Robotic handheld surgical instrument systems and methods

Abstract

A system is provided that includes a robotic instrument for use with a tool. In some versions, the robotic instrument includes a handheld portion for being held by a user and a tool support movably coupled to the handheld portion for supporting the tool. The robotic instrument further includes an actuator assembly operably attached to the tool support and the handheld portion and configured to move the tool support relative to the handheld portion in multiple degrees of freedom. The robotic instrument may include a handle alignment member extending from the handheld portion. When the tool support has an optimal range of motion relative to the handheld portion, at least a portion of the handle alignment member and a tool plane defined by the tool are aligned.

Description

[Technical Field]

[0001] The present disclosure relates generally to robotic handheld surgical instrument systems and methods of use. [Background technology]

[0002] Physical cutting guides are used to constrain surgical tools when resecting tissue from a patient. In some cases, physical cutting guides constrain such surgical tools for the purpose of preparing a joint to receive a replacement implant. The time required to position and secure a physical cutting guide to a patient can represent a significant portion of the overall time required to perform a surgical procedure.

[0003] A navigation system (also called a tracking system) can be used to properly align and secure the jig and track the position and / or orientation of the surgical tool used to resect tissue from the patient. Tracking systems typically use one or more trackers associated with the tool and the tissue being resected. A display can then be viewed by the user to determine the current position of the tool relative to the desired cutting path of the tissue being resected. The display can be positioned in a manner that requires the user to look away from the tissue and surgical site to visualize the progress of the tool. This can distract the user from focusing on the surgical site. It can also be difficult for the user to position the tool in the desired manner.

[0004] Robotic-assisted surgery typically relies on large robots with robotic arms capable of moving in six degrees of freedom (DOF). These large robots can be cumbersome to drive and operate in the operating room.

[0005] Additionally, robotic handheld surgical instruments that use actuators to align the tool with a desired target object have a limited range of adjustability. Therefore, the operator must hold these instruments within a predetermined distance and / or angle of the desired target object to align the instrument with the desired target object. However, it can be difficult for the operator to recognize how much adjustability the instrument has at any given moment during the procedure.

[0006] Therefore, there is a need for systems and methods to address one or more of these challenges. Summary of the Invention

[0007] One aspect of the present disclosure includes a handheld surgical robotic system. The handheld surgical robotic system includes a handheld portion, a blade support movably coupled to the handheld portion and including a blade mount defining a blade plane, and a saw blade removably coupled to the blade support and positioned in the blade plane. The saw blade defines a longitudinal axis and a lateral axis. The handheld surgical robotic system also includes an actuator assembly operably attached to the blade support and the handheld portion. The actuator assembly is configured to move the blade support relative to the handheld portion in multiple degrees of freedom. The handheld surgical robotic system further includes a handle alignment member extending from the handheld portion. The handle alignment member includes a handle alignment protrusion extending toward the blade mount, at least a portion of the handle alignment protrusion being oblique to the longitudinal and lateral axes of the saw blade, and the portion of the handle alignment protrusion and the blade plane are aligned when the blade support has an optimal range of motion relative to the handheld portion.

[0008] The actuator assembly includes a plurality of actuators, each of which is configured to move between a first position and a second position to move the blade support relative to the handheld portion, and a home position can be a midpoint between the first position and the second position of each of the plurality of actuators, with the blade support having an optimal range of motion when at least two of the plurality of actuators are in the home position.

[0009] When the handheld portion is in a pose that does not provide an optimal range of motion, the blade plane and the handle alignment protrusion may be misaligned, providing a visual indication that the handheld portion is in a pose that does not provide an optimal range of motion for the blade support.

[0010] The actuator assembly is configured to adjust at least one of the pitch, height, and roll of the blade support relative to the handheld portion. A first spatial arrangement of the handle alignment protrusions relative to the blade plane may provide a visual indication of at least one of a first pitch relationship, a first height relationship, and a first roll relationship of the blade support relative to the handheld portion. Thus, the first spatial arrangement provides a visual indication that the handle alignment protrusions and the blade plane are aligned and the blade support has an optimal range of motion relative to the handheld portion. A second spatial arrangement of the handle alignment protrusions relative to the blade plane provides a visual indication of at least one of a second pitch relationship, a second height relationship, and a second roll relationship of the blade support relative to the handheld portion. Thus, the second spatial arrangement provides a visual indication that the handheld portion is in a pose relative to the blade support that does not provide the blade support with an optimal range of motion.

[0011] The first spatial arrangement may provide a visual indication of a first pitch relationship of the blade support relative to the handheld portion, and the second spatial arrangement may provide a visual indication of a second pitch relationship of the blade support relative to the handheld portion. When the actuator pitches the blade support relative to the handheld portion, the second pitch relationship provides a visual indication of the pitch of the blade support relative to the handheld portion, with the first portion of the handle alignment protrusion being farther from the blade plane along the longitudinal axis in the direction of the pitch than the second portion of the handle alignment protrusion.

[0012] The first spatial arrangement may also provide a visual indication of a first height relationship of the blade support relative to the handheld portion, and the second spatial arrangement may also provide a visual indication of a second height relationship of the blade support relative to the handheld portion, such that the second height relationship provides a visual indication of the height of the blade support relative to the handheld portion, with the handle alignment protrusion at least partially above or below the blade plane in the height direction.

[0013] The first spatial arrangement may further provide a visual indication of a first roll relationship of the blade support relative to the handheld portion, and the second spatial arrangement may further provide a visual indication of a second roll relationship of the blade support relative to the handheld portion, such that the second roll relationship provides a visual indication of the roll of the blade support relative to the handheld portion, with the lateral portions of the handle alignment protrusions being farther from the blade plane than the central portion of the handle alignment protrusions in the direction of the roll.

[0014] The handheld surgical robotic system may include a second handle alignment member extending from the handheld portion at a location separate from the first handle alignment member, the second handle alignment member including a second handle alignment protrusion extending toward the blade mount, at least a portion of the second handle alignment protrusion being oblique to the longitudinal and lateral axes of the saw blade. As above, when the blade support has an optimal range of motion relative to the handheld portion, the first handle alignment protrusion and the second handle alignment protrusion are aligned with the blade plane.

[0015] The handheld surgical robotic system may further include a tool alignment member extending from the blade support. The tool alignment member includes a tool alignment protrusion extending toward the blade mount, at least a portion of the tool alignment protrusion being oblique to the longitudinal and lateral axes of the saw blade. The tool alignment protrusion may define a tool alignment edge, and the handle alignment member defines a handle alignment edge that is oblique to the longitudinal and lateral axes of the saw blade. The tool alignment edge may be defined such that the tool alignment edge is offset from and parallel to the handle alignment edge when the blade support is aligned with the handheld portion. When the handheld portion is in a pose that does not provide an optimal range of motion, the tool alignment protrusion and the handle alignment protrusion may be misaligned, providing a visual indication that the handheld portion is in a pose that does not provide an optimal range of motion for the blade support.

[0016] The handle alignment protrusion and the tool alignment protrusion may include a first visual marking and a second visual marking, where the first visual marking is visually distinguishable from the second visual marking. The first visual marking on the handle alignment protrusion and the first visual marking on the tool alignment protrusion may be aligned when the tool alignment protrusion and the handle alignment protrusion are aligned, providing a visual indication that the blade support has an optimal range of motion for the handheld portion. The first visual marking on the handle alignment protrusion and the first visual marking on the tool alignment protrusion may be misaligned when the tool alignment protrusion and the handle alignment protrusion are misaligned, providing a visual indication that the handheld portion is in a pose that does not provide an optimal range of motion for the blade support. The first visual marking may be a first color, and the second visual marking is a second color.

[0017] Another aspect of the present disclosure includes a handheld surgical robotic system for supporting a saw blade. The handheld surgical robotic system includes a handheld portion, a tool support movably coupled to the handheld portion and defining a tool support plane, and an actuator assembly operably attached to the tool support and the handheld portion. The actuator assembly is configured to move the tool support relative to the handheld portion in multiple degrees of freedom. The handheld surgical robotic system further includes a handle alignment member extending from the handheld portion, the handle alignment member including a handle hook-shaped portion. The handle hook-shaped portion and the tool support plane are aligned when the tool support has an optimal range of motion relative to the handheld portion.

[0018] Yet another aspect of the present disclosure includes a handheld surgical robotic system. The handheld surgical robotic system includes a handheld portion, a tool support movably coupled to the handheld portion and defining a tool support plane, and a tool removably coupled to the tool support. The tool defines a longitudinal axis and a lateral axis. The handheld surgical robotic system also includes an actuator assembly operably attached to the tool support and the handheld portion. The actuator assembly is configured to move the tool support relative to the handheld portion in multiple degrees of freedom. The handheld surgical robotic system further includes a handle alignment member extending from the handheld portion, the handle alignment member including a handle alignment protrusion extending toward the tool support, at least a portion of the handle alignment protrusion being disposed at an angle greater than 0 degrees and less than 90 degrees relative to the longitudinal axis. When the tool support has an optimal range of motion relative to the handheld portion, a portion of the handle alignment protrusion and the tool support plane are aligned.

[0019] Yet another aspect of the present disclosure includes a handheld surgical robotic system for supporting a tool. The handheld surgical robotic system includes a handheld portion and a tool support movably coupled to the handheld portion. The tool support is configured to support a tool defining a tool plane. The handheld surgical robotic system also includes an actuator assembly operably attached to the tool support and the handheld portion. The actuator assembly is configured to move the tool support relative to the handheld portion in multiple degrees of freedom. The handheld surgical robotic system further includes a handle alignment member extending from the handheld portion. The handle alignment member includes a handle support arm extending between a first handle support arm end and a second handle support arm end. The handle support arm includes a handle coupling portion coupled to the first handle support arm end and detachably coupled to the handheld portion. The handle alignment member also includes a handle alignment member mount coupled to the second handle support arm end and a handle alignment indicator coupled to the handle alignment member mount. The handle coupling portion may include a handle coupling member configured to couple to a corresponding coupling member disposed on the handheld portion to couple the handle alignment member to the handheld portion.

[0020] Another aspect of the present disclosure includes a mechanical alignment device configured for use with a handheld surgical robotic system to provide a visual indication of the pose of a handheld portion of the handheld surgical robotic system relative to a tool support of the handheld surgical robotic system. The mechanical alignment device includes a support arm extending between a first support arm end and a second support arm end. The support arm includes a coupling portion coupled to the first support arm end and configured to be removably coupled to one of the handheld portion and the tool support of the handheld surgical robotic system. The mechanical alignment device also includes an alignment member mount coupled to the second support arm end and an alignment indicator coupled to the alignment member mount.

[0021] An additional aspect of the present disclosure includes a handheld surgical robotic system for supporting a saw blade. The handheld surgical robotic system also includes a handheld portion. The system also includes a blade support movably coupled to the handheld portion. The blade support is configured to support the saw blade. The system also includes an actuator assembly operably attached to the blade support and the handheld portion. The actuator assembly is configured to move the blade support relative to the handheld portion in multiple degrees of freedom. The system also includes a tool alignment member coupled to and extending from the blade support and a handle alignment member coupled to and extending from the handheld portion, wherein at least a portion of the tool alignment member and at least a portion of the handle alignment member are aligned when the blade support has a desired range of motion relative to the handheld portion.

[0022] Another aspect of the present disclosure includes a handheld robotic system for supporting a saw blade. The handheld robotic system also includes a handheld portion. The system also includes a blade support movably coupled to the handheld portion for supporting the saw blade. The system also includes an actuator assembly operably attached to the blade support and the handheld portion. The actuator assembly is configured to move the blade support relative to the handheld portion in multiple degrees of freedom. The system also includes first and second tool alignment members coupled to and extending on opposite sides from the blade support. The system also includes first and second handle alignment members coupled to and extending from the handheld portion, wherein the first and second tool alignment members are aligned with the first and second handle alignment members, respectively, when the blade support has a desired range of motion relative to the handheld portion.

[0023] Yet another aspect of the present disclosure includes a visual indication system for use with a handheld robotic system. The visual indication system includes a shroud coupled to the blade support and the handheld portion and extending between the blade support and the handheld portion, the shroud enclosing at least one of the plurality of actuators. The shroud defines at least two shroud landmarks configured to move relative to each other when the blade support and the handheld portion are misaligned to provide a visual indication of a pose of the blade support relative to the handheld portion.

[0024] Another aspect of the present disclosure includes a handheld robotic system for supporting a saw blade. The handheld robotic system includes a handheld portion and a blade support movably coupled to the handheld portion for supporting the saw blade. The system also includes a plurality of actuators operatively interconnecting the blade support and the handheld portion and configured to move the blade support relative to the handheld portion in multiple degrees of freedom. The system also includes a light source on the blade support. The system also includes first and second tool alignment members coupled to the blade support and extending from opposite sides thereof. The system also includes first and second handle alignment members coupled to the handheld portion and extending from the handheld portion. When the blade support has a desired range of motion relative to the handheld portion, the first and second tool alignment members are aligned with the first and second handle alignment members, respectively. The light source is illuminated when the blade support has a desired range of motion to indicate that the blade support and the handheld portion are within a specified range of alignment with the cutting plane.

[0025] Another further aspect of the present disclosure includes a handheld surgical robotic system for supporting a saw blade. The handheld surgical robotic system includes a handheld portion. The system also includes a blade support movably coupled to the handheld portion. The blade support is configured to support the saw blade. The system also includes a plurality of actuators operably interconnecting the blade support and the handheld portion, the plurality of actuators configured to move the blade support relative to the handheld portion in a plurality of degrees of freedom. The system further includes a tool alignment member coupled to and extending from the blade support and a handle alignment member coupled to and extending from the handheld portion, the handle alignment member being removably connected to the handheld portion.

[0026] An additional aspect of the present disclosure includes a surgical system for treating an anatomical structure according to multiple target planes. The surgical system includes an instrument including a saw blade, a handheld portion, an actuator system that may include multiple actuators, and a blade support for supporting and moving the saw. The multiple actuators extend between the blade support and the handheld portion, and the blade support may include a saw drive motor coupled to the saw mount. The system also includes a tracker for coupling to the navigation system and the blade support, the tracker configured to determine a current tool plane and including a tracker frame, with at least six optical markers coupled to the tracker frame. The tracker frame includes at least two faces, the at least two faces being non-planar with respect to one another, and at least three of the at least three to six optical markers coupled to each of the at least two faces. The system also includes a control system in communication with the navigation system and the tracker, the control system configured to control the actuator system to align the current tool plane with at least one of the multiple target planes.

[0027] Another additional aspect of the present disclosure includes a surgical method for controlling a surgical system including a handheld robotic instrument, a saw blade, a handheld portion, an actuator system including a plurality of actuators, and a blade support for supporting and moving the saw. The surgical method includes determining a current tool plane with a tool tracker and a navigation system, selecting one of a plurality of target planes with an input device on the tracker, and adjusting the tool support with the plurality of actuators to align the current plane with the selected target plane. The controlling also includes selecting a different one of the plurality of target planes with the input device.

[0028] A final aspect of the present disclosure includes a surgical instrument tracker for tracking a surgical saw. The surgical instrument tracker includes a tracker frame defining an instrument engagement opening for receiving a proximal portion of the saw, the tracker frame including a mount. The tracker also includes at least six optical markers coupled to the tracker frame, the tracker frame including at least two faces, the at least two faces being non-planar with respect to one another, and at least three of the at least three to six optical markers coupled to each of the at least two faces. When the mount of the saw tracker is coupled to the accessory mount, the tracker frame at least partially surrounds the accessory mount.

[0029] The advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 1 is a perspective view of a robot system. [Figure 2] FIG. 1 is a perspective view of a robotic instrument used to cut five planes into the femur to receive the prosthetic knee implant. [Figure 3A]1A-1C are diagrams of various pitch orientations of a robotic instrument. [Figure 3B] 1A-1C are diagrams of various pitch orientations of a robotic instrument. [Figure 3C] 1A-1C are diagrams of various pitch orientations of a robotic instrument. [Figure 4A] 1A-1C are diagrams of various roll orientations of a robotic instrument. [Figure 4B] 1A-1C are diagrams of various roll orientations of a robotic instrument. [Figure 4C] 1A-1C are diagrams of various roll orientations of a robotic instrument. [Figure 5A] FIG. 10 illustrates various z-axis translation positions of the robotic instrument. [Figure 5B] FIG. 10 illustrates various z-axis translation positions of the robotic instrument. [Figure 5C] FIG. 10 illustrates various z-axis translation positions of the robotic instrument. [Figure 6] FIG. 10 is a front perspective view of the robotic instrument showing one particular pose of the tool support relative to the handheld portion. [Figure 7] 1 is a block diagram of the control system, also showing the various software modules. [Figure 8] FIG. 1 is a rear perspective view of the robotic instrument. [Figure 9] FIG. 1 is a side view of a robotic instrument. [Figure 10] 1A-1D are schematic diagrams of various transformations of a handheld robotic surgical system. [Figure 11] FIG. 1 is a partial cross-sectional view of a robotic instrument. [Figure 12] FIG. 12 is a rear perspective view of a robotic instrument including a guide array. [Figure 13] FIG. 13 is a side view of a robotic instrument including the guide array of FIG. 12. [Figure 14] FIG. 13 is a top view of a robotic instrument including the guide array of FIG. 12. [Figure 15] FIG. 13 is another rear perspective view of the robotic instrument including the guide array of FIG. 12. [Figure 16] FIG. 13 is an exploded rear perspective view of a robotic instrument including the guide array of FIG. 12. [Figure 17] FIG. 13 is a rear perspective view of a robotic instrument including the guide array of FIG. 12 arranged in a first spatial configuration. [Figure 18] FIG. 12 is a rear perspective view of a robotic instrument including guide arrays arranged in a predetermined pitch relationship. [Figure 19] FIG. 19 is another rear perspective view of the robotic instrument including guide arrays arranged in the pitch relationship of FIG. 18. [Figure 20] FIG. 19 is a side view of a robotic instrument including a first guide array arranged in the pitch relationship of FIG. 18. [Figure 21] FIG. 19 is a rear view of a robotic instrument including guide arrays arranged in the pitch relationship of FIG. 18. [Figure 22] FIG. 12 is a rear perspective view of a robotic instrument including guide arrays arranged in a predetermined roll relationship. [Figure 23] FIG. 23 is another rear perspective view of the robotic instrument including the guide arrays arranged in the roll relationship of FIG. 22. [Figure 24] FIG. 23 is a rear view of the robotic instrument including the guide arrays arranged in the roll relationship of FIG. 22. [Figure 25] FIG. 12 is a rear perspective view of a robotic instrument including guide arrays arranged in a predetermined height relationship. [Figure 26] FIG. 26 is another rear perspective view of the robotic instrument including the guide arrays arranged in the height relationship of FIG. 25. [Figure 27] FIG. 26 is a side view of a robotic instrument including a guide array arranged in the height relationship of FIG. 25. [Figure 28] FIG. 26 is a rear view of a robotic instrument including guide arrays arranged in the height relationship of FIG. 25. [Figure 29] FIG. 10 is a rear perspective view of a robotic instrument including an alternative configuration of a guide array. [Figure 30] FIG. 30 is a front perspective view of a robotic instrument including the guide array of FIG. 29, with the handle alignment member removed from the robotic instrument. [Figure 31] FIG. 30 is a front perspective view of a robotic instrument including the guide array of FIG. 29 with a handle alignment member attached to the robotic instrument. [Figure 32]FIG. 30 is a rear perspective view of a robotic instrument including the guide array of FIG. 29 arranged in a first spatial configuration. [Figure 33] FIG. 10 is a rear perspective view of a robotic instrument including yet another configuration of a guide array. [Figure 34] FIG. 34 is a rear perspective view of yet another configuration of a robotic instrument including the guide array of FIG. 33 arranged in a first spatial configuration. [Figure 35] FIG. 10 is a rear perspective view of a robotic instrument including a further configuration of a guide array. [Figure 36] FIG. 36 is a side view of a further configuration of a robotic instrument including the guide array of FIG. 35. [Figure 37] FIG. 36 is a rear perspective view of yet another configuration of a robotic instrument including the guide array of FIG. 35 arranged in a first spatial configuration. [Figure 38] FIG. 10 is a rear perspective view of a robotic instrument including an additional configuration of a guide array. [Figure 39] FIG. 39 is a rear perspective view of an additional configuration of the robotic instrument including the guide array of FIG. 38 arranged in a first spatial configuration. [Figure 40] FIG. 12 is a rear perspective view of a configuration of the robotic instrument including a first visual indicia. [Figure 41] FIG. 41 is another rear perspective view of the robotic instrument configuration of FIG. 40 in a different spatial orientation. [Figure 42] FIG. 12 is a rear perspective view of a configuration of a robotic instrument including a light emitter. [Figure 43] FIG. 43 is another rear perspective view of the configuration of the robotic instrument of FIG. 42 in a different spatial configuration. [Figure 44] FIG. 12 is a front perspective view of a configuration of a robotic instrument including a shroud. [Figure 45] FIG. 10 is a partial front perspective view of a robotic instrument configuration including a shroud and a shroud alignment member spaced apart from the robotic instrument. [Figure 46] FIG. 12 is a rear perspective view of a configuration of a robotic instrument including a shroud. [Figure 47] FIG. 12 is a rear perspective view of a configuration of a robotic instrument including a shroud disposed in a first position. [Figure 48] FIG. 10 is a rear perspective view of a configuration of a robotic instrument including a shroud disposed in a second position. [Figure 49] FIG. 10 is a rear perspective view of a configuration of a robotic instrument including a shroud disposed in an alternative second position. [Figure 50] FIG. 10 is a rear perspective view of a configuration of a robotic instrument including a shroud disposed in an alternative second position. [Figure 51] FIG. 10 is a rear perspective view of a tool tracker of the robotic instrument. [Figure 52] FIG. 10 is a side view of the robotic instrument showing the potential range of motion of the tool support relative to the handheld portion. [Figure 53] FIG. 10 is a front view of the robotic instrument showing the potential range of motion of the tool support relative to the handheld portion. [Figure 54] FIG. 10 is a rear perspective view of a robotic instrument including yet another embodiment of a guide array. [Figure 55] FIG. 55 is a side view of a robotic instrument including the guide array of FIG. 54. [Figure 56] FIG. 55 is a top view of a robotic instrument including the guide array of FIG. 54. [Figure 57] FIG. 55 is a rear perspective view of a robotic instrument including the guide array of FIG. 54 arranged in a first spatial configuration. [Figure 58] FIG. 55 is an exploded rear perspective view of a robotic instrument including the guide array of FIG. 54. [Figure 59] FIG. 55 is a rear perspective view of a robotic instrument including the guide arrays of FIG. 54 arranged in a predetermined pitch relationship. [Figure 60] FIG. 59 is another rear perspective view of a robotic instrument including the guide arrays of FIG. 54 arranged in the pitch relationship of FIG. [Figure 61] FIG. 59 is a side view of a robotic instrument including the guide array of FIG. 54 arranged in the pitch relationship of FIG. [Figure 62] FIG. 59 is a rear view of a robotic instrument including the guide array of FIG. 54 arranged in the pitch relationship of FIG. [Figure 63]FIG. 55 is a rear perspective view of a robotic instrument including the guide array of FIG. 54 arranged in a predetermined roll relationship. [Figure 64] FIG. 64 is another rear perspective view of a robotic instrument including the guide array of FIG. 54 positioned in the roll relationship of FIG. 63. [Figure 65] FIG. 64 is a side view of a robotic instrument including the guide array of FIG. 54 arranged in the roll relationship of FIG. 63. [Figure 66] FIG. 64 is a rear view of a robotic instrument including the guide array of FIG. 54 positioned in the roll relationship of FIG. 63. [Figure 67] FIG. 55 is a rear perspective view of a robotic instrument including the guide arrays of FIG. 54 arranged in a predetermined height relationship. [Figure 68] FIG. 68 is another rear perspective view of a robotic instrument including the guide array of FIG. 54 arranged in the height relationship of FIG. 67. [Figure 69] FIG. 68 is a side view of a robotic instrument including the guide array of FIG. 54 arranged in the height relationship of FIG. 67. [Figure 70] 68 is a rear view of a robotic instrument including the guide array of FIG. 54 arranged in the height relationship of FIG. 67. FIG. [Figure 71] FIG. 55 is a side view of a robotic instrument including the guide arrays of FIG. 54 arranged in another spatial relationship. [Figure 72] FIG. 72 is a rear view of a robotic instrument including the guide array of FIG. 54 arranged in the configuration of FIG. 71. [Figure 73] FIG. 72 is a first perspective rear view of a robotic instrument including the guide array of FIG. 54 arranged in the configuration of FIG. 71. [Figure 74] FIG. 72 is a front perspective view of a robotic instrument including the guide array of FIG. 54 arranged in the configuration of FIG. 71. [Figure 75] FIG. 72 is a second rear perspective view of a robotic instrument including the guide array of FIG. 54 arranged in the configuration of FIG. 71. [Figure 76] FIG. 55 is a rear perspective view of a robotic instrument including the guide array of FIG. 54 arranged in a first spatial relationship and including visual indicia. [Figure 77] FIG. 55 is a rear perspective view of a robotic instrument including the guide array of FIG. 54 arranged in a second spatial relationship and including visual indicia. [Figure 78] FIG. 10 is a front perspective view of another configuration of a robotic instrument including one configuration of guide arrays and trackers. [Figure 79] FIG. 79 is a rear perspective view of the robotic instrument of FIG. 78. [Figure 80] FIG. 10 is an exploded view of one configuration of the guide array. [Figure 81] FIG. 10 is an exploded view of one configuration of the handle alignment member. [Figure 82] 82 is a partial perspective cross-sectional view of the handle alignment member of FIG. 81. FIG. [Figure 83] 82 is another partial perspective cross-sectional view of the handle alignment member of FIG. 81. [Figure 84] FIG. 10 is a rear perspective view of yet another configuration of a robotic instrument including another configuration of a guide array. [Figure 85] FIG. 10 is a rear perspective view of a further configuration of a robotic instrument including yet another configuration of a guide array. [Figure 86] FIG. 1 is a schematic diagram of a tracker in communication with a control system. DETAILED DESCRIPTION OF THE INVENTION

[0031] 〔overview〕 Referring to FIG. 1 , a robotic system 10 is shown performing a total knee replacement surgery on a patient 12 to resect portions of the femur F and tibia T of the patient 12 so that the patient 12 can receive a prosthetic knee implant IM. The robotic system 10 may be used to perform other types of surgical procedures, including procedures requiring hard / soft tissue removal or other forms of treatment. For example, the treatment may include cutting tissue, coagulating tissue, cauterizing tissue, stapling tissue, suturing tissue, etc. In some examples, the surgical procedure may include knee surgery, hip surgery, shoulder surgery, spine surgery, and / or ankle surgery, and may include removing tissue to be replaced by a surgical implant, such as a knee implant, hip implant, shoulder implant, spinal implant, and / or ankle implant. The robotic system 10 and techniques disclosed herein may be used to perform other procedures, surgical or non-surgical, and in industrial or other applications where robotic systems are utilized.

[0032] 1 and 2, the robotic system 10 includes an instrument 14. In some examples, a user holds and supports the instrument 14 in their hands (as shown in FIG. 1). In some examples, the user may hold the instrument 14 in their hands while the instrument is supported, at least partially or completely, by an auxiliary device, such as a passive arm (e.g., a link arm with a locking joint, a weight-balanced arm), an active arm, and / or the like. As best shown in FIGS. 1 and 2, the instrument 14 includes a handheld portion 16 for being grasped and / or supported in their hands by the user and / or an auxiliary device.

[0033] The tool 14 may be freely moved and supported by a user without a guide arm configured to be held by a human user while physically removing material, such that the weight of the tool is supported solely by the user's hand during the procedure. In other words, the tool 14 may be configured so that the user's hand supports the tool 14 against gravity. The tool 14 may weigh 8 lbs. or less, 6 lbs. or less, 5 lbs. or less, or 3 lbs. or less. The tool 14 may have a weight that complies with ANSI / AAMI HE75:2009. The tool 14 also includes a tool support 18 for receiving the tool 20. In some examples, if the tool 20 is a saw blade 380, the tool support 18 may be referred to as a blade support. A method of operating the tool 14 may include the user hanging the weight of the tool 14 without any assistance from a passive arm or a robotic arm. Alternatively, the weight of instrument 14 may be supported through the use of a counterbalanced passive arm, an auxiliary device, or an active robotic arm so that the user does not have to support the entire weight of the instrument. In such cases, the user may still grasp handheld portion 16 to interact with and / or guide instrument 14. Passive arms and the contents of U.S. Patent No. 9,060,794 to Kang et al. are incorporated herein by reference. Furthermore, robotic system 10 may, in some instances, not have a robotic arm with more than two joints in series.

[0034] The tool 20 couples to the tool support 18 to interact with anatomical structures during certain operations of the robotic system 10, as described further below. The tool 20 may be referred to as an end effector. The tool 20 may be removable from the tool support 18 so that a new / different tool 20 can be attached when needed. The tool 20 may be permanently fixed to the tool support 18. The tool 20 may include an energy applicator designed to contact tissue of the patient 12. In some examples, the tool 20 may be a saw blade, as shown in FIGS. 1 and 2, or other types of cutting accessories. In such examples, the tool support 18 may be referred to as a blade support. It should be appreciated that in all instances where a blade support is mentioned, the term "tool support" may be substituted, and vice versa. However, other tools may be contemplated, such as those described in U.S. Patent No. 9,707,043 to Bozung, which is incorporated herein by reference. In some examples, the tool 20 may be a drill bit, an ultrasonically vibrated tip, a burr, a stapler, or the like. The tool 20 may include a blade assembly and drive motor for producing vibration of the blade as shown in U.S. Patent No. 9,820,753 or U.S. Patent No. 10,687,823 to Walen et al., which are incorporated herein by reference. Such drive components may include a transmission TM coupled to the drive motor M for converting rotational motion from the drive motor M into vibration of the tool 20.

