Systems using surgical tools for removing soft tissue

Abstract

Systems and methods using surgical tools for removing soft tissue are provided. The surgical tool may include a drive assembly for rotating at least one cutting sprocket or cutting tool. The drive assembly may include a roller chain having one or more extended pins that are received in corresponding valleys between adjacent teeth of the at least one cutting sprocket. Rotation of the roller chain thus rotates the at least one cutting sprocket.

Description

SYSTEMS USING SURGICAL TOOLS FOR REMOVING SOFT TISSUEBACKGROUND

[0001] The present disclosure is generally directed to surgical tools, and relates more particularly to surgical tools for removing soft tissue such as, for example, disc and / or cartilage.

[0002] A surgeon or other medical provider may use one or more surgical tools when carrying out a surgical procedure. Removal of certain tissues may be difficult due to a geometry of the patient anatomy, limited access pathways, decreased reachability, and / or tissue quality.BRIEF SUMMARY

[0003] Example aspects of the present disclosure include:

[0004] A surgical tool according to at least one embodiment of the present disclosure comprises: a drive assembly comprising a drive shaft configured to be rotated by a motor, a drive sprocket connected to the drive shaft, and a roller chain driven by the drive sprocket, the roller chain having one or more extended pins; and at least one cutting sprocket having a plurality of teeth, wherein the one or more extended pins are received in corresponding valleys between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one cutting sprocket.

[0005] Any of the aspects herein, wherein the at least one cutting sprocket comprises a first cutting sprocket and a second cutting sprocket.

[0006] Any of the aspects herein, wherein the first cutting sprocket defines a first plane and the second cutting sprocket defines a second plane, wherein the first plane and the second plane are parallel to each other and spaced apart from each other.

[0007] Any of the aspects herein, wherein a distance between the first plane and the second plane is less than a thickness of a vertebral disc space.

[0008] Any of the aspects herein, wherein the surgical tool is at least one of oriented and operated by a robotic arm or manually oriented and operated.

[0009] Any of the aspects herein, further comprising: a housing configured to house at least a portion of the chain drive assembly; a first tube extending from the housing; and a second tube extending from the house.

[0010] Any of the aspects herein, wherein the first tube is connected to a fluid source to supply fluids to the at least one cutting sprocket and the second tube is connected to a receptacle and a vacuum source to remove fluids and soft tissue from the at least one cutting sprocket.

[0011] Any of the aspects herein, the sprocket is at least one of circular or oval in shape when viewed from the top.

[0012] Any of the aspects herein, further comprising at least one sensor configured to sense at least one value of the surgical tool.

[0013] Any of the aspects herein, wherein the at least one value comprises force.

[0014] A surgical tool according to at least one embodiment of the present disclosure comprises: a chain drive assembly comprising a drive shaft configured to be rotated by a motor, a drive sprocket connected to the drive shaft, and a roller chain driven by the drive sprocket, the roller chain having one or more extended pins; at least one driven sprocket having a plurality of teeth; and at least one shaving tool coupled to the at least one driven sprocket, wherein the one or more extended pins are received in corresponding valleys between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one at least one driven sprocket and the at least one shaving tool.

[0015] Any of the aspects herein, wherein the at least one shaving tool comprises a sheet having at least one of a plurality of raised features on a surface of the solid sheet or a plurality of openings extending through the solid sheet.

[0016] Any of the aspects herein, wherein the sheet includes at least one serrated edge.

[0017] Any of the aspects herein, wherein the sheet comprises a metal sheet.

[0018] Any of the aspects herein, wherein the at least one shaving tool comprises a plurality of arms, a shaving feature extending from each arm of the plurality of arms, and at least one opening on each arm of the plurality of arms.

[0019] Any of the aspects herein, further comprising at least one sensor configured to sense at least one value of the surgical tool.

[0020] Any of the aspects herein, wherein the at least one shaving tool comprises a first shaving tool and a second shaving tool, wherein the first shaving tool defines a first plane and the second shaving tool defines a second plane, wherein the first plane and the second plane are parallel to each other and spaced apart from each other.

[0021] Any of the aspects herein, wherein a distance between the first plane and the second plane is less than a thickness of a vertebral disc space.

[0022] A system according to at least one embodiment of the present disclosure comprises a surgical tool comprising: a chain drive assembly having a drive shaft configured to be rotated by a motor, a drive sprocket connected to the drive shaft, and a roller chain driven by the drive sprocket, the roller chain having one or more extended pins; and at least one cutting sprocket having a plurality of teeth, wherein the one or more extended pins are received in corresponding valleys between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one cutting sprocket; and a robotic arm configured to orient and operate the surgical tool.

[0023] Any of the aspects herein, further comprising: at least one sensor configured to sense at least one value of the surgical tool; a processor; and a memory storing data for processing by the processor, the data, when processed, causes the processor to: receive sensor data from the at least one sensor; and generate notification when the sensor data meets or exceeds a predetermined threshold.

[0024] Any aspect in combination with any one or more other aspects.

[0025] Any one or more of the features disclosed herein.

[0026] Any one or more of the features as substantially disclosed herein.

[0027] Any one or more of the features as substantially disclosed herein in combination with any one or more other features as substantially disclosed herein.

[0028] Any one of the aspects / features / embodiments in combination with any one or more other aspects / features / embodiments.

[0029] Use of any one or more of the aspects or features as disclosed herein.

[0030] It is to be appreciated that any feature described herein can be claimed in combination with any other feature / s) as described herein, regardless of whether the features come from the same described embodiment.

[0031] The details of one or more aspects of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the techniques described in this disclosure will be apparent from the description and drawings, and from the claims.

[0032] The phrases “at least one”, “one or more”, and “and / or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and / or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. When each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or class of elements, such as XI -Xn, Yl- Ym, and Zl-Zo, the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., XI and X2) as well as a combination of elements selected from two or more classes (e.g., Y 1 and Zo).

[0033] The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.

[0034] The preceding is a simplified summary of the disclosure to provide an understanding of some aspects of the disclosure. This summary is neither an extensive nor exhaustive overview of the disclosure and its various aspects, embodiments, and configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

[0035] Numerous additional features and advantages of the present disclosure will become apparent to those skilled in the art upon consideration of the embodiment descriptions provided hereinbelow.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0036] The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, explain the principles of the disclosure. The drawings simply illustrate preferred and alternative examples of how the disclosure can be made and used and are not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the variousaspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.

[0037] Fig. 1 is a block diagram of a system according to at least one embodiment of the present disclosure;

[0038] Fig. 2A is a tilted view of a surgical tool according to at least one embodiment of the present disclosure;

[0039] Fig. 2B is a tilted, detailed, exploded view of the surgical tool of Fig. 2A according to at least one embodiment of the present disclosure;

[0040] Fig. 2C is a top view of a cutting tool of the surgical tool of Fig. 2A according to at least one embodiment of the present disclosure;

[0041] Fig. 2D is a side view of the cutting tool of the surgical tool of Fig. 2A according to at least one embodiment of the present disclosure;

[0042] Fig. 3 is a tilted view of a surgical tool according to at least one embodiment of the present disclosure;

[0043] Fig. 4A is a tilted view of a surgical tool according to at least one embodiment of the present disclosure;

[0044] Fig. 4B is a tilted, detailed, exploded view of the surgical tool of Fig. 4A according to at least one embodiment of the present disclosure;

[0045] Fig. 4C is a top view of a cutting tool of the surgical tool of Fig. 4A according to at least one embodiment of the present disclosure;

[0046] Fig. 4D is a side view of the cutting tool of the surgical tool of Fig. 4A according to at least one embodiment of the present disclosure;

[0047] Fig. 5A is a tilted view of a surgical tool according to at least one embodiment of the present disclosure;

