A camera tracking system for computer-aided surgical navigation.

Abstract

To provide a camera tracking system for computer-assisted navigation during surgery.SOLUTION: The system is configured to: identify locations of markers of a reference array in images obtained from tracking cameras 600 that image devices; determine measured coordinate locations of a feature of a device in the images based on the identified locations of the markers and based on a relative location relationship between the markers and the feature; and process a region of interest in the images identified based on the measured coordinate locations through a neural network 604 configured to output a prediction of coordinate locations of the feature in the images. The neural network has been trained based on training images containing the feature of a computer model rendered at known coordinate locations. Operations track the pose of the feature of the device in 3D space based on the prediction of coordinate locations of the feature of the real device in the images.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present disclosure relates to medical devices and systems, and more particularly to camera tracking systems used for computer-assisted navigation during surgery. [Background technology]

[0002] Computer-aided surgical navigation systems have become a well-established technique in the operating room to provide surgeons with computerized visualization of how surgical instruments or other devices posed relative to a patient correlate to their poses relative to medical images of the patient's anatomy, and how those poses correlate to preoperative surgical plans. Camera tracking systems for computer-aided surgical navigation typically use a set of tracking cameras to track the pose of a reference array on a surgical instrument, which is positioned by the surgeon during surgery, relative to a patient reference array ("dynamic reference base" (DRB)) that is fixed to the patient. A computer model of the actual instrument is associated with a reference element so that the computer model can be overlaid on a registered image of the patient's anatomy. The camera tracking system uses the relative pose of the reference array to determine how the actual instrument is posed relative to the patient, and how the computer model of the actual instrument is correspondingly posed as an overlay on the medical images. The surgeon can then use real-time visual feedback of the relative pose to navigate the surgical instrument during the patient's surgical procedure.

[0003] To ensure the fidelity of the instrument computer model overlay on the medical image, the accuracy of the actual instrument relative to the computer model needs to be verified before use. The accuracy check can be performed by placing the tip of the tracked actual instrument into a divot associated with another reference element. The divot is typically a cone-shaped depression. FIG. 5 illustrates an instrument that can be tracked by a camera tracking system when its tip is contacted with a verification divot on an arm supporting a tracked reference array, which is also tracked by the camera tracking system. The predicted position of the instrument tip, determined based on the instrument computer model, is compared to a measured position, determined based on the tracked position of the divot. Assuming that the user has properly positioned the instrument tip in the divot, the distance between the predicted and measured positions determines the accuracy of the tracked instrument. If the accuracy check is not passed, the instrument is not verified and should not be used.

[0004] Exemplary sources of inaccuracy during instrument validation include: 1. Deformed instruments, e.g., bent tips. 2. Note that a deformed reference element, e.g. a bent reference array fixture or a bent marker mounting post, and a relatively small angular shift in the reference element may result in a correspondingly very small error in the tracking of the reference element, but may result in a much larger error in the tracking of the instrument tip. 3. Inaccuracy of the optical marker due to manufacturing defects, contamination, or incorrect mounting of the optical marker on the marker mounting post or in the marker mounting socket.

[0005] Validation of the instrument during use may allow inaccuracies to be compensated for and improve tracking fidelity so that the measured location of the physical tip matches the model-based predictions. Summary of the Invention

[0006] Some embodiments of the present disclosure are directed to a camera tracking system for computer-assisted navigation during surgery. The system includes at least one processor configured to perform operations including identifying locations of markers of a reference array in a set of images acquired from tracking cameras imaging a real device having at least partially overlapping fields of view. The operations determine measured coordinate locations of features of the real device in the set of images based on the identified locations of the markers and based on a relative location relationship between the markers and the features. The operations process regions of interest in the set of images identified based on the measured coordinate locations through a neural network configured to output predictions of coordinate locations of the features in the set of images. The neural network has been trained based on training images including features of a computer model rendered at known coordinate locations. The operations track a pose of the features of the real device in three-dimensional (3D) space based on the predictions of coordinate locations of the features of the real device in the set of images.

[0007] Some other embodiments of the present disclosure are directed to another camera tracking system for computer-assisted navigation during surgery. The system includes at least one processor configured to perform operations including acquiring images from an accuracy camera imaging a calibration pattern having at least a partially overlapping field of view, the accuracy camera connected to a reference array of markers through a rigid fixture. The operations identify an actual calibration pattern in the images from the accuracy camera. The operations calculate an expected calibration pattern in the images from the accuracy camera based on a relative pose of the accuracy camera. The operations adjust the relative pose of the accuracy camera based on a difference between the actual calibration pattern and the expected calibration pattern in the images from the accuracy camera.

[0008] Some other embodiments of the present disclosure are directed to another camera tracking system for computer-assisted navigation during surgery. The system includes at least one processor configured to perform operations including identifying coordinates of a pattern of spaced apart areas of light-reflective material along a continuous surface of a fiducial marker attached to a real device in images acquired from a tracking camera that images the fiducial marker having at least partially overlapping fields of view. The operations track a pose of the fiducial marker in 3D space based on the identified coordinates of the pattern of spaced apart areas of light-reflective material along the continuous surface of the fiducial marker.

[0009] Some other embodiments of the present disclosure are directed to a fiducial marker configured to be tracked by a camera tracking system for computer-assisted navigation during surgery. The fiducial marker includes an object having a surface of one of a light absorbing material and a light reflecting material, and a cover layer extending over the surface of the object. The cover layer is the other of the light absorbing material and the light reflecting material. The cover layer has a pattern of openings exposing spaced areas of the surface of the object.

[0010] Other camera tracking systems and fiducial markers according to embodiments of the present subject matter will be or become apparent to one of ordinary skill in the art upon review of the following figures and detailed description. All such additional camera tracking systems and fiducial markers are intended to be included within this specification, be within the scope of the present subject matter, and be protected by the accompanying claims. Furthermore, it is intended that all embodiments disclosed herein may be implemented separately or combined in any manner and / or combination. [Brief description of the drawings]

