Systems and methods for inspecting components of surgical kits

Abstract

A surgical kit inspection system for inspecting a surgical kit including a plurality of parts is provided. The system includes a camera device, a workpiece support device configured to position one of the plurality of parts relative to the camera device, and one or more controllers. The one or more controllers are configured obtain inspection instructions and command inspection of the one of the plurality of parts with the camera device based upon the inspection instructions. The controllers commanding inspection includes operating the camera device to capture an image of the one of the plurality of parts and detecting a flaw in the one of the plurality of parts in the image. The controllers commanding inspection further includes classifying the one of the plurality of parts based upon the detected flaw and generating an output for the one of the plurality of parts based upon the classifying.

Description

SYSTEMS AND METHODS FOR INSPECTING COMPONENTS OF SURGICAL KITSCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] The subject patent application claims priority to and all the benefits of United States Provisional Patent Application No. 63 / 671,454 filed on July 15, 2024, the disclosure of which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] Surgical kits include pails of different types that assist in performing surgical procedures. The pails may include implants, reusable pails (e.g., surgical instruments), and disposable parts. Usually, some parts (e.g., some of the implants and disposable parts) are consumed during the surgical procedure. The reusable parts may be damaged or worn or may have been inadvertently discarded or misplaced. A part may accumulate or receive a coating of biological material which may be described as bioburden. For these reasons, after the surgical procedure has been performed, any surgical kits used in performing the surgical procedure need to be inspected to determine which parts are missing, damaged, or worn.

[0003] Once the used surgical kit is received at an inspection location, the inspection procedure involves discarding disposable parts (if any), comparing the parts in the used surgical kit against a list of parts that makeup a complete surgical kit, and inspecting each part of the used surgical kit for damage or wear, and to ensure proper placement of the part within the surgical kit. Once the inspection procedure is complete, missing, damaged, and / or worn parts are replaced, and the surgical kit is processed (e.g., sterilized) to be ready for the next surgical procedure.

[0004] Some inspection procedures are still, in large part, performed manually by an operator. The process may begin, for example, by the operator printing off the list of parts that makeup a complete surgical kit. The operator then manually inspects every pail in the used surgical kit and compares the pails to the list. The operator marks the used surgical kit as “complete” when no items are missing or “as is” when there are missing parts. The operator may also visually inspect the parts for damage or wear. The operator creates a list of missing, damaged, and / or worn parts through an inventory system and pails may subsequently be replaced. Manual inspection by the operator of every part is time consuming and prone to operator error.SUMMARY

[0005] A surgical kit inspection system is provided for inspecting a surgical kit including a plurality of parts. The surgical kit inspection system comprises a camera device and a workpiece support device configured to position one of the plurality of parts relative to the camera device. One or more controllers is configured to obtain inspection instructions and command inspection of the one of the plurality of parts with the camera device based upon the inspection instructions. The one or more controllers commanding inspection of the one of the plurality of parts includes operating the camera device to capture an image of the one of the plurality of pails; detecting a flaw in the one of the plurality of parts in the image; classifying the one of the plurality of parts based upon the detected flaw; and generating an output for the one of the plurality of parts based upon the classifying.

[0006] A method is provided for inspecting surgical kits having a plurality of parts using a camera device. The method comprises the steps of, within one or more controllers, obtaining inspection instructions and commanding inspection of the one of the plurality of pails with the camera device based upon the inspection instructions. The step of commanding inspection of the one of the plurality of pails includes: operating the camera device to capture an image of the one of the plurality of parts at each of the plurality of poses; detecting a flaw in the one of the plurality of parts in the image; classifying the one of the plurality of parts based upon the detected flaw; and generating an output for the one of the plurality of pails based upon the classifying.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present disclosure will become more fully understood from the detailed description and the accompanying drawings.

[0008] FIG. 1 is a perspective view of an example inspection system.

[0009] FIG. 2 is a block diagram of a control system of the inspection system.

[0010] FIG. 3 A is an elevational view of the inspection system of FIG. 1.

[0011] FIG. 3B is a partially exploded view of the vision unit.

[0012] FIG. 3C is an assembled view of the vision unit.

[0013] FIGS. 4 A and 4B are perspective views of loose parts of a surgical kit set up on a light surface.

[0014] FIG. 5 illustrates perspective views of a first tray, a second tray, and loose parts of a surgical kit.

[0015] FIG. 6 is a top view of the inspection system of FIG. 1 .

[0016] FIGS. 7A-7D arc images of parts in a surgical kit captured by the vision unit.

[0017] FIG. 8A is a block diagram of a kitRecipe class used to create a kit inspection recipe object for a surgical kit.

[0018] FIG. 8B is a block diagram of a kitinspection class used to create a kit inspection results object for a surgical kit.

[0019] FIG. 8C is a block diagram of steps carried out in an example method performed by the inspection system.

[0020] FIG. 9 is an elevational view of an alternative example inspection system.

[0021] FIG. 10 is an additional elevational view of the inspection system of FIG. 4.

[0022] FIG. 11 is an additional elevational view of the inspection system of FIG. 4.

[0023] FIG. 12 is an elevational view of an alternative example inspection system.

[0024] FIG. 13 is an elevational, partially sectional view of a part holder.

[0025] FIG. 14 is a perspective view of the part holder of FIG. 8 and a vision unit.

[0026] FIG. 15 is flowchart illustrating an example method to utilize an inspection system to inspect a plurality of parts of a surgical kit.

[0027] FIG. 16 is flowchart illustrating an alternative example method to utilize an inspection system to inspect a plurality of parts of a surgical kit.

[0028] FIG. 17 is flowchart illustrating an alternative example method to utilize an inspection system to inspect a plurality of parts of a surgical kit.

[0029] FIG. 18 is flowchart illustrating an alternative example method to utilize an inspection system to inspect a plurality of parts of a surgical kit.

[0030] FIG. 19 is flowchart illustrating an alternative example method to utilize an inspection system to inspect a plurality of parts of a surgical kit.DETAILED DESCRIPTION

[0031] With reference to FIG. 1, an inspection system 100 is presented. The inspection system 100 provides a workstation including a robot 104, a vision unit 108, a working table 116 having zones 120, light surface units 118 having light surfaces 124, and a human machine interface HMI that allows an operator to interface with the inspection system 100. The inspection system 100 may work in collaboration with the operator to inspect and inventory surgical kits. The inspection system 100 may also be referred to as a semi- automated inspection system. Theinspection system 100 may be employed by vendors that supply the surgical kits to users of the surgical kits (e.g., hospitals, etc.) or the inspection system 100 may be employed by the users themselves. While FIG. 1 illustrates the inspection system 100 configured for utilizing the robot 104 to move the vision unit 108, other versions of the inspection system 100 are envisioned, for example, including a robotic arm configured for acquiring and manipulating parts or portions of surgical kits to be inspected, including an alternative stationary vision unit 108, including a mobile light unit, and including utilizing a fixture or part holder to place parts to be inspected into preprogrammed or known physical orientations for inspection.

[0032] The inspection system 100 receives used surgical kits and inspects the used surgical kits in conjunction with the operator based on an electronic kit inspection recipe 126 to identify missing, damaged, worn, and / or misplaced pails. The kit inspection recipe 126 may be stored in a database DB, such as local databases, cloud-based databases, or other type of database. The kit inspection recipe 126 provides information regarding all the parts required for a complete surgical kit and information as to how the robot 104, the vision unit 108, and / or the light surface units 118 are to be positioned and / or operated when inspecting each part, and which identification methods are to be employed to inspect each of the parts. In one version, the kit inspection recipe 126 may be described as a plurality of part-specific inspection instructions. Once the inspection procedure is complete, the inspection system 100 generates and stores output (e.g., an electronic inspection report) indicating which pails are missing, damaged, and / or worn. In some cases, the inspection reports may be electronically transmitted to a surgical kit management system, an enterprise resource planning (ERP) system, and / or a warehouse management system (WMS), to update a bill of materials for each of the surgical kits. This may be done automatically or in response to user input via the human machine interface HMI. The human machine interface HMI and one or more of these systems may be integrated to communicate with each other. Missing, damaged, and / or worn parts can then be replaced, and the surgical kit processed (e.g., sterilized) to be ready for the next surgical procedure. The inspection system 100 reduces the possibility for operator error and thus provides an improved way of inspecting surgical kits. It should be appreciated that although the inspection system 100 is described throughout for inspecting surgical kits, it may also be used for inspecting kits other than surgical kits.

[0033] The robot 104 includes a robotic manipulator 128 having a base 130 and a robotic arm 132 extending from the base 130. The robotic manipulator 128 supports and carries the visionunit 108 to move the vision unit 108 to a plurality of different poses in view of the each of the parts being inspected for each of the surgical kits. The base 130 of the robotic manipulator 128 may be mounted to the working table 116 at the center of the working table 116 or at any other suitable position where the robotic manipulator 128 is able to position the vision unit 108 in view of each of the zones 120. In some versions, the robotic manipulator 128 may include additional robotic arms 132, or any other suitable robotic structure to move the vision unit 108. In the version shown, the robotic arm 132 is a serial robotic arm. Parallel robotic arms, or any other suitable mechatronic structure for moving the vision unit 108 may be employed.

[0034] Examples of parts which may be inspected by the inspection system 100 may include surgical components, such as screws, bolts, and implants, and surgical tools, such as drill bits, bums, and saws. In one example, a part to be inspected may include a cannulated item with a hollow central portion extending through the part. Other examples are envisioned, and the disclosure is not intended to be limited to the examples provided herein.

