCS-TCP) between the BCS and the TCP is calculated based on the current position of each actuator (described above). The transformation between the BCS and the CP is used to associate a variety of coordinate systems back to the handheld portion 16, because the command posture can be determined relative to the BCS. Conceptually, the command posture is an update to the BCS to TCP transformation, which causes the TCP to be aligned with the planned virtual object 184 (target plane TP) in this example.

[0215] It should be understood that the phrase "TCP of the instrument" has been used interchangeably with the phrase 'position of the saw blade'. Thus, in any case where the TCP of an instrument / tool ​​is used, it may be replaced with the position of the saw blade, and vice versa. Of course, it is also contemplated that, alternatively, the position of the 'saw blade' may be the position of a tool (e.g., a drill, a drill bit, a guide tube, a screwdriver, a tap, a pin, etc.) having any suitable configuration.

[0216] Throughout the specification, unless otherwise specified, any example of a pose may be a command pose, a current pose, a past pose, or a past command pose. Although each of these poses may be different from each other, due to the control frequency, the difference in position and / or orientation between these poses may be minimal in each control iteration.

[0217] It should be understood that the combination of the position and orientation of an object is referred to as the pose of the object. Throughout this disclosure, it is contemplated that the term pose may be replaced by position and / or orientation, and vice versa, to achieve applicable alternatives to the concepts described herein. In other words, any use of the term pose may be replaced by position, and any use of the term position may be replaced by pose.

[0218] operate

[0219] During operation, the robotic system 10 is initially powered on and a software application for operating the system is started. The trackers 52, 54, 56, PT are initialized and placed on the instrument 14 and the target anatomical structure (e.g., femur F and tibia T). With the trackers 54, 56 mounted to the anatomical structure, the anatomical structure and / or associated image / model is registered to the trackers 54, 56 using known registration techniques. This may require the user to touch certain surfaces or landmarks on the anatomical structure with the indicator 57. For example, this may require the user to touch several points on the surface of the anatomical structure while pressing a selection button on the indicator 57 or pressing a foot switch of the navigation system 32. This "maps" points on the surface in the navigation system 32 for matching with the preoperative and / or intraoperative images / models of the anatomical structure. The preoperative images and / or intraoperative images / models of the anatomical structure are loaded into the navigation system 32. The tracked portion of the anatomical structure is registered to the preoperative / intraoperative images / models. This thereby allows the robotic system 10 to present a graphical representation of the actual position and orientation of the anatomical structure on the display 38 as the anatomical structure is moved.

[0220] During the calibration / registration process, the orientation and position of the tracker 52 is calibrated / registered relative to the tool support 18 by referencing the fixed and known position of the calibration dimple CD or other reference point. In some examples, one or more trackers 52 may be positioned on the tool support 18, the handheld portion 16, or both, such that the position of the tool support 18 and / or the handheld portion 16 is tracked by the navigation system 32. In examples where the tracker 52 is integrated into the instrument 14, such calibration would not be necessary because the relative position of the tracker 52 relative to the tool support 18 is known.

[0221] Also defined / obtained are virtual objects (e.g., virtual boundaries 184) for controlling the operation of the instrument 14. Software (e.g., boundary generator 182) running on the instrument controller 28 generates / obtains the initial definition of the virtual objects. The user may have the ability and option to adjust the properties / placement of the virtual objects as desired.

[0222] In an exemplary configuration, the control system 60 defines a plurality of regions at a predetermined distance and / or position from the target site and / or anatomical structure. Each of these regions can be defined in a coordinate system associated with the anatomical structure and / or virtual boundary 184. In some cases, these regions are defined as spheres or other geometric primitives surrounding the target site and / or anatomical structure. In other examples, these regions (and other regions described below) can be defined with respect to the instrument 14, the tool support 18, the handheld portion 16, the tool 20, the target site / anatomical structure, or a combination thereof. When the region defined by the handheld portion 16, the tool support 18, the tool 20, the target site / anatomical structure, or a combination thereof approaches a specific virtual boundary / virtual cutting guide feature, the control system 60 can control the instrument 14.

[0223] Specifically, the instrument controller 28 generates a set of target rotor positions to which the rotor 148 integrated into the motor 142 must rotate to maintain the tool 20 in the desired posture. In other words, if the user moves the handheld portion 16 in a manner that causes the tool 20 to move away from its desired posture, this is sensed by the navigation system 32. In response to this movement, the instrument controller 28 determines the distance that the tool 20 has moved away from the desired posture based on data from the navigation system 32, and compensates for this movement by driving the actuators 21, 22, 23 as needed to return the tool 20 to the desired posture. It should be understood that such deviations from the desired posture will generally be small because the instrument controller 28 will operate at a high frequency (e.g., a frame rate) to continuously account for such deviations in substantially real time.

[0224] The target rotor positions are determined based on the relationship between the actuation of the actuators 21, 22, 23 and the resulting movement (e.g., kinematics). For example, if the desired posture requires a z-axis translation relative to the handheld portion 16, there is a first-order relationship between the extent to which the tool 20 will move along the z-axis and the amount of rotation of each rotor 148 (e.g., how many counts are associated with such a z-axis movement). There is also a relationship between the extent to which the tool 20 will change its pitch orientation in response to actuation of the third actuator 23 alone or in combination with actuation of one or both of the first actuator 21 and the second actuator 22. Finally, there is a relationship between the extent to which the tool 20 will change its roll orientation in response to actuation of one or both of the first actuator 21 and the second actuator 22 with or without actuation of the third actuator 23. Based on these relationships, the instrument controller 28 determines the target rotor positions of each rotor 148 required to maintain the desired posture of the tool 20. The instrument controller 28 operates the motor 142 based on these target rotor positions. For example, the console 33 may transmit a data packet including these target rotor positions to the motor controllers, and each motor controller may apply appropriate excitation signals to the associated motor 142. These excitation signals cause rotation of the rotor 148, which results in repositioning of the lead screw 150, which displaces the tool support 18 / tool ​​20 as needed to maintain the tool 20 in the desired posture.

[0225] As previously described, when the user arranges the handheld portion 16 guided by the alignment members 502, 504 toward the desired plane, the actuators 21, 22, 23 are maintained in the original position or other predetermined position. By maintaining the actuators 21, 22, 23 in their original positions or other predetermined positions, the user may find it easier to adjust the tool 20 relative to the target and align it with the desired plane and the instrument posture. However, when the tool is in the desired posture, the visual guide is intended to guide the user how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, 23 near their original positions or other predetermined positions. For example, the user may need to move the handheld portion 16 upward along the z-axis direction to move all the actuators 21, 22, 23 closer to their original positions while maintaining the tool 20 in the desired posture. In other words, the actuators 21, 22, 23 can be almost fully extended. To achieve this, the direction indication from the guide array 500 is upward. In this case, the guide array 500 is actually guiding the user to move the handheld portion 16 upward so that the actuators 21, 22, 23 operate toward their original positions to maximize the adjustability of the actuators 21, 22, 23. As the user moves the handheld portion 16 upward, the actuators 21, 22, 23 continue to operate to keep the tool 20 in a desired posture (e.g., on the virtual boundary 184). As a result, the actuators 21, 22, 23 retract, such as retracting toward their original positions. Ideally, when the user begins cutting the bone, each actuator 21, 22, 23 can reach the maximum amount of travel in either direction. Otherwise, if one or more of the actuators 21, 22, 23 have almost reached their available travel in either direction, even a slight movement of the handheld portion 16 may cause the instrument controller 28 to be unable to keep the tool 20 in the desired posture, and inaccurate cutting may be performed.

[0226] Additionally and / or alternatively, in some versions, tool 20 may be moved to a desired pose, and the user may then adjust hand-held portion 16 to a more comfortable position within the threshold of the available travel of actuators 21, 22, 23 to perform a cut while maintaining tool 20 in its desired position. The user may then elect to move to a freehand mode by activating an input device (e.g., a button and / or foot switch) or selecting on a touch screen, wherein the pose of hand-held portion 16 relative to the pose of tool 20 is maintained or frozen in its current spatial relationship. It is contemplated that the maintained pose of hand-held portion 16 relative to the pose of tool 20 changes the virtual threshold of actuators 21, 22, 23, thereby constraining actuator movement to maintain the maintained pose once the user has selected an operating mode.

[0227] Visual guidance

[0228] like Figure 12-28As shown, the instrument 14 also includes a guide array 500. The guide array 500 provides a visual indication to the operator of the attitude of the saw blade support 18 relative to the handheld portion 16 during operation of the instrument 14. Therefore, the guide array 500 provides a visual indication to the operator of the required changes in the pitch orientation, roll orientation, and z-axis translation of the handheld portion 16 to achieve the desired attitude of the tool 20 while providing maximum adjustability for the plurality of actuators 21, 22, 23 to maintain the tool 20 on the target plane TP. The guide array 500 includes a tool alignment member 502 coupled to the saw blade support 18 and a handle alignment member 504 coupled to the handheld portion 16 for guiding the user how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, 23 near their original positions or other predetermined positions. In some configurations, when the actuators 21, 22, 23 are in their respective home positions, at least a portion of the tool alignment member 502 and at least a portion of the handle alignment member 504 may be aligned. Figure 12-17 In the illustrated configuration, the top surface 503 of the tool alignment member 502 is aligned with the top surface 505 of the handle alignment member 504 when the actuators 21 , 22, 23 are in their respective home positions.

[0229] In some configurations, the term "aligned" is defined as at least a portion of the tool alignment member 502 being substantially coplanar with at least a portion of the handle alignment member 504 or intersecting within an applicable tolerance. For example, when at least a portion of the tool alignment member 502 is aligned with at least a portion of the handle alignment member 504, the tool alignment member 502 and the handle alignment member 504 provide a visual indication to the operator of the instrument 14 that the saw blade support 18 has a desired range of motion relative to the handheld portion 16. Specifically, when in the home position, the adjustable amount of the actuators 21, 22, 23 is maximized to maintain the tool 20 in a desired posture. In some examples, the alignment between the tool alignment member and the handle alignment member can be aligned 99% or more, aligned 90% or more, aligned 70% or more, or even aligned 60% or more. In other examples, the applicable alignment can be within a specified proximity of the target posture on each individual degree of freedom, such as within a range of 1% deviation from the target posture, 5% deviation from the target posture, 10% deviation from the target posture, or even 20% or more deviation from the target posture. Likewise, suitable alignment may be within 1 mm of the target attitude, within 2 mm of the target attitude, or even within 5 mm or more of the target attitude in each individual degree of freedom. Additionally, suitable alignment may be within 1 degree or more of the target attitude, within 5 degrees or more of the target attitude, within 15 degrees or more of the target attitude, or even within 30 degrees or more of the target attitude in roll and / or pitch.

[0230] In one configuration, reference Figure 12-28 The tool alignment member 502 may be a member extending away from the saw blade support 18. For example, the tool alignment member 502 may include a tool alignment portion 510 that defines a tool alignment plane 512 (eg, parallel to or even coplanar with the saw blade plane BP) that is parallel to or coplanar with the saw blade plane BP. Fig.17 ) and provide a visual indication of the attitude of the saw blade plane BP to the operator of the instrument 14. The terms tool plane and saw blade plane BP may be used interchangeably. The tool alignment member 502 may have any shape or structure capable of providing a visual indication of the attitude of the saw blade plane BP relative to the handle alignment member 504. In one example, as Figure 12-28As shown, the tool alignment portion 510 of the tool alignment member 502 can define a "U" shape. In this example, the tool alignment portion 510 defines an elongated body and two protrusions that allow the tool alignment portion to wrap around the handle alignment portion 524 when the tool alignment member 502 and the handle alignment member 504 are aligned when the actuators 21, 22, 23 are in their respective home positions. Each portion of the tool alignment portion 510 can be generally planar, having a length, width, and height that define a three-dimensional shape that is used to provide a visual indication of alignment and misalignment with the handle alignment member. The "U" shaped profile of the tool alignment member 502 can allow an operator to view the attitude of the handle alignment portion relative to the elongated member and the protrusions, thereby further helping to provide a visual indication of the attitude of the saw blade support 18 relative to the handheld portion 16.

[0231] refer to Fig.15 and Fig.16 For example, the tool alignment member 502 may also include a mounting portion 506 configured to be mounted to the saw blade support 18. The mounting portion 506 may be mounted to the saw blade support 18 at any suitable location using any suitable means (e.g., fasteners, magnets, adhesives, etc.) to facilitate the function of the tool alignment member 502 (discussed in further detail below). The tool alignment member 502 may also include a support portion 508. The support portion 508 may extend from the mounting portion 506 to support the tool alignment portion 510. In some examples, the tool alignment member 502 may be rigid relative to the saw blade support 18 to facilitate the function of the tool alignment member 502. The tool alignment member 502 may be formed of any suitable material (e.g., plastic, aluminum, steel, composite materials, etc., or combinations thereof). In addition, the tool alignment member may be formed using any suitable production method (including 3D printing, casting, machining, injection molding, stamping, etc., or combinations thereof). It is contemplated that the tool alignment portion 510 is formed into other shapes (described in further detail below). In other configurations, the tool alignment member 502 may be the tool 20 itself. For example, when the actuators 21, 22, 23 are in their respective home positions, the tool 20 and the handle alignment member 504 may be aligned.

[0232] In one example, for example Figure 12-28 As shown, the handle alignment member 504 can extend from the handheld portion 16. The handle alignment member 504 can include a handle alignment plane 526 (shown in FIG. Fig.17The handle alignment member 504 includes a handle alignment portion 524 that provides a visual indication to the operator of the instrument 14 of the posture of the handheld portion 16. It is noteworthy that when the actuators 21, 22, 23 are in their respective original positions, the handle alignment plane 526 is aligned with the tool alignment plane 512. The handle alignment member 504 can have any suitable shape or configuration that will provide a visual indication to the user that one or more of the actuators 21, 22, 23 have been moved away from their respective original positions. In some examples, for example Figure 12-28 As shown, the handle alignment portion 524 of the handle alignment member 504 defines a planar rectangular member having a length, height, and width that define a three-dimensional shape. The relative shape and size of the handle alignment member 504 provides a visual indication when the actuators 21, 22, 23 are moved away from their respective original positions by exposing specific features of the handle alignment member relative to the tool alignment member 502.

[0233] See also Fig.15 and Fig.16 , the handle alignment member 504 may also include a mounting clamp 516, which includes a first portion 518 and a second portion 520. Together, the first portion 518 and the second portion 520 are configured to be coupled to each other to form the mounting clamp 516 and to mount the handle alignment member 504 to the grip 72 of the handheld portion 16. The first portion 518 and the second portion 520 may be coupled using any applicable means. In some examples, fasteners such as screws, bolts, clamps, or combinations thereof may be used. The mounting clamp 516 may be mounted to the handheld portion 16 at any applicable location to facilitate the functionality of the handle alignment member 504 (discussed in further detail below). In addition, as Fig.16 As best shown in , the handle alignment member 504 can be removably coupled to the mounting clip 516 of the handheld portion 16. For example, the handle alignment member 504 can be magnetically coupled to the handheld portion 16 so that the handle alignment member 504 can be separated as needed or in the event that the operator's hand is clamped between the tool alignment member 502 and the handle alignment member 504. Any suitable means of removably coupling the handle alignment member 504 to the handheld portion is contemplated (e.g., magnets, latches, clamps, fasteners, shackles, the like, and combinations thereof).

[0234] The handle alignment member 504 may also include a support arm 522. The support arm 522 may extend from the mounting clamp 516 to support the handle alignment portion 524. Figure 12-17As best shown in FIG. 5 , support arm 522 extends upward from grip 72 of hand-held portion 16 so that when actuators 21, 22, 23 are in their respective home positions, handle alignment portion 524 of handle alignment member 504 is aligned with tool alignment portion 510 of tool alignment member 502. In some examples, handle alignment member 504 is rigid relative to hand-held portion 16 to facilitate the function of handle alignment member 504. Handle alignment member 504 can be formed of any suitable material (e.g., plastic, aluminum, steel, composite material, etc., or a combination thereof). In addition, handle alignment member 504 can be formed using any suitable production method (which includes 3D printing, casting, machining, injection molding, stamping, etc., or a combination thereof).

[0235] In some configurations, the guide array 500 may include two or more tool alignment members and two or more handle alignment members. In some examples, the guide array 500 may include a first tool alignment member 502 and a second tool alignment member 528. Likewise, in some examples, the guide array 500 may include a first handle alignment member 504 and a second handle alignment member 530. It is contemplated that in some examples, there may be four or more, or six or more, or even more tool alignment members and handle alignment members, respectively. For example, referring to Figure 12-28 In some configurations, the first alignment members 502, 504 and the second alignment members 528, 530 extend from opposite sides of the handheld portion 16 so as to be arranged in a mirror image of each other. Fig.17 As shown, when the actuators 21, 22, 23 are in their respective home positions, the first tool alignment member 502 and the first handle alignment member 504 and the second tool alignment member 528 and the second handle alignment member 530 are aligned with each other, respectively, thereby providing a visual indication that the saw blade support 18 has a desired range of motion relative to the handheld portion 16. It is worth noting that the alignment members 502, 504, 528, 530 can have any suitable shape to provide an indication of the alignment of the tool alignment members 502, 528 with the handle alignment members 504, 530, respectively. For example, the alignment members 502, 504, 528, 530 can be generally planar, prismatic, define a protrusion that facilitates visual indication (e.g., define an "X-shaped" cross-section, define an "L-shaped" cross-section), cylindrical, spherical, etc., or a combination thereof.