[0011] Aspects of the present disclosure are illustrated by way of example and not limitation in the accompanying drawings, in which: [Figure 1]FIG. 1 is a top view of a surgical system positioned during a surgical procedure in an operating room, including a camera tracking system for navigated surgery, and may further include a surgical robot for robotic assistance, in accordance with some embodiments. [Diagram 2] 1 illustrates a camera tracking system and a surgical robot positioned relative to a patient, according to some embodiments. [Diagram 3] 1 further illustrates a camera tracking system and a surgical robot configured in accordance with some embodiments. [Figure 4] 1 illustrates a block diagram of a surgical system including an XR headset, a computer platform, an imaging device, and a surgical robot, configured to operate in accordance with some embodiments. [Diagram 5] Illustrates an instrument that may be tracked by a camera tracking system as its tip is contacted with a verification divot on an arm that supports a tracked reference array, the tracked reference array also being tracked by the camera tracking system. [Figure 6] 1 illustrates components of a camera tracking system, including a neural network for predicting coordinate locations of device features in images from a tracking camera, according to some embodiments. [Figure 7] 1 illustrates a flowchart of operations for identifying, training, testing, and deploying neural networks in a computer-automated manner according to some embodiments. [Figure 8] 1 illustrates a top view of a camera tracking system including a pair of accuracy cameras used to verify instruments or other devices for computer-assisted navigation during surgery, according to some embodiments. [Figure 9] 10 illustrates another top view of the camera tracking system of FIG. 8 including a calibration pattern used to calibrate the relative pose of the accuracy cameras, in accordance with some embodiments. [Figure 10]10 illustrates a flowchart of operations that may be performed by the camera tracking system of FIG. 8 to calibrate the positioning of the accuracy camera, according to some embodiments. [Figure 11] 10 illustrates a flowchart of operations that may be performed by the camera tracking system of FIG. 8 for computer-assisted navigation during surgery, according to some embodiments. [Figure 12] 1 illustrates a fiducial marker attached to a post of an instrument or other device, according to some embodiments. [Figure 13] 1 illustrates portions of different embodiments of a fiducial marker having a cover layer with a pattern of openings that expose spaced areas of an underlying object surface for tracking by a camera tracking system. [Figure 14a] 1 illustrates portions of different embodiments of a fiducial marker having a cover layer with a pattern of openings that expose spaced areas of an underlying object surface for tracking by a camera tracking system. [Figure 14b] 1 illustrates portions of different embodiments of a fiducial marker having a cover layer with a pattern of openings that expose spaced areas of an underlying object surface for tracking by a camera tracking system. [Figure 15a] 1 illustrates portions of different embodiments of a fiducial marker having a cover layer with a pattern of openings that expose spaced areas of an underlying object surface for tracking by a camera tracking system. [Figure 15b] 1 illustrates portions of different embodiments of a fiducial marker having a cover layer with a pattern of openings that expose spaced areas of an underlying object surface for tracking by a camera tracking system. [Figure 16] 1 illustrates portions of different embodiments of a fiducial marker having a cover layer with a pattern of openings that expose spaced areas of an underlying object surface for tracking by a camera tracking system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] It is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the description herein or illustrated in the drawings. The teachings of the disclosure can be used and implemented in other embodiments and can be practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for the purpose of description and should not be considered as limiting. The use of "including," "comprising," or "having," and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. Unless otherwise specified or limited, the terms "mounted," "connected," "attached," "supported," and "coupled," and variations thereof, are used broadly and include both direct and indirect mounting, connecting, attaching, supporting, and coupling. Moreover, "connected" and "coupled" are not limited to physical or mechanical connections or couplings.

[0013] The following discussion is presented to enable those skilled in the art to make and use the embodiments of the present disclosure. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the principles of the present disclosure may be applied to other embodiments and applications without departing from the embodiments of the present disclosure. Thus, the embodiments are not intended to be limited to the embodiments shown, but should be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description should be read with reference to the drawings, in which like elements in different drawings have like reference numerals. The figures are not necessarily to scale, depict selected embodiments, and are not intended to limit the scope of the embodiments. Those skilled in the art will recognize that the examples provided herein have many useful alternatives and are within the scope of the embodiments.

[0014] Some embodiments of the present disclosure are directed to various camera tracking systems for verifying instruments and other devices in use and tracking the pose of instruments and other devices during computer-assisted navigation during surgery. Some other embodiments are directed to fiducial markers configured to be tracked by a camera tracking system for computer-assisted navigation during surgery. Before describing these embodiments in detail, various components that may be used to implement the embodiments in a navigated surgical system will be described with reference to FIGS.

[0015] Figure 1 is a top view of a surgical system positioned during a surgical procedure in an operating room, including a camera tracking system 200 for navigated surgery, and may further include a surgical robot 100 for robotic assistance, according to some embodiments. Figure 2 illustrates the camera tracking system 200 and surgical robot 100 positioned relative to a patient, according to some embodiments. Figure 3 further illustrates the camera tracking system 200 and surgical robot 100 configured according to some embodiments. Figure 4 illustrates a block diagram of a surgical system including an XR headset 150, a computer platform 400, an imaging device 420, and a surgical robot 100 configured to operate according to some embodiments.

[0016] The XR headset 150 may be configured to augment a real-world scene with a computer-generated XR image while worn by personnel in an operating room. The XR headset 150 may be configured to provide an augmented reality (AR) viewing environment by displaying the computer-generated XR image on a see-through display screen that allows light from the real-world scene to pass through for combined viewing by the user. Alternatively, the XR headset 150 may be configured to provide a virtual reality (VR) viewing environment by preventing or substantially preventing light from the real-world scene from being viewed directly by the user while the user is viewing the computer-generated AR image on the display screen. The XR headset 150 may be configured to provide both AR and VR viewing environments. Thus, the term XR headset may be referred to as an AR headset or a VR headset.

[0017] 1-4, a surgical robot 100 may include, for example, one or more robotic arms 104, a display 110, an end effector 112 including, for example, a guide tube 114, and an end effector fiducial array that may include one or more tracking markers. A patient fiducial array 116 (DRB) has a plurality of tracking markers 117 and is fixed directly to a patient 210 (e.g., to a bone of the patient 210). A fiducial array 170 is attached to or formed on an instrument, a surgical tool, a surgical implant device, or the like.

[0018] The camera tracking system 200 includes tracking cameras 204, which may be spaced apart stereo cameras configured to have overlapping fields of view, may have any suitable configuration of arms 202 for moving, orienting and supporting the tracking cameras 204 at desired locations, and may include at least one processor operable to track the location of individual markers and the pose of the array of markers.

[0019] As used herein, the term "pose" refers to the location (e.g., along three orthogonal axes) and / or rotation angle (e.g., around three orthogonal axes) of a marker (e.g., DRB) relative to another marker (e.g., surveillance marker) and / or a defined coordinate system (e.g., camera coordinate system). Thus, a pose may be defined based solely on a multi-dimensional location of a marker relative to another marker and / or a defined coordinate system, based solely on a multi-dimensional rotation angle relative to other markers and / or a defined coordinate system, or based on a combination of a multi-dimensional location and a multi-dimensional rotation angle. Thus, the term "pose" is used to refer to a location, a rotation angle, or a combination thereof.

[0020] The tracking camera 204 may include an infrared camera (e.g., bifocal or stereo photogrammetry camera) operable to identify active and passive tracking markers relative to a single marker (e.g., a surveillance marker) and a reference array, which may be formed on or attached to, for example, the patient 210 (e.g., a patient reference array, DRB), the end effector 112 (e.g., an end effector reference array), the XR headset 150 worn by the surgeon 120 and / or the surgical assistant 126, etc., in a given measurement volume of a camera coordinate system while being visible from the viewpoint of the tracking camera 204. The tracking camera 204 may scan the given measurement volume and detect light emitted or reflected from the markers to identify and determine the location of the individual markers and the pose of the reference array in three dimensions. For example, an active reference array may include infrared emitting markers that are activated by an electrical signal (e.g., infrared light emitting diodes (LEDs)), and a passive reference array may include retroreflective markers that reflect infrared light emitted by an illuminator on the tracking camera 204 or other suitable device (e.g., reflect incident IR radiation in the direction of the incident light).

[0021] XR headset 150 may include tracking cameras (e.g., spaced stereo cameras) that may track the locations of surveillance markers and the pose of reference arrays within the XR camera headset's field-of-view (FOV) 152 and 154, respectively. Thus, as illustrated in FIG. 1 , the locations of surveillance markers and the pose of reference arrays on various objects may be tracked while within the FOVs 152 and 154 of XR headset 150 and / or the FOV 600 of tracking camera 204.

[0022] 1 and 2 illustrate potential configurations for placement of a camera tracking system 200 and a surgical robot 100 within a surgical room environment. Computer-assisted navigated surgery may be provided by the camera tracking system controlling an XR headset 150 for displaying surgical navigation information and / or other displays 34, 36, and 110. The surgical robot 100 is optional during computer-assisted navigated surgery.

