Surgical robotic system and method of establishing spatial relationship thereof

Abstract

The application provides a surgical robot system and a spatial relationship establishing method thereof. The spatial relationship establishing method comprises the following steps: before a target object is introduced, making a robot execution system be in a preset pose, and based on a tracking result of a first positioning tool by an optical navigation system, performing initial calibration on the robot execution system and the optical navigation system to obtain an initial calibration relationship; after the target object is introduced, making the robot execution system be in the preset pose again, and based on the initial calibration relationship, performing re-calibration on the robot execution system and the optical navigation system to obtain a current calibration relationship; after the current calibration relationship meets a preset condition, associating a second positioning tool with the target object; and based on tracking results of the first positioning tool and the second positioning tool by the optical navigation system, establishing a spatial relationship among the robot execution system, the optical navigation system and the target object. By using the above technical scheme, the positioning accuracy and positioning efficiency can be improved.

Description

Technical Field

[0001] This invention relates to the field of medical device technology, specifically to a surgical robot system and a method for establishing spatial relationships therein. Background Technology

[0002] Robot-assisted total knee arthroplasty (TKA) is an effective treatment for end-stage knee osteoarthritis. Through the coordinated operation of a navigation system and robotic arms, it significantly improves the precision of osteotomy and the accuracy of prosthesis placement. Robot-assisted total knee arthroplasty has become an important direction in the development of joint surgery.

[0003] Currently, the technology related to total knee replacement surgery robots is becoming increasingly mature. How to further improve the accuracy of osteotomy, optimize the surgical procedure and operating experience has become a key factor in enhancing the clinical applicability and competitiveness of the products.

[0004] During surgery, the positioning of the navigation system directly affects the accuracy and smoothness of the procedure, playing a decisive role in the precision and stability of the optical navigation system. Improper positioning can cause optical tools mounted on bones or instruments to be at the edge of the camera's field of view or even completely out of sight. This is especially true during knee flexion and extension movements, where positioning tools are prone to losing signal due to being out of the field of view, leading to navigation interruptions, increased osteotomy errors, and other problems. Summary of the Invention

[0005] In view of this, the present invention provides a surgical robot system and a method for establishing spatial relationships therewith, which can improve positioning accuracy and positioning efficiency.

[0006] In a first aspect, the present invention provides a method for establishing spatial relationships in a surgical robot system. The surgical robot system includes a robot execution system, an optical navigation system, a first positioning tool disposed on the robot execution system, and a second positioning tool for associating with a target object. The method for establishing spatial relationships includes: Before the target object is introduced, the robot execution system is positioned in a preset pose, and based on the tracking results of the optical navigation system on the first positioning tool, the robot execution system and the optical navigation system are initially calibrated to obtain an initial calibration relationship. After the target object is introduced, the robot execution system is brought back to the preset pose, and based on the initial calibration relationship, the robot execution system and the optical navigation system are recalibrated to obtain the current calibration relationship; After the current calibration relationship meets the preset conditions, the second positioning tool is associated with the target object; Based on the tracking results of the optical navigation system on the first positioning tool and the second positioning tool, a spatial relationship is established between the robot execution system, the optical navigation system, and the target object.

[0007] In a second aspect, the present invention provides a surgical robot system, comprising: a robot execution system, an optical navigation system, a first positioning tool disposed on the robot execution system and a second positioning tool for associating with a target object, and a processor adapted to perform a spatial relationship establishment method for the surgical robot system as described in any of the foregoing embodiments.

[0008] Compared with the prior art, the technical solution of the embodiments of the present invention has the following advantages: In the spatial relationship establishment method of the surgical robot system provided in this embodiment of the invention, an initial calibration is performed before the target object is introduced, so that a set of initial calibration relationships that satisfy distance conditions, orientation conditions, and target placement area indication conditions are pre-established between the robot execution system and the optical navigation system. Since this initial calibration relationship is established without being affected by the target object, support device, or surgical environment, it can provide a reproducible spatial reference for the subsequent system positioning after the target object is introduced. Thus, after the target object is introduced, by placing the robot execution system in the same preset initial pose again and recalibrating based on the initial calibration relationship, the preset tracking conditions between the optical navigation system and the first positioning tool can be satisfied again. At the same time, the target part of the target object is guided to the target placement area near the end effector, thereby avoiding the robot execution system deviating from the suitable workspace and reducing the risk that the optical navigation system cannot stably identify the first positioning tool. Furthermore, by introducing a second positioning tool only after the current calibration relationship meets preset conditions, the installation and attitude adjustment of the second positioning tool are based on the fact that the robot execution system and the optical navigation system are already in a stable spatial relationship. This reduces repeated adjustments after the second positioning tool is installed. Simultaneously, orientation judgments that previously relied on operator experience can be transformed into quantifiable angle judgments, improving the consistency and reliability of the positioning tool's state recognition. Therefore, positioning accuracy and efficiency are improved, while reducing the difficulty of intraoperative adjustments. Attached Figure Description

[0009] Figure 1 This invention provides a method for establishing spatial relationships in a surgical robot system.

[0010] Figure 2 This is a schematic diagram illustrating an application scenario of an initial calibration method provided in an embodiment of the present invention.

[0011] Figure 3 This is a schematic diagram illustrating an application scenario of a recalibration method provided in an embodiment of the present invention.

[0012] Figure 4 This is a flowchart of an initial calibration method provided in an embodiment of the present invention.

[0013] Figure 5 This is a schematic diagram of a scenario for determining a preset orientation, provided by an embodiment of the present invention. Detailed Implementation

[0014] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0015] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0016] As described in the background section, improper positioning of the navigation device may cause optical tools mounted on bones or instruments to be at the edge of the camera's field of view or even completely out of the field of view. Especially during knee flexion and extension movements, the positioning tool is prone to losing signal due to being out of the field of view, which can lead to problems such as navigation interruption and increased osteotomy errors.

[0017] In a typical total knee replacement surgery procedure, there is a lack of clear and uniform positioning standards and guidance mechanisms regarding the relative spatial relationships between the robotic arm trolley, the navigation trolley, and the patient.