[0236] Additionally, the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 (which may be collectively referred to as the guide array 500) are arranged about the saw blade support 18 and the handheld portion 16 such that the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 are visible from the proximal end 560 of the saw blade support 18 throughout the range of motion of the saw blade support 18 relative to the handheld portion 16. In other words, the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 are configured to be visible to an operator holding the instrument 14 such that the operator can see the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 throughout the range of motion of the saw blade support 18 relative to the handheld portion 16. Furthermore, the guide array 500 may be arranged such that the guide array 500 provides a visual indication of the posture of the saw blade support 18 relative to the handheld portion 16 in all cutting postures of the instrument 14 (eg, during a distal femoral cut or a posterior chamfer cut).

[0237] During operation of the instrument 14, the target plane TP of the instrument 14, at least one of the tool alignment members 502, 528, and at least one of the handle alignment members 504, 530 can be arranged so that when the tool 20 is located on the target plane TP and the actuators 21, 22, 23 are in their respective home positions, they are aligned in a first spatial relationship. Fig.17 As shown in the configuration shown, for example, when the tool alignment plane 512, the handle alignment plane 526 are coplanar with the target plane TP, the target plane TP, the tool alignment members 502, 528 and the handle alignment members 504, 530 are arranged in a first spatial relationship. Fig.17 , when the tool alignment members 502, 528 and the handle alignment members 504, 530 are arranged in the first spatial relationship, the "U"-shaped tool alignment portion 510 surrounds the rectangular handle alignment portion 524, and the top surface 503 of the tool alignment portion 510 is coplanar with the top surface 505 of the handle alignment member portion 524, thereby indicating that the actuators 21, 22, 23 are in their respective home positions. The first spatial relationship provides a visual indication that the tool 20 is aligned with the target plane TP and the actuators 21, 22, 23 are in their respective home positions, so that the actuators 21, 22, 23 have a maximum adjustable amount to maintain the tool 20 in a desired posture, thereby providing the handheld surgical robot system with maximum adjustment of pitch, roll, and z-axis translation (i.e., lift) to maintain the tool 20 on the target plane TP.

[0238] Notably, to facilitate visual indication throughout the range of motion of the actuators 21, 22, 23, the tool alignment members 502, 528 and the handle alignment members 504, 530 are arranged and dimensioned relative to one another such that the tool alignment members 502, 528 and the handle alignment members 504, 530 do not collide at any position between the first position and the second position of each of the plurality of actuators 21, 22, 23. The first position and the second position of each of the plurality of actuators 21, 22, 23 together define a potential range of motion of the saw blade support 18 relative to the handheld portion 16. The potential range of motion may define a space within which the saw blade support 18 may be moved relative to the handheld portion 16. For example, Fig.52 and Fig.53 Possible positions of the blade supports 18 relative to the handheld portion are shown overlapping each other. In one configuration, for example, the blade support 18 can move relative to the handheld portion 16 within a space having a height of about 150 mm and a width of about 115 mm. It is contemplated that the height and width of the space can vary based on the geometry of the instrument 14 and the limits of the actuators 21, 22, 23.

[0239] Furthermore, during operation of the instrument 14, at least one of the tool alignment members 502, 528 and at least one of the handle alignment members 504, 530 may be arranged so that when the saw blade support 18 is in a posture relative to the handheld portion 16 that does not provide a desired range of motion (in the Figure 18-28 14 ), they are respectively misaligned with each other to form a second spatial relationship. The second spatial relationship provides a visual indication that the saw blade support 18 is in a posture relative to the hand-held portion 16 that does not provide the desired range of motion for the device 14, and therefore indicates that the operator must adjust the posture of the hand-held portion 16 so that the tool alignment members 502, 528 and the handle alignment members 504, 530 are aligned to form the first spatial relationship in order to provide maximum adjustability for the device 14. It is worth noting that the addition of the second tool alignment member 528 and the second handle alignment member 530 is used to further help provide a visual indication of the posture of the saw blade support 18 relative to the hand-held portion 16.

[0240] There are a variety of situations in which the tool alignment members 502, 528 may be misaligned with the handle alignment members 504, 530 to be in a second spatial relationship. For example, the saw blade support 18 may be pitched relative to the handheld portion 16 about the transverse axis 558 (shown in FIG. Figure 18-21 ), the saw blade support 18 can be tilted relative to the handheld portion 16 about the longitudinal axis 552 (shown in Figure 22-24 ), and / or the saw blade support 18 can be displaced (ie, lifted) relative to the handheld portion 16 along the vertical axis 554 (shown in Figure 25-28). It should be understood that other misalignments caused by movement of the blade support 18 relative to the hand portion 16 in other degrees of freedom are contemplated. It should also be understood that combinations of the above-described misalignments may occur simultaneously. For example, the blade support 18 may be simultaneously pitched and rolled relative to the hand portion 16. When the tool alignment member 502 is misaligned with the handle alignment member 504, the resulting second spatial relationship provides a visual indication of the attitude of the blade support 18 relative to the hand portion 16, even if the misalignment occurs in multiple degrees of freedom.

[0241] In some configurations, the first spatial relationship may provide a visual indication that the blade support 18 is aligned with the handheld portion 16 in the pitch degree of freedom about the transverse axis 558. However, as described above, the plurality of actuators 21, 22, 23 may be configured to at least adjust the pitch of the blade support 18 relative to the handheld portion 16 to maintain the tool 20 in the target plane TP. For example, Figure 18-21 The saw blade support 18 is shown pitched relative to the hand-held portion 16 by an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the saw blade support 18 is pitched relative to the hand-held portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, at least one of the tool alignment members 502, 528 may be misaligned with at least one of the handle alignment members 504, 530, respectively, to be in a second spatial arrangement. The second spatial arrangement may include a pitch relationship. The pitch relationship may provide a visual indication of the magnitude of the pitch of the saw blade support 18 relative to the hand-held portion 16 about the transverse axis.

[0242] For example, Figure 18-21 As shown, the tool alignment member 502 and the handle alignment member 504 may be arranged in a pitch relationship when the distal portion 542 of the handle alignment member 504 is further away from the saw blade plane BP (shown as a distance D1) than the proximal portion 544 of the handle alignment member 504 (shown as a distance D2) in the pitch direction along the longitudinal axis 552 of the handle alignment member 504. In addition, for example, as Fig.21As best shown, when the second tool alignment member 528 is pitched relative to the second handle alignment member 530 so that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the longitudinal distal portion 542 of the second handle alignment member 530 is further away from the saw blade plane BP (shown as a distance D3) in the pitch direction along the longitudinal axis 552 of the second handle alignment member 530 than the longitudinal proximal portion 544 of the second handle alignment member 530 (shown as a distance D4). In other words, when the saw blade support 18 is pitched relative to the hand-held portion 16 so that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one end of the handle alignment member 504, 528 is further away from the saw blade plane BP in the moving direction along the longitudinal axis of the tool 20 than the other end. Thus, the arrangement of the alignment members 502, 504, 528, 530 in a pitch relationship can provide a visual indication that the saw blade support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the posture of the handheld portion 16 so that the tool alignment members 502, 528 and the handle alignment members 504, 530 are aligned to be in a first spatial relationship, thereby providing maximum adjustability for the instrument 14.

[0243] In other configurations, the first spatial relationship may provide a visual indication that the blade support 18 is aligned with the hand-held portion 16 in the roll degree of freedom about the longitudinal axis 552. The plurality of actuators 21, 22, 23 may be configured to at least adjust the roll of the blade support 18 relative to the hand-held portion 16 to maintain the tool 20 in the target plane TP. For example, Figure 22-24 The saw blade support 18 is shown tilted relative to the hand-held portion 16 by an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the saw blade support 18 is tilted relative to the hand-held portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, at least one of the tool alignment members 502, 528 may be misaligned with the handle alignment members 504, 530, respectively, to be in a second spatial arrangement. The second spatial arrangement may include a tilted relationship. The tilted relationship may provide a visual indication of the magnitude of the tilt of the saw blade support 18 relative to the hand-held portion 16 about the longitudinal axis 552.

[0244] For example, Figure 22-24 As shown, the tool alignment member 502 and the handle alignment member 504 may be arranged in a tilted relationship when the distal portion 546 of the handle alignment member 504 is further away from the saw blade plane BP (shown as a distance D1) than the proximal portion 548 of the handle alignment member 504 (shown as a distance D2) in the tilt direction along the transverse axis 558 of the handle alignment member 504. In addition, for example, Fig.24The lateral distal portion 546 of the second handle alignment member 530 is shown as being further away from the saw blade plane BP (shown as a distance D3) along the lateral axis 558 in the roll direction than the lateral proximal portion 548 of the second handle alignment member 530 (shown as a distance D4). Fig.24 , the second spatial relationship formed by the first tool alignment member 502 and the first handle alignment member 504 in combination with the second spatial relationship formed by the second tool alignment member 528 and the second handle alignment member 530 can provide another visual indication of the posture of the saw blade support 18 relative to the handheld portion 16, compared to the use of only the first tool alignment member 502 and the first handle alignment member 504 in the second spatial relationship alone. Specifically, the first handle alignment member 504 and the second handle alignment member 530 can cumulatively define the handle alignment plane 526 (shown in Fig.24 ), the handle alignment plane 526 may be tilted relative to the tool alignment plane 512 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, thereby providing a visual indication of the attitude of the saw blade support 18 relative to the hand portion. Thus, another visual indication is provided to the operator that the saw blade support 18 does not have an optimal range of motion relative to the hand portion 16. In other words, when the saw blade support 18 is tilted relative to the hand portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment member 504, 528 will be displaced in the offset direction further away from the saw blade plane BP than the other side of the handle alignment member 504, 528. Thus, the arrangement of the alignment members 502, 504, 528, 530 in a tilted relationship can provide a visual indication that the saw blade support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the posture of the handheld portion 16 so that the tool alignment member 502 and the handle alignment member 504 are aligned to be in a first spatial relationship to provide maximum adjustability for the instrument 14.

[0245] In another configuration, the first spatial relationship can provide a visual indication of the absence of any vertical displacement (i.e., lift) of the blade support 18 relative to the handheld portion 16 about the vertical axis 554. The plurality of actuators 21, 22, 23 can be configured to at least adjust the lift of the blade support 18 relative to the handheld portion 16 to maintain the tool 20 at the target plane TP. For example, Figure 25-28The saw blade support 18 is shown to be lifted relative to the hand-held portion 16 by an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the saw blade support 18 is lifted relative to the hand-held portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, at least one of the tool alignment members 502, 528 may be misaligned with at least one of the handle alignment members 504, 530, respectively, to be in a second spatial arrangement. The second spatial arrangement may include a lifted relationship. The lifted relationship may provide a visual indication of the extent to which the saw blade support 18 has been lifted relative to the hand-held portion 16. For example, as Figure 25-28 As shown, when the tool alignment member 502 is displaced in the lifting direction to a position above and at a distance D1 from the handle alignment member 504, the tool alignment member 502 and the handle alignment member 504 can be arranged in a lifting relationship. In addition, for example, Fig.26 and Fig.28 The second handle alignment member 530 is shown displaced above and a distance D3 from the second tool alignment member 528. Thus, the arrangement of the alignment members 502, 504, 528, 530 in an elevated relationship can provide a visual indication that the blade support 18 does not have a desired range of motion relative to the handheld portion 16 and that the operator must adjust the posture of the handheld portion 16 so that the tool alignment members 502, 528 and the handle alignment members 504, 530 are aligned in a first spatial relationship to provide maximum adjustability for the instrument 14.

[0246] In view of the above description, it should be appreciated that the guide array 500 provides a number of benefits to the operation of the instrument 14. For example, the guide array 500 reduces the magnitude of the focus shift required for the operator to determine the attitude of the saw blade support 18 relative to the handheld portion 16. In other words, because the guide array 500 is arranged relative to the tool 20 so that the guide array 500 is substantially within the author's line of sight, the operator does not substantially have to shift his focus (e.g., turn his head) to receive a visual indication of the attitude of the saw blade support 18 relative to the handheld portion 16. At the same time, when the guide array 500 is substantially within the author's line of sight, the guide array 500 is arranged toward the proximal portion 560 of the tool support so that the user can view the guide array 500 and the distal tip of the tool 20 so that the user can focus on cutting and aligning at the same time. In other words, the guide array 500 is positioned at a particular distance from the distal tip of the tool 20 so that the user will have an unobstructed view to the surgical site and the tool 20. In addition, the guidance array 500 provides the operator with an easily discernible visual indication of the attitude of the saw blade support 18 relative to the handheld portion 16, thereby reducing the need for auxiliary components (e.g., auxiliary navigation displays) to provide visual indications. In addition, the guidance array 500 has minimal parallax. In addition, because the guidance array 500 provides visual indications primarily through mechanical structures, there is no lag problem in providing visual indications of operation compared to electronic guidance.

[0247] exist Figure 29-32 , another configuration of the guide array 600 is shown. In the illustrated configuration of the guide array 600, the tool alignment member 602 may include a tool alignment portion 610 defining a cylindrical shape. Similarly, the handle alignment member 604 may include a handle alignment portion 624 defining a cylindrical shape. Fig.32 As shown in the configuration shown in , for example, when the tool alignment portion 610, the handle alignment portion 624, and the target plane TP intersect, the target plane TP, the tool alignment member 602, and the handle alignment member 604 are arranged in a first spatial relationship, thereby providing a visual indication that the tool 20 is aligned with the target plane TP and the actuators 21, 22, 23 are in their respective original positions. In some configurations, the term "intersecting" is defined as at least a portion of the tool alignment member 602 and at least a portion of the handle alignment member 604 being substantially aligned within applicable tolerances when viewed from the proximal end 560 of the handheld surgical system 10 (as described above). Reference Fig.32, the tool alignment portion 610 and the handle alignment portion 624 may include indicia in the form of a first color 666 and a second color 668, respectively. The indicia 666 on the tool alignment portion 610 and the indicia 668 on the handle alignment portion 624 are used to provide a visual indication of the alignment of the saw blade support 18 with the handheld portion 16. For example, when the indicia 666, 668 are aligned so that the indicia 666, 668 are viewed by an operator from the proximal end 560 of the handheld instrument 14 (e.g., Fig.32 16 ), a visual indication is provided to the operator that the saw blade support 18 has a maximum adjustable range relative to the handheld portion 16. Notably, the markings 666, 668 each have a length that defines a tolerance for applicable overlap for which the saw blade support 18 will have an optimal range of motion relative to the handheld portion 16. The tool alignment member 602 and the handle alignment member 604 may be arranged such that they are misaligned to be in a second spatial relationship (as described above) when the saw blade support 18 is in a posture that does not provide a desired range of motion relative to the handheld portion 16. Additionally, as shown Fig.30 and Fig.31 As best shown in FIG. 1 , the handle alignment member 604 can be removably coupled to the handheld portion 16. For example, the handle alignment member 604 can be magnetically coupled to the handheld portion 16 so that the handle alignment member 604 can be separated as desired. However, any suitable means (e.g., latches, clips, fasteners, shackles, etc. and combinations thereof) for removably coupling the handle alignment member 604 to the handheld portion are contemplated.

[0248] It is noteworthy that the guide array 600 may include a second tool alignment member 628 and a second handle alignment member 630 to provide further indication of the attitude of the saw blade support 18 relative to the handheld portion 16. For example, if the saw blade support 18 is to be moved away from the handheld portion 16, the guide array 600 may include a second tool alignment member 628 and a second handle alignment member 630 to provide further indication of the attitude of the saw blade support 18 relative to the handheld portion 16. Fig.32If the handle alignment member 604, 628 is tilted in the direction of the illustrated configuration by an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment member 604, 628 will be displaced in the offset direction further away from the saw blade plane BP than the other side of the handle alignment member 604, 628. In other words, the mark 668 on the handle alignment portion 624 will be displaced in the offset direction away from the mark 666 on the tool alignment portion 610 so that the handle alignment portion 624 is misaligned with the tool alignment portion 610, thereby providing a visual indication that the saw blade support 18 does not have the desired range of motion relative to the handheld portion 16 and the operator must adjust the posture of the handheld portion 16 so that the tool alignment members 602, 628 and the handle alignment members 604, 630 are aligned in a first spatial relationship to provide maximum adjustability for the instrument 14. Similarly, the second tool alignment member 628 and the second handle alignment member 630 will provide further indication of the posture of the saw blade support 18 relative to the handheld portion 16 in the pitch and lift degrees of freedom.