[0035] The systems and methods described in PCT / US2020 / 042128, filed July 15, 2020, and entitled "Robotic Handheld Surgical Instrument Systems and Methods," are also incorporated herein by reference.

[0036] An actuator assembly 400, including one or more actuators 21, 22, 23, moves the tool support 18 in three degrees of freedom relative to the handheld portion 16 to provide robotic motion that assists in placing the tool 20 in a desired position and / or orientation (e.g., a desired pose relative to the femur F and / or tibia T during resection) while the user holds the handheld portion 16. The actuator assembly 400 may include actuators 21, 22, 23 arranged in parallel, series, or a combination thereof. In some examples, the actuators 21, 22, 23 move the tool support 18 in more than two degrees of freedom relative to the handheld portion 16. In some examples, the actuator assembly 400 is configured to move the tool support 18 relative to the handheld portion 16 in at least two degrees of freedom, such as pitch and z-axis translation. In some examples, as shown herein, actuators 21, 22, and 23 move tool support 18 and its associated tool support coordinate system (TCS) in only three degrees of freedom relative to handheld portion 16 and its associated base coordinate system (BCS). For example, tool support 18 and its tool support coordinate system (TCS) may rotate about its y-axis to provide pitch motion, rotate about its x-axis to provide roll motion, and translate along axis Z, which coincides with the z-axis of the base coordinate system (BCS), to provide z-axis translation motion. Permitted motions in pitch, roll, and z-axis translation are indicated by arrows in FIG. 2 and the schematic diagrams of FIGS. 3A-3C, 4A-4C, and 5A-5C, respectively. FIG. 6 provides an example of the pose of tool support 18 and handheld portion 16 within the range of motion of instrument 14. In some examples, although not shown, actuators may move tool support 18 in four or more degrees of freedom relative to handheld portion 16.

[0037] Referring again to FIG. 2 , a constraint assembly 24 having passive links 26 may be used to constrain movement of the tool support 18 relative to the handheld portion 16 in the remaining three degrees of freedom. The constraint assembly 24 may include any suitable link (e.g., one or more links having any suitable shape or configuration) for constraining movement as described herein. In the example shown in FIG. 2 , the constraint assembly 24 operates to limit movement of the tool support coordinate system TCS by constraining rotation about the z-axis of the base coordinate system BCS to constrain yaw movement, constraining translation in the x-axis direction of the base coordinate system BCS to constrain x-axis translation, and constraining translation in the y-axis direction of the base coordinate system BCS to constrain y-axis translation. The actuators 21, 22, 23 and constraint assembly 24 are controlled to effectively mimic the function of a physical cutting guide, such as a physical saw cutting guide, in certain circumstances described further below.

[0038] Referring to FIG. 7 , an instrument controller 28 or other type of control unit is provided for controlling the instrument 14. The instrument controller 28 may include one or more computers or any other suitable type of controller that directs the operation of the instrument 14 and the movement of the tool support 18 (and tool 20) relative to the handheld portion 16. The instrument controller 28 may have a central processing unit (CPU) and / or other processor, memory, and storage (not shown). The instrument controller 28 is loaded with software as described below. The processor may include one or more processors for controlling the operation of the instrument 14. The processor can be any type of microprocessor, multiprocessor, and / or multicore processing system. The instrument controller 28 may additionally or alternatively include one or more microcontrollers, field programmable gate arrays, systems-on-chips, discrete circuits, and / or other suitable hardware, software, or firmware capable of performing the functions described herein. The term processor is not intended to limit any embodiment to a single processor. The instrument 14 may also include a user interface UI comprising one or more displays and / or input devices (e.g., triggers, push buttons, foot switches, keyboards, mice, microphones (voice activated), gesture controls, touch screens, etc.).

[0039] The control system 60 further includes one or more software programs and modules. The software modules may be part of one or more programs operating in the navigation controller 36, the instrument controller 28, or both, to process data to assist in controlling the robotic system 10. The software programs and / or modules include computer-readable instructions stored in non-transitory memory 64 in the navigation controller 36, the instrument controller 28, or both, for execution by one or more processors 70 of the controllers 28, 36. The memory 64 may be any suitable configuration of memory, such as RAM, non-volatile memory, or may be implemented locally or from a remote database. Additionally, software modules for prompting and / or communicating with a user may form part of one or more programs and may include instructions stored in memory 64 in the navigation controller 36, the instrument controller 28, or both. A user may interact with any of the input devices of the navigation user interface UI or other user interface UIs to communicate with the software modules. The user interface software may operate on a device separate from the navigation controller 36 and / or the instrument controller 28.

[0040] The instrument controller 28 controls the operation of the tool 20, such as by controlling power to the tool 20 (e.g., the drive motor M of the tool 20 that controls the cutting motion) and by controlling the movement of the tool support 18 relative to the handheld portion 16 (e.g., by controlling the actuators 21, 22, 23). The instrument controller 28 controls the state (e.g., position and / or orientation) of the tool support 18 and the tool 20 relative to the handheld portion 16. The instrument controller 28 can control the velocity (linear or angular velocity), acceleration, or other derivatives of the movement of the tool 20 relative to the handheld portion 16 and / or anatomical structure caused by the actuators 21, 22, 23.

[0041] 2, the tool controller 28 may include a control housing 29 attached to the tool support 18, and / or the handheld portion 16, or a combination thereof, with one or more control boards 31 (e.g., one or more printed circuit boards and associated electronic components) disposed within the control housing 29. The control board 31 may include a microcontroller, field programmable gate array (FPGA), drivers, memory, sensors, or other electronic components for controlling the actuators 21, 22, 23 and the drive motor M (e.g., via a motor controller). The tool controller 28 may also include an off-board control console 33 in data and power communication with the control board 31. The sensors S, actuators 21, 22, 23, and / or drive motor M described herein may provide signals to the control board 31, which sends data signals to the console 33 for processing, and the console 33 may again provide control commands (e.g., current commands, torque commands, velocity commands, angle commands, position commands, or combinations thereof, as well as various control and configuration parameters) to the control board 31 to power and control the actuators 21, 22, 23, and / or drive motor M. It is contemplated that processing may be performed on the control board of the control housing. In some examples, processing of the control algorithms may be distributed between the console and the control housing. In one example, position control and velocity control calculations may be performed in the console, and current control may be performed in a field programmable gate array located in the control housing. Of course, it is contemplated that a separate control housing is not required and / or that processing may be performed in any number of different locations.

[0042] In some versions, the console 33 may include one console for powering and controlling the actuators 21, 22, 23 and the drive motor M. In some versions, the console 33 may include one console for powering and controlling the actuators 21, 22, 23 and a separate console for powering and controlling the drive motor M. One such console for powering and controlling the drive motor M may be similar to that described in U.S. Patent No. 7,422,582, filed September 30, 2004, entitled "Control Console to which Powered Surgical Handpieces are Connected, the Console Configured to Simultaneously Energize more than one and less than all of the Handpieces," which is incorporated herein by reference. A flexible circuit FC, also known as a flex circuit, may interconnect the actuators 21, 22, 23 and / or other components to the instrument controller 28. For example, a flexible circuit F C may be provided between the actuators 21, 22, 23 and the control board 31. Other types of connections, wired or wireless, may additionally or alternatively exist between the components.

[0043] Referring briefly back to FIG. 1 , the robotic system 10 further includes a navigation system 32. One example of a navigation system 32 is described in U.S. Patent No. 9,008,757, filed September 24, 2013, entitled “Navigation System Including Optical and Non-Optical Sensors,” which is incorporated herein by reference. The navigation system 32 tracks the movement of various objects. Such objects include, for example, instruments 14, tools 20, and anatomical structures, such as the femur F and tibia T. The navigation system 32 tracks these objects to collect state information for each object relative to a (navigation) localizer coordinate system LCLZ. As used herein, object state includes, but is not limited to, data that defines the position and / or orientation (e.g., its coordinate system) of the tracked object or equivalents / derivatives of position and orientation. For example, the state may be the pose of the object and / or may include linear velocity data, angular velocity data, etc.

[0044] The navigation system 32 may include a cart assembly 34 that houses a navigation controller 36 and / or other types of control units. A navigation user interface UI is in operative communication with the navigation controller 36. The navigation user interface UI includes one or more displays 38. The navigation system 32 can display a graphical depiction of the relative state of the tracked objects to a user using the one or more displays 38. The navigation user interface UI further includes one or more input devices for inputting information into the navigation controller 36 or otherwise selecting / controlling certain aspects of the navigation controller 36. Such input devices include interactive touchscreen displays. However, the input devices may include any one or more of push buttons, pointers, foot switches, keyboards, mice, microphones (voice-activated), gesture controls, etc. In some examples, a user may use buttons located on the pointer to navigate through icons and menus in the user interface UI, make selections, configure the robotic surgical system 10, and / or advance through a workflow.

[0045] The navigation system 32 also includes a localizer 44 coupled to the navigation controller 36. In one example, the localizer 44 is an optical localizer and includes a camera unit 46. The camera unit 46 has an outer casing 48 that houses one or more optical sensors 50. The localizer 44 may include its own localizer controller 49 and may further include a video camera VC.

[0046] The navigation system 32 includes one or more trackers. In some examples, the trackers include a pointer tracker PT, a tool tracker 52, a first patient tracker 54, and a second patient tracker 56. In the illustrated example of FIG. 1 , the tool tracker 52 is rigidly attached to the instrument 14, the first patient tracker 54 is rigidly attached to the femur F of the patient 12, and the second patient tracker 56 is rigidly attached to the tibia T of the patient 12. In this example, the patient trackers 54, 56 are rigidly attached to sections of bone. The trackers 52, 54, 56 and the pointer tracker are registered to their respective objects (e.g., bones, tools) and the navigation system 32 manually, automatically, or a combination thereof. In some examples, the pointer tracker PT is rigidly fixed to the pointer 57 and is used to register anatomical structures to one or more coordinate systems, including the localizer coordinate system LCLZ, and / or for other calibration and / or registration functions. In one example, pointer 57 may be used to register patient trackers 54, 56 to the bone to which trackers 54, 56 are attached, respectively, and to register tool tracker 52 (and optionally 53) to tool support 18, tool 20, handheld portion 16, or a combination thereof. In some examples, pointer tracker PT may be used to register TCP of instrument 14 to tracker 52 relative to the tracker coordinate system. In this way, as localizer 44 is moved in position, instrument 14 registration is positioned relative to tool tracker 52. However, other means of registering trackers 52, 54, 56 are contemplated and may be implemented together or separately from pointer tracker PT. Other tracker locations are also contemplated.

[0047] Throughout this specification, various variants are described, such as "bone to tracker" or "instrument TCP to tracker," i.e., to the "tracker coordinate system" rather than to the LCTZ coordinate system. The localizer coordinate system may be used as an intermediate coordinate system during registration and bone preparation, since all tracked objects are measured relative to the LCTZ. During registration, the various localizer reference poses are finally mathematically combined, and the registration result is stored "with respect to the tracker," so that even if the camera (i.e., the LCTZ) moves, the registration remains valid.

[0048] The tool trackers 52 may be attached to any suitable component of the instrument 14, and in some versions may be attached directly to the handheld portion 16, the tool support 18, the tool 20, or a combination thereof. The trackers 52, 54, 56, and PT may be secured to their respective components in any suitable manner, such as with fasteners, clamps, etc. For example, the trackers 52, 54, 56, and PT may be rigidly secured, flexibly connected (fiber optics), or not physically connected (ultrasound), so long as there is an appropriate (auxiliary) method for determining the relationship (measurement) of their respective trackers to the associated object. Any one or more of the trackers 52, 54, 56, and PT may include active markers 58. The active markers 58 may include light-emitting diodes (LEDs). Alternatively, the trackers 52, 54, 56, and PT may have passive markers, such as reflectors, that reflect light emitted from the camera unit 46. Printed markers or other suitable markers not specifically described herein may also be utilized.

[0049] Various coordinate systems may be used to track objects. For example, the coordinate systems may include a localizer coordinate system (LCLZ), a tool support coordinate system (TCS), a base coordinate system (BCS), coordinate systems associated with each tracker (52, 54, 56, PT), one or more coordinate systems associated with the anatomical structure, one or more coordinate systems associated with preoperative and / or intraoperative images (e.g., CT images, MRI images, etc.) and / or models (e.g., 2D or 3D models) of the anatomical structure, such as an implant coordinate system and a TCP (Tool Center Point) coordinate system. In some examples, the robotic system 10 does not rely on preoperative and / or intraoperative imaging to form a 2D or 3D model of the target bone. Rather, the robotic system may be used in an imageless system that uses a pointer tracker (PT) to register the target anatomical structure and capture various anatomical landmarks, which are then processed by the control system 60 to morph the nominal bone model to match the captured data. In other examples, preoperative and intraoperative imaging is used to image the target area of ​​the patient and then convert the 2D and / or 3D images into a 3D model of the target bone. It is also contemplated that the robotic surgical system 10 may use a combination of imaging and imageless procedures in generating the 3D model of the target surgical area. One exemplary system is described in U.S. Patent No. 8,617,174, which is incorporated herein by reference. Coordinates in various coordinate systems may be transformed to other coordinate systems using transformations, such as through registration, calibration, geometric relationships, measurements, etc., when establishing relationships between the coordinate systems.

[0050] As shown in FIG. 2 , in some examples, the TCP is a predetermined reference point or origin of a TCP coordinate system defined at the distal end of the tool 20. The geometry of the tool 20 may be defined with respect to the TCP coordinate system and / or the tool support coordinate system TCS. The tool 20 may include one or more geometric characteristics, such as a perimeter, circumference, radius, diameter, width, length, height, volume, area, surface / plane, extent of motion envelope (along any one or more axes), etc., defined with respect to the TCP coordinate system and / or the tool support coordinate system TCS and stored in non-volatile memory on the control board 31 in the control housing 29 of the instrument 14, the navigation system 32, the instrument controller 28, or a combination thereof. For example, the tool 20 may define a longitudinal axis 910 (see FIG. 68 ) extending the length of the tool and a transverse axis 912 extending across the width of the tool. The tool center point (TCP), in another example, is a predetermined reference point and corresponding coordinate system defined in the tool 20. The TCP has a known or calculable (i.e., not necessarily static) pose relative to another coordinate system. The TCP coordinate system includes an origin and a set of axes (e.g., x-axis, y-axis, z-axis) that define the pose of the TCP. By tracking the TCP (or knowing the pose of the TCP), the system 10 may calculate the position and orientation of the tool 14 based on the pose of the TCP and the known positional relationship between the TCP and features of the tool 14. In some examples, the tool 20 has a tool plane (e.g., for the saw blade), which is described for convenience and ease of illustration but is not intended to limit the tool 20 to any particular form. For example, the tool support 18 may include a tool mount 18a that defines a blade plane BP. Points, primitives, meshes, other 3D models, etc., can be used to virtually represent the tool 20. The origin of the TCP coordinate system may be located at the center of the sphere of the burr of the tool 20 or the distal end of the saw blade 27, such that the TCP coordinate system is tracked relative to an origin at the distal tip of the tool 20. Alternatively, the TCP may be tracked using multiple trace points.The TCP may be defined in various formats depending on the configuration of the tool 20. The tool may use joint / motor encoders or any other non-encoder position sensing method, and thus the control system 60 may determine the pose and / or position of the TCP relative to the handheld portion 16 and BCS. The tool support 18 may use joint measurements to determine the TCP pose and / or may employ techniques to measure the TCP pose directly. Control of the tool 20 is not limited to a center point. For example, any suitable primitive, mesh, etc. may be used to represent the tool 20. It should be appreciated that the TCP may alternatively be defined as a point, as opposed to a coordinate system. The TCP coordinate system allows for the pose of the saw blade or other tool to be determined, allowing for the calculation of required reference points or geometric aspects of the tool.

[0051] The TCP coordinate system, the tool support coordinate system TCS, and the coordinate system of the tool tracker 52 may be defined in various forms depending on the configuration of the tool 20. For example, a pointer 57 may be used with a calibration divot CD on the tool support 18 and / or tool 20 to: register (calibrate) the pose of the tool support coordinate system TCS relative to the coordinate system of the tool tracker 52; determine the pose of the TCP coordinate system relative to the coordinate system of the tool tracker 52; and / or determine the pose of the TCP coordinate system relative to the tool support coordinate system TCS. Other techniques can be used to directly measure the pose of the TCP coordinate system, such as by attaching and fixing one or more additional trackers / markers directly to the tool 20. In some versions, the trackers / markers may be attached and fixed to the handheld portion 16, the tool support 18, or both. In examples where the handheld portion includes a tracker, the pose of the handheld portion relative to the localizer coordinate system LCLZ may be measured directly. In yet other alternatives, the TCP may be defined relative to the tool tracker using an intermediate tool support coordinate system TCS.

[0052] Because tool support 18 is movable in multiple degrees of freedom relative to handheld portion 16 via actuators 21, 22, 23, instrument 14 may use encoders, Hall effect sensors (with analog or digital output), and / or any other position sensing method to measure the pose of the TCP coordinate system and / or tool support coordinate system TCS relative to the base coordinate system BCS. In one example, as described further below, instrument 14 may use measurements from sensors that measure actuation of actuators 21, 22, 23 to determine the pose of the TCP coordinate system and / or tool support coordinate system TCS relative to the base coordinate system BCS.

[0053] The localizer 44 monitors the trackers 52, 54, 56, PT (e.g., their coordinate systems) to determine the state of each tracker 52, 54, 56, PT, which corresponds to the state of the object attached thereto. The localizer 44 may implement known techniques to determine the state of the trackers 52, 54, 56, PT and associated objects (such as tools, patients, tool supports, and handheld portions). The localizer 44 provides the states of the trackers 52, 54, 56, PT to the navigation controller 36. In some examples, the navigation controller 36 determines the states of the trackers 52, 54, 56, PT and communicates them to the instrument controller 28.

[0054] The navigation controller 36 may include one or more computers or any other suitable type of controller. The navigation controller 36 has a central processing unit (CPU) and / or other processor, memory, and storage (not shown). The processor can be any type of processor, microprocessor, or multiprocessor system. The navigation controller 36 is loaded with software. The software converts signals received from, for example, the localizer 44 into data representing the position and / or orientation of the tracked object. The navigation controller 36 may additionally or alternatively include one or more microcontrollers, field programmable gate arrays, systems-on-chips, discrete circuits, and / or other suitable hardware, software, or firmware capable of performing the functions described herein. The term processor is not intended to limit any embodiment to a single processor.

[0055] Although one example of the navigation system 32 is shown for determining object status, the navigation system 32 may have any other suitable configuration for tracking the instrument 14, tool 20, and / or patient 12. In another example, the navigation system 32 and / or the localizer 44 are ultrasound-based. For example, the navigation system 32 may include an ultrasound imager coupled to the navigation controller 36. The ultrasound imager images the object, e.g., any of the instrument 14, tool 20, and / or patient 12, and generates a status signal to the navigation controller 36 based on the ultrasound image. The ultrasound image may be 2D, 3D, or a combination of both. The navigation controller 36 may process the image in near real time to determine the object status. The ultrasound imager may have any suitable configuration and may be different from the camera unit 46 shown in FIG. 1 .

[0056] In another example, the navigation system 32 and / or the localizer 44 are radio frequency (RF) based. For example, the navigation system 32 may include an RF transceiver coupled to the navigation controller 36. The instrument 14, tool 20, and / or patient 12 may include RF emitters or transponders attached thereto. The RF emitters or transponders may be passive or actively energized. The RF transceivers transmit RF tracking signals and generate status signals to the navigation controller 36 based on RF signals received from the RF emitters. The navigation controller 36 may analyze the received RF signals and associate relative status therewith. The RF signals may be of any suitable frequency. The RF transceivers may be positioned in any suitable location to effectively use the RF signals to track objects. Furthermore, the RF emitters or transponders may have any suitable structural configuration, which may differ significantly from the trackers 52, 54, 56, PT shown in FIG. 1 .

[0057] In yet another example, the navigation system 32 and / or the localizer 44 are electromagnetic-based. For example, the navigation system 32 may include an electromagnetic (EM) transceiver coupled to the navigation controller 36. The instrument 14, tool 20, and / or patient 12 may include EM components attached thereto, such as any suitable magnetic, electromagnetic, or inductive trackers. The trackers may be passive or actively energized. The EM transceiver generates an EM field and generates status signals to the navigation controller 36 based on EM signals received from the trackers. The navigation controller 36 may analyze the received EM signals and associate relative statuses with them. Again, such examples of the navigation system 32 may have structural configurations that differ from the configuration of the navigation system 32 shown in FIG. 1 .

[0058] The navigation system 32 may have any other suitable components or structures not specifically listed herein. Additionally, any of the techniques, methods, and / or components described above with respect to the illustrated navigation system 32 may be implemented or provided for any of the other examples of the navigation system 32 described herein. For example, the navigation system 32 may utilize inertial tracking alone or any combination of tracking technologies, and may additionally or alternatively include fiber optic-based tracking, machine vision tracking, etc.

[0059] Referring to FIG. 7 , the robotic system 10 includes a control system 60 that includes, among other components, an instrument controller 28 and a navigation controller 36. The control system 60 further includes one or more software programs and software modules. The software modules may be part of one or more programs operating in the instrument controller 28, the navigation controller 36, or a combination thereof to process data to assist in controlling the robotic system 10. The software programs and / or modules include computer-readable instructions stored in memory 64 in the instrument controller 28, the navigation controller 36, or a combination thereof for execution by one or more processors 70 of the controller 28. The memory 64 may be any suitable configuration of memory, such as non-transitory memory, RAM, non-volatile memory, etc., and may be implemented locally or from a remote database. Additionally, software modules for prompting and / or communicating with a user may form part of one or more programs and may include instructions stored in memory 64 in the instrument controller 28, the navigation controller 36, or a combination thereof. A user may interact with any of the input devices of the navigation user interface UI or other user interface UI to communicate with the software modules. The user interface software may operate on a device separate from the instrument controller 28 and / or the navigation controller 36. The instrument 14 may communicate with the instrument controller 28 via a power / data connection, shown in FIG. 7 as BUS / COMM connection 37, which may provide a path for inputs and outputs used to control the instrument 14 based on position and orientation data generated by the navigation system 32 and transmitted to the instrument controller 28.

[0060] The control system 60 may include any suitable configuration of inputs, outputs, and processing devices suitable for performing the functions and methods described herein. The control system 60 may include the appliance controller 28, the navigation controller 36, or a combination thereof, and / or may include only one of these controllers or additional controllers. The controllers may communicate via a wired bus or communication network, shown in one example as BUS / COMM connection 37 in FIG. 7, via wireless communication, or otherwise. The control system 60 may also be referred to as a controller. The control system 60 may include one or more microcontrollers, field programmable gate arrays, systems-on-chips, discrete circuits, sensors, displays, user interfaces, indicators, and / or other suitable hardware, software, or firmware capable of performing the functions described herein.

[0061] [Instruments] In one exemplary configuration, instrument 14 is best shown in Figures 8 and 9. Instrument 14 includes a handheld portion 16 that is held by a user, a tool support 18 movably coupled to handheld portion 16 for supporting a tool 20, an actuator assembly 400 comprising a plurality of actuators 21, 22, 23 operatively interconnecting tool support 18 and handheld portion 16 for moving tool support 18 in at least three degrees of freedom relative to handheld portion 16, and a constraint assembly 24 having a passive link 26 operatively interconnecting tool support 18 and handheld portion 16.

[0062] The handheld portion 16 includes a grip 72 for grasping by a user to allow the user to manipulate, guide, and / or grasp the instrument 14. The handheld portion 16 may be configured with ergonomic features, such as a grip for the user's hand to hold, a textured or blended material coating to prevent the user's hand from slipping when wet and / or bloody. The handheld portion 16 may include a contoured taper to match the contours of a user's hand and / or fingers to accommodate users with a variety of different hand sizes. The handheld portion 16 also includes a base 74 to which the grip 72 is attached by one or more fasteners, adhesives, welding, etc. In the illustrated version, the base 74 includes a sleeve 76 having a generally hollow cylindrical shape. Joint supports 77, 78, and 79 extend from the sleeve 76. The actuators 21, 22, and 23 may be movably coupled to the base 74 at the joint supports 77, 78, and 79 via joints described further below.

[0063] The tool support 18 includes a tool support body 80 to which the tool tracker 52 can be fixedly or removably mounted via one or more tracker mounts secured to the tool support 18 at one or more mounting locations 82. In one example, the tool tracker 52 is integral with the tool support 18. In another example, the tool tracker 52 is removably mounted at one or more mounting locations 82. The tool 20 is removably coupled to the tool support 18 in the version shown. In particular, the tool support 18 includes a tool coupler, such as a head 84 to which the tool 20 is mounted, as described in U.S. Pat. No. 9,820,753 to Walen et al., incorporated herein by reference. The head 84 may be configured to utilize oscillating and sagittal-style saw blades. A drive motor M that drives the operation of the tool 20 is disposed in the tool support body 80 (e.g., to drive the oscillation of the saw blade in some versions). Tool 20 may be attached to and released from head 84 in the manner disclosed in U.S. Patent No. 9,820,753 to Walen et al., which is incorporated herein by reference. As best shown in FIG. 9 , tool support 18 also includes a plurality of actuator mounts 86, 88, 90 to which actuators 21, 22, 23 are movably coupled to tool support 18 via joints, as described further below. Actuator mounts 86, 88, 90 may include brackets or the like suitable for mounting actuators 21, 22, 23 such that tool support 18 can move in at least three degrees of freedom relative to handheld portion 16.

[0064] The actuators 21, 22, and 23, in the version shown, comprise electrical linear actuators extending between the base 74 and the tool support body 80. When actuated, the effective lengths of the actuators 21, 22, and 23 change to vary the distance between the tool support body 80 and the base 74 along the corresponding axes of the actuators 21, 22, and 23. Thus, the control system 60 commands the actuators 21, 22, and 23 to act in a coordinated manner in response to individual inputs provided to each actuator 21, 22, and 23, respectively, by the control system 60 to vary the effective lengths and move the tool support 18 to a target pose relative to the handheld portion 16 in at least three degrees of freedom. In the version shown, three actuators 21, 22, and 23 are provided and may be referred to as first, second, and third actuators 21, 22, and 23, or as the front actuators 21, 22, and the rear actuator 23. The first, second, and third actuators 21, 22, and 23 have adjustable effective lengths along first actuation axis AA1, second actuation axis AA2, and third actuation axis AA3 (see FIG. 9 ). The first, second, and third actuators 21, 22, and 23 have independently adjustable effective lengths to adjust one or more of the pitch orientation, roll orientation, and z-axis translation of the tool support 18 relative to the handheld portion 16, as previously described. More actuators may be provided in some examples. The actuators may include rotary actuators in some examples. The actuators 21, 22, and 23 may include linkages having one or more links of any suitable size or shape. The actuators 21, 22, and 23 may have any suitable configuration to enable movement of the tool support 18 relative to the handheld portion 16 in at least three degrees of freedom. For example, in some versions, there may be one forward actuator and two rearward actuators, or other arrangements of actuators.

[0065] In this version, the actuators 21, 22, and 23 are coupled to the base 74 and the tool support body 80 via a plurality of active joints. The active joints include a set of first active joints 92 that couple the actuators 21, 22, and 23 to the tool support body 80 at actuator mounts 86, 88, and 90. In one version, as shown in FIG. 9 , the first active joints 92 include active U-joints. The U-joints include a first pivot pin 94 and a joint block 96. The first pivot pin 94 rotatably connects the joint block 96 to the actuator mounts 86, 88, and 90 via a through-hole 98 in the joint block 96. A set screw 100 may secure the first pivot pin 94 to the actuator mounts 86, 88, and 90. The U-joints may also include a second pivot pin 104. The joint block 96 has a cross bore 102 for receiving the second pivot pin 104. The second pivot pin 104 has a through hole 103 for receiving the first pivot pin 94, such that the first pivot pin 94, joint block 96, and second pivot pin 104 form a cross of a U-joint. The first pivot pin 94 and second pivot pin 104 of each U-joint define an intersecting axis of rotation PA. The second pivot pin 104 rotatably connects the pivot yoke 106 of the actuators 21, 22, and 23 to the joint block 96. As a result, the actuators 21, 22, and 23 can move in two degrees of freedom relative to the tool support body 80. Other types of active joints are also contemplated, such as an active spherical joint including a ball with a slot that receives the pin.

[0066] Referring to FIG. 9 , the active joint also includes a set of second active joints 108 that couple the front two actuators 21, 22 to the base 74 of the handheld portion 16. In the version shown, the second active joints 108 are supported on the joint supports 77, 78. Each of the second active joints 108 includes a swivel yoke 110 arranged to pivot relative to the base 74 of the handheld portion 16 about a swivel axis SA. Each swivel yoke 110 has a swivel head 112 and a post 114 extending from the swivel head 112 to rotatably engage the base 74 at one of the joint supports 77, 78. A nut 115 is threadably connected to one end of the post 114 to capture the post 114 to the base 74 while allowing the respective swivel yoke 110 to freely rotate relative to the respective joint support 77, 78.