[0018] Furthermore, the relative spatial relationships largely depend on the surgeon's temporary judgment and adjustments based on the operating room conditions and their own experience, which involves a high degree of subjectivity and uncertainty. Therefore, during surgery, unstable recognition or decreased positioning accuracy of the positioning tool often occurs. This is usually due to the lack of objective navigation device positioning guidance, and the positioning tool is easily placed at the edge of the camera's field of view, causing frequent alarms or even interruptions in the navigation system, affecting the continuity of the surgery.

[0019] To regain a stable signal, the position of the navigation system needs to be adjusted midway, which not only prolongs the operation time but can also lead to positioning errors.

[0020] Furthermore, some positioning guidance schemes directly focus on planning the relative positions of the robotic arm carriage and the navigation carriage at the patient's bedside during surgery. However, based on feedback from actual clinical applications, in order to save surgical time and reduce the risk of collisions within the surgical area, routine clinical practice tends to register the robotic arm in areas outside the surgical area.

[0021] During the registration process of the robotic arm, the end-effector and the base positioning tool should always be kept within the field of view of the navigator.

[0022] Therefore, it is necessary to design a positioning guidance method specifically for the registration stage of the robotic arm, that is, to establish an optimal and reproducible spatial relationship between the robotic arm and the navigator, and to seamlessly transfer this relationship to the subsequent intraoperative osteotomy operation stage, so as to ensure the final osteotomy accuracy while ensuring the smoothness and safety of the operation.

[0023] Based on this, the present invention designs a systematic positioning scheme that can guide doctors to adjust the position of the navigation device trolley and the angle and height of the navigation device to a suitable position. Through standardized operating procedures, it reduces reliance on the doctor's personal experience, avoids various problems caused by improper equipment positioning, saves surgical time, improves surgical smoothness, and improves osteotomy accuracy.

[0024] To enable those skilled in the art to better understand and implement this solution, the following detailed description of the specific solution, principles, advantages, and effects of the present invention is provided with reference to the accompanying drawings and specific embodiments.

[0025] In this embodiment, initial calibration is not limited to completing the final coordinate registration, but refers to confirming or establishing the relative position, relative attitude, tracking status, target placement area, etc. between the robot execution system and the optical navigation system before the target object is introduced, so as to obtain an initial calibration relationship that can be reproduced after the target object is introduced.

[0026] Recalibration refers to adjusting the spatial relationship between the robot execution system, optical navigation system, and target object based on the initial calibration relationship after the target object is introduced, so that the current calibration relationship meets the preset conditions.

[0027] "Directly facing" or "preset orientation condition" refers to the orientation state of the positioning tool relative to the optical navigator, which is suitable for stable identification. This state can be determined by whether the angle between the normal vector of the marking surface of the positioning tool and the optical axis of the optical navigator is less than a preset angle threshold.

[0028] See Figures 1 to 3 , Figure 1 This invention provides a method for establishing spatial relationships in a surgical robot system. Figure 2This is a schematic diagram illustrating an application scenario of an initial calibration method provided in an embodiment of the present invention. Figure 3 This is a schematic diagram illustrating an application scenario of a recalibration method provided in an embodiment of the present invention.

[0029] like Figures 1 to 3 The surgical robot system may include a robot execution system 100, an optical navigation system 200, a first positioning tool disposed on the robot execution system 100, and a second positioning tool for associating with a target object 300.

[0030] Specifically, the robot execution system 100 includes a robotic arm trolley 110, a robotic arm 120 mounted on the robotic arm trolley 110, and an end effector 130 mounted at the end of the robotic arm 120.

[0031] The end effector 130 can be a oscillating saw, a grinding tool, a drilling tool, a clamping tool, a probe tool, or other tools used to perform target operations.

[0032] In a knee joint robot-assisted surgery scenario, the end effector 130 may include a oscillating saw.

[0033] The first positioning tool may include an end-effector positioning tool 141 and a base positioning tool 142. The end-effector positioning tool 141 may be located at the end of the robotic arm 120, the end effector 130, the tool connector, or near the end effector 130. The base positioning tool 142 may be located on the robotic arm trolley 110.

[0034] The optical navigation system 200 includes an optical navigator 210, a navigator carriage 220 supporting the optical navigator 210, a support frame 230 mounted on the navigator carriage 210, an adjustment member 250 mounted on the support frame for adjusting the attitude of the optical navigator 210, and an indicator component 240 mounted on the optical navigator 210. The support frame 230 can adjust the pitch angle, yaw angle, and / or height of the optical navigator 210. The indicator component 240 can be a laser locator, a spot projector, a projection device, an image display device, an augmented reality display device, an audio prompt device, or a visual prompt device.

[0035] The laser beam emitted by the indicator component 240 is aligned with the central axis of the navigator's optical field of view. Therefore, the location of the laser spot is the central area of ​​the navigator's field of view. This design provides an intuitive visual reference for guiding the placement of the navigator.

[0036] In addition, the optical navigator 210 also features an infrared camera 211. The high-precision infrared camera can identify and track the spatial orientation of the positioning tools used in surgery in real time.

[0037] These positioning tools typically consist of multiple infrared reflective spheres or actively emitting LEDs arranged in a specific geometric configuration to form a unique spatial marker in the optical system.

[0038] The target object 300 can be a patient's anatomical structure, bones, joints, models, prostheses, experimental pieces, or objects to be processed.

[0039] In this embodiment, the target object 300 is the patient's knee joint to be operated on, and the target part is the knee joint area.

[0040] The second positioning tool is used to associate with the target object 300. The second positioning tool can be rigidly connected, detachably connected, temporarily fixedly connected, or indirectly associated with the target object 300.

[0041] In knee joint applications, the second positioning tool may include a femoral positioning tool 320 and a tibial positioning tool 310, wherein the femoral positioning tool 320 is mounted on the femur 340 and the tibial positioning tool 310 is mounted on the tibia 330.

[0042] Accordingly, methods for establishing spatial relationships include: S101, before the target object is introduced, the robot execution system is positioned in a preset pose, and based on the tracking result of the optical navigation system on the first positioning tool, the robot execution system and the optical navigation system are initially calibrated to obtain an initial calibration relationship.