[0249] Fig.33 and Fig.34 Yet another configuration of the guide array 600' is shown. In the illustrated configuration of the guide array 600', the tool alignment member 602' may include a tool alignment portion 610' defining a spherical shape. Similarly, the handle alignment member 604' may include a handle alignment portion 624' defining a spherical shape. In some configurations, for example Fig.34 As shown, the tool alignment portion 610' is arranged on the saw blade plane BP. Fig.34 As shown in the configuration shown in , for example, when the tool alignment portion 610', the handle alignment portion 624' and the target plane TP intersect, the target plane TP, the tool alignment member 602' and the handle alignment member 604' are arranged in a first spatial relationship, thereby providing a visual indication that the tool 20 is aligned with the target plane TP and the actuators 21, 22, 23 are in their respective original positions. Fig.34 , the tool alignment portion 610' and the handle alignment portion 624' can be sized so that an operator can easily discern that the guide array 600' is aligned when viewing the guide array 600' from the proximal end 560 of the instrument 14, thereby providing a visual indication of the optimal amount of travel for the saw blade support 18 relative to the handheld portion 16. In addition, the tool alignment member 602' and the handle alignment member 604' can be arranged so that they are aligned in a second spatial relationship (as described above) when the saw blade support 18 is in a posture that does not provide a desired range of motion relative to the handheld portion 16. Notably, the guide array 600' can include a second tool alignment member 628' and a second handle alignment member 630' to provide further indication of the posture of the saw blade support 18 relative to the handheld portion 16.

[0250] It is noteworthy that the guide array 600' may include a second tool alignment member 628' and a second handle alignment member 630' to provide further indication of the attitude of the saw blade support 18 relative to the handheld portion 16. For example, if the saw blade support 18 is moved away from the handheld portion 16 Fig.34 If the illustrated configuration is tilted an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment member 604', 628' will be displaced in the offset direction further away from the saw blade plane BP than the other side of the handle alignment member 604', 628'. In other words, the ball handle alignment portion 624' will be displaced in the offset direction away from the ball tool alignment portion 610', thereby misaligning the ball handle alignment portion 624' with the ball tool alignment portion 610', thereby providing a visual indication that the saw blade support 18 does not have the desired range of motion relative to the handheld portion 16 and the operator must adjust the posture of the handheld portion 16 so that the tool alignment members 602', 628' and the handle alignment members 604', 630' are aligned to be in a first spatial relationship to provide maximum adjustability for the instrument 14. Likewise, the second tool alignment member 628 ′ and the second handle alignment member 630 ′ will provide further indication of the attitude of the blade support 18 relative to the handheld portion 16 in the pitch and lift degrees of freedom.

[0251] Figure 35-37 Another example of a guide array 600" is shown. In the illustrated example of the guide array 600", the tool alignment member 602" includes a tool alignment portion 610", and the handle alignment member 604" includes a handle alignment portion 624". However, it is worth noting that Fig.36 As shown in the illustrated configuration, when the tool alignment member 602" and the handle alignment member 604" are arranged in a first spatial relationship, the tool alignment portion 610" and the handle alignment portion 624" can be offset relative to the saw blade plane BP so that the tool alignment member 602" and the handle alignment member 604" do not interfere with the line of sight of the surgical navigation system 32 to any tracking mark 584 (discussed below). For example, Fig.36 As shown, the tool alignment portion 610" and the handle alignment portion 624" are aligned along a plane defined between the saw blade plane BP and the grip 72 of the handheld portion 16. In other words, Figure 35-37In the illustrated configuration, when the tool alignment member 602" and the handle alignment member 604" are arranged in a first spatial relationship such that they are aligned (i.e., substantially parallel), the tool alignment portion 610" and the handle alignment portion 624" are not coplanar with the saw blade plane BP. However, when the tool alignment member 602" and the handle alignment member 604" are arranged in the first spatial relationship, the tool alignment portion 610" and the handle alignment portion 624" are parallel to the saw blade plane BP, thereby providing a visual indication that the tool 20 is aligned with the target plane TP and the actuators 21, 22, 23 are in their respective home positions. In addition, the tool alignment member 602" and the handle alignment member 604" may be arranged such that they are not aligned to be in a second spatial relationship (as described above) when the saw blade support 18 is in a posture that does not provide the desired range of motion relative to the handheld portion 16. Notably, the guide array 600" may include a second tool alignment member 628" and a second handle alignment member 630" to provide further indication of the posture of the saw blade support 18 relative to the handheld portion 16.

[0252] It is noteworthy that the guide array 600" may include a second tool alignment member 628" and a second handle alignment member 630" to provide further indication of the attitude of the saw blade support 18 relative to the handheld portion 16. For example, if the saw blade support 18 is moved away from the handheld portion 16 Fig.37 If the illustrated configuration is tilted an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment member 604", 628" will be displaced in the offset direction further away from the tool alignment plane 512 than the other side of the handle alignment member 604", 628". In other words, the handle alignment portion 624" will be displaced in the offset direction away from the tool alignment portion 610", thereby causing the handle alignment portion 624" to be misaligned with the tool alignment portion 610", thereby providing a visual indication that the saw blade support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the posture of the handheld portion 16 such that the tool alignment members 602", 628" and the handle alignment members 604", 630" are aligned to be in a first spatial relationship to provide maximum adjustability for the instrument 14. Similarly, the second tool alignment member 628" and the second handle alignment member 630" will provide further indication of the posture of the saw blade support 18 relative to the handheld portion 16 in the pitch and lift degrees of freedom.

[0253] Fig.38 and Fig.39Another configuration of the guide array 600"' is shown. In the illustrated configuration of the guide array 600"', the tool alignment member 602"' includes a tool alignment portion 610"', and the handle alignment member 604"' includes a handle alignment portion 624"'. However, it is worth noting that Figure 12-28 and Figure 35-37 Unlike the configuration shown, the tool alignment member 602'' is aligned with only one side of the handle alignment member 604'', while in Figure 12-28 and Figure 39-42 In the configuration of , the tool alignment member 502 is aligned with both the distal and proximal ends of the handle alignment member 504. Fig.39 As shown in the illustrated configuration, for example, when the tool alignment portion 610'", the handle alignment portion 624'" are aligned with the target plane TP, the target plane TP, the tool alignment member 602'" and the handle alignment member 604'" are arranged in a first spatial relationship, thereby providing a visual indication that the tool 20 is aligned with the target plane TP and the actuators 21, 22, 23 are in their respective original positions. Moreover, the tool alignment member 602'" and the handle alignment member 604'" may be arranged so that when the saw blade support 18 is in a posture that does not provide the desired range of motion relative to the handheld portion 16, they are not aligned to be in a second spatial relationship (as described above). It is worth noting that the guide array 600'" may include a second tool alignment member 628'" and a second handle alignment member 630'" to provide further indication of the posture of the saw blade support 18 relative to the handheld portion 16.

[0254] It is noteworthy that the guide array 600"' may include a second tool alignment member 628"' and a second handle alignment member 630"' to provide further indication of the attitude of the saw blade support 18 relative to the handheld portion 16. For example, if the saw blade support 18 is moved away from the handheld portion 16 Fig.39If the configuration shown is tilted a certain amount so that the multiple actuators 21, 22, and 23 no longer have maximum adjustability, one side of the handle alignment members 604', 628' will be displaced in the offset direction away from the saw blade plane BP than the other side of the handle alignment members 604', 628'. In other words, the handle alignment portion 624' will be displaced away from the tool alignment portion 610' in the offset direction, so that the handle alignment portion 624' is misaligned with the tool alignment portion 610' to provide a visual indication that the saw blade support 18 does not have the desired range of motion relative to the handheld portion 16 and the operator must adjust the posture of the handheld portion 16 so that the tool alignment members 602', 628' and the handle alignment members 604', 630' are aligned to be in a first spatial relationship to provide maximum adjustability for the instrument 14. Likewise, the second tool alignment member 628'" and the second handle alignment member 630'" will provide further indication of the attitude of the blade support 18 relative to the handheld portion 16 in the pitch and lift degrees of freedom.

[0255] It is worth noting that Figure 29-39 and Fig.51 As shown in the illustrated configuration, the tool alignment members 602, 602', 602", 602'" can be integrally formed with a tool tracker 574 of the surgical navigation system, which can be removably coupled to the saw blade support 18. Integrating the tool alignment members 602, 602', 602", 602'" with the tool tracker 574 reduces the mounting space required on the saw blade support 18 and allows the tool tracker to be closer to the tip of the tool 20, thereby facilitating more accurate surgical navigation. The tool tracker 574 may include side walls 580 to which a cross member 582 is attached, each side wall 580 including one or more of a plurality of markers 584. In some configurations, the plurality of markers may be arranged on each of the side walls 580 in a mirrored configuration. The profile of the side wall 580 may match the profile of the tool support 18. Additionally, in some configurations, the markers 584 may be active, passive, or a combination thereof. In other configurations, the markers 584 may be arranged on the tool alignment members 602, 602', 602", 602'" to improve the line of sight using the surgical navigation system 32. To mount the tool tracker 574 to the saw blade support 18, the tool tracker 574 may include a guide slot 576, and the saw blade support 18 may include a guide rail 578 at the distal end of the saw blade support 18 (e.g., Fig.35 The guide slot 576 of the tool tracker 574 is sized to receive the guide rail 578 of the saw blade support 18, thereby allowing the tool tracker 574 to be connected to the distal end of the saw blade support 18.

[0256] Additionally, the tool alignment member 602 and / or the handle alignment member 604 may include one or more visual indicia. In some configurations, for example Fig.32 and Fig.34 As shown, the tool alignment member 602 includes at least a first visual marker 562, and the handle alignment member 604 includes at least a second visual marker 564. It is worth noting that the first visual marker 562 is visually distinguishable from the second visual marker 564. Fig.32 and Fig.34 In the illustrated embodiment, for example, the first visual marker 562 may be arranged such that when the tool alignment member 602 and the handle alignment member 604 are not aligned (i.e., in the second spatial arrangement), the first visual marker 562 is visible from the proximal end 560 of the handheld portion 16. Conversely, the second visual marker 564 is arranged such that when the tool alignment member 602 and the handle alignment member 604 are aligned (i.e., in the first spatial arrangement), it is visible from the proximal end of the handheld portion 16. Thus, the first visual indicator 562 and the second visual indicator 564 provide the operator with an easily recognizable visual indication of the alignment of the tool alignment member 602 with the handle alignment member 604. In some embodiments, the visual marker includes one or more visual cues (e.g., patterns, lights, colors, combinations thereof, etc.). For example, see Fig.32 , visual markings may include colored marks 666, 668.

[0257] In e.g. Figures 47-48 In another configuration shown, for example, the tool alignment member 502 and the handle alignment member 504 each have a first visual marker 562 and a second visual marker 564. For example, the first visual marker 562 can be a first color 566, and the second visual marker 564 can be a second color 568. In this configuration, when the tool alignment member is aligned with the handle alignment member, the first color 566 is visible along the edge of the tool alignment member 502 adjacent to the handle alignment member 504 (at Fig.35 , Fig.37 and Fig.40 ), and conversely, when the tool alignment member 502 is not aligned with the handle alignment member 504, at least one of the second visual indicia 564 is visible along an edge of the tool alignment member 502 adjacent to the handle alignment member 504 (in Fig.40). To facilitate this configuration, the top surface 503 of the tool alignment member 502 and the top surface 505 of the handle alignment member 504 may include a first visual marker 562. Similarly, the side surface 570 of the tool alignment member 502 and the side surface 572 of the handle alignment member 504 may include a second visual marker 564, such that when the tool alignment member 502 and the handle alignment member 504 are misaligned with each other, the second visual marker 564 is revealed, thereby providing an indication that one or more of the plurality of actuators 21, 22, 23 have moved away from their original positions. The visual markers 562, 564 allow an operator to quickly distinguish between the surface of the tool alignment member 502 and the surface of the handle alignment member 504, so as to quickly discern whether the tool alignment member 502 and the handle alignment member 504 are misaligned. For example, if Fig.40 As shown, when the tool alignment member 502 is misaligned with the handle alignment member 504, at least one of the second visual marks 564 (in the form of a second color 568 and disposed on the side surface 572) is visible, thereby providing an indication that one or more of the multiple actuators 21, 22, 23 have left their original position.

[0258] See also Fig.42 and Fig.43 , the apparatus 14 may include a light emitter (e.g., an LED) 586 at any applicable location within the operator's line of sight (e.g., the tool alignment member 502, the handle alignment member 504, or the saw blade support 18). The light emitter 586 may be configured to be illuminated when the saw blade support 18 has a desired range of motion, thereby providing a visual indication that the saw blade support 18 and the handheld portion 16 are within a specified alignment range aligned with the target plane TP. For example, the light emitter 586 may be configured to indicate that the actuators 21, 22, 23 are in a first spatial arrangement (i.e., have a desired range of motion). Alternatively, the light emitter 586 may be configured to be illuminated when the saw blade support 18 is in a second spatial arrangement. For example, when the first visual indicator 201 is operated to indicate that the handheld portion 16 needs to be moved, the visual indicator 201 indicates that one or more of the actuators 21, 22, 23 are too far from their original position, thereby misaligning the tool alignment member with the handle alignment member to indicate that the handheld portion 16 needs to be moved.

[0259] In some examples, the controller may control the light emitter 586 based on the commanded position of the actuators 21, 22, 23 and the available travel of the actuators 21, 22, 23. For example, the first color may be based on the operating range of the actuators 21, 22, 23 and the first travel range within the commanded position of the actuators 21, 22, 23, and the second color may be based on the operating range of the actuators 21, 22, 23 and the second travel range within the commanded position of the actuators 21, 22, 23, the second travel range being different from the first travel range. A third color representing a third travel range of the actuators 21, 22, 23 within the available travel, the third travel range being different from the second travel range, may also be included. For example, the first color is red and is associated with the command position of the actuator 21, 22, 23 that is closest to the outer limit of the available travel, the second color is yellow and is associated with the command position of the actuator 21, 22, 23 that is further away from the outer limit of the available travel, and the third color is green, which indicates that the command position of the actuator 21, 22, 23 is far from the limit of the available travel range.

[0260] In another example, the colors associated with the light emitter 586 may represent several actuator parameters, such that the light emitter 586 will convey to the user a first color representing the amount of travel required to bring at least one actuator 21, 22, 23 to the command position and a second color representing the direction required to move the handheld portion 16 to bring the tool 20 into the operating range of the actuator. As described above, the third color may correspond to the outermost range of available travel (i.e., the smallest travel remaining available relative to the command position), the second color may correspond to the middle range of available travel, and the first color may correspond to the innermost range of available travel (i.e., the largest travel remaining available relative to the command position). In some examples, when the light emitter 586 is configured to be split into two or more portions, each of the respective portions may be illuminated in a different state to indicate the desired direction of movement of the handheld portion 16. In some versions, the illumination of the upper and lower portions of the light emitter 586 may be operated in the same state based on the command position and available travel of the handheld portion 16.

[0261] Alternatively, the light emitter 586 or other marker may be controlled based on one or more components of the command posture and one or more ranges of motion in a particular degree of freedom. More specifically, the light emitter 586 or other marker may be controlled based on the pitch component of the command posture and the pitch motion range. Alternatively or in combination, the light emitter 586 may be controlled based on the roll component of the command posture and the roll motion range. The pitch and roll motion ranges may be defined by a series of nested ranges. When the pitch component of the command posture is within the innermost range of the pitch motion range and the roll component of the command posture is within the innermost range of the roll motion range, the control system 60 may control the light emitter to emit a first color of light. Alternatively, when the pitch component of the command posture is within the relatively outer range of the pitch motion range or the roll component of the command posture is within the relatively outer range of the roll motion range, the control system 60 may control the light emitter to emit a second color of light, or prevent power from being supplied to the light emitter. By controlling the light emitter 586 in this manner, the light indicia can indicate that the user is in a good posture with respect to pitch and roll, or that the user needs to adjust one of the pitch and roll. Similarly, the control system 60 can also emit a first color of light only when another condition exists (for example, when the lift component of the command posture also falls within the innermost range of the lift range of motion). In addition, when any of the pitch component, the roll component, or the lift component is outside its corresponding innermost range of motion, the control system 60 can control the light emitter 586 to emit a second color of light, or prevent power from being supplied to the light emitter 586. Although lift, pitch, and roll are mentioned here, it is also contemplated that the light emitter 586 can be controlled based on the components of the command posture in other degrees of freedom associated with their corresponding ranges of motion.