[0035] As shown in FIG. 2, a robot controller 134 controls movement of the robotic manipulator 128 based on robot positioning instructions embodied in the kit inspection recipe 126 and based on operator input. The robot controller 134 may control positioning of the robotic manipulator 128, and by extension, the vision unit 108, by sensing a current pose (position and orientation) of the robotic manipulator 128 and / or vision unit 108 at each processing time step (e.g., frame) and determining a new commanded pose to which to move the robotic manipulator 128 and / or vision unit 108 based on the kit inspection recipe 126. The current pose and the new commanded pose may be defined with respect to a coordinate reference frame, such as a coordinate reference frame of the robotic manipulator 128 (e.g., fixed to its base 130), a coordinate reference frame of the vision unit 108 (e.g., associated with a moving tool center point (TCP) of the vision unit 108), or a coordinate reference frame of a tray of the surgical kit. Registration and calibration processes can be used to transform coordinates in one coordinate reference frame to another. As described further below, in some versions, the coordinate reference frame of the robotic manipulator 128 and / or the vision unit 108 are transformed to the coordinate reference frame of the tray being inspected (or vice versa) so that the robot controller 134 is able to accurately position the vision unit 108 relative to the parts in the tray.

[0036] The robot controller 134 determines how to move one or more joints of the robotic manipulator 128 (via joint motors M) to achieve movement to the new commanded pose. Therobotic manipulator 128 may have position sensors S (e.g., joint and / or motor encoders) at each of the joints to determine the current pose of the robotic manipulator 128 in the coordinate reference frame of the robotic manipulator 128 via kinematic data associated with the robotic manipulator 128. The robot controller 134 can thereby also determine the current pose of the vision unit 108 (e.g., the TCP thereof) attached to the robotic manipulator 128 in the coordinate reference frame of the robotic manipulator 128 via a known and stored geometric relationship between the vision unit 108 (e.g., its TCP) and the robotic manipulator 128, which can be determined during manufacturing or via a calibration procedure. The robot controller 134 may instruct the robotic manipulator 128 to perform a sequence of movements to position the vision unit 108 in one or more poses as dictated by the kit inspection recipe 126 for each surgical kit. The kit inspection recipe 126 may provide a predefined set (and sequence) of poses to which to move the robotic manipulator 128 in one of the coordinate reference frames previously mentioned. The predefined set (and sequence) of poses can be determined by teaching the robotic manipulator 128 the poses (and sequence) via a teach pendant, and / or by programming the poses via other methods. In some versions, the robot 104 may be a model UR5e robot manufactured by Universal Robots of Denmark.

[0037] The robot 104 may also include one or more sensors to detect operator applied forces and torques. In the version shown, a force-torque sensor F-T is attached to a coupling CP (see FIG. 1) of the robotic arm 132. The vision unit 108 is attached to the coupling CP. The forcetorque sensor F-T interconnects the coupling CP and the remaining portions of the robotic arm 132 so that the force-torque sensor F-T can detect forces and torques applied to the vision unit 108 by the operator. The force-torque sensor F-T may be a six degree-of-freedom type force-torque sensor to measure forces and torques in six degrees of freedom. Additionally, or alternatively, one or more torque sensors may be located at each joint of the robotic manipulator 128 to measure external forces and torques. The robotic manipulator 128 may have six joints to move the vision unit 108 in six degrees of freedom. When the operator wishes to manually cause movement of the robotic manipulator 128, the operator may apply forces and torques on the vision unit 108. As a result, the force-torque sensor F-T measures the forces and torques and sends corresponding output to the robot controller 134. The robot controller 134 is then able to evaluate the force and torques to determine a new commanded pose for the vision unit 108 based on the measurements, thereby effectively causing movement of the robotic manipulator 128 in a manner expected by the operator.Such collaborative robotic arms are well-known for responding to user-applied forces and torques.

[0038] With reference to FIGS. 3 A through 3C, the vision unit 108 includes one or more camera units to capture images of the parts of the surgical kits. In the version shown, the vision unit 108 includes a first camera unit 136 and a second camera unit 138. The first camera unit 136 may be configured to capture images of parts of a first type under dynamic conditions such as when lighting conditions are changing or working distances are changing. The first camera unit 136 may include one or more cameras (e.g., machine vision cameras) and one or more lenses, including fixed focal length lenses, and lenses for automated adjustment of focal length and aperture. In some versions, referring to FIG. 3B, the first camera unit 136 includes a first camera 140, a first imaging lens 142 having a fixed focal length (e.g., 16mm), and a first liquid lens 144 having a variable focus. In some examples, the first camera unit 136 may include camera model: CAM-CIC-5000-17-GC, manufactured by Cognex Corporation of Natick, MA with an ENMT lens manufactured by Opto-Engineering of Mantova, Italy. In some versions, the first camera unit 136 may include camera model: Alvium 1800 U-129C, manufactured by Allied Vision Technologies GmbH of Stadtroda, Germany with a 16mm imaging lens, model: C-series #59-870 and a liquid lens, model: EL-10-30-Ci-VIS-LD-MV from Optotune Switzerland AG of Dietikon, Switzerland.

[0039] The second camera unit 138 may be configured to capture or read text, symbols, or other characters associated with parts of a second type. For example, the second camera unit 138 may be configured to read etched or laser marked pail numbers on implants, such as screws. The second camera unit 138 may include one or more cameras (e.g., machine vision cameras) and one or more lenses, including fixed focal length lenses, and lenses for automated adjustment of focal length and aperture. In some versions, the second camera unit 138 includes a second camera 146, a second imaging lens 148 having a fixed focal length (e.g., 35mm), different than the first imaging lens 142, and a second liquid lens 150 having a variable focus. The second camera unit 138 may also include a specialty lens configured to allow for magnification up to a predetermined factor. The predetermined factor may be equal to 1.5 times or any other suitable factor. In some examples, the second camera unit 138 may include camera model: CAM-CIC-5000-17-GC manufactured by Cognex Corporation of Natick, MA with a MC150X lens manufactured by Opto-Engineering of Mantova, Italy. In some versions, the second camera unit 138 may include camera model: Alvium 1800 U-129, manufactured by Allied Vision Technologies GmbH of Stadtroda, Germany with a 35mm imaging lens, model: C-series #59-872 and a liquid lens, model: EL-10-30-Ci-VIS-LD-MVfrom Optotune Switzerland AG of Dietikon, Switzerland.

[0040] In some versions, the vision unit 108 may include one or more light sources to illuminate the parts of the surgical kits to improve imaging of the parts. For example, a first light 152 may be mounted to the robotic manipulator 128 as part of the first camera unit 136. The first light 152 may be model: DL194-WHI-I3S, manufactured by Advanced Illumination of Rochester, VT to generate diffuse, white, strobed light when capturing images with the first camera 140. A second light 154 may be mounted to the robotic manipulator 128 as part of the second camera unit 138. The second light 154 may be model: DL2230-WHI-I3S, manufactured by Advanced Illumination of Rochester, VT to generate diffuse, white, strobed light when capturing images with the second camera 146.

[0041] The vision unit 108 includes one or more camera controllers to control operation of the vision unit 108. In the version shown, the vision unit 108 includes a first camera controller 156 to control the first camera unit 136 and a second camera controller 158 to control the second camera unit 138. The camera controllers 156, 158 are coupled to their respective cameras 140, 146, liquid lenses 144, 150, and lights 152, 154 to control operation thereof in accordance with the kit inspection recipe 126.

[0042] As shown in FIG. 3C, the vision unit 108 has a support structure 155 with a mounting plate 157 that is mounted to the distal end of the robotic arm 132 of the manipulator 128. The support structure 155, in the version shown, has a plurality of mounting plates and brackets to which the components of the camera units 136, 138 are mounted. The camera units 135, 138 are thus supported by the support structure to move with the manipulator 128.

[0043] The working table 116 has one or more working surfaces to support the surgical kits during inspection. The working table may include lockable casters, storage, and guides to help orient trays on the working surface. In some versions, the working table 116 and / or other portions of the workstation may be formed at least partially of Formica. This may be helpful, for example, to avoid interference with RFID readers that could be placed all around the workstation (at the sides / above / below) to automatically identify tagged parts (e.g., with RFID tags) placed on the working table 116 at the workstation. The tagged parts could be set on the working surface of the working table 116 (either directly or in a container) and then automatically counted. In this case, the inspection system 100 would be able to identify the tagged parts that are present and compare to a list of tagged parts that should be present in the surgical kit. In some versions, the workingtable 116 is formed primarily of stainless steel and the inspection system 100 operates without reading any tagged parts.

[0044] The light surface units 118 with light surfaces 124 are provided to assist in inspecting loose parts PRTS from each of the surgical kits. As shown in FIG. 1, the light surface units 118 may include a first light surface unit 118-1 having a first light surface 124-1 and a second light surface unit 118-2 having a second light surface 124-2. The first light surface 124-1 and the second light surface 124-2 may be arranged at opposing sides of the workstation. The first light surface 124-1 may be arranged between a first zone 120-1 and a third zone 120-3 while the second light surface 124-2 may be arranged between a second zone 120-2 and a fourth zone 120-4; however, other configurations are contemplated. The light surfaces 124 may form an upper surface of the light surface units 118 shaped to receive the loose pails PRTS and contain the loose parts PRTS to keep them on the light surface 124. The light surface units 118 may also be referred to as light tables, light containers, or light boxes.

[0045] Referring to FIGS. 4A and 4B, each light surface unit 118 may include a light source 160, such as one or more white LED backlights and / or any other suitable light(s), configured to illuminate the light surfaces 124 and the loose pails PRTS from beneath the light surfaces 124 for enhanced imaging of the loose parts PRTS placed on the light surfaces 124. FIGS. 4A and 4B show a light surface 124 in a first state SI (FIG. 4A) in which the light surface 124 is not illuminated by the light source 160 and in a second state (FIG. 4B) in which the light surface 124 is illuminated by the light source 160 to allow for better imaging (e.g., better contrast) to make identification via the inspection system 100 easier owing to the improved images captured by the vision unit 108 due to the light source 160.