[0048] Fig. 5B is a tilted, detailed, exploded view of the surgical tool of Fig. 5A according to at least one embodiment of the present disclosure;

[0049] Fig. 5C is a top view of a shaving tool of the surgical tool of Fig. 5A according to at least one embodiment of the present disclosure;

[0050] Fig. 5D is a side view of the shaving tool of the surgical tool of Fig. 5A according to at least one embodiment of the present disclosure;

[0051] Fig. 6A is a top tilted view of a pair of shaving tools according to at least one embodiment of the present disclosure;

[0052] Fig. 6B is a bottom tilted view of the pair of shaving tools of Fig. 6A according to at least one embodiment of the present disclosure;

[0053] Fig. 7A is a top tilted view of a shaving tool according to at least one embodiment of the present disclosure;

[0054] Fig. 7B is a top view of the shaving tool of Fig. 7 A according to at least one embodiment of the present disclosure;

[0055] Fig. 8A is a top tilted view of a shaving tool according to at least one embodiment of the present disclosure;

[0056] Fig. 8B is a top view of the shaving tool of Fig. 8A according to at least one embodiment of the present disclosure; and

[0057] Fig. 9 is a flow chart according to at least one embodiment of the present disclosure.DETAILED DESCRIPTION

[0058] It should be understood that various aspects disclosed herein may be combined in different combinations than the combinations specifically presented in the description and accompanying drawings. It should also be understood that, depending on the example or embodiment, certain acts or events of any of the processes or methods described herein may be performed in a different sequence, and / or may be added, merged, or left out altogether (e.g., all described acts or events may not be necessary to carry out the disclosed techniques according to different embodiments of the present disclosure). In addition, while certain aspects of this disclosure are described as being performed by a single module or unit for purposes of clarity, it should be understood that the techniques of this disclosure may be performed by a combination of units or modules associated with, for example, a computing device and / or a medical device.

[0059] In one or more examples, the described methods, processes, and techniques may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored as one or more instructions or code on a computer-readable medium and executed by a hardware -based processing unit. Alternatively or additionally, functions may be implemented using machine learning models, neural networks, artificial neural networks, or combinations thereof (alone or in combination with instructions). Computer- readable media may include non-transitory computer-readable media, which corresponds to atangible medium such as data storage media (e.g., RAM, ROM, EEPROM, flash memory, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer).

[0060] Instructions may be executed by one or more processors, such as one or more digital signal processors (DSPs), general purpose microprocessors (e.g., Intel Core i3, i5, i7, or i9 processors; Intel Celeron processors; Intel Xeon processors; Intel Pentium processors; AMD Ryzen processors; AMD Athlon processors; AMD Phenom processors; Apple A10 or 10X Fusion processors; Apple Al l, A12, A12X, A12Z, or A13 Bionic processors; or any other general purpose microprocessors), graphics processing units (e.g., Nvidia GeForce RTX 2000- series processors, Nvidia GeForce RTX 3000-series processors, AMD Radeon RX 5000-series processors, AMD Radeon RX 6000-series processors, or any other graphics processing units), application specific integrated circuits (ASICs), field programmable logic arrays (FPGAs), or other equivalent integrated or discrete logic circuitry. Accordingly, the term “processor” as used herein may refer to any of the foregoing structure or any other physical structure suitable for implementation of the described techniques. Also, the techniques could be fully implemented in one or more circuits or logic elements.

[0061] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Further, the present disclosure may use examples to illustrate one or more aspects thereof. Unless explicitly stated otherwise, the use or listing of one or more examples (which may be denoted by “for example,” “by way of example,” “e.g.,” “such as,” or similar language) is not intended to and does not limit the scope of the present disclosure.

[0062] The terms proximal and distal are used in this disclosure with their conventional medical meanings, proximal being closer to the operator or user of the system, and further fromthe region of surgical interest in or on the patient, and distal being closer to the region of surgical interest in or on the patient, and further from the operator or user of the system.

[0063] Surgical procedures such as, for example, disc and / or cartilage removal may be difficult to perform manually by a user such as, for example, a physician due to due to cumbersome geometry, limited access pathways, decreased reachability, and / or tissue viscoelastic and density qualities particularly in between joints. Further, the disc and / or cartilage removal may be difficult due to the lack of clear visibility and repetitive actions that commonly leave partial tissue present.

[0064] Moreover, for procedures involving fusion, disc and / or cartilage removal is needed to achieve joint fusion or clearance of a joint space for implants placement and a slight scraping of the bone cortex is needed to increase the chances of successful fusion. Conventional methods for removing the disc and / or cartilage include tearing tissue in a repetitive manner, which may result in a poor surface and space for the implant. More specifically, limited disc and or cartilage removal affects implant placement, which may prevent joint angulation and / or intra space separation.

[0065] Surgical tools and systems for removing the disc and / or cartilage in a continuous and precise manner according to embodiments of the present disclosure are provided. The surgical tool(s) may be powered and used as a standalone tool, as a navigated tool, and / or oriented and operated by a robotic arm of a robot to access limited surgical pathway. The surgical tool(s) are also capable of removing disc and / or cartilage tissue in multiple planes simultaneously. The surgical tool(s) can also be manually advanced, or advanced automatically using, for example, sensors for monitoring a force exerted by or exerted on the surgical tool during advancement. The surgical tool(s) may also provide fluids to a cutting tool of the surgical tool and may also provide a vacuum for removing the fluids and soft tissue.

[0066] The surgical tool(s) may include a surgical tool for removing a majority of disc material and / or cartilage from a disc space. The surgical tool(s) may also include a shaver tool that expands while removing soft tissue near hard tissue such as, for example, end plates or bone cortex. The shaver tool scrapes the hard tissue surface, but does not damage or fracture the hard tissue surface.

[0067] Target soft tissue to remove (e.g., disc material, cartilage, etc.) can be planned preoperatively and a navigation system and / or robotic system can assist and guide a user such as the physician to reach the planned location. Furthermore, the robotic system can perform theprocedure in a robotic assisted guidance manual physician driven, as well as semi automatic or fully automatic.

[0068] Embodiments of the present disclosure provide technical solutions to one or more of the problems of (1) removing soft tissue in regions with limited access or limited pathways, (2) removing soft tissue in a precise manner without damaging nearby hard tissue, and (3) reducing operating time thereby increasing patient and surgical team safety.

[0069] Turning first to Fig. 1, a block diagram of a system 100 according to at least one embodiment of the present disclosure is shown. The system 100 may be used to operate one or more surgical tools 126 for soft tissue removal and / or preparing a surface of hard tissue (e.g., rasping) and / or to carry out one or more other aspects of one or more of the methods disclosed herein. More specifically, the soft tissue may be, for example, disc material such as cartilage, the nucleus pulposus, and / or the annulus fibrosus. The soft tissue may be removed and the hard tissue (e.g., gone) may be prepared by, for example, rasping to facilitate, for example, installation of an implant for a fusion procedure.

[0070] The system 100 comprises a computing device 102, a robot 114, one or more controller(s) 124, one or more surgical tool(s) 126, a navigation system 118, a database 130, and / or a cloud or other network 134. Systems according to other embodiments of the present disclosure may comprise more or fewer components than the system 100. For example, the system 100 may not include the robot 114, the controller 124, the navigation system 118, one or more components of the computing device 102, the database 130, and / or the cloud 134.

[0071] The computing device 102 comprises a processor 104, a memory 106, a communication interface 108, and a user interface 110. Computing devices according to other embodiments of the present disclosure may comprise more or fewer components than the computing device 102.