[0043] In some embodiments, before the target object 300 is introduced, the posture of the robot execution system 100 is pre-configured so that the robot execution system 100 is in a preset initial posture.

[0044] In this embodiment, the preset initial pose is the intermediate pose within the motion range of the robot execution system, and the preset initial pose corresponds to the approximate central region of the robot registration point and / or the target operation path.

[0045] By setting a preset initial pose, the robot execution system 100 can be placed in a more ideal workspace position, avoiding excessive extension, excessive contraction or approaching the motion limit of the robot execution system during subsequent operations. This ensures that the robot execution system 100 has sufficient motion margin and avoids it being in extreme poses or near unreachable areas.

[0046] When the robot execution system 100 is in a preset pose, the optical navigation system 200 is activated, enabling it to track the first positioning tool. Different tracking results are achieved when the optical navigation system 200 and the robot execution system 100 have different relative poses or spatial relationships.

[0047] Among multiple tracking results, at least one tracking result satisfies the calibration requirements. At this point, the pose of the optical navigation system 200 relative to the robot execution system 100 is the initial calibration relationship.

[0048] In this embodiment, the first positioning tool includes an end-effector positioning tool 141 disposed at the end effector 130 of the robot execution system 100, and a base positioning tool 142 disposed at the robotic arm trolley 110 of the robot execution system 100.

[0049] The optical navigation system 200 includes an optical navigator 210, a navigator carriage 220 supporting the optical navigator 210, a support frame 230 mounted on the navigator carriage 210, an adjustment member 250 mounted on the support frame for adjusting the attitude of the optical navigator 210, and an indicator member 240 mounted on the optical navigator 210. The support frame 230 can adjust the pitch angle, yaw angle, and / or height of the optical navigator 210.

[0050] Accordingly, see Figure 4 , Figure 4 This is a flowchart of an initial calibration method provided in an embodiment of the present invention.

[0051] S201, Adjust the robot execution system to the preset initial pose.

[0052] In some embodiments, the preset initial pose can be pre-set by the system or determined based on the target operation path, end effector type, robot motion range, or target object type.

[0053] In knee joint applications, the preset initial pose can be set to the middle region of the robotic arm 120's range of motion, and the end effector 130 can be positioned near the approximate center of the subsequent registration point and subsequent osteotomy path. This ensures that the robotic arm 120 will neither overextend nor overcontract during subsequent operations.

[0054] It should be noted that after the robotic arm 120 is in the preset initial pose, the end effector positioning tool 141 and the base positioning tool 142 are installed. The end effector positioning tool 141 is used to reflect the spatial position and attitude of the end effector 130 or the end effector of the robotic arm, and the base positioning tool 142 is used to reflect the spatial position and attitude of the base or the robotic arm trolley 110.

[0055] S202, adjust the position and direction of the navigation trolley so that the distance between the optical navigation device and the end positioning tool, and the distance between the optical navigation device and the base positioning tool, respectively meet the preset distance conditions.

[0056] In some embodiments, when the robot execution system 100 is in the preset initial pose, the position and orientation of the navigation trolley 220 are coarsely adjusted so that the distance between the optical navigator 210 and the end-positioning tool 141 meets the corresponding preset distance range, and at the same time, the distance between the optical navigator 210 and the base positioning tool 142 meets the corresponding preset distance range.

[0057] The preset distance range can be determined based on the effective recognition distance of the optical navigator 210, the size of the positioning tool, the arrangement of optical markers, and the surgical environment. For example, the distance between the optical navigator 210 and the end-effector positioning tool 141 can be set to be within a first distance range, and the distance between the optical navigator 210 and the base positioning tool 142 can be set to be within a second distance range. The first distance range and the second distance range can be the same or different.

[0058] In this embodiment, the distance condition is used to ensure that the positioning tool is within the effective working range of the optical navigator 210. If the distance is too close, the positioning tool may be outside the field of view of the optical navigator 210; if the distance is too far, the optical marker may be difficult to identify stably, or the identification accuracy may decrease.

[0059] In one example, the distance is determined as follows: the three-dimensional coordinates of the origin of the positioning tool's coordinate system in the optical navigator's coordinate system are obtained; wherein the positioning tool includes a first positioning tool and a second positioning tool; the distance between the origin of the positioning tool's coordinate system and the origin of the navigator's coordinate system is calculated based on the three-dimensional coordinates.

[0060] Specifically, the optical navigator can acquire in real time the three-dimensional coordinates of the tool coordinate system origin in the navigator coordinate system. ,in These represent the position components of the tool along the three coordinate axes in the navigator's coordinate system. The straight-line distance between the positioning tool and the navigator is: .

[0061] S203, adjust the attitude of the adjusting member so that the end positioning tool and the base positioning tool respectively meet the preset orientation conditions relative to the optical navigator.

[0062] In some embodiments, when the distance condition is met, the operator adjusts the attitude of the adjustment member 250, such as adjusting the pitch angle, yaw angle and / or height of the adjustment member 250, so that the end positioning tool 141 and the base positioning tool 142 respectively meet the preset orientation conditions relative to the optical navigator 210.

[0063] The preset orientation condition can be understood as the positioning tool's marker surface being directly or nearly directly facing the optical navigator 210. This condition can be determined by whether the angle between the normal vector of the positioning tool's marker surface and the optical axis of the optical navigator 210 is less than a preset angle threshold.

[0064] The preset angle threshold can be determined based on the recognition capability of the optical navigation system 200. For example, it can be 30°, or 20°, 25°, 35° or other suitable angles.

[0065] This embodiment provides two methods for determining the preset orientation, which are described below.

[0066] Example 1 See Figure 5 , Figure 5 This is a schematic diagram of a scenario for determining a preset orientation, provided by an embodiment of the present invention.

[0067] The three-dimensional coordinates of at least three non-collinear optical marker points 150 on the end-effector positioning tool 141 and the base positioning tool in the positioning tool coordinate system are obtained respectively, and denoted as:

[0068] According to the plane equation Substitute the three-dimensional coordinates of the optical marker points in the coordinate system of the positioning tool into the plane equation, and solve it using the least squares method to determine at least the coefficients of the plane equation. .

