Tracked Assembly and Robotic System

Abstract

An assembly (10) for tracking the position and orientation of a robotic arm (100) is provided. The assembly includes a handgrip (50) disposed between its proximal and distal ends (22, 24). The assembly also includes a first external portion (42, 44) at the proximal end and a second external portion (46) at the distal end (24). Optical markers (30) are provided on the external portions (42, 44, 46) and distributed along a central axis (A) of the assembly. The handgrip (50) is smaller in size around the central axis (A) than the first external portion (42, 44).

Description

[Technical Field]

[0001] The present disclosure relates to a tracking assembly for tracking the position and orientation of a robotic arm, and to a robotic system including such a tracking assembly. In particular, the present disclosure relates to a tracking assembly for use in a robotic surgical system. [Background technology]

[0002] Robotic surgical systems are frequently used in surgical interventions to assist surgeons in positioning tool guides in desired orientations relative to the surgical subject. After the tool guide is in place, the surgeon inserts a surgical tool into the tool guide and manipulates the surgical tool into a predetermined position and orientation. Alternatively, the tool guide can be replaced with a tool holder configured to hold the surgical tool in a predetermined position relative to the robotic arm. Other examples of robotic surgical systems are disclosed in US 2011 / 0290060, US 2020 / 0360092, US 2020 / 0155241, and US 2010 / 0168562.

[0003] Robotic surgical systems often utilize x-ray fluoroscopy to generate real-time images of the patient's interior, allowing for real-time navigation of the robotic surgical arm during surgery. In particular, fluoroscopy is used in surgical procedures such as orthopedic, spine, and trauma surgery to monitor fracture reduction and determine the precise location and orientation for inserting surgical tools and / or placing implants relative to surrounding bone fragments.

[0004] In order to navigate a surgical robotic arm using X-ray fluoroscopy, the robotic arm is provided with a tracking assembly that allows real-time location of the robotic arm and corresponding end effector relative to the surgical subject. EP 3821843 discloses an example of such a tracking assembly that allows tracking and maintaining the position and orientation of the robotic arm and end effector relative to the surgical subject.

[0005] Accurate localization of a robotic arm and its corresponding end effector is crucial to the success of a surgical intervention, and therefore, in the field of surgical robotics, considerable effort has been devoted to improving the localization accuracy of robotic arms and end effectors.

[0006] Surgeons using robotic surgical systems also need to reduce the overall size of the tracking assembly to improve maneuverability and reach of surgical tools, but a relatively small tracking assembly tends to make accurate localization of the surgical tool difficult. Summary of the Invention

[0007] One object of the present disclosure is to provide a tracking assembly that is reduced in size yet still allows for accurate localization of a surgical tool attached to the tracking assembly.

[0008] According to one aspect of the present disclosure, there is provided an assembly for tracking the position and orientation of a robotic arm, the assembly including: a support extending along a central axis and having a proximal end and a distal end opposite the proximal end, the proximal end configured to be attached to a robotic arm and the distal end configured to be attached to a tool holder or tool guide, the support further extending about the central axis and having a hand grip configured to provide a grip for a user to control the robotic arm; and at least three optical markers disposed on the support and distributed about the central axis. The hand grip is disposed between the proximal end and the distal end, and the support further comprises at least one first outer portion extending around the central axis and disposed at the proximal end or between the hand grip and the proximal end, each first outer portion having at least one optical marker provided thereon, and at least one second outer portion extending around the central axis and disposed at the distal end or between the distal end and the hand grip, each second outer portion having at least one optical marker provided thereon, the first outer portion having an outermost edge farther from the central axis in a direction perpendicular to the central axis than the outermost edge of the hand grip.

[0009] According to one aspect of the present disclosure, the support may be a single piece.

[0010] According to one aspect of the present disclosure, the assembly may further comprise at least one operating button for controlling the robotic arm, the at least one operating button being provided on a hand grip of the support.

[0011] According to one aspect of the present disclosure, at least one of the first and second outer portions may be tapered toward a distal end.