[0023] The camera tracking system 200 may operate using tracking information and other information provided by multiple XR headsets 150, such as inertial tracking information and optical tracking information (frames of tracking data). The XR headsets 150 may operate to display visual information and play audio information to the wearer. This information may be from local sources (e.g., the surgical robot 100 and / or other medical equipment), remote sources (e.g., a patient medical image server), and / or other electronic devices. The camera tracking system 200 may track markers with 6 degrees-of-freedom (6DOF) relative to three axes of a 3D coordinate system and the angle of rotation about each axis. The XR headsets 150 may also operate to track hand poses and gestures to enable gesture-based interaction with "virtual" buttons and interfaces displayed through the XR headsets 150, and may interpret hand or finger pointing or gestures as various defined commands. Additionally, the XR headsets 150 may have a digital color camera sensor with 1-10x magnification, called a digital magnifying glass. In some embodiments, one or more of the XR headsets 150 are minimalist XR headsets that display local or remote information, but contain fewer sensors and are therefore lighter in weight.

[0024] The "outside-in" machine vision navigation bar supports a tracking camera 204 and may include a color camera. The machine vision navigation bar generally does not move as frequently or quickly as the XR headset 150 while positioned on the wearer's head, and therefore has a more stable view of the environment. The patient reference array 116 (DRB) is generally rigidly attached to the patient with a stable pitch and roll relative to gravity. This local precision patient reference 116 can serve as a common reference frame for other tracked arrays, such as the reference array on the end effector 112, the instrument reference array 170, and the reference array on the XR headset 150.

[0025] During a surgical procedure using surgical navigation, a surveillance marker may be fixed to the patient to provide information on whether the patient fiducial array 116 has shifted. For example, during a spinal fixation procedure with planned placement of pedicle screw fixation, two small incisions are made across either side of the posterior superior iliac spine. A DRB and a surveillance marker are then fixed to either side of the posterior superior iliac spine. If the location of the surveillance marker changes relative to the patient fiducial array 116, the camera tracking system 200 may display a gauge indicating the amount of movement and / or display a pop-up warning message to inform the user that the patient fiducial array may have been bumped. If the patient fiducial array is actually bumped, the alignment of the patient fiducial array to the tracked coordinate system may be invalid, resulting in erroneous navigation off target.

[0026] When present, the surgical robot (also referred to as "robot") may be positioned near or next to the patient 210. The robot 100 may be positioned in any suitable location near the patient 210 depending on the area of ​​the patient 210 that will undergo the surgical procedure. The camera tracking system 200 may be separate from the robot system 100 and positioned at the feet of the patient 210. This location allows the tracking camera 200 to have a direct line of sight to the surgical area 208. In the configuration shown, the surgeon 120 may be positioned across from the robot 100 but still be able to operate the end effector 112 and the display 110. The surgical assistant 126 may also be positioned across from the surgeon 120 with access to both the end effector 112 and the display 110. If desired, the locations of the surgeon 120 and assistant 126 may be reversed. The anesthesiologist 122, nurse, or scrub technician can operate equipment that may be connected to display information from the camera tracking system 200 on the display 34.

[0027] As with the other components of the robot 100, a display 110 may be mounted on the surgical robot 100 or at a remote location. The end effector 112 may be coupled to the robotic arm 104 and controlled by at least one motor. In some embodiments, the end effector 112 may include a guide tube 114 configured to receive and orient a surgical instrument, tool, or implant used to perform a surgical procedure on a patient 210.

[0028] As used herein, the term "end effector" is used interchangeably with the terms "end effector" and "effector element." The term "instrument" is used non-limitingly and interchangeably with "tool" and "implant" and may generally refer to any type of device that may be used during a surgical procedure according to the embodiments disclosed herein. The more general term device may refer to structures such as end effectors. Exemplary instruments, tools, and implants include, without limitation, drills, screwdrivers, saws, dilators, retractors, probes, implant inserters, and implant devices such as screws, spacers, interbody fusion devices, plates, rods, and the like. Although generally shown with a guide tube 114, it will be understood that the end effector 112 may be replaced with any suitable instrument suitable for use in a surgical procedure. In some embodiments, the end effector 112 may comprise any known structure for effecting movement of a surgical instrument in a desired manner.

[0029] The surgical robot 100 is operable to control the translation and orientation of the end effector 112. The robot 100 may move the end effector 112 under computer control, for example, along the x, y, and z axes. The end effector 112 may be configured to selectively rotate about one or more of the x, y, and z axes, as well as the Z frame axis, such that one or more of the Euler angles (e.g., roll, pitch, and / or yaw) associated with the end effector 112 may be selectively computer controlled. In some embodiments, selective control of the translation and orientation of the end effector 112 may enable the performance of medical procedures with significantly improved accuracy, as compared to, for example, conventional robots that utilize 6DOF robotic arms that include only rotational axes. For example, the surgical robot 100 may be used to operate on a patient 210, where the robotic arm 104 may be positioned over the body of the patient 210, and the end effector 112 is selectively angled relative to the z axis toward the body of the patient 210.

[0030] In some exemplary embodiments, the XR headset 150 can be controlled to dynamically display an updated graphical representation of the surgical instrument pose so that the user is constantly aware of the surgical instrument pose during the procedure.

[0031] In some further embodiments, the surgical robot 100 may be operable to correct the path of the surgical instrument guided by the robotic arm 104 if the surgical instrument deviates from a selected pre-planned trajectory. The surgical robot 100 may be operable to allow for stopping, modifying, and / or manual control of the movement of the end effector 112 and / or surgical instrument. Thus, in use, a surgeon or other user may use the surgical robot 100 as part of a computer-assisted navigated procedure and have the option to stop, modify, or manually control the autonomous or semi-autonomous movement of the end effector 112 and / or surgical instrument.

[0032] Reference arrays of markers may be formed on or connected to the robotic arms 102 and / or 104, the end effector 112 (e.g., end effector array 114 of FIG. 2), and / or the surgical instrument (e.g., instrument array 170) to track 6DOF poses along and rotations about three orthogonal axes. The reference arrays allow each of the marked objects (e.g., end effector 112, patient 210, and surgical instruments) to be tracked by the tracking camera 200, and the tracked poses may be used to provide navigated guidance during a surgical procedure and / or used to control the movement of the surgical robot 100 to guide the end effector 112 and / or instruments manipulated by the end effector 112.

[0033] 3, the surgical robot 100 may include a display 110, an upper arm 102, a lower arm 104, an end effector 112, a vertical column 312, casters 314, a table 318, and a ring 324 that uses lights to indicate status and other information. The cabinet 106 may house the electrical components of the surgical robot 100, including but not limited to a battery, a power distribution module, a platform interface board module, and a computer. The camera tracking system 200 may include a display 36, a tracking camera 204, the arm 202, a computer housed in a cabinet 330, and other components.

[0034] In computer-assisted navigated surgery, vertical 2D scan slices, such as axial, sagittal, and / or coronal views of the patient's anatomy, are displayed to allow a user visualization of the patient's anatomy along with the relative pose of the surgical instruments. An XR headset or other display can be controlled to display one or more 2D scan slices of the patient's anatomy along with a 3D graphical model of the anatomy. The 3D graphical model can be generated from a 3D scan of the patient, for example, by a CT scanning device, and / or can be generated based on a baseline model of the anatomy that is not necessarily formed from a scan of the patient.

[0035] Exemplary Surgical Systems: FIG. 4 illustrates a block diagram of a surgical system including an XR headset 150, a computer platform 400, an imaging device 420, and a surgical robot 100 configured to operate according to some embodiments.