[0072] The processor 104 of the computing device 102 may be any processor described herein or any similar processor. The processor 104 may be configured to execute instructions stored in the memory 106, which instructions may cause the processor 104 to carry out one or more computing steps utilizing or based on data received from the controller 124, the surgical tool 126 (more specifically, at least one sensor 128 of the surgical tool 126), the robot 114, the navigation system 118, the database 130, and / or the cloud 134.

[0073] The memory 106 may be or comprise RAM, DRAM, SDRAM, other solid-state memory, any memory described herein, or any other tangible, non-transitory memory for storingcomputer-readable data and / or instructions. The memory 106 may store information or data useful for completing, for example, any step of the method 900 described herein, or of any other methods. The memory 106 may store, for example, instructions and / or machine learning models that support one or more functions of the robot 114. For instance, the memory 106 may store content (e.g., instructions and / or machine learning models) that, when executed by the processor 104 or the controller 124, enable sensor data processing 120 and / or notification generation 122.

[0074] The sensor data processing 120 enables the processor 104 to process signals (received from for example, the sensor 128) into sensor data. The sensor data may include, for example, force data, acceleration data, vibration data, and / or pressure data.

[0075] The notification generation 122 enables the processor 104 to generate a notification when a value such as the sensor data meets or exceeds a predetermined threshold. It will be appreciated that in some embodiments, the notification may be generated when the sensor data is below the predetermined threshold. In still other embodiments, the notification may be generated when a difference between the sensor data and an expected sensor data meets or exceeds the predetermined threshold. The notification may be an audible and / or a visual notification (which may be displayed on, for example, the user interface 110).

[0076] Such content, if provided as in instruction, may, in some embodiments, be organized into one or more applications, modules, packages, layers, or engines. Alternatively or additionally, the memory 106 may store other types of content or data (e.g., machine learning models, artificial neural networks, deep neural networks, etc.) that can be processed by the processor 104 to carry out the various method and features described herein. Thus, although various contents of memory 106 may be described as instructions, it should be appreciated that functionality described herein can be achieved through use of instructions, algorithms, and / or machine learning models. The data, algorithms, and / or instructions may cause the processor 104 to manipulate data stored in the memory 106 and / or received from or via the controller 124, the sensor 128, the robot 114, the database 130, and / or the cloud 134.

[0077] The memory 106 may also store a surgical plan 125. The surgical plan 125 may comprise, for example, one or more steps for performing a surgical procedure and / or one or more expected or predetermined thresholds for monitoring one or more values (e.g., the sensor data) during the surgical procedure. In some embodiments, the surgical procedure may be a spinal procedure (e.g., a spinal alignment, installing implants, osteotomy, fusion, and / or any other spinalprocedure) to correct a spinal deformity. For example, the surgical plan 125 may comprise one or more surgical steps for removing disc material in preparation for a fusion procedure. In such embodiments, the surgical plan 125 may include one or more steps for operating one or more surgical tools 126 to remove the disc material and to prepare hard tissue in the disc space for receiving an implant. It will be appreciated that the surgical plan 125 may also be stored in the database 130.

[0078] The computing device 102 may also comprise a communication interface 108. The communication interface 108 may be used for receiving sensor data or other information from an external source (such as the controller 124, the sensor 128, the robot 114, the navigation system 118, the database 130, the cloud 134, and / or any other system or component not part of the system 100), and / or for transmitting instructions, images, or other information to an external system or device (e.g., another computing device 102, the controller 124, the sensor 128, the robot 114, the navigation system 118, the database 130, the cloud 134, and / or any other system or component not part of the system 100). The communication interface 108 may comprise one or more wired interfaces (e.g., a USB port, an Ethernet port, a Firewire port) and / or one or more wireless transceivers or interfaces (configured, for example, to transmit and / or receive information via one or more wireless communication protocols such as 802.11a / b / g / n, Bluetooth, NFC, ZigBee, and so forth). In some embodiments, the communication interface 108 may be useful for enabling the device 102 to communicate with one or more other processors 104 or computing devices 102, whether to reduce the time needed to accomplish a computing-intensive task or for any other reason.

[0079] The computing device 102 may also comprise one or more user interfaces 110. The user interface 110 may be or comprise a keyboard, mouse, trackball, monitor, television, screen, touchscreen, and / or any other device for receiving information from a user and / or for providing information to a user. The user interface 110 may be used, for example, to receive a user selection or other user input regarding any step of any method described herein. Notwithstanding the foregoing, any required input for any step of any method described herein may be generated automatically by the system 100 (e.g., by the processor 104, the controller 124, or another component of the system 100) or received by the system 100 from a source external to the system 100. The user interface 110 may also be used to display, for example, a notification. In some embodiments, the user interface 110 may be useful to allow a surgeon or other user to modifyinstructions to be executed by the processor 104 according to one or more embodiments of the present disclosure, and / or to modify or adjust a setting of other information displayed on the user interface 110 or corresponding thereto.

[0080] Although the user interface 110 is shown as part of the computing device 102, in some embodiments, the computing device 102 may utilize a user interface 110 that is housed separately from one or more remaining components of the computing device 102. In some embodiments, the user interface 110 may be located proximate one or more other components of the computing device 102, while in other embodiments, the user interface 110 may be located remotely from one or more other components of the computer device 102.

[0081] The robot 114 may be any surgical robot or surgical robotic system. The robot 114 may be or comprise, for example, the Mazor X™ Stealth Edition robotic guidance system. The robot 114 may be configured to position the surgical tool 126 at one or more precise position(s) and orientation / s), and / or to return the surgical tool 126 to the same position(s) and orientation / s) at a later point in time. The robot 114 may additionally or alternatively be configured to manipulate the surgical tool 126 (whether based on guidance from the navigation system 118 or not) to accomplish or to assist with a surgical task. In some embodiments, the robot 114 may be configured to hold and / or manipulate an anatomical element during or in connection with a surgical procedure. The robot 114 may comprise one or more robotic arms 116. In some embodiments, the robotic arm 116 may comprise a first robotic arm and a second robotic arm, though the robot 114 may comprise more than two robotic arms. In some embodiments, one or more of the robotic arms 116 may be used to hold and / or maneuver the surgical tool 126. Each robotic arm 116 may be positionable independently of the other robotic arm. The robotic arms 116 may be controlled in a single, shared coordinate space, or in separate coordinate spaces.

[0082] The robot 114, together with the robotic arm 116, may have, for example, one, two, three, four, five, six, seven, or more degrees of freedom. Further, the robotic arm 116 may be positioned or positionable in any pose, plane, and / or focal point. The pose includes a position and an orientation. As a result, the surgical tool 126 or other object held by the robot 114 (or, more specifically, by the robotic arm 116) may be precisely positionable in one or more needed and specific positions and orientations. The robotic arm(s) 116 may comprise one or more sensors that enable the processor 104 (or a processor of the robot 114 or the controller 124) to determinea precise pose in space of the robotic arm (as well as any object or element held by or secured to the robotic arm).

[0083] In some embodiments, reference markers (e.g., navigation markers) may be placed on the robot 114 (including, e.g., on the robotic arm 116), the surgical tool 126, or any other object in the surgical space. The reference markers may be tracked by the navigation system 118, and the results of the tracking may be used by the robot 114 and / or by an operator of the system 100 or any component thereof. In some embodiments, the navigation system 118 can be used to track other components of the system (e.g., surgical tool 126) and the system can operate without the use of the robot 114 (e.g., with the surgeon manually manipulating the surgical tool 126 and / or one or more surgical tools, based on information and / or instructions generated by the navigation system 118, for example).