[0262] refer to Figure 44-50 In another configuration, the instrument 14 may include a guard 700 coupled to and extending between the blade support 18 and the handheld portion 16. Figure 29-39As shown, the shield 700 can be included on the instrument 14 at the same time as the tool alignment member 502 and the handle alignment member 504. The shield 700 can be formed of any suitable material, such as plastic, rubber, composite material, etc., or a combination thereof, which is compatible with sterilization processes (e.g., autoclave or hydrogen peroxide sterilization processes). The shield 700 can be coupled to the tool support 18 and the handheld portion 16 using any suitable means (e.g., clamps, fasteners, adhesives, etc., or a combination thereof). In some configurations, the shield 700 can surround at least one of the plurality of actuators 21, 22, 23. The shield 700 can include accordion-like folds that can expand and bend as the saw blade support 18 is moved relative to the handheld portion 16. In addition, in some configurations, the shield 700 defines at least two shield landmarks 702 (described in further detail below). In some configurations, there can be two or more, five or more, ten or more, or even more shield landmarks 702. As the blade support 18 moves relative to the handheld portion 16, the displacement of the guard landmarks 702 relative to each other provides a visual indication of the attitude of the blade support 18 relative to the handheld portion 16. Fig.45 , the instrument 14 may include one or more shield alignment members 706 that are removably coupled to the handheld portion 16. For example, in some configurations, the instrument 14 may include at least two shield alignment members 706. The shield alignment members 706 may be transparent and include shield alignment marks 708. For example, referring to Fig.47 , the shield alignment mark 708 can indicate when the multiple actuators 21, 22, 23 are in their respective home positions and therefore indicate when the instrument 14 has an optimal range of motion. In some configurations, there may be two or more, or four or more, or even multiple shield alignment members 706. For example, Figures 47-50 A handheld surgical robotic system is shown including a second guard alignment feature 714 for providing another visual indication of the posture of the saw blade support 18 relative to the handheld portion 16 .

[0263] In some configurations, at least two guard landmarks 702 include at least two creases 704. In some configurations, the creases 704 may be defined by accordion-like folds. The creases 704 may define a plane 716 (e.g., a plane 716) that provides a visual indication of the attitude of the saw blade support 18 relative to the handheld portion 16. Fig.46). For example, the fold 704 may be substantially parallel to the plane 716 and offset a distance relative to the corresponding guard alignment mark 708, so that the plane 716 is aligned with the guard alignment mark 708 in the first position 710, thereby providing a visual indication that the plurality of actuators 21, 22, 23 are in their respective home positions and the machine 14 therefore has an optimal range of motion. However, in addition, when the saw blade support 18 and the hand-held portion 16 are moved to the second position 712, the plane 716 is vertically and obliquely displaced, thereby providing a visual indication that the saw blade support 18 does not have an optimal range of motion relative to the hand-held portion 16.

[0264] Figures 47-50 5. As shown, similar to the tool alignment member 502 and the handle alignment member 504, the guard 700 can be configured so that the guard 700 provides the operator with a visual indication of the attitude of the saw blade support 18 relative to the handheld portion 16. For example, Fig.48 The guard 700 is shown when the blade support 18 is pitched relative to the handheld portion. Fig.49 The guard 700 is shown when the blade support 18 is tilted relative to the handheld portion 16 . Fig.50 The guard 700 is shown with the blade support 18 raised relative to the handheld portion. Figures 48-50 In each of the drawings, the attitude of the fold 704 relative to the guard alignment mark 708 provides the operator with a visual indication of the attitude of the saw blade support 18 relative to the handheld portion 16.

[0265] In some configurations, similar to the tool alignment member 502 and the handle alignment member 504, at least two guard landmarks 702 may include a first visual marker 562 and a second visual marker 564. In addition, likewise, the first visual marker 562 may be visually distinguishable from the second visual marker 564 such that they provide an easily recognizable visual indication to the operator of the attitude of the saw blade support 18 relative to the handheld portion. For example, the first visual marker 562 may be a first color and the second visual marker 564 may be a second color. In this configuration, the first color is visible when the saw blade support 18 is in the first position (i.e., the plurality of actuators 21, 22, 23 are in their respective home positions), and the second color is visible when the saw blade support 18 is in the second position (i.e., the saw blade support 18 does not have an optimal range of motion relative to the handheld portion 16).

[0266] In another configuration, Figure 54-77As shown, the instrument 14 also includes a guide array 900. The guide array 900 provides a visual indication to the operator of the attitude of the tool support 18 relative to the handheld portion 16 during operation of the instrument 14, thereby providing a visual indication to the operator of the required changes in the pitch orientation, roll orientation, and z-axis translation of the handheld portion 16 to achieve the desired attitude of the tool 20 while providing maximum adjustability for the actuator assembly 400 (as described above) to maintain the tool 20 on the target plane TP. The guide array 900 includes a handle alignment member 904 extending from the handheld portion 16 for providing a visual indication to the operator to guide the operator on how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, 23 of the actuator assembly 400 near their original positions or other predetermined positions.

[0267] The handle alignment member 904 may have any suitable shape or configuration that will provide an operator user with a visual indication that one or more of the actuators 21, 22, 23 of the actuator assembly 400 has moved from its respective original position. Figure 54-77 , the handle alignment member 904 may include a handle alignment protrusion 906. The handle alignment protrusion 906 may extend toward the tool mounting seat 18a. It is worth noting that, with reference to Figure 54-77 , the handle alignment protrusion 906 may be shaped such that at least a portion 908 of the handle alignment protrusion 906 is disposed at an oblique angle to the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18. For example, the handle alignment protrusion 906 may define a handle alignment edge 914 disposed at an oblique angle to the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18. The "oblique" angle of the handle alignment protrusion 906 to the longitudinal axis 910 and the transverse axis 912 may include, for example, an arrangement of the handle alignment protrusion 906 at an angle greater than 0 degrees and less than 90 degrees to both the longitudinal axis 910 and the transverse axis 912. For example, the tool alignment protrusion 906 may define a tool alignment edge 914 at a 45 degree angle to the longitudinal axis 910 and the transverse axis 912.

[0268] In one configuration, for example, Figure 54-77 As shown, the handle alignment member 904 can define a hook-shaped handle alignment protrusion 906. The hook-shaped handle alignment protrusion 906 can define an arcuate handle alignment edge 914 that sweeps inwardly toward the tool support 18 to define the above-mentioned angle of inclination. Figure 54-77The configuration in FIG. 1 shows a hook-shaped handle alignment protrusion 906, but any suitable edge defining an angle of inclination is contemplated, such as (but not limited to) a polygonal edge, a stepped edge, etc. It is noteworthy that, as will be discussed in further detail below, the angles of inclination of the handle alignment protrusion 906 with the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18 can allow the user to more accurately discern the posture of the tool support 18 relative to the handheld portion 16 in multiple degrees of freedom simultaneously.

[0269] In some configurations, such as Figure 54-57 As shown in the configuration of , when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, at least a portion of the handle alignment protrusion 906 and the tool plane BP can be aligned, thereby providing a visual indication to the operator that the tool support 18 has an optimal range of motion relative to the handheld portion 16. In certain configurations, the term "aligned" is defined as at least a portion of the handle alignment protrusion 906 being substantially coplanar or intersecting with the tool plane BP within an applicable tolerance. Specifically, when in the home position, the adjustable amount of the actuators 21, 22, 23 of the actuator assembly 400 is maximized to maintain the tool 20 in a desired posture. In some examples, the alignment between at least a portion of the handle alignment protrusion 906 and the tool plane BP can be 99% or more aligned, 90% or more aligned, 70% or more aligned, or even 60% or more aligned. In other examples, the applicable alignment may be within a specified proximity of the target pose in each individual degree of freedom, such as within a range of 1% deviation from the target pose, 5% deviation from the target pose, 10% deviation from the target pose, or even 20% or more deviation from the target pose. Similarly, the applicable alignment may be within 1 mm of the target pose, within 2 mm of the target pose, or even within 5 mm or more of the target pose in each individual degree of freedom. In addition, the applicable alignment may be within 1 degree or more deviation from the target pose, within 5 degrees or more deviation from the target pose, within 15 degrees or more deviation from the target pose, or even within 30 degrees or more deviation from the target pose in terms of roll and / or pitch.

[0270] Conversely, tool plane BP and handle alignment tab 906 are configured to be misaligned when handheld portion 16 is in a posture that does not provide an optimal range of motion, thereby providing a visual indication that handheld portion 16 is in a posture that does not provide an optimal range of motion for tool support 18 and therefore requires adjustment by the operator (discussed in further detail below). In some configurations, guide array 900 may also include tool alignment member 902. In one configuration, for example, with reference to Figure 54-77, the tool alignment member 902 may extend from the tool support 18. The tool alignment member 902 may have any shape or structure capable of providing a visual indication of the posture of the tool plane BP relative to the handle alignment member 904. For example, the tool alignment member 902 may include a tool alignment protrusion 916 extending toward the tool mount 18a. Figure 54-77 For example, similar to the handle alignment protrusion 906, the tool alignment protrusion 916 may have at least a portion 920 disposed at an oblique angle to the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18. In some configurations, for example, the tool alignment protrusion 916 may define a tool alignment edge 918 that is inclined relative to the longitudinal axis 910 and the transverse axis 912 of the tool 20.

[0271] It is contemplated that the optimal range of motion may be the maximum range of motion in one, two, three or more degrees of freedom. It is also contemplated that the optimal range of motion may not necessarily be the maximum range of motion, but rather the range of motion required for a preferred posture of the tool support for making a particular cut using a saw or other pre-planned virtual object (e.g., a planned cut or planned axis). In some configurations, the optimal range of motion need not be the center of the range of motion in one or more degrees of freedom, but may be the center of the range of motion in one, two or three degrees of freedom.

[0272] In one configuration, for example, Figure 54-77 As shown, the tool alignment member 902 may define a hook-shaped tool alignment protrusion 916. The hook-shaped tool alignment protrusion 916 may define an arcuate tool alignment edge 918 that sweeps inwardly toward the tool support 18 to define the aforementioned angle of inclination. Figure 54-77 The configuration in FIG. 1 shows a hook-shaped tool alignment protrusion 916, but any suitable edge defining an angle of inclination is contemplated, such as (but not limited to) a polygonal edge, a stepped edge, etc. It is noteworthy that the hook-shaped tool alignment protrusion 916 and the hook-shaped handle alignment protrusion 906 can be configured to be aligned when the tool support 18 has an optimal range of motion relative to the hand-held portion 16, and can also be configured to be misaligned when the hand-held portion 16 is in a posture that does not provide the optimal range of motion for the tool support 18, thereby providing a visual indication that the hand-held portion 16 is in a posture that does not provide the optimal range of motion for the tool support 18.

[0273] In some examples, when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, the tool alignment edge may be offset relative to and parallel with the handle alignment edge, thereby providing a visual indication to the operator that the tool support 18 has a desired range of motion relative to the handheld portion 16. Additionally, in some examples, the tool alignment member 916 is disposed closer to the tool support 18 than the handle alignment member 906.

[0274] In some configurations, the tool alignment protrusion 916 is substantially aligned with the tool plane BP. For example, the tool alignment protrusion 916 can be coplanar with the tool plane BP. In this way, the tool alignment protrusion 916 can be used as a visual representation of the orientation of the tool plane BP to facilitate providing a visual indication of the posture of the handheld portion 16 relative to the tool support 18. However, it is important to note that the handle alignment member 904 can be used to provide a visual indication of the posture of the handheld portion 16 relative to the tool support 18 without adding the tool alignment member 902. Specifically, the user can still perceive the relationship of the tool support 18 relative to the handheld portion 16 by examining the relationship between the handle alignment member 904 and the tool 20.

[0275] The handle alignment member 904 may be removably coupled to the handheld portion 16. For example, the handle alignment member 904 may include a handle coupling portion 922 configured to be coupled to the handheld portion 16. Fig.58 As best shown in , the handle coupling portion 922 of the handle alignment member 904 can be removably coupled to the handheld portion 16. For example, the handle coupling portion 922 can be magnetically coupled to the handheld portion 16 so that the handle alignment member 904 can be separated as needed or in the event that an operator's hand is pinched between the handle alignment member 904 and the tool alignment member 902 and / or the tool support 18. Any suitable means of removably coupling the handle alignment member 904 to the handheld portion 16 are contemplated (e.g., magnets, latches, clips, fasteners, shackles, etc. and combinations thereof).

[0276] The handle alignment member 904 may also include a support arm 924. The support arm 924 may extend from the handle coupling portion 922 to support the handle alignment member 904. Figure 54-58As best shown in FIG. 1 , support arm 924 extends upward from grip 72 of handheld portion 16 so that when actuators 21, 22, 23 of actuator assembly 400 are in their respective home positions, handle alignment member 904 is aligned with tool plane BP. In some examples, handle alignment member 904 is rigid relative to handheld portion 16 to facilitate the function of handle alignment member 904. Handle alignment member 904 may be formed of any applicable material (e.g., plastic, aluminum, steel, composite material, etc., or a combination thereof). In addition, handle alignment member 904 may be formed using any applicable production method (including 3D printing, casting, machining, injection molding, stamping, etc., or a combination thereof).

[0277] Likewise, reference Fig.58 , the tool alignment member 902 may also include a tool coupling portion 926 configured to be coupled to the tool support 18. The tool coupling portion 926 may be mounted to the tool support 18 at any suitable location using any suitable means (e.g., fasteners, magnets, adhesives, etc.) to facilitate the function of the tool alignment member 802. For example, the tool support 18 may include a tool mounting rail 928 extending laterally from the tool support 18. The tool coupling portion 926 of the tool alignment member 902 may define a tool mounting channel 930 that is configured to engage with the tool mounting rail 928 to removably secure the tool alignment member 902 to the tool support 18.

[0278] The tool alignment member 902 may also include a support portion 932. The support portion 932 may extend from the tool coupling portion 926 to support the tool alignment member 902. In some examples, the tool alignment member 902 may be rigid relative to the tool support 18 to facilitate the function of the tool alignment member 902. The tool alignment member 902 may be formed of any suitable material (e.g., plastic, aluminum, steel, composite materials, etc., or combinations thereof). In addition, the tool alignment member may be formed using any suitable production method (which includes 3D printing, casting, machining, injection molding, stamping, etc., or combinations thereof).

[0279] In some configurations, the guide array 900 may include two or more handle alignment members and two or more tool alignment members. Any number of corresponding tool alignment members and handle alignment members are contemplated. For example, the guide array 900 may include a first handle alignment member 904 and a second handle alignment member 934 extending from the handheld portion 16 at a position separate from the first handle alignment member 904. Likewise, the second handle alignment member 934 may include a second handle alignment protrusion 936. The second handle alignment protrusion 936 may extend toward the tool mount 18a. It is noteworthy that reference Figure 54-77, the second handle alignment protrusion 936 can be shaped such that at least a portion 938 of the second handle alignment protrusion 936 is disposed at an oblique angle to the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18. For example, the second handle alignment protrusion 936 can define a second handle alignment edge 940 disposed at an oblique angle to the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18.

[0280] In some examples, the guide array 900 may include a first tool alignment member 902 and a second tool alignment member 942 extending from the handheld portion 16 at a location separate from the first tool alignment member 902. For example, referring to Figure 54-77 In some configurations, the first alignment members 902, 904 and the second alignment members 934, 942 extend from opposite sides of the handheld portion 16 so as to be arranged in a mirror image with respect to each other.

[0281] The second tool alignment member 942 may include a second tool alignment protrusion 944 extending toward the tool mount 18. The second tool alignment protrusion 944 may have at least a portion 946 that is arranged at an oblique angle to the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18. In some configurations, for example, the second tool alignment protrusion 944 may define a second tool alignment edge 948 that is inclined relative to the longitudinal axis 910 and the transverse axis 912 of the tool 20 / tool ​​support 18. In some examples, when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, the second tool alignment edge 948 may be offset relative to and parallel with the second handle alignment edge 940, thereby providing a visual indication to the operator that the tool support 18 has an optimal range of motion relative to the handheld portion 16. For example, referring to Fig.54 and Fig.56 , when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, the handle alignment edges 914, 940 and the tool alignment edges 918, 948 are offset and parallel relative to each other. It is worth noting that the alignment members 902, 904, 934, 942 can have any suitable shape to provide an indication that the tool alignment members 902, 934 are aligned with the handle alignment members 904, 942, respectively. It is contemplated that in some examples, there may be four or more, or six or more, or even multiple tool alignment members and handle alignment members, respectively.

[0282] like Figure 54-57As shown, when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, the first tool alignment protrusion 916 and the first handle alignment protrusion 906 and the second tool alignment protrusion 942 and the second handle alignment protrusion 936 are aligned with each other, respectively, thereby providing a visual indication that the tool support 18 has an optimal range of motion relative to the handheld portion 16. In contrast, the first tool alignment protrusion 916 and the first handle alignment protrusion 906 and the second tool alignment protrusion 944 and the second handle alignment protrusion 936 are configured to be misaligned with each other when the handheld portion 16 is in a posture that does not provide an optimal range of motion, respectively, thereby providing a visual indication that the handheld portion 16 is in a posture that does not provide an optimal range of motion for the tool support 18 and therefore needs to be adjusted by the operator.