[0036] The imaging device 420 may include a C-arm imaging device, an O-arm imaging device, and / or a patient image database. The XR headset 150 provides an improved human interface for performing navigated surgical procedures. The XR headset 150 may be configured to provide functionality including, for example, via the computer platform 400, any one or more of the following: identification of hand gesture-based commands, display of XR graphical objects on the display device 438 of the XR headset 150 and / or another display device. The display device 438 may include a video projector, a flat panel display, etc. A user may view the XR graphical objects as overlays anchored to certain real-world objects viewed through a see-through display screen. The XR headset 150 may additionally or alternatively be configured to display video streams on the display device 438 from one or more cameras attached to the XR headset 150 and other cameras.

[0037] The electrical components of the XR headset 150 may include multiple cameras 430, microphones 432, gesture sensors 434, attitude sensors (e.g., inertial measurement units (IMUs)) 436, a display device 438, and a wireless / wired communication interface 440. The cameras 430 of the XR headset 150 may be visible light capture cameras, near infrared capture cameras, or a combination of both.

[0038] The camera 430 may be configured to operate as a gesture sensor 434 by tracking hand gestures of an identified user performed within the field of view of the camera 430. Alternatively, the gesture sensor 434 may be a proximity sensor and / or a touch sensor that senses hand gestures performed in proximity to the gesture sensor 434 and / or senses physical contact, e.g., a tap on the sensor 434 or its housing. The attitude sensor 436, e.g., an IMU, may include a multi-axis accelerometer, a tilt sensor, and / or another sensor that can sense rotation and / or acceleration of the XR headset 150 along one or more defined coordinate axes. Some or all of these electrical components may be housed in the head-mounted component housing, or in a separate housing configured to be worn elsewhere, such as on the waist or shoulder.

[0039] As described above, the surgical system includes the camera tracking system 200, which may be connected to a computer platform 400 for motion processing and may include a navigation controller 404 and / or provide other motion functions of the XR headset controller 410. The surgical system may include a surgical robot 100. The navigation controller 404 may be configured to provide visual navigation guidance to the operator for moving and positioning the surgical tools relative to the patient's anatomy, for example, based on a surgical plan from a surgical planning function that defines where on the anatomical structure a surgical procedure is to be performed using the surgical tools, and based on the pose of the anatomical structure determined by the camera tracking system 200. The navigation system 404 may be further configured to generate navigation information based on the target pose of the surgical tool, the pose of the patient's anatomical structures, and the pose of the surgical tool and / or the end effector of the surgical robot 100, and steering information is displayed through the display device 438 of the XR headset 150 and / or another display device to indicate where the surgical tool and / or the end effector of the surgical robot 100 should be moved to perform the surgical plan.

[0040] The electrical components of the XR headset 150 may be operatively connected to the electrical components of the computer platform 400 through a wired / wireless interface 440. The electrical components of the XR headset 150 may be operatively connected to various imaging devices 420, such as a C-arm imaging device, an I / O arm imaging device, a patient image database, and / or other medical equipment through the wired / wireless interface 440, for example, through the computer platform 400 or directly.

[0041] The surgical system may include an XR headset 150, a computer platform 400, and / or an XR headset controller 410, which may reside at least partially in another system component connected via a wired cable and / or wireless communication link. Various functions are provided by software executed by the XR headset controller 410. The XR headset controller 410 is configured to receive information from the camera tracking system 200 and the navigation controller 404 and generate an XR image based on the information for display on the display device 438.

[0042] The XR headset controller 410 may be configured to operatively process frames of tracking data from the tracking camera 430 (tracking camera), signals from the microphone 1620, and / or information from the attitude sensor 436 and gesture sensor 434 to generate information for display as an XR image on the display device 438 and / or as other for display on other display devices for viewing by a user. Thus, the XR headset controller 410 illustrated as a circuit block within the XR headset 150 should be understood as being operatively connected to the other illustrated components of the XR headset 150, but not necessarily within a common housing or otherwise transportable by a user. For example, the XR headset controller 410 may be present within the computer platform 400, which in turn may be present within the cabinet 330 of the camera tracking system 200, the cabinet 106 of the surgical robot 100, etc.

[0043] Camera tracking system with neural network prediction of device feature coordinate locations: Some embodiments are directed to various camera tracking systems configured to directly track an instrument tip or other feature of a device using a navigation camera for verification, calibration, and / or navigation during a surgical procedure. Although various embodiments are described in the context of tracking an instrument tip, they are not limited thereto and may be used to track any visually recognizable feature of a real device that is modeled within a computer model (e.g., computer-aided drawing) of the real device. The real device may correspond to an instrument, end effector, or other apparatus.

[0044] 6 illustrates components of a camera tracking system, including a neural network configured to predict coordinate locations of device features in images from a tracking camera, according to some embodiments. With reference to FIG. 6, the camera tracking system 200 includes a tracking camera 600, such as the camera 204 of FIG. 1, an image processing module 602, a neural network 604, such as a convolutional neural network, and an instrument validation and tracking module 606.

[0045] According to some embodiments, the image processing module 602 identifies the locations of the markers of the reference array in a set of images acquired from the tracking cameras 600 that image the real device with at least partially overlapping fields of view. The image processing module 602 determines the measured coordinate locations of the features of the real device in the set of images based on the identified locations of the markers and based on the relative location relationship between the markers and the features. The system 200 processes the regions of interest in the set of images identified based on the measured coordinate locations through a neural network 604 configured to output predictions of the coordinate locations of the features in the set of images. The neural network 604 is trained based on training images that include features of a computer model rendered at known coordinate locations. The instrument validation and tracking module 606 tracks the pose of the features of the real device in three-dimensional (3D) space based on the predictions of the coordinate locations of the features of the real device in the set of images.

[0046] In a further embodiment, the prediction of the coordinate location of the feature on the actual device indicates the predicted pixel coordinate of the feature in the set of images based on the output of the neural network 604.

[0047] In a further embodiment, the instrument validation and tracking module 606 determines a predicted 3D pose of the real device feature in the tracked space based on triangulation of predictions of two-dimensional (2D) coordinate locations of the real device feature in a pair of sets of images from a pair of tracking cameras 600. The instrument validation and tracking module 606 determines a measured 3D pose of the real device feature in the tracked space based on triangulation of locations of markers of the reference array in the pair of sets of images, and calibrates the feature offset based on a comparison of the predicted 3D pose of the feature and the measured 3D pose of the feature.

[0048] To track real features, also called datums, of the real device datum, a computer model (e.g., known CAD data) can be used to train the neural network 604 to return image pixel coordinates of the requested features (datums). In an exemplary scenario, a high contrast optical marker can have a tracked location in the same image frame as the instrument tip to allow the operation to calibrate the marker and the instrument tip to the same rigid body. In this way, the need for a mechanical "verification divot" is eliminated and real-time and automated measurement of instruments and devices can be operationally performed. After finding the tip location with the left and right stereo cameras, the 3D location is determined using triangulation of the 2D location. The markers can be similarly identified in the 2D image before being triangulated to determine their 3D location.

[0049] In a further embodiment, the instrument validation and tracking module 606 validates the feature of the actual device based on whether the measured coordinate location of the feature of the actual device is within a threshold distance of a prediction of the coordinate location of the feature of the actual device.

[0050] In a further embodiment, training images including features of a computer model rendered at known coordinate locations in the training images are processed through a neural network 604 to output predictions of the coordinate locations of the features of the computer model in the training images. The known coordinate locations of the features in the training images are compared to the predictions of the coordinate locations of the features of the computer model in the training images, and parameters 604 of the neural network are trained based on the comparison.