[0046] The light surface units 118 include one or more light surface controllers to control operation of the light surface units 118. In the version shown, each light surface unit 118 has a separate light surface controller 162, but a single light surface controller could control all the light surface units 118. The light surface controllers 162 are coupled to their respective light sources 160 to control operation thereof in accordance with the kit inspection recipes 126. As described in greater detail below, each kit inspection recipe 126 may include instructions for relevant settings / states for the light sources 160 of the light surface units 118 (e.g., active, inactive, etc.). In some cases, the operator may control the light surface units 118 via input received by the light surface controllers 162.

[0047] Referring to FIG. 2, a block diagram of a control system of the inspection system 100 is depicted. The human machine interface HMI may use software or firmware to implement the techniques and / or methods introduced herein. The software or firmware may be stored on a non-transitory computer readable medium or memory 164. The human machine interface HMI includes a system controller 166 to control operation of the human machine interface HMI and the inspection system 100. The system controller 166 may be embodied in a computer system that runs the software for the robot 104, the vision unit 108, and / or the light surface units 118. The system controller 166 includes one or more processors 168 to execute one or more software modules / programs, such as an inspection module 170. In some versions, the system controller 166 may employ a learning module 171, which may be realized as a part of the inspection module 170 or may otherwise communicate with the inspection module 170 or other portions of the system controller 166. These software modules / programs collaborate to receive and or transmit data to the robot controller 134, camera controllers 156, 158, and / or light surface controllers 162, via any suitable communication protocol. Each of the robot controller 134, camera controllers 156, 158, and light surface controllers 162 may have their own memory 164 and one or more processors 168 and may coordinate with the system controller 166 to implement the techniques and / or methods described herein. More or fewer controllers may be used in the control system. In some versions, the system controller 166 controls and operates the robot 104, the vision unit 108, and / or the light surface units 118. In some versions, collectively, the system controller 166, robot controller 134, camera controllers 156, 158, and / or light surface controllers 162 may be embodied in one or more computers.

[0048] The inspection module 170 may be configured to provide inspection instructions by transmitting associated instructions based on the kit inspection recipes 126 to the robot controller 134, camera controllers 156, 158, and / or the light surface controllers 162. Each of the kit inspection recipes includes a unique set of instructions for the robot controller 134, camera controllers 156, 158, and / or the light surface controllers 162 to control the robotic manipulator 128, camera units 136, 138, and light surface units 118 during inspection of surgical kits. For instance, each surgical kit has a unique kit inspection recipe 126 that includes various instructions for controlling the robotic manipulator 128 and the camera units 136, 138 based on a layout of the surgical kits. Once inspection of each of the surgical kits is complete, the inspection module 170 may receive kit inspection results (discussed in greater detail with respect to FIG. 8B) back fromthe robot controller 134 and / or camera controllers 156, 158 and store the kit inspection results in the one or more databases DB. The inspection module 170 may be configured to maintain the database DB of records pertaining to surgical kits including respective kit inspection recipes 126 for each surgical kit and an inspection history for each surgical kit including kit inspection results. Images associated with parts that were improperly identified and therefore resulted in a need for correction by the operator may be flagged. These images may be used as training images. The inspection module 170 and / or the learning module 171, as discussed in greater detail below, may be configured to learn from the flagged training images using one or more machine learning algorithms or models (e.g., an automated supervised learner model or a reinforcement learner model) to increase a rate at which the inspection system 100 is correctly identifying parts within surgical kits, as well as to otherwise optimize control of the robotic manipulator 128, camera units 136, 138, and light surface units 118 during inspection of surgical kits.

[0049] The operator is configured to collaborate with the robot 104, the vision unit 108, and / or the light surface units 118 via a user interface UI coupled to the system controller 166. In some versions, separate user interfaces UI may be coupled to each of the system controller 166, robot controller 134, camera controllers 156, 158, and / or light surface controllers 162. The user interfaces UI may each include one or more displays 172 (e.g., Hat panel LED display, OLED display, etc.) and one or more user input devices 174 (e.g., touchscreen, keyboard, computer mouse, pushbuttons, foot pedals, sensors, gesture control, voice control, etc.) to facilitate interaction with the operator. For example, the inspection module 170, via a GUI on the display 172, may prompt the operator for certain information, as discussed in greater detail below, prior to, during, and subsequent to inspection of the surgical kits. The operator may provide input to the inspection module 170 via the GUI shown on the display 172.

[0050] A reader device 176 (e.g., barcode scanner, RFID tag reader) may be coupled to the system controller 166. The reader device 176 may include an optical scanner, one or more radio frequency antennas, etc. that can read and decode the barcodes, RFID tags, etc. from the surgical kits and provide identification information to the inspection module 170.

[0051] The user interface UI coupled to the system controller 166, and the reader device 176, may be slidably mounted to the working table 116 via a slider 177. A rail 179 fixed to the working table 116 slidably supports the slider 177 (see FIG. 3A). The user interface UI and the reader device 176 are mounted to and supported by the slider 177 such that the operator may slidethe user interface UI and the reader device 176 as desired. Any suitable mounting system may be used. A second, slidable user interface UI and / or reader device 176 may be included on an opposite side of the working table 116, such as for processing multiple kits at the working table 116 and / or for multiple operators. In some cases, the same operator may process multiple kits at the working table 116 with multiple robots 104 and vision units 108 (not shown).

[0052] With reference to FIG. 5, an example surgical kit 178 is shown. The surgical kit 178 includes a first tray 180 with surgical instruments INST, a second tray 182 with surgical implants IMP, and loose parts PRTS. While, in the example provided, the surgical kit 178 includes the two trays, 180, 182 and loose parts PRTS, the surgical kit 178 may include any number of trays and any number of loose parts. In surgical kits where there is only one tray and no loose parts, a surgical tray and a surgical kit are the same for practical purposes. The first tray 180 may include a first unique identifier idl (e.g., embodied in a bar code, RFID tag, etc.) and the second tray 182 may include a second unique identifier id2 (e.g., embodied in a bar code, RFID tag, etc.). The first and / or second unique identifiers idl, id2 may be scanned by the reader device 176 and used by the inspection module 170 to retrieve a matching surgical kit inspection recipe 126 and associated instructions. The first unique identifier idl and the second unique identifier id2 may be the same to identify the surgical kit, may be different to uniquely identify each tray, and / or may uniquely identify the tray and the surgical kit.

[0053] The inspection module 170 retrieves and provides the inspection system 100 with the kit inspection recipe 126 in response to the human machine interface HMI receiving the unique identifier idl and / or id2 associated with the surgical kit. For example, the operator may scan into the human machine interface HMI, a barcode (or another suitable unique identifier) associated with the surgical kit via the reader device 176. The human machine interface HMI uses the scanned barcode to determine the associated id and the inspection module 170 retrieves the kit inspection recipe 126 associated with the surgical kit. In some configurations, the surgical kit may include a barcode that is separate from the barcodes of any trays in the surgical kit. For the surgical kit 178, for example, the surgical kit may have an id that is separate from the unique identifiers idl, id2 of the first and second trays 180, 182 and that is separately scanned by the reader device 176 and used to retrieve the kit inspection recipe 126. In other configurations, each tray of the surgical kit 178 may have the same kit id (e.g., idl and id2 are the same, or both identify the same surgical kit) and the human machine interface HMI may be configured to retrieve the kit inspection recipe 126based on the first and / or second identifiers idl , id2 of the first and second trays 180, 182.

[0054] With reference to FIG. 6, the zones at which surgical trays may be inspected include the first zone 120-1, the second zone 120-2, the third zone 120-3, and the fourth zone 120-4. The first zone 120-1 may correspond to “Zone A”, the second zone may correspond to “Zone B”, the third zone may correspond to “Zone C”, and the fourth zone 120-4 may correspond to “Zone D.” Each of the zones 120 may include one or more bins 122. For example, the first zone 120-1 may include a first bin 122-1 and a second bin 122-2, the second zone 120-2 may include a third bin 122-3 and a fourth bin 122-4, the third zone 120-3 may include a fifth bin 122-5 and a sixth bin 122-6, and the fourth zone 120-4 may include a seventh bin 122-7 and an eighth bin 122-8.

[0055] The operator may load the one or more trays of the surgical kit into any of the zones and any loose pails PRTS can be placed onto one or more of the light surfaces 124-1, 124-2. For example, with respect to the surgical kit 178, the first tray 180 and the second tray 182 are in the seventh bin 122-7 and the eighth bin 122-8, respectively, in the fourth zone 120-4 (i.e., “Zone D”) and the loose parts PRTS are set up on the second light surface 124-2. While the robot 104 is inspecting the surgical kit 178, the operator may set up additional surgical kits in the remaining zones 120-1, 120-2, 120-3, and on the other light surface 124-1.

[0056] During inspection, the inspection system 100 captures one or more images of the parts in the surgical kit to determine one or more of the following for each part: (i) is the part present or missing; (ii) is the part in the proper location in the surgical kit (if there is a specific location at which the part is to be located); (iii) is the part damaged; (iv) is the part worn; and (v) how many times has the pail been in the surgical kit. Any other characteristics of the parts can be determined by identifying the parts in the surgical kit.