[0012] According to one aspect of the present disclosure, each of the first outer portions may have an outermost edge located at a distance from the central axis in a direction perpendicular to the central axis that is equal to or greater than the outermost edge of the second outer portion.

[0013] According to one aspect of the present disclosure, the support may include two first outer portions and one second outer portion spaced apart from one another along the central axis.

[0014] According to one aspect of the present disclosure, each optical marker may be disposed within a recess formed on the corresponding exterior portion such that the optical marker is substantially flush with the surface of the corresponding exterior portion.

[0015] According to one aspect of the present disclosure, the optical markers may be light emitting elements.

[0016] According to one aspect of the present disclosure, the assembly may further include a visible light emitting ring extending around the central axis.

[0017] According to one aspect of the present disclosure, the assembly may further include a memory device that stores data for tracking the position and orientation of the robotic arm.

[0018] According to one aspect of the present disclosure, the assembly may further include at least one electrical connector disposed within the support, the at least one electrical connector configured to engage a corresponding electrical connector on the robotic arm.

[0019] According to one aspect of the present disclosure, the electrical connector may be electrically connected to at least one of the operation button, the light emitting element, the visible light emitting ring, and the storage device.

[0020] According to one aspect of the present disclosure, there is provided a robotic system comprising an articulated robotic arm and the above-described assembly attached to a distal flange of the robotic arm.

[0021] According to one aspect of the present disclosure, the proximal end of the support may be attached to the robotic arm such that the distal flange of the robotic arm is received within the proximal end.

[0022] According to one aspect of the present disclosure, the robotic system further includes a sterile cover surrounding the robotic arm and the support, which may fit over the first and second exterior portions of the support. [Brief explanation of the drawings]

[0023] Embodiments of the present disclosure will be described in further detail with reference to the accompanying drawings. [Figure 1] FIG. 1 is a perspective view illustrating a robotic surgical system including a tracking assembly according to one embodiment. [Figure 2] FIG. 1 is a perspective view showing a tracking assembly. [Figure 3] FIG. 10 is a perspective view showing the tracking assembly from the proximal end where it is coupled to the robotic arm. [Figure 4] FIG. 1 is a side view showing a tracking assembly. [Figure 5] FIG. 10 is a cross-sectional view showing the connection between the tracking assembly and the robot arm. DETAILED DESCRIPTION OF THE INVENTION

[0024] The subject matter disclosed herein relates to means for assisting in surgical interventions performed on a patient's body, including, but not limited to, implanting orthopedic implants such as pedicle screws into the spine, implanting various orthopedic implants into bone, reducing and fixating fractures during traumatological procedures, or positioning a guide or cannula at a desired location relative to a surgical subject.

[0025] According to one embodiment, an assembly 10 is provided for tracking the position and orientation of a robotic arm 100. The assembly 10 includes a support 20 extending along a central axis A. The support 20 has a proximal end 22 and a distal end 24 opposite the proximal end 22. The assembly 10 is configured to be attached to the robotic arm 100 at the proximal end 22 (see FIG. 1 ). The assembly 10 is configured to be attached to an end effector, such as a tool holder or tool guide, at the distal end 24.

[0026] The support 20 includes a handgrip 50 extending about a central axis A. The handgrip 50 is disposed between the proximal end 22 and the distal end 24. The handgrip 50 is configured to provide a grip for a user, typically a surgeon, to control the robotic arm 100. The handgrip 50 may have an ergonomic design to ensure a secure grip by the user.

[0027] The support 20 includes at least one first outer portion 42, 44 extending about the central axis A. In one embodiment, the at least one first outer portion 42, 44 may be disposed at the proximal end 22. In another embodiment, the at least one first outer portion may be disposed between the hand grip 50 and the proximal end 22. In one embodiment, the first outer portions 42, 44 may have a generally cylindrical shape.