[0069] According to the coefficient Determine the unit normal vector of the positioning tool in the positioning tool coordinate system.

[0070] For example, the unit normal vector This vector is the normal direction of the positioning tool in the tool coordinate system.

[0071] Wherein, the coefficient d represents the distance parameter of the plane relative to the origin of the positioning tool's coordinate system, which is only used to determine the spatial position of the plane and does not participate in the calculation of the unit normal vector.

[0072] Based on the rotation matrix from the positioning tool coordinate system to the optical navigator coordinate system acquired in real time by the optical navigator. The unit normal vector Switch to the coordinate system of the optical navigator.

[0073] Right now: .

[0074] Calculate the angle between the unit normal vector in the coordinate system of the optical navigator and the optical axis direction of the optical navigator.

[0075] Specifically, the Z-axis direction of the optical navigation system is... The included angle is:

[0076] When the included angle is less than a preset angle threshold, it is determined that the positioning tool meets the preset orientation condition.

[0077] In this embodiment, the preset angle threshold is 30°.

[0078] Using the scheme of Embodiment 1, at least three non-collinear optical marker points on the positioning tool are acquired, and a plane containing the marking surface of the positioning tool is fitted based on these multiple optical marker points. The unit normal vector of this plane is then calculated, and this unit normal vector is transformed into the coordinate system of the optical navigator and its angle with the optical axis of the optical navigator is calculated. This transforms the problem of whether the positioning tool is facing the optical navigator—which originally relied on manual observation and experience—into a quantitative judgment based on geometric relationships. Since this judgment method directly originates from the spatial distribution of the marker points on the positioning tool itself and the pose information acquired in real time by the optical navigator, it can objectively reflect the orientation state of the positioning tool relative to the optical navigator.

[0079] Example 2 Obtain the three-dimensional coordinates of each optical marker point on the positioning tool in the optical navigator coordinate system at the current moment; fit the plane where the optical marker point is located based on the three-dimensional coordinates in the optical navigator coordinate system, and determine the unit normal vector of the plane in the optical navigator coordinate system; calculate the angle between the unit normal vector and the optical axis direction of the optical navigator; when the angle is less than the preset angle threshold, determine that the positioning tool meets the preset orientation condition.

[0080] The scheme in Example 2 directly uses a plane fitting method based on the three-dimensional coordinates of the marker points in the optical navigator coordinate system to determine orientation. This allows for orientation determination without relying on pre-stored coordinates of the marker points in the tool's coordinate system, thereby improving the applicability and redundancy of the orientation determination method. This scheme can improve the accuracy, consistency, and automation of orientation determination for positioning tools and helps reduce the risk of identification instability caused by poor orientation of the positioning tool.

[0081] S204, the indicator component indicates the target placement area located near the end effector.

[0082] In some embodiments, when distance and orientation conditions are met, the indicator component 240 disposed on the optical navigator 210 is activated. If the indicator component 240 can be a laser locator, the laser locator 241 emits a laser beam and forms a laser spot L in space.

[0083] By adjusting the attitude of the optical navigator 210, the laser spot L is projected onto the target placement area near the end effector 130.

[0084] In this embodiment, the target placement area is located at a preset distance range of 80mm to 120mm below the end effector.

[0085] In one embodiment, the end effector 130 includes a oscillating saw, with the target placement area located within a preset distance range below the handle of the oscillating saw.

[0086] For example, the target placement area can be located approximately 80mm to 120mm below the handle of the oscillating saw, preferably 100mm. This location can be used to simulate the area where the target part of the subsequent target object 300 is located, such as simulating the area of ​​a patient's knee joint.

[0087] In this embodiment, the target placement area is used to guide the placement of the target object 300 during subsequent recalibration. This area can be a point, a spatial region, a circular region, a projection region, or a three-dimensional tolerance range.

[0088] S205, when the preset distance condition, the preset orientation condition, and the indication condition of the target placement area are all satisfied, the initial calibration relationship is obtained.

[0089] In some embodiments, when the preset distance condition, preset orientation condition, and indication condition of the target placement area are all satisfied, it means that the initial calibration is completed and the initial calibration relationship is obtained when the indicating component can indicate the target placement area.

[0090] In one implementation, the system can output an initial calibration completion prompt. This prompt can be a visual prompt, an audible prompt, an indicator light prompt, or an interface status prompt. After obtaining the initial calibration relationship, the trolley containing the robot execution system and the trolley containing the optical navigation system are locked.

[0091] It should be noted that the initial calibration relationship does not necessarily represent the final surgical registration relationship, but rather a recommended spatial relationship between the robotic execution system and the optical navigation system that can be reproduced after the target object is introduced.

[0092] By adopting the above technical solution, the initial state of the robot execution system, the spatial position of the optical navigator, the observation posture of the optical navigator, and the spatial area that the target object should subsequently enter are defined in sequence. Therefore, a set of reproducible initial calibration relationships can be formed before the target object is introduced. The initial calibration relationship takes into account the robot's workspace, the optical navigation recognition range, and the target placement position, thereby providing a clear spatial reference for subsequent recalibration and reducing blind adjustments and repeated placement after the target object is introduced.

[0093] S102, after the target object is introduced, the robot execution system is brought back to the preset pose, and based on the initial calibration relationship, the robot execution system and the optical navigation system are recalibrated to obtain the current calibration relationship.

[0094] In some embodiments, after the target object 300 is introduced, the robot execution system 100 is controlled to move back to the preset initial pose, so that the robot execution system 100 is in the same or substantially the same pose state before and after the target object 300 is introduced.

[0095] Therefore, after the target object 300 is introduced, the robot execution system 100 can still maintain a relatively sufficient motion margin, avoiding the robot execution system 100 from approaching the motion limit or unreachable area due to the placement, fixation or space occupation of the target object 300.

[0096] During the introduction of the target object 300, the relative spatial relationship between the robot execution system 100, the optical navigation system 200, the first positioning tool, or the target object 300 may change.