[0051] Neural network 604 may be trained using, for example, tens of thousands or millions of images. Alpha images may be generated using a computer-generated representation of the device rendering based on the computer model and may be rendered with a transparent background. The alpha images may then be augmented with different synthetic backgrounds to generate training images for use in training neural network 604. In one embodiment, training images are generated to include features of the computer model rendered at known coordinate locations within the training images, with different rendered backgrounds, different rendered lighting conditions, and / or different rendered poses of the features of the computer model among at least some of the training images.

[0052] Training parameters of the neural network 604 may include adapting weights and / or firing thresholds assigned to connection nodes of at least one layer of the neural network 604 based on training images that include computer-modeled features rendered at known coordinate locations within the training images.

[0053] A convolutional neural network 604 (CNN) may be used that is configured to provide real-time or near real-time processing of images from the tracking camera 600. CNNs are also known as Shift Invariant or Space Invariant Artificial Neural Networks (SIANNs) based on a shared weight architecture of convolution kernels or filters that slide along image input features and provide translationally equivariant responses known as feature maps.

[0054] In CNN, the input is a tensor with shape: (number of inputs) × (input height) × (input width) × (input channels). After passing through the convolutional layers, the image will be abstracted into a feature map, also called an activation map, with shape: (number of inputs) × (feature map height) × (feature map width) × (feature map channels). The convolutional layer convolves the input and passes the result to the next layer.

[0055] Rather than training one neural network to track multiple different types of instruments (which may require an excessively large architecture and be very time consuming), in some embodiments, different neural networks are trained and used to predict feature coordinate locations for different types of devices. Effective training may require thousands of labeled images used in a supervised training operation, at least in some scenarios. Training hundreds of relatively small device type-specific neural networks to accommodate hundreds of different types of instruments and other equipment may be impractical and very time consuming. Some embodiments are therefore directed to automating the training, evaluation, and deployment via a simulator training operation. The simulator may include a light sphere (optionally HORI) with dynamic lighting. Relevant instruments are added to the scene, and a virtual navigation camera with very similar lens characteristics captures the reference element and the instrument tip at thousands of different poses with widely varying backgrounds. The output images are then processed during training to match the navigation camera itself. For example, the images may be made monochrome, a brightness constant may be applied, and noise may be applied with a blur kernel.

[0056] Once the neural network is fully expanded with thousands to over a million simulated images, it is trained using the simulated images. Evaluating the performance of the neural network involves testing the neural network against thousands of different test images that are not in the training dataset (i.e., not seen by the neural network). Depending on the results of comparing the predicted measurements to the known ground truth, the neural network is either deployed as successful (for use in the operating room according to embodiments herein) or fails and is sent back for continued training improvement. Neural networks can be fast enough that an ensemble of a few to tens of neural networks can be trained and run in the field. If there is excessive variance between the neural networks, the measurement is rejected. Averaging the ensemble output can also improve accuracy by about 10% to 30%.

[0057] FIG. 7 illustrates a flowchart of operations for identifying, training, testing, and deploying neural networks in a computer-automated manner according to some embodiments.

[0058] Referring to FIG. 7, a computer model of a new instrument type is constructed (700), which may include designing a 3D model of the instrument in a computer-aided design tool. A computer-generated image of the tool is rendered in training images with a variety of different backgrounds and lighting conditions (702). A neural network is trained (i.e., parameters are trained) using the training images and tested (704). The test accuracy is determined (706), and if the test accuracy is within an acceptable range, the trained neural network for the new tool type is integrated into the camera tracking system (708). The neural network may then be run during a surgical procedure on live image data to verify the accuracy of the features (datum) of the actual instrument corresponding to the new instrument type and to track the location of the features (datum) of the actual instrument (710).

[0059] In contrast, when it is determined (706) that the test accuracy is not within an acceptable range, the operations evaluate (712) the results and a determination is made (714) as to whether a rule is satisfied that indicates that the test accuracy for the new instrument may be improved through further training of the neural network. If the rule is satisfied, the operations adapt (716) the neural network and / or the training image data based on the evaluation (712) (e.g., by changing background and lighting conditions) and the neural network is further trained and tested (704). In contrast, when the rule is not satisfied, the operations indicate (718) a denial of support for tracking the requested feature (datum).

[0060] Camera Tracking System with Accuracy Camera for Device Feature Verification: If the navigation camera is not sufficiently calibrated or if the operating room conditions are too uncontrolled and dynamic, other operations can be performed using a dedicated validation and calibration fixture attached to a visible light optical camera (also called an "accuracy camera"). The calibration fixture and associated operations can be used as an alternative approach to the above techniques of neural network-based validation of instruments, or can be used in combination with the above approaches.

[0061] The operation may use computer vision techniques applied to an accuracy camera operating in parallel with an existing near-infrared (NIR) tracking camera 200 (FIG. 2). The computer vision techniques may also utilize neural networks such as any of the embodiments described above.

[0062] The operation may provide the user with meaningful visual feedback, including a live feed of accuracy camera video data with diagnostic overlays. When used with an XR headset, the display may present a floating window containing either the left or right tracking camera and / or accuracy camera, along with a computer-rendered overlay of predicted versus actual computer models, e.g., computer-aided design (CAD) information. Visual guidance to the user may also be shown (e.g., via arrows), instructing the user to move the instrument or other device in one direction or another for improved measurement view relative to the accuracy camera. Similarly, a 3D model may be attached to the edge of the instrument or other device for spatial awareness. This information may be scaled or enlarged for enhanced visibility.

[0063] Live or paused image or video information may be displayed on a 2D monitor during or after the validation and / or calibration process. Graphic overlays of measured versus expected information, including numerical values ​​or other diagnostics, may be shown.

[0064] In either case, the visualizations can be updated in real time as instruments and / or other devices are moved around, providing intuitive feedback independent of automated measurements. In the case of an imprecise instrument or implant installation, etc., errors can become immediately and intuitively known to the surgical staff from these visualizations.

[0065] In some embodiments, multiple views of the tracked instrument are captured using an accuracy camera that is itself tracked by the tracking camera 200. The instrument and the accuracy camera include reference elements that are tracked by the tracking camera 200.

[0066] 8 illustrates a top view of a camera tracking system including a pair of accuracy cameras 800 used to verify instruments or other devices for computer-assisted navigation during surgery, according to some embodiments. The accuracy cameras 800 are connected to a reference array of markers 812 through a rigid fixture 810 to eliminate any movement between the accuracy cameras 800. The accuracy cameras 800 are oriented by the fixture 810 such that they have at least partially overlapping fields of view of a verification space 820 in which instrument features may be located during a verification operation. The accuracy cameras 800 may have a higher pixel resolution but a narrower field of view than the tracking cameras 200 because the instrument features are positioned relatively closer to the accuracy cameras 800 in the verification space 820.

[0067] Screen 830 may extend from fixture 810 so as to be located behind verification space 820 relative to accuracy camera 800. Screen 830 may have stable or tunable color and / or provide lighting, e.g., an electroluminescent panel, to create a desired background for the instrument being verified while being imaged by accuracy camera 800. The desired background may improve the repeatability, reliability, and accuracy of computer vision techniques when determining the 3D location of instrument features in images from accuracy camera 800.

[0068] The accuracy camera 800 may be covered with a thin, sterile, transparent drape pulled tightly (or made from a hard shell) so as not to affect the camera's visibility or add distortion or refraction.