[0028] The support 20 includes at least one second outer portion 46 extending about the central axis A. In one embodiment, the second outer portion 46 may be disposed at the distal end 24. In another embodiment, the second outer portion may be disposed between the distal end 24 and the hand grip 50. In one embodiment, the second outer portion 46 may have a generally cylindrical shape.

[0029] The assembly 10 is disposed on the support 20 and includes at least three optical markers 30 distributed around the central axis A. At least one optical marker 30 is provided on each of the first outer portions 42 and 44 and each of the second outer portion 46. In one embodiment, two or more optical markers 30 may be provided on the first outer portions 42 and 44 and / or the second outer portion 46. Each optical marker 30 may be disposed at a different position around the central axis A and spaced apart from one another in the axial and circumferential directions.

[0030] In one embodiment, the optical markers 30 may be positioned to optimize localization of the robot arm 100 and corresponding end effector, regardless of the orientation of the robot arm 100 .

[0031] In one embodiment, the optical marker group may be formed from three or more optical markers 30 distributed around the central axis A and provided on the first external portions 42 and 44 and the second external portion 46, respectively. One or more of such optical marker groups may be provided on the support 20. Each optical marker group allows for localization of the robot arm 100 and the end effector independently of one another, preferably regardless of the position and orientation of the robot arm 100. However, each optical marker group may have a different configuration from the others with respect to the number of optical markers and / or the arrangement of the optical markers 30 on the support 20.

[0032] In one embodiment, the support 20 may include two first outer portions 42 and 44 and one second outer portion 46 spaced apart from one another along the central axis A. In one embodiment, the two first outer portions 42 and 44 may be separated by a cylindrical portion 48 that is not provided with optical markers 30.

[0033] First outer portions 42 and 44 have outermost edges 421 and 441 that are located farther from central axis A in a direction perpendicular to (or radially from) central axis A than outermost edge 501 of hand grip 50. Optionally, outermost edge 461 of second outer portion 46 may also be located farther radially from central axis A than outermost edge 501 of hand grip 50.

[0034] In use, the assembly 10 is attached to the wrist 110 of a robotic arm 100 via the distal flange 102 (see Figures 1 and 5).

[0035] A variety of end effectors, including, but not limited to, tool holders and tool guides (not shown), can be attached to the distal end 24 of the assembly 10. The robotic system 11 can be equipped with a sensor, such as a camera, configured to detect optical markers 30 provided on the assembly 10 as reference points. Similar optical markers can also be provided on the surgical object for detection by the sensor. Such optical markers can also be provided at one or more points near the surgical object.

[0036] The end effector may include a passive or active tool holder or guide. A passive tool holder may be configured to hold a tube through which a surgical tool can slide. An active tool holder may be configured to hold an active surgical tool, such as a drill, ultrasonic cutter, surgical burr, or other active tool. The end effector may be provided with one or more optical markers that are detected by sensors of the robotic system 11.

[0037] Based on the detected reference points provided with the optical markers 30, the robotic system 11 generates real-time data regarding the position of the assembly 10 and surgical tools relative to the robotic arm 100 and / or surgical subject.

[0038] According to the tracking assembly 10 described above, the hand grip 50 is disposed between the first external portion 42, 44 and the second external portion 46. Furthermore, the optical markers 30 are provided not only at or near the proximal end 22 of the assembly 10, but also at or near the distal end 24. Therefore, the optical markers 30, i.e., the detectable reference points, are distributed over a relatively wide area along the central axis A, substantially along the entire length of the assembly 10 along the central axis A. This wide distribution of the optical markers 30 can improve the accuracy of detecting the optical markers 30 to determine the position and orientation of the assembly 10. Therefore, the robotic system 11 can provide accurate localization of the assembly 10 and, ultimately, of a surgical tool attached to the assembly 10.

[0039] The above-mentioned advantages can be achieved without extending the axial length of the assembly 10 or adding extensions to achieve a wider distribution of the optical markers 30, thereby minimizing the distance between the surgical tool and the wrist 110 of the robotic arm 100. Thus, accurate location of the surgical tool is possible without affecting the maneuverability and reach of the surgical tool by the user.