[0097] For example, the introduction of the target object 300 may cause changes in the field of view of the optical navigation system 200, the visibility of the first positioning tool, the workspace of the robot execution system 100, or the target operation area. Therefore, relying solely on the initial calibration relationship obtained before the introduction of the target object 300 may not accurately reflect the spatial correspondence between the robot execution system 100 and the optical navigation system 200 under the current actual operating conditions.

[0098] When the robot execution system 100 is in the preset pose again, the optical navigation system 200 tracks the first positioning tool again to obtain the current tracking result. Since the robot execution system 100 is in the same or substantially the same preset pose as the initial calibration, the current tracking result can correspond to the initial calibration relationship, thereby allowing for matching, correction, or error assessment of the current tracking result based on the initial calibration relationship.

[0099] In some embodiments, the initial calibration relationship is used to determine the initial spatial transformation relationship between the optical navigation system 200 and the robot execution system 100, and serves as a reference benchmark for recalibration. Based on the initial calibration relationship, the expected tracking range or expected pose of the first positioning tool under the optical navigation system 200 can be determined, and the spatial relationship between the robot execution system 100 and the optical navigation system 200 can be corrected according to the deviation between the current tracking result and the expected pose.

[0100] By placing the robot execution system 100 back into the preset pose after the target object 300 is introduced, and recalibrating based on the initial calibration relationship, the impact of the introduction process of the target object 300 on the spatial relationship of the system can be reduced, and the accuracy and reliability of the current calibration relationship between the robot execution system 100 and the optical navigation system 200 can be improved, thereby providing a more accurate spatial reference for subsequent robot registration, path planning and target operation.

[0101] In one example, step S102 may include: After the target object is introduced, the robot execution system is moved to the area where the target object is located, and the robot execution system is brought back to the preset initial pose.

[0102] In some embodiments, the robotic arm trolley 110 is moved to the area where the target object 300 is located, such as near the operating table 400, and the robotic arm 120 is brought back to the preset initial pose.

[0103] Since the preset initial pose is the same as the pose used during the initial calibration, the initial calibration relationship can be reproduced by using the same robot state as a reference during the recalibration.

[0104] Adjust the position of the target object and / or the support device carrying the target object so that the target part of the target object is located in the target placement area near the end effector.

[0105] In some embodiments, in a knee joint application scenario, the patient's knee on the side to be operated on can be flexed to a preset angle, such as approximately 90°. Then, by adjusting the height of the operating table 400, the position of the patient's limb, and the relative position between the robotic arm trolley 110 and the operating table 400, the patient's knee on the side to be operated on is positioned within the target placement area below the end effector 130.

[0106] For example, the laser locator can be activated so that the laser spot L illuminates the area where the knee joint is located. The operator can then determine whether the knee joint is within the target placement area based on the laser spot L.

[0107] Move the optical navigation system to the area where the target object is located, and adjust the position and direction of the navigation trolley so that the distance between the optical navigation device and the end-point positioning tool, and the distance between the optical navigation device and the base positioning tool, once again meet the preset distance conditions.

[0108] In some embodiments, the optical navigation system 200 is moved to the area where the target object 300 is located, such as near the operating table 400.

[0109] Preferably, after the optical navigation system 200 is moved, the attitude of the adjustment component 250 at the initial calibration is not changed. Instead, the position and direction of the navigation trolley 220 are adjusted so that the distance between the optical navigation device 210 and the end positioning tool 141, and the distance between the optical navigation device 210 and the base positioning tool 142, meet the preset distance conditions again.

[0110] This allows for the reproduction of the spatial relationship between the optical navigator 210 and the robot execution system 100 during the initial calibration, reducing the time required for readjustment.

[0111] This ensures that the end-positioning tool and the base positioning tool once again meet the preset orientation conditions relative to the optical navigator.

[0112] In some embodiments, when the distance condition is met, it is further confirmed whether the end-point positioning tool 141 and the base positioning tool 142 meet the preset orientation condition relative to the optical navigator 210. This determination can be made using the normal vector angle calculation method described in the foregoing embodiments.

[0113] If the end-positioning tool 141 or the base positioning tool 142 does not meet the preset orientation conditions, the position and direction of the navigation trolley 220 can be adjusted, or the attitude of the adjustment component 250 can be finely adjusted if necessary, so that the positioning tool meets the preset orientation conditions.

[0114] The indicator component confirms that the target part of the target object is located in the target placement area.

[0115] In some embodiments, when the laser spot L illuminates the area where the knee joint to be operated is located, and the knee joint is within a preset distance range below the end effector 130, the target part 310 can be considered to be located within the target placement area.

[0116] Once the end-positioning tool and the base positioning tool again satisfy the preset distance condition and the preset orientation condition, and the target part of the target object is located in the target placement area, the current calibration relationship is obtained.

[0117] In some embodiments, when all requirements are met, it is determined that the calibration requirements are met, i.e., the current calibration relationship is obtained.

[0118] It should be noted that after obtaining the current calibration relationship, the trolley where the optical navigation system is located should be locked. Alternatively, the wheel brakes of the robotic arm trolley can be locked to reduce changes in the equipment position during subsequent processes.

[0119] By employing the above technical solution, after the target object is introduced, the robot execution system is brought back to a preset initial pose, and the position of the target object or its supporting device is adjusted so that the target part of the target object is located in the target placement area near the end effector. This guides the target object to a suitable working area predetermined by the robot execution system. Furthermore, by moving the optical navigation system and adjusting the position and direction of the navigation trolley, the preset distance and orientation conditions between the optical navigation system, the end effector, and the base positioning tool are met again. This allows the current calibration relationship after the target object is introduced to replicate the initial calibration relationship. Since the recalibration simultaneously verifies the tracking conditions of the robot-side positioning tool and the positional conditions of the target part relative to the target placement area, it ensures that the robot execution system, the optical navigation system, and the target object form a mutually matching spatial layout. This reduces the risk of subsequent registration failures or repeated adjustments due to target object placement deviations or navigation device positioning deviations.

[0120] It should be noted that for more information on determining the current calibration relationship, please refer to the relevant statements in the aforementioned examples.