[0283] During operation of the instrument 14, the handle alignment tabs 906, 936 and the tool plane BP can be arranged so that when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, they are aligned in a first spatial relationship 950. For example, referring to Figure 54-57 When the handle alignment protrusions 906, 936 and the tool plane BP are arranged in the first spatial relationship 950, the handle alignment protrusions 906, 936 are aligned with the tool plane BP, thereby providing a visual indication that the actuators 21, 22, 23 of the actuator assembly 400 are in their respective original positions.

[0284] In addition, refer to Fig.57 , when the instrument 14 is holding the tool support 18 so that the tool 20 is maintained in the target plane TP, the target plane TP, the handle alignment protrusions 906, 936 and the tool plane BP are configured to be arranged in a first spatial relationship 950 when the handle alignment protrusions 906, 936, the tool plane BP and the target plane TP are aligned, thereby providing a visual indication that the tool 20 is aligned with the target plane TP and the actuators 21, 22, 23 are in their respective original positions, so that the actuators 21, 22, 23 have a maximum adjustable amount to maintain the tool 20 in the desired posture, thereby providing the instrument 14 with maximum adjustment of pitch, roll and z-axis translation (i.e., lift) to maintain the tool 20 on the target plane TP.

[0285] During operation of the instrument 14, the handle alignment projections 906, 936 may be arranged such that they are misaligned with the tool plane BP to be in a second spatial relationship 952 (e.g., when the tool support 18 is in a posture that does not provide a desired range of motion relative to the handheld portion 16). Figure 59-75). The second spatial relationship 952 provides a visual indication that the tool support 18 is in a posture relative to the hand portion 16 that does not provide the desired range of motion for the instrument 14, and therefore indicates that the operator must adjust the posture of the hand portion 16 so that the one or more handle alignment tabs 906, 936 are aligned with the tool plane BP in the first spatial relationship 950 to provide maximum adjustability of the instrument 14.

[0286] Likewise, during operation of the instrument 14 that also includes at least one of the tool alignment members 902, 942 having the tool alignment tabs 916, 944, the handle alignment tabs 906, 936 and the tool alignment tabs 916, 944 may be arranged such that when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, they are aligned to be in the first spatial relationship 950. For example, referring to Figure 54-57 When the handle alignment protrusions 906, 936 and the tool alignment protrusions 916, 944 are arranged in a first spatial relationship 950, the handle alignment protrusions 906, 936 are aligned with the tool alignment protrusions 916, 944, respectively, thereby providing a visual indication that the actuators 21, 22, 23 are in their respective original positions.

[0287] In addition, refer to Fig.57 When the instrument 14 is holding the tool support 18 so that the tool 20 is maintained in the target plane TP, the target plane TP, the handle alignment protrusions 906, 936 and the tool alignment protrusions 916, 944 are configured to be arranged in a first spatial relationship when the handle alignment protrusions 906, 936, the tool alignment protrusions 916, 944 are aligned with the target plane TP, thereby providing a visual indication that the tool 20 is aligned with the target plane TP and the actuators 21, 22, 23 are in their respective original positions, so that the actuators 21, 22, 23 have a maximum adjustable amount to maintain the tool 20 in the desired posture, thereby providing the instrument 14 with maximum adjustment for pitch, roll and z-axis translation (i.e., lift) to maintain the tool 20 on the target plane TP.

[0288] Additionally, during operation of the instrument 14 that also includes at least one of the tool alignment members 902, 942, the tool alignment tabs 916, 944 and the handle alignment tabs 902, 942 may be arranged such that they are respectively misaligned with each other to be in a second spatial relationship 952 (shown in FIG. 1 ) when the tool support 18 is in a posture that does not provide a desired range of motion relative to the handheld portion 16. Figure 59-75950). The second spatial relationship 952 provides a visual indication that the tool support 18 is in a posture relative to the hand portion 16 that does not provide the desired range of motion for the instrument 14, and therefore indicates that the operator must adjust the posture of the hand portion 16 so that the one or more tool alignment protrusions 916, 944 and the one or more handle alignment protrusions 906, 936 are aligned to be in the first spatial relationship 950 to provide maximum adjustability for the instrument 14. It is worth noting that the addition of the second tool alignment member 942 and the second handle alignment member 934 is used to further help provide a visual indication of the posture of the tool support 18 relative to the hand portion 16. It is noteworthy that in order to facilitate visual indication throughout the entire range of motion of the actuators 21, 22, 23, the tool alignment members 902, 942 and the handle alignment members 904, 934 are arranged and sized relative to each other so that the tool alignment members 902, 942 and the handle alignment members 904, 934 do not collide at any position between the first position and the second position of each of the multiple actuators 21, 22, 23 of the actuator assembly 400.

[0289] There are various scenarios where the handle alignment protrusions 906, 936 may be misaligned with the tool plane BP and / or the tool alignment protrusions 916, 944 to be in the second spatial relationship 952. For example, the tool support 18 may be pitched relative to the handheld portion 16 about the transverse axis 912 (shown in FIG. Figure 59-62 ), the tool support 18 can be tilted relative to the handheld portion 16 about the longitudinal axis 910 (shown in Figure 63-66 ), and / or the tool support 18 may be displaced (ie, lifted) relative to the handheld portion 16 along the vertical axis 954 (shown in Figures 67-70 944). It should be understood that other misalignments caused by movement of the tool support 18 relative to the hand portion 16 in other degrees of freedom are contemplated. It should also be understood that combinations of the above-described misalignments may occur simultaneously. For example, the tool support 18 may be simultaneously pitched and rolled relative to the hand portion 16. When one or more handle alignment tabs 906, 936 are misaligned with the tool plane BP and / or one or more tool alignment tabs 916, 944, the resulting second spatial relationship 952 provides a visual indication of the posture of the tool support 18 relative to the hand portion 16, even if misalignment occurs in multiple degrees of freedom.

[0290] In some configurations, the first spatial relationship 950 may include a first pitch relationship 956 that provides a visual indication that the tool support 18 is aligned in the pitch degree of freedom relative to the handheld portion 16 about the transverse axis 912. However, as described above, the plurality of actuators 21, 22, 23 of the actuator assembly 400 may be configured to at least adjust the pitch of the tool support 18 relative to the handheld portion 16 to maintain the tool 20 on the target plane TP. For example, Figure 59-62 The tool support 18 is shown pitched relative to the handheld portion 16 by an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the tool support 18 is pitched relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the handle alignment tabs 906, 936 may be misaligned with the tool plane BP and / or the tool alignment tabs 916, 944, respectively, to be in a second spatial arrangement 952. The second spatial arrangement 952 may include a second pitch relationship 958. The second pitch relationship 958 may provide a visual indication of the magnitude and direction of the pitch of the tool support 18 relative to the handheld portion 16 about the transverse axis 912.

[0291] For example, Figure 59-62 As shown, when the first portion 960 of the handle alignment protrusion 906, 936 is further away from the tool plane BP and / or the tool alignment protrusion 916, 944 in the pitch direction than the second portion 962 of the handle alignment protrusion 906, 936, the handle alignment protrusion 906, 936 and the tool plane BP and / or the tool alignment protrusion 916, 944 may be arranged in a second pitch relationship 958. Figure 59-62 For example, the distal portion 964 of the handle alignment protrusion 906, 936 is further away from the tool plane BP and / or the tool alignment protrusion 916, 944 along the longitudinal axis 910 than the proximal portion 966 of the handle alignment protrusion 906, 936. Figure 59-62 As shown, the handle alignment protrusions 906, 936 are pitched below the tool alignment protrusions 916, 944 so that the distal ends of the handle alignment protrusions 906, 936 are located below the distal ends of the tool alignment protrusions 916, 944, thereby providing a visual indication to the user that the grip 72 should be pivoted to eliminate the pitch condition.

[0292] In other words, when the tool support 18 is pitched relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one end of the handle alignment protrusion 906, 936 is further away from the tool plane BP and / or the tool alignment protrusion 916, 944 than the other end in the pitch direction along the longitudinal axis 910. Thus, the second pitch relationship 958 may provide a visual indication that the tool support 18 does not have a desired range of motion relative to the handheld portion 16 and the operator must adjust the posture of the handheld portion 16 so that the handle alignment protrusion 906, 936 is aligned with the tool plane BP and / or the tool alignment protrusion 916, 944 to form the first spatial relationship 950, thereby providing maximum adjustability for the instrument 14.

[0293] In other configurations, the first spatial relationship 950 may include a first roll relationship 968 that provides a visual indication that the tool support 18 is aligned relative to the handheld portion 16 in the roll degree of freedom. The plurality of actuators 21, 22, 23 may be configured to at least adjust the roll of the tool support 18 relative to the handheld portion 16 about the longitudinal axis 910 to maintain the tool 20 on the target plane TP. For example, Figure 63-66 The tool support 18 is shown tilted relative to the handheld portion 16 by an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the tool support 18 is tilted relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the handle alignment protrusions 906, 936 may be misaligned with the tool plane BP and / or the tool alignment protrusions 916, 944, respectively, to form a second spatial relationship 952. The second spatial relationship 952 may include a second tilt relationship 970. The second tilt relationship 970 may provide a visual indication of the magnitude and direction of the tilt of the tool support 18 relative to the handheld portion 16 about the longitudinal axis 910.

[0294] For example, Figure 63-66 As shown, when the outer portion 972 of the handle alignment protrusion 906, 936 is further away from the tool plane BP and / or the tool alignment protrusion 916, 944 in the roll direction than the inner portion 974 of the handle protrusion 906, 936, the handle alignment protrusion 906, 936 and the tool plane BP and / or the tool alignment protrusion 916, 944 can be arranged in a second roll relationship 970. It is worth noting that, with reference to Fig.66, compared to only the second spatial relationship 952 between the first handle alignment protrusion 906 and the tool plane BP and / or the first tool alignment protrusion 916, the second spatial relationship 952 between the first handle alignment protrusion 906 and the tool plane BP and / or the first tool alignment protrusion 916, combined with the second spatial relationship 952 between the second handle alignment protrusion 936 and the tool plane BP and / or the second tool alignment protrusion 944, can provide another visual indication of the posture of the tool support 18 relative to the handheld portion 16.

[0295] Specifically, the addition of the second tool alignment member 942 and the second handle alignment member 934 provides the operator with another visual indication that the tool support 18 does not have an optimal range of motion relative to the handheld portion 16. Figure 63-66 When the tool support 18 is tilted relative to the hand-held portion 16 so that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment protrusion 906, 936 will be displaced further away from the tool plane BP and / or the tool alignment protrusion 916, 944 in the tilt direction than the other side of the handle alignment protrusion 906, 936. For example, Figure 63-66 As shown, the lateral portion 972 of the first handle alignment protrusion 906 is located below the first tool alignment protrusion 916, while the lateral portion 972 of the second handle alignment protrusion 916 is located above the second tool alignment protrusion 944, thereby indicating that the handheld portion 16 is tilted in a clockwise direction relative to the tool support 18. Therefore, the operator is provided with the following feedback: the handheld portion 16 should be adjusted in a clockwise direction to return the instrument 14 to a position with maximum adjustability. Therefore, the second tilt relationship 970 can provide a visual indication that the tool support 18 does not have a desired range of motion relative to the handheld portion 16, and the operator must adjust the posture of the handheld portion 16 so that the handle alignment protrusions 906, 936 are aligned with the tool plane BP and / or the tool alignment protrusions 916, 944 to form a first spatial relationship 950 to provide maximum adjustability for the instrument 14.

[0296] In an additional configuration, the first spatial relationship 950 may include a first lift relationship 978 that provides a visual indication of the absence of any vertical displacement (i.e., lift) of the tool support 18 relative to the hand portion 16 about the vertical axis 954. The plurality of actuators 21, 22, 23 of the actuator assembly 400 may be configured to at least adjust the lift of the tool support 18 relative to the hand portion 16 to maintain the tool 20 on the target plane TP. For example, Figures 67-70The tool support 18 is shown to be lifted relative to the handheld portion 16 by an amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the tool support 18 is lifted relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the handle alignment protrusions 906, 936 may be misaligned with the tool plane BP and / or the tool alignment protrusions 916, 944, respectively, to form a second spatial relationship 952. The second spatial relationship 952 may include a second lifting relationship 980. The second lifting relationship 980 may provide a visual indication of the magnitude of the lift of the tool support 18 relative to the handheld portion 16.

[0297] For example, Figures 67-70 As shown, when the handle alignment protrusions 906, 936 are displaced in the lifting direction below the tool plane BP and / or the tool alignment protrusions 916, 944, the handle alignment protrusions 906, 936 and the tool plane BP and / or the tool alignment protrusions 916, 944 may be arranged in a second lifting relationship 980. In other words, when the tool support 18 is lifted relative to the hand-held portion 16 so that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the handle alignment protrusions 906, 936 will be spaced apart above or below the tool plane BP and / or the tool alignment protrusions 916, 944 along the vertical axis 954 in the lifting direction. Thus, the arrangement of the handle alignment tabs 906, 936 in the second elevated relationship 980 relative to the tool alignment tabs 916, 944 may provide a visual indication that the tool support 18 does not have an optimal range of motion relative to the handheld portion 16 and that the operator must adjust the posture of the handheld portion 16 so that the handle alignment tabs 906, 936 are aligned with the tool plane BP and / or the tool alignment tabs 916, 944 in the first spatial relationship 950 to provide maximum adjustability for the instrument 14. For example, the tool alignment tabs 916, 944 may be positioned in the first spatial relationship 950. Figures 67-70 14 is shown above the handle alignment protrusions 906, 936 on either side of the instrument 14, thereby providing a visual indication to the user that the handheld portion 16 needs to be moved upward to align the handheld portion 16 with the tool support 18 to place the instrument 14 in a position having maximum adjustability.

[0298] It should be appreciated that in view of the above description, the guide array 900 provides a number of benefits to the operation of the instrument 14. For example, the handle alignment protrusions 906, 936 (and the handle alignment edges 914, 940 defined thereby) may be arranged at an oblique angle to the longitudinal axis 910 and the transverse axis 912 defined by the tool 20 / tool ​​support 18. The arrangement of the portions 908, 938 of the handle alignment protrusions 906, 936 at an oblique angle to the longitudinal axis 910 and the transverse axis 912 provides the advantage of enabling the operator to perceive the alignment of the handle alignment protrusions 906, 936 with the tool plane BP and / or the tool alignment protrusions 916, 944 in multiple degrees of freedom simultaneously.

[0299] For example, Figures 71-75 As shown, in some configurations, the actuator assembly 400 is configured to simultaneously adjust the pitch and roll of the tool support 18 relative to the handheld portion 16. For example, referring to Figures 71-75 , wherein the tool support 18 is displaced simultaneously in both the pitch and roll degrees of freedom, the arrangement of the inclined portions 908, 938 of the handle alignment projections 906, 936 relative to the tool plane BP and / or the tool alignment projections 916, 944 provides a visual indication of the attitude of the handheld portion 16 relative to the tool support in at least two degrees of freedom. Specifically, the second spatial arrangement 952 of the handle alignment projections 906, 936 relative to the tool plane BP and / or the tool alignment projections 916, 944, respectively, provides a visual indication of at least a second pitch relationship 958 and a second roll relationship 970 of the tool support BP relative to the handheld portion 16, thereby providing a visual indication that the handheld portion 16 is in an attitude relative to the tool support 18 that does not provide an optimal range of motion for the tool support 18. Therefore, the operator is warned that the operator must adjust the posture of the handheld portion 16 so that the handle alignment protrusions 906, 936 are aligned with the tool plane BP and / or the tool alignment protrusions 916, 944 to form a first spatial relationship 944 to provide maximum adjustability for the instrument 14.

[0300] As an example of feedback in multiple degrees of freedom, Figures 71-75One end of one or more handle alignment protrusions 906, 936 is shown as being further away from tool plane BP and / or tool alignment protrusions 916, 944 in the pitch direction along the longitudinal axis 910 than the other end, and one side of the handle alignment protrusion 906, 936 is displaced further away from tool plane BP and / or tool alignment protrusions 916, 944 in the roll direction than the other side of the handle alignment protrusion 906, 936. Thus, the angled arrangement of the handle alignment protrusions 906, 936 (and in some configurations, the tool alignment protrusions 916, 944) facilitates visual indication of the attitude of the tool support 18 relative to the handheld portion 16 by providing a first visual reference toward the lateral portion 972 of the handle alignment protrusion 906, 936, which provides a visual indication in the roll degree of freedom, and a second visual reference toward the first portion 960 of the handle alignment protrusion 906, 936, which provides a visual indication in the pitch degree of freedom. Cumulatively, therefore, the angled portions 908, 938 of the handle alignment tabs 906, 936 provide enhanced functionality for the visual indication as compared to an orthogonal arrangement of the handle alignment tabs.