[0067] Each of the second active joints 108 includes a carrier 116 rotatably coupled to one of the swivel yokes 110. The carrier 116 has internally threaded through-holes 117 for receiving lead screws 150 of the two forward actuators 21, 22, as described further below. Each carrier 116 also includes opposed trunnions 118 that are seated in pockets in the swivel yoke 110, allowing the carrier 116 to rotate relative to the swivel yoke 110 about a rotation axis PA (see FIG. 9 ). In some versions, for each of the second active joints 108, the swivel axis SA intersects the rotation axis PA to define a vertex about which the actuators 21, 22 move in two degrees of freedom.

[0068] The cover is secured to the swivel head 112 and defines one of the pockets, while the swivel head 112 defines the other pocket. During assembly, the carrier is first positioned so that one of the trunnions is located in the pocket in the swivel head 112, and then the cover is secured onto the other trunnion, such that the carrier is captured between the cover and the swivel head 112 and can rotate relative to the swivel yoke 110 via the trunnion and pocket. Due to the configuration of the swivel yoke 110 and associated carrier, i.e., the carrier's ability to pivot about swivel axis SA and rotate about pivot axis PA, the second active joint 108 enables two degrees of freedom of movement of the front two actuators 21, 22 relative to the base 74. Other joint arrangements between the front two actuators 21, 22 and the base 74 are also possible.

[0069] The active joints also include a third active joint 124 that couples the rear (third) actuator 23 to the base 74 of the handheld portion 16. In the version shown, the third active joint 124 is supported on the joint support 79. The third active joint 124 includes a pivot housing 126 fixed to the joint support 79 of the base 74.

[0070] The third active joint 124 includes a carrier rotatably coupled to the pivot housing 126 via a trunnion. A fastener having a pocket is attached to each side of the pivot housing 126 via a through-hole to engage the trunnion. The fastener is positioned so that the carrier can rotate via the trunnion, which is located in the pocket after assembly. The carrier has an internally threaded through-hole to receive the lead screw 150 of the aft actuator 23, as described further below. Due to the configuration of the pivot housing 126 and associated carrier, i.e., the ability of the associated carrier to only rotate (e.g., not pivot) about the pivot axis PA, the third active joint 124 allows for only one degree of freedom of movement of the aft actuator 23 relative to the base 74. Other joint arrangements between the aft actuator 23 and the base 74 are also possible.

[0071] Each actuator 21, 22, 23 includes a housing. The housing includes a canister and a cap threadably connected to the canister. A pivot yoke 106, which forms part of the first active joint 92, is secured to the housing such that the housing and pivot yoke 106 can move together relative to the tool support 18 via the first active joint 92. The cap captures an annular shoulder of the pivot yoke 106 to secure the pivot yoke 106 to the canister.

[0072] In some versions, the pivot yokes 106 and canisters include one or more alignment features for aligning each pivot yoke 106 with its respective canister in a predetermined relative orientation. Such alignment features may include mating portions, keys / keyways, etc. During assembly, the pivot yokes 106 may first be secured to the canister in the predetermined relative orientation, and then a cap may be threaded onto the canister (e.g., via mating male and female threads) to capture the pivot yokes 106 to the canister in the predetermined relative orientation. This predetermined relationship is maintained by the flex circuit F CThis may be useful when routing and / or aligning the canister, may be useful to prevent rolling of the pivot yoke 106 relative to the canister, and / or for other purposes.

[0073] Each actuator 21, 22, 23 also includes a motor disposed in its respective housing. The motor has a casing disposed in the housing and a motor winding assembly disposed within the casing. The motor winding assembly may also be aligned in a predetermined relative orientation to the canister, such as via a set screw or other alignment feature, as described above. Each motor also has a rotor secured to a lead screw 150. The lead screw 150 is supported for rotation in the housing by one or more bushings and / or bearings. The rotor and associated lead screw 150 are configured to rotate relative to the housing upon selective energization of the motor. The lead screw 150 has precise pitch and lead angles to prevent backdriving (i.e., the lead screw is self-locking). As a result, a load placed on the tool 20 does not easily backdrive the motor. In some examples, the lead screw 150 has 8 to 36 Class 3 threads, producing a lead of 0.02 to 0.03 inches per revolution. Other thread types / sizes may also be used.

[0074] Each actuator 21, 22, 23 may be controlled by a separate motor controller. The motor controller may be separately wired to each actuator 21, 22, 23 to individually direct each actuator 21, 22, 23 to a given target position. In some examples, the motor controller is a proportional-integral-derivative (PID) controller. In some examples, the motor controller may include cascaded control loops relating to position, velocity, and torque (current). Additionally and / or alternatively, the motor controller may include only a torque (current) control loop. In another example, the position control loop may directly feed the torque (current) control loop. Each of these control stages may be implemented as a PID controller, a state-space controller, and / or may utilize alternative or additional control techniques (e.g., velocity feedforward, torque feedforward, etc.). In some cases, the torque (current) control loop is implemented using field-oriented control and space vector modulation. The control loop stages can be distributed among various components of the system. In some examples, the position and velocity loops are implemented in the instrument controller, and the torque control loop is implemented directly on the control board 31 as part of the control housing 29 in the instrument 14, mitigating the effects of data communication latency from the instrument 14 through a connection to the console 33 because the current control loop does not require any data feedback via the console 33. The position and velocity control loops are not sensitive to communication latency and can be implemented in the console 33. In some examples, the motor controller can be integrated with or form part of the instrument controller 28. For ease of illustration, the motor controller is described herein as part of the instrument controller 28.

[0075] The power supply provides a 32 VDC power signal to the motors, for example, via console 33. The 32 VDC signal is applied to the motors through tool controller 28. Tool controller 28 selectively provides a power signal to each motor to selectively activate the motors. This selective activation of the motors positions tool 20. The motors may be any suitable type of motor, including brushless DC servo motors, permanent magnet synchronous motors, other types of DC motors, etc. The power supply also provides power to tool controller 28 to energize its internal components. In some examples, the actuator motors may be three-phase brushless motors. The actuator motors may be DC motors. The actuator motors may be permanent magnet synchronous motors. Each actuator motor may be configured with a sinusoidal back EMF and may be configured to achieve limited mechanical cogging, allowing smooth, specific motion and limiting torque ripple. However, other motor types are contemplated. It should be appreciated that the power supply may provide other types of power signals, such as 12 VDC, 24 VDC, 40 VDC, etc. The appliance uses electronic switches, e.g., MOSFETs or GaN FETs, to PWM a voltage signal to turn a three-phase motor on and off at a high frequency, e.g., a rate typically at least 16 kHz and up to 256 kHz or more.

[0076] In one possible implementation, one or more sensors S (see also FIG. 7 ) send signals back to the tool controller 28, enabling the tool controller 28 to determine the current position and / or angle (i.e., measured position) of the associated actuators 21, 22, 23. The level of these signals may vary with respect to the rotational position of the associated rotor. In one implementation, the sensors S may resolve the rotor's rotational position within a given rotation with high resolution. These sensors S may be Hall-effect sensors that output analog and / or digital signals based on detected magnetic fields from the rotor or from other magnets (e.g., two-pole magnets) disposed on the lead screw 150. A low voltage signal, e.g., 5 VDC, for energizing the Hall-effect sensors may be provided by a motor controller associated with the motor with which the Hall-effect sensors are associated. In some examples, two Hall-effect sensors are disposed on the housing and spaced 90 degrees from each other around the rotor to detect joint position, enabling the tool controller 28 to determine position and count incremental rotor rotations. In some versions, the Hall effect sensor output digital signal represents an incremental count. Various types of motors and sensor arrangements are possible. In some examples, the motor is a brushless DC servo motor, and two or more internal Hall effect sensors may be spaced 90 degrees, 120 degrees, or any other suitable distance from each other around the rotor. The sensor S may also include an absolute or incremental encoder, which may be used to detect the rotor's rotational position and count rotor rotations. Other types of encoders may be used as one or more sensors. The sensors may be placed in any suitable location on the actuator and its surrounding components, such as on a housing, nut, screw, or the like, suitable for determining the position of each actuator when adjusted. In yet another configuration, sensorless motor control may be utilized. In such an implementation, the position of each rotor may be determined by measuring the motor's back EMF and / or inductance.One suitable example may be found in US Pat. No. 7,422,582, which is incorporated herein by reference in its entirety.

[0077] In some examples, the sensors and / or encoders may measure position feedback for joint position control and / or to determine the position of the tool support 18 relative to the handheld portion 16 when used in conjunction with a kinematic model of the instrument 14. In some examples, the sensors and / or encoders rely on multi-turn measurements, which accumulate rotation by rotation and are used to determine the absolute position of the actuators 21, 22, 23 along their axes, in conjunction with a known pitch (i.e., revolutions per inch of the lead screw). Additionally or alternatively, the sensors and / or encoders may be used to determine the "electrical angle of the rotor" for use in electronic commutation of the motor. For example, the sensors and / or encoders may be used to determine the rotor position and apply an appropriate energy supply signal to achieve optimal (efficient) torque generation. In this example, the sensors and / or encoders may utilize a single turn or sub-turn (within one electrical rotation) rotated over each electrical rotation. The number of electrical rotations is equal to the number of mechanical rotations divided by the number of magnetic poles (e.g., the number of pole pairs) of the motor. However, it is also conceivable that a sensorless method may be implemented.

[0078] In some examples, output signals from the Hall effect sensors are transmitted to the instrument controller 28. The instrument controller 28 monitors the received signals for changes in their levels. Based on these signals, the instrument controller 28 determines the joint position. The joint position may be considered the degree of rotation of the rotor from an initial or home position. The rotor can rotate 360° multiple times. Therefore, the joint position can exceed 360°. A scalar value, called a count, represents the joint position from the home position. The rotor rotates clockwise and counterclockwise. Each time the signal levels of multiple signals (analog or digital) undergo a defined change of state, the instrument controller 28 increments or decrements the count, indicating a change in joint position. For each complete 360° rotation of the rotor, the instrument controller 28 increments or decrements the value of the count by a fixed number of counts. In some examples, the count is incremented or decremented by 100 to 3,000 for each 360° rotation of the rotor. In some examples, such as when incremental encoders are used to monitor joint position, there are 1024 positions (counts) per 360° rotation of the rotor. Internal to the implement controller 28, a counter is associated with each actuator 21, 22, 23. The counter stores a value equal to the cumulative number of counts that have been incremented or decremented. The count value can be positive, zero, or negative. In some versions, the count value defines the incremental movement of the rotor. Thus, the rotor of an actuator 21, 22, 23 may first be moved to a known position, called a home position (described further below), and then the count value is used to define the rotor's current position.

[0079] As previously described, the carriers have internally threaded throughbores for threadably receiving the lead screws 150, thereby allowing each lead screw 150 to rotate relative to a corresponding one of the carriers to adjust the effective length of a corresponding one of the plurality of actuators 21, 22, 23, thereby varying the count measured by the instrument controller 28. Each housing and corresponding carrier are constrained from relative movement in at least one degree of freedom to allow the lead screw 150 to rotate relative to the carrier. More specifically, the pivot yoke 106, which cannot rotate about its associated active axis AA1, AA2, AA3 (i.e., the pivot yoke 106 is limited in such rotational movement by the configuration of the first active joint 92), and the carrier, which cannot rotate about its associated active axis AA1, AA2, AA3 (i.e., the carrier is limited in such rotational movement by the configuration of the second active joint 108 and the third active joint 124), allow the lead screw 150 to rotate relative to the carrier.

[0080] Stops 152, such as threaded fasteners and shoulders formed on the lead screws 150, are secured to the lead screws 150. The stops 152 are sized to abut the carrier 116 at the end of each lead screw 150's travel.

[0081] As previously described, the actuators 21, 22, and 23 have actively adjustable effective lengths to allow movement of the tool support 18 relative to the handheld portion 16. One example of this effective length is indicated by "EL" on the third actuator 23, where the effective length EL is measured from the pivot axis PA to the center of the associated first active joint 92. As each actuator 21, 22, and 23 is adjusted, the effective length EL changes by changing how far the lead screw 150 threads into or out of the associated carrier, thereby changing the distance from the center of the associated carrier to the center of the associated first active joint 92. The actuators 21, 22, and 23 are adjustable between minimum and maximum effective lengths EL. The effective length EL of each actuator 21, 22, 23 can be expressed / measured in any suitable manner to indicate the distance between the tool support 18 and the handheld portion 16 along the active axes AA1, AA2, AA3 that change to cause various movements of the tool support 18 relative to the handheld portion 16.

[0082] The constraint assembly 24 works in cooperation with the actuators 21, 22, 23 to constrain the movement provided by the actuators 21, 22, 23. The actuators 21, 22, 23 provide movement in three degrees of freedom, while the constraint assembly 24 constrains movement in three degrees of freedom. In the version shown, the constraint assembly 24 includes a passive linkage 26 and a passive linkage joint 156 that couples the passive linkage 26 to the tool support 18.

[0083] 9 , the passive linkage joint 156 includes a passive linkage U-joint. The U-joint includes a first pivot pin 158 and a joint block 160. The first pivot pin 158 rotatably connects the joint block 160 to a passive linkage mount 162 on the tool support body 80 via a through-hole 164 in the joint block 160. A set screw 166 may secure the first pivot pin 158 to the passive linkage mount 162. The U-joint also includes a second pivot pin 170. The joint block 160 has a cross-bore 168 for receiving the second pivot pin 170. The second pivot pin 170 rotatably connects a passive linkage pivot yoke 172 of the passive linkage 26 to the joint block 160. The second pivot pin 170 has a through hole 171 for receiving the first pivot pin 158, such that the first pivot pin 158, joint block 160, and second pivot pin 170 form a cross of a U-joint. The first pivot pin 158 and the second pivot pin 170 define an intersecting pivot axis PA. As a result, the passive linkage 26 can move in two degrees of freedom relative to the tool support body 80. Other types of passive linkage joints are also contemplated, such as a passive linkage spherical joint including a ball with a slot that receives a pin.

[0084] Passive linkage 26 includes a shaft 174 fixed to passive linkage pivot yoke 172. Passive linkage 26 also includes a sleeve 76 in base 74 configured to receive shaft 174 along constraint axis CA. Passive linkage 26 is configured to allow shaft 174 to slide axially relative to sleeve 76 along constraint axis CA and to constrain movement of shaft 174 radially relative to constraint axis CA during actuation of one or more of actuators 21, 22, 23.

[0085] The passive linkage 26 further includes a key to constrain rotation of the shaft 174 relative to the sleeve 76 about the constraint axis CA. The key fits into opposing keyways in the shaft 174 and the sleeve 76 to rotationally lock the shaft 174 to the sleeve 76. Other arrangements for preventing relative rotation of the shaft 174 and the sleeve 76, such as an integral key / slot arrangement, are also contemplated. The passive linkage 26 operably interconnects the tool support 18 and the handheld portion 16 independently of the actuators 21, 22, and 23. The passive linkage passively adjusts the effective length EL along the constraint axis CA during actuation of one of the actuators 21, 22, and 23. The sleeve 76, shaft 174, and key 176 represent one combination of links for the passive linkage 26. Other sizes, shapes, and numbers of links connected in any suitable manner may be used for the passive linkage 26.

[0086] In the version shown, the passive linkage joint 156 can rotate about two pivot axes PA relative to the tool support 18. Other configurations are possible.

[0087] Also, in the version shown, the first active joint 92 and the passive linkage joint 156 define pivot axes PA disposed in a common plane. Non-parallel pivot axes PA, parallel pivot axes PA disposed in different planes, combinations thereof, and / or other configurations are also contemplated.

[0088] In some versions, the head 84 of the tool support 18 is positioned such that the tool 20 is positioned with a tool plane BP (e.g., blade plane) parallel to the common plane CP when the tool 20 is coupled to the tool support 18. In some examples, the tool plane BP is spaced from the common plane CP by 2.0 inches or less, 1.0 inches or less, 0.8 inches or less, or 0.5 inches or less.

[0089] In the version shown, the actuators 21, 22, and 23 are arranged such that the active axes AA1, AA2, and AA3 are in a tilted configuration relative to the constraint axis CA at all positions of the actuators 21, 22, and 23, including their home positions. Tilting the axes AA1, AA2, and AA3 generally tapers the actuator array in a manner that allows for a slimmer, more compact base 74 and associated grip 72. Other configurations are contemplated, including those in which the active axes AA1, AA2, and AA3 are in a configuration that is not tilted relative to the constraint axis CA. Such configurations may include those in which the actuator axes AA1, AA2, and AA3 are parallel to one another at the home position.

[0090] Additional configurations of actuators, active joints, and constraint assemblies are possible. It is contemplated that the described control techniques may be applied to other mechanical configurations not mentioned, particularly configurations for controlling a tool or saw blade relative to a handheld portion in one or more degrees of freedom. In some versions, the constraint assembly may be absent, and the tool support 18 of the instrument 14 may be able to move in additional degrees of freedom relative to the handheld portion 16. For example, the instrument may include linear actuators, rotary actuators, or a combination thereof. The instrument may include two, three, four, five, six, or more different actuators arranged in parallel or series.

[0091] [Virtual Boundary] The software used by the control system 60 to control the operation of the instrument 14 includes a boundary generator 182 (see FIG. 7 ). The boundary generator 182 may be implemented on the instrument controller 28, the navigation controller 36, and / or other components, such as on a separate controller. The boundary generator 182 may also be part of a separate system operating remotely from the instrument 14. With reference to FIG. 7 , the boundary generator 182 is a software program or module that generates one or more virtual boundaries 184 for constraining the movement and / or motion of the instrument 14. In some examples, the boundary generator 182 provides the virtual boundary 184 that defines a virtual cutting guide (e.g., a virtual saw cutting guide). The virtual boundary 184 may be provided to delineate various motion / control regions, as described below. The virtual boundary 184 may be one-dimensional (1D), two-dimensional (2D), or three-dimensional (3D) and may include points, lines, axes, trajectories, planes (such as infinite planes or planar segments or other boundaries bounded by anatomical structures), volumes, or other shapes, including complex geometric shapes. The virtual boundary 184 may be represented by points, a point cloud, voxels, a triangular mesh, other 2D or 3D models, combinations thereof, etc. U.S. Patent Application Publication No. 2018 / 0333207 and U.S. Patent No. 8,898,043 are incorporated by reference, any of whose features may be used to facilitate planning or execution of a surgical procedure.

[0092] The virtual boundary 184 may be used in a variety of ways. For example, the control system 60 may control certain movements of the tool 20 to stay within the boundary; may control certain movements of the tool 20 to stay outside the boundary; may control certain movements of the tool 20 to stay on the boundary (e.g., stay on a point, trajectory, and / or plane); may control certain movements of the tool 20 to approach the boundary (attractive boundary) or be repelled from the boundary (repulsive boundary); and / or may control certain operations / functions of the instrument 14 based on the relationship (e.g., spatial, velocity, etc.) of the instrument 14 to the boundary. Other uses of the boundary 184 are also contemplated.

[0093] In some examples, one of the virtual boundaries 184 is a desired cutting plane, as shown in FIG. 2 . The control system 60 ultimately functions in some versions to maintain the tool 20 on the desired cutting plane. The virtual boundary 184 that controls the positioning of the tool 20 may be a volume boundary, such as one having a thickness slightly greater than the blade thickness to constrain the saw blade to stay within the boundary and on the desired cutting plane, as shown in FIG. 2 . Thus, the desired cutting plane may be defined by a virtual planar boundary, a virtual volume boundary, or other form of virtual boundary. The virtual boundary 184 may also be referred to as a virtual object. The virtual boundary 184 may be defined with respect to an anatomical model AM, such as a 3D bone model (see FIG. 2 , which shows the anatomical model AM virtually superimposed on the actual femur F through their registration). In other words, points, lines, axes, trajectories, planes, volumes, etc. associated with the virtual boundary 184 may be defined in a coordinate system that is fixed relative to the coordinate system of the anatomical model AM, such that tracking of the anatomical model AM (e.g., via tracking of registered associated anatomical structures) also enables tracking of the virtual boundary 184.

[0094] The anatomical model AM is registered with the first patient tracker 54 such that a virtual boundary 184 is associated with the anatomical model AM and an associated coordinate system. The virtual boundary 184 may be implant-specific, e.g., defined based on the implant's size, shape, volume, etc., and / or patient-specific, e.g., defined based on the patient's anatomy. The virtual boundary 184 may be a boundary generated pre-operatively, intra-operatively, or a combination thereof. In other words, the virtual boundary 184 may be defined before the surgical procedure begins, during the surgical procedure (including during tissue removal), or a combination thereof. The virtual boundary 184 may be provided in many ways, such as by the control system 60, generating them, receiving them from other sources / systems, etc. The virtual boundary 184 may be stored in memory for retrieval and / or updating.

[0095] In some cases, such as when preparing a femur F to receive a knee prosthesis IM (see FIG. 1 ), the virtual boundary 184 includes multiple planar boundaries that can be used to delineate multiple cutting planes (e.g., five cutting planes) for the knee prosthesis IM and are associated with a 3D model of the distal end of the femur F. These multiple virtual boundaries 184 can be actuated one at a time by the control system 60 to constrain the cutting to one plane at a time.

[0096] The tool controller 28 and / or navigation controller 36 track the state of the tool 20 with respect to the virtual boundary 184. In one example, the state of the TCP coordinate system (e.g., the pose of the saw blade) is measured with respect to the virtual boundary 184 to determine target positions for the actuators 21, 22, 23 so that the tool 20 remains in the desired state. In some cases, the control system 60 controls / positions the tool 14 in a manner that emulates the way a physical handpiece would respond in the presence of a physical boundary / barrier.

[0097] Referring again to FIG. 7 , two additional software programs or modules operate on the instrument controller 28 and / or navigation controller 36. One software module performs behavior control 186. Behavior control 186 is a process that calculates data indicative of the next commanded / desired position and / or orientation (e.g., desired pose) for tool 20. In some cases, only the desired position of the TCP is output from behavior control 186, while in some cases, the commanded pose of tool 20 is output. Output from boundary generator 182 (e.g., the current position and / or orientation of virtual boundary 184 in one or more of the coordinate systems) may be provided as an input to behavior control 186 to determine the next commanded position of actuators 21, 22, 23 and / or orientation for tool 20. Behavior control 186 may process this input, along with one or more other inputs, described further below, to determine the commanded pose.

[0098] The instrument controller 28 may control one or more actuators 21, 22, 23 by sending command signals to each actuator 21, 22, 23 to adjust the tool 20 toward a desired pose. The instrument controller 28 may know the overall length that the actuators 21, 22, 23 may adjust the tool support 18 relative to the handheld portion 16. In some examples, the instrument controller 28 knows the overall length that the actuators 21, 22, 23 can adjust and may send command signals to the actuators 21, 22, 23 to move a measured distance position by position. The measured position may be a known position or the distance between the current position of the actuator 21, 22, 23 and the actuator limits. Each position that the actuators 21, 22, 23 move to may be a measured distance from the positive and negative limits of the actuator travel (i.e., the position between the two ends of the lead screw). The instrument controller 28 may command the actuators 21, 22, 23 to and from the measured positions as described below.

[0099] The instrument controller 28 may send command signals to each actuator 21, 22, 23 to move the actuators 21, 22, 23 from a first position to a commanded position that places the tool 20 in the desired pose. In some examples, the commanded position may be determined by the instrument controller 28 in conjunction with the navigation system 32, which determines the position of the tool 20 and tool support 18 relative to the handheld portion 16, the patient trackers PT, 54, 56, a virtual object such as a desired cutting plane, or a combination thereof, and sends signals to the actuators 21, 22, 23 to adjust a distance or commanded position to place the tool 20 in the desired pose. The instrument controller 28 may command the actuators 21, 22, 23 to a predetermined position to reach the desired adjustment of the tool 20. The instrument controller 28 may control the actuators 21, 22, 23 to move linearly a calculated distance to adjust the tool 20 toward the desired pose. In other examples, such as when an absolute encoder is used, the tool control device may send signals to the actuators 21, 22, 23 to place each actuator 21, 22, 23 in a commanded position based on the known position of the tool support 18 relative to the handheld portion as determined by the absolute encoder.

[0100] The instrument controller 28 may know the overall length over which the actuators 21, 22, 23 can adjust the tool support 18 relative to the handheld portion 16. In some examples, the instrument controller 28 knows the overall length over which the actuators 21, 22, 23 can be adjusted and may send command signals to the actuators 21, 22, 23 to move a measured distance position by position (e.g., by commanding a desired amount of linear movement via a commanded rotation). The measured position may be a known position or the distance between the current position of the actuators 21, 22, 23 and an actuator limit. Each position to which the actuators 21, 22, 23 move may be a measured distance from the positive and negative limits of the actuator travel (i.e., the position between the two ends of a lead screw). The instrument controller 28 may command the actuators 21, 22, 23 to or from positions as described below. The instrument controller may command the actuators 21, 22, 23 to a predetermined position to reach the desired adjustment of the tool 20. The instrument controller 28 may control the actuators 21, 22, and 23 to linearly move the calculated distance to adjust the tool 20 toward the desired pose. In other examples, such as when absolute encoders are used, the instrument controller may send signals to the actuators 21, 22, and 23 to position each actuator 21, 22, and 23 at a commanded position based on the known positions of the actuators 21, 22, and 23 between their respective actuator travel limits determined by the absolute encoders. Alternatively, in one example, incremental encoders may be used in conjunction with a homing procedure performed during system setup, as described in U.S. Patent Application Publication No. 2017 / 0156799, which is incorporated herein by reference. The homing procedure may be used to position the actuators 21, 22, and 23 and joints in a centered position and then determine the absolute offset of the incremental encoder. By determining the offset of the incremental encoder, the incremental encoder may function as a forward-moving absolute encoder.

[0101] In some examples, if a homing position is used, the homing process establishes an initial rotor position (zero position) for the actuators 21, 22, and 23. The home position is effectively the position of the rotor 148 that provides the maximum possible movement in each direction along the active axes AA1, AA2, and AA3. In some examples, the home position is generally located so that the home point HP of the lead screw 150, centered halfway between the stops 152, is centered on the associated carrier 116 (see FIG. 12 , which shows two of the actuators 22 and 23 in the home position). Even if a homing procedure is not used, such as with absolute encoders, setting the actuators 21, 22, and 23 to the home point HP may be included before or after executing other modes (such as the approach mode, described further below). The instrument controller 28 may be configured to control the actuators 21, 22, and 23 to a home position between the minimum and maximum effective lengths EL of the actuators 21, 22, and 23.

[0102] When in the home position, the amount of adjustability of the actuators 21, 22, and 23 is maximized to maintain the tool 20 at a desired pose. Various levels of adjustability are possible depending on the particular geometry and configuration of the instrument 14. In some examples, when all actuators 21, 22, and 23 are in the home position, the tool 20 may be adjusted at a pitch orientation of approximately ±18° relative to the home position, assuming zero change in roll orientation and no z-axis translation. In some examples, when all actuators 21, 22, and 23 are in the home position, the tool 20 may be adjusted at a roll orientation of approximately ±33° relative to the home position, assuming zero change in pitch orientation and no z-axis translation. In some examples, when all actuators 21, 22, and 23 are in the home position, the tool 20 may be adjusted at a z-axis translation of approximately ±0.37 inches relative to the home position, assuming zero change in pitch and roll orientations. Tool 20 may, of course, be adjusted in pitch, roll, and z-axis translation simultaneously, sequentially, or a combination thereof during operation.

[0103] In some examples, when one or more of the actuators 21, 22, 23 reach their limits, the instrument controller 28 may request that the handheld portion 16 be adjusted to return the tool 20 to the range within which the actuators can adjust the tool 20 toward the desired pose. In such cases, a simulated commanded position may be used to show the user how to move the handheld portion 16 to return the tool 20 and actuators 21, 22, 23 to alignment with the desired pose. The simulated commanded position may be a position determined by the instrument controller 28 in conjunction with navigation data from the navigation system 32 to which the handheld portion 16 must be moved to adjust the tool 20 toward the desired pose without adjusting the actuators 21, 22, 23. The simulated commanded position works in conjunction with the one or more displays 38 to send a signal to the user that the handheld portion 16 needs to be moved in a particular manner to place the tool 20 in the desired pose. In some examples, the guidance array 500 sends signals to the user to move the handheld portion 16 in the same manner as if the actuators 21, 22, 23 were adjusting the tool 20, but relies on the user to modify the pose of the tool 20 by manipulating the handheld portion 16 while the actuators remain in place.

[0104] A second software module performs motion control 188. One aspect of motion control 188 is control of instrument 14. Motion control 188 receives data from behavior control 186 defining a next commanded pose. Based on this data, motion control 188 determines (e.g., via inverse kinematics) a next rotor position for rotor 148 of each actuator 21, 22, 23, thereby enabling instrument 14 to position tool 20 as commanded by behavior control 186, e.g., at a commanded pose. In other words, motion control 188 processes a commanded pose, which may be defined in Cartesian space, into actuator positions (e.g., rotor positions) of instrument 14, such that instrument controller 28 can correspondingly command motors 142 to move actuators 21, 22, 23 of instrument 14 to commanded positions, such as commanded rotor positions, that correspond to the commanded pose of tool 20. In one version, the motion control 188 adjusts the rotor position of each motor 142 and continuously adjusts the torque output by each motor 142 to ensure as precisely as possible that the motor 142 drives the associated actuator 21, 22, 23 to the commanded rotor position.