[0121] In some embodiments, during recalibration, the adjusting member is maintained in the same posture as during the initial calibration, and the position and orientation of the navigation trolley are adjusted so that the end-effector positioning tool and the base positioning tool again meet the preset distance condition and the preset orientation condition. When adjusting the position and orientation of the navigation trolley fails to meet the preset distance condition, the preset orientation condition, and / or the indication condition of the target placement area, the posture of the adjusting member is adjusted, and the current calibration relationship is reconfirmed to ensure that the preset conditions are met.

[0122] Specifically, the pitch and yaw angles of the optical navigator, which were adjusted during the initial calibration, should not be changed during the recalibration. The operator mainly reproduces the initial calibration relationship by moving the position and direction of the navigator trolley.

[0123] The advantage of this method is that it can reduce the need for repeated adjustments to the orientation of the optical navigator during surgery, and keep the relationship between the observation direction of the optical navigator, the laser indication direction, and the orientation of the positioning tool as consistent as possible.

[0124] However, in real-world environments, factors such as operating table height, patient size, limb placement, sterile drape coverage, floor conditions, or equipment placement space limitations may prevent adjusting the position and orientation of the navigation trolley from simultaneously meeting distance, orientation, and target placement area indication requirements. In such cases, fine-tuning of the support frame may be permissible.

[0125] After adjusting the support frame, the following conditions should be reconfirmed: Does the distance between the optical navigator and the end-point positioning tool meet the preset distance conditions?

[0126] Does the distance between the optical navigator and the base positioning tool meet the preset distance conditions?

[0127] Does the end-point positioning tool meet the preset orientation conditions?

[0128] Does the base positioning tool meet the preset orientation conditions?

[0129] Whether the indicator component can still correctly indicate the target placement area.

[0130] Is the target part of the target object still within the target placement area?

[0131] In other words, the current calibration relationship is confirmed to meet the preset conditions only when the above conditions are met.

[0132] S103, after the current calibration relationship meets the preset conditions, the second positioning tool is associated with the target object.

[0133] In some embodiments, after the current calibration relationship satisfies the preset conditions, the second positioning tool is installed on the target object; the installation posture of the second positioning tool is adjusted so that the second positioning tool satisfies the preset orientation conditions relative to the optical navigator; after the second positioning tool satisfies the preset orientation conditions, the position of the second positioning tool is locked.

[0134] In one embodiment, a second positioning tool is mounted on the target object 300, and the mounting posture of the second positioning tool is adjusted so that the second positioning tool meets a preset orientation condition relative to the optical navigator 210. After the second positioning tool meets the preset orientation condition, the position of the second positioning tool is locked.

[0135] In knee joint applications, the second positioning tools include a femoral positioning tool 320 and a tibial positioning tool 310. The femoral positioning tool 320 is mounted on the femur, and the tibial positioning tool 310 is mounted on the tibia. During installation, the femoral positioning tool 320 and the tibial positioning tool 310 can be positioned approximately parallel to the axis of the leg bones, and both tools are oriented towards the optical navigator 210.

[0136] If the femoral positioning tool 320 or the tibial positioning tool 310 does not meet the preset orientation conditions relative to the optical navigator 210, the pitch angle, yaw angle or installation direction of the femoral positioning tool 320 or the tibial positioning tool 310 can be adjusted until the preset orientation conditions are met.

[0137] The orientation determination of the second positioning tool can also adopt the method in the aforementioned embodiments, that is, fitting a plane based on the optical markers on the positioning tool and calculating the angle between the normal vector and the optical axis of the optical navigator. When the angle is less than a preset angle threshold, the second positioning tool is considered to meet the preset orientation condition.

[0138] It should be noted that the second positioning tool should preferably be installed or locked only after the current calibration relationship meets the preset conditions. This avoids the need for repeated adjustments to the second positioning tool if the robotic arm trolley, navigation trolley 220, or target object 300 is not yet in a suitable spatial relationship.

[0139] S104, Based on the tracking results of the optical navigation system on the first positioning tool and the second positioning tool, establish the spatial relationship between the robot execution system, the optical navigation system and the target object.

[0140] In some embodiments, after the relationship calibration is completed, the spatial relationship between the robot execution system, the optical navigation system, and the target object is further established based on the tracking results of the first positioning tool and the second positioning tool by the optical navigation system.

[0141] In one example, step S104 may include: establishing a transformation relationship between the coordinate system of the robot execution system, the coordinate system of the optical navigation system, the coordinate system of the first positioning tool, the coordinate system of the second positioning tool, and the coordinate system of the target object; wherein, when the target object includes the knee joint to be operated, the second positioning tool includes a femoral positioning tool and a tibial positioning tool, the femoral positioning tool is installed on the femur, the tibial positioning tool is installed on the tibia, and registration between the robot execution system, the optical navigation system, the femur, and the tibia is completed based on the tracking results of the femoral positioning tool and the tibial positioning tool by the optical navigation system.

[0142] Specifically, after both the first and second positioning tools can be stably identified by the optical navigation system, the spatial relationship between the robot execution system 100, the optical navigation system 200, and the target object 300 is established.

[0143] Specifically, the following transformation relationships can be established between coordinate systems: robot execution system coordinate system; optical navigation system coordinate system; end effector coordinate system; base positioning tool coordinate system; second positioning tool coordinate system; target object coordinate system; end effector tool coordinate system.

[0144] In one specific implementation, the optical navigator 210 determines the position and orientation of the robot execution system 100 relative to the optical navigation system 200 by identifying the end-effector positioning tool 141 and the base positioning tool 142; it determines the position and orientation of the target object 300 relative to the optical navigation system 200 by identifying the second positioning tool; and then, in conjunction with the registration data of the target object 300, it establishes a target object coordinate system.

[0145] Taking the knee joint application as an example, after the optical navigator 210 identifies the femoral positioning tool 320 and the tibial positioning tool 310, it can establish femoral coordinate systems and tibial coordinate systems respectively. Subsequently, by collecting anatomical landmarks, bone surface points, registration points, or preset feature points, the registration between the femur and the femoral positioning tool 320, as well as the registration between the tibia and the tibial positioning tool 310, is completed. Then, by combining the coordinate transformation relationship between the robot execution system 100 and the optical navigation system 200, the final registration between the robot execution system 100, the optical navigation system 200, the femur, and the tibia can be completed.