[0040] According to the disclosed configuration, at least a portion of the optical markers 30 are located at or near the proximal end 22 of the assembly 10. During a surgical intervention, the space near the distal end 24 of the assembly 10 is typically surrounded by instruments or tools associated with the surgical procedure being performed. Thus, the optical markers 30 located at the proximal end 22 of the assembly 10 can contribute to optimizing the space available for the surgical procedure, improving maneuverability of the robotic system 11, and improving visibility of the surgical area. Additionally, the risk of collision with the patient's body or the surrounding environment can be reduced.

[0041] According to one aspect of the present disclosure, multiple sets of optical markers can be provided to provide a redundant design, with each set of optical markers independently capable of accurately locating the robotic arm 100, so that tracking of the robotic arm 100 and end effector is not interrupted even if an object such as bodily fluid blocks the view of a sensor aimed at one of the optical markers.

[0042] According to the disclosed configuration, the hand grip 50 has a smaller diameter in the radial direction away from the central axis A than the outer portions 42, 44 on which the optical marker 30 is provided. This reduces the risk that the user's hand touching the hand grip 50 will block the view of the sensor for detecting the optical marker 30.

[0043] According to one embodiment, the support 20 of the assembly 10 may be a single piece. A single piece support 20 has the advantage that the relative positions of the optical markers 30 remain constant after use, e.g., once the relative positions are set at the factory, no further readjustment is required.

[0044] In another embodiment, the support 20 may be made up of two or more parts, in which case the relative positions of the optical markers 30 must be determined each time the parts are disassembled to ensure accurate localization of the surgical tool.

[0045] According to one embodiment, the assembly 10 may comprise at least one operating button 60 for controlling the robot arm 100. The at least one operating button 60 may be provided on the hand grip 50 of the support 20.

[0046] By providing the operating button 60 on the hand grip 50, which is relatively small in size radially from the central axis A, the user can operate the operating button 60 without affecting the tracking of the position and orientation of the surgical tool based on position identification by the optical marker 30.

[0047] In one embodiment, two or more operation buttons 60 may be provided spaced apart from one another in the circumferential direction, for example, at 90° intervals, around the central axis A. By providing a gap between each operation button 60, it is possible to prevent the operation button 60 from being accidentally operated.

[0048] In another embodiment, two pairs of operation buttons 60 may be provided, with each operation button 60 spaced apart from the other along the central axis A. By providing two pairs of operation buttons 60, multiple operation modes may be selectively activated, including, but not limited to, a hand-guided mode in which the robotic arm 100 is freely movable by a user, a calculated trajectory mode in which the robotic arm 100 moves to a target position according to a calculated trajectory, and a servo-controlled mode in which the robotic arm 100 moves autonomously to maintain the distal end 24 of the assembly 10 relative to a surgical subject.

[0049] In one embodiment, the control buttons 60 may have different textures, concave shapes, convex shapes, or other shapes to help the user distinguish between the buttons. In one embodiment, for added security, the robotic system 11 may require the simultaneous pressing of two buttons or an additional control, such as a foot pedal, to activate one of the control modes or to transition from one control mode to another.

[0050] In one embodiment, the optical marker 30 may be a light emitting element. In one embodiment, the optical marker 30 may be an infrared transmitter, such as an LED (light emitting diode). In another embodiment, the optical marker 30 may be a passive optical marker, for example, a refractive object having a substantially spherical or spheroidal shape.

[0051] According to one embodiment, the robotic system 11 includes a sterile cover (not shown) that surrounds the robotic arm 100 and the support 20, respectively. The sterile cover is configured to fit over the first and second outer portions 42, 44, 46 of the support 20. The sterile cover serves to protect the assembly 10 from bodily fluids, pathogens, or other sources of contamination before, during, and after a surgical intervention. In one embodiment, the sterile cover can be securely fastened to the assembly 10 using magnets or straps.