[0057] Example images taken of the parts from the surgical kit 178 are shown in FIGS. 7 A through 7D. In FIG. 7A, the first camera unit 136 was placed at a predefined pose relative to the first tray 180 based on the kit inspection recipe 126 and then employed to capture an image in which a part no. of a part (e.g., 703882) could be seen and electronically translated via optical character recognition (OCR). The inspection module 170 can compare the characters found in the image and translated via OCR to characters that the kit inspection recipe 126 indicates should be seen in the image captured at that pose to determine if there is a match. If there is a match, then the inspection system 100 indicates that the pail is present. If there is no match, then the inspection system 100 indicates that the part is missing. In some cases, there may be a match, but thecharacters are found in a position and / or orientation not expected by the inspection module 170, i.c., the part is misplaced. The inspection system 100 may report the misplacement to the operator and once the inspection is complete, the operator may place all misplaced parts in their proper location.

[0058] In FIG. 7B, the second camera unit 138 was placed at a predefined pose relative to the second tray 182 based on the kit inspection recipe 126 and then employed to capture an image in which a part no. and / o r lot code of a part (e.g., 657318 or v07603) could be seen and electronically translated via optical character recognition (OCR). In this example, the second camera unit 138 is used to provide high resolution images of small parts (e.g., a head of a 3.5mm screw is shown). The inspection module 170 can compare the characters found in the image and translated via OCR to characters that the kit inspection recipe 126 indicates should be seen in the image captured at that pose to determine if there is a match. If there is a match, then the inspection system 100 indicates that the pail is present. If there is no match, then the inspection system 100 indicates that the part is missing or misplaced.

[0059] In FIG. 7C, the loose parts PRTS are shown on the light surface 124 being back illuminated and the first camera unit 136 has captured an image of all the loose pails PRTS to count / identify which parts are present / missing. In this case, pattern recognition algorithms may again be used. For example, the image shown in FIG. 7C shows two types of parts, those with enlarged portions and those without. The kit inspection recipe 126 may provide one or more patterns expected to be seen in the image of the loose parts PRTS, including different patterns for different parts. For example, the kit inspection recipe 126 for the surgical kit 178 may provide a geometric pattern for the enlarged portion. The inspection system 100 can then count the number of enlarged portions that can be seen in the image via pattern matching the geometric pattern associated with the enlarged portion to the image and then counting how many times the pattern is found - five times in the example of FIG. 7C (as indicated by the pattern matching indicator boxes).

[0060] In FIG. 7D, the first camera unit 136 was placed at a predefined pose relative to the first tray 180 based on the kit inspection recipe 126 and then employed to capture an image of one of the instruments INST. The kit inspection recipe 126 provides one or more patterns (e.g., unique geometric shapes, etc.) expected to be seen in the image captured. The image is then processed via the inspection module 170 using pattern recognition algorithms to determine if any of the one ormore patterns are found in the image. Tf the one or more patterns are found (matched) in the image, then the inspection system 100 indicates that the part is present. If no matches arc found, then the inspection system 100 indicates that the part is missing. In some cases, there may be a match, but the pattern is found in a position and / or orientation not expected by the inspection module 170, i.e., the pail is misplaced. The inspection system 100 may report the misplacement to the operator and once the inspection is complete, the operator may place all misplaced parts in their proper location. In FIG. 7D, the pattern matching indicator box indicates that the pattern was found in the image.

[0061] The kit inspection recipe 126 can dictate which camera unit 136, 138 to use to inspect each part, and the type of part identification used for each part (e.g., pattern recognition, OCR, and the like). In addition to identifying whether the part is present or missing, the inspection module 170 may also determine if the part is damaged (e.g., has one or more defects) or is worn. This may be accomplished by comparing the captured images to images of undamaged or unworn parts to find differences. This can also be accomplished by the one or more of the controllers 134, 156, 158, 162, 166 employing deep learning algorithms as an identification method to further inspect the parts in the surgical kit, such as may be facilitated by the learning module 171 or other parts of the system controller 166. In some versions, these types of deep learning algorithms may rely on training of neural networks using images of undamaged / unwom parts and / or images of damaged / wom pails, including parts that have nicks, scratches, etc. Accordingly, in some versions, one or more of the controllers 134, 156, 158, 162, 166 can analyze the parts to detect defects and can classify those defects (e.g., as a “scratch” or “nick”, etc.). Both the first camera unit 136 and the second camera unit 138 can capture images that allow the inspection system 100 to identify such defects. The inspection system 100 can then utilize deep learning algorithms that are sufficiently trained to determine whether each of the pails is damaged, worn, etc. Furthermore, deep learning algorithms and methods may be employed to promote improved inspection of surgical kits by, among other things, optimizing control of the robotic manipulator 128, camera units 136, 138, and / or light surface units 118 during inspection of specific pails. Deep learning algorithms and methods that may be employed by the inspection system 100 include those found in VisionPro® ViDi™ deep learning-based image analysis software from Cognex Corporation of Natick, MA, including those utilized in VisionPro® ViDi™ v 3.1 and Vidi2. Deep learning algorithms and methods that may be employed by the inspection system 100 for pattern matching,string matching, detecting defects, and the like may include those described in U.S. Patent Application Pub. No. 2020 / 0005069 to Wang et al., entitled “System And Method For Finding And Classifying Patterns In An Image With A Vision System,” filed on June 6, 2019, which is hereby incorporated herein by reference.

[0062] As will be described further below, each kit inspection recipe 126 provides information to be transmitted to one or more of the controllers 134, 156, 158, 162, 166 as to how the robot 104, vision unit 108, and / or light surface units 118 are to move and / or operate to inspect each of the parts, such as each of instruments INST in tray 180, each of the implants IMP in tray 182, and each of the loose parts PRTS. Such information includes, for example: (i) the pose (i.e., coordinates x, y, z, u, v, w) to which the robotic manipulator 128 should move to capture one or more images of the pail; (ii) which camera unit 136, 138 (e.g., one or both) should be operated at each pose to capture the one or more images of the part; (iii) one or more lens settings and / or lighting settings for the camera unit 136, 138 being operated; (iv) settings for the light surface unit 118, if used; and / or (iv) the identification method used to identify the part in the one or more images.

[0063] With reference to FIG. 8A, example block diagrams of various classes (i.e., program code templates) are shown for creating objects associated with the kit inspection recipe 126. The kit inspection recipe 126 may be created in advance based on operator input and is unique to each surgical kit. For surgical kits that are different, a separate kit inspection recipe 126 is provided. Once created, the kit inspection recipes 126 may be stored in the database DB or any suitable location for later retrieval by the inspection system 100. To start the inspection process, as described further below, the inspection system 100 retrieves the kit inspection recipe 126 based on the identification of the surgical kit being inspected. If there is no kit inspection recipe 126 for a surgical kit, then the operator must create a new kit inspection recipe 126.

[0064] An example block diagram of a kitRecipe class 212 is shown for creating the kit inspection recipe 126 (i.e., the kitRecipe class 212 is instantiated to create the kitRecipe object). The kitRecipe class 212 may include one or more variables such as id, recipeVersion, recipe VersionDate, kitld, kitDisplayName, and multipleTrays. The id variable may be assigned a unique identifier for each of the surgical kits (e.g., such as the unique identifiers idl, id2 for the surgical kit 178). The recipeVersion variable may be assigned a version of the kit inspection recipe 126, for example, “first version,” “second version,” etc. The kitld variable may be assigneda name indicative of the type of surgical kit, or may correlate to an existing part number for the kit, etc. The kitDisplayNamc variable may be assigned a name indicative of the type of surgical kit, which is to be displayed on the GUI of the inspection module 170. The kitld and the kitDisplayName may be the same in some cases. The multipleTrays variable may be assigned a boolean value, for example, with true indicating that multiple trays are present in the surgical kit and false indicating that there is just a single tray or only loose parts PRTS for a particular surgical kit. For example, the kit inspection recipe 126 for the surgical kit 178 would have this variable being assigned a true value since there are two trays 180, 182 and loose parts PRTS (also considered a “tray” in the kit inspection recipe 126.

[0065] The kitRecipe class 212 may also include a trayRecipe subclass 216. The inspection module 170 may use the trayRecipe subclass 216 to create a trayRecipeObject for each tray in the surgical kit and for the loose pails PRTS. For example, for the surgical kit 178, the trayRecipe subclass 216 would be instantiated to create three tray RecipeObjects for the kitRecipe object - one for the first tray 180, one for the second tray 182, and one for the loose parts PRTS.

[0066] The trayRecipe subclass 216 may include one or more variables such as tray ID, trayDisplayName, and trayLayoutlmage. The traylD variable may be assigned a unique identifier for each tray of the surgical kit (e.g., such as the unique identifiers idl, id2 for the surgical kit 178). The trayDisplayName may be assigned a name to be displayed for each tray on the GUI of the inspection module 170, for example for the first tray 180 the name shown on the GUI may correspond to “Instrument Tray.” The trayLayoutlmage may be assigned an image of a tray, for example an image of the first tray 180, second tray 182, etc. The trayRecipe subclass 216 may also include a subclass such as a partRecipe subclass 220.

[0067] The inspection module 170 may use the partRecipe subclass 220 to create a partrecipeObject for each part of a tray, for example, for each instrument INST in the first surgical tray 180, for each implant IMP in the second surgical tray 182, and collectively for the loose pails PRTS. Each partrecipeObject may include a unique set of instructions that the robot controller 134, the camera controllers 156, 158, the light surface controllers 162, and / or the system controller 166 use to control the robot 104 and the vision unit 108 to inspect each part in the surgical kit. The partRecipe subclass 220 may include variables such as partRecipeld, partRecipeVersion, pailRecipeVersionDate, partNumber, pailDisplayName, and partRecipeld. The partRecipeld may be assigned a unique identifier for each part of the surgical kit. The partRecipeVersion may beassigned a recipe version, for example, a first version, a second version, etc. The partRccipcVcrsionDatc may be assigned a date and / or time that the corresponding version of the part recipe was created or generated. The partNumber variable may be assigned an existing part number of a part (e.g., serial number, etc.). The partDisplayName variable may be assigned a name of a part to be displayed on the GUI of the inspection module 170.