[0084] In the illustrated embodiment, the robot 114 includes the controller 124, though in some embodiments the robot 114 may not include the controller 124. In other embodiments, the controller 124 may be a component separate from the robot 114 and in still other embodiments, the controller 124 may be integrated with the computing device 102. The controller 124 may be an electronic, a mechanical, or an electro-mechanical controller. The controller 124 may comprise or may be any processor described herein. The controller 124 may comprise a memory storing instructions for executing any of the functions or methods described herein as being carried out by the controller 124. In some embodiments, the controller 124 may be configured to simply convert signals received from the computing device 102 (e.g., via a communication interface 108) into commands for operating the robot 114 and / or operating the surgical tool 126. In other embodiments, the controller 124 may be configured to process and / or convert signals received from the sensor 128. Further, the controller 124 may receive signals from one or more sources (e.g., the sensor 128, the computing device 102, the navigation system 118, and / or the robot 114) and may output signals to one or more sources.

[0085] The navigation system 118 may provide navigation for a surgeon and / or a surgical robot during an operation. The navigation system 118 may be any now -known or future-developed navigation system, including, for example, the Medtronic StealthStation™ S8 surgical navigation system or any successor thereof. The navigation system 118 may include one or more cameras or other sensor(s) for tracking one or more reference markers, navigated trackers, or other objects within the operating room or other room in which some or all of the system 100 is located. Theone or more cameras may be optical cameras, infrared cameras, or other cameras. In some embodiments, the navigation system 118 may comprise one or more electromagnetic sensors. In various embodiments, the navigation system 118 may be used to track a position and orientation (e.g., a pose) of the surgical tool 126, the robot 114 and / or robotic arm 116, and / or one or more surgical tools (or, more particularly, to track a pose of a navigated tracker attached, directly or indirectly, in fixed relation to the one or more of the foregoing). The navigation system 118 may include a display for displaying one or more images from an external source (e.g., the computing device 102, the controller 124, or other source) or for displaying an image and / or video stream from the one or more cameras or other sensors of the navigation system 118. In some embodiments, the system 100 can operate without the use of the navigation system 118. The navigation system 118 may be configured to provide guidance to a surgeon or other user of the system 100 or a component thereof, to the robot 114, or to any other element of the system 100 regarding, for example, a pose of one or more anatomical elements, whether or not a tool is in the proper trajectory, and / or how to move a tool into the proper trajectory to carry out a surgical task according to a preoperative or other surgical plan.

[0086] The one or more surgical tools 126 may comprise any surgical tool such as, for example, a cutting tool and / or a shaver tool. The surgical tool 126 may be supported and / or oriented by, for example, the robotic arm 116. In other examples, the surgical tool 126 may be semi-autonomously operated with the robotic arm 116 or the surgical tool 126 may be manually operated by a user such as, for example, a surgeon or other medical provider. The surgical tool 126 may be power driven and may be powered by, for example, the robot 114, an external power source, or an internal / integrated power source. The surgical tool 126 may include a motor 136 (powered by the power source) and at least one sensor 128. In some embodiments, the surgical tool 126 may not include the motor 136. The motor 136 is configured to rotate the surgical tool 126 and may receive instructions from, for example, the controller 124, the computing device 102, and / or the robot 114. The motor 136 may be an electric motor, a pneumatic motor, a hydraulic motor, a gear motor, an AC brushless motor, a DC brushed motor, a DC brushless motor, a servo motor, or any other type of motor. The surgical tool 126 may also include a fluid source for supplying fluids to the cutting tool (or any tool) via a first tube 210, 310, 410, 510 and a vacuum source for suctioning or removing fluids and / or tissue from the surgical site from a second tube 212, 312, 412, 512 (shown in Figs. 2A, 3, 4A, and 5A).

[0087] The sensor 128 may be configured to sense at least one value of the surgical tool 126 and yield sensor data. The sensor 128 may be used to, for example monitor the surgical tool 126. For example, the sensor 128 may be used to sense a force exerted by the surgical tool 126 such that operation of the surgical tool 126 can be stopped or adjusted and / or a notification may be generated if the force meets or exceeds a predetermined threshold. The sensor 128 may correspond to transducers that are configured to convert physical phenomena into an electrical signal that is capable of being processed by the controller 124 or the processor 104 of the computing device 102. Non-limiting examples of the sensor 128 include force sensors, gyroscopic sensor, pressure sensor, accelerometers, strain gauges, impact sensor, vibration detectors, etc. The sensor 128 may include one or more or any combination of components that are electrical, mechanical, electro-mechanical, magnetic, electromagnetic, or the like. In some embodiments, the sensor 128 may include a memory for storing sensor data. In still other examples, the sensor 128 may output signals (e.g., sensor data) to one or more sources (e.g., the controller 124, the computing device 102, the navigation system 118 and / or the robot 114).

[0088] The sensor 128 may be positioned adjacent to or integrated with the surgical tool 126. In some embodiments, the sensor 128 may be positioned adjacent to or integrated with the robotic arm 116 or the robot 114. In some embodiments, the sensor 128 is positioned as a standalone component. The sensor 128 may include a plurality of sensors and each sensor may be positioned at the same location or a different location as any other sensor. The sensor 128 may send the sensor data to the controller 124 and / or the computing device 102 continuously or for a time period. Further, in some embodiments, the sensor 128 may send data to the computing device 102 to display on the user interface 110 or otherwise notify the surgeon or operator of a change in the sensor data such as, for example, when the values of the sensor data meet or exceeds a predetermined threshold.

[0089] The surgical tool(s) 126 enables the removal of soft tissue in areas that are difficult to reach and conventionally are manually extracted. For example, in a conventional vertebral disc removal procedure, disc material and cartilage are removed manually or piece by piece. The surgical tool(s) 126 enable continuous removal of the disc material and cartilage. Further, the surgical tool(s) 126 enable the accurate removal of soft tissue. More specifically, for example, dimensions of the disc space (tissue, cartilage, nucleus pulposus, etc.) are known through imaging and based on known dimensions of the surgical tool(s) 126, a known quantity of softtissue can be removed from the disc space (whether automatically by the robotic arm 116, manually by a user, or semi-autonomously).

[0090] The database 130 may store information that correlates one coordinate system to another (e.g., one or more robotic coordinate systems to a patient coordinate system and / or to a navigation coordinate system). The database 130 may additionally or alternatively store, for example, one or more surgical plans 124 (including, for example, pose information about a target and / or image information about a patient’s anatomy at and / or proximate the surgical site, for use by the robot 114, the navigation system 118, and / or a user of the computing device 102 or of the system 100); one or more images useful in connection with a surgery to be completed by or with the assistance of one or more other components of the system 100; sensor data; and / or any other useful information. The database 130 may be configured to provide any such information to the computing device 102 or to any other device of the system 100 or external to the system 100, whether directly or via the cloud 134. In some embodiments, the database 130 may be or comprise part of a hospital image storage system, such as a picture archiving and communication system (PACS), a health information system (HIS), and / or another system for collecting, storing, managing, and / or transmitting electronic medical records including image data.

[0091] The cloud 134 may be or represent the Internet or any other wide area network. The computing device 102 may be connected to the cloud 134 via the communication interface 108, using a wired connection, a wireless connection, or both. In some embodiments, the computing device 102 may communicate with the database 130 and / or an external device (e.g., a computing device) via the cloud 134.

[0092] The system 100 or similar systems may be used, for example, to carry out one or more aspects of any of the method 400 described herein. The system 100 or similar systems may also be used for other purposes.

[0093] Turning to Figs. 2A-8B, embodiments of the one or more surgical tools 126 will be described.