[0052] In one embodiment, the sterile cover may be formed from an extremely thin film, having a thickness of a few tens of micrometers. In one embodiment, the cover may be manufactured from TPU (thermoplastic polyurethane). An extremely thin TPU cover has the advantage of having very little refractive effect, which does not affect the accurate localization of the assembly 10 and the surgical tools attached thereto. In one embodiment, the cover may be manufactured by welding two or more parts together. In this case, the weld line should be located somewhere other than over the optical marker 30 so as not to affect the accurate localization of the surgical tools.

[0053] In one embodiment, at least one of the first and second outer portions 42, 44, 46 may be formed to taper toward the distal end 24. In one embodiment, at least one of the first and second outer portions 42, 44, 46 may have a conical shape that decreases in diameter toward the distal end 24. This configuration allows a sterile cover to be applied to the assembly 10 like a glove from the distal end 24 toward the proximal end 22 while maintaining a tight seal on the assembly 10.

[0054] In embodiments in which the outer portions 42, 44, 46 and hand grip 50 have a generally cylindrical shape, attaching a sterile cover to the assembly 10 is advantageously facilitated.

[0055] According to one embodiment, each of the first outer portions 42 and 44 has an outermost edge, in a direction perpendicular to the central axis A, that is an equal or greater distance from the central axis A than the outermost edge 461 of the second outer portion 46. This configuration prevents the sterile cover from being bound by the second outer portion 46, thereby facilitating attachment of the sterile cover to the assembly 10.

[0056] According to one embodiment, each optical marker 30 may be disposed within a recess formed in the corresponding exterior portion 42, 44, 46 such that the optical marker 30 is substantially flush with the surface of the corresponding exterior portion 42, 44, 46. This configuration avoids protrusions on the exterior surface of the assembly 10, creating no constraints during the process of attaching the sterile cover to the assembly 10 and also allows the cover to fit snugly against the assembly 10.

[0057] According to the disclosed configuration, the hand grip 50 of the assembly 10 is relatively small in size radially away from the central axis A. The smaller hand grip 50, located between the first outer portion (42, 44) and the second outer portion (46), can provide tension relief while the sterile cover is being attached to the assembly 10, thereby facilitating the sterile cover attachment process.

[0058] According to one embodiment, the proximal end 22 of the support 20 is attached to the robot arm 100 such that the distal flange 102 of the robot arm 100 is located inside the proximal end 22 (see FIG. 5 ). This configuration contributes to reducing the distance between the distal end 24 of the assembly 10 and the wrist 110 of the robot arm 100.

[0059] According to one embodiment, the assembly 10 can include a visible light emitting ring 70 extending about the central axis A. The emitting ring 70 serves as an indicator for the user to recognize which operational mode is currently being used. In one embodiment, the emitting ring 70 can include a plurality of LEDs configured to emit a predetermined color and / or a predetermined blinking pattern depending on the selected operational mode. The emitting ring 70 can be located on or near the hand grip 50, substantially axially spaced from the optical markers 30.

[0060] In one embodiment, assembly 10 may include a memory device (not shown) that stores data for tracking the position and orientation of robotic arm 100. In one embodiment, the data stored in the memory device is calibration data for optical markers 30, including, but not limited to, data relating patterns of optical markers 30 to the position and orientation of assembly 10.

[0061] According to one embodiment, the assembly 10 may comprise a communication module for transmitting calibration data to a control unit of the robotic system 11 .

[0062] According to one embodiment, the robotic system 11 may include a monitor display (not shown) for displaying information regarding the position of the surgical tool relative to the surgical subject or the current operating mode of the robotic arm 100.

[0063] According to one embodiment, the assembly 10 includes at least one electrical connector 90 disposed inside the support 20, the at least one electrical connector 90 configured to mate with a corresponding electrical connector of the robotic arm 100. According to one embodiment, the electrical connector 90 may be electrically connected to at least one operation button 60, the light-emitting element of the optical marker 30, the visible light-emitting ring 70, and the memory device. By providing an electrical connector within the assembly 10 where the assembly 10 is coupled to the robotic arm 100, the mechanical connection between the two can also provide the electrical connection necessary for transmitting electrical signals or supplying power, facilitating the setup process of the robotic system 11.