[0146] Once the spatial relationship is established, the robot execution system 100 can perform subsequent operations based on this spatial relationship, such as osteotomy path planning, robotic arm registration, tool trajectory control, safety boundary control, or operation path verification.

[0147] In some embodiments, if one of the following occurs during or after the establishment of spatial relationships, recalibration can be performed again: The following errors occur: End-effector 141 is lost; Base positioning tool 142 is lost; Second positioning tool is lost; The recognition error of any positioning tool exceeds a preset error threshold; The position of the robotic arm trolley 110 changes; The position of the navigation trolley 220 changes; The position of the target object 300 changes; The second positioning tool becomes loose; The posture of the support frame 230 changes; The optical navigator 210 cannot stably recognize at least one positioning tool.

[0148] When recalibrating, the robot execution system 100 can be put back into the preset initial pose, and the distance and orientation conditions between the optical navigator 210 and the end-effector positioning tool 141 and the base positioning tool 142 can be reconfirmed. At the same time, it can be confirmed whether the target part of the target object 300 is still located in the target placement area.

[0149] If the conditions are not met, the position and attitude of the navigation trolley 220, the robotic arm trolley, the support device, or the target object 300 shall be readjusted according to the recalibration process.

[0150] The following uses the knee joint as an example to explain in detail the spatial alignment scheme in the embodiments of the present invention.

[0151] First, within the non-surgical area, the robotic arm is adjusted to a preset initial pose. This preset initial pose is located in the central region of the robotic arm's range of motion, corresponding to the approximate central region of the subsequent robotic arm registration points and osteotomy path. The end effector and base positioning tools are then installed.

[0152] Then, adjust the position and direction of the navigation trolley so that the distance between the optical navigation device and the end-point positioning tool, and the distance between the optical navigation device and the base positioning tool, are both within the preset distance range.

[0153] Next, adjust the pitch and yaw angles of the support frame so that both the end-positioning tool and the base positioning tool are directly facing the optical navigation device.

[0154] Then, the laser locator is activated, and the support frame is adjusted so that the laser spot is projected onto a preset distance position, approximately 100mm, below the handle of the oscillating saw. This position is used to simulate the target area of ​​the knee joint during subsequent surgery.

[0155] When the distance, orientation, and laser spot conditions are all met, lock the robotic arm trolley and the navigation trolley to complete the initial calibration.

[0156] Next, at the operating table, flex the patient's knee on the side to be operated on to approximately 90°. Push the robotic arm trolley to the operating table and readjust the robotic arm to the preset initial position. Adjust the height of the operating table so that the knee joint is approximately below the handle of the oscillating saw.

[0157] Next, push the navigation trolley to the side of the operating table, prioritizing maintaining the support frame's posture from the initial calibration, and only adjust the position and orientation of the navigation trolley. Turn on the laser locator so that the laser spot illuminates the knee joint area.

[0158] Simultaneously confirm that the distance between the optical navigator and the end-point positioning tool and the base positioning tool meets the preset distance conditions, and confirm that the end-point positioning tool and the base positioning tool are both directly facing the optical navigator. When the conditions are met, lock the navigator trolley.

[0159] Next, install the femoral and tibial positioning tools. During installation, ensure that the femoral and tibial positioning tools are as parallel as possible to the axis of the leg bones and that they are oriented towards the optical navigation device.

[0160] If the femoral or tibial positioning tool is not directly facing the optical navigation system, adjust its pitch angle until the preset orientation conditions are met. Once the conditions are met, lock the positions of the femoral and tibial positioning tools.

[0161] Finally, the optical navigator simultaneously tracks the end-effector positioning tool, the base positioning tool, the femoral positioning tool, and the tibia positioning tool. Based on the tracking results, the system establishes the final spatial relationship between the robot execution system, the optical navigation system, the femur, and the tibia, and then proceeds to the subsequent bone registration, osteotomy path planning, and robot-assisted execution processes.

[0162] The spatial relationship establishment method of the surgical robot system has been described above with reference to the embodiments. To facilitate understanding and implementation by those skilled in the art, the surgical robot system is further described below.

[0163] In this embodiment, the surgical robot system includes: a robot execution system, an optical navigation system, a first positioning tool disposed on the robot execution system and a second positioning tool for associating with a target object, and a processor adapted to perform the spatial relationship establishment method of the surgical robot system as described in any of the foregoing embodiments.

[0164] While the embodiments disclosed in this specification are as described above, the present invention is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A method for establishing spatial relationships in a surgical robot system, characterized in that, The surgical robot system includes a robot execution system, an optical navigation system, a first positioning tool mounted on the robot execution system, and a second positioning tool for associating with a target object. The spatial relationship establishment method includes: Before the target object is introduced, the robot execution system is positioned in a preset pose, and based on the tracking results of the optical navigation system on the first positioning tool, the robot execution system and the optical navigation system are initially calibrated to obtain an initial calibration relationship. After the target object is introduced, the robot execution system is brought back to the preset pose, and based on the initial calibration relationship, the robot execution system and the optical navigation system are recalibrated to obtain the current calibration relationship; After the current calibration relationship meets the preset conditions, the second positioning tool is associated with the target object; Based on the tracking results of the optical navigation system on the first positioning tool and the second positioning tool, a spatial relationship is established between the robot execution system, the optical navigation system, and the target object.

2. The spatial relationship establishment method according to claim 1, characterized in that, The first positioning tool includes an end-effector positioning tool disposed at the end effector of the robot execution system, and a base positioning tool disposed on the robotic arm trolley of the robot execution system; the optical navigation system includes an optical navigator, a navigation trolley carrying the optical navigator, a support frame disposed on the navigation trolley, an adjustment component disposed on the support frame for adjusting the attitude of the optical navigator, and an indicator component disposed on the optical navigator; The process of obtaining the initial calibration relationship includes: Adjust the robot execution system to the preset initial pose; Adjust the position and orientation of the navigation trolley so that the distance between the optical navigation device and the end-point positioning tool, and the distance between the optical navigation device and the base positioning tool, respectively meet preset distance conditions; Adjust the attitude of the adjusting component so that the end positioning tool and the base positioning tool respectively meet the preset orientation conditions relative to the optical navigator; The indicator component indicates the target placement area located near the end effector; When the preset distance condition, the preset orientation condition, and the indication condition of the target placement area are all satisfied, the initial calibration relationship is obtained.