[0094] Fig. 2A is a tilted view of a surgical tool 200; Fig. 2B is a tilted, detailed, exploded view of a cutting end 202 of the surgical tool 200; Fig. 2C is a top view of a cutting sprocket 204 of the surgical tool 200; and Fig. 2D is a side view of the cutting sprocket 204 of the surgical tool 200 of Fig. 2 A. The surgical tool 200 may be the same as or similar to the surgical tool 126 described above. The surgical tool 200 includes a housing 206 that houses at least a portion of a chain driveassembly 208 (or a drive assembly). It will be appreciated that in some embodiments, the surgical tool 200 (or any surgical tool) may be driven by any type of drive assembly such as, for example, a belt assembly.

[0095] The surgical tool 200 also includes a first tube 210 and a second tube 212. The first tube 210 or the second tube 212 may be used to deliver fluids from a fluid source. The other tube of the first tube 210 or the second tube 212 may be used to remove fluids and / or tissue from a cutting region using a vacuum source. Though not shown, the first tube 210 and / or the second tube 212 may be connected to the fluid source and / or a receptacle for delivering and receiving the fluids and / or tissue.

[0096] The chain drive assembly 208 includes a drive shaft 214 that can be connected to, for example, a motor such as the motor 136. The motor 136 may rotate the drive shaft 214, which rotates a first or drive sprocket 216 that drives a roller chain 218 around a frame 230. The roller chain 218 includes extending pins 220 (labelled in Fig. 2B) that interconnect with corresponding valleys 222 (labelled in Fig. 2C) between adjacent teeth 224 of at least one second or cutting sprocket 204 such that when the roller chain 218 is rotated in a first direction, the cutting sprocket 204 is rotated in the first direction. Similarly, when the roller chain 218 is rotated in a second direction, the cutting sprocket 204 is rotated in the second direction. As shown, the at least one cutting sprocket 204 includes two cutting sprockets 204. In other embodiments, the at least one cutting sprocket 204 includes one cutting sprocket, two cutting sprockets, or more than two cutting sprockets.

[0097] The at least one cutting sprocket 204 is circular in shape when viewed from the top, as shown in Fig. 2C. In other embodiments, the at least one cutting sprocket 204 may be any shape when viewed from the top. In the illustrated embodiments where the at least one cutting sprocket 204 includes two cutting sprockets 204, a first cutting sprocket 204A may include a receiver 226 and a second cutting sprocket 204B may include a protrusion 228 that fits in the receiver 226 to connect the first cutting sprocket 204A to the second cutting sprocket 204B. The protrusion 228 of the second cutting sprocket 204B may be, for example, press fitted into the receiver 226 of the first cutting sprocket 204A, though it will be appreciated that in other embodiments the first cutting sprocket 204 A and the second cutting sprocket 204B may be connected in any way. In still other embodiments, the first cutting sprocket 204 A and the second cutting sprocket 204B may not be connected to each other and may be independently rotated by the roller chain 218.Y1

[0098] The surgical tool 200 may be useful for, for example, simultaneously removing material in two parallel, spaced apart planes Pl, P2, shown in Fig. 2D. It will be appreciated that in other embodiments, the surgical tool 200 may remove material in any number of planes simultaneously. The two planes Pl, P2 may be defined by corresponding cutting sprockets 204. In other words, the surgical tool 200 may be useful for removing a majority of material with a volume. For example, the surgical tool 200 may be useful for removing disc material from a disc space between two adjacent vertebrae. In such examples, a distance D between the two planes Pl, P2 may be about or less than a thickness of the disc space such that as much disc material within the disc space can be removed by the surgical tool 200.

[0099] Turning to Fig. 3, a surgical tool 300 is shown in a tilted, top view. The surgical tool 300 is the same as or similar to the surgical tool 200, except that the surgical tool 300 includes a handle 332. It will be appreciated that the surgical tool 200 may not include a handle, as shown in Fig. 2A, or may include a handle as shown in Fig. 3. It will also be appreciated that any surgical tool described may include a handle or may not include a handle.

[0100] Fig. 4A is a tilted view of a surgical tool 400; Fig. 4B is a tilted, detailed, exploded view of a cutting end 402 of the surgical tool 400; Fig. 4C is a top view of a cutting sprocket 402 of the surgical tool 400; and Fig. 4D is a side view of the cutting sprocket 402 of the surgical tool 400 of Fig. 4A. The surgical tool 400 may be the same as or similar to the surgical tools 126, 200, 300 described above. The surgical tool 400 includes a housing 406 and a handle 432 extending from the housing 406. The surgical tool 400 also includes a first tube 410 and a second tube 412. The first tube 410 or the second tube 412 may be used to deliver fluids from a fluid source. The other tube of the first tube 410 or the second tube 412 may be used to remove fluids and / or tissue from a cutting region using a vacuum source. Though not shown, the first tube 410 and / or the second tube 412 may be connected to the fluid source and / or a receptacle for receiving the fluids and / or tissue.

[0101] The housing 406 houses at least a portion of a chain drive assembly 408, which may be the same as or similar to the chain drive assembly 208 described above. The chain drive assembly 408 includes a drive shaft 414 that can be connected to, for example, a motor such as the motor 146. The drive shaft 414 rotates a first or drive sprocket 416 that drives a roller chain 418. The roller chain 418 includes extended pins 420 that interconnect with corresponding valleys 422 (labelled in Fig. 4C) between adjacent teeth 424 of at least one second or cutting sprocket 404such that when the roller chain 418 is rotated in a first direction, the cutting sprocket 404 is rotated in the first direction. Similarly, when the roller chain 418 is rotated in a second direction, the cutting sprocket 404 is rotated in the second direction. As shown, the at least one cutting sprocket 404 includes two cutting sprockets 404. In other embodiments, the at least one cutting sprocket 404 includes one cutting sprocket, two cutting sprockets, or more than two cutting sprockets.

[0102] The at least one cutting sprocket 404 is oval in shape when viewed from the top, as shown in Fig. 4C. In other embodiments, the at least one cutting sprocket 404 may be any shape or size when viewed from the top. In the illustrated embodiments where the at least one cutting sprocket 404 includes two cutting sprockets 404, a first cutting sprocket 404A may include a receiver 426 and a second cutting sprocket 404B may include a protrusion 428 that fits in the receiver 426 to connect the first cutting sprocket 404A to the second cutting sprocket 404B. The protrusion 428 of the second cutting sprocket 404B may be, for example, press fitted into the receiver 426 of the first cutting sprocket 404A, though it will be appreciated that in other embodiments the first cutting sprocket 404A and the second cutting sprocket 404B may be connected in any way. In still other embodiments, the first cutting sprocket 404 A and the second cutting sprocket 404B may not be connected to each other and may be independently rotated by the roller chain 418.

[0103] The surgical tool 400 may be useful for, for example, simultaneously removing material in two parallel, spaced apart planes Pl, P2, shown in Fig. 4D. It will be appreciated that in other embodiments the surgical tool 400 may remove material in any number of planes simultaneously. The two planes Pl, P2 may be defined by corresponding cutting sprockets 404. In other words, the surgical tool 400 may be useful for removing a large volume of material such as, for example, soft tissue. For example, the surgical tool 400 may be useful for removing disc material from a disc space between two adjacent vertebrae. In such examples, a distance D between the two planes P 1 , P2 may be about or less than a thickness of the disc space such that as much disc material within the disc space can be removed by the surgical tool 400.

[0104] Fig. 5A is a tilted view of a surgical tool 500; Fig. 5B is a tilted, detailed, exploded view of a shaving end 502 of the surgical tool 500; Fig. 5C is a top view of a shaving tool 502 of the surgical tool 500; and Fig. 5D is a side view of the shaving tool 502 of the surgical tool 500 of Fig. 5A. The surgical tool 500 may be the same as or similar to the surgical tools 126, 200, 300,400 described above. The surgical tool 500 includes a housing 506 and a handle 532 extending from the housing 506. The surgical tool 500 also includes a first tube 510 and a second tube 512. The first tube 510 or the second tube 512 may be used to deliver fluids from a fluid source. The other tube of the first tube 510 or the second tube 512 may be used to remove fluids and / or tissue from a cutting region using a vacuum source. Though not shown, the first tube 510 and / or the second tube 512 may be connected to the fluid source and / or a receptacle for receiving the fluids and / or tissue.