[0068] The partRecipe subclass 220 may also include one or more subclasses such as a visionTool subclass 224, an opticalSettings subclass 228, and a coordinates subclass 232. The coordinates subclass 232 may include variables x, y, z, u, v, and w that correspond to robot coordinates, including position (x, y, z) and orientation (u, v, w) for a coordinate reference frame, such as a coordinate reference frame associated with the tray in which the part resides. The inspection module 170 may use the coordinates subclass 232 to create a coordinatesObject for each part in a tray, for example, each instrument INST in the first tray 180 or for each implant IMP in the second tray 182, or may create one coordinatesObject for the loose parts PRTS. The robot controller 134 may position the robot 104 / vision unit 108 at the coordinates associated with each part as determined by the coordinatesObject for each part.

[0069] The inspection module 170 may also be configured to explore the system statespace (i.e. , the six locomotive degrees of freedom combined with the focal depth of the liquid lens and integration time of the image sensor sensor) via policy gradient algorithms optimize control policies for locating each part. In some versions, the control policy may be defined as the state vector which maximizes the confidence score returned by the inspection module 170. For example, when a part is not located at the specified location in the kit inspection recipe 126, the inspection module 170 may instruct the robot 104 to explore the state- space using the policy gradient algorithms to locate the part within the tray while maximizing the confidence score. The learning module 171 may cooperate with the inspection module 170 to improve optimized identification and handling of such scenarios.

[0070] The visionTool subclass 224 may include variables such as type, region, matchPattern, and matchString. The type variable may be assigned a value associated with either the first camera unit 136, the second camera unit 138, or both camera units 136, 138. The region variable may be assigned coordinates and / or dimensions for a rectangle that dictates how large of a region should be imaged, for example. The matchPattern may be assigned an image associated with a pattern that is to be found in the image captured by the vision unit 108 to verify the presenceof the part. For example, the matchPattern image may be a pattern that is to be matched in the one or more images captured by the first camera unit 136, the second camera unit 138, or both the camera units 136, 138. During inspection, if there is a match in the captured image to this stored image, this indicates that the part is present. If there is no match, then the part is determined by the inspection module 170 to be missing. Matching of the images may be determined by known pattern recognition algorithms, including deep learning-based pattern matching algorithms such as those described in U.S. Patent Application Pub. No. 2020 / 0005069 to Wang el al., incorporated herein by reference. The matchString variable may be assigned a particular string of characters that need to be matched in one or more images captured by the first camera unit 136, the second camera unit 138, or both the camera units 136, 138 to determine if the part is present. During inspection, the one or more images captured may be processed using optical character recognition (OCR), including deep learning-based OCR, to determine the characters or strings of characters present in the one or more images. These characters or strings of characters can then be compared to the matchString variable to see if there is a match. If the characters match, then the part is determined to be present. In some versions, the first camera unit 136 is used to capture images for parts that are identified via matching patterns and the second camera unit 138 is used to capture images for parts that are identified via matching strings. The inspection module 170 may use the visionTool subclass 224 to create a visionToolsObject for each pail of a tray.

[0071] The opticalSettings subclass 228 may include one or more variables for adjusting a setting of one or both of the first camera unit 136 and / or the second camera unit 138 including a strobe / flash length, an exposure length, and a focal power adjustment. The strobe / flash variable determines the duration of the flash or strobe. The exposure length (i.e., shutter speed) determines a duration that an image sensor inside the camera unit is exposed (i.e., open) to light. The focal power adjustment variables determine the focal length (i.e., the distance between an optical center of a lens and the image sensor when the subject is in focus).

[0072] The above-mentioned classes and subclasses are shown in an example overall kit inspection recipe class schema 236. These classes and subclasses are instantiated to create corresponding objects for each kit inspection recipe 126. For simplicity of illustration purposes, the overall class schema 236 does not show multiple trays or multiple parts per tray; however, it is contemplated that the kit inspection recipe 126 may contain any number of tray Recipe objects and any number of partRecipe objects. Once the kit inspection recipe 126 is created, it may besaved to the database DB and retrieved at a later time for inspection of the associated surgical kit.

[0073] As previously discussed, images associated with pails that were improperly identified and therefore resulted in a need for correction by the operator may be flagged and used as training images. Periodically, the inspection module 170 and / or the learning module 171 may use the training images to optimize processes, such as to update the kit inspection recipes, update search policies for specific parts, and the like. The inspection module 170 may update any portion of the kit inspection recipes such as any value for any variable associated with the partRecipeObject, the visionToolObject, theCoordinatesObject, opticalSettingObject, the kitRecipeObject and / or the trayRecipeObject. In some versions, the inspection module 170 may update the opticalSettingObject to refine the focal length variable of the opticalSettingObject based on the training images. In some versions, the inspection module 170 may update one or more of the variables of the coordinate object to refine the position in which the robot controller 134 positions the robot 104 / vision unit 108 when inspecting a particular pail.

[0074] Once the kit inspection recipe 126 has been updated, the kit inspection recipe 126 may be tested. When the number of tests exceeds a certain threshold, an operator can review the inspection history of the robot 104 and determine whether or not performance was improved when compared to the performance of a prior inspection recipe. In reviewing performance, the operator van evaluate whether the rate at which parts were correctly identified improves compared to the prior inspection recipe. When the operator deems that the kit inspection recipe 126 is producing satisfactory results and performance has improved when compared to the prior kit inspection recipe, the operator may confirm that the kit inspection recipe 126 is ready for use. In the event that an update to the kit inspection recipe 126 leads to a less desirable outcome, the inspection module may restore the previous kit inspection recipe or restore a default kit inspection recipe.

[0075] Referring to FIG. 8B, the software operated by the inspection system 100 also provides inspection results for viewing and storing. The results are compiled in objects that are instances of inspection classes set forth in FIG. 8B. A kitinspection class 240 may be used to create a kit inspection result 260 (i.e., kit inspection results object). The kitinspection class 240 may include variables such as id, systemid, inspectionStartTime, inspectionEndTime, kitlnspectionComplete, andkitDisplayName. The id variable may be assigned the unique identifier associated with the surgical kit. The systemid variable may be assigned a name or a unique identifier associated with the inspection system 100 used to inspect the surgical kit. TheinspectionStartTime variable may be assigned a time corresponding to the time that the robot 104 and / or the vision unit 108 began inspection of the first part, the time that a kitinspection object was created, or the like. The inspectionEndTime may be assigned a time corresponding to when the robot 104 and / or the vision unit 108 finished inspection of the last part, the time the robot 104 was set to idle after the last tray was inspected, the time the inspection results were submitted to the inspection module 170, or the like. The kitlnspectionComplete may be assigned a Boolean value, for example, true or false, with true indicating that the robot 104 and / or the vision unit 108 finished inspecting the surgical kit and false indicating that the robot 104 and / or vision unit 108 did not finish inspecting the surgical kit.

[0076] The kitinspection class 240 may also include a trayinspection subclass 244. The trayinspection subclass 244 may be used to create a traylnspectionObject for each tray in the surgical kit, for example, a traylnspectionObject for the first tray 180, a traylnspectionObject for the second tray 182, and a traylnspectionObject for the loose parts PRTS. The tray Inspection subclass 244 may include one or more variables such as traylnspectionStartTime, traylnspectionEndTime, traylnspectionComplete, and trayDisplayName.

[0077] The traylnspectionStartTime variable may be assigned a time corresponding to when the robot 104 and / or the vision unit 108 started inspection of the first part in the tray. The traylnspectionEndTime variable may be assigned a time corresponding to when the robot 104 and / or the vision unit 108 finished inspection of the last part in the tray. The traylnspectionComplete variable may be assigned a Boolean value with true indicating that the robot 104 and / or the vision unit 108 finished inspecting the tray and false indicating that the robot 104 and / or the vision unit 108 did not finish inspecting the tray.

[0078] The tray Inspection subclass 244 may also include a partinspection subclass 248. The partinspection subclass 248 may be used to create a partlnspectionObject for each part of the tray. The partinspection subclass 248 may include one or more variables such as partNumber, partDisplayName, partlnspectionResult, foundQuantity, algorithmld, and image. The partNumber variable, as previously discussed, may be assigned an existing part number of a part (e.g., serial number, etc.). The partDisplayName variable may be assigned a name of a part to be displayed for the part on the GUI of the inspection module 170. The partlnspectionResult may be assigned a partlnspectionResultType as shown in 252. The partlnspectionResultType may include one or more predetermined values such as “Pass”, “Fail”, or “Operator Determination Required.” ThefoundQuantity variable may include a number of parts found that have the same partNumber. In some cases, the foundQuantity may be cither “1” (part present) or “0” (part missing). The partlnspectionResultType may also include a confidence score associated with “Pass” and “Fail” which represents the degree of confidence that the correct result was returned. The algorithmld variable may correspond to a type of algorithm (identification method) used to process the one or more images captured by the first camera unit 136 and / or the second camera unit 138 for that part to determine if the part is present or missing (e.g., pattern recognition, OCR, etc.). The image variable may be assigned an image captured of the pail.