[0105] In some versions, the tool controller 28 determines, for each actuator 21, 22, 23, the difference between the measured position and the commanded position of the rotor 148. The tool controller 28 outputs a target current (proportional to the torque of the rotor) and varies the voltage to adjust the current in the actuator from the initial current to the target current. The target current results in movement of the actuators 21, 22, 23, moving the tool 20 from the measured pose to the commanded pose. This may occur after the commanded pose is converted to joint positions. In one example, the measured position of each rotor 148 may be derived from the sensors S described above, such as encoders.

[0106] The boundary generator 182, behavior control 186, and motion control 188 may be subsets of a software program. Alternatively, each may be a software program operating separately and / or independently in any combination thereof. The term “software program” is used herein to describe computer-executable instructions configured to perform various capabilities of the described technical solutions. For simplicity, the term “software program” is intended to encompass at least any one or more of the boundary generator 182, behavior control 186, and / or motion control 188. The software program may be implemented in the instrument controller 28, the navigation controller 36, or any combination thereof, or may be implemented in any suitable form by the control system 60.

[0107] A clinical application 190 may be provided to handle user interaction. The clinical application 190 handles many aspects of user interaction and coordinates the surgical workflow, including pre-operative planning, implant placement, registration, bone preparation visualization, and post-operative evaluation of implant fit. The clinical application 190 is configured to output to the display 38. The clinical application 190 may run on its own separate processor or may run in parallel with the instrument controller 28 and / or navigation controller 36. In one example, the clinical application 190 interfaces with the boundary generator 182 after implant placement has been set by the user and then sends the virtual boundary 184 returned by the boundary generator 182 to the instrument controller 28 for execution.

[0108] The initial position of the base coordinate system BCS can be determined based on the known geometric relationship between the tool support coordinate system TCS and the base coordinate system BCS when the actuators 21, 22, and 23 are in the home position or other predetermined positions. This relationship changes as the actuators 21, 22, and 23 are adjusted, and the associated change can be determined based on the motion of the robot system 10 (e.g., establishing a dynamic transformation between these coordinate systems). Alternatively, or additionally, a separate tracker can be mounted and fixed relative to the base coordinate system BCS to directly track the pose of the base coordinate system BCS relative to the tool support coordinate system TCS. Thus, the robot system 10 knows the position of the tool 20, such as at the home position, and its relationship to the pose of the handheld portion 16. Thus, as the tool 20 is moved by the user and its pose is tracked using the tool tracker 52, the robot system 10 also tracks the pose of the handheld portion 16 and its base coordinate system BCS. In some examples, the position of the tool 20 relative to the tool support 18 is assumed to be known as a result of a previous calibration process.

[0109] In some versions, the home position is determined by first determining the pose of the handheld portion 16 (e.g., base coordinate system BCS) relative to the tool support 18 in a common coordinate system (e.g., relative to the tool support coordinate system TCS) by using a separate tracker fixed to the handheld portion 16. This spatial relationship between the handheld portion 16 and the tool support 18 can also be determined by registration using a pointer 57 and a known calibration divot on the handheld portion 16, or through other navigation methods. The current rotor position of each actuator 21, 22, 23 can then be derived from this spatial relationship based on the movement of the tool 14. Knowing the current rotor position and using the encoders (and corresponding encoder signals) to measure the change from the current rotor position, the tool controller 28 can then actuate each actuator 21, 22, 23 until the home position is reached. The home position can be stored in memory in the tool controller 28.

[0110] Essentially, the tool controller 28 uses tracking data obtained by the navigation system 32 from the tracker 52 coupled to the tool support 18 and handheld portion 16 of the tool 14 to determine the positions of the actuators 21, 22, 23, which then allows the incremental encoders to operate as absolute encoders.

[0111] For example, instruction data packets are transmitted from the console 33 or another component of the instrument controller 28 to the motor controllers. These instruction data packets include target positions (or actuator target positions) for the rotors 148 of the motors 142, where each target position may be a positive or negative number representing a target cumulative count for the associated rotor 148. The console 33 or other component of the instrument controller 28 generates and transmits these instruction data packets to each motor controller at a rate of one packet every 0.05 to 4 milliseconds. In some examples, each motor controller receives an instruction data packet at least once every 0.125 milliseconds.

[0112] During use, the robotic system 10 determines the pose (current pose) of the tool 20 using the navigation system 32 via a tracker 52 disposed on the tool support 18. The tool controller 28 may determine the current position of each actuator 21, 22, 23 based on the output encoder signals from one or more encoders disposed on each actuator 21, 22, 23. Once the current position of each actuator 21, 22, 23 is received, the tool controller 28 may calculate the current pose of the handheld portion 16 (e.g., current pose in a base coordinate system BCS with respect to a desired coordinate system, such as the TCP coordinate system using forward motion to transform from actuator position to pose (TCP with respect to BCS)). Once the instrument controller 28 has the current relative pose of the tool support 18 and handheld portion 16 in the desired coordinate system, the instrument controller 28 may then determine a commanded pose of the tool 20 based on the current pose of the tool 20 determined by the navigation system 32, the current pose of the handheld portion 16 calculated by the current positions of each of the actuators 21, 22, and 23, and the position and / or orientation of the planned virtual object, subject to the desired cutting plane. The instrument calculates a pose of the TCP (the commanded pose) in the desired plane or with respect to the BCS that results in the TCP aligned with the planned virtual object. The instrument controller 28 may send command instructions to the actuators 21, 22, and 23 to move to the commanded positions, thereby changing the pose of the tool support 18 and tool 20. In one example, the commanded pose of the tool 20 is further based on the target cutting plane, so the instrument controller 28 calculates the current pose of the tool support 18 and the current positions of the actuators 21, 22, 23 to determine the current pose of the handheld portion 16. Knowing the current pose of the tool support 18, the current positions of the actuators 21, 22, 23, and the current pose of the handheld portion 16, the instrument controller 28 can send command signals to the actuators 21, 22, 23 to adjust the tool support 18 and tool 20 based on the desired plane.The controller calculates the commanded pose by assuming that the handheld part pose (BCS) is stationary relative to the patient anatomy for an instant (during one iteration). The actual movement of the BCS is adjusted by updating the corresponding pose each time.

[0113] With reference to FIG. 11 , exemplary control is described with respect to various transformations. The TCP is determined by tracking the tool 20 at the LCLZ with the tracker 52 (LCLZ-TT) and using registration data to determine the transformation (TT-TCP) between the tool tracker 52 and the TCP of the tool 20, such as a saw. Similarly, the patient is tracked at the LCLZ using a patient tracker PT (shown as 54) (LCLZ-PT). A transformation (PT-TP) is determined between the patient tracker PT and each planned virtual object 184 (TP) using registration data and planning information. As mentioned above, the transformation between the BCS and the TCP (BCS-TCP) is calculated based on the current position of each actuator (discussed above). The transformation between the BCS and the TCP is utilized to relate the various coordinate systems back to the handheld portion 16, since commanded poses may be determined with respect to the BCS. Conceptually, the commanded pose is an update to the transformation from the BCS to the TCP, so that the TCP is aligned with the planned virtual object 184 (target plane TP) in this example.

[0114] It should be appreciated that the phrase "TCP of the instrument" is used interchangeably with the phrase "position of the saw blade." Thus, in any instance where the TCP of the instrument / tool ​​is used, it may be substituted by the position of the saw blade, or vice versa. Of course, the position of the "saw blade" may alternatively be the position of a tool of any suitable configuration, such as a drill, burr, guide tube, screwdriver, tap, pin, etc.

[0115] Throughout this description, unless otherwise specified, any example of a pose may be a commanded pose, a current pose, a past pose, or a past commanded pose. Each of these poses may differ from one another depending on the frequency of control, but the difference in position and / or orientation between these poses may be minimal in each control iteration.

[0116] It should be understood that the combination of an object's position and orientation is referred to as the object's pose. Throughout this disclosure, the term pose may be replaced with position and / or orientation, and vice versa, to achieve suitable alternatives to the concepts described herein. In other words, any use of the term pose may be replaced with position, and any use of the term position may be replaced with pose.

[0117] 〔operation〕 During operation, the robotic system 10 is initially powered on and the software application for operating the system is started. The trackers 52, 54, 56, and PT are initialized, and the trackers 52, 54, and 56 are placed on the instrument 14 and the target anatomical structure (e.g., the femur F and the tibia T). With the trackers 54 and 56 attached to the anatomical structure, the anatomical structure and / or associated images / models are registered to the trackers 54 and 56 using known registration techniques. This may require the user to touch a surface or landmark on the anatomical structure with the pointer 57. For example, this may require the user to touch multiple points on the surface of the anatomical structure while pressing a select button on the pointer 57 or a foot switch on the navigation system 32. This "paints" points on the surface in the navigation system 32 to match the preoperative and / or intraoperative images / models of the anatomical structure. The preoperative and / or intraoperative images / models of the anatomical structure are loaded into the navigation system 32. The tracked portions of the anatomy are registered to the pre- / intra-operative images / models. By extension, this allows the robotic system 10 to display on the display 38 a graphical representation of the actual position and orientation of the anatomy as it moves.

[0118] During the calibration / registration procedure, the orientation and position of the tracker 52 is calibrated / registered relative to the tool support 18 by referencing the fixed, known location of the calibration divot CD or other reference point. In some examples, one or more trackers 52 may be disposed on the tool support 18, the handheld portion 16, or both, such that the position of the tool support 18 and / or the handheld portion 16 is tracked by the navigation system 32. In examples where the tracker 52 is integrated into the instrument 14, such calibration is not necessary because the relative position of the tracker 52 with respect to the tool support 18 is known.

[0119] Virtual objects (e.g., virtual boundary 184) used to control the operation of the instrument 14 are also defined / captured. Software running on the instrument controller 28 (e.g., boundary generator 182) generates / captures the initial definition of the virtual objects. The user may have the ability and option to adjust the properties / placement of the virtual objects if desired.

[0120] In one exemplary configuration, the control system 60 defines various regions at predetermined distances and / or locations from the target site and / or anatomical structure. Each of these regions may be defined in a coordinate system relative to the anatomical structure and / or virtual boundary 184. In some cases, these regions are defined as spheres or other geometric primitives around the target site and / or anatomical structure. In other examples, the regions (and others described below) may be defined relative to the instrument 14, the tool support 18, the handheld portion 16, the tool 20, the target site / anatomical structure, or a combination thereof. The control system 60 may control the instrument 14 when a region defined by the handheld portion 16, the tool support 18, the tool 20, the target site / anatomical structure, or a combination thereof, approaches a particular virtual boundary / virtual cutting guide feature.

[0121] In particular, instrument controller 28 generates a set of target rotor positions to which rotor 148, integral to motor 142, must rotate to maintain tool 20 at the desired pose. In other words, when the user moves handheld portion 16 in a manner that moves tool 20 away from the desired pose, this is detected by navigation system 32. In response to this movement, instrument controller 28 determines, based on data from navigation system 32, how far tool 20 has moved away from the desired pose and compensates for such movement by driving actuators 21, 22, and 23 as necessary to return tool 20 to the desired pose. It should be appreciated that such deviations from the desired pose will typically be small because instrument controller 28 operates at a high frequency (e.g., frame rate) to continuously counteract such deviations in substantially real time.

[0122] The target rotor positions are determined based on the relationship between the actuation of the actuators 21, 22, and 23 and the resulting movement (e.g., motion). For example, if the desired pose requires z-axis translation relative to the handheld portion 16, then there is a linear relationship between the degree to which the tool 20 moves in the z-axis and the amount of rotation of each rotor 148 (e.g., how many counts are associated with such z-axis movement). There is also a relationship between the degree to which the tool 20 changes pitch orientation in response to actuation of the third actuator 23, alone or in combination with one or both of the first and second actuators 21 and 22. Finally, there is a relationship between the degree to which the tool 20 changes roll orientation in response to actuation of one or both of the first and second actuators 21 and 22, with or without actuation of the third actuator 23. Based on these relationships, the instrument controller 28 determines the target rotor positions for each rotor 148 required to maintain the desired pose of the tool 20. The instrument controller 28 then activates the motors 142 based on these target rotor positions. For example, the console 33 may send packets containing these target rotor positions to the motor controllers, and each motor controller may apply the appropriate energy supply signals to the associated motor 142. These energy supply signals cause the rotor 148 to rotate, resulting in repositioning of the lead screw 150, which moves the tool support 18 / tool ​​20 as needed to maintain the tool 20 at the desired pose.

[0123] As previously described, when the user positions the handheld portion 16 toward the desired plane while being guided by the alignment members 502 and 504, the actuators 21, 22, and 23 are held in a home position or other predetermined position. By maintaining the actuators 21, 22, and 23 in the home position or other predetermined position, the user may find it easier to adjust the tool 20 and align the tool 20 with the instrument pose relative to the desired plane and target. However, when the tool is in the desired pose, the visual guidance is intended to guide the user on how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, and 23 near the home position or other predetermined position. For example, the user may need to move the handheld portion 16 upward in the z-axis to move all of the actuators 21, 22, and 23 closer to the home position while maintaining the tool 20 in the desired pose. In other words, the actuators 21, 22, and 23 may be nearly fully extended. To accomplish this, the directional instruction from guidance array 500 is upward. In this case, guidance array 500 is actually guiding the user to move handheld portion 16 upward, which causes actuators 21, 22, and 23 to actuate toward their home positions to maximize the adjustability of actuators 21, 22, and 23. As the user moves handheld portion 16 upward, actuators 21, 22, and 23 continue to actuate to maintain tool 20 in the desired pose (e.g., on virtual boundary 184). As a result, actuators 21, 22, and 23 retract, such as retract toward their home positions. Ideally, the maximum amount of movement is available in each direction for each actuator 21, 22, and 23 as the user begins to cut the bone.Otherwise, if one or more of the actuators 21, 22, 23 have nearly reached the available travel in their respective directions, slight movement of the handheld portion 16 may result in the tool control device 28 being unable to maintain the tool 20 in the desired pose, potentially resulting in an inaccurate cut.

[0124] Additionally and / or alternatively, in some versions, tool 20 may be moved to a desired pose, and then the user may adjust handheld portion 16 to a more comfortable position within the available movement thresholds of actuators 21, 22, 23 to perform the cut while tool 20 is maintained in the desired position. The user may then select, by activating an input device such as a button and / or footswitch or making a selection on a touchscreen, to move to a freehand mode in which the pose of handheld portion 16 relative to the pose of tool 20 is held or frozen in its current spatial relationship. The held pose of handheld portion 16 relative to the pose of tool 20 is thought to change the virtual thresholds of actuators 21, 22, 23, limiting the movement of the actuators to maintain the held pose when the user selects the actuation mode.

[0125] [Visual Guidance] As shown in FIGS. 12-28 , the instrument 14 also includes a guidance array 500. The guidance array 500 provides the operator with a visual indication of the pose of the blade support 18 relative to the handheld portion 16 during operation of the instrument 14. Thus, the guidance array 500 provides the operator with a visual indication of the required changes in pitch orientation, roll orientation, and z-axis translation of the handheld portion 16 to achieve the desired pose of the tool 20 while providing maximum adjustability for the multiple actuators 21, 22, and 23 to maintain the tool 20 at the target plane TP. The guidance array 500 includes a tool alignment member 502 coupled to the blade support 18 and a handle alignment member 504 coupled to the handheld portion 16 to guide the user as to how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, and 23 near their home positions or other predetermined positions. In some configurations, at least a portion of the tool alignment member 502 and at least a portion of the handle alignment member 504 may be aligned when the actuators 21, 22, and 23 are in their respective home positions. For example, in the configurations shown in Figures 12-17, the top surface 503 of the tool alignment member 502 and the top surface 505 of the handle alignment member 504 are aligned when the actuators 21, 22, and 23 are in their respective home positions.

[0126] In one configuration, the term "aligned" is defined as at least a portion of the tool alignment member 502 and at least a portion of the handle alignment member 504 being substantially coplanar or intersecting within an appropriate tolerance. For example, when at least a portion of the tool alignment member 502 and at least a portion of the handle alignment member 504 are aligned, the tool alignment member 502 and the handle alignment member 504 provide a visual indication to the operator of the instrument 14 that the blade support 18 has a desired range of motion relative to the handheld portion 16. Particularly in the home position, the amount of adjustability of the actuators 21, 22, and 23 is maximized to maintain the tool 20 in a desired pose. In some examples, the alignment portion of the tool alignment member and the handle alignment member may be 99 percent or more aligned, 90 percent or more aligned, 70 percent or more aligned, or even 60 percent or more aligned. In other examples, proper alignment may be within a specified proximity to the target pose, such as within 1 percent deviation from the target pose, 5 percent deviation from the target pose, 10 percent deviation from the target pose, or even 20 percent or more deviation from the target pose, in each individual degree of freedom. Similarly, proper alignment may be within 1 mm of the target pose, within 2 mm of the target pose, or even 5 mm or more deviation from the target pose, in each individual degree of freedom. Additionally, proper alignment may be 1 degree or more deviation from the target pose, 5 degrees or more deviation from the target pose, 15 degrees or more deviation from the target pose, or even 30 degrees or more deviation from the target pose, in roll and / or pitch.

[0127] 12-28, the tool alignment member 502 may be a member that extends away from the blade support 18. For example, the tool alignment member 502 may include a tool alignment portion 510 that defines a tool alignment plane 512 (shown in FIG. 17), which is parallel to or even coplanar with the blade plane BP, providing an operator of the instrument 14 with a visual indication of the pose of the blade plane BP. The terms tool plane and blade plane BP may be used interchangeably. The tool alignment member 502 may have any shape or structure capable of providing a visual indication of the pose of the blade plane BP relative to the handle alignment member 504. In one example, as shown in FIGS. 12-28, the tool alignment portion 510 of the tool alignment member 502 may define a "U" shape. In this example, the tool alignment portion 510 defines an elongated body and two protrusions that allow the tool alignment portion to surround the handle alignment portion 524 when the tool alignment member 502 and the handle alignment member 504 are aligned when the actuators 21, 22, and 23 are in their home positions. Each portion of the tool alignment portion 510 may be generally planar, having a length, width, and height that define a three-dimensional shape for providing a visual indication of alignment and misalignment with the handle alignment member. The “U”-shaped profile of the tool alignment member 502 allows the operator to view the pose of the handle alignment portion relative to the elongated members and protrusions, further assisting in providing a visual indication of the pose of the blade support 18 relative to the handheld portion 16.

[0128] 15 and 16 , for example, the tool alignment member 502 may also include a mounting portion 506 configured to be attached to the blade support 18. The mounting portion 506 may be attached to the blade support 18 using any suitable means (e.g., fasteners, magnets, adhesives, etc.) at any suitable location to facilitate function of the tool alignment member 502 (described in more detail below). The tool alignment member 502 may further include a support portion 508. The support portion 508 may extend from the mounting portion 506 to support the tool alignment portion 510. In some examples, the tool alignment member 502 may be rigid relative to the blade support 18 to facilitate function of the tool alignment member 502. The tool alignment member 502 may be formed from any suitable material, such as plastic, aluminum, steel, composites, etc., or combinations thereof. Furthermore, the tool alignment member may be formed using any suitable manufacturing method, including 3D printing, casting, machining, injection molding, stamping, etc., or combinations thereof. It is contemplated that the tool alignment portion 510 may be formed as other shapes (described in more detail below). In other configurations, the tool alignment member 502 may be the tool 20 itself. For example, the tool 20 and the handle alignment member 504 may be aligned when the actuators 21, 22, and 23 are in their home positions.

[0129] In one example, as shown in FIGS. 12-28 , the handle alignment member 504 may extend from the handheld portion 16. The handle alignment member 504 may include a handle alignment portion 524 that defines a handle alignment plane 526 (shown in FIG. 17 ) that provides an operator of the instrument 14 with a visual indication of the pose of the handheld portion 16. In particular, the handle alignment plane 526 is aligned with the tool alignment plane 512 when the actuators 21, 22, and 23 are in their respective home positions. The handle alignment member 504 may be of any suitable shape or configuration that provides a user with a visual indication that one or more of the actuators 21, 22, and 23 have moved from their respective home positions. In some examples, as shown in FIGS. 12-28 , the handle alignment portion 524 of the handle alignment member 504 defines a planar rectangular member having a length, height, and width that define a three-dimensional shape. By exposing certain features of the handle alignment member relative to the tool alignment member 502, the relative shape and size of the handle alignment member 504 provides a visual indication when the actuators 21, 22, 23 have been moved from their respective home positions.

[0130] 15 and 16 , the handle alignment member 504 may also include a mounting collar 516 including a first portion 518 and a second portion 520. Collectively, the first and second portions 518, 520 form the mounting collar 516 and are configured to be coupled to one another to attach the handle alignment member 504 to the grip 72 of the handheld portion 16. The first and second portions 518, 520 may be coupled using any suitable means. In some examples, fasteners such as screws, bolts, clamps, etc., or combinations thereof, may be used. The mounting collar 516 may be attached to the handheld portion 16 in any suitable location to facilitate function of the handle alignment member 504 (described in more detail below). Additionally, as best shown in FIG. 16 , the handle alignment member 504 may be removably coupled to the mounting collar 516 of the handheld portion 16. For example, the handle alignment member 504 may be magnetically coupled to the handheld portion 16 so that the handle alignment member 504 can be separated as needed or if an operator's hand becomes pinched between the tool alignment member 502 and the handle alignment member 504. Any suitable means for removably coupling the handle alignment member 504 to the handheld portion is contemplated (e.g., magnets, latches, clips, fasteners, hook and loop, etc., and combinations thereof).

[0131] The handle alignment member 504 may also include a support arm 522. The support arm 522 may extend from the mounting collar 516 to support a handle alignment portion 524. In particular, as best shown in FIGS. 12-17 , the support arm 522 extends upward from the grip 72 of the handheld portion 16 so that the handle alignment portion 524 of the handle alignment member 504 is aligned with the tool alignment portion 510 of the tool alignment member 502 when the actuators 21, 22, and 23 are in their respective home positions. In some examples, the handle alignment member 504 is rigid relative to the handheld portion 16 to facilitate function of the handle alignment member 504. The handle alignment member 504 may be formed from any suitable material, such as plastic, aluminum, steel, composites, etc., or combinations thereof. Furthermore, the handle alignment member 504 may be formed using any suitable manufacturing method, including 3D printing, casting, machining, injection molding, stamping, etc., or combinations thereof.

[0132] In some configurations, the guidance array 500 may include two or more tool alignment members and two or more handle alignment members. In some examples, the guidance array 500 may include a first tool alignment member 502 and a second tool alignment member 528. Similarly, in some examples, the guidance array 500 may include a first handle alignment member 504 and a second handle alignment member 530. In some examples, it is contemplated that there may be four or more, six or more, or even multiple tool alignment members and handle alignment members, respectively. For example, with reference to FIGS. 12-28, in some configurations, the first alignment members 502, 504 and the second alignment members 528, 530 extend from opposite sides of the handheld portion 16 and have mirror image arrangements. 17 , when the actuators 21, 22, 23 are in their respective home positions, both the first tool alignment member 502 and first handle alignment member 504, and the second tool alignment member 528 and second handle alignment member 530, respectively, are aligned with one another, providing a visual indication that the blade support 18 has a desired range of motion relative to the handheld portion 16. In particular, the alignment members 502, 504, 528, 530 may be of any suitable shape to provide an indication of the alignment of the tool alignment members 502, 528 with respect to the handle alignment members 504, 530, respectively. For example, the alignment members 502, 504, 528, 530 may be generally flat, prism-shaped, define protrusions to aid in the visual indication (e.g., define an "X" cross section, define an "L" cross section), cylindrical, spherical, etc., or combinations thereof.

[0133] Additionally, the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 (which may be collectively referred to as the guidance array 500) are arranged around the blade support 18 and handheld portion 16 such that the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 are visible from the proximal end 560 of the blade support 18 throughout the range of motion of the blade support 18 relative to the handheld portion 16. In other words, the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 are configured to be visible to an operator holding the instrument 14 such that the operator has a line of sight to the first and second tool alignment members 502, 528 and the first and second handle alignment members 504, 530 throughout the range of motion of the blade support 18 relative to the handheld portion 16. Furthermore, the guidance array 500 may be positioned such that in all cutting positions of the instrument 14 (e.g., during distal femoral cutting or posterior cutting), the guidance array 500 provides a visual indication of the pose of the blade support 18 relative to the handheld portion 16.

[0134] During operation of the instrument 14, the target plane TP of the instrument 14, at least one of the tool alignment members 502, 528, and at least one of the handle alignment members 504, 530 may be arranged to be aligned in a first spatial relationship when the tool 20 is in the target plane TP and the actuators 21, 22, 23 are in their respective home positions. As shown in the configuration illustrated in FIG. 17, for example, when the tool alignment plane 512, the handle alignment plane 526, and the target plane TP are coplanar, the target plane TP, the tool alignment members 502, 528, and the handle alignment members 504, 530 are arranged in a first spatial relationship. 17 , when the tool alignment members 502, 528 and the handle alignment members 504, 530 are arranged in a first spatial relationship, the “U”-shaped tool alignment portion 510 surrounds the rectangular handle alignment portion 524, and the top surfaces 503, 505 of both the tool alignment portion 510 and the handle alignment member portion 524, respectively, are coplanar, indicating that the actuators 21, 22, 23 are in their home positions. The first spatial relationship provides a visual indication that the tool 20 is aligned with the target plane TP and that the actuators 21, 22, 23 are in their home positions, and provides the handheld surgical robotic system with maximum adjustment of pitch, roll, and z-axis translation (i.e., height) to maintain the tool 20 on the target plane TP, so that the actuators 21, 22, 23 have the maximum amount of adjustability to maintain the tool 20 at a desired pose.

[0135] In particular, to facilitate visual indication throughout the range of motion of the actuators 21, 22, 23, the tool alignment members 502, 528 and the handle alignment members 504, 530 are positioned and sized relative to one another so as to avoid collision between the tool alignment members 502, 528 and the handle alignment members 504, 530 at any point between the first and second positions of each of the plurality of actuators 21, 22, 23. Collectively, the first and second positions of each of the plurality of actuators 21, 22, 23 define a potential range of motion of the blade support 18 relative to the handheld portion 16. The potential range of motion may define a space within which the blade support 18 may move relative to the handheld portion 16. For example, FIGS. 52 and 53 show potential positions of the blade support 18 relative to the handheld portions stacked on top of one another. In one configuration, for example, the blade support 18 may move relative to the handheld portion 16 within a space having a height of approximately 150 mm and a width of approximately 115 mm. It is contemplated that the height and width of the space may vary based on the geometry of the instrument 14 and the limitations of the actuators 21, 22, 23.

[0136] Additionally, during operation of the instrument 14, when the blade support 18 is in a pose that does not provide the desired range of motion relative to the handheld portion 16 (shown in FIGS. 18-28 ), at least one of the tool alignment members 502, 528 and at least one of the handle alignment members 504, 530 may be positioned out of alignment with one another in a second spatial relationship. The second spatial relationship provides a visual indication that the blade support 18 is in a pose relative to the handheld portion 16 that does not provide the desired range of motion for the instrument 14, and therefore indicates that the operator should adjust the pose of the handheld portion 16 so that the tool alignment members 502, 528 and the handle alignment members 504, 530 are aligned in the first spatial relationship to provide maximum adjustability for the instrument 14. Notably, the addition of the second tool alignment member 528 and the second handle alignment member 530 serves to further assist in providing a visual indication of the pose of the blade support 18 relative to the handheld portion 16.

[0137] There are various scenarios in which the tool alignment members 502, 528 may be misaligned with the handle alignment members 504, 530 in the second spatial relationship. For example, the blade support 18 may pitch relative to the handheld portion 16 about the lateral axis 558 (shown in FIGS. 18-21 ), the blade support 18 may roll relative to the handheld portion 16 about the longitudinal axis 552 (shown in FIGS. 22-24 ), and / or the blade support 18 may move (i.e., lift) along the vertical axis 554 relative to the handheld portion 16 (shown in FIGS. 25-28 ). It should be appreciated that other misalignments are possible resulting from movement of the blade support 18 relative to the handheld portion 16 in other degrees of freedom. It should also be appreciated that combinations of the above-mentioned misalignments may occur simultaneously. For example, the blade support 18 may be pitched and rolled relative to the handheld portion 16 at the same time. When the tool alignment member 502 is misaligned with respect to the handle alignment member 504, the resulting second spatial relationship provides a visual indication of the pose of the blade support 18 relative to the handheld portion 16, even if the misalignment occurs in multiple degrees of freedom.

[0138] In some configurations, the first spatial relationship may provide a visual indication that the blade support 18 is aligned in the pitch degree of freedom relative to the handheld portion 16 about the lateral axis 558. However, as described above, the multiple actuators 21, 22, 23 may be configured to adjust at least the pitch of the blade support 18 relative to the handheld portion 16 to maintain the tool 20 over the target plane TP. For example, FIGS. 18-21 illustrate that the blade support 18 is pitched a predetermined amount relative to the handheld portion 16 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability. When the blade support 18 is pitched relative to the handheld portion 16 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability, at least one of the tool alignment members 502, 528 may be out of alignment with at least one of the handle alignment members 504, 530, respectively, in a second spatial arrangement. The second spatial arrangement may include a pitch relationship. The pitch relationship may provide a visual indication of the magnitude of the pitch of the blade support 18 relative to the handheld portion 16 about the lateral axis.