[0301] In addition, if Figures 76-77 As shown, the tool alignment member 902 and / or the handle alignment member 904 may include one or more visual indicia for facilitating a user's visual perception of the alignment of the handle alignment protrusions 906, 936 with the tool alignment protrusions 916, 944. For example, the handle alignment protrusions 906, 936 and / or the tool alignment protrusions 916, 944 may each include at least one of a first visual indicia 986 and a second visual indicia 988, the first visual indicia 986 being visually distinguishable from the second visual indicia 988. The first visual indicia 986 and / or the second visual indicia 988 may be disposed on the handle alignment protrusions 906, 936 and / or the tool alignment protrusions 916, 944, for example, on an inclined surface 990 and / or a side surface 992 of the handle alignment protrusions 906, 936 and / or the tool alignment protrusions 916, 944. However, any suitable surface of the handle alignment protrusions 906, 936 and / or the tool alignment protrusions 916, 944 is contemplated to facilitate the operator's visual perception of the alignment of the handle alignment protrusions 906, 936 with the tool alignment protrusions 916, 944. Thus, the first visual marker 986 and / or the second visual marker 988 provide the operator with an easily recognizable visual indication of the alignment of the tool alignment protrusion 916 with the handle alignment protrusion 906. In some versions, the visual marker includes one or more different visual cues (e.g., patterns, lights, colors, combinations thereof, etc.). For example, referring to Figures 76-77 , visual markings may include colored markings.

[0302] exist Figures 76-77In the illustrated version, for example, the visual indicia may be arranged such that when the tool alignment tab 916 is aligned with the handle alignment tab 906, the first visual indicia 986 of the handle alignment tab 906 is aligned with the first visual indicia 986 of the tool alignment tab 916, thereby providing a visual indication that the tool support 18 has an optimal range of motion relative to the handheld portion 16. Conversely, the first visual indicia 986 of the handle alignment tab 906 and the first visual indicia 986 of the tool alignment tab may be configured to be misaligned when the tool alignment tab 916 and the handle alignment tab 906 are not aligned, thereby providing a visual indication that the handheld portion 16 is in a posture that does not provide an optimal range of motion for the tool support 18.

[0303] Figures 78-85 Yet another configuration of a guidance array 1000 for use with a handheld surgical robotic system 10 is shown. Similar to the configurations described above, the guidance array 1000 provides a visual indication to the operator of the posture of the tool support 18 relative to the handheld portion 16 during operation of the instrument 14, thereby providing the operator with a visual indication of the required changes in the pitch orientation, roll orientation, and z-axis translation of the handheld portion 16 to achieve the desired posture of the tool 20 while providing maximum adjustability for the actuator assembly 400 (as described above) to maintain the tool 20 at the target plane TP. The guidance array 1000 includes a handle alignment member 1004 extending from the handheld portion 16 for providing a visual indication to the operator, thereby guiding the operator on how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, 23 of the actuator assembly 400 near their original positions or other predetermined positions.

[0304] refer to Figures 80-83 For example, the handle alignment member 1004 includes a handle support arm 1106. The handle support arm 1106 extends between a first handle support arm end 1108 and a second handle support arm end 1110. The handle support arm 1106 includes a handle coupling portion 1112 (best shown in FIG. 1 ) coupled to the first handle support arm end 1108. Fig.81 and Fig.82 The handle coupling portion is configured to couple the handle alignment member 1004 to the handheld portion 16 of the instrument 14. For example, in some configurations, the handle coupling portion 1112 includes a handle coupling member 1114 configured to couple to a corresponding coupling member 1116 disposed on the handheld portion 16.

[0305] refer to Figures 80-82In some configurations, the handle coupling portion 1112 of the handle alignment member 1004 is magnetically coupled to the handheld portion 16 of the instrument 14. Thus, the handle alignment member 1004 can be quickly magnetically attached and detached from the handheld portion 16. To facilitate such magnetic connection, one of the handle coupling member 1114 and the coupling member disposed on the handheld portion 16 can include one or more magnets 1118, and the other of the handle coupling member 1114 and the coupling member disposed on the handheld portion 16 can include one or more magnets 1118 and / or ferromagnetic material 1120, so that the handle coupling member 1114 and the coupling member disposed on the handheld portion 16 are configured to be magnetically coupled to each other to couple the handle alignment member 1004 to the handheld portion 16.

[0306] refer to Fig.81 and Fig.83 , the handle alignment member 1004 also includes a handle alignment member mounting seat 1122 connected to the second handle support arm end 1110. Fig.81 and Fig.83 In the illustrated configuration, the handle alignment member 1004 also includes a handle alignment indication member 1124 coupled to the handle alignment member mount 1122. The handle alignment indication member 1124 may have any suitable shape or configuration that will provide an operator user with a visual indication that one or more of the actuators 21, 22, 23 of the actuator assembly 400 have left their respective home positions. For example, in one configuration, similar to the other configurations described above, the handle alignment member 1004 may define a hook-shaped protrusion. Also similar to as described above, when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, at least a portion of the handle alignment indication member 1124 and the tool plane BP may be aligned, thereby providing the operator with a visual indication that the tool support 18 has an optimal range of motion relative to the handheld portion 16. In contrast, tool plane BP and handle alignment indication member 1124 are configured to be misaligned when the handheld portion 16 is in a posture that does not provide an optimal range of motion, thereby providing a visual indication that the handheld portion 16 is in a posture that does not provide an optimal range of motion for the tool support 18 and therefore requires adjustment by the operator.

[0307] Still reference Fig.81 and Fig.83, the handle alignment indication member 1124 can be removably coupled to the handle alignment member mount 1122 using one or more fasteners 1128. In addition, the handle alignment indication member 1124 can be constructed of a material suitable for autoclaving. Suitable materials include, but are not limited to, stainless steel and autoclave-resistant polymers, such as polyphenylsulfone. Examples of methods of manufacturing the handle alignment indication member 1124 include: forming the handle alignment indication member 1124 by stamping a stainless steel sheet, machining the handle alignment indication member 1124 from an autoclave-resistant polymer block such as polyphenylsulfone, and molding the handle alignment indication member 1124 from an autoclave-resistant polymer such as polyphenylsulfone.

[0308] In some configurations, refer to Figures 78-86 , the guide array 1000 may also include a tool alignment member 1126. In one configuration, for example, the tool alignment member 1126 may extend from the tool support 18. Similar to the above description for other configurations, when the tool support 18 has an optimal range of motion relative to the handheld portion 16, the handle alignment member 1004 and the tool alignment member 1126 are aligned. In addition, similar to the handle alignment member 1004 described above, the tool alignment member 1126 may include a tool support arm 1130 extending between a first tool support arm end 1132 and a second tool support arm end 1134. The tool support arm 1130 includes a tool coupling portion 1136 (best shown in FIG. 1 ) coupled to the first tool support arm end 1132. Fig.81 ). The tool coupling portion 1136 is configured to couple the tool alignment member 1026 to the tool support 18 of the instrument 14. For example, in some configurations, the tool coupling portion 1136 includes a tool coupling member (not shown) that is configured to couple to a corresponding coupling member 1138 disposed on the tool support 18. Also similar to as described above, the tool alignment member 1126 can be magnetically coupled to the tool support 18.

[0309] The tool alignment member 1126 also includes a tool alignment member mount 1140 coupled to the second support arm end 1134. The tool alignment member 1126 also includes a tool alignment indication member 1142. The tool alignment indication member 1142 can be coupled to the tool alignment member mount 1140 using, for example, fasteners. The tool alignment indication member 1142 can be made of similar materials and produced by similar methods as the handle alignment indication member 1124. In some configurations, the handle alignment indication member 1124 and the tool alignment indication member 1142 can have the same shape and size to improve manufacturing efficiency and cost.

[0310] In addition, refer to Fig.80 and Fig.85, the handle alignment indication member 1124 and / or the tool alignment indication member 1142 may include a laser mark 1144 to facilitate visual indication of the posture of the handle alignment indication member 1124 relative to the tool alignment indication member 1142 and / or the tool plane BP. Therefore, when the tool support 18 does not have an optimal range of motion relative to the handheld portion 16, the laser mark 1144 enhances the visual indication provided to the operator of the need to adjust the posture of the handheld portion. Although a laser can be used to form the laser mark, other methods of forming the mark on the handle alignment indication member 1124 and / or the tool alignment indication member 1142 are contemplated, such as but not limited to printing, scribing, etching, etc. In another configuration, see Fig.85 , the polymer used to form the handle alignment indication member 1124 and / or the tool alignment indication member 1142 may be dyed to provide a contrasting color to surrounding components, thereby enhancing the visual indication provided to the operator.

[0311] As briefly described above, the instrument 14 may include a tracker that enables the posture of the instrument 14 to be tracked by the surgical navigation system. Figures 78-86 , the instrument 14 may include a tracker 1150 coupled to the saw blade support 18 or other tool support. Thus, the tracker 1150 enables the robotic surgery system 10 to determine the current position of the tool plane BP in space or the axis of the tool in space. The tracker 1150 includes a tracker frame 1152. The tracker frame 1152 includes at least two faces 1156. At least two faces 1156 are non-planar with respect to each other. For example, Fig.78 At least two faces are shown arranged in a wedge shape relative to each other. The tracker 1150 also includes at least six optical markers 1154 coupled to the tracker frame. At least three of the six optical markers 1154 are attached to each of the at least two faces 1156. In some configurations, the multiple markers 1154 coupled to the at least two faces 1156 are arranged to be mirror images of each other, while in other configurations, the multiple markers 1154 are arranged asymmetrically. In other configurations, the at least two faces 1156 may be located on opposite sides of a plane that bisects the device 14.

[0312] In addition, the tracker frame 1152 may define an instrument engagement hole 1170 for receiving a proximal portion of the instrument 14. Thus, the instrument 14 may include a mount 1172 for engaging and retaining the tracker frame 1152 relative to the instrument 14. For example, when the tracker 1150 is coupled to the instrument 14, the tracker frame 1152 may partially surround the mount 1172. In some examples, the mount 1172 may be a notch. The tracker 1150 may also include a battery 1174 for powering the tracker 1150. For example, in some configurations, the optical marker 1154 may be an active marker having a light source (e.g., an infrared LED) that emits light. The battery may also power the antenna 1162, which will be described in further detail below. For example, one or more of the at least six optical markers 1154 may be LED emitters, and the one or more LED emitters are arranged to form at least two arrays, wherein each array includes at least one LED emitter.

[0313] As also described above, the robotic surgical system 10 includes a control system 60. Fig.86 The control system 60 includes the navigation system 32 and the instrument controller 28 and other components. The control system 60 is configured to control the actuators 21, 22, 23 to align the tool plane BP of the instrument 14 with at least one target plane 184. Fig.86 , the tracker 1150 includes an input device 1160, an antenna 1162, and a tracker controller 1164. The tracker controller 1164 is coupled to the input device 1160 and the antenna 1162 to provide input signals to the navigation system 32. Therefore, the control system 60 may be configured to sense the input signal from the input device 1160, and to change the position change of the tool support 18 through the actuators 21, 22, 23 to align the tool support 18 with a different one of a plurality of target planes 184. In addition, the navigation system 32 may be configured to determine the tool plane BP of the saw blade 20 based on a target surface, which is based on the selected target plane 184. Alternatively, the control system 60 may be configured to sense the input signal from the input device and to align the tool support with a different one of a plurality of axes (as opposed to a plane), and / or the navigation system may be configured to determine the posture of the tool support based on a target surface, which is based on the selected target axis.

[0314] On the other hand, the robotic surgery system 10 may be configured to determine the current tool plane BP using the tool tracker 1150 and the navigation system 32. Therefore, the robotic surgery system 10 may select one of the plurality of target planes 184 using the input device 1160, and adjust the tool support 18 using the plurality of actuators 21, 22, 23 to place the current plane BP in accordance with the selected target plane 184.

[0315] Now turn to Figures 87-90 In addition to the different types of connections between the tool alignment protrusions 1203, 1210 and the tool support 18, the instrument 14 also includes a variety of support arms 1224, 1254 for the handle alignment member 1204. Fig.87 and Fig.88 , the instrument 14 includes an integrated handle alignment member 1202 wherein a handle alignment protrusion 1203 protrudes from the tool support 18 . Fig.87 The instrument is shown in a disengaged state 1219 and includes a handle support arm 1224 configured as a deformable support. The handle alignment member 1204 includes a base 1208 connected to the support arm 1224, and the support arm 1224 is connected to the handle alignment protrusion 1206. The base 1208 of the handle alignment member 1204 includes a mating feature 1213, which is configured to be received by a receiver 1214 at a mounting area 1216 on the handheld portion 16. In this example, the mating feature 1213 is a pin, however, other accessories are contemplated, such as magnets, fasteners, biasing members, or combinations thereof as described above. In this example, the tool alignment member 1202 and the tool alignment protrusion 1203 are integral with the tool support 18.

[0316] and Fig.87 similar, Fig.88 Also included is an integral tool alignment member 1202 and a tool alignment tab 1203. However, in this example, the handle alignment member 1204 includes a non-deformed solid support arm 1254. In contrast, when there is a mutual relationship between the handle alignment member 1204 and the tool alignment member 1202, the base 1208 will disengage from the mounting area 1216 when a threshold force is applied to the handle alignment member 1204, thereby transitioning the handle alignment member 1204 from the engaged position 1218 to the disengaged position 1219.

[0317] Fig.89 and Fig.90 The instrument 14 is shown with an obstacle 1260 between the tool alignment member 1202 and the handle alignment member 1204. Fig.89 , the tool alignment member 1202 is a removable component having a base 1217 connected to the tool support at the mounting area 1220. The base 1217 of the tool alignment member 1202 is connected to the tool alignment protrusion 1210. The obstacle 1260 is sandwiched between the tool alignment protrusion 1210 and the handle alignment protrusion 1206. In this example, the tool alignment member 1202 is transitioning from a retaining state to a disengaged state to prevent squeezing of the obstacle 1260 and avoid damage to the instrument 14. Similarly, Fig.90An obstacle 1260 is shown between the tool alignment protrusion 1203 and the handle alignment protrusion 1206. In this example, the deformable support arm 1224 is biased away from the obstacle 1260 to prevent squeezing the obstacle 1260 and avoid damaging the instrument 14.

[0318] In the Figures 91-98 In another configuration of the apparatus 14, the apparatus 14 is shown with a guide array 1300. The guide array 1300 provides a visual indication to the operator of the attitude of the tool support 18 relative to the handheld portion 16 during operation of the apparatus 14, thereby providing the operator with a visual indication of the required changes in the pitch orientation, roll orientation, and z-axis translation of the handheld portion 16 to achieve the desired attitude of the tool 20 while providing maximum adjustability for the actuator assembly 400 (as described above) to maintain the tool 20 at the target plane TP. The guide array 1300 includes a handle alignment member 1304 extending from the handheld portion 16 for providing a visual indication to the operator to guide the operator on how to move the handheld portion 16 to provide sufficient adjustability for the apparatus 14 by maintaining the actuators 21, 22, 23 of the actuator assembly 400 near their original positions or other predetermined positions.

[0319] The handle alignment member 1304 may have any suitable shape or configuration that will provide an operator user with a visual indication that one or more of the actuators 21, 22, 23 of the actuator assembly 400 has moved from its respective original position. Figures 91-98 , the handle alignment member 1304 may include a handle alignment protrusion 1306. The handle alignment protrusion 1306 may extend toward the tool support 18. It is worth noting that, with reference to Figures 91-98 , the handle alignment protrusion 1306 may be shaped such that at least a portion 1324 of the handle alignment protrusion 1306 is disposed at an oblique angle to the longitudinal axis and the transverse axis of the tool 20 / tool ​​support 18 as described above.

[0320] In one example, the handle alignment member 1304 can define a hook-shaped handle alignment protrusion 1306. The hook-shaped handle alignment protrusion 1306 can define an arcuate handle alignment edge that sweeps inwardly toward the tool support 18 to define the above-mentioned angle of inclination. Figures 91-98 The configuration in FIG. 1 shows a hook-shaped handle alignment protrusion 1306 , but any suitable edge defining an angle of inclination is contemplated, such as, but not limited to, a polygonal edge, a stepped edge, etc.

[0321] In some configurations, such as Figures 91-98As shown, when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions, at least a portion of the handle alignment protrusion 1306 and the tool plane BP can be aligned, thereby providing a visual indication to the operator that the tool support 18 has an optimal range of motion relative to the handheld portion 16. In some configurations, the term "aligned" is defined as at least a portion of the handle alignment protrusion 1306 being substantially coplanar or intersecting with the tool plane BP within an applicable tolerance. Specifically, when in the home position, the adjustable amount of the actuators 21, 22, 23 of the actuator assembly 400 is maximized to maintain the tool 20 in a desired posture. In some examples, the alignment between at least a portion of the handle alignment protrusion 1306 and the tool plane BP can be 99% or more aligned, 90% or more aligned, 70% or more aligned, or even 60% or more aligned. In other examples, the applicable alignment may be within a specified proximity of the target pose in each individual degree of freedom, such as within a range of 1% deviation from the target pose, 5% deviation from the target pose, 10% deviation from the target pose, or even 20% or more deviation from the target pose. Similarly, the applicable alignment may be within 1 mm of the target pose, within 2 mm of the target pose, or even within 5 mm or more of the target pose in each individual degree of freedom. In addition, the applicable alignment may be within 1 degree or more deviation from the target pose, within 5 degrees or more deviation from the target pose, within 15 degrees or more deviation from the target pose, or even within 30 degrees or more deviation from the target pose in terms of roll and / or pitch.