[0079] The above-mentioned classes are shown in an example overall kitinspection Results class schema 256. These classes and subclasses are instantiated to create corresponding objects for each kit inspection result 260. For illustration purposes, the overall kitinspection Results class schema 256 does not show classes for multiple trays or multiple parts per tray; however, it is contemplated that the kit inspection results 260 may contain any number of tray Inspectionobjects and any number of partlnspectionObjects. Once the kit inspection result 260 is completed, it may be saved to the database DB and retrieved by the inspection module 170 at a later time. The kit inspection result 260 may be retrieved to determine how to replenish the surgical kit, for billing purposes, etc. The kit inspection result 260 may also be retrieved in order to determine if any adjustments need to be made to the kit inspection recipes 126 to increase a rate at which the inspection system 100 is correctly identifying parts. The kit inspection result 260 may also include a confidence score for each part, representing the degree of confidence in the inspection system correctly identifying each of the surgical parts.

[0080] FIG. 8C shows a high-level block diagram of steps carried out by the inspection system 100. At 270, the operator initially scans in one or more trays of a surgical kit using the reader device 176. The system controller 166 then determines the id of the surgical kit based on the scan. At 272, the system controller 166 then determines if a kit inspection recipe 126 exists by scanning the database DB storing the kit inspection recipes to see if any are associated with the id of the surgical kit. If a kit inspection recipe 126 exists that is associated with the id, the system controller 166 retrieves the associated kit inspection recipe 126 from the database DB. If there is no associated kit inspection recipe 126, the operator is prompted to find the kit inspection recipe 126 from a list of kit inspection recipes or to create a new kit inspection recipe using the classes / objects previously described with respect to FIG. 8A. Once the kit inspection recipe 126 isretrieved or created, then the robot 104 and the vision unit 108 are activated to execute the kit inspection recipe 126 at 274. The results of the kit inspection arc displayed to the operator at 276 and then submitted to one or more locations at 278, e.g., stored in the database DB, submitted to a replenishing system, billing system, etc. Use of an inspection system and inspection recipes is described in commonly owned U.S. Patent Application Pub. No. 2021 / 0383523-Al to Simson et al., which is incorporated herein by reference.

[0081] In the version of FIG. 1, parts may exist as freely floating parts within the zones 120. In other versions, the pails of the surgical kit may be supported or held by a workpiece support device configured to position one of the plurality of parts relative to a camera device. With reference to FIG. 9, an alternative version of an inspection system 1000 is presented. The inspection system 1000 may provide a workstation including a robot configured to operate as a workpiece support device including a robotic manipulator 1028, a vision unit 108, and a working table 1016. The inspection system 1000 may include a robotic controller similar to the robotic controller 134 of FIG. 2. The inspection system 1000 may include a light surface unit similar to the light surface unit 118 of FIGS. 1 and 2. The inspection system 1000 may include an HMI similar to the HMI of FIGS. 1 and 2. The inspection system 1000 may work in collaboration with the operator to inspect and inventory surgical kits. The inspection system 1000 may also be referred to as a semi-automated inspection system. The inspection system 1000 may be employed by vendors that supply the surgical kits to users of the surgical kits (e.g., hospitals, etc.) or the inspection system 1000 may be employed by the users themselves. FIG. 9 illustrates the inspection system 1000 configured for utilizing the robotic manipulator 1028 to move one or parts 1042 from the surgical kit 1040 into a field of view of the vision unit 108 for inspection.

[0082] The robotic manipulator 1028 may be configured to orient or rotate one of the parts 1042 in a plurality of various poses. The robotic manipulator is illustrated including a first arm 1061, a second arm 1060, a first rotating joint 1029, a second joint 1054, and a third joint 1052. The first rotating joint 1029 may be an elbow-type joint, permitting the second arm 1060 to change an angle relative to the first arm 1061. The first arm 1061 and the second arm 1060 are exemplary, the robot may include any number of arms 1061, 1060, and the disclosure is not intended to be limited to the illustrated example. An end effector 1050 is illustrated attached to the second arm 1060 by the second joint 1054. The third joint 1052 enables a portion of the second arm 1060 to rotate around a longitudinal axis 1062 of the second arm 1060, thereby enabling rotation of theend effector 1050 about the longitudinal axis 1062. The second joint 1054 may include rotation about one or more axes or alternatively may include a gimbal joint, permitting three-dimensional rotation about a point.

[0083] The end effector 1050 may include a gripper device 1056 which may include a variety of mechanical gripping features, vacuum-powered features, magnetic features, or other features which enable the end effector 1050 to selectively acquire and hold the part 1042 for manipulation. The gripper device 1056 is illustrated including a pair of articulable fingers capable of opening and closing for the purpose of selectively closing around a part 1042. The fingers may include rough or toothed gripping surfaces configured to improve gripping force upon the part 1042. The fingers may additionally or alternatively include a rubberized or polymerized coating configured to improve a gripping force upon the part 1042 and may provide a cushioned grip of the part 1042 to avoid creating scuffs or other flaws upon the part 1042 being gripped. The end effector 1050 may include a camera device 1058 to aid in localizing the gripper device 1056 to the part 1042 and / or aid in identification of the part 1042 so that a part- specific inspection instruction from the part 1042 may be referenced.

[0084] FIGS. 10 and 11 illustrate sequential operation of the inspection system 1000, including the robotic manipulator 1028 manipulating the part 1042 to be within a field of view of the vision unit 108. FIG. 10 illustrates the robotic manipulator 1028 including the first joint 1029, the second arm 1060, and the gripper device 1056. In comparison with the robotic manipulator 1028 of FIG. 9, the robotic manipulator 1028 of FIG. 10 has utilized the gripper device 1056 to selectively grip one of the parts 1042. The robotic manipulator 1028 has adjusted the joint 1029 such that the second arm 1060 is vertically lifted, such that the gripper device 1056 has moved closer to the vision unit 108. The robotic unit 1028 may continue to manipulate the part 1042 such that the part 1042 is disposed within a field of view of vision unit 108 in front of the vision unit 108. The robotic manipulator 1028 may further adjust any of the joints 1029, 1052, 1054 of FIG. 9 thereupon to adjust a pose or a position and an orientation of the part 1042 in the field of view of the vision unit 108.

[0085] FIG. 11 illustrates the robotic manipulator 1028 having further adjusted position and orientation of the part 1042 to achieve a pose of the part 1042 such that the pail 1042 is directly in front of the vision unit 108 such that the vision unit 108 may create one or more images of the part 1042. The robotic manipulator 1028 is illustrated with adjusted positions and orientations ofthe first arm 1061 , the second arm 1060, and the gripper 1056 and corresponding adjustments made to the first joint 1029, the second joint 1054 and the third joint 1052. The part 1042 has been rotated about a plurality of axes in order to position and orient the part 1042 before the vision unit 108 in a desired pose. The vision unit 108 may capture or create one or more images of the part 1042 in the illustrated pose. Lighting may be altered between created images, for example, with intensity and location of the light source changing to provide multiple alternative images which may be more or less useful than other images in identifying a particular flaw upon the part 1042. Further, while a plurality of images is being created, the precise pose of the part 1042 may be altered by the robotic manipulator, for example, slightly tilting and moving the part 1042 away from the vision unit 108 as a sequence of images are created. In another example, the pose of the part 1042 may change entirely, for example, with the robotic manipulator turning the part 1042 around 180 degrees to enable capturing images of a reverse side of the part 1042. The plurality of images and the changes between the plurality of images may provide data to software configured to recognize features in the images that indicate a presence of flaws, for example, including bioburden deposits, scuffs, or other wear, upon the part 1042.

[0086] With reference to FIG. 12, an alternative version of an inspection system 300 is presented. The inspection system 300 may provide a workstation including a first robot including a robotic manipulator 328A, a second robotic manipulator 328B, a vision unit 108, and a working table 316. The inspection system 300 may include one or more robotic controllers similar to the robotic controller 134 of FIG. 2. The inspection system 300 includes a light surface unit 118. The inspection system 300 may include an HMI similar’ to the HMI of FIGS. 1 and 2. The inspection system 300 may work in collaboration with the operator to inspect and inventory surgical kits. The inspection system 300 may also be referred to as a semi- automated inspection system. The inspection system 300 may be employed by vendors that supply the surgical kits to users of the surgical kits (e.g., hospitals, etc.) or the inspection system 300 may be employed by the users themselves. FIG. 12 illustrates the inspection system 300 configured for utilizing the robotic manipulator 328A as a workpiece support device to manipulate pail 342 and additionally for utilizing the robotic manipulator 328B to manipulate the vision unit 108, such that the vision unit 108 and the part 342 are aligned with the light surface unit 118 to achieve a desired pose of the part 342 and a desired illumination effect.

[0087] In the example of FIG. 12, the part 342 is illustrated including a cannulation 344 ora hollow center portion extending through the part 342. The inspection system 300 in FIG. 12 is configured to enable the vision unit 108 to create images of details of the interior surface of the cannulation 344. By aligning the vision unit 108, the pail 342, and the light surface unit 118, images may be used to capture a profile of the cannulation 344. For example, wherein the cannulation 344 includes a circular sectional profile, if there is no bioburden within the cannulation 344, the profile of the interior surface of the cannulation 344 viewed against the light surface unit 118 may appear as a circular profile. However, if a bioburden deposit is present within the cannulation 344, the bioburden deposit may appear as a flaw or an indentation in the circular profile visible within images created by the vision unit 108. In one version, wherein the part 342 is curved and includes a corresponding curved cannulation 344, the disclosed system and method may include creating an image down one side of the cannulation 344, rotating the part 342, and then creating another image down the second side of the cannulation 344.

[0088] The robotic manipulators 128, 1028, 328A, 328B of FIGS. 1, 9, and 12 may include features enabling objects such as parts 1042, 342 and vision units 108 to be moved and rotated through ranges of positions and orientations in three dimensions. Other variations of robotic manipulators 128, 1028, 328A, 328B may be utilized, for example, adjusting exemplary parts 1042, 342 and / or vision units 108 in fewer dimensions, for example, with the robotic manipulator moving an item along a line or within an XY coordinate system along a real or imaginary planar surface. The robotic manipulators 128, 1028, 328A, 328B provided herein are non-limiting examples, and the disclosure is not intended to be limited to the examples provided herein.