[0139] 18-21, the tool alignment member 502 and the handle alignment member 504 may be disposed in a pitch relationship when the distal portion 542 of the handle alignment member 504 is farther from the blade plane BP (shown as distance D1) in the direction of pitch along the longitudinal axis 552 of the handle alignment member 504 than the proximal portion 544 of the handle alignment member 504 (shown as distance D2). Also, for example, as best shown in FIG. 21, when the second tool alignment member 528 is pitched relative to the second handle alignment member 530 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the longitudinally distal portion 542 of the second handle alignment member 530 is farther from the blade plane BP (shown as distance D3) in the direction of pitch along the longitudinal axis 552 of the second handle alignment member 530 than the longitudinally proximal portion 544 of the second handle alignment member 530 (shown as distance D4). In other words, when the blade support 18 is pitched relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one end of the handle alignment members 504, 528 is farther from the blade plane BP in the direction of movement along the longitudinal axis of the tool 20 than the other end. Thus, the arrangement of the alignment members 502, 504, 528, 530 in a pitch relationship may provide a visual indication that the blade support 18 does not have a desired range of motion relative to the handheld portion 16 and that the operator must adjust the pose of the handheld portion 16 so that the tool alignment members 502, 528 and the handle alignment members 504, 530 are aligned in the first spatial relationship, providing maximum adjustability for the instrument 14.

[0140] In other configurations, the first spatial relationship may provide a visual indication that the blade support 18 is aligned in the roll degree of freedom relative to the handheld portion 16 about the longitudinal axis 552. The multiple actuators 21, 22, 23 may be configured to adjust the roll of at least the blade support 18 relative to the handheld portion 16 to maintain the tool 20 on the target plane TP. For example, FIGS. 22-24 show the blade support 18 rolled relative to the handheld portion 16 a predetermined amount such that the multiple actuators 21, 22, 23 no longer have maximum adjustability. When the blade support 18 is rolled relative to the handheld portion 16 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability, at least one of the tool alignment members 502, 528 may be misaligned with the handle alignment members 504, 530, respectively, in the second spatial arrangement. The second spatial arrangement may include a roll relationship. The roll relationship may provide a visual indication of the amount of roll of the blade support 18 relative to the handheld portion 16 about the longitudinal axis 552 .

[0141] 22-24, the tool alignment member 502 and the handle alignment member 504 may be disposed in a roll relationship when the distal portion 546 of the handle alignment member 504 is farther from the blade plane BP (shown as distance D1) in the direction of roll along the lateral axis 558 of the handle alignment member 504 than the proximal portion 548 of the handle alignment member 504 (shown as distance D2). Also, for example, FIG. 24 shows the laterally distal portion 546 of the second handle alignment member 530 (shown as distance D3) farther from the blade plane BP than the laterally proximal portion 548 of the second handle alignment member 530 (shown as distance D4) along the lateral axis 558 in the direction of roll. 24 , the combination of the second spatial relationship of the first tool alignment member 502 to the first handle alignment member 504 and the second spatial relationship of the second tool alignment member 528 to the second handle alignment member 530 may provide a further visual indication of the pose of the blade support 18 relative to the handheld portion 16 than simply the first tool alignment member 502 to the first handle alignment member 504. In particular, the first handle alignment member 504 and the second handle alignment member 530 may cumulatively define a handle alignment plane 526 (shown in FIG. 24 ), which may be rolled relative to the tool alignment plane 512 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability, providing a visual indication of the pose of the blade support 18 relative to the handheld portion. Thus, the operator is provided with another visual indication that the blade support 18 does not have an optimal range of motion relative to the handheld portion 16. In other words, when the blade support 18 is rolled relative to the handheld portion 16 so that the multiple actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment members 504, 528 is moved further from the blade plane BP in the direction of deviation than the other side of the handle alignment members 504, 528.Thus, the arrangement of the alignment members 502, 504, 528, 530 in a roll relationship may provide a visual indication that the blade support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the pose of the handheld portion 16 so that the tool alignment member 502 and the handle alignment member 504 are aligned in a first spatial relationship, providing maximum adjustability for the instrument 14.

[0142] In an additional configuration, the first spatial relationship may provide a visual indication that the blade support 18 does not have any vertical displacement (i.e., height) relative to the handheld portion 16 about the vertical axis 554. The multiple actuators 21, 22, 23 may be configured to adjust at least the height of the blade support 18 relative to the handheld portion 16 to maintain the tool 20 over the target plane TP. For example, FIGS. 25-28 show the blade support 18 elevated a predetermined amount relative to the handheld portion 16 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability. When the blade support 18 is elevated relative to the handheld portion 16 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability, at least one of the tool alignment members 502, 528 may not be aligned with at least one of the handle alignment members 504, 530, respectively, in the second spatial arrangement. The second spatial arrangement may include a height relationship. The height relationship may provide a visual indication of the height magnitude of the blade support 18 relative to the handheld portion 16. For example, as shown in FIGS. 25-28 , the tool alignment member 502 and the handle alignment member 504 may be disposed in a height relationship when the tool alignment member 502 is moved in a height direction above the handle alignment member 504 by a distance D1. Also, for example, FIGS. 26 and 28 show the second handle alignment member 530 moved above the second tool alignment member 528 by a distance D3. Thus, the placement of the alignment members 502, 504, 528, and 530 in a height relationship may provide a visual indication that the blade support 18 does not have a desired range of motion relative to the handheld portion 16 and that the operator should adjust the pose of the handheld portion 16 so that the tool alignment members 502, 528, and the handle alignment members 504, 530 are aligned in the first spatial relationship, providing maximum adjustability for the instrument 14.

[0143] In view of the above discussion, it should be appreciated that the guidance array 500 provides many benefits to the operation of the instrument 14. For example, the guidance array 500 reduces the amount of focus shift required for the operator to ascertain the pose of the blade support 18 relative to the handheld portion 16. In other words, the guidance array 500 is positioned relative to the tool 20 so that the guidance array 500 is substantially within the operator's line of sight, so that the operator does not need to substantially shift their focus (e.g., rotate their head) to receive visual indication of the pose of the blade support 18 relative to the handheld portion 16. At the same time, while the guidance array 500 is substantially within the operator's line of sight, the guidance array 500 is positioned toward the proximal portion 560 of the tool support so that the user can view the guidance array 500 and the distal tip of the tool 20, thereby allowing the user to simultaneously focus on cutting and alignment. In other words, the guidance array 500 is positioned a specific distance from the distal tip of the tool 20 so that the user has an unobstructed view of the surgical site and the tool 20. Additionally, the guidance array 500 provides the operator with an easily identifiable visual indication of the pose of the blade support 18 relative to the handheld portion 16, reducing the need for auxiliary components (e.g., auxiliary navigation displays) to provide the visual indication. Also, the guidance array 500 has minimal parallax. Furthermore, because the guidance array 500 provides visual indication primarily through mechanical structures, there is no delay in providing operational visual indication compared to electronic navigation.

[0144] 29-32 illustrate alternative configurations of the guidance array 600. In the illustrated configuration of the guidance array 600, the tool alignment member 602 may include a tool alignment portion 610 that defines a cylindrical shape. Similarly, the handle alignment member 604 may include a handle alignment portion 624 that defines a cylindrical shape. As shown in the configuration illustrated in FIG. 32, for example, when the tool alignment portion 610, the handle alignment portion 624, and the target plane TP intersect, the target plane TP, the tool alignment member 602, and the handle alignment member 604 are disposed in a first spatial relationship, providing a visual indication that the tool 20 is aligned with the target plane TP and that the actuators 21, 22, and 23 are in their respective home positions. In one configuration, the term "intersect" is defined as at least a portion of the tool alignment member 602 and at least a portion of the handle alignment member 604 being substantially aligned (as described above) when viewed from the proximal end 560 of the handheld surgical system 10 within an appropriate tolerance range. 32 , the tool alignment portion 610 and the handle alignment portion 624 may include markings in the form of a first color 666 and a second color 668, respectively. The markings (666, 668) on the tool alignment portion 610 and the handle alignment portion 624 function to provide a visual indication of the alignment of the blade support 18 relative to the handheld portion 16. For example, when the marks (666, 668) are aligned such that they overlap when viewed by an operator from the proximal end 560 of the handheld instrument 14 (as shown in FIG. 32 ), the operator is provided with a visual indication that the blade support 18 has the maximum range of adjustability relative to the handheld portion 16. In particular, the marks (666, 668) each have a length that defines an appropriate overlap tolerance for the blade support 18 to have an optimal range of movement relative to the handheld portion 16. The tool alignment member 602 and the handle alignment member 604 may be arranged so that they are not aligned in a second spatial relationship when the blade support 18 is in a pose that does not provide the desired range of motion for the handheld portion 16 (as described above).30 and 31, the handle alignment member 604 may also be removably coupled to the handheld portion 16. For example, the handle alignment member 604 may be magnetically coupled to the handheld portion 16 such that the handle alignment member 604 may be detached as needed. However, any suitable means for removably coupling the handle alignment member 604 to the handheld portion is contemplated (e.g., latches, clips, fasteners, hook and loops, etc., and combinations thereof).

[0145] In particular, the guidance array 600 may include a second tool alignment member 628 and a second handle alignment member 630 to provide further indication of the pose of the blade support 18 relative to the handheld portion 16. For example, when the blade support 18 is rolled a predetermined amount in a predetermined direction relative to the handheld portion 16 away from the configuration shown in FIG. 32 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment members 604, 628 will be moved further from the blade plane BP than the other side of the handle alignment members 604, 628 in the direction of deviation. In other words, the mark 668 on the handle alignment portion 624 moves away from the mark 666 on the tool alignment portion 610 in the direction of deviation, misaligning the handle alignment portion 624 with respect to the tool alignment portion 610, providing a visual indication that the blade support 18 does not have the desired range of motion with respect to the handheld portion 16, and that the operator must adjust the pose of the handheld portion 16 so that the tool alignment members 602, 628 and the handle alignment members 604, 630 are aligned in the first spatial relationship, providing maximum adjustability for the instrument 14. Similarly, the second tool alignment member 628 and the second handle alignment member 630 provide further indication of the pose of the blade support 18 with respect to the handheld portion 16 in pitch and height degrees of freedom.

[0146] 33 and 34 show yet another configuration of the guidance array 600′. In the shown configuration of the guidance array 600′, the tool alignment member 602′ may include a tool alignment portion 610′ that defines a spherical shape. Similarly, the handle alignment member 604′ may include a handle alignment portion 624′ that defines a spherical shape. In some configurations, such as that shown in FIG. 34 , the tool alignment portion 610′ is disposed in the blade plane BP. As shown in the configuration shown in FIG. 34 , for example, when the tool alignment portion 610′, the handle alignment portion 624′, and the target plane TP intersect, the target plane TP, the tool alignment member 602′, and the handle alignment member 604′ are disposed in a first spatial relationship, providing a visual indication that the tool 20 is aligned with the target plane TP and that the actuators 21, 22, and 23 are in their respective home positions. 34 , the tool alignment portion 610′ and the handle alignment portion 624′ may be sized so that an operator can easily identify that they are aligned when viewing the guidance array 600′ from the proximal end 560 of the instrument 14, providing a visual indication that the blade support 18 has an optimal amount of movement relative to the handheld portion 16. Additionally, the tool alignment member 602′ and the handle alignment member 604′ may be positioned such that they are not aligned in a second spatial relationship when the blade support 18 is in a pose that does not provide the desired range of motion relative to the handheld portion 16 (as described above). In particular, the guidance array 600′ may include a second tool alignment member 628′ and a second handle alignment member 630′ to provide further indication of the pose of the blade support 18 relative to the handheld portion 16.

[0147] In particular, the guidance array 600' may include a second tool alignment member 628' and a second handle alignment member 630' to provide further indication of the pose of the blade support 18 relative to the handheld portion 16. For example, when the blade support 18 is rolled a predetermined amount relative to the handheld portion 16 away from the configuration shown in FIG. 34 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment members 604', 628' is moved further from the blade plane BP in the direction of deviation than the other side of the handle alignment members 604', 628'. In other words, the spherical handle alignment portion 624' moves away from the spherical tool alignment portion 610' in the direction of deviation, misaligning the spherical handle alignment portion 624' relative to the spherical tool alignment portion 610', providing a visual indication that the blade support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the pose of the handheld portion 16 so that the tool alignment members 602', 628' and handle alignment members 604', 630' are aligned in the first spatial relationship, providing maximum adjustability for the instrument 14. Similarly, the second tool alignment member 628' and second handle alignment member 630' provide further indication of the pose of the blade support 18 relative to the handheld portion 16 in pitch and height degrees of freedom.

[0148] 35-37 show another example of a guidance array 600″. In the shown example of the guidance array 600″, the tool alignment member 602″ includes a tool alignment portion 610″ and the handle alignment member 604″ includes a handle alignment portion 624″. Notably, however, as shown in the configuration shown in FIG. 36 , when the tool alignment member 602″ and the handle alignment member 604″ are disposed in a first spatial relationship, the tool alignment portion 610″ and the handle alignment portion 624″ may be offset from the blade plane BP so that the tool alignment member 602″ and the handle alignment member 604″ do not obstruct the line of sight of the surgical navigation system 32 to any tracking marks 584 (as described below). For example, as shown in FIG. 36 , the tool alignment portion 610″ and the handle alignment portion 624″ are aligned along a plane defined between the blade plane BP and the grip 72 of the handheld portion 16. In other words, in the configurations shown in FIGS. 35-37 , when the tool alignment member 602″ and the handle alignment member 604″ are positioned in a first spatial relationship such that they are aligned (i.e., substantially parallel), the tool alignment portion 610″ and the handle alignment portion 624″ are not coplanar with the blade plane BP. However, when the tool alignment member 602″ and the handle alignment member 604″ are positioned in the first spatial relationship, the tool alignment portion 610″ and the handle alignment portion 624″ are parallel to the blade plane BP, providing a visual indication that the tool 20 is aligned with the target plane TP and that the actuators 21, 22, and 23 are in their home positions. Also, when the blade support 18 is in a pose that does not provide the desired range of motion for the handheld portion 16 (as described above), the tool alignment member 602″ and the handle alignment member 604″ may be positioned so that they are not aligned in the second spatial relationship. In particular, the guidance array 600 ″ may include a second tool alignment member 628 ″ and a second handle alignment member 630 ″ to provide further guidance of the pose of the blade support 18 relative to the handheld portion 16 .

[0149] In particular, the guidance array 600'' may include a second tool alignment member 628'' and a second handle alignment member 630'' to provide further indication of the pose of the blade support 18 relative to the handheld portion 16. For example, when the blade support 18 is rolled a predetermined amount relative to the handheld portion 16 away from the configuration shown in FIG. 37 so that the multiple actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment members 604'', 628'' will be moved further from the tool alignment plane 512 in the direction of the deviation than the other side of the handle alignment members 604'', 628''. In other words, the handle alignment portion 624'' moves away from the tool alignment portion 610'' in the direction of deviation, misaligning the handle alignment portion 624'' relative to the tool alignment portion 610'', providing a visual indication that the blade support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the pose of the handheld portion 16 so that the tool alignment members 602'', 628'' and the handle alignment members 604'', 630'' are aligned in the first spatial relationship, providing maximum adjustability for the instrument 14. Similarly, the second tool alignment member 628'' and the second handle alignment member 630'' provide further indication of the pose of the blade support 18 relative to the handheld portion 16 in pitch and height degrees of freedom.

[0150] 38 and 39 show further configurations of guidance array 600'". In the shown configuration of guidance array 600'", tool alignment member 602'" includes tool alignment portion 610'", and handle alignment member 604'" includes handle alignment portion 624'". Notably, however, unlike the configurations shown in FIGS. 12-28 and 35-37, where tool alignment member 602'" aligns with only one side of handle alignment member 604'", in the configurations of FIGS. 12-28 and 39-42, tool alignment member 502 aligns with both the distal and proximal ends of handle alignment member 504. As shown in the configuration illustrated in FIG. 39 , for example, when the tool alignment portion 610′″, handle alignment portion 624′″, and target plane TP are aligned, the target plane TP, tool alignment member 602′″, and handle alignment member 604′″ are positioned in a first spatial relationship to provide a visual indication that the tool 20 is aligned with the target plane TP and that the actuators 21, 22, and 23 are in their respective home positions. Additionally, the tool alignment member 602′″ and handle alignment member 604′″ may be positioned such that they are not aligned in a second spatial relationship when the blade 18 is in a pose that does not provide the desired range of motion relative to the handheld portion 16 (as described above). In particular, the guidance array 600′″ may include a second tool alignment member 628′″ and a second handle alignment member 630′″ to provide further indication of the pose of the blade support 18 relative to the handheld portion 16.

[0151] In particular, the guidance array 600''' may include a second tool alignment member 628''' and a second handle alignment member 630''' to provide further indication of the pose of the blade support 18 relative to the handheld portion 16. For example, when the blade support 18 is rolled a predetermined amount relative to the handheld portion 16 away from the configuration shown in FIG. 39 so that the multiple actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment members 604''', 628''' will be moved further from the blade plane BP than the other side of the handle alignment members 604''', 628''' in the direction of deviation. In other words, the handle alignment portion 624''' moves away from the tool alignment portion 610''' in the direction of deviation, misaligning the handle alignment portion 624''' relative to the tool alignment portion 610''', providing a visual indication that the blade support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the pose of the handheld portion 16 so that the tool alignment members 602''', 628''' and handle alignment members 604''', 630''' are aligned in the first spatial relationship, providing maximum adjustability for the instrument 14. Similarly, the second tool alignment member 628''' and second handle alignment member 630''' provide further indication of the pose of the blade support 18 relative to the handheld portion 16 in pitch and height degrees of freedom.

[0152] 29-39 and 51, the tool alignment members 602, 602', 602'', 602''' may be integrally formed with a tool tracker 574 of a surgical navigation system that may be removably coupled to the blade support 18. Forming the tool alignment members 602, 602', 602'', 602''' integrally with the tool tracker 574 reduces the mounting space required on the blade support 18 and allows the tool tracker to be closer to the tip of the tool 20, facilitating more accurate surgical navigation. The tool tracker 574 may include side walls 580 attached to a cross member 582, with each side wall 580 including one or more of a plurality of markers 584. In some configurations, the plurality of markers may be arranged in a mirror image configuration on each side wall 580. The side walls 580 may be shaped to match the profile of the blade support 18. Additionally, in some configurations, the markers 584 may be active, passive, or a combination thereof. In other configurations, the markers 584 may be positioned on the tool alignment members 602, 602', 602'', 602''' to improve line of sight with the surgical navigation system 32. To attach the tool tracker 574 to the blade support 18, the tool tracker 574 may include a guide slot 576, and the blade support 18 may include a guide rail 578 at the distal end of the blade support 18 (shown in FIG. 35 ). The guide slot 576 of the tool tracker 574 is sized to receive the guide rail 578 of the blade support 18, allowing the tool tracker 574 to be connected to the distal end of the blade support 18.

[0153] Additionally, the tool alignment member 602 and / or the handle alignment member 604 may include one or more visual indicia. For example, as shown in FIGS. 32 and 34 , in some configurations, the tool alignment member 602 includes at least a first visual indicia 562 and the handle alignment member 604 includes at least a second visual indicia 564. In particular, the first visual indicia 562 is visually distinguishable from the second visual indicia 564. For example, in the version shown in FIGS. 32 and 34 , the first visual indicia 562 may be positioned such that it is visible from the proximal end 560 of the handheld portion 16 when the tool alignment member 602 and the handle alignment member 604 are unaligned (i.e., in the second spatial arrangement). Conversely, the second visual indicia 564 is positioned such that it is visible from the proximal end 560 of the handheld portion 16 when the tool alignment member 602 and the handle alignment member 604 are aligned (i.e., in the first spatial arrangement). Thus, first visual indicator 562 and second visual indicator 564 provide the operator with a readily discernible visual indication of the alignment of tool alignment member 602 relative to handle alignment member 604. In some versions, the visual indicia include one or more visual cues (e.g., a pattern, a light, a color, a combination thereof, etc.). For example, with reference to FIG. 32 , the visual indicia may include colored marks 666, 668.

[0154] 47-48, the tool alignment member 502 and the handle alignment member 504 each have a first visual indicia 562 and a second visual indicia 564. For example, the first visual indicia 562 may be a first color 566, and the second visual indicia 564 may be a second color 568. In this configuration, the first color 566 is visible along the edges where the tool alignment member 504 and the handle alignment member 504 abut when the tool alignment member and the handle alignment member 504 are aligned (best shown in FIGS. 35, 37, and 40), and conversely, at least one of the second visual indicia 564 is visible along the edges where the tool alignment member 504 and the handle alignment member 504 abut when the tool alignment member 502 and the handle alignment member 504 are not aligned (best shown in FIG. 40). To facilitate this configuration, the top surface 503 of the tool alignment member 502 and the top surface 505 of the handle alignment member 504 may include a first visual indicia 562. Similarly, the side surface 570 of the tool alignment member 502 and the side surface 572 of the handle alignment member 504 may include a second visual indicia 564 such that the second visual indicia 564 appears when the tool alignment member 502 and the handle alignment member 504 are misaligned with one another, providing an indication that one or more of the plurality of actuators 21, 22, 23 have moved from their home positions. The visual indicia 562, 564 allow an operator to quickly distinguish between the surfaces of the tool alignment member 502 and the handle alignment member 504 to quickly identify if the tool alignment member 502 and the handle alignment member 504 are misaligned. For example, as shown in FIG. 40, when the tool alignment member 502 and the handle alignment member 504 are misaligned, at least one of the second visual indicia 564 (in the form of a second color 568 and provided on the side 572) is visible, providing an indication that one or more of the plurality of actuators 21, 22, 23 has moved from the home position.

[0155] 42 and 43 , the instrument 14 may include an illuminator 586, such as an LED, at any suitable location within the operator's line of sight, such as on the tool alignment member 502, the handle alignment member 504, or the blade support 18. The illuminator 586 may be configured to illuminate when the blade support 18 has a desired range of motion, providing a visual indication that the blade support 18 and handheld portion 16 are within a specified range of alignment with the target plane TP. For example, the illuminator 586 may be configured to indicate that the actuators 21, 22, and 23 are in a first spatial arrangement (i.e., have a desired range of motion). Alternatively, the illuminator 586 may be configured to illuminate when the blade support 18 is in a second spatial arrangement. For example, when the first visual indicator 201 is activated to indicate that movement of the handheld portion 16 is required, the visual indicator 201 indicates that one or more of the actuators 21, 22, 23 are too far from the home position and are not aligning the tool alignment member with the handle alignment member, indicating that the handheld portion 16 needs to be moved.

[0156] In some examples, the controller may control the light emitters 586 based on the commanded positions of the actuators 21, 22, 23 and the available travel of the actuators 21, 22, 23. For example, a first color may be based on a first range of travel within the operating range of the actuators 21, 22, 23 and the commanded positions of the actuators 21, 22, 23, and a second color may be a second range of travel within the operating range of the actuators 21, 22, 23 and the commanded positions of the actuators 21, 22, 23 that is different from the first range of travel. A third color may also be included that represents a third range of travel of the actuators 21, 22, 23 within the available travel, the third range of travel being different from the second range of travel. For example, a first color may be red and correlate to a commanded position of the actuators 21, 22, 23 closest to the outer limits of the available travel, a second color may be yellow and correlate to a commanded position of the actuators 21, 22, 23 further away from the outer limits of the available travel, and a third color may be green and indicate that the commanded position of the actuators 21, 22, 23 is away from the limits of the available range of travel.

[0157] In a further example, the colors associated with the light 586 may represent multiple actuator parameters, such that the light 586 communicates to the user a first color representing the amount of movement required to bring at least one actuator 21, 22, 23 to a commanded position and a second color representing the direction required to move the handheld portion 16 to bring the tool 20 into the actuator's operating range. As described above, the third color may correspond to the outermost range of available movement (i.e., the least remaining movement available relative to the commanded position), the second color may correspond to the middle range of available movement, and the first color may correspond to the innermost range of available movement (i.e., the most remaining movement available relative to the commanded position). In some examples, the light 586 is configured to be divided into two or more sections. Each respective section may illuminate in a different state to indicate the desired direction of movement of the handheld portion 16. In some versions, the illumination of the upper and lower portions of the light 586 may be activated in the same state based on the commanded position and available movement of the handheld portion 16 .

[0158] Alternatively, the light emitter 586 or other indicia may be controlled based on one or more components of the commanded pose and one or more ranges of motion in a particular degree of freedom. More specifically, the light emitter 586 or other indicia may be controlled based on the pitch component of the commanded pose and the pitch range of motion. Alternatively, or in combination, the light emitter 586 may be controlled based on the roll component of the commanded pose and the roll range of motion. The pitch and roll ranges of motion may be defined by a series of overlapping ranges. The control system 60 may control the light emitter to emit a first color when the pitch component of the commanded pose is within the innermost range of the pitch range of motion and the roll component of the commanded pose is within the innermost range of the roll range of motion. Alternatively, the control system 60 may control the light emitter to emit light of a second color or to prevent power to the light emitter when the pitch component of the commanded pose is within a relatively outer range of the pitch range of motion or the roll component of the commanded pose is within a relatively outer range of the roll range of motion. By controlling light emitter 586 in this manner, a light indicia can indicate that the user is in a good pose with respect to pitch and roll or that the user needs to adjust one of the pitch and roll. Similarly, control system 60 may further emit a first color only if an additional condition exists, such as when the height component of the commanded pose is also within the innermost range of the height range of movement. Furthermore, control system 60 may control light emitter 586 to emit a second color of light or prevent power to light emitter 586 if any of the pitch, roll, or height components is outside the respective innermost range of movement. Although height, pitch, and roll are mentioned here, light emitter 586 can be controlled based on the respective ranges of the commanded pose components and movement in relative other degrees of freedom.

[0159] 44-50, in another configuration, the instrument 14 may include a shroud 700 coupled to and extending between the blade support 18 and the handheld portion 16. Specifically, as shown in FIGS. 29-39, the shroud 700 may be included in the instrument 14 along with the tool alignment member 502 and the handle alignment member 504. The shroud 700 may be formed from any suitable material, such as plastic, rubber, composites, or the like, or combinations thereof, that is compatible with a sterilization process, such as an autoclave sterilization process or a hydrogen peroxide sterilization process. The shroud 700 may be coupled to the blade support 18 and the handheld portion 16 using any suitable means, such as clamps, fasteners, adhesives, or the like, or combinations thereof. In some configurations, the shroud 700 may enclose at least one of the plurality of actuators 21, 22, 23. The shroud 700 may include accordion-like folds that can expand and curve when the blade support 18 moves relative to the handheld portion 16. Additionally, in some configurations, the shroud 700 defines at least two shroud landmarks 702 (described in more detail below). In some configurations, two or more, five or more, ten or more, or even multiple shroud landmarks 702 may be provided. As the blade support 18 moves relative to the handheld portion 16, the movement of the shroud landmarks 702 relative to one another provides a visual indication of the pose of the blade support 18 relative to the handheld portion 16. With particular reference to FIG. 45 , the instrument 14 may include one or more shroud alignment members 706 removably coupled to the handheld portion 16. For example, in some configurations, the instrument 14 may include at least two shroud alignment members 706. The shroud alignment members 706 may be transparent and may include shroud alignment marks 708. 47, the shroud alignment marks 708 may indicate when the actuators 21, 22, 23 are in their home positions and therefore the instrument 14 has an optimal range of motion. In some configurations, two or more, four or more, or even multiple shroud alignment members 706 may be provided.For example, FIGS. 47-50 show a handheld surgical robotic system that includes a second shroud alignment member 714 to provide an additional visual indication of the pose of the blade support 18 relative to the handheld portion 16.

[0160] In some configurations, the at least two shroud landmarks 702 include at least two folds 704. In some configurations, the folds 704 may be defined by accordion-like folds. The folds 704 may define a plane 716 (shown in FIG. 46 ) that provides a visual indication of the pose of the blade support 18 relative to the handheld portion 16. The folds 704, e.g., the plane 716, may be substantially parallel and offset a distance corresponding to the shroud alignment mark 708 such that in the first position 710, the plane 716 is aligned with the shroud alignment mark 708, providing a visual indication that the multiple actuators 21, 22, 23 are in their home positions and, therefore, the instrument 14 has an optimal range of motion. However, when the blade support 18 and handheld portion 16 are moved to the second position 712, the plane 716 may also move vertically and angularly, providing a visual indication that the blade support 18 does not have an optimal range of motion relative to the handheld portion 16.

[0161] 47-50 illustrate that, like tool alignment member 502 and handle alignment member 504, shroud 700 can be configured to provide the operator with a visual indication of the pose of blade support 18 relative to handheld portion 16. For example, FIG. 48 shows shroud 700 when blade support 18 is pitched relative to handheld portion 16. FIG. 49 shows shroud 700 when blade support 18 is rolled relative to handheld portion 16. FIG. 50 shows shroud 700 when blade support 18 is raised relative to handheld portion 16. In each of FIGS. 48-50, the pose of fold line 704 relative to shroud alignment mark 708 provides the operator with a visual indication of the pose of blade support 18 relative to handheld portion 16.

[0162] In some configurations, similar to the tool alignment member 502 and the handle alignment member 504, the at least two shroud landmarks 702 may include a first visual indicia 562 and a second visual indicia 564. Similarly, the first visual indicia 562 may be visually distinguishable from the second visual indicia 564 to provide the operator with an easily identifiable visual indication of the pose of the blade support 18 relative to the handheld portion 16. For example, the first visual indicia 562 may be a first color and the second visual indicia 564 may be a second color. In this configuration, the first color is visible when the blade support 18 is in a first position (i.e., when the multiple actuators 21, 22, 23 are in their home positions), and the second color is visible when the blade support 18 is in a second position (i.e., when the blade support 18 does not have an optimal range of motion relative to the handheld portion 16).