[0105] The housing 506 houses at least a portion of a chain drive assembly 508, which may be the same as or similar to the chain drive assembly 208, 408, described above. The chain drive assembly 508 includes a drive shaft 514 that can be connected to, for example, a motor such as the motor 156. The drive shaft 514 rotates a first or drive sprocket 516 that drives a roller chain. Though the roller chain is not shown, the roller chain may be the same as or similar to the roller chains 218, 418. The roller chain includes extended pins that interconnect with corresponding valleys 522 (labelled in Fig. 5B) between adjacent teeth 524 of at least one driven sprocket 534 such that when the roller chain is rotated in a first direction, the driven sprocket 534 is rotated in the first direction. Similarly, when the roller chain is rotated in a second direction, the driven sprocket 534 is rotated in the second direction. As shown, the at least one driven sprocket 534 includes two driven sprockets 534. In other embodiments, the at least one driven sprocket 534 includes one driven sprocket, two driven sprockets, or more than two driven sprockets. Further, as shown, the surgical tool 500 includes at least one shaving tool 504 connected to the at least one driven sprocket 534.

[0106] The at least one shaving tool 504 is rectangular in shape when viewed from the top, as shown in Fig. 5C. In other embodiments, the at least one shaving tool 504 may be any shape or size when viewed from the top. As further shown, the at least one shaving tool 504 may include two flat edges 538 and two serrated edges 540, though the at least one shaving tool 504 may have any number of and any type of edges. For example, further embodiments of the at least one shaving tool 504 are shown in Figs. 6A-8B. The serrated edges 540 may be used to remove soft tissue in front of the at least one shaving tool 504. The at least one shaving tool 504 also includes one or more raised features 536 for removing small amounts of soft tissue without damaging nearby hard tissue. For example, the one or more raised features 536 may be used near end plates of adjacent vertebrae to remove any remaining layers of soft tissue near the end plates. The oneor more raised features 536 may include any pattern or number of features. The shaving tool 504 can be used to both remove soft tissue adjacent to or in front of the at least shaving tool 504 using the serrated edges 540 and soft tissue above or below the shaving tool 504 using the one or more raised features 536.

[0107] The at least one shaving tool 504 may be formed of, for example, a solid sheet such as a metal sheet. It will be appreciated that the at least one shaving tool 504 may be formed from any material. In the illustrated embodiments, the at least one shaving tool 504 includes an aperture 542 which may receive a protrusion 550 from the at least one driven sprocket 534 to couple the at least one shaving tool 504 to the at least one driven sprocket 534. The protrusion 550 may be a press fit with the aperture 542, though the at least one shaving tool 504 may be coupled to the at least one driven sprocket 534 in any way.

[0108] As previously described, the surgical tool 500 may be useful for, for example, simultaneously removing material in two parallel, spaced apart planes Pl, P2, shown in Fig. 5D. It will be appreciated that in other embodiments, the surgical tool 500 may be used to remove material in any number of planes simultaneously. The two planes Pl, P2 may be defined by corresponding shaving tools 504 such a first shaving tool 504A and a second shaving tool 504B. In other words, the surgical tool 500 may be useful for material from two planes simultaneously, which beneficially reduces an amount of time for removing material. For example, the surgical tool 500 may be useful for removing remaining soft tissue from two discs between two adjacent vertebrae. In such examples, a distance D between the two planes Pl, P2 may be about the same as or less than a thickness of the disc space such that the surgical tool 500 can be inserted into the disc space to remove any remaining soft tissue on end plates of the vertebrae within the disc space.

[0109] Turning to Figs. 6A-6B, another set of shaving tools 604 is shown from a top, tilted view and a bottom, tilted view, respectively. The shaving tools 604 may be used with any of the surgical tools 126, 200, 300, 400, 500 described above. As shown, the shaving tools 604 include a first shaving tool 604A and a second shaving tool 604B. The first shaving tool 604A may be the same as or similar to the at least one shaving tool 604 described in Figs 5B-5D. The first shaving tool 604A and the second shaving tool 604 are rectangular in shape when viewed from the top, though in other embodiments, the first shaving tool 604A and the second shaving tool 604 may be any shape or size when viewed from the top. As further shown, the first shaving tool 604A andthe second shaving tool 604 may each include two flat edges 638 and two serrated edges 640, though the first shaving tool 604A and the second shaving tool 604 may have any type of edges. The first shaving tool 604A also includes one or more raised features 636 for removing small amounts of soft tissue. For example, the one or more raised features 636 may be used near end plates of adjacent vertebrae to remove any remaining layers of soft tissue near the end plates. The one or more raised features 636 may include any pattern or number of features. The second shaving tool 604B is also rectangular and includes a plurality of apertures 642 that can also be used to remove remaining layers of soft tissue from, for example, end plates of one or more vertebrae. It will be appreciated that the second shaving tool 604B may include any number, size, or pattern of apertures.

[0110] Turning to Figs. 7A-7B, a top, tilted view of a shaving tool 704 and a top view of the shaving tool 704 are shown respectively. Though one shaving tool 704 is shown in the illustrated embodiment, it will be appreciated that more than one shaving tool 704 may be used with any of the surgical tools 126, 200, 300, 400, 500. The shaving tool 704 includes a shaving feature 746 protruding from at least one arm 744 for removing any remaining tissue in front of the shaving tool 704. The shaving feature 746 may extend from, for example, a 90 degree angle from the arm 744, though the shaving feature 746 may extend at any angle from the arm 744. The shaving tool 704 also includes a plurality of openings 742 extending along a length of each arm 744. Each of the plurality of openings 742 may be U-shaped, though the openings 742 may be any shape. Further, each of the plurality of openings 742 may have different shapes or patterns. The plurality of openings 742 may be used to remove small amounts of tissue. For example, the plurality of openings 742 may be used near end plates of adjacent vertebrae to remove any remaining layers of soft tissue near the end plates.

[0111] Turning to Figs. 8A-8B, a top, tilted view of a shaving tool 804 and a top view of the shaving tool 804 are shown respectively. Though one shaving tool 804 is shown in the illustrated embodiment, it will be appreciated that more than one shaving tool 804 may be used with any of the surgical tools 126, 500. The shaving tool 804 may be the same as or similar to the shaving tool 704 described above, except that a length of at least one arm 844 of the shaving tool 804 is less than a length of the at least one arm 844 of the shaving tool 704. Thus, the shaving tool 804 also includes a shaving feature 846 protruding from the at least one arm 844. The shaving feature 846 may extend from, for example, a 90 degree angle from the arm 844, though the shavingfeature 846 may extend at any angle from the arm 844. The shaving tool 804 also includes a plurality of openings 842 extending along a length of each arm 844. Each of the plurality of openings 842 may be U-shaped, though the openings 842 may be any shape. Further, each of the plurality of openings 842 may have different shapes or patterns.

[0112] Fig. 9 depicts a method 900 that may be used, for example, for operating a surgical tool such as the surgical tools 126, 200, 300, 400, 500.