[0069] The calibration pattern may be used to calibrate the relative pose between the accuracy cameras 800. FIG. 9 illustrates another top view of the camera tracking system of FIG. 8 including a calibration pattern 900 that may be used to calibrate the relative pose of the accuracy cameras 800, according to some embodiments. The calibration pattern 900 is displayed in the validation space 820 for inclusion in images acquired from the accuracy cameras 800. The operations identify an actual calibration pattern in the images from the accuracy cameras 800 and calculate an expected calibration pattern in the images from the accuracy cameras 800 based on the relative pose of the accuracy cameras 800. The operations then adjust the relative pose of the accuracy cameras 800 based on the difference between the actual calibration pattern and the expected calibration pattern in the images from the accuracy cameras 800. The adjustment of the relative pose may include adjusting a predetermined relationship that characterizes the distance and angular offset between the accuracy cameras 800.

[0070] FIG. 10 illustrates a flowchart of operations that may be performed by the camera tracking system of FIG. 8 to calibrate the positioning of the accuracy camera 800, according to some embodiments.

[0071] 10, the operation estimates (1002) a relative pose between the accuracy cameras 800 based on, for example, a baseline relative pose defined according to the accuracy cameras 800 and fixture 810. The operation calculates (1000) an expected calibration pattern that is expected to be captured in images from the accuracy cameras 800 based on a defined pattern of the calibration pattern and based on the estimate of the relative pose. The operation calculates (1004) a difference between the expected calibration pattern and an actual calibration pattern identified in images from the accuracy cameras 800. When the difference is determined to satisfy a defined rule, such as by being less than a threshold error (1006), the relative pose between the accuracy cameras 800 is calibrated (1010) based on the then-existing estimate. In contrast, when it is determined (1006) that the difference does not satisfy the defined rules, the estimate of the relative pose is adjusted (1008) and the operation is repeated to calculate another expected pattern (1000), calculate the difference (1004), and determine (1006) whether the difference satisfies the defined rules.

[0072] FIG. 11 illustrates a flowchart of operations that may be performed by the camera tracking system of FIG. 8 for computer-assisted navigation during surgery, according to some embodiments.

[0073] 11, the operations estimate 1100 a pose of an instrument feature, e.g., a tip, based on a coordinate location of an identified feature in a set of images acquired from an accuracy camera. The operations determine 1104 an expected pose of the instrument feature. Determining 1104 may include measuring a pose of a marker of a reference array attached to the instrument in a set of images acquired from a tracking camera that images the reference array and the instrument with at least a partially overlapping field of view. Determining 1104 further includes determining an expected pose of the instrument feature based on a computer model 1102 of the instrument and the feature, and the measured pose of the marker of the reference array. In some embodiments, determining 1104 an expected pose of the instrument feature may be performed using a neural network to estimate a location of the instrument feature in images from the accuracy camera 800, which may be converted to a 3D pose using operations similar to those described for one or more of the above embodiments.

[0074] The operations adjust the calibrated pose of the instrument feature based on the difference between the estimated pose and the expected pose of the instrument feature. The adjustment operations may include calculating (1106) the difference between the estimated pose and the expected pose of the instrument feature. When the difference does not satisfy a defined rule (e.g., a feature validation rule), such as by being less than a threshold error, the calibrated pose of the instrument feature may be adjusted (1110) and / or an indication that the instrument feature is unvalidated may be generated (e.g., displayed to a user), and the operations are repeated to determine (1104) the expected pose of the instrument feature, calculate (1106) the difference, and determine (1108) whether the difference satisfies the defined rule. When the difference is determined (1108) to satisfy the defined rule, the calibrated pose of the instrument feature may be output (1112) for use in tracking the pose of the instrument feature using a tracking camera, and / or an indication that the instrument feature is validated may be generated (e.g., displayed to a user). When it is determined that the defined rules are satisfied (1108), the operation may enable tracking of the pose of the instrument feature based on the pose of the markers of a reference array attached to the instrument in images acquired from the tracking camera and based on the calibrated pose of the instrument feature.

[0075] In one particular implementation of FIG. 11, a system for calibrating a surgical device includes a tracking camera system 200 having multiple tracking cameras 204 for tracking a navigated surgical device, a calibration fixture 810 having a reference array marker 218 attached thereto and an accuracy camera 800 arranged orthogonally to each other to have at least partially overlapping fields of view and configured to acquire images of a surgical device (e.g., see FIG. 5) having a reference array marker such as shown as element 170 in FIG. 1, and a processor for performing surgical device calibration.

[0076] A surgical device requiring calibration is placed in the calibration fixture 810. The processor then images the surgical device and performs the following operations.

[0077] It estimates the pose (e.g., 3D position and orientation) of a physical feature (such as a tip) of the surgical device based on the coordinate locations of the features identified in the set of images acquired from the accuracy camera 800, and determines the pose of the calibration fixture 810 relative to the tracked camera 204 based on the calibration fixture fiducial array markers 812 seen by the tracked camera. Based on the above operations, the processor determines the pose of the physical feature of the surgical device relative to the tracked camera.

[0078] The process further determines an expected pose of the surgical device feature based on the computer model of the surgical device and the measured pose of the fiducial array markers of the surgical device included in the set of images acquired from the tracking camera 204. The processor then adjusts the pose of the surgical device feature in the computer model based on the difference between the estimated pose and the expected pose of the surgical device feature.

[0079] The focal length of the accuracy camera that is needed to track only the surgical device being calibrated is typically very small (e.g., in the range of 10 cm to 60 cm) relative to the large focal lengths (e.g., greater than 100 cm) of tracking cameras used to track all navigated tools and instruments in the operating room.

[0080] Optical tracking of fiducial markers using negative space (exposed contrast concave surface): Surgical navigation using fiducial markers tracked by a tracking camera has become a desired technique in the operating room. Fiducial elements are identified using unique geometric patterns created by the optical markers. Active optical markers typically emit infrared light in response to a trigger emitted by the optical camera. Passive optical markers shine brightly in the spectral band of interest, typically infrared, while the rest of the scene is relatively dark.

[0081] Two techniques for passive markers include spheres and disks. Spherical markers can be mounted on posts, which allow for wide-angle tracking due to their spherical shape and can be relatively simple to assemble. FIG. 12 illustrates a spherical marker 1200 (fiducial marker) attached to a post 1210 of an instrument or other device, according to some embodiments. The marker 1200 can include a socket that extends into the marker 1200 and is adapted to releasably connect the post 1210 of an instrument, other device, or reference frame. However, spherical markers are prone to manufacturing defects that create imperfect spheres, have high disposable costs as they are not reusable between surgeries, and performance can be compromised if a foreign object prevents the reflective surface of the spherical marker from being imaged. In contrast, disk markers can be mounted in a socket. Disc markers may be easier to manufacture than spherical markers, but still have a disposable cost, have a more limited angle of view compared to spherical markers, and performance may be compromised if a foreign object blocks the reflective surface of the disc marker from being imaged.

[0082] Reusable optical markers may have a reflective surface that is protected by a protective lens cover that allows it to be wiped clean during surgery to remove debris.

[0083] Various further embodiments of the present disclosure are directed to a fiducial marker configured to be tracked by a camera tracking system for computer-assisted navigation during surgery. The fiducial marker includes an object (e.g., a sphere or disk marker) having a surface of one of light-absorbing and light-reflecting material and a cover layer extending over the surface of the object. The cover layer is the other of the light-absorbing and light-reflecting material. The cover layer has a pattern of openings that expose spaced-apart areas of the surface of the object. The openings may be formed as cutouts through the cover layer and may have any shape. The exposed spaced-apart areas of the surface of the underlying object form a negative space that may be tracked using a tracking camera.