[0163] 54-77, the instrument 14 also includes a guidance array 900. The guidance array 900 provides the operator with a visual indication of the pose of the tool support 18 relative to the handheld portion 16 during operation of the instrument 14, and provides the operator with a visual indication of the required changes in pitch orientation, roll orientation, and z-axis translation of the handheld portion 16 to achieve the desired pose of the tool 20 while providing maximum adjustability for the actuator assembly 400 (described above) to maintain the tool 20 at the target plane TP. The guidance array 900 includes a handle alignment member 904 extending from the handheld portion 16 to provide visual indication to the operator to guide the operator as to how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, and 23 of the actuator assembly 400 near a home position or other predetermined position.

[0164] The handle alignment member 904 may be of any suitable shape or configuration that provides a visual indication to an operator user that one or more of the actuators 21, 22, 23 of the actuator assembly 400 have moved from their respective home positions. For example, with reference to FIGS. 54-77 , the handle alignment member 904 may include a handle alignment protrusion 906. The handle alignment protrusion 906 may extend toward the tool mount 18a. With particular reference to FIGS. 54-77 , the handle alignment protrusion 906 may be shaped such that at least a portion 908 of the handle alignment protrusion 906 is disposed at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18. For example, the handle alignment protrusion 906 may define a handle alignment edge 914 that is disposed at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18. The "oblique" angle of the handle alignment protrusion 906 relative to the longitudinal axis 910 and the lateral axis 912 may include, for example, disposing the handle alignment protrusion 906 at an angle greater than 0 degrees and less than 90 degrees relative to both the longitudinal axis 910 and the lateral axis 912. For example, the tool alignment protrusion 906 may define a tool alignment edge 914 having an angle of 45 degrees relative to the longitudinal and lateral axes 910, 912.

[0165] In one configuration, for example, as shown in FIGS. 54-77 , the handle alignment member 904 may define a hook-shaped handle alignment protrusion 906. The hook-shaped handle alignment protrusion 906 may define a curved handle alignment edge 914 that sweeps inward toward the tool support 18 to define the oblique angle. While the configurations in FIGS. 54-77 show a hook-shaped handle alignment protrusion 906, any suitable edge defining the oblique angle is contemplated, such as, but not limited to, a polygonal edge, a stepped edge, etc. In particular, as described in further detail below, the oblique angle of the handle alignment protrusion 906 relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18 may provide a user with more accurate insight into the pose of the tool support 18 relative to the handheld portion 16 in multiple degrees of freedom simultaneously.

[0166] In some configurations, such as those shown in FIGS. 54-57 , when the actuators 21, 22, and 23 of the actuator assembly 400 are in their respective home positions, at least a portion of the handle alignment protrusion 906 may be aligned with the tool plane BP, providing a visual indication to the operator that the tool support 18 has an optimal range of motion relative to the handheld portion 16. In one configuration, the term “aligned” is defined as at least a portion of the handle alignment protrusion 906 being substantially coplanar with or intersecting the tool plane BP within an appropriate tolerance range. In particular, in the home position, the amount of adjustability of the actuators 21, 22, and 23 of the actuator assembly 400 is maximized to maintain the tool 20 at a desired pose. In some examples, the alignment of at least a portion of the handle alignment protrusion 906 with the tool plane BP may be 99 percent or more aligned, 90 percent or more aligned, 70 percent or more aligned, or 60 percent or more aligned. In other examples, proper alignment may be within a specified proximity to the target pose, such as within 1 percent deviation from the target pose, 5 percent deviation from the target pose, 10 percent deviation from the target pose, or even 20 percent or more deviation from the target pose in each individual degree of freedom. Similarly, proper alignment may be within 1 mm of the target pose, within 2 mm of the target pose, or even 5 mm or more of the target pose in each individual degree of freedom. Additionally, proper alignment may be within 1 degree or more deviation from the target pose, 5 degrees or more deviation from the target pose, 15 degrees or more deviation from the target pose, or even 30 degrees or more deviation from the target pose in roll and / or pitch.

[0167] Conversely, when the handheld portion 16 is in a pose that does not provide an optimal range of motion, the tool plane BP and the handle alignment protrusion 906 are configured to be misaligned, providing a visual indication that the handheld portion 16 is in a pose that does not provide an optimal range of motion for the tool support 18 and therefore needs to be adjusted by the operator (described in more detail below). In some configurations, the guidance array 900 may also include a tool alignment member 902. In one configuration, for example, with reference to FIGS. 54-77 , the tool alignment member 902 may extend from the tool support 18. The tool alignment member 902 may have any shape or structure capable of providing a visual indication of the pose of the tool plane BP relative to the handle alignment member 904. For example, the tool alignment member 902 may include a tool alignment protrusion 916 that extends toward the tool mount 18a. 54-77, similar to the handle alignment protrusion 906, the tool alignment protrusion 916 may have at least a portion 920 disposed at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18. In some configurations, for example, the tool alignment protrusion 916 may define a tool alignment edge 918 that is oblique relative to the longitudinal axis 910 and lateral axis 912 of the tool 20.

[0168] It is contemplated that the optimal range of motion may be the maximum range of motion in one, two, three or more degrees of freedom. It is contemplated that the optimal range of motion may not necessarily be the maximum range of motion, but rather may be the range of motion desired for a preferred pose of the tool support for a particular cut with the saw, or other pre-planned virtual object, such as a planned cut or planned axis. The optimal range of motion need not be the center of the range of motion in one or more degrees of freedom, but may be the center of the range of motion in one, two or three degrees of freedom in some configurations.

[0169] For example, in one configuration as shown in FIGS. 54-77 , the tool alignment member 902 may define a hook-shaped tool alignment protrusion 916. The hook-shaped tool alignment protrusion 916 may define a curved tool alignment edge 918 that sweeps inward toward the tool support 18 to define the oblique angle described above. While the configurations in FIGS. 54-77 show a hook-shaped tool alignment protrusion 916, any suitable edge that defines the oblique angle is contemplated, such as, but not limited to, a polygonal edge, a stepped edge, etc. In particular, the hook-shaped tool alignment protrusion 916 and the hook-shaped handle alignment protrusion 906 may be configured to be aligned when the tool support 18 has an optimal range of motion relative to the handheld portion 16, and further configured to be unaligned when the handheld portion 16 is in a pose that does not provide the optimal range of motion for the tool support 18, providing a visual indication that the handheld portion 16 is in a pose that does not provide the optimal range of motion for the tool support 18.

[0170] In some examples, when the actuators 21, 22, 23 of the actuator assembly 400 are in their home positions, the tool alignment edge may be offset from and parallel to the handle alignment edge, providing a visual indication to the operator that the tool support 18 has a desired range of motion relative to the handheld portion 16. Also, in some examples, the tool alignment member 902 is positioned closer to the tool support 18 than the handle alignment member 906.

[0171] In some configurations, the tool alignment protrusion 916 is substantially aligned with the tool plane BP. For example, the tool alignment protrusion 916 may be coplanar with the tool plane BP. In this manner, the tool alignment protrusion 916 may serve as a visual indication of the orientation of the tool plane BP to facilitate providing a visual indication of the pose of the handheld portion 16 relative to the tool support 18. However, it is important to note that the handle alignment member 904 may function to provide a visual indication of the pose of the handheld portion 16 relative to the tool support 18 without the addition of the tool alignment member 902. In particular, a user may further appreciate the relationship of the tool support 18 to the handheld portion 16 by examining the relationship of the handle alignment member 904 to the tool 20.

[0172] The handle alignment member 904 may be removably coupled to the handheld portion 16. For example, the handle alignment member 904 may include a handle coupling portion 922 configured to couple to the handheld portion 16. As best shown in FIG. 58 , the handle coupling portion 922 of the handle alignment member 904 may be removably coupled to the handheld portion 16. For example, the handle coupling portion 922 may be magnetically coupled to the handheld portion 16 such that the handle alignment member 904 can be separated as needed or if an operator's hand is pinched between the handle alignment member 904 and the tool alignment member 902 and / or tool support 18. Any suitable means for removably coupling the handle alignment member 904 to the handheld portion 16 is contemplated (e.g., magnets, latches, clips, fasteners, hook and loops, etc., and combinations thereof).

[0173] The handle alignment member 904 may also include a support arm 924. The support arm 924 may extend from the handle coupling portion 922 to support the handle alignment member 904. In particular, as best shown in FIGS. 54-58 , the support arm 924 extends upward from the grip 72 of the handheld portion 16 so that the handle alignment member 904 is aligned with the tool plane BP when the actuators 21, 22, and 23 of the actuator assembly 400 are in their home positions. In some examples, the handle alignment member 904 is rigid with respect to the handheld portion 16 to facilitate function of the handle alignment member 904. The handle alignment member 904 may be formed from any suitable material, such as plastic, aluminum, steel, composites, etc., or combinations thereof. Furthermore, the handle alignment member 904 may be formed using any suitable manufacturing method, including 3D printing, casting, machining, injection molding, stamping, etc., or combinations thereof.

[0174] 58 , the tool alignment member 902 may also include a tool coupling portion 926 configured to be coupled to the tool support 18. The tool coupling portion 926 may be attached to the tool support 18 using any suitable means (e.g., fasteners, magnets, adhesive, etc.) in any suitable location to facilitate function of the tool alignment member 802. For example, the tool support 18 may include a tool mounting rail 928 extending laterally from the tool support 18. The tool coupling portion 926 of the tool alignment member 902 may define a tool mounting channel 930 configured to be engaged with the tool mounting rail 928 to removably secure the tool alignment member 902 to the tool support 18.

[0175] The tool alignment member 902 may further include a support portion 932. The support portion 932 may extend from the tool coupling portion 926 to support the tool alignment member 902. In some examples, the tool alignment member 902 may be rigid relative to the tool support 18 to facilitate function of the tool alignment member 902. The tool alignment member 902 may be formed from any suitable material, such as plastic, aluminum, steel, composite materials, etc., or combinations thereof. Furthermore, the tool alignment member may be formed using any suitable manufacturing method, including 3D printing, casting, machining, injection molding, stamping, etc., or combinations thereof.

[0176] In some configurations, the guidance array 900 may include two or more handle alignment members and two or more tool alignment members. Any number of corresponding tool alignment members and handle alignment members is contemplated. For example, the guidance array 900 may include a first handle alignment member 904 and a second handle alignment member 934 extending from the handheld portion 16 at a location spaced from the first handle alignment member 904. Similarly, the second handle alignment member 934 may include a second handle alignment protrusion 936. The second handle alignment protrusion 936 may extend toward the tool mount 18a. With particular reference to FIGS. 54-77 , the second handle alignment protrusion 936 may be shaped such that at least a portion 938 of the second handle alignment protrusion 936 is disposed at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18. For example, the second handle alignment protrusion 936 may define a second handle alignment edge 940 disposed at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18 .

[0177] In some examples, the guidance array 900 may include a first tool alignment member 902 and a second tool alignment member 942 extending from the handheld portion 16 at a location spaced apart from the first tool alignment member 902. For example, with reference to FIGS. 54-77, in some configurations, the first alignment members 902, 904 and the second alignment members 934, 942 extend from opposite sides of the handheld portion 16 and have mirror image arrangements.

[0178] The second tool alignment member 942 may include a second tool alignment protrusion 944 extending toward the tool mount 18. The second tool alignment protrusion 944 may have at least a portion 946 disposed at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18. In some configurations, for example, the second tool alignment protrusion 944 may define a second tool alignment edge 948 that is oblique relative to the longitudinal axis 910 and lateral axis 912 of the tool 20 / tool ​​support 18. In some examples, when the actuators 21, 22, 23 of the actuator assembly 400 are in their home positions, the second tool alignment edge 948 may be offset from and parallel to the second handle alignment edge 940, providing a visual indication to the operator that the tool support 18 has an optimal range of motion relative to the handheld portion 16. 54 and 56, when actuators 21, 22, 23 of actuator assembly 400 are in their home positions, handle alignment edges 914, 940 and tool alignment edges 918, 948 are offset from and parallel to one another. In particular, alignment members 902, 904, 934, 942 may be of any suitable shape to provide indication of alignment of tool alignment members 902, 934 relative to handle alignment members 904, 942, respectively. It is contemplated that in some instances, four or more, six or more, or even more tool alignment members and handle alignment members, respectively, may be provided.

[0179] 54-57 , the first tool alignment protrusion 916 and the first handle alignment protrusion 906, and the second tool alignment protrusion 942 and the second handle alignment protrusion 936 are aligned with each other when the actuators 21, 22, and 23 of the actuator assembly 400 are in their home positions, providing a visual indication that the tool support 18 has an optimal range of motion relative to the handheld portion 16. Conversely, the first tool alignment protrusion 916 and the first handle alignment protrusion 906, and the second tool alignment protrusion 944 and the second handle alignment protrusion 936 are configured to be misaligned with each other when the handheld portion 16 is in a pose that does not provide an optimal range of motion, providing a visual indication that the handheld portion 16 is in a pose that does not provide an optimal range of motion for the tool support 18 and therefore needs to be adjusted by the operator.

[0180] During operation of the instrument 14, the handle alignment protrusions 906, 936 and the tool plane BP may be positioned such that they are aligned in a first spatial relationship 950 when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions. For example, with reference to Figures 54-57, when the handle alignment protrusions 906, 936 and the tool plane BP are positioned in the first spatial relationship 950, the handle alignment protrusions 906, 936 and the tool plane BP are aligned to provide a visual indication that the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions.

[0181] Additionally, referring to FIG. 57, when the instrument 14 maintains the tool support 18 so that the tool 20 remains at the target plane TP, the target plane TP, the handle alignment protrusions 906, 936 and the tool plane BP are configured to be disposed in a first spatial relationship 950 when the handle alignment protrusions 906, 936, the tool plane BP and the target plane TP are aligned, providing a visual indication that the tool 20 is aligned with the target plane TP and that the actuators 21, 22, 23 are in their respective home positions so that the actuators 21, 22, 23 have a maximum amount of adjustability to maintain the tool 20 at a desired pose, and providing maximum adjustment of pitch, roll and z-axis translation (i.e., height) to the instrument 14 to maintain the tool 20 at the target plane TP.

[0182] During operation of the instrument 14, the handle alignment protrusions 906, 936 may be positioned so as to be misaligned from the tool plane BP in the second spatial relationship 952 when the tool support 18 is in a pose that does not provide the desired range of motion relative to the handheld portion 16 (shown in FIGS. 59-75 ). The second spatial relationship 952 provides a visual indication that the tool support 18 is in a pose relative to the handheld portion 16 that does not provide the desired range of motion for the instrument 14, and therefore indicates that the operator should adjust the pose of the handheld portion 16 so that the handle alignment protrusions 906, 936 are aligned with the tool plane BP in the first spatial relationship 950 to provide maximum adjustability for the instrument 14.

[0183] Similarly, during operation of the instrument 14, which further includes at least one of the tool alignment members 902, 942 having a tool alignment protrusion 916, 944, the handle alignment protrusions 906, 936 and the tool alignment protrusions 916, 944 may be positioned such that they are aligned in a first spatial relationship 950 when the actuators 21, 22, 23 of the actuator assembly 400 are in their respective home positions. For example, with reference to FIGS. 54-57 , when the handle alignment protrusions 906, 936 and the tool alignment protrusions 916, 944 are positioned in the first spatial relationship 950, the handle alignment protrusions 906, 936 and the tool alignment protrusions 916, 944, respectively, are aligned, providing a visual indication that the actuators 21, 22, 23 are in their respective home positions.

[0184] Also similarly, referring to FIG. 57, when the instrument 14 maintains the tool support 18 so that the tool 20 remains at the target plane TP, the target plane TP, the handle alignment protrusions 906, 936 and the tool alignment protrusions 916, 944 are configured to be disposed in a first spatial relationship when the handle alignment protrusions 906, 936, the tool alignment protrusions 916, 944 and the target plane TP are aligned, providing a visual indication that the tool 20 is aligned with the target plane TP and that the actuators 21, 22, 23 are in their respective home positions so that the actuators 21, 22, 23 have the maximum amount of adjustability to maintain the tool 20 at the desired pose, and providing the instrument 14 with maximum adjustment of pitch, roll and z-axis translation (i.e., height) to maintain the tool 20 at the target plane TP.

[0185] Additionally, during operation of an instrument 14 further including at least one of the tool alignment members 902, 942, the tool alignment protrusions 916, 944 and the handle alignment protrusions 902, 942 may be positioned such that when the tool support 18 is in a pose that does not provide the desired range of motion relative to the handheld portion 16 (shown in FIGS. 59-75 ), they are not aligned with one another in the second spatial relationship 952. The second spatial relationship 952 provides a visual indication that the tool support 18 is in a pose relative to the handheld portion 16 that does not provide the desired range of motion for the instrument 14, and therefore indicates that the operator should adjust the pose of the handheld portion 16 so that the tool alignment protrusions 916, 944 and the handle alignment protrusions 906, 936 are aligned in the first spatial relationship 950 to provide maximum adjustability for the instrument 14. In particular, the addition of the second tool alignment member 942 and the second handle alignment member 934 serves to further assist in providing a visual indication of the pose of the tool support 18 relative to the handheld portion 16. In particular, to facilitate visual indication throughout the range of motion of the actuators 21, 22, 23, the tool alignment members 902, 942 and the handle alignment members 904, 934 are positioned and sized relative to one another such that there is no collision between the tool alignment members 902, 942 and the handle alignment members 904, 934 at any point between the first and second positions of each of the plurality of actuators 21, 22, 23 of the actuator assembly 400.

[0186] There are various scenarios in which the handle alignment protrusions 906, 936 may be misaligned with the tool plane BP and / or the tool alignment protrusions 916, 944 in the second spatial relationship 952. For example, the tool support 18 may pitch relative to the handheld portion 16 about the lateral axis 912 (shown in FIGS. 59-62 ), the tool support 18 may roll relative to the handheld portion 16 about the longitudinal axis 910 (shown in FIGS. 63-66 ), and / or the tool support 18 may move along the vertical axis 954 (i.e., height) relative to the handheld portion 16 (shown in FIGS. 67-70 ). It should be appreciated that other misalignments resulting from movement of the tool support 18 relative to the handheld portion 16 in other degrees of freedom are possible. It should also be appreciated that combinations of the above-mentioned misalignments may occur simultaneously. For example, the tool support 18 may pitch and roll relative to the handheld portion 16 simultaneously. When the handle alignment protrusions 906, 936 are not aligned with respect to the tool plane BP and / or the tool alignment protrusions 916, 944, the resulting second spatial relationship 952 provides a visual indication of the pose of the tool support 18 relative to the handheld portion 16, even if the misalignment occurs in multiple degrees of freedom.

[0187] In some configurations, the first spatial relationship 950 may include a first pitch relationship 956 that provides a visual indication that the tool support 18 is aligned in the pitch degree of freedom relative to the handheld portion 16 about the lateral axis 912. However, as described above, the plurality of actuators 21, 22, 23 of the actuator assembly 400 may be configured to adjust at least the pitch of the tool support 18 relative to the handheld portion 16 to maintain the tool 20 at the target plane TP. For example, FIGS. 59-62 show the tool support 18 pitched a predetermined amount relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the tool support 18 is pitched relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, in the second spatial arrangement 952, the handle alignment protrusions 906, 936 may be misaligned with the tool plane BP and / or the tool alignment protrusions 916, 944, respectively. The second spatial arrangement 952 may include a second pitch relationship 958. The second pitch relationship 958 may provide a visual indication of the magnitude and direction of the pitch of the tool support 18 relative to the handheld portion 16 about the lateral axis 912.

[0188] 59-62 , the handle alignment protrusions 906, 936, the tool plane BP, and / or the tool alignment protrusions 916, 944 may be disposed in a second pitch relationship 958 when a first portion 960 of the handle alignment protrusions 906, 936 is farther from the tool plane BP and / or the tool alignment protrusions 916, 944 in the direction of pitch than a second portion 962 of the handle alignment protrusions 906, 936. With reference to FIGS. 59-62 , for example, the distal portion 964 of the handle alignment protrusions 906, 936 is farther from the tool plane BP and / or the tool alignment protrusions 916, 944 along the longitudinal axis 910 than a proximal portion 966 of the handle alignment member protrusions 906, 936. For example, as shown in Figures 59-62, the handle alignment protrusions 906, 936 are pitched below the tool alignment protrusions 916, 944 so that the distal ends of the handle alignment protrusions 906, 936 are below the distal ends of the tool alignment protrusions 916, 944, providing a visual indication to the user that the grip 72 should be rotated to eliminate the pitch condition.

[0189] In other words, when the tool support 18 is pitched relative to the handheld portion 16 such that the multiple actuators 21, 22, 23 no longer have maximum adjustability, one end of the handle alignment protrusions 906, 936 is further away from the tool plane BP and / or the tool alignment protrusions 916, 944 in the direction of the pitch than the other end along the longitudinal axis 910. Thus, the second pitch relationship 958 may provide a visual indication that the tool support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator must adjust the pose of the handheld portion 16 so that the handle alignment protrusions 906, 936 are aligned with the tool plane BP and / or the tool alignment protrusions 916, 944 in the first spatial relationship 950, providing maximum adjustability for the instrument 14.

[0190] In other configurations, the first spatial relationship 950 may include a first roll relationship 968 that provides a visual indication that the tool support 18 is aligned in the roll degree of freedom relative to the handheld portion 16. The plurality of actuators 21, 22, 23 may be configured to adjust at least the roll of the tool support 18 about the longitudinal axis 910 relative to the handheld portion 16 to maintain the tool 20 at the target plane TP. For example, FIGS. 63-66 show the tool support 18 rolled relative to the handheld portion 16 a predetermined amount such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the tool support 18 is rolled relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the handle alignment protrusions 906, 936 may be misaligned with the tool plane BP and / or the tool alignment protrusions 916, 944, respectively, in the second spatial array 952. The second spatial arrangement 952 may include a second roll relationship 970. The second roll relationship 970 may provide a visual indication of the magnitude and direction of the roll of the tool support 18 relative to the handheld portion 16 about the longitudinal axis 910.

[0191] For example, as shown in Figures 63-66, when the outer portion 972 of the handle alignment protrusion 906, 936 is farther from the tool plane BP and / or the tool alignment protrusion 916, 944 in the direction of roll than the inner portion 974 of the handle alignment protrusion 906, 936, the handle alignment protrusion 906, 936, the tool plane BP and / or the tool alignment protrusion 916, 944 may be disposed in a second roll relationship 970. In particular, with reference to FIG. 66 , the combination of the second spatial relationship 952 of the first handle alignment protrusion 906 relative to the tool plane BP and / or the first tool alignment protrusion 916 and the second spatial relationship 952 of the second handle alignment protrusion 936 relative to the tool plane BP and / or the second tool alignment protrusion 944 may provide a more visual indication of the pose of the tool support 18 relative to the handheld portion 16 than simply the second spatial relationship 952 of the first handle alignment protrusion 906 relative to the tool plane BP and / or the first tool alignment protrusion 916.

[0192] In particular, the addition of the second tool alignment member 942 and the second handle alignment member 934 provides another visual indication to the operator that the tool support 18 does not have an optimal range of motion relative to the handheld portion 16. In other words, with reference to Figures 63-66, when the tool support 18 is rolled relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, one side of the handle alignment protrusions 906, 936 is moved further from the tool plane BP and / or the tool alignment protrusions 916, 944 in the direction of the roll than the other side of the handle alignment protrusions 906, 936. For example, as shown in FIGS. 63-66 , the outer portion 972 of the first handle alignment protrusion 906 is below the first tool alignment protrusion 916, while the outer portion 972 of the second handle alignment protrusion 916 is above the second tool alignment protrusion 944, indicating that the handheld portion 16 has been rolled in a clockwise direction relative to the tool support 18. Thus, the operator is provided feedback that the handheld portion 16 should be adjusted in a clockwise direction to return the instrument 14 to a position with maximum adjustability. The second roll relationship 970 may therefore provide a visual indication that the tool support 18 does not have the desired range of motion relative to the handheld portion 16 and that the operator should adjust the pose of the handheld portion 16 so that the handle alignment protrusions 906, 936, the tool plane BP, and / or the tool alignment protrusions 916, 944 are aligned in the first spatial relationship 950, providing maximum adjustability for the instrument 14.

[0193] In an additional configuration, the first spatial relationship 950 may include a first height relationship 978 that provides a visual indication that the tool support 18 does not have any vertical movement (i.e., height) relative to the handheld portion 16 along the vertical axis 954. The plurality of actuators 21, 22, 23 of the actuator assembly 400 may be configured to adjust at least the height of the tool support 18 relative to the handheld portion 16 to maintain the tool 20 at the target plane TP. For example, FIGS. 67-70 show the tool support 18 elevated a predetermined amount relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability. When the tool support 18 is elevated relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the handle alignment protrusions 906, 936 may not be aligned with the tool plane BP and / or the tool alignment protrusions 916, 944, respectively, in the second spatial array 952. The second spatial arrangement 952 may include a second height relationship 980. The second height relationship 980 may provide a visual indication of the height dimension of the tool support 18 relative to the handheld portion 16.

[0194] 67-70 , when the handle alignment protrusion 906, 936 is moved heightwise below the tool plane BP and / or the tool alignment protrusion 916, 944, the handle alignment protrusion 906, 936, the tool plane BP, and / or the tool alignment protrusion 916, 944 may be disposed in the second height relationship 980. In other words, when the tool support 18 is raised relative to the handheld portion 16 such that the plurality of actuators 21, 22, 23 no longer have maximum adjustability, the handle alignment protrusion 906, 936 is heightwise above or below the tool plane BP and / or the tool alignment protrusion 916, 944 along the vertical axis 954. Thus, the positioning of the handle alignment protrusions 906, 936 relative to the tool alignment protrusions 916, 944 in the second height relationship 980 may provide a visual indication that the tool support 18 does not have an optimal range of motion relative to the handheld portion 16 and that the operator should adjust the pose of the handheld portion 16 so that the handle alignment protrusions 906, 936 are aligned with the tool plane BP and / or the tool alignment protrusions 916, 944 in the first spatial relationship 950, providing maximum adjustability for the instrument 14. For example, the tool alignment protrusions 916, 944 are shown above the handle alignment protrusions 906, 936 on each side of the instrument 14 in FIGS. 67-70 , providing a visual indication to the user that the handheld portion 16 needs to be moved upward to align it with the tool support 18 in order to place the instrument 14 in a position with maximum adjustability.

[0195] It should be appreciated in light of the above description that the guidance array 900 provides many benefits to the operation of the instrument 14. For example, the handle alignment protrusions 906, 936 (and the handle alignment edges 914, 940 defined thereby) may be disposed at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 defined by the tool 20 / tool ​​support 18. The disposition of the portions 908, 938 of the handle alignment protrusions 906, 936 at an oblique angle relative to the longitudinal axis 910 and lateral axis 912 provides the advantage of allowing an operator to perceive the alignment of the handle alignment protrusions 906, 936 relative to the tool plane BP and / or the tool alignment protrusions 916, 944 in multiple degrees of freedom simultaneously.

[0196] 71-75, in some configurations, the actuator assembly 400 is configured to simultaneously adjust at least the pitch and roll of the tool support 18 relative to the handheld portion 16. For example, referring to FIGS. 71-75 where the tool support 18 is moved simultaneously in both the pitch and roll degrees of freedom, the arrangement of the angled portions 908, 938 of the handle alignment protrusions 906, 936 relative to the tool plane BP and / or the tool alignment protrusions 916, 944 provides a visual indication of the pose of the handheld portion 16 relative to the tool support in at least two degrees of freedom. In particular, the second spatial arrangement 952 of the handle alignment protrusions 906, 936 relative to the tool plane BP and / or the tool alignment protrusions 916, 944, respectively, provides a visual indication of at least a second pitch relationship 958 and a second roll relationship 970 of the tool support BP relative to the handheld portion 16, providing a visual indication that the handheld portion 16 is in a pose relative to the tool support 18 that does not provide an optimal range of motion for the tool support 18. Thus, the operator is alerted that the operator must adjust the pose of the handheld portion 16 so that the handle alignment protrusions 906, 936, the tool plane BP and / or the tool alignment protrusions 916, 944 are aligned in the first spatial relationship 944, providing maximum adjustability for the instrument 14.

[0197] As an example of this feedback in multiple degrees of freedom, Figures 71-75 show that one end of the handle alignment protrusion 906, 936 is further away from the tool plane BP and / or tool alignment protrusion 916, 944 along the longitudinal axis 910 in the pitch direction than the other end, and one side of the handle alignment protrusion 906, 936 is moved further from the tool plane BP and / or tool alignment protrusion 916, 944 in the roll direction than the other side of the handle alignment protrusion 906, 936. Thus, the diagonal arrangement of the handle alignment protrusions 906, 936 (and in some configurations, the tool alignment protrusions 916, 944) facilitates visual indication of the pose of the tool support 18 relative to the handheld portion 16 by providing a first visual reference toward the outer portion 972 of the handle alignment protrusions 906, 936 that provides visual indication in the roll degree of freedom, and a second visual reference toward the first portion 960 of the handle alignment protrusions 906, 936 that provides visual indication in the pitch degree of freedom. Thus, cumulatively, the diagonal portions 908, 938 and the handle alignment protrusions 906, 936 provide increased functionality for visual indication compared to an orthogonal arrangement of the handle alignment protrusions.