[0089] As an alternative workpiece support device, the disclosed inspection systems 100, 1000, 300 of FIGS. 1, 9, and 12 may alternatively include a pail holder with shapes, cavities, or other fixturing elements configured to hold parts 1042, 342 in a desired pose relative to a vision unit 108. With reference to FIG. 13, a pail holder 410 is provided. The part holder 410 is illustrated including an optional base 474. The part holder 410 is configured to hold one or more parts 442 for inspection. The parts 442 may be manually or automatically placed into the part holder 410. The part holder 410 may be configured to permit the parts 442 to be disposed within the part holder 410 in a single desired pose, for example, with a position, an orientation, and a rotation of the part 442 fixed within a cavity 472 of the pail holder 410. The part holder 410 may be configured to permit a single or a certain number of degrees of freedom for the parts 442 within the cavity 472, for example, with a part 442 within an exemplary cylindrical outer shape beingcapable of being rotated within the cavity 472. In another example, the part 442 may be reversible, with the pail 442 being able to be disposed within the cavity in cither an upright or a flipped / inverted orientation. In some versions, the part 442 may include a key feature or non- symmetrical feature which may be used to limit how the part 442 may fit within the cavity 472.

[0090] The part holder 410 may include an integrated light surface unit 418 within the pail holder. In the version of FIG. 13. light emitted by the light surface unit 418 may project upwardly through the cavities 472. The example illustrated of the pails 442 includes a cannulation 444. The light emitted by the light surface unit 418 may project upwardly through the cannulation 444 to provide an ability to detect flaws such as bioburden within the cannulation 444.

[0091] As described herein, a workpiece support device may be defined as the pail holder 410 including a working end to receive the one of the plurality of parts 442 in a predetermined pose relative to a camera device. In one version, the part holder 410 is stationary. In another version, the part holder 410 further includes a base and a linkage operatively attached to the base and to the working end for manually adjusting the predetermined pose relative to the camera device.

[0092] With reference to FIG. 14, the part holder 410 is illustrated in use with a vision unit 108 mounted to a robotic manipulator 428. The part holder 410 is illustrated including six exemplary cavities 472 configured to hold six of the parts 442. In other versions, the part holder 410 may be configured to hold three of the parts 442 and additionally configured to hold a plurality of other parts of a surgical kit. The robotic manipulator 428 may be configured to move the vision unit 108 over the face of the pail holder 410 such that the vision unit 108 may create images of the parts 442 in any of the cavities 472. The robotic manipulator 428 may be configured or controlled to maintain the vision unit 108 in a perpendicular alignment to a face of the part holder 410. In another version, the robotic manipulator 428 may be configured to enable the vision unit to tilt relative to the face of the part holder 410.

[0093] The vision unit 108 is provided as an example of a camera device or system that may be utilized to create images of parts 1042, 342, 442. Other types of camera devices may similarly be utilized, and the disclosure is not intended to be limited to the examples provided herein. Similarly, the light surface unit 118, 418 is provided herein as an example of a light or a light emitting device useful to illuminate parts 1042, 342, 442 for the purpose of creating detailed and useful images of the parts 1042, 342, 442. Other types of light emitting devices may beutilized, and the disclosure is not intended to be limited to the examples provided herein.

[0094] With reference to FIG. 15, an example of a method 500 to utilize an inspection system 100, 1000, 300 of FIGS. 1, 9, and 12, respectively, to inspect a plurality of pails 1042, 342, 442 of a surgical kit. While the method 500 is being disclosed as being useful with the inspection systems 100, 1000, 300 disclosed herein, the method may similarly be utilized upon other versions of inspection systems. The method 500 starts at step 502. At step 504, a surgical kit is surveyed and at least one part to be inspected is inventoried. Such a survey may be performed manually, for example, with a user entering an identity or description of the surgical kit or identities of the parts with the kit. In another example, such a survey may be taken automatically, for example, with a first image from a camera being used to identify unique shapes and / or pail numbers on parts for the purposes of identifying what parts are to be inspected. At step 506, a pail to be inspected is selected from the surgical kit. At step 508, a part-specific inspection instruction is referenced, providing instructions for a camera device to create one or more images useful for analyzing the part to determine whether any flaws exist upon the part. At step 510, the camera device is used to create the one or more images of the part using the part-specific inspection instructions. At step 512, the one or more images of the pails are analyzed, and a determination is made whether a flaw exists upon the part. At step 514, an output is generated based upon the analysis of the one or more images. The output may be a visual output such as an indication upon a display screen, an illumination of an indicator lights, such as a green light for no flaws being detected and a red light for detected flaws, a printed output upon a sticker or part label to be affixed to the part, a part description to be entered in a rallied report, or other similar outputs. At step 516, a determination is made whether all of the parts to be inspected have been inspected. If all of the pails have been inspected, the method 500 advances to step 518 where the method 500 ends. If all of the parts have not been inspected, the method 500 returns to the step 506 where another pail is selected for inspection. The method 500 is provided as an example of a method to inspect a plurality of pails in a surgical kit. The method 500 is exemplary, a number of additional or alternative method steps are envisioned, and the disclosure is not intended to be limited to the examples provided herein.

[0095] With reference to FIG. 16, an example of a method 600 to utilize an inspection system 100 or 300 of FIGS. 1 and 7, respectively, to inspect a plurality of parts 1042, 342, 442 of a surgical kit, wherein a robotic manipulator 128, 328B is useful to maneuver a camera device relative to the part to be inspected. While the method 600 is being disclosed as being useful withthe inspection systems 100, 300 disclosed herein, the method may similarly be utilized upon other versions of inspection systems, for example, with systems utilizing the part holder 410 of FIG. 8. The method 600 starts at step 602. At step 604, a part to be inspected is identified, for example, with a first image from a camera being used to identify unique shapes and / or pail numbers on parts for the purposes of identifying what pails are to be inspected. At step 606, a part-specific inspection instruction is referenced, providing instructions for a camera device to create one or more images useful for analyzing the part to determine whether any bioburden exist upon the part. At step 608, a position and orientation of the part to the inspected is registered to a reference XYZ coordinate system. For example, a part holder location may be referenced to a location of a base of a robot being used to manipulate the camera device being used. At step 610, a camera device such as the vision unit 108 of FIG. 1 is maneuvered according to the part-specific inspection instructions to create one or more images of the pail. At step 612, the one or more images of the parts are analyzed and a determination is made whether bioburden exists upon the part. At step 614, an output is generated based upon the analysis of the one or more images. The output may be a visual output such as an indication upon a display screen, an illumination of an indicator lights, such as a green light for no bioburden being detected and a red light for detected bioburden, a printed output upon a sticker or part label to be affixed to the part, a part description to be entered in a rallied report, or other similar outputs. At step 616 where the method 600 ends. The method 600 is provided as an example of a method to inspect a plurality of parts in a surgical kit. The method 600 is exemplary, a number of additional or alternative method steps are envisioned, and the disclosure is not intended to be limited to the examples provided herein.

[0096] With reference to FIG. 17, an example of a method 700 to utilize an inspection system 1000, 300 of FIGS. 4 and 7, respectively, to inspect a plurality of parts 1042, 342, 442 of a surgical kit, wherein a robotic manipulator 1028, 328 A is useful to maneuver the part to be inspected. While the method 700 is being disclosed as being useful with the inspection systems 1000, 300 disclosed herein, the method may similarly be utilized upon other versions of inspection systems. The method 700 starts at step 702. At step 704, a part to be inspected is selected. At step 706, a part identification camera is used to determine an identity of the part. At step 708, partspecific inspection instruction is referenced based upon the identity of the part, providing instructions for a camera device to create one or more images useful for analyzing the paid to determine whether any bioburden exists upon the part. At step 710, a vision unit 108 as describedin relation to FIGS. 1 -3C is used to create the one or more images of the part using the part-specific inspection instructions. At step 712, the one or more images of the parts arc analyzed, and a determination is made whether bioburden is detected upon the pail. At step 714, an output is generated based upon the analysis of the one or more images. The output may be a visual output such as an indication upon a display screen, an illumination of an indicator lights, such as a green light for no flaws being detected and a red light for detected flaws, a printed output upon a sticker or part label to be affixed to the part, a part description to be entered in a rallied report, or other similar outputs. At step 718, the method 700 ends. The method 700 is provided as an example of a method to inspect a plurality of parts in a surgical kit. The method 700 is exemplary, a number of additional or alternative method steps are envisioned, and the disclosure is not intended to be limited to the examples provided herein.

[0097] With reference to FIG. 18, an example of a method 800 to utilize an inspection system 100, 1000, 300 of FIGS. 1, 9, and 12, respectively, to inspect a plurality of parts 1042, 342, 442 of a surgical kit using a parts holder 410 of FIG. 8. While the method 800 is being disclosed as being useful with the inspection systems 100, 1000, 300 disclosed herein, the method may similarly be utilized upon other versions of inspection systems. The method 800 stalls at step 802. At step 804, a part holder is utilized to fixture a part to be inspected. The part is held in a pose, (i.e., a location and an orientation) facilitating inspection of the part. At step 806, a part-specific inspection instruction is referenced which provides instructions for inspecting the part fixtured in the part holder. At step 808, a vision unit 108 as described in relation to FIGS. 1-3C is utilized to create one or more images of the pail according to the instructions. At step 810, the one or more images of the parts are analyzed, and a determination is made whether bioburden is detected upon the part. At step 812, an output is generated based upon the analysis of the one or more images. The output may be a visual output such as an indication upon a display screen, an illumination of an indicator lights, such as a green light for no flaws being detected and a red light for detected flaws, a printed output upon a sticker or part label to be affixed to the part, a part description to be entered in a rallied report, or other similar outputs. At step 814, the method 800 ends. The method 800 is provided as an example of a method to inspect a plurality of parts in a surgical kit using a part holder. The method 800 is exemplary, a number of additional or alternative method steps are envisioned, and the disclosure is not intended to be limited to the examples provided herein.