[0084] Figures 13, 14a, 14b, 15a, 15b, and 16 illustrate portions of different embodiments of a fiducial marker having a cover layer with a pattern of openings that expose spaced areas of the underlying object surface for tracking by a camera tracking system.

[0085] 13, a top view and corresponding cross-sectional side view show a cover layer 1300 having a pattern of openings 1310 that expose spaced-apart areas of an underlying object 1302. The object 1302 may be a sphere, and the cover layer 1300 may extend across the surface of the sphere. Alternatively, the object 1302 may be a disk, and the cover layer 1300 may extend across the surface of the disk.

[0086] In the embodiment illustrated in Fig. 13, the surface of the object 1302 is a light reflective material, such as anodized aluminum. To provide optical contrast, the cover layer is then a light absorbing material, such as a black anodized material. In another embodiment, the surface of the object 1302 is a light absorbing material and the cover layer is a light reflective material. An exemplary thickness of the cover layer 1300 may be 200 microns, but the cover layer 1300 may be any thickness that provides sufficient depth when viewed sufficiently off-camera axis to prevent one of the spaced apart areas from being imaged by one or more of the tracking cameras.

[0087] The spaced areas of the surface of the object 1302 exposed through the openings 1302 in the cover layer 1300 are circular in shape in some embodiments, in other embodiments the spaced areas may have any other shape including oval, square, rectangular, etc.

[0088] The opaque cover layer 1300 may have a thickness sufficient to obscure some of the patterned, spaced-apart areas (negative space) of the surface of the object 1302 when imaged by a tracked camera at an off-axis angle relative to the line of sight of the camera (e.g., camera 204 in FIGS. 1 and 2). Some further embodiments are directed to avoiding obscuring the patterned, spaced-apart areas of the surface of the object 1302 when imaged at an off-axis angle by forming openings in the cover layer to have sloping sidewall surfaces.

[0089] 14a is a side cross-sectional view of a portion of another fiducial marker including a cover layer 1400 having a pattern of openings 1410 exposing spaced areas of an underlying object 1402, configured according to one embodiment. The object 1402 may be a sphere or a disk, and the cover layer 1400 may extend across the surface of the sphere or disk. In contrast to the openings 1310 of FIG. 13, the openings 1410 in the cover layer 1400 are formed to have a sloping sidewall surface. The sloping sidewall openings 1410 may allow a greater view of the spaced areas of the pattern of the surface of the object 1302 by the tracking camera without being obscured by the cover layer 1400.

[0090] 14b is a side cross-sectional view of a portion of another fiducial marker including a cover layer 1400 having a pattern of openings 1420, 1422, and 1424 that expose spaced-apart areas of an underlying object 1402, configured in accordance with one embodiment. The openings 1420, 1422, and 1424 in the cover layer 1400 are formed to have sloping sidewall surfaces and different viewing angles relative to the line of sight of a tracking camera. The different viewing angles of the openings 1420, 1422, and 1424 may allow a much narrower view of the spaced-apart areas of the pattern of the surface of the object 1302 exposed through the openings 1420, 1422, and 1424 by the tracking camera.

[0091] The fiducial markers do not have to have a flat surface. Instead, the fiducial markers can have any shape and can be custom molded (e.g., as a sleeve) to fit an angled or spherical surface of a device such as an end effector or tool.

[0092] FIG. 15a is a side cross-sectional view of a portion of another fiducial marker including a cover layer 1500 having a pattern of openings 1510, 1512, 1514 exposing spaced apart areas of an underlying object 1502 having an inclined surface, configured according to an embodiment. FIG. 15b is a side cross-sectional view of a portion of another fiducial marker including a cover layer 1500 having a pattern of openings 1520, 1522, 1524 exposing spaced apart areas of an underlying object 1502 having an inclined surface, configured according to an embodiment. The object 1502 may be a sphere, a disk with a raised central area, or other shape, and the cover layer 1400 may extend across the surface. The shape of the inclined sidewall opening 1410 affects the view of the spaced apart areas of the pattern of the surface of the object 1302 exposed through the openings 1510, 1512, 1514, 1520, 1522, and 1524 by the tracking camera without being obscured by the cover layer 1400. For example, openings 1510, 1512, and 1514 have a wider field of view than openings 1520, 1522, and 1524.

[0093] To ensure that the pattern of openings is aligned with the underlying surface of the object, it may be important that the cover layer attaches to the same location on the surface. Furthermore, the cover layer should not move relative to the object underlying the fiducial markers during tracking. The cover layer may be attached to the underlying surface of the object using a kinematic mount that uses pins that fit into holes, raised edges that fit into slots, or magnets.

[0094] Some other related embodiments are directed to a camera tracking system for computer-assisted navigation during surgery for use with a fiducial marker having a cover including an opening that exposes a pattern of spaced apart areas of an underlying object, such as the various fiducial markers disclosed herein. The camera tracking system may be configured to operate to identify coordinates of the pattern of spaced apart areas of light reflective material along a continuous surface of the fiducial marker attached to the actual device in images acquired from a tracking camera that images the fiducial markers having at least partially overlapping fields of view. The camera tracking system is further configured to track a pose of the fiducial marker in 3D space based on the identified coordinates of the pattern of spaced apart areas of light reflective material along the continuous surface of the fiducial marker.

[0095] In some embodiments, the tracking camera may be used to calibrate small fiducial errors introduced due to tolerances in the cover and / or mating features. Such calibration may operate to reduce the cost of the cover while also improving the accuracy of tracking. In such embodiments, the cover may be made from a flexible, disposable black plastic that conforms to the relevant surface of the underlying object, e.g., snaps tightly using compliant features in the cover design.

[0096] Referring first to FIG. 16 , a top view and corresponding side cross-sectional view show a cover layer 1600 having a pattern of openings 1610 that expose spaced apart areas of an underlying object 1602. The object 1602 can be a sphere and the cover layer 1600 can extend across the surface of the sphere. Alternatively, the object 1602 can be a disk and the cover layer 1600 can extend across the surface of the disk. The cover layer 1610 can be formed as a thin disposable film or as a reusable hard material, e.g., metal. The relative thickness of the cover layer 1600 avoids the edges of the opening cutouts obscuring the view of the exposed areas of the underlying object 1602. When the cover layer 1600 is removable, it can be attached to a defined area of ​​a tracking plate 1604 attached to or connected to the object 1602, and / or the pattern of openings 1610 can be calibrated using image processing techniques. For example, a rectangular shaped cover layer 1600 may be aligned in space relative to the tracking plate 1604, and the pattern of openings 1610 may be aligned relative to the tracking plate 1604 to enable more accurate tracking of spaced-apart areas of the underlying object 1602, and thereby the fiducial markers.

[0097] In some embodiments, the surgical robot 100 may be configured to respond to the detection of a metal instrument inserted into the guide tube 114 by turning off active markers to prevent undesired movement when the instrument is in contact with the patient. This may require the end effector to be “active”, i.e., requiring power, driving up design complexity and cost. The end effector 112 may include notches forming a pattern of spaced apart light-reflective material near the guide tube 114 that may be tracked by a tracking camera. The instrument array may include a cover that will cover the notches when the instrument is inserted into the guide tube. When the tracking camera is unable to detect the notches of the end effector 112 near the guide tube 114, the system may determine that the instrument is within the guide tube 114 and initiate responsive safety mitigation, such as stopping all movement or only allowing slow movement in a “safe” direction, e.g., away from the patient. In another embodiment, when an instrument is inserted into the guide tube 114, the instrument displaces the cover which exposes cutouts forming a pattern of spaced apart light reflective material that was not visible to the camera prior to insertion of the instrument.