[0198] 76-77 , the tool alignment member 902 and / or the handle alignment member 904 may include one or more visual indicia to facilitate a user's visual recognition of the alignment of the handle alignment protrusion 906, 936 with respect to the tool alignment protrusion 916, 944. For example, the handle alignment protrusion 906, 936 and / or the tool alignment protrusion 916, 944 may each include at least one of a first visual indicia 986 and a second visual indicia 988, where the first visual indicia 986 is visually distinguishable from the second visual indicia 988. The first visual indicia 986 and / or the second visual indicia 988 may be disposed on the handle alignment protrusion 906, 936 and / or the tool alignment protrusion 916, 944, for example, on the beveled surface 990 and / or the side surface 992 of the handle alignment protrusion 906, 936 and / or the tool alignment protrusion 916, 944. However, it is contemplated that any suitable surface of the handle alignment protrusion 906, 936 and / or the tool alignment protrusion 916, 944 will facilitate the operator's visual recognition of the alignment of the handle alignment protrusion 906, 936 relative to the tool alignment protrusion 916, 944. Thus, the first visual indicia 986 and / or the second visual indicia 988 provide the operator with a readily identifiable visual indication of the alignment of the tool alignment protrusion 916 relative to the handle alignment protrusion 906. In some versions, the visual indicia include one or more overt visual cues (e.g., a pattern, a light, a color, a combination thereof, etc.). For example, with reference to FIGS. 76-77 , the visual indicia may include a colored marking.

[0199] 76-77 , for example, the visual indicia may be positioned such that when the tool alignment protrusion 916 and the handle alignment protrusion 906 are aligned, the first visual indicia 986 of the handle alignment protrusion 906 and the first visual indicia 986 of the tool alignment protrusion 916 are aligned, providing a visual indication that the tool support 18 has an optimal range of motion relative to the handheld portion 16. Conversely, the first visual indicia 986 of the handle alignment protrusion 906 and the first visual indicia 986 of the tool alignment protrusion may be configured to be misaligned when the tool alignment protrusion 916 and the handle alignment protrusion 906 are not aligned, providing a visual indication that the handheld portion 16 is in a pose that does not provide an optimal range of motion for the tool support 18.

[0200] 78-85 show yet another configuration of a guidance array 1000 for use with the handheld surgical robotic system 10. Similar to the configurations described above, the guidance array 1000 provides the operator with a visual indication of the pose of the tool support 18 relative to the handheld portion 16 during operation of the instrument 14, and provides the operator with a visual indication of the required changes in pitch orientation, roll orientation, and z-axis translation of the handheld portion 16 to achieve the desired pose of the tool 20 while providing maximum adjustability for the actuator assembly 400 (described above) to maintain the tool 20 at the target plane TP. The guidance array 1000 includes a handle alignment member 1004 extending from the handheld portion 16 to provide visual indication to the operator to guide the operator as to how to move the handheld portion 16 to provide sufficient adjustability for the instrument 14 by maintaining the actuators 21, 22, and 23 of the actuator assembly 400 near their home or other predetermined positions.

[0201] 80-83 , for example, the handle alignment member 1004 includes a handle support arm 1106. The handle support arm 1106 extends between a first handle support arm end 1108 and a second handle support arm end 1110. The handle support arm 1106 includes a handle coupling portion 1112 coupled to the first handle support arm end 1108 (best shown in FIGS. 81 and 82 ). The handle coupling portion is configured to couple the handle alignment member 1004 to the handheld portion 16 of the instrument 14. For example, in some configurations, the handle coupling portion 1112 includes a handle coupling member 1114 configured to couple to a corresponding coupling member 1116 disposed on the handheld portion 16.

[0202] 80-82 , in some configurations, the handle coupling portion 1112 of the handle alignment member 1004 is magnetically coupled to the handheld portion 16 of the instrument 14. Thus, the handle alignment member 1004 can be quickly magnetically attached to and detached from the handheld portion 16. To facilitate this magnetic connection, the handle coupling member 1114 and one of the coupling members disposed on the handheld portion 16 may include one or more magnets 1118, while the handle coupling member 1114 and the other of the coupling members disposed on the handheld portion 16 may include one or more magnets 1118 and / or ferromagnetic material 1120, such that the handle coupling member 1114 and the coupling member disposed on the handheld portion 16 are configured to magnetically couple to each other to couple the handle alignment member 1004 to the handheld portion 16.

[0203] 81 and 83 , the handle alignment member 1004 further includes a handle alignment member mount 1122 coupled to the second handle support arm end 1110. Additionally, in the configuration shown in FIGS. 81 and 83 , the handle alignment member 1004 also includes a handle alignment indicator member 1124 coupled to the handle alignment member mount 1122. The handle alignment indicator member 1124 may be of any suitable shape or configuration that provides a visual indication to an operator user that one or more of the actuators 21, 22, and 23 of the actuator assembly 400 have moved from their respective home positions. For example, in one configuration, similar to the other configurations described above, the handle alignment member 1004 may define a hook-shaped protrusion. Also similar to the configurations described above, the handle alignment indicator member 1124 and at least a portion of the tool plane BP may be aligned when the actuators 21, 22, and 23 of the actuator assembly 400 are in their respective home positions, providing a visual indication to the operator that the tool support 18 has an optimal range of motion relative to the handheld portion 16. Conversely, when the handheld portion 16 is in a pose that does not provide an optimal range of motion, the tool plane BP and handle alignment indicator member 1124 are configured to be misaligned, providing a visual indication that the handheld portion 16 is in a pose that does not provide an optimal range of motion for the tool support 18 and therefore needs to be adjusted by the operator.

[0204] 81 and 83 , the handle alignment indicator 1124 may be removably coupled to the handle alignment indicator mount 1122 using one or more fasteners 1128. Additionally, the handle alignment indicator 1124 may be made of a material suitable for autoclaving. Suitable materials include, but are not limited to, stainless steel and autoclavable polymers such as polyphenylsulfone. Examples of methods for manufacturing the handle alignment indicator 1124 include forming the handle alignment indicator 1124 by stamping a sheet of stainless steel, machining the handle alignment indicator 1124 from a block of an autoclavable polymer such as polyphenylsulfone, or molding the handle alignment indicator 1124 from an autoclavable polymer such as polyphenylsulfone.

[0205] 78-86 , the guidance array 1000 also includes a tool alignment member 1126. In one configuration, for example, the tool alignment member 1126 may extend from the tool support 18. As with the other configurations described above, the handle alignment member 1004 and the tool alignment member 1126 are aligned when the tool support 18 has an optimal range of motion relative to the handheld portion 16. Also, similar to the handle alignment member 1004 described above, the tool alignment member 1126 may include a tool support arm 1130 extending between a first tool support arm end 1132 and a second tool support arm end 1134. The tool support arm 1130 includes a tool coupling portion 1136 coupled to the first tool support arm end 1132 (best shown in FIG. 81 ). The tool coupling portion 1136 is configured to couple the tool alignment member 1026 to the tool support 18 of the instrument 14. For example, in some configurations, the tool coupling portion 1136 includes a tool coupling member (not shown) configured to couple to a corresponding coupling member 1138 disposed on the tool support 18. Also, similar to what was described above, the tool alignment member 1126 may be magnetically coupled to the tool support 18.

[0206] The tool alignment member 1126 also includes a tool alignment member mount 1140 coupled to the second support arm end 1134. The tool alignment member 1126 further includes a tool alignment indicator 1142. The tool alignment indicator 1142 may be coupled to the tool alignment member mount 1140 using, for example, fasteners. The tool alignment indicator 1142 may be made of the same material and manufactured by the same method as the handle alignment indicator member 1124. In some configurations, the handle alignment indicator member 1124 and the tool alignment indicator member 1142 may have the same shape and size to improve manufacturing efficiency and cost.

[0207] 80 and 85, the handle alignment indicating member 1124 and / or the tool alignment indicating member 1142 may include laser marks 1144 to facilitate a visual indication of the pose of the tool alignment indicating member 1142 and / or the handle alignment indicating member 1124 relative to the tool plane BP. Thus, when the tool support 18 does not have an optimal range of motion relative to the handheld portion 16, the laser marks 1144 enhance the visual indication provided to the operator that an adjustment to the pose of the handheld portion is needed. While the laser marks may be formed using a laser, other methods of forming marks on the handle alignment indicating member 1124 and / or the tool alignment indicating member 1142 are contemplated, such as, but not limited to, printing, scoring, etching, etc. In another configuration, referring to FIG. 85, the polymer used to form the handle alignment indicating member 1124 and / or the tool alignment indicating member 1142 may be dyed to provide a contrasting color to surrounding components to enhance the visual indication provided to the operator.

[0208] As briefly described above, the instrument 14 may include a tracker that allows the pose of the instrument 14 to be tracked by a surgical navigation system. For example, with reference to FIGS. 78-86 , the instrument 14 may include a tracker 1150 coupled to the blade support 18 or other tool support. The tracker 1150 thus allows the robotic surgical system 10 to determine the current location of the tool plane BP in space or the tool axis in space. The tracker 1150 includes a tracker frame 1152. The tracker frame 1152 includes at least two faces 1156. The at least two faces 1156 are non-planar with respect to one another. For example, FIG. 78 illustrates at least two faces wedged relative to one another. The tracker 1150 also includes at least six optical markers 1154 coupled to the tracker frame. At least three of the six optical markers 1154 are attached to each of the at least two faces 1156. In some configurations, the plurality of markers 1154 are coupled to at least two surfaces 1156 and are arranged as mirror images of one another, while in other configurations, the plurality of markers 1154 are arranged asymmetrically. In other configurations, the at least two surfaces 1156 may be on opposite sides of a plane that bisects the instrument 14.

[0209] Additionally, the tracker frame 1152 may define an instrument engagement opening 1170 for receiving a proximal portion of the instrument 14. Accordingly, the instrument 14 may include a mount 1172 for engaging the tracker frame 1152 and holding the tracker frame 1152 relative to the instrument 14. For example, the tracker frame 1152 may partially surround the mount 1172 when the tracker 1150 is coupled to the instrument 14. In some examples, the mount 1172 may be a slot. The tracker 1150 may further include a battery 1174 for powering the tracker 1150. For example, in some configurations, the optical marker 1154 may be an active marker having a light-emitting source, such as an infrared LED. The battery may also power the antenna 1162, as described in more detail below. For example, one or more of the at least six optical markers 1154 may be LED emitters, with the one or more LEDs arranged to form two arrays, each array including at least one LED emitter.

[0210] As previously described above, the robotic surgical system 10 includes a control system 60. Referring to FIG. 86 , the control system 60 includes, among other components, a navigation system 32 and an instrument controller 28. The control system 60 is configured to control the actuators 21, 22, and 23 to align the tool plane BP of the instrument 14 with at least one target plane 184. With continued reference to FIG. 86 , the tracker 1150 includes an input device 1160, an antenna 1162, and a tracker controller 1164. The tracker controller 1164 is coupled to the input device 1160 and the antenna 1162 to provide input signals to the navigation system 32. Thus, the control system 60 may be configured to detect an input signal from the input device 1160 and cause the actuators 21, 22, and 23 to change the position of the tool support 18 to align the tool support 18 with a different one of the plurality of target planes 184. Additionally, the navigation system 32 may be configured to determine a tool plane BP of the saw blade 20 based on the target plane, the target plane being based on the selected target plane 184. Alternatively, the control system 60 may be configured to detect an input signal from an input device and align the tool support with a different one of a plurality of axes (as opposed to a plane), and / or the navigation system may be configured to determine a pose of the tool support based on the target plane, the target plane being based on the selected target axis.

[0211] In another embodiment, the robotic surgical system 10 may be configured to determine a current tool plane BP using the tool tracker 1150 and the navigation system 32. Accordingly, the robotic surgical system 10 may select one of a plurality of target planes 184 via the input device 1160 and adjust the tool support 18 via the plurality of actuators 21, 22, 23 to position the current plane BP in alignment with the selected target plane 184.

[0212] Additional provisions of the present invention include: I. A handheld surgical robotic system for supporting a saw blade, the handheld surgical robotic system comprising: The handheld part and a blade support movably coupled to the handheld portion, the blade support configured to support a saw blade; an actuator assembly operably attached to the blade support and the handheld portion, the actuator assembly configured to move the blade support relative to the handheld portion in multiple degrees of freedom; a tool alignment member coupled to and extending from the blade support; a handle alignment member coupled to and extending from the handheld portion; A handheld surgical robotic system for supporting a saw blade, wherein at least a portion of the tool alignment member and at least a portion of the handle alignment member are aligned when the blade support has a desired range of motion relative to the handheld portion. II. The handheld robot system of clause I, wherein the actuator assembly includes a plurality of actuators, each of the plurality of actuators configured to move between a first position and a second position to move the blade support relative to the handheld portion, the home position being a midpoint between the first position and the second position of each of the plurality of actuators, and wherein the blade support has a desired range of motion when at least two of the plurality of actuators are in the home position. III. A handheld robotic system as described in clause II, wherein when the handheld portion is in a pose that does not provide the desired range of motion, the tool alignment member and the handle alignment member are not aligned, providing a visual indication that the handheld portion is in a pose that does not provide the blade support with the desired range of motion. IV. A handheld robotic system as described in any one of clauses I to III, wherein the tool alignment member and the handle alignment member are positioned and sized relative to each other so as to avoid collision between the tool alignment member and the handle alignment member at any point between the first and second positions of each of the plurality of actuators, and the collective first and second positions of each of the plurality of actuators define a potential range of motion of the blade support relative to the handheld portion, and the potential range of motion defines a space having a height of approximately 150 mm and a width of approximately 115 mm. V. A handheld robotic system described in any one of clauses I to IV, wherein a portion of the tool alignment member and a portion of the handle alignment member are positioned above the grip of the handheld portion, and wherein the tool alignment member is disposed on the blade support and the handle alignment member is disposed on the handheld portion so as to be visible from the proximal end of the blade support when the multiple actuators move the blade support relative to the handheld portion. VI. a plurality of actuators configured to adjust at least the pitch of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first pitch relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second pitch relationship of the blade support relative to the handheld portion; A handheld robot system as described in any one of clauses I to V, wherein the first spatial arrangement provides a visual indication that the tool alignment member and the handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and the second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of the pitch of the blade support relative to the handheld portion, and the distal portion of the tool alignment member is farther from the tool plane along the longitudinal axis in the direction of the pitch than the proximal portion of the tool alignment member. VII. a plurality of actuators configured to adjust at least a height of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first height relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second height relationship of the blade support relative to the handheld portion; A handheld robot system described in any one of clauses I to VI, wherein the first spatial arrangement provides a visual indication that the tool alignment member and handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and the second spatial arrangement provides a visual indication of the height of the blade support relative to the handheld portion, and the tool alignment member is at least partially above or below the handle alignment member in the height direction. VIII. a plurality of actuators configured to adjust at least a roll of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first roll relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second roll relationship of the blade support relative to the handheld portion; A handheld robot system as described in any one of clauses I to VII, wherein the spatial arrangement provides a visual indication that the tool alignment member and handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and the second spatial arrangement provides a visual indication of the roll of the blade support relative to the handheld portion, and the distal portion of the tool alignment member is farther from the tool plane along the lateral axis in the direction of the roll than the proximal portion of the tool alignment member. IX. the tool alignment member includes a first tool alignment member and a second tool alignment member, the first tool alignment member and the second tool alignment member extending from opposite sides of the blade support; the handle alignment member includes a first handle alignment member and a second handle alignment member, the first handle alignment member and the second handle alignment member extending from the handheld portion; when the blade support has a desired range of motion relative to the handheld portion, the first tool alignment member and the first handle alignment member, and the second tool alignment member and the second handle alignment member, respectively, intersect with each other; A handheld robot system as described in any one of clauses I to VIII, wherein the first and second tool alignment members and the first and second handle alignment members are visible from the proximal end for the blade support throughout the entire range of motion of the blade support relative to the handheld portion. X. a plurality of actuators configured to adjust at least the pitch of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first pitch relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second pitch relationship of the blade support relative to the handheld portion; A handheld robot system as described in clause IX, wherein the first spatial arrangement provides a visual indication that the tool alignment member and handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and the second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of the pitch of the blade support relative to the handheld portion, and a distal portion of at least one of the tool alignment members is farther from the tool plane along the longitudinal axis in the direction of the pitch than a proximal portion of the tool alignment member. XI. a plurality of actuators configured to adjust at least a height of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first height relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second height relationship of the blade support relative to the handheld portion; A handheld robot system as described in any one of clauses IX and X, wherein the first spatial arrangement provides a visual indication that the tool alignment member and handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and the second spatial arrangement provides a visual indication of the height of the blade support relative to the handheld portion, and the tool alignment member is at least partially above or below the handle alignment member in the height direction. XII. a plurality of actuators are configured to adjust at least a roll of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first roll relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second roll relationship of the blade support relative to the handheld portion; A handheld robot system as described in any one of clauses IX to XI, wherein the spatial arrangement provides a visual indication that the tool alignment member and handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and the second spatial arrangement provides a visual indication of the roll of the blade support relative to the handheld portion, and a distal portion of at least one of the tool alignment members is farther from the tool plane along the lateral axis in the direction of the roll than a proximal portion of the tool alignment member. XIII. A handheld robot system described in any one of clauses IX to XII, wherein the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively, when the blade support has a desired range of motion relative to the handheld portion. XIV. The handheld robotic system of clause III, wherein the tool alignment member and the handle alignment member provide a first visual indicia and a second visual indicia, the first visual indicia being visually distinguishable from the second visual indicia, and wherein the first visual indicia is visible from the proximal end of the handheld portion when the tool alignment member and the handle alignment member are not aligned, and the second visual indicia is visible from the proximal end of the handheld portion when the tool alignment member and the handle alignment member are aligned. XV. The handheld robotic system of clause XIV, wherein the tool alignment member and the handle alignment member have a first visual indicia and a second visual indicia, respectively. XVI. The handheld robotic system of clause XV, wherein the first visual indicia is a first color and the second visual indicia is a second color, and wherein the first color is visible when the tool alignment member and the handle alignment member are aligned, and at least one of the second visual indicia is visible when the tool alignment member and the handle alignment member are not aligned. XVII. The tool alignment member and the handle alignment member further include a top surface and a side surface; The handheld robotic system of clause XVI, wherein the top surface includes a first visual indicia and the side surface includes a second visual indicia, whereby when the tool alignment member and the handle alignment member are not aligned with one another, the second visual indicia appears to provide an indication that one or more of the plurality of actuators has moved from a home position. XVIII. The handheld robotic system of any one of clauses I to XVII, wherein the tool alignment member is a saw blade. XIX. The handheld robotic system of any one of clauses I to XVIII, further comprising a tracker for the surgical navigation system, the tracker being removably coupled to the blade support, the tracker including a tracking element for identifying the position of the tool alignment member, and the tracker being part of the tool alignment member. XX. A handheld robotic system for supporting a saw blade, the handheld robotic system comprising: The handheld part and a blade support removably coupled to the handheld portion for supporting the saw blade; an actuator assembly operably attached to the blade support and the handheld portion, the actuator assembly configured to move the blade support relative to the handheld portion in multiple degrees of freedom; a first tool alignment member and a second tool alignment member coupled to opposite sides of the blade support and extending from the blade support on opposite sides; a first handle alignment member and a second handle alignment member coupled to and extending from the handheld portion; A handheld robotic system for supporting a saw blade, wherein the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively, when the blade support has a desired range of motion relative to the handheld portion. XXI. An actuator assembly including a plurality of actuators, each of the plurality of actuators configured to move between a first position and a second position to move the blade support relative to the handheld portion through a predetermined range of motion; The handheld robot system of clause XX, wherein the home position is a midpoint between the first position and the second position of each of the plurality of actuators, and when each of the plurality of actuators is in the home position, the blade support and the handheld portion have a desired range of motion. XXII. The handheld robotic system described in clause XXI, wherein when the blade support and handheld portion are moved to a position other than the home position, the first tool alignment member and the second tool alignment member are not aligned with the first and second handle alignment members, respectively, providing a visual indication that the blade support and handheld portion are in a position that does not have a desired range of motion. XXIII. The tool alignment member and the handle alignment member further comprise a top surface and a side surface; The handheld robotic system of clause XXII, wherein the top surface includes a first visual indicia and the side surface includes a second visual indicia, the first visual indicia being different from the second visual indicia, such that when the tool alignment member and the handle alignment member are not aligned with one another, the second visual indicia appears on one of the tool alignment member, the handle alignment member, or both, providing an indication that one or more of the plurality of actuators has moved from a home position. XXIV. A plurality of actuators are configured to adjust at least the pitch of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first pitch relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second pitch relationship of the blade support relative to the handheld portion; A handheld robot system as described in clause XXIII, wherein a first spatial arrangement provides a visual indication that the tool alignment member and the handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of the pitch of the blade support relative to the handheld portion, and a distal portion of at least one of the tool alignment members is farther from the tool plane along the longitudinal axis in the direction of the pitch than a proximal portion of the tool alignment member. XXV. A plurality of actuators are configured to adjust at least a height of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first height relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second height relationship of the blade support relative to the handheld portion; A handheld robot system as described in any one of clauses XXIII and XXIV, wherein a first spatial arrangement provides a visual indication that the tool alignment member and the handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and a second spatial arrangement provides a visual indication of the height of the blade support relative to the handheld portion, and the tool alignment member is at least partially above or below the handle alignment member in the height direction. XXVI. A plurality of actuators are configured to adjust at least a roll of the blade support relative to the handheld portion, wherein a first spatial arrangement of the tool alignment member relative to the handle alignment member provides a visual indication of a first roll relationship of the blade support relative to the handheld portion, and a second spatial arrangement of the tool alignment member relative to the handle alignment member provides a second roll relationship of the blade support relative to the handheld portion; A handheld robot system as described in any one of clauses XXIII to XXV, wherein a spatial arrangement provides a visual indication that the tool alignment member and the handle alignment member are aligned and the blade support has a desired range of motion relative to the handheld portion, and a second spatial arrangement provides a visual indication of the roll of the blade support relative to the handheld portion, and a distal portion of at least one of the tool alignment members is farther from the tool plane along the lateral axis in the direction of the roll than a proximal portion of the tool alignment member. XXVII. A visual indication system for use with a handheld robotic system, the handheld robotic system including a tool, a handheld portion, a blade support movably coupled to the handheld portion for supporting the tool, and a plurality of actuators operatively interconnecting the blade support and the handheld portion and configured to move the blade support relative to the handheld portion in a plurality of degrees of freedom, the visual indication system comprising: a shroud coupled to the blade support and the handheld portion to enclose at least one of the plurality of actuators and extending between the blade support and the handheld portion; A visual indication system for use with a handheld robotic system, wherein the shroud defines at least two shroud landmarks configured to move relative to one another when the blade support and the handheld portion are not aligned with one another to provide a visual indication of the pose of the blade support relative to the handheld portion. XXVIII. The visual indication system of clause XXVII, wherein the at least two shroud landmarks include at least two folds, the folds defining substantially parallel planes in a first position, the planes being offset from one another by a first distance when the blade support and handheld portion are displaced from one another, and when the blade support and handheld portion are moved to a second position, the at least two defined planes intersect. XXIX. The visual indication system of clause XXVIII, wherein the blade support defines a blade plane, and when the blade support and handheld portion are in the first position, the at least two folds are substantially parallel to the blade plane. XXX. The at least two shroud landmarks include a first visual mark and a second visual mark, the first visual mark being visually distinguishable from the second visual mark, the first visual mark being a first color, and the second visual mark being a second color; The visual indication system of clause XXIX, wherein the first color is visible when the blade support is in the first position and at least one of the second visual indicia is visible when the blade support is in the second position. XXXI. A handheld robotic system for supporting a saw blade, the handheld robotic system comprising: The handheld part and a blade support movably coupled to the handheld portion for supporting the saw blade; a plurality of actuators operatively interconnecting the blade support and the handheld portion and configured to move the blade support relative to the handheld portion in a plurality of degrees of freedom; a light source on the blade support; first and second tool alignment members coupled to and extending on opposite sides from the blade support; a first handle alignment member and a second handle alignment member coupled to and extending from the handheld portion; when the blade support has a desired range of motion relative to the handheld portion, the first tool alignment member and the second tool alignment member are aligned with the first handle alignment member and the second handle alignment member, respectively; A handheld robotic system for supporting a saw blade, wherein a light source is illuminated when the blade support has a desired range of motion to indicate that the blade support and handheld portion are within a specified range of alignment with the cutting plane. XXXII. A handheld surgical robotic system for supporting a saw blade, the handheld surgical robotic system comprising: The handheld part and a blade support movably coupled to the handheld portion and configured to support a saw blade; a plurality of actuators in operative interaction with the blade support and the handheld portion, the plurality of actuators configured to move the blade support relative to the handheld portion in a plurality of degrees of freedom; a tool alignment member coupled to and extending from the blade support; a handle alignment member coupled to and extending from the handheld portion; A handheld surgical robotic system for supporting a saw blade, wherein a handle alignment member is removably connected to the handheld portion. XXXIII. The handheld surgical robotic system of clause XXXII, wherein the handle alignment member is magnetically connected to the handheld portion such that the handle alignment member is removably connected to the handheld portion. XXXIV. A surgical system for treating an anatomical structure according to multiple target planes, comprising: The device is provided with an instrument, A saw blade and The handheld part and an actuator system including a plurality of actuators; a blade support for supporting and moving the saw, the blade support including a saw drive motor coupled to a saw mount, the blade support having a plurality of actuators extending between the blade support and the handheld portion; A navigation system, 1. A tracker for coupling to a blade support configured to determine a current tool plane, the tracker comprising: a tracker frame; a tracker including: at least six optical markers coupled to a tracker frame, the tracker frame including at least two faces, the at least two faces being non-planar with respect to one another, and at least three of the at least six optical markers being coupled to each of the at least two faces; A surgical system for treating an anatomical structure according to a plurality of target planes, comprising: a control system in communication with a navigation system and a tracker, the control system being configured to control an actuator system to align a current tool plane with at least one of the plurality of target planes. XXXV. Input device; The antenna and The surgical system of clause XXXIV, further comprising: a controller coupled to the input device and the antenna, the controller configured to provide an input signal to the navigation system. XXXVI. The control system further comprises: (a) detecting an input signal from an input device of the tracking unit; (b) varying the positional change of the blade support by an actuator system to align the tool support with a different one of a plurality of target planes; It is structured as follows: The surgical system of clause XXXV, wherein the navigation system is configured to determine a tool plane of the saw blade based on the target surface, the target surface being based on a selected target plane. XXXVII. A surgical system described in any one of clauses XXXIV to XXXVI, wherein the plurality of optical markers is at least six optical markers, and at least three of the at least six optical markers are coupled to each of the at least two surfaces. XXXVIII. The surgical system of any one of clauses XXXIV to XXXVII, wherein the trackers coupled to at least two surfaces are arranged as mirror images of each other. XXXIX. The surgical system of any one of clauses XXXIV to XXXVIII, wherein the plurality of trackers coupled to at least two surfaces are asymmetrically positioned. XL. A surgical method of controlling a surgical system, the surgical system comprising: a handheld robotic instrument; a saw blade; a handheld portion; an actuator system including a plurality of actuators; a blade support for supporting and moving the saw, the plurality of actuators extending between the blade support and the handheld portion, the blade support including a saw drive motor coupled to a saw mount; a navigation system; a tool tracker for coupling to the blade support, the tool tracker configured to determine a current tool plane; and a control system in communication with the navigation system and the tracker, the control system configured to control the actuator system to align the current tool plane with at least one of a plurality of target planes, each of the plurality of target planes corresponding to a cutting plane, the method comprising: determining a current tool plane using a tool tracker and navigation system; selecting one of a plurality of target planes using an input device on the tracker; adjusting the tool support by the plurality of actuators to position the current plane in alignment with the selected target plane; selecting a different one of a plurality of target planes with an input device. XLI. A surgical instrument tracker for tracking a surgical saw or other tool, the tracker comprising: a tracker frame defining an instrument engagement opening for receiving a proximal portion of a saw, the tracker frame including a mount; at least six optical markers coupled to a tracker frame, the tracker frame including at least two surfaces, the at least two surfaces being non-planar with respect to one another, and at least three of the at least six optical markers being coupled to each of the at least two surfaces; A surgical instrument tracker for tracking a surgical saw or other tool, wherein the tracker frame at least partially surrounds the accessory mount when the tracker mount is coupled to the accessory mount. XLII. The instrument tracker of clause XLI, wherein the mount is a slot. XLIII. The instrument tracker of any one of clauses XLI and XLII, wherein at least two of the surfaces are on opposite sides of a plane that bisects the surgical saw or tool. XLIV. The instrument tracker of any one of clauses XLI to XLIII, wherein the tracker frame further includes an input device operably coupled to the control system. XLV. The instrument tracker of clause XLIV, further comprising a battery configured to power one or more of the at least six optical markers, the input device, or both, the battery being removably coupled to the tracker frame. XLVI. The instrument tracker of clause XLV, further comprising an antenna operably coupled to the battery and configured to transmit and receive information to and from the control system. XLVII. The instrument tracker of clause XLVI, wherein the instrument tracker further includes a controller coupled to at least one of the at least six optical markers, the battery, and the antenna. XLVIII. The instrument tracker of any one of clauses XLV to XLVII, wherein one or more of the at least six optical markers are LED emitters, and wherein the one or more LED emitters are arranged to form at least two arrays, each array including at least one LED emitter. XLIX. A mechanical alignment device configured for use with a handheld surgical robotic system to provide a visual indication of a pose of a handheld portion of the handheld surgical robotic system relative to a tool support of the handheld surgical robotic system, the mechanical alignment device comprising: a support arm extending between a first support arm end and a second support arm end, the support arm including a coupling portion coupled to the first support arm end and configured to be removably coupled to one of a handheld portion and a tool support of a handheld surgical robotic system; an alignment member mount coupled to the second support arm end; an alignment indicator coupled to the alignment member mount.