[0064] In one embodiment, the proximal end 22 of the assembly 10 is coupled to the robotic arm 100 via a pogo pin connector. This configuration facilitates establishing electrical as well as mechanical connections between the assembly 10 and the robotic arm 100.

[0065] The detailed description is provided by way of example and is not intended to limit the scope of the invention, which is rather defined by the appended claims.

Claims

1. An assembly (10) for tracking the position and orientation of a robotic arm (100), comprising: a support (20) extending along a central axis (A) and having a proximal end (22) and a distal end (24) opposite the proximal end, the proximal end configured to be attached to the robot arm (100) and the distal end (24) configured to be attached to a tool holder or tool guide, the support (20) further having a hand grip (50) extending around the central axis and configured to provide a grip for a user to control the robot arm; at least three optical markers (30) disposed on the support and distributed around the central axis; the hand grip is disposed between the proximal end and the distal end; The support further comprises: at least one first outer portion (42, 44) extending around the central axis and disposed at or between the hand grip and the proximal end, each first outer portion being provided with at least one optical marker (30); at least one second outer portion (46) extending around the central axis and disposed at the distal end or between the distal end and the hand grip, each second outer portion being provided with at least one optical marker (30); The assembly (10) is characterized in that the first outer portion has an outermost edge (421, 441) that is farther from the central axis in a direction perpendicular to the central axis than an outermost edge (501) of the hand grip.

2. The assembly (10) of claim 1, wherein the support (20) is a single piece.

3. 3. The assembly according to claim 1 or 2, further comprising at least one operating button (60) for controlling the robot arm, the at least one operating button being provided on the hand grip (50) of the support (20).

4. The assembly (10) of any one of claims 1 to 3, wherein at least one of the first and second outer portions (42, 44, 46) tapers toward the distal end.

5. 5. The assembly (10) of claim 1, wherein each of the first outer portions (42, 44) has an outermost edge that is located at a distance from the central axis (A) in a direction perpendicular to the central axis that is equal to or greater than the outermost edge (461) of the second outer portion (46).

6. 6. The assembly (10) of claim 1, wherein the support comprises two first outer portions (42, 44) and one second outer portion (46) spaced apart from one another along the central axis.

7. 7. The assembly of claim 1, wherein each of the optical markers (30) is provided in a recess formed on the corresponding external portion (42, 44, 46) and configured such that the optical marker is substantially flush with the surface of the corresponding external portion (42, 44, 46).

8. The assembly (10) of any one of claims 1 to 7, wherein the optical marker (30) is a light emitting element.

9. 9. The assembly of any one of claims 1 to 8, further comprising a visible light emitting ring (70) extending around the central axis.

10. The assembly of any preceding claim, further comprising a memory device that stores data for tracking the position and orientation of the robotic arm.

11. The assembly of any one of claims 1 to 10, further comprising at least one electrical connector (90) disposed within the support, the at least one electrical connector configured to engage with a corresponding electrical connector of the robot arm (100).

12. 12. The assembly of claim 11, further comprising any one of the configurations of claims 3, 8, 9 and 10, wherein the electrical connector is electrically connected to the at least one operating button (60), the light emitting element, the visible light emitting ring (70), and the memory device.

13. An articulated robot arm (100); and an assembly (10) according to any one of claims 1 to 12 attached to a distal flange (102) of the robot arm.

14. 14. The robotic system of claim 13, wherein the proximal end (22) of the support (20) is attached to the robot arm such that the distal flange of the robot arm is received within the proximal end.

15. 15. The robotic system of claim 13 or 14, further comprising a sterile cover surrounding the robot arm (100) and the support (20), the sterile cover fitting over the first and second outer portions (42, 44, 46) of the support.

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