[0098] Further definitions and embodiments: In the above description of various embodiments of the inventive concept, it should be understood that the terms used herein are for the purpose of describing specific embodiments only, and are not intended to limit the inventive concept. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which the inventive concept belongs. It will be further understood that terms such as those defined in commonly used dictionaries should be interpreted to have a meaning consistent with their meaning in the context of this specification and related art, and should not be interpreted in the ideal or overly formal sense explicitly defined in this specification.

[0099] When an element is referred to as being "connected," "coupled," "responsive" to another element, or variations thereof, it may be directly connected, coupled, or responsive to the other element, or there may be intervening elements. In contrast, when an element is referred to as being "directly connected," "directly coupled," "directly responsive" to another element, or variations thereof, there are no intervening elements. Like numbers refer to like elements throughout. Furthermore, as used herein, "coupled," "connected," "responsive," or variations thereof may include being wirelessly coupled, connected, or responsive. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. Well-known features or structures may not be described in detail for brevity and / or clarity. The term "and / or" includes any and all combinations of one or more of the associated listed items.

[0100] In this specification, terms such as first, second, third, etc. may be used to describe various elements / operations, but it is understood that these elements / operations should not be limited by these terms. These terms are only used to distinguish one element / operation from another. Thus, a first element / operation in some embodiments may be called a second element / operation in other embodiments without departing from the teachings of the inventive concept. The same reference numbers or the same reference characters refer to the same or similar elements throughout this specification.

[0101] As used herein, the words "comprise", "comprising", "comprises", "include", "including", "includes", "have", "has", "having", or variations thereof, are open ended and include one or more stated features, integers, elements, steps, components, or functions, but do not exclude the presence or addition of one or more other features, integers, elements, steps, components, functions, or groups thereof. Furthermore, as used herein, the common abbreviation "eg", derived from the Latin phrase "exempli gratia", may be used to introduce or designate a general example or examples of the preceding items and is not intended to be limiting of such items. The common abbreviation "ie", derived from the Latin phrase "id est", may be used to designate a particular item from a more general list.

[0102] Exemplary embodiments are described herein with reference to block diagrams and / or flowchart illustrations of computer-implemented methods, apparatus (systems and / or devices) and / or computer program products. It will be understood that blocks of the block diagrams and / or flowchart illustrations, and combinations of blocks in the block diagrams and / or flowchart illustrations, can be implemented by computer program instructions executed by one or more computer circuits. These computer program instructions can be provided to general-purpose computer circuits, special-purpose computer circuits, and / or processor circuits of other programmable data processing circuits to produce machines such that the instructions, executed via a processor of a computer and / or other programmable data processing apparatus, transform and control transistors, values ​​stored in memory locations, and other hardware components in such circuits to implement the function / operation specified in the block diagram and / or flowchart block or blocks, thereby forming means (functions) and / or structure for performing the function / operation specified in the block diagram and / or flowchart block or blocks.

[0103] These computer program instructions may also be stored on a computer-readable medium that can instruct a computer or other programmable data processing apparatus to function in a particular manner to produce an article of manufacture that includes instructions that cause the instructions to implement the function / act specified in the block or blocks of the flowcharts and / or block diagrams.Thus, embodiments of the inventive concepts may be embodied in hardware and / or software (including firmware, resident software, microcode, etc.) running on a processor, such as a digital signal processor, which may collectively be referred to as a "circuit," "module," or variations thereof.

[0104] It should also be noted that in some alternative implementations, the functions / acts noted in the blocks may also occur in a different order than that noted in the flowcharts. For example, two blocks shown in succession may in fact be executed substantially simultaneously, or the blocks may sometimes be executed in the reverse order, depending on the functions / acts involved. Furthermore, the functionality of a given block of the flowcharts and / or block diagrams may be separated into multiple blocks, or the functionality of two or more blocks of the flowcharts and / or block diagrams may be at least partially integrated. Finally, other blocks may be added / inserted between the illustrated blocks and / or blocks / acts may be omitted without departing from the scope of the inventive concept. Furthermore, while some diagrams include arrows on communication paths to indicate a primary direction of communication, it should be understood that communication may occur in the opposite direction to the depicted arrows.

[0105] Many variations and modifications can be made to the embodiments without substantially departing from the principles of the inventive concept. All such variations and modifications are intended to be included herein within the scope of the inventive concept. Thus, the above subject matter should be considered illustrative and not limiting, and the accompanying examples of embodiments are intended to cover all such modifications, enhancements, and other embodiments that are within the spirit and scope of the inventive concept. Thus, to the maximum extent permitted by law, the scope of the inventive concept should be determined by the broadest permissible interpretation of this disclosure, including the following examples of embodiments and their equivalents, and is not limited or restricted by the foregoing detailed description.

Claims

1. 1. A camera tracking system for computer-assisted navigation during surgery, comprising: identifying locations of markers of a reference array within a set of images acquired from tracking cameras imaging a real device having at least partially overlapping fields of view; determining measured coordinate locations of features of the actual device within the set of images based on the identified locations of the markers and based on a relative location relationship between the markers and the features; processing areas of interest in the set of images identified based on the measured coordinate locations through a neural network configured to output predictions of coordinate locations of the features in the set of images, the neural network being trained based on training images including the features of a computer model rendered at known coordinate locations; and tracking a pose of the feature of the real device in three-dimensional (3D) space based on the prediction of a coordinate location of the feature of the real device in the set of images.

2. The camera tracking system of claim 1 , wherein the prediction of a coordinate location of the feature on the actual device indicates a predicted pixel coordinate of the feature within the set of images.

3. The at least one processor: determining a predicted 3D pose of the feature of the real device in a tracked space based on triangulation of the predictions of two-dimensional (2D) coordinate locations of the feature of the real device in the pair of the set of images from the pair of tracked cameras; determining a measured 3D pose of the feature of the actual device in the tracked space based on triangulation of the locations of the markers of the reference array in the pairs of the set of images; 2. The camera tracking system of claim 1, further operable to: calibrate a feature offset based on a comparison of the predicted 3D pose of the feature and the measured 3D pose of the feature.

4. The at least one processor:

2. The camera tracking system of claim 1, further operable to validate the feature of the real device based on whether the measured coordinate location of the feature of the real device is within a threshold distance of the prediction coordinate location of the feature of the real device.

5. The at least one processor: processing training images including the features of the computer model rendered at the known coordinate locations in the training images through the neural network to output predictions of coordinate locations of the features of the computer model in the training images; comparing the known coordinate locations of the features in the training images to the predictions of coordinate locations of the features of the computer model in the training images; The camera tracking system of claim 4 , further operable to: train parameters of the neural network based on the comparison.

6. The at least one processor:

6. The camera tracking system of claim 5, further operable to generate the training images including the features of the computer model rendered at the known coordinate locations in the training images, with different rendered backgrounds, different rendered lighting conditions, and / or different rendered poses of the features of the computer model between at least some of the training images.

7. 5. The camera tracking system of claim 4, wherein the act of training the parameters of the neural network comprises adapting weights and / or firing thresholds assigned to connection nodes of at least one layer of the neural network based on the training images including the features of the computer model rendered at the known coordinate locations in the training images.

Images