[0322] In contrast, tool plane BP and handle alignment tab 1306 are configured to be misaligned when handheld portion 16 is in a posture that does not provide an optimal range of motion, thereby providing a visual indication that handheld portion 16 is in a posture that does not provide an optimal range of motion for tool support 18 and therefore requires adjustment by the operator (discussed in further detail below). In some configurations, guide array 1300 also includes tool alignment member 1302. In one configuration, for example, with reference to Figures 91-98 , the tool alignment member 1302 can be part of the tool support 18. The tool alignment member 1302 can have any shape or structure that can provide a visual indication of the posture of the tool plane BP relative to the handle alignment member 1304. Figures 91-96 In this example, the tool alignment member 1302 is a portion of the tool support 18 that surrounds at least a portion of the actuator assembly 400. In another example, for example, Fig.97 and 98, the tool alignment member 1302 is a tool alignment protrusion 1303 that is configured as a shroud clamp that conforms to the shape of the tool support 18. In some examples, similar to the handle alignment protrusion 1306, the tool alignment members 1302, 1303 may have at least a portion that is arranged at an oblique angle to the longitudinal axis and the transverse axis of the tool 20 / tool ​​support 18 as described above. In some examples, the oblique angle is a formed part of the tool support. Although the handle alignment protrusion 1306 and the tool alignment protrusion 1303 are described as being oblique, other shapes are contemplated.

[0323] It is contemplated that the optimal range of motion may be the maximum range of motion in one, two, three or more degrees of freedom. It is also contemplated that the optimal range of motion may not necessarily be the maximum range of motion, but rather the range of motion required for a preferred posture of the tool support for making a particular cut using a saw or other pre-planned virtual object (e.g., a planned cut or planned axis). In certain configurations, the optimal range of motion need not be the center of the range of motion in one or more degrees of freedom, but may be the center of the range of motion in one, two or three degrees of freedom.

[0324] In some configurations, the tool alignment member 1302 and / or the tool alignment protrusion 1303 may be substantially aligned with the tool plane BP. For example, the tool alignment member 1302 and / or the tool alignment protrusion 1303 may be coplanar with the tool plane BP. In this way, the tool alignment member 1302 and / or the tool alignment protrusion 1303 may be used as a visual representation of the orientation of the tool plane BP in order to provide a visual indication of the posture of the handheld portion 16 relative to the tool support 18. However, it is important to note that the handle alignment member 1304 can be used to provide a visual indication of the posture of the handheld portion 16 relative to the tool support 18 without adding the tool alignment protrusion 1303. Specifically, the user can still perceive the relationship of the tool support 18 relative to the handheld portion 16 by examining the relationship between the handle alignment member 1304 and the tool support 18.

[0325] The handle alignment member 1304 may be removably coupled to the handheld portion 16. Figures 91-98 In the example shown, the handle alignment member 1304 is shown as a unitary member having a first arm 1307 and a second arm 1309 connected by a retainer 1308. The first arm 1307, the second arm 1309 and the retainer 1308 together form a coupling that generates a biasing force on the handheld portion 16 at a mounting location 1316 (also referred to as a mount). The handle alignment member 1304 has a shape that is complementary to at least a portion of the handheld portion 16.

[0326] In some examples, the handle alignment member 1304 is removably coupled to the handheld portion 16 such that the handle alignment member 1304 can be separated as desired or in the event that an operator's hand is pinched between the handle alignment member 1304 and the tool alignment member 1302 and / or the tool alignment tab 1303 of the tool support 18. Any suitable means of removably coupling the handle alignment member 1304 to the handheld portion 16 are contemplated (e.g., magnets, latches, clips, fasteners, shackles, etc. and combinations thereof).

[0327] In some examples, the handle alignment member 1304 is configured to transition between a retaining state 1318 in which the handle alignment member 1304 is connected to the hand-held portion 16 and a disengaged state 1319 in which the handle alignment member 1304 is separated from the hand-held portion 16. In the retaining state 1318, the first arm 1307, the second arm 1309, and the retainer 1308 of the handle alignment member 16 provide a biasing force on the hand-held portion 16. During operation or when it is desired to remove the handle alignment member 1304, when a threshold force greater than the biasing force of the handle alignment member 1304 is applied to the handle alignment member 1304, the handle alignment member 1304 is transitioned from the retaining state 1318 to the disengaged state 1319, thereby causing the handle alignment member 1304 to be disengaged and / or separated from the hand-held portion 16. In some examples where the handle alignment member 1304 utilizes a biasing force to maintain connection with the handheld portion 16, the retainer 1308, the first arm 1307, and the second arm 1309 may be made of plastic. In other examples where the handle alignment member 1304 utilizes a biasing force to couple with the handheld portion 16, the retainer 1308, the first arm 1307, and the second arm 1309 may be made of metal (e.g., titanium).

[0328] In some examples, to secure the handle alignment member 1304 to the handheld portion 16, the first arm 1307 and the second arm 1309 include a protrusion 1313 for interfacing with a mounting seat 1316 on the handheld portion 16. In this example, the mounting seat 1316 has a complementary channel 1317 for receiving the protrusion 1313. Figures 93-96 In the example specifically shown in FIG. 1 , the protrusion 1313 is an elongated protrusion having a rounded profile. Similarly, each channel 1317 of the mounting location 1316 has a rounded recessed shape to receive the protrusion 1313 of the handle alignment member 1304. Similarly, in other examples, such as Fig.99 As shown, the handle alignment member 1404 includes a log-shaped protrusion 1413 on the arms 1407, 1409 extending from the retainer 1408. In another example, for example Fig.100As shown, the handle alignment member 1504 includes two circular protrusions 1513 on arms 1507, 1509 extending from the retainer 1508. In addition, it is contemplated that the hand-held portion 16 may have a protrusion at the mounting location 1316, and the handle alignment member 1304 may include a complementary channel for receiving the protrusion of the hand-held portion 16. Moreover, in addition to the biasing retention force, a combination of retention methods may be used, such as magnetic features.

[0329] The handle alignment member 1304 may further include support arms 1324. Each support arm 1324 may extend from the first arm 1307 and the second arm 1309, respectively, to support the handle alignment protrusion 1306. Figures 91-98 As seen in the figure, the support arm 1324 extends upward from the first arm 1307 and the second arm 1309 of the handle alignment member 1304 so that when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective original positions, the handle alignment protrusion 1306 is aligned with the tool plane BP. In some examples, the handle alignment member 1304 is rigid relative to the handheld portion 16 to facilitate the function of the handle alignment member 1304. The handle alignment member 1304 can be formed by any applicable material (e.g., plastic, aluminum, steel, composite materials, etc. or a combination thereof). In some examples, the handle alignment member 1304 can be made of titanium. In other examples, the handle alignment member 1304 can be made of plastic. In other examples, a combination of materials can be used to form the handle alignment member 1304. In addition, the handle alignment member 1304 can be formed using any applicable production method (which includes 3D printing, casting, machining, injection molding, stamping, etc. or a combination thereof).

[0330] The handle alignment tab 1306 is connected to the first arm 1307 and the second arm 1309 of the handle alignment member 1304. The handle alignment tab 1306 can be used to help the user determine the best position to place the handheld portion 16 relative to the tool support 18 by providing a visual indication of the position of the handheld portion 16 and the tool support 18 relative to each other. To assist in the visual indication, the handle alignment tab 1306 may include one or more visual markings to provide greater visibility of any differences in the movement of the handheld portion 16 and the tool support 18 relative to each other away from the original position of the actuator assembly 400. In some examples, the handle alignment tab may include one or more colors. In other examples, a pattern or texture may be used. Fig.96 One example of a handle alignment protrusion 1306 is shown, which includes several grooves 1314 running along the length of the top side of the handle alignment protrusion 1306. Likewise, Figures 99-101Also included are grooves 1414, 1514, 1614 that run along the length of the top side of the handle alignment protrusions 1406, 1506, 1606. In other examples, the handle alignment protrusions 1306, 1406, 1506, 1606 may include ridges that extend above the surface of the handle alignment protrusions 1306, 1406, 1506, 1606. In further examples, adding one or more colors to the handle alignment protrusions 1306, 1406, 1506, 1606 will provide additional visual guidance. In some examples, depending on the materials and manufacturing processes used to manufacture the handle alignment members 1304, 1404, 1504, 1604, colors may be added to the handle alignment members 1304, 1404, 1504, 1604, particularly the handle alignment protrusions 1306, 1406, 1506, 1606, by injection molding, 3D printing, anodizing, or a combination thereof.

[0331] refer to Fig.97 and 98 , the tool alignment member 1302 may also include a tool alignment tab 1303 configured to be coupled to the tool support 18. In this example, the tool alignment tab 1303 is a fixture disposed around a portion of the tool support 18, the fixture having a size and thickness for use as the tool alignment member 1302. Although a fixture is used as the tool alignment member 1302 and the tool alignment tab 1303, any other applicable means for providing at least one visual marker at any applicable location to facilitate the function of the tool alignment member 1302 may be envisioned. Similar to the handle alignment member 1304 discussed above, the tool alignment member 1302 may be formed of any applicable material (e.g., plastic, aluminum, steel, composite materials, etc., or combinations thereof). In addition, the tool alignment member may be formed using any applicable production method (which includes 3D printing, casting, machining, injection molding, stamping, etc., or combinations thereof).

[0332] Similar to Figures 91-100 , Fig.101 1604. The handle alignment member 1604 includes a first arm 1607 and a second arm 1609 connected by a retainer 1608. The first arm 1607 and the second arm 1609 each include a protrusion 1613 for connecting with the hand-held portion 16 in the retaining state 1318. The first arm 1607 and the second arm 1609 are each connected to a support arm 1624, which is coupled to the handle alignment protrusion 1606. In this example, the retainer 1608 includes a recess 1610 for increasing the elasticity of the handle alignment member 1604. In some examples, adding the recess 1610 to the retainer 1608 allows a harder material (e.g., titanium) to have greater compliance, thereby reducing the force required to connect and disconnect the handle alignment member 1604 from the hand-held portion 16.

[0333] refer to Fig.102 In another configuration, the instrument 14 may include a shield 1700 coupled to the tool support 18 and the hand portion 16 and extending therebetween. The shield 1700 may be included on the instrument 14 simultaneously with the tool alignment member 1702. The shield 1700 may be formed of any suitable material (e.g., plastic, rubber, composite material, etc., or a combination thereof) that is compatible with a sterilization process (e.g., an autoclave process or a hydrogen peroxide sterilization process). The shield 1700 may be coupled to the saw blade support 18 and the hand portion 16 using any suitable means (e.g., clamps, fasteners, adhesives, etc., or a combination thereof). In some configurations, the shield 1700 may surround at least one of the plurality of actuators 21, 22, 23. The shield 1700 may include an accordion-like fold that is capable of expanding and bending when the saw blade support 18 is moved relative to the hand portion 16. In addition, in some configurations, the shield 1700 defines at least two shield landmarks 1708 (described in further detail below). In some configurations, there may be two or more, five or more, ten or more, or even a plurality of guard landmarks 1708. As the blade support 18 is moved relative to the hand-held portion 16, the displacement of the guard landmarks 1708 relative to each other and relative to the tool alignment member 1702 provides a visual indication of the attitude of the tool support 18 relative to the hand-held portion 16. It is also contemplated that the guard 1700 and various landmarks may be used with a handle alignment member, a tool alignment member, or both.

[0334] In some configurations, at least two shield landmarks 1708 include at least a first visual indicator and a second visual indicator. In one example, for example Fig.102 As shown, at least one of the shield landmarks 1708 can be a crease 1704, and another shield landmark can be a colored section 1705 of the shield 1700. In some configurations, the crease 1704 can be defined by an accordion-like fold. The crease 1704 can define a plane that can help provide a visual indication of the posture of the tool support 18 relative to the handheld portion 16. In some examples, the colored section 1705 can be positioned on a portion of the crease 1704 to highlight the plane defined by at least one crease 1704, thereby providing a visual indication relative to the tool alignment member 1702 that the plurality of actuators 21, 22, 23 are in their respective home positions and that the instrument 14 therefore has an optimal range of motion.

[0335] Although not shown, additional variations of the shield 1700 are contemplated that include alternative configurations of the shield landmarks 1704 , 1705 . For example, the shield 1700 may include variations of the shield landmarks 1704 , 1705 that position the color segments 1705 along one or more segments of the fold 1704 .

[0336] Additional provisions of the present invention are included below:

[0337] I. A handheld surgical robot system for supporting a saw blade, the handheld surgical robot system comprising:

[0338] Handheld part;

[0339] a saw blade support movably coupled to the handheld portion, the saw blade support being configured to support a saw blade;

[0340] an actuator assembly operatively attached to the blade support and the hand-held portion, the actuator assembly being configured to move the blade support relative to the hand-held portion in multiple degrees of freedom;

[0341] a tool alignment member coupled to and extending from the saw blade support; and

[0342] a handle alignment member coupled to and extending from the hand-held portion;

[0343] Wherein, when the saw blade support has a desired range of motion relative to the handheld portion, at least a portion of the tool alignment member is aligned with at least a portion of the handle alignment member.

[0344] II. A handheld robotic system as described in claim I, wherein the actuator assembly includes a plurality of actuators, and each of the plurality of actuators is configured to move between a first position and a second position to move the saw blade support relative to the handheld portion, an original position being a midpoint between the first position and the second position of each of the plurality of actuators, and when at least two of the plurality of actuators are in their original positions, the saw blade support has the desired range of motion.

[0345] III. A handheld robotic system as described in clause II, wherein, when the handheld portion is in a posture that does not provide the desired range of motion, the tool alignment member is misaligned with the handle alignment member, thereby providing a visual indication that the handheld portion is in a posture that does not provide the desired range of motion to the saw blade support.

[0346] IV. A handheld robotic system as described in any of clauses I-III, wherein the tool alignment member and the handle alignment member are arranged and sized relative to each other so that the tool alignment member and the handle alignment member do not collide at any position between the first position and the second position of each of the plurality of actuators, the first position and the second position common to each of the plurality of actuators defining a potential range of motion of the saw blade support relative to the handheld portion, the potential range of motion defining a space having a height of approximately 150 mm and a width of approximately 115 mm.

[0347] V. A handheld robotic system as described in any of clauses I-IV, wherein the tool alignment member is arranged on the saw blade support and the handle alignment member is arranged on the handheld portion, so that a portion of the tool alignment member and a portion of the handle alignment member are positioned above the grip of the handheld portion and are visible from the proximal end of the saw blade support when the multiple actuators move the saw blade support relative to the handheld portion.

[0348] VI. A handheld robotic system as described in any of clauses IV, wherein the plurality of actuators are configured to adjust at least the pitch of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first pitch relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second pitch relationship of the saw blade support relative to the handheld portion;

[0349] wherein the first spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the hand-held portion, and the second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of the pitch of the saw blade support relative to the hand-held portion, with the distal portion of the tool alignment member being further away from the tool plane along the longitudinal axis in the direction of the pitch than the proximal portion of the tool alignment member.

[0350] VII. A handheld robotic system as described in any of clauses I-VI, wherein the plurality of actuators are configured to at least adjust the elevation of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first elevation relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second elevation relationship of the saw blade support relative to the handheld portion;

[0351] wherein the first spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the hand-held portion, and wherein the second spatial arrangement provides a visual indication of the elevation of the saw blade support relative to the hand-held portion, the tool alignment member being at least partially located above or below the handle alignment member in the direction of the elevation.

[0352] VIII. A handheld robotic system as described in any of clauses I-VII, wherein the plurality of actuators are configured to adjust at least a roll of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first roll relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second roll relationship of the saw blade support relative to the handheld portion;

[0353] wherein the spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the hand-held portion, and wherein the second spatial arrangement provides a visual indication of the tilt of the saw blade support relative to the hand-held portion, with the distal portion of the tool alignment member being further away from the tool plane along the transverse axis in the direction of the tilt than the proximal portion of the tool alignment member.

[0354] IX. A handheld robotic system as described in any of clauses I-VIII, wherein:

[0355] The tool alignment member includes a first tool alignment member and a second tool alignment member, wherein the first tool alignment member and the second tool alignment member extend from opposite sides of the saw blade support;

[0356] The handle alignment member includes a first handle alignment member and a second handle alignment member, wherein the first handle alignment member and the second handle alignment member extend from the hand-held portion;

[0357] wherein, when the saw blade support has the desired range of motion relative to the handheld portion, the first tool alignment member and the first handle alignment member and the second tool alignment member and the second handle alignment member intersect each other, respectively; and

[0358] wherein the first and second tool alignment members and the first and second handle alignment members are visible from a proximal end of the saw blade support throughout a range of motion of the saw blade support relative to the handheld portion.