3. The spatial relationship establishment method according to claim 2, characterized in that, Adjusting the attitude of the adjusting member so that the end-effector positioning tool and the base positioning tool respectively meet preset orientation conditions relative to the optical navigator includes: The three-dimensional coordinates of at least three non-collinear optical marker points on the end effector and the base positioning tool in the positioning tool coordinate system are obtained respectively, and denoted as: According to the plane equation Substitute the three-dimensional coordinates of the optical marker points in the coordinate system of the positioning tool into the plane equation, and solve it using the least squares method to determine at least the coefficients of the plane equation. ; According to the coefficient Determine the unit normal vector of the positioning tool in the positioning tool coordinate system. The coefficient d represents the distance parameter of the plane relative to the origin of the positioning tool's coordinate system. It is only used to determine the spatial position of the plane and does not participate in the calculation of the unit normal vector. Based on the rotation matrix from the positioning tool coordinate system to the optical navigator coordinate system obtained in real time by the optical navigator, the unit normal vector is transformed into the optical navigator coordinate system; Calculate the angle between the unit normal vector in the coordinate system of the optical navigator and the optical axis direction of the optical navigator; When the included angle is less than a preset angle threshold, it is determined that the positioning tool meets the preset orientation condition; or, Obtain the three-dimensional coordinates of each optical marker point on the positioning tool in the optical navigation system as measured by the optical navigation instrument at the current moment; The plane containing the optical marker point is fitted based on the three-dimensional coordinates in the optical navigator coordinate system, and the unit normal vector of the plane in the optical navigator coordinate system is determined. Calculate the angle between the unit normal vector and the optical axis of the optical navigator; When the included angle is less than the preset angle threshold, it is determined that the positioning tool meets the preset orientation condition.

4. The spatial relationship establishment method according to claim 2, characterized in that, The distance is determined in the following manner: Obtain the three-dimensional coordinates of the origin of the positioning tool's coordinate system in the optical navigation instrument's coordinate system; wherein, the positioning tool includes a first positioning tool and a second positioning tool; The distance between the origin of the positioning tool's coordinate system and the origin of the navigator's coordinate system is calculated based on the three-dimensional coordinates.

5. The spatial relationship establishment method according to any one of claims 2 to 4, characterized in that, Meet one or more of the following conditions: The preset initial pose is the intermediate pose within the motion range of the robot execution system, and the preset initial pose corresponds to the approximate central region of the robot registration point and / or the target operation path. The indicating component is a laser locator, the target placement area is indicated by the laser spot emitted by the laser locator, and the target placement area is located within a preset distance range below the end effector; The end effector is a oscillating saw; The target placement area is located at a preset distance of 80mm to 120mm below the end effector.

6. The spatial relationship establishment method according to claim 2, characterized in that, The step of recalibrating the robot execution system and the optical navigation system to obtain the current calibration relationship includes: After the target object is introduced, the robot execution system is moved to the area where the target object is located, and the robot execution system is brought back to the preset initial pose; Adjust the position of the target object and / or the support device carrying the target object so that the target part of the target object is located in the target placement area near the end effector; Move the optical navigation system to the area where the target object is located, and adjust the position and direction of the navigation trolley so that the distance between the optical navigation device and the end positioning tool, and the distance between the optical navigation device and the base positioning tool, once again meet the preset distance conditions; The end-positioning tool and the base positioning tool are made to meet the preset orientation conditions relative to the optical navigator again; The indicator component confirms that the target part of the target object is located in the target placement area; Once the end-positioning tool and the base positioning tool again satisfy the preset distance condition and the preset orientation condition, and the target part of the target object is located in the target placement area, the current calibration relationship is obtained.

7. The spatial relationship establishment method according to claim 6, characterized in that, Also includes: During the recalibration, the adjusting component is kept in the posture of the initial calibration, and the position and orientation of the navigation trolley are adjusted so that the end positioning tool and the base positioning tool meet the preset distance condition and the preset orientation condition again. When adjusting the position and direction of the navigation trolley fails to meet the preset distance condition, the preset orientation condition, and / or the indication condition of the target placement area, the attitude of the adjusting member is adjusted, and the current calibration relationship is reconfirmed to ensure that the preset conditions are met.

8. The spatial relationship establishment method according to claim 2, characterized in that, The step of associating the second positioning tool with the target object after the current calibration relationship meets the preset conditions includes: installing the second positioning tool on the target object after the current calibration relationship meets the preset conditions; adjusting the installation posture of the second positioning tool so that the second positioning tool meets the preset orientation conditions relative to the optical navigator; and locking the position of the second positioning tool after the second positioning tool meets the preset orientation conditions. Establishing the spatial relationship between the robot execution system, the optical navigation system, and the target object includes: Establish the transformation relationship between the coordinate system of the robot execution system, the coordinate system of the optical navigation system, the coordinate system of the first positioning tool, the coordinate system of the second positioning tool, and the coordinate system of the target object; When the target object includes the knee joint to be operated, the second positioning tool includes a femoral positioning tool and a tibial positioning tool. The femoral positioning tool is installed on the femur, and the tibial positioning tool is installed on the tibia. Based on the tracking results of the femoral positioning tool and the tibial positioning tool by the optical navigation system, the registration between the robot execution system, the optical navigation system, the femur, and the tibia is completed.

9. The spatial relationship establishment method according to claim 1, characterized in that, After obtaining the initial calibration relationship, the trolley where the robot execution system is located and the trolley where the optical navigation system is located are locked; After obtaining the current calibration relationship, the trolley where the optical navigation system is located is locked.

10. A surgical robot system, characterized in that, include: The system includes a robot execution system, an optical navigation system, a first positioning tool disposed on the robot execution system, a second positioning tool for associating with a target object, and a processor adapted to perform the spatial relationship establishment method of the surgical robot system as described in any one of claims 1 to 9.

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