[0113] The method 900 (and / or one or more steps thereof) may be carried out or otherwise performed, for example, by at least one processor. The at least one processor may be the same as or similar to the processor(s) 104 of the computing device 102 described above. The at least one processor may be part of a robot (such as a robot 114) or part of a navigation system (such as a navigation system 118). A processor other than any processor described herein may also be used to execute the method 900. The at least one processor may perform the method 900 by executing elements stored in a memory such as the memory 106. The elements stored in memory and executed by the processor may cause the processor to execute one or more steps of a function as shown in method 900. One or more portions of a method 900 may be performed by the processor executing any of the contents of memory, such as sensor data processing 120 and / or notification generation 122.

[0114] The method 900 comprises receiving a surgical plan (step 904). The surgical plan may be the same as or similar to the surgical plan 125. The surgical plan may be received from, for example, a memory such as the memory 106, a cloud such as the cloud 134, and / or a database such as the database 130. As previously described, the surgical plan may include, for example, one or more steps for performing a surgical procedure and / or one or more expected or predetermined thresholds for monitoring one or more values (e.g., the sensor data) during a surgical procedure. In some embodiments, the surgical procedure may be a spinal procedure (e.g., a spinal alignment, installing implants, osteotomy, fusion, and / or any other spinal procedure) to correct a spinal deformity. For example, the surgical plan may include one or more surgical steps for removing disc material. In such embodiments, the surgical plan may include one or more steps for operating one or more surgical tools such as the surgical tools 126, 200, 300, 400, 500 to remove the disc material and to prepare hard tissue in the disc space for receiving an implant.

[0115] The surgical plan may also include information about soft tissue at a target region to be removed such as, for example, dimensions of the target soft tissue to remove. In at least oneexample, the target soft tissue may be disc material to be removed from a disc space between two adjacent vertebrae.

[0116] The method 900 also comprises causing a first surgical tool to remove soft tissue from the target region (step 908). The first surgical tool may be, for example, the surgical tool 200, 300, or 400. As previously described, the first surgical tool may include a chain drive assembly such as the chain drive assembly 208, 308, 408 driven by a motor such as the motor 136 to rotate at least one cutting sprocket such as the at least one cutting sprocket 204, 304, 404. The at least one cutting sprocket may include two cutting sprockets such that the two cutting sprockets can each remove material at the same time. In other words, the surgical tool may be used for, for example, removing material in two parallel, spaced apart planes such as the planes Pl, P2 defined by corresponding cutting sprockets. In other words, the surgical tool may be useful for removing a large volume of material such as, for example, soft tissue. For example, the surgical tool may be useful for removing disc material from a disc space between two adjacent vertebrae. In such examples, a distance D between the two planes Pl, P2 may be about or less than a thickness of the disc space such that as much disc material within the disc space can be removed by the surgical tool.

[0117] The method 900 also comprises causing a second surgical tool to remove remaining soft tissue from the target region (step 912). The second surgical tool may be the same as or similar to the surgical tool 500. The surgical tool 500 includes a chain drive assembly such as the chain drive assembly 508 driven by a motor such as the motor 136 to rotate at least one driven sprocket such as the at least one driven sprocket 534. The at least one driven sprocket is connected to at least one shaving tool which may be the same as or similar to the shaving tool(s) 504, 604, 704, 804. As previously described, the at least one shaving tool may include one or more raised features such as the one or more raised features 536, 636 for removing small amounts of soft tissue. For example, the one or more raised features may be used near end plates of adjacent vertebrae to remove any remaining layers of soft tissue near the end plates.

[0118] The at least one cutting tool may alternatively or additionally include a plurality of openings such as the plurality of openings 642, 742, 842. The plurality of openings may be any shape or size including, for example, apertures, U-shaped, etc. The plurality of openings may also have any pattern or number of openings. The plurality of openings may also be used to removesmall amounts of tissue. For example, the plurality of openings may be used near end plates of adjacent vertebrae to remove any remaining layers of soft tissue near the end plates.

[0119] The at least one cutting tool may also include at least one serrated edge such as the serrated edge 540, 640. The serrated edge can be used to remove soft tissue in front of the cutting tool. In such configuration, the cutting tool can be used to both remove soft tissue adjacent to or in front of the at least cutting tool using the serrated edges and soft tissue above or below the cutting tool using the one or more raised features and / or the plurality of openings.

[0120] The method 900 also comprises receiving sensor data (step 916). The sensor data may include, for example, force data, acceleration data, vibration data, and / or pressure data. The sensor data may be received from, for example, a sensor such as the sensor 128. The sensor may be configured to sense at least one value of the surgical tool and yield the sensor data. More specifically, the sensor 128 may correspond to transducers that are configured to convert physical phenomena into an electrical signal that is capable of being processed by, for example, a processor such as the processor 104 using a sensor data processing such as the sensor data processing 120. Non-limiting examples of the sensor include force sensors, gyroscopic sensor, pressure sensor, accelerometers, strain gauges, impact sensor, vibration detectors, etc. The sensor may include one or more or any combination of components that are electrical, mechanical, electro-mechanical, magnetic, electromagnetic, or the like.

[0121] The sensor may be positioned adjacent to or integrated with the surgical too. In some embodiments, the sensor may be positioned adjacent to or integrated with the robotic arm or the robot. In some embodiments, the sensor is positioned as a standalone component. The sensor may include a plurality of sensor and each sensor may be positioned at the same location or a different location as any other sensor. The sensor may send the sensor data to a computing device such as the computing device 102 continuously or for a time period. Further, in some embodiments, the sensor may send data to the computing device to display on a user interface such as the user interface 110 or otherwise notify the surgeon or operator of a change in the sensor data such as, for example, when the values of the sensor data meet or exceeds a predetermined threshold.

[0122] The method 900 also comprises generating a notification when the sensor data meets or exceeds a predetermined threshold (step 920). The notification may be generated by the processor using a notification generation such as the notification generation 122. The notification generation enables the processor to generate a notification when the sensor data meets or exceedsa predetermined threshold. For example, a notification may be generated when a force exerted by the surgical tool exceeds a force threshold. It will be appreciated that in some embodiments, the notification may be generated when the sensor data is below the predetermined threshold. In still other embodiments, the notification may be generated when a difference between the sensor data and an expected sensor data meets or exceeds the predetermined threshold. The notification may be an audible and / or a visual notification (which may be displayed on, for example, the user interface).

[0123] The present disclosure encompasses embodiments of the method 900 that comprise more or fewer steps than those described above, and / or one or more steps that are different than the steps described above. For example, the method 900 may not include the steps 904 and / or 920. For example, the step 920 may not occur if the sensor data does not meet or exceed the predetermined threshold.

[0124] As noted above, the present disclosure encompasses methods with fewer than all of the steps identified in Fig. 9 and the corresponding description of the method 900), as well as methods that include additional steps beyond those identified in Fig. 9 (and the corresponding description of the method 900). The present disclosure also encompasses methods that comprise one or more steps from one method described herein, and one or more steps from another method described herein. Any correlation described herein may be or comprise a registration or any other correlation.

[0125] The surgical tool(s) 126, 200, 300, 400, 500 beneficially enable the removal of soft tissue in areas that are difficult to reach and conventionally are manually extracted. For example, in a conventional vertebral disc removal procedure, disc material and cartilage are removed manually or piece by piece. The surgical tool(s) 126, 200, 300, 400, 500 also enable continuous removal of the disc material and cartilage. Further, the surgical tool(s) 126, 200, 300, 400, 500 enables the precise removal of soft tissue. More specifically, for example, dimensions of the disc space (tissue, cartilage, nucleus pulposus, etc.) are known through imaging and based on known dimensions of the surgical tool(s) 126, 200, 300, 400, 500, a known quantity of soft tissue can be removed from the disc space (whether automatically by the robotic arm 116, manually by a user, or semi-autonomously).

[0126] The following Examples disclose various embodiments of the invention.