[0359] X. A handheld robotic system as described in clause IX, wherein the plurality of actuators are configured to adjust at least the pitch of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first pitch relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second pitch relationship of the saw blade support relative to the handheld portion;

[0360] wherein the first spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the handheld portion, and the second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of the pitch of the saw blade support relative to the handheld portion, the distal portion of at least one of the tool alignment members being further away from the tool plane along the longitudinal axis in the direction of the pitch than the proximal portion of the tool alignment member.

[0361] XI. A handheld robotic system as described in any of clauses IX and X, wherein the plurality of actuators are configured to at least adjust the elevation of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first elevation relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second elevation relationship of the saw blade support relative to the handheld portion;

[0362] wherein the first spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the handheld portion, and wherein the second spatial arrangement provides a visual indication of the elevation of the saw blade support relative to the handheld portion, the tool alignment member being at least partially located above or below the handle alignment member in the direction of the elevation.

[0363] XII. A handheld robotic system as described in any of clauses IX-XI, wherein the plurality of actuators are configured to adjust at least a roll of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first roll relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second roll relationship of the saw blade support relative to the handheld portion;

[0364] wherein the spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the hand-held portion, and wherein the second spatial arrangement provides a visual indication of the tilt of the saw blade support relative to the hand-held portion, the distal portion of at least one of the tool alignment members being further away from the tool plane along the transverse axis in the direction of the tilt than the proximal portion of the tool alignment member.

[0365] XIII. A handheld robotic system as described in any of clauses IX-XII, wherein the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively, when the saw blade support has a desired range of motion relative to the handheld portion.

[0366] XIV. A handheld robotic system as described in clause III, wherein the tool alignment member and the handle alignment member provide a first visual mark and a second visual mark, the first visual mark being visually distinguishable from the second visual mark, and when the tool alignment member is not aligned with the handle alignment member, the first visual mark is visible from the proximal end of the handheld portion, and when the tool alignment member is aligned with the handle alignment member, the second visual mark is visible from the proximal end of the handheld portion.

[0367] XV. The handheld robotic system of clause XIV, wherein the tool alignment member and the handle alignment member each have the first visual marker and the second visual marker.

[0368] XVI. A handheld robotic system as described in clause XV, wherein the first visual mark is a first color and the second visual mark is a second color, the first color is visible when the tool alignment member is aligned with the handle alignment member, and at least one of the second visual marks is visible when the tool alignment member is not aligned with the handle alignment member.

[0369] XVII. A handheld robotic system as described in clause XVI, wherein the tool alignment member and the handle alignment member further include a top surface and a side surface; and

[0370] wherein the top surface includes the first visual mark and the side surface includes the second visual mark, so that when the tool alignment member and the handle alignment member are not aligned with each other, the second visual mark is revealed, thereby providing an indication that one or more of the plurality of actuators have left their original position.

[0371] XVIII. A handheld robotic system as described in any of clauses I-XVII, wherein the tool alignment member is a saw blade.

[0372] XIX. A handheld robotic system as described in any of clauses I-XVIII, wherein the system also includes a tracker for a surgical navigation system, the tracker being detachably connected to the saw blade support, the tracker including a tracking element for positioning and the tool alignment member; and the tracker is part of the tool alignment member.

[0373] XX. A handheld robotic system for supporting a saw blade, the handheld robotic system comprising:

[0374] Handheld part;

[0375] a saw blade support movably coupled to the handheld portion to support the saw blade;

[0376] an actuator assembly operatively attached to the blade support and the hand-held portion, the actuator assembly being configured to move the blade support relative to the hand-held portion in multiple degrees of freedom;

[0377] first and second tool alignment members coupled to and extending from the saw blade support on both sides; and

[0378] a first handle alignment member and a second handle alignment member coupled to and extending from the hand-held portion;

[0379] Wherein, when the saw blade support has a desired range of motion relative to the handheld portion, the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively.

[0380] XXI. The handheld robotic system of clause XX, wherein the actuator assembly comprises a plurality of actuators, and each of the plurality of actuators is configured to move between a first position and a second position to move the saw blade support relative to the handheld portion within a range of motion; and

[0381] wherein the home position is a midpoint between the first position and the second position of each of the plurality of actuators, and wherein the blade support and the handheld portion have the desired range of motion when each of the plurality of actuators is in its home position.

[0382] XXII. A handheld robotic system as described in clause XXI, wherein, when the saw blade support and the handheld portion are moved to a position other than the original position, the first tool alignment member and the second tool alignment member are misaligned with the first handle alignment member and the second handle alignment member, respectively, thereby providing a visual indication that the saw blade support and the handheld portion are in a position that does not have the desired range of motion.

[0383] XXIII. A handheld robotic system as described in clause XXII, wherein the tool alignment member and the handle alignment member further include a top surface and a side surface; and

[0384] wherein the top surface includes a first visual mark and the side surface includes a second visual mark, the first visual mark being different from the second visual mark such that when the tool alignment member and the handle alignment member are not aligned with each other, the second visual mark is revealed on one or both of the tool alignment member and the handle alignment member, thereby providing an indication that one or more of the plurality of actuators have left their original positions.

[0385] XXIV. A handheld robotic system as described in clause XXIII, wherein the plurality of actuators are configured to adjust at least the pitch of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first pitch relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second pitch relationship of the saw blade support relative to the handheld portion;

[0386] wherein the first spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the handheld portion, and the second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of the pitch of the saw blade support relative to the handheld portion, the distal portion of at least one of the tool alignment members being further away from the tool plane along the longitudinal axis in the direction of the pitch than the proximal portion of the tool alignment member.

[0387] XXV. A handheld robotic system as described in any of clauses XXIII and XXIV, wherein the plurality of actuators are configured to at least adjust the elevation of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first elevation relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second elevation relationship of the saw blade support relative to the handheld portion;

[0388] wherein the first spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the handheld portion, and wherein the second spatial arrangement provides a visual indication of the elevation of the saw blade support relative to the handheld portion, the tool alignment member being at least partially located above or below the handle alignment member in the direction of the elevation.

[0389] XXVI. A handheld robotic system as described in any of clauses XXIII-XXV, wherein the plurality of actuators are configured to adjust at least a roll of the saw blade support relative to the handheld portion, and a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first roll relationship of the saw blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a second roll relationship of the saw blade support relative to the handheld portion;

[0390] wherein the spatial arrangement provides a visual indication that the tool alignment member is aligned with the handle alignment member and that the saw blade support has the desired range of motion relative to the hand-held portion, and wherein the second spatial arrangement provides a visual indication of the tilt of the saw blade support relative to the hand-held portion, the distal portion of at least one of the tool alignment members being further away from the tool plane along the transverse axis in the direction of the tilt than the proximal portion of the tool alignment member.

[0391] XXVII. A visual indication system for use with a handheld robotic system comprising a tool, a handheld portion, a saw blade support movably coupled to the handheld portion to support the tool, and a plurality of actuators operatively interconnecting the saw blade support and the handheld portion and configured to move the saw blade support relative to the handheld portion in a plurality of degrees of freedom, the visual indication system comprising:

[0392] a guard coupled to the blade support and the hand portion and extending between the tool support and the hand portion such that the guard surrounds at least one of the plurality of actuators;

[0393] Wherein, the guard defines at least two guard landmarks, and the at least two guard landmarks are configured to shift relative to each other when the saw blade support and the handheld portion are misaligned with each other to provide a visual indication of the posture of the saw blade support relative to the handheld portion.

[0394] XXVIII. A visual indication system as described in clause XXVII, wherein the at least two guard markers include at least two creases, the creases defining planes that are substantially parallel in a first position, the planes being offset a first distance relative to each other when the saw blade support and the hand holding portion are moved to the first position, and the at least two defined planes intersecting when the saw blade support and the hand holding portion are moved to the second position.

[0395] XXIX. A visual indication system as described in clause XXVIII, wherein the saw blade support defines a saw blade plane, and when the saw blade support and the handheld portion are in the first position, the at least two folds are substantially parallel to the saw blade plane.

[0396] XXX. The visual indicator system of clause XXIX, wherein the at least two shield landmarks include a first visual marker and a second visual marker, the first visual marker being visually distinguishable from the second visual marker, and the first visual marker being a first color and the second visual marker being a second color; and

[0397] Wherein, when the saw blade support is in the first position, the first color is visible, and when the saw blade support is in the second position, at least one of the second visual indicia is visible.

[0398] XXXI. A handheld robotic system for supporting a saw blade, the handheld robotic system comprising:

[0399] Handheld part;

[0400] a saw blade support movably coupled to the handheld portion to support the saw blade;

[0401] a plurality of actuators operatively interconnecting the blade support and the hand-held portion and configured to move the blade support relative to the hand-held portion in a plurality of degrees of freedom;

[0402] a light source located on the saw blade support;

[0403] first and second tool alignment members coupled to and extending from the saw blade support on both sides; and

[0404] a first handle alignment member and a second handle alignment member coupled to and extending from the hand-held portion;

[0405] wherein the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively, when the saw blade support has a desired range of motion relative to the handheld portion; and

[0406] Wherein, when the saw blade support has the desired range of motion, the light source is illuminated ...

Claims

1. A handheld surgical robot system, comprising: defining a hand-held portion of the mount; a tool support movably coupled to the handheld portion, the tool support including a tool mount defining a tool plane; a work tool removably coupled to the tool support; an actuator assembly operatively attached to the tool support and the handheld portion, the actuator assembly configured to move the tool support relative to the handheld portion in multiple degrees of freedom; as well as a handle alignment member detachably coupled to the hand-held portion, the handle alignment member having: a coupling shaped to releasably engage the mount and operable between: a retaining state in which a retaining force is applied to one of the mount and the coupler to inhibit relative movement between the handle alignment member and the hand-held portion; as well as A disengaged state in which the retaining force is not applied to one of the mount and the coupler.

2. The handheld surgical robot system according to claim 1, wherein: The handle alignment member disengages from the hand-held portion at a threshold force greater than the retaining force.

3. The handheld surgical robot system according to claim 1, wherein: The coupler has a shape complementary to at least a portion of the handheld portion.

4. The handheld surgical robot system according to claim 3, wherein: The coupler of the handle alignment member has a first arm and a second arm connected by a retainer, the first arm, the second arm and the retainer being biased against the mount in the retained state to apply the retaining force to the hand-held portion.

5. The handheld surgical robot system according to claim 4, wherein: The first arm and the second arm each include a protrusion, and the mount includes a receiving channel on the handheld portion that is complementary to the protrusions on the first arm and the second arm.

6. The handheld surgical robot system according to claim 5, wherein: The protrusion has a rounded shape, and the receiving channel is rounded to receive the protrusion.

7. The handheld surgical robot system according to claim 4, wherein: Each of the first and second arms includes a rounded channel, and the mount includes complementarily shaped protrusions on at least two sides of the handheld portion.

8. The handheld surgical robot system according to claim 1, wherein: The handheld surgical robotic system also includes a tool alignment member extending from the tool support, the tool alignment member including a tool alignment tab extending at least partially toward the handle alignment member.

9. The handheld surgical robot system according to claim 8, wherein: The tool alignment member is removably connected to the tool support.

10. The handheld surgical robot system according to claim 8, wherein: The handheld surgical robotic system also includes a shroud surrounding the actuator assembly between the handheld portion and the tool support, the shroud being attached to the tool support by a clamp, and the clamp being the tool alignment member.

11. The handheld surgical robot system according to claim 1, wherein: The handle alignment member is made of plastic.

12. The handheld surgical robot system according to claim 1, wherein: The handle alignment member is made of titanium.

13. The handheld surgical robot system according to claim 12, wherein: The handle alignment member is 3D printed.

14. The handheld surgical robot system according to claim 12, wherein: The handle alignment member includes a visual indicia that is at least one groove along the handle alignment member.

15. The handheld surgical robot system according to claim 4, wherein: The coupler includes a shield between the coupler and the handheld portion.

16. The handheld surgical robot system of claim 1, wherein: The handle alignment feature includes one or more visual indicia.

17. The handheld surgical robot system of claim 8, wherein: The handle alignment feature includes a first visual indicia and the tool alignment feature includes a second visual indicia.

18. The handheld surgical robot system of claim 17, wherein: The first visual indicia is a first color and the second visual indicia is a second color.

19. The handheld surgical robot system of claim 18, wherein: The handle alignment member and the tool alignment member each further include an inclined surface and a side surface.

20. The handheld surgical robot system of claim 19, wherein: The inclined surface includes the first visual indicia, and the side surface includes the second visual indicia.

21. The handheld surgical robot system of claim 17, wherein: The first visual indicia is a first color and the second visual indicia is at least one groove.

22. The handheld surgical robot system of claim 4, wherein: The biasing member is made of plastic.

23. The handheld surgical robot system of claim 4, wherein: The biasing member is made of titanium.

24. The handheld surgical robot system of claim 4, wherein: The handle alignment member further comprises two handle alignment protrusions, each of the handle alignment protrusions being connected to the first arm and the second arm, respectively, and Wherein, the handle alignment member is monolithic.

25. The handheld surgical robot system of claim 4, wherein: The retainer includes a recessed portion for increasing the elasticity of the coupling.

26. A handheld surgical robot system, comprising: Handheld part; a tool support movably coupled to the handheld portion, the tool support being configured to support a work tool; a plurality of actuators operatively interconnecting the tool support and the handheld portion, the plurality of actuators being configured to move the tool support relative to the handheld portion in a plurality of degrees of freedom; a shroud surrounding the plurality of actuators between the handheld portion and the tool support; a tool alignment member coupled to and extending from the tool support; as well as A handle alignment member extends from the hand-held portion, the handle alignment member being removably connected to the hand-held portion using a first connector.

27. The handheld robotic system of claim 26, wherein: The tool alignment member is removably connected to the handheld portion and includes a second connector, the first connector of the handle alignment member and the second connector of the tool alignment member being different.

28. The handheld robotic system of claim 26, wherein: The tool alignment member is removably connected to the handheld portion and includes a second connector, the first connector and the second connector being the same type of connector.

29. The handheld robotic system of claim 26, wherein: The shield is connected to the tool support by a clamp, and the clamp is the tool alignment member.

30. The handheld surgical robotic system of claim 26, wherein: The shroud defines at least two shroud landmarks configured to shift relative to each other when the tool support and the hand portion are misaligned relative to each other so that the hand portion is in a posture that does not provide an optimal range of motion to provide a visual indication of the posture of the tool support relative to the hand portion, wherein the at least two shield landmarks include at least two folds defining planes that are substantially parallel and offset relative to each other by a first distance, the tool support having an optimal range of motion relative to the handheld portion; and Wherein, when the tool support and the hand-held portion are misaligned relative to each other, the at least two folds are shifted a second distance relative to each other so that the hand-held portion is in a posture that does not provide the optimal range of motion to provide a visual indication of the posture of the tool support relative to the hand-held portion.

31. The handheld surgical robotic system of claim 26, wherein: The shield is a first color and the tool alignment member is a second color, the first color and the second color being different colors.

32. The handheld surgical robotic system of claim 27, wherein: The first connector is a protrusion on the handle alignment member that is received by a complementary channel on the hand-held portion, and the second connector is a clamp that connects the tool alignment member to the tool support above the shroud.

33. A handheld surgical robot system, comprising: Handheld part; a tool support movably coupled to the handheld portion, the tool support being configured to support a work tool; a plurality of actuators operatively interconnecting the tool support and the handheld portion, the plurality of actuators being configured to move the tool support relative to the handheld portion in a plurality of degrees of freedom; a tool alignment member removably coupled to and extending from the tool support; as well as a handle alignment member removably coupled to and extending from the hand-held portion; Wherein, the handle alignment member is connected to the handheld portion using a first connector, and the tool alignment member is connected to the handheld portion using a second connector.

34. The handheld surgical robot according to claim 33, wherein: The handle alignment member is operable between the following states: a holding state for inhibiting relative movement between the handle alignment member and the hand-held portion; as well as A disengaged state in which the handle alignment member is separated from the handheld portion.

35. The handheld surgical robot according to claim 33, wherein: The tool alignment member is operable between the following states: a holding state for inhibiting relative movement between the tool alignment member and the tool support; and A disengaged state in which the tool alignment member is separated from the tool support.

36. The handheld surgical robot according to claim 34, wherein: The handle alignment guide includes a coupler shaped to releasably engage a base on the hand-held portion, wherein in the retained state a retaining force is exerted on one of the base and the coupler to inhibit relative movement between the handle alignment member and the hand-held portion.

37. The handheld surgical robot according to claim 36, wherein: The handle alignment member disengages from the hand-held portion at a threshold force greater than the retaining force.

38. The handheld surgical robot according to claim 36, wherein: The tool alignment guide includes a connector configured to releasably engage a mounting seat on the tool support, wherein in the retained state a retaining force is applied to one of the mounting seat and the connector to inhibit relative movement between the tool alignment member and the tool support.

39. The handheld surgical robot according to claim 38, wherein: The tool alignment member disengages from the tool support at a threshold force greater than the retaining force.

Images