[0213] Multiple embodiments are set forth in the foregoing description. However, the embodiments described herein are not intended to be exhaustive or to limit the invention to any particular form. The terminology used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations are possible in light of the above teachings, and the invention may be embodied in forms other than those specifically described. The technical concepts that can be understood from the above-described embodiments will be described below. [Aspect 1] 1. A handheld surgical robotic system, comprising: The handheld part and a blade support movably coupled to the handheld portion, the blade support including a blade mount defining a blade plane; a saw blade removably coupled to the blade support and disposed in the blade plane, the saw blade defining a longitudinal axis and a lateral axis perpendicular to the longitudinal axis; an actuator assembly operably attached to the blade support and the handheld portion, the actuator assembly configured to move the blade support relative to the handheld portion in multiple degrees of freedom; a handle alignment member extending from the handheld portion, the handle alignment member including a handle alignment protrusion extending toward the blade mount, at least a portion of the handle alignment protrusion being oblique to the longitudinal and lateral axes of the saw blade; Equipped with A handheld surgical robotic system, wherein a portion of the handle alignment protrusion and the blade plane are aligned when the blade support has an optimal range of motion relative to the handheld portion. [Aspect 2] A handheld surgical robot system as described in aspect 1, wherein the actuator assembly includes a plurality of actuators, each of the plurality of actuators configured to move between a first position and a second position to move the blade support relative to the handheld portion, a home position being at a midpoint between the first position and the second position for each of the plurality of actuators, and the blade support having an optimal range of motion when at least two of the plurality of actuators are in the home position. [Aspect 3] A handheld surgical robotic system as described in aspect 2, wherein when the handheld portion is in a pose that does not provide the optimal range of motion, the blade plane and the handle alignment protrusion are not aligned, providing a visual indication that the handheld portion is in a pose that does not provide the optimal range of motion for the blade support. [Aspect 4] A handheld surgical robot system as described in aspect 2 or 3, wherein the handle alignment member is positioned and sized relative to the blade support so that the handle alignment member does not collide with the blade support at any point between the first position and the second position of each of the multiple actuators of the actuator assembly. [Aspect 5] A handheld surgical robotic system as described in aspect 4, wherein the first position and the second position of the plurality of actuators define a range of motion of the distal end of the saw blade relative to the handheld portion, the range of motion defining a space having a maximum height of approximately 150 mm and a maximum width of approximately 115 mm. [Aspect 6] the actuator assembly is configured to adjust at least one of a pitch, a height, and a roll of the blade support relative to the handheld portion; a first spatial arrangement of the handle alignment protrusion relative to the blade plane to provide a visual indication of at least one of a first pitch relationship, a first height relationship, and a first roll relationship of the blade support relative to the handheld portion; the first spatial arrangement provides a visual indication that the handle alignment protrusion and the blade plane are aligned and that the blade support has an optimal range of motion relative to the handheld portion; a second spatial arrangement of the handle alignment protrusion relative to the blade plane to provide a visual indication of at least one of a second pitch relationship, a second height relationship, and a second roll relationship of the blade support relative to the handheld portion; A handheld surgical robotic system according to any one of aspects 1 to 5, wherein the second spatial arrangement provides a visual indication that the handheld portion is in a pose relative to the blade support that does not provide the blade support with the optimal range of motion. [Aspect 7] the actuator assembly is configured to adjust at least the pitch of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first pitch relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second pitch relationship of the blade support relative to the handheld portion; A handheld surgical robot system as described in aspect 6, wherein the second pitch relationship provides a visual indication of the pitch of the blade support relative to the handheld portion, and a first portion of the handle alignment protrusion is farther from the blade plane along the longitudinal axis in the direction of the pitch than a second portion of the handle alignment protrusion. [Aspect 8] the actuator assembly is configured to adjust at least the height of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first height relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second height relationship of the blade support relative to the handheld portion; A handheld surgical robot system as described in aspect 6 or 7, wherein the second height relationship provides a visual indication of the height of the blade support relative to the handheld portion, and the handle alignment protrusion is at least partially above or below the blade plane in the height direction. [Aspect 9] the actuator assembly is configured to adjust at least the roll of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first roll relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second roll relationship of the blade support relative to the handheld portion; A handheld surgical robot system according to any one of aspects 6 to 8, wherein the second roll relationship provides a visual indication of the roll of the blade support relative to the handheld portion, and an outer portion of the handle alignment protrusion is farther from the blade plane in the direction of the roll than an inner portion of the handle alignment protrusion. [Aspect 10] the actuator assembly is configured to adjust at least the pitch and the roll of the blade support relative to the handheld portion; A handheld surgical robot system according to any one of aspects 6 to 9, wherein the portion of the angled handle alignment protrusion provides a visual indication of the pose of the handheld portion relative to the blade support in at least two degrees of freedom, whereby the second spatial arrangement of the handle alignment protrusion relative to the blade plane provides a visual indication of at least the second pitch relationship and the second roll relationship of the blade support relative to the handheld portion, and provides a visual indication that the handheld portion is in a pose relative to the blade support that does not provide the blade support with the optimal range of motion. [Aspect 11] the handle alignment member is a first handle alignment member, the handle alignment protrusion is a first handle alignment protrusion, and the handheld surgical robot system further comprises: a second handle alignment member extending from the handheld portion at a location spaced from the first handle alignment member, the second handle alignment member including a second handle alignment protrusion extending toward the blade mount, at least a portion of the second handle alignment protrusion being oblique to the longitudinal axis and the lateral axis of the saw blade; A handheld surgical robot system according to any one of aspects 6 to 10, wherein the first handle alignment protrusion and the second handle alignment protrusion are aligned with the blade plane when the blade support has the optimal range of motion relative to the handheld portion. [Aspect 12] the actuator assembly is configured to adjust at least the pitch of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first pitch relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second pitch relationship of the blade support relative to the handheld portion; A handheld surgical robot system as described in aspect 11, wherein the second pitch relationship provides a visual indication of the pitch of the blade support relative to the handheld portion, and a first portion of each of the first handle alignment protrusion and the second handle alignment protrusion is farther from the blade plane in the direction of the pitch along the longitudinal axis than a second portion of each of the first handle alignment protrusion and the second handle alignment protrusion. [Aspect 13] the actuator assembly is configured to adjust at least the height of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first height relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second height relationship of the blade support relative to the handheld portion; A handheld surgical robot system as described in aspect 11 or 12, wherein the second height relationship provides a visual indication of the height of the blade support relative to the handheld portion, and the first handle alignment protrusion and the second handle alignment protrusion are at least partially above or below the blade plane in the height direction. [Aspect 14] the actuator assembly is configured to adjust at least the roll of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first roll relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second roll relationship of the blade support relative to the handheld portion; A handheld surgical robot system according to any one of aspects 11 to 13, wherein the second roll relationship provides a visual indication of the roll of the blade support relative to the handheld portion, and an outer portion of each of the first handle alignment protrusion and the second handle alignment protrusion is farther from the blade plane in the direction of the roll than an inner portion of each of the first handle alignment protrusion and the second handle alignment protrusion. [Aspect 15] the actuator assembly is configured to adjust at least the pitch and the roll of the blade support relative to the handheld portion; A handheld surgical robot system according to any one of aspects 11 to 14, wherein the slanted portions of the first and second handle alignment protrusions provide a visual indication of the pose of the handheld portion relative to the blade support in at least two degrees of freedom, whereby a second spatial arrangement of the first and second handle alignment protrusions relative to the blade plane provides a visual indication of at least the second pitch relationship and the second roll relationship of the blade support relative to the handheld portion, and provides a visual indication that the handheld portion is in a pose relative to the blade support that does not provide the optimal range of motion for the blade support. [Aspect 16] a shroud coupled to and extending between the blade support and the handheld portion; A handheld surgical robotic system according to any one of aspects 1 to 15, wherein the shroud defines at least two shroud landmarks configured to move relative to one another when the blade support and the handheld portion are not aligned with one another, whereby the handheld portion is in a pose that does not provide the optimal range of motion to provide a visual indication of the pose of the blade support relative to the handheld portion. [Aspect 17] the at least two shroud landmarks include at least two folds, the folds defining planes that are substantially parallel and offset from one another by a first distance, and the blade support has an optimal range of motion relative to the handheld portion; A handheld surgical robot system as described in aspect 16, wherein when the blade support and the handheld portion are not aligned relative to each other, the at least two folds move to a second distance from each other and the handheld portion is in a pose that does not provide the optimal range of motion to provide a visual indication of the pose of the blade support relative to the handheld portion. [Aspect 18] A handheld surgical robot system as described in aspect 17, wherein when the blade support and the handheld portion are aligned with respect to each other, the at least two folds are substantially parallel to the blade plane. [Aspect 19] the handle alignment member includes at least two shroud alignment members; the at least two shroud alignment members are configured to be aligned with the at least two shroud landmarks when the blade support is aligned with the handheld portion; A handheld surgical robot system according to any one of aspects 16 to 18, wherein when the blade support and the handheld portion are not aligned relative to each other, the at least two shroud alignment members are not aligned with the at least two shroud landmarks, thereby causing the handheld portion to be in a pose that does not provide the optimal range of motion to provide a visual indication of the pose of the blade support relative to the handheld portion. [Aspect 20] 20. The handheld surgical robot system of any one of aspects 2 to 19, further comprising a tool alignment member extending from the blade support, the tool alignment member including a tool alignment protrusion extending toward the blade mount, at least a portion of the tool alignment protrusion being oblique to the longitudinal axis and the lateral axis of the saw blade. [Aspect 21] A handheld surgical robotic system as described in aspect 20, wherein at least a portion of the tool alignment protrusion is oblique to the longitudinal axis and the lateral axis of the saw blade. [Aspect 22] the tool alignment protrusion defining a tool alignment edge, and the handle alignment member defining a handle alignment edge oblique to the longitudinal and lateral axes of the saw blade; A handheld surgical robot system as described in aspect 21, wherein the tool alignment edge is defined such that when the blade support is aligned with the handheld portion, the tool alignment edge is offset from and parallel to the handle alignment edge. [Aspect 23] A handheld surgical robotic system according to aspect 21 or 22, wherein when the handheld portion is in a pose that does not provide the optimal range of motion, the tool alignment protrusion and the handle alignment protrusion are not aligned, providing a visual indication that the handheld portion is in a pose that does not provide the optimal range of motion for the blade support. [Aspect 24] 24. The handheld surgical robot system of any one of aspects 21 to 23, wherein the actuator assembly includes a plurality of actuators, the tool alignment member and the handle alignment member being positioned and sized relative to each other so as not to collide with each other at any point between the first and second positions of each of the plurality of actuators, the collective first and second positions of each of the plurality of actuators defining a potential range of motion of the blade support relative to the handheld portion, and the potential range of motion defining a space having a height of approximately 150 mm and a width of approximately 115 mm. [Aspect 25] the actuator assembly is configured to adjust at least one of a pitch, a height, or a roll of the blade support relative to the handheld portion; a first spatial arrangement of the handle alignment protrusion relative to the tool alignment protrusion provides a visual indication of at least one of a first pitch relationship, a first height relationship, and a first roll relationship of the blade support relative to the handheld portion; the first spatial arrangement provides a visual indication that the handle alignment protrusion and the tool alignment protrusion are aligned and that the blade support has an optimal range of motion relative to the handheld portion; a second spatial arrangement of the handle alignment protrusion relative to the tool alignment protrusion provides a visual indication of at least one of a second pitch relationship, a second height relationship, or a second roll relationship of the blade support relative to the handheld portion; Aspect 25. The handheld surgical robotic system of any one of aspects 21 to 24, wherein the second spatial arrangement provides a visual indication that the handheld portion is in a pose that does not provide the blade support with the optimal range of motion. [Aspect 26] the actuator assembly is configured to adjust at least the pitch of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first pitch relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second pitch relationship of the blade support relative to the handheld portion; A handheld surgical robot system as described in aspect 25, wherein the second pitch relationship provides a visual indication of the pitch of the blade support relative to the handheld portion, and a first portion of the handle alignment protrusion is farther from the tool alignment protrusion along the longitudinal axis in the direction of the pitch than a second portion of the handle alignment protrusion. [Aspect 27] the actuator assembly is configured to adjust at least a height of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first height relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second height relationship of the blade support relative to the handheld portion; A handheld surgical robot system as described in aspect 25 or 26, wherein the second height relationship provides a visual indication of the height of the blade support relative to the handheld portion, and the tool alignment protrusion is at least partially above or below the handle alignment protrusion in the height direction. [Aspect 28] the actuator assembly is configured to adjust at least the roll of the blade support relative to the handheld portion, the first spatial arrangement providing a visual indication of the first roll relationship of the blade support relative to the handheld portion, and the second spatial arrangement providing a visual indication of the second roll relationship of the blade support relative to the handheld portion; A handheld surgical robot system according to any one of aspects 25 to 27, wherein the second roll relationship provides a visual indication of the roll of the blade support relative to the handheld portion, and an outer portion of the handle alignment protrusion is farther from the tool alignment protrusion in the direction of the roll than the outer portion of the handle alignment protrusion. [Aspect 29] the actuator assembly is configured to adjust at least the pitch and the roll of the blade support relative to the handheld portion; A handheld surgical robot system according to any one of aspects 25 to 28, wherein a portion of the handle alignment protrusion that is slanted provides a visual indication of the pose of the handheld portion relative to the tool alignment protrusion in at least two degrees of freedom, whereby the second spatial arrangement of the handle alignment protrusion relative to the tool alignment protrusion provides a visual indication of at least the second pitch relationship and the second roll relationship of the blade support relative to the handheld portion, and provides a visual indication that the handheld portion is in a pose relative to the blade support that does not provide the optimal range of motion for the blade support. [Aspect 30] Aspect 30. The handheld surgical robot system of any one of aspects 21 to 29, wherein the handle alignment protrusion and the tool alignment protrusion include a first visual mark and a second visual mark, and the first visual mark is visually distinguishable from the second visual mark. [Aspect 31] when the tool alignment protrusion and the handle alignment protrusion are aligned, the first visual indicia on the handle alignment protrusion and the first visual indicia on the tool alignment protrusion are aligned, providing a visual indication that the blade support has the optimal range of motion relative to the handheld portion; A handheld surgical robot system as described in aspect 30, wherein when the tool alignment protrusion and the handle alignment protrusion are not aligned, the first visual marking on the handle alignment protrusion and the first visual marking on the tool alignment protrusion are not aligned, providing a visual indication that the handheld portion is in a pose that does not provide the blade support with the optimal range of motion. [Aspect 32] 32. The handheld surgical robotic system of aspect 30 or 31, wherein the first visual indicia is a first color and the second visual indicia is a second color. [Aspect 33] Aspect 33. The handheld surgical robotic system of any one of aspects 30 to 32, wherein the handle alignment protrusion and the tool alignment protrusion each further include a beveled surface and a side surface. [Aspect 34] A handheld surgical robot system as described in aspect 33, wherein the beveled surface includes the first visual marking and the side surface includes the second visual marking. [Aspect 35] Aspect 35. Th...

Claims

1. 1. A handheld surgical robotic system, comprising: The handheld part and a blade support movably coupled to the handheld portion, the blade support including a blade mount defining a blade plane; a saw blade removably coupled to the blade support and disposed in the blade plane, the saw blade defining a longitudinal axis and a lateral axis perpendicular to the longitudinal axis; an actuator assembly operably attached to the blade support and the handheld portion, the actuator assembly configured to move the blade support relative to the handheld portion in multiple degrees of freedom, the actuator assembly including a plurality of actuators, each of the plurality of actuators configured to move between a first position and a second position to move the blade support relative to the handheld portion; a handle alignment member extending from the handheld portion, the handle alignment member including a handle alignment protrusion extending toward the blade mount, at least a portion of the handle alignment protrusion being oblique to the longitudinal and lateral axes of the saw blade; Equipped with a home position of each of the plurality of actuators at a midpoint between the first position and the second position; A handheld surgical robotic system, wherein when the blade support has an optimal range of motion relative to the handheld portion, a portion of the handle alignment protrusion and the blade plane are aligned, and when at least two of the plurality of actuators are in the home position, the blade support has the optimal range of motion.

2. A handheld surgical robot system as described in claim 1, wherein when the handheld portion is in a pose that does not provide the optimal range of motion, the blade plane and the handle alignment protrusion are not aligned, providing a visual indication that the handheld portion is in a pose that does not provide the optimal range of motion for the blade support.

3. A handheld surgical robot system as described in claim 1 or 2, wherein the handle alignment member is positioned and sized relative to the blade support so that the handle alignment member does not collide with the blade support at any point between the first position and the second position of each of the plurality of actuators of the actuator assembly.

4. A handheld surgical robot system as described in claim 3, wherein the first and second positions of the plurality of actuators define a range of motion of the distal end of the saw blade relative to the handheld portion, the range of motion defining a space having a maximum height of 150 mm and a maximum width of 115 mm.

5. The actuator assembly is configured to adjust at least one of pitch, height, and roll of the blade support relative to the handheld portion; a first spatial arrangement of the handle alignment protrusion relative to the blade plane to provide a visual indication of at least one of a first pitch relationship, a first height relationship, and a first roll relationship of the blade support relative to the handheld portion; the first spatial arrangement provides a visual indication that the handle alignment protrusion and the blade plane are aligned and that the blade support has the optimal range of motion relative to the handheld portion; a second spatial arrangement of the handle alignment protrusion relative to the blade plane provides a visual indication of at least one of a second pitch relationship, a second height relationship, and a second roll relationship of the blade support relative to the handheld portion; 5. The handheld surgical robotic system of claim 1, wherein the second spatial arrangement provides a visual indication that the handheld portion is in a pose relative to the blade support that does not provide the blade support with the optimal range of motion.

6. The handle alignment member is a first handle alignment member, the handle alignment protrusion is a first handle alignment protrusion, the handheld surgical robotic system further includes a second handle alignment member extending from the handheld portion at a location spaced from the first handle alignment member, the second handle alignment member including a second handle alignment protrusion extending toward the blade mount, at least a portion of the second handle alignment protrusion being oblique to the longitudinal axis and the lateral axis of the saw blade; 6. The handheld surgical robot system of claim 5, wherein the first handle alignment protrusion and the second handle alignment protrusion are aligned with the blade plane when the blade support has the optimal range of motion relative to the handheld portion.

7. The actuator assembly is configured to adjust at least the pitch and the roll of the blade support relative to the handheld portion; 7. The handheld surgical robot system of claim 6, wherein portions of the first and second handle alignment protrusions that are angled provide a visual indication of the pose of the handheld portion relative to the blade support in at least two degrees of freedom, whereby a second spatial arrangement of the first and second handle alignment protrusions relative to the blade plane provides a visual indication of at least the second pitch relationship and the second roll relationship of the blade support relative to the handheld portion, and provides a visual indication that the handheld portion is in a pose relative to the blade support that does not provide the optimal range of motion for the blade support.

8. The method of claim 7, further comprising: providing a shroud coupled to the blade support and the handheld portion and extending between the blade support and the handheld portion; 8. The handheld surgical robot system of claim 1, wherein the shroud defines at least two shroud landmarks configured to move relative to one another when the blade support and the handheld portion are not aligned with one another, whereby the handheld portion is in a pose that does not provide the optimal range of motion to provide a visual indication of the pose of the blade support relative to the handheld portion.

9. The at least two shroud landmarks include at least two folds, the folds defining planes that are substantially parallel and offset from one another by a first distance, and the blade support has the optimal range of motion relative to the handheld portion; 9. The handheld surgical robotic system of claim 8, wherein when the blade support and the handheld portion are not aligned relative to one another, the at least two folds move to a second distance from one another to provide a visual indication of the pose of the blade support relative to the handheld portion, with the handheld portion in a pose that does not provide the optimal range of motion.

10. A handheld surgical robot system as described in claim 9, wherein when the blade support and the handheld portion are aligned with each other, the at least two folds are substantially parallel to the blade plane.

11. The handle alignment member includes at least two shroud alignment members; the at least two shroud alignment members are configured to be aligned with the at least two shroud landmarks when the blade support is aligned with the handheld portion; 11. The handheld surgical robot system of claim 8, wherein when the blade support and the handheld portion are not aligned relative to one another, the at least two shroud alignment members are not aligned with the at least two shroud landmarks, thereby causing the handheld portion to be in a pose that does not provide the optimal range of motion to provide a visual indication of the pose of the blade support relative to the handheld portion.

12. A handheld surgical robot system as described in any one of claims 1 to 11, further comprising a tool alignment member extending from the blade support, the tool alignment member including a tool alignment protrusion extending toward the blade mount, at least a portion of the tool alignment protrusion being oblique to the longitudinal axis and the lateral axis of the saw blade.

13. A handheld surgical robot system as described in claim 12, wherein at least a portion of the tool alignment protrusion is oblique to the longitudinal axis and the lateral axis of the saw blade.

14. The tool alignment protrusion defines a tool alignment edge, and the handle alignment member defines a handle alignment edge oblique to the longitudinal axis and the lateral axis of the saw blade; 14. The handheld surgical robotic system of claim 13, wherein the tool alignment edge is defined such that the tool alignment edge is offset from and parallel to the handle alignment edge when the blade support is aligned with the handheld portion.

15. A handheld surgical robot system as described in claim 13 or 14, wherein when the handheld portion is in a pose that does not provide the optimal range of motion, the tool alignment protrusion and the handle alignment protrusion are not aligned, providing a visual indication that the handheld portion is in a pose that does not provide the optimal range of motion for the blade support.

16. The actuator assembly is configured to adjust at least one of a pitch, a height, or a roll of the blade support relative to the handheld portion; a first spatial arrangement of the handle alignment protrusion relative to the tool alignment protrusion provides a visual indication of at least one of a first pitch relationship, a first height relationship, and a first roll relationship of the blade support relative to the handheld portion; the first spatial arrangement provides a visual indication that the handle alignment protrusion and the tool alignment protrusion are aligned and that the blade support has the optimal range of motion relative to the handheld portion; a second spatial arrangement of the handle alignment protrusion relative to the tool alignment protrusion provides a visual indication of at least one of a second pitch relationship, a second height relationship, or a second roll relationship of the blade support relative to the handheld portion; 16. The handheld surgical robotic system of claim 13, wherein the second spatial arrangement provides a visual indication that the handheld portion is in a pose that does not provide the optimal range of motion for the blade support.

17. The actuator assembly is configured to adjust at least the pitch of the blade support relative to the handheld portion, wherein the first spatial arrangement provides a visual indication of the first pitch relationship of the blade support relative to the handheld portion, and the second spatial arrangement provides a visual indication of the second pitch relationship of the blade support relative to the handheld portion; 17. The handheld surgical robot system of claim 16, wherein the second pitch relationship provides a visual indication of the pitch of the blade support relative to the handheld portion, and wherein a first portion of the handle alignment protrusion is farther from the tool alignment protrusion along the longitudinal axis in the direction of the pitch than a second portion of the handle alignment protrusion.

18. A handheld surgical robot system as described in any one of claims 13 to 17, wherein the handle alignment protrusion and the tool alignment protrusion include a first visual mark and a second visual mark, and the first visual mark is visually distinguishable from the second visual mark.

19. When the tool alignment protrusion and the handle alignment protrusion are aligned, the first visual marking on the handle alignment protrusion and the first visual marking on the tool alignment protrusion are aligned to provide a visual indication that the blade support has the optimal range of motion relative to the handheld portion; 20. The handheld surgical robotic system of claim 18, wherein when the tool alignment protrusion and the handle alignment protrusion are not aligned, the first visual indicia on the handle alignment protrusion and the first visual indicia on the tool alignment protrusion are not aligned, providing a visual indication that the handheld portion is in a pose that does not provide the optimal range of motion for the blade support.

20. A handheld surgical robot system as described in claim 18 or 19, wherein the first visual indicia is a first color and the second visual indicia is a second color.

21. A handheld surgical robot system as described in any one of claims 18 to 20, wherein the handle alignment protrusion and the tool alignment protrusion each further include a beveled surface and a side surface.

22. A handheld surgical robot system as described in claim 21, wherein the beveled surface includes the first visual marking and the side surface includes the second visual marking.

23. A handheld surgical robot system as described in any one of claims 1 to 22, wherein the handle alignment member is configured to be removably coupled to the handheld portion.

24. A handheld surgical robot system as described in claim 12, wherein the tool alignment member is configured to be removably coupled to the blade support.

25. A handheld surgical robot system as described in any one of claims 1 to 24, wherein the portion of the handle alignment protrusion that is oblique to the longitudinal axis and the lateral axis defines a curve.

26. A handheld surgical robot system as described in claim 12, wherein the tool alignment member is closer to the blade support than the handle alignment member.

27. A handheld surgical robotic system for supporting a saw blade, comprising: The handheld part and a tool support movably coupled to the handheld portion and defining a tool support plane; an actuator assembly operably attached to the tool support and the handheld portion, the actuator assembly configured to move the tool support relative to the handheld portion in multiple degrees of freedom, the actuator assembly including a plurality of actuators, each of the plurality of actuators configured to move between a first position and a second position to move the tool support relative to the handheld portion; a handle alignment member extending from the handheld portion, the handle alignment member including a handle hook-shaped portion; Equipped with a home position of each of the plurality of actuators at a midpoint between the first position and the second position; a handheld surgical robotic system, wherein the tool support has an optimal range of motion relative to the handheld portion when the handle hook-shaped portion and the tool support plane are aligned and when at least two of the plurality of actuators are in the home position; 28. A handheld surgical robotic system, comprising: The handheld part and a tool support movably coupled to the handheld portion and defining a tool support plane; a tool removably coupled to the tool support, the tool defining a longitudinal axis and a lateral axis; an actuator assembly operably attached to the tool support and the handheld portion, the actuator assembly configured to move the tool support relative to the handheld portion in multiple degrees of freedom, the actuator assembly including a plurality of actuators, each of the plurality of actuators configured to move between a first position and a second position to move the tool support relative to the handheld portion; a handle alignment member extending from the handheld portion, the handle alignment member including a handle alignment protrusion extending toward the tool support, at least a portion of the handle alignment protrusion being disposed at an angle greater than 0 degrees and less than 90 degrees relative to the longitudinal axis; Equipped with a home position of each of the plurality of actuators at a midpoint between the first position and the second position; a handheld surgical robotic system, wherein when the tool support has an optimal range of motion relative to the handheld portion, a portion of the handle alignment protrusion and the tool support plane are aligned, and when at least two of the plurality of actuators are in the home position, the tool support has the optimal range of motion.

29. A handheld surgical robotic system for supporting a tool, comprising: The handheld part and a tool support movably coupled to the handheld portion, the tool support configured to support a tool defining a tool plane; and an actuator assembly operably attached to the tool support and the handheld portion, the actuator assembly configured to move the tool support relative to the handheld portion in multiple degrees of freedom; a handle alignment member extending from the handheld portion; Equipped with The handle alignment member a handle support arm extending between a first handle support arm end and a second handle support arm end, the handle support arm including a handle coupling portion coupled to the first handle support arm end and removably coupled to the handheld portion; a handle alignment member mount coupled to the second handle support arm end; a handle alignment member coupled to the handle alignment member mount; A handheld surgical robotic system.

30. A handheld surgical robotic system, comprising: The handheld part and a blade support movably coupled to the handheld portion, the blade support including a blade mount defining a blade plane; a saw blade removably coupled to the blade support and disposed in the blade plane, the saw blade defining a longitudinal axis and a lateral axis perpendicular to the longitudinal axis; an actuator assembly operably attached to the blade support and the handheld portion, the actuator assembly including a plurality of actuators configured to move the blade support relative to the handheld portion in a plurality of degrees of freedom, each of the plurality of actuators configured to move between a first position and a second position to move the blade support relative to the handheld portion; a handle alignment member extending from the handheld portion, the handle alignment member including a handle alignment protrusion extending toward the blade mount, at least a portion of the handle alignment protrusion being oblique to the longitudinal and lateral axes of the saw blade; Equipped with A handheld surgical robotic system, wherein a portion of the handle alignment protrusion and the blade plane are aligned to indicate that the blade support has an optimal range of motion when at least two of the plurality of actuators are in a home position, the home position providing the actuators with maximum movement in each direction.

31. A handheld surgical robotic system, comprising: The handheld part and a blade support movably coupled to the handheld portion, the blade support including a blade mount defining a blade plane; a saw blade removably coupled to the blade support and disposed in the blade plane, the saw blade defining a longitudinal axis and a lateral axis perpendicular to the longitudinal axis; an actuator assembly operably attached to the blade support and the handheld portion, the actuator assembly including a plurality of actuators configured to move the blade support relative to the handheld portion in a plurality of degrees of freedom, each of the plurality of actuators configured to move between a first position and a second position to move the blade support relative to the handheld portion; a handle alignment member extending from the handheld portion, the handle alignment member including a handle alignment protrusion extending toward the blade mount, at least a portion of the handle alignment protrusion being oblique to the longitudinal and lateral axes of the saw blade; Equipped with A handheld surgical robotic system, wherein a portion of the handle alignment protrusion and the blade plane are aligned to indicate that the blade support has an optimal range of motion when at least two of the plurality of actuators have a maximum amount of movement possible in either direction.

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