[0127] Example 1. A surgical tool comprising: a drive assembly comprising a drive shaft configured to be rotated by a motor, a drive sprocket connected to the drive shaft, and a roller chain driven by the drive sprocket, the roller chain having one or more extended pins; and at least one cutting sprocket having a plurality of teeth, wherein the one or more extended pins are received in corresponding valleys between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one cutting sprocket.

[0128] Example 2. The surgical tool of Example 1, wherein the at least one cutting sprocket comprises a first cutting sprocket and a second cutting sprocket.

[0129] Example 3. The surgical tool of Example 2, wherein the first cutting sprocket defines a first plane and the second cutting sprocket defines a second plane, wherein the first plane and the second plane are parallel to each other and spaced apart from each other.

[0130] Example 4. The surgical tool of Example 3, wherein a distance between the first plane and the second plane is less than a thickness of a vertebral disc space.

[0131] Example 5. The surgical tool of any one of the preceding Examples, wherein the surgical tool is at least one of oriented and operated by a robotic arm or manually oriented and operated.

[0132] Example 6. The surgical tool of any one of the preceding Examples, further comprising: a housing configured to house at least a portion of the drive assembly; a first tube extending from the housing; and a second tube extending from the house.

[0133] Example 7. The surgical tool of Example 6, wherein the first tube is connected to a fluid source to supply fluids to the at least one cutting sprocket and the second tube is connected to a receptacle and a vacuum source to remove fluids and soft tissue from the at least one cutting sprocket.

[0134] Example 8. The surgical tool of any one of the preceding Examples, wherein the sprocket is at least one of circular or oval in shape when viewed from the top.

[0135] Example 9. The surgical tool of any one of the preceding Examples, further comprising at least one sensor configured to sense at least one value of the surgical tool.

[0136] Example 10. The surgical tool of any one of the preceding Examples, wherein the at least one value comprises force.

[0137] Example 11. A surgical tool comprising: a chain drive assembly comprising a drive shaft configured to be rotated by a motor, a drive sprocket connected to the drive shaft, and aroller chain driven by the drive sprocket, the roller chain having one or more extended pins; at least one driven sprocket having a plurality of teeth; and at least one shaving tool coupled to the at least one driven sprocket, wherein the one or more extended pins are received in corresponding valleys between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one at least one driven sprocket and the at least one shaving tool.

[0138] Example 12. The surgical tool of Example 11, wherein the at least one shaving tool comprises a sheet having at least one of a plurality of raised features on a surface of the solid sheet or a plurality of openings extending through the solid sheet.

[0139] Example 13. The surgical tool of Example 12, wherein the sheet includes at least one serrated edge.

[0140] Example 14. The surgical tool of Example 12, wherein the sheet comprises a metal sheet.

[0141] Example 15. The surgical tool of any one of the preceding Examples, wherein the at least one shaving tool comprises a plurality of arms, a shaving feature extending from each arm of the plurality of arms, and at least one opening on each arm of the plurality of arms.

[0142] Example 16. The surgical tool of any one of the preceding Examples, further comprising at least one sensor configured to sense at least one value of the surgical tool.

[0143] Example 17. The surgical tool of any one of the preceding Examples, wherein the at least one shaving tool comprises a first shaving tool and a second shaving tool, wherein the first shaving tool defines a first plane and the second shaving tool defines a second plane, wherein the first plane and the second plane are parallel to each other and spaced apart from each other.

[0144] Example 18. The surgical tool of Example 17, wherein a distance between the first plane and the second plane is less than a thickness of a vertebral disc space.

[0145] Example 19. A system comprising: a surgical tool comprising: a chain drive assembly having a drive shaft configured to be rotated by a motor, a drive sprocket connected to the drive shaft, and a roller chain driven by the drive sprocket, the roller chain having one or more extended pins; and at least one cutting sprocket having a plurality of teeth, wherein the one or more extended pins are received in corresponding valleys between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one cutting sprocket; and a robotic arm configured to orient and operate the surgical tool.

[0146] Example 20. The system of Example 19, further comprising: at least one sensor configured to sense at least one value of the surgical tool; a processor; and a memory storing data for processing by the processor, the data, when processed, causes the processor to: receive sensor data from the at least one sensor; and generate notification when the sensor data meets or exceeds a predetermined threshold.

[0147] The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features of the disclosure are grouped together in one or more aspects, embodiments, and / or configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and / or configurations of the disclosure may be combined in alternate aspects, embodiments, and / or configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claims require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspect, embodiment, and / or configuration. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

[0148] Moreover, though the foregoing has included description of one or more aspects, embodiments, and / or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and / or configurations to the extent permitted, including alternate, interchangeable and / or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and / or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

Claims

CLAIMSWhat is claimed is:

1. A surgical tool (126) comprising: a drive assembly (208) comprising a drive shaft (214) configured to be rotated by a motor (136), a drive sprocket (216) connected to the drive shaft, and a roller chain (218) driven by the drive sprocket, the roller chain having one or more extended pins (220); and at least one cutting sprocket (204) having a plurality of teeth, wherein the one or more extended pins are received in corresponding valleys (222) between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one cutting sprocket.

2. The surgical tool of claim 1, wherein the at least one cutting sprocket comprises a first cutting sprocket (204A) and a second cutting sprocket (204B).

3. The surgical tool of claim 2, wherein the first cutting sprocket defines a first plane and the second cutting sprocket defines a second plane, wherein the first plane and the second plane are parallel to each other and spaced apart from each other.

4. The surgical tool of claim 3, wherein a distance (D) between the first plane (Pl) and the second plane (P2) is less than a thickness of a vertebral disc space.

5. The surgical tool of any one of the preceding claims, wherein the surgical tool is at least one of oriented and operated by a robotic arm (116) or manually oriented and operated.

6. The surgical tool of any one of the preceding claims, further comprising: a housing (406) configured to house at least a portion of the drive assembly; a first tube (410) extending from the housing; and a second tube (412) extending from the house.

7. The surgical tool of claim 6, wherein the first tube is connected to a fluid source to supply fluids to the at least one cutting sprocket and the second tube is connected to a receptacle and a vacuum source to remove fluids and soft tissue from the at least one cutting sprocket.

8. The surgical tool of any one of the preceding claims, wherein the sprocket is at least one of circular or oval in shape when viewed from the top.

9. The surgical tool of any one of the preceding claims, further comprising at least one sensor (128) configured to sense at least one value of the surgical tool.

10. The surgical tool of any one of the preceding claims, wherein the at least one value comprises force.

11. A surgical tool (126) comprising: a chain drive assembly (208) comprising a drive shaft (214) configured to be rotated by a motor (136), a drive sprocket connected to the drive shaft (216), and a roller chain (218) driven by the drive sprocket, the roller chain having one or more extended pins (220); at least one driven sprocket (534) having a plurality of teeth (524); and at least one shaving tool (504) coupled to the at least one driven sprocket, wherein the one or more extended pins are received in corresponding valleys between adjacent teeth of the plurality of teeth such that rotation of the roller chain rotates the at least one at least one driven sprocket and the at least one shaving tool.

12. The surgical tool of claim 11, wherein the at least one shaving tool comprises a sheet having at least one of a plurality of raised features (536) on a surface of the solid sheet or a plurality of openings (742) extending through the solid sheet.

13. The surgical tool of claim 12, wherein the sheet includes at least one serrated edge (540).

14. The surgical tool of claim 12, wherein the sheet comprises a metal sheet.

15. The surgical tool of any one of claims 11-14, wherein the at least one shaving tool comprises a plurality of arms (844), a shaving feature (846) extending from each arm of the plurality of arms, and at least one opening (842) on each arm of the plurality of arms.

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