[0098] With reference to FIG. 19, an example of a method 900 to utilize an inspectionsystem 100, 1000, 300 of FIGS. 1 , 9, and 12, respectively, to inspect a plurality of parts 1042, 342, 442 of a surgical kit. While the method 900 is being disclosed as being useful with the inspection systems 100, 1000, 300 disclosed herein, the method may similarly be utilized upon other versions of inspection systems. The method 900 starts at step 902. At step 904, a camera device is utilized to create a first image of a part to be inspected. At step 906, an identity of the part to be inspected is determined based upon the first image. At step 908, a plurality of stored inspection instructions is referenced, and a part-specific inspection instruction is selected based upon the identity of the part to be inspected. At step 910, a camera device is utilized to take a second image of the pail to be inspected based upon the part-specific inspection instruction. At step 912, the second image is analyzed, and a determination is made whether a flaw exists upon the part. At step 914, if the part is determined to have a flaw, the method 900 advances to step 916 where the part is labeled as including a flaw. The labeling of the part may be a physical label or an electronic indication tied to the pail. After step 916 is completed, the method 900 advances to step 918 wherein the part is handled as a flawed part. Handling the part as a flawed part may include retaining the flawed part within the surgical kit while noting in association with the kit that that part is flawed, moving the part to a flawed part bin or container, or flagging the pail to be discarded or reconditioned. After step 916 is completed, the method 900 advances to step 924 where the method 900 ends.

[0099] At step 914, if the pail is determined to not have a flaw, the method 900 advances to step 920 wherein the part is labeled as not including a flaw. The labeling of the part may be a physical label, an electronic indication tied to the part, or retaining the part in the surgical kit, wherein only passing parts or parts determined to not include a flaw are permitted to remain within the kit. After step 920 is complete, the method 900 advances to step 922, wherein the part is handled as a part not including a flaw. After step 922 is complete, the method 900 advances to the step 924 wherein the method 900 ends. The method 900 is provided as an example of a method to inspect a plurality of parts in a surgical kit. The method 900 is exemplary, a number of additional or alternative method steps are envisioned, and the disclosure is not intended to be limited to the examples provided herein.

[0100] The foregoing disclosure is not intended to be exhaustive or limit the invention to any particular form. The terminology which has been 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 practiced otherwise than as specifically described.

[0101] The present disclosure also comprises the following clauses, with specific features laid out in dependent clauses, that may specifically be implemented as described in greater detail with reference to the configurations and drawings above.CLAUSESI. A surgical kit inspection system for inspecting a surgical kit including a plurality of parts, the surgical kit inspection system comprising: a camera device; a workpiece support device configured to position one of the plurality of parts relative to the camera device; and one or more controllers being configured to: obtain inspection instructions; and command inspection of the one of the plurality of parts with the camera device based upon the inspection instructions including: operating the camera device to capture an image of the one of the plurality of parts; detecting a flaw in the one of the plurality of parts in the image; classifying the one of the plurality of pails based upon the detected flaw; and generating an output for the one of the plurality of parts based upon the classifying.II. The surgical kit inspection system of clause I, wherein the workpiece support device is further defined as a robotic manipulator configured to automatically arrange the one of the plurality of pails in a predetermined pose relative to the camera device.III. The surgical kit inspection system of clause II, wherein the robotic manipulator is further configured to acquire the one of the plurality of parts.IV. The surgical kit inspection system of any of clauses II-III, wherein the one of the plurality of parts defines a lumen extending along a longitudinal axis; and wherein the predetermined pose relative to the camera device is defined with the camera device disposed along the longitudinal axis of the lumen.V. The surgical kit inspection system of clause IV, further comprising a light source arranged to at least partially illuminate the lumen.VI. The surgical kit inspection system of any of clauses II-V, wherein the robotic manipulator is further configured to selectively position the one of the plurality of parts at a plurality of poses relative to the camera device.VII. The surgical kit inspection system of any preceding clause, wherein the workpiece support device is further defined as a pail holder including a working end to receive the one of the plurality of parts in a predetermined pose relative to the camera device.VIII. The surgical kit inspection system of clause VII, wherein the part holder is a stationary pail holder.IX. The surgical kit inspection system of any of clauses VII- VIII, wherein the one of the plurality of parts defines a lumen extending along a longitudinal axis; and wherein the predetermined pose relative to the camera device is defined with the camera device disposed along the longitudinal axis of the lumen.X. The surgical kit inspection system of clause IX, further comprising a light source arranged to at least partially illuminate the lumen.XI. The surgical kit inspection system of any preceding clause, wherein the camera device is configured to obtain images of unique geometric features of the one of the plurality of parts.XII. The surgical kit inspection system of any preceding clause, wherein the camera device is configured to obtain images of characters on the one of the plurality of parts.XIII. The surgical kit inspection system of any preceding clause, wherein the camera device includes: a first camera having a first lens to obtain images of unique geometric features of a first type on the one of the plurality of parts; and a second camera having a second lens, different than the first lens, to obtain images of unique geometric features of a second type on the one of the plurality of parts.XIV. The surgical kit inspection system of clause XIII, further comprising a robotic camera manipulator supporting the first and second cameras such that the first and second cameras are capable of being moved by the robotic camera manipulator relative to the one of the plurality of parts.XV. The surgical kit inspection system of clause XIV, wherein the one or more controllers are further configured to command inspection of the one of the plurality of parts with the first camera and the second camera; andwherein the inspection instructions include: positioning the robotic camera manipulator to dispose the first camera and the second camera at a plurality of poses relative to the one of the plurality of parts in accordance with the inspection instructions; operating one or both of the first camera and the second camera at each of the plurality of poses to capture images of the one of the plurality of parts at each of the plurality of poses; and detecting the flaw in the one of the plurality of parts in the images captured at each of the plurality of poses using a first identification method when utilizing the images captured by the first camera and using a second identification method when utilizing the images captured by the second camera.XVI. The surgical kit inspection system of any preceding clause, further comprising a light source arranged to at least partially illuminate the one of the plurality of parts.XVII. The surgical kit inspection system of clause XVI, wherein the light source is further defined as a light table, a light container, or a light box.XVIII. The surgical kit inspection system of any preceding clause, wherein generating the output for the one of the plurality of parts based upon the classifying includes designating the one of the plurality of parts for disposal.XIX. The surgical kit inspection system of any preceding clause, wherein generating the output for the one of the plurality of parts based upon the classifying includes designating the one of the plurality of parts for reconditioning.XX. The surgical kit inspection system of any preceding clause, wherein detecting the flaw in the one of the plurality of parts includes detecting bioburden upon the one of the plurality of pails.XXI. The surgical kit inspection system of clause XX, wherein classifying the one of the plurality of parts includes classifying the one of the plurality of parts as contaminated.XXII. The surgical kit inspection system of any of clauses XX-XXI, wherein the one of the plurality of parts defines a lumen extending along a longitudinal axis; wherein the camera device is arranged to capture an image along a longitudinal axis of the lumen; andwherein detecting bioburden upon the one of the plurality of parts includes analyzing the image along the longitudinal axis of the lumen.XXIII. The surgical kit inspection system of clause XXII, wherein the one or more controllers are further configured to: receive a first image of the one of the plurality of pails; analyze the first image to identify the one of the plurality of parts as an identified part; reference a part-specific instruction for capturing images of the identified pail; operate the camera device to capture at least one additional image of the one of the plurality of pails; detect bioburden upon the one of the plurality of parts in the at least one additional image; and classify the one of the plurality of pails as contaminated based upon the detected bioburden.XXIV. The surgical kit inspection system of clause XXIII, further comprising a robotic camera manipulator supporting the camera device such that the camera device is capable of being moved by the robotic camera manipulator relative to the one of the plurality of parts.XXV. The surgical kit inspection system of clause XXIV, wherein the one or more controllers are further configured to control the robotic camera manipulator based upon the partspecific instruction to selectively orient the camera device relative to the one of the plurality of parts to capture the at least one additional image of the one of the plurality of pails.XXVI. The surgical kit inspection system of any of clauses XXIV-XXV, wherein the at least one additional image is further defined as a plurality of additional images; and wherein the one or more controllers are further configured to control the robotic camera manipulator based upon the part-specific instruction to selectively orient the camera device relative to the one of the plurality of parts to capture the plurality of additional images of the one of the plurality of parts at a plurality of poses.XXVII. The surgical kit inspection system of any of clauses XXIII-XXVI, wherein the workpiece support device is further defined as a robotic manipulator configured to automatically arrange the one of the plurality of parts in a predetermined pose relative to the camera device; andwherein the one or more controllers are further configured to control the robotic manipulator based upon the part-spccific instruction to selectively orient the one of the plurality of parts relative to the camera device to capture the at least one additional image of the one of the plurality of parts.XXVIII. The surgical kit inspection system of clause XXVII, wherein the at least one additional image is further defined as a plurality of additional images; and wherein the one or more controllers are further configured to control the robotic manipulator based upon the part-specific instruction to selectively orient the one of the plurality of parts relative to the camera device to capture the plurality of additional images of the one of the plurality of parts at a plurality of poses.XXIX. A method for inspecting surgical kits having a plurality of pails using a camera device, the method comprising the steps of: within one or more controllers, obtaining inspection instructions; and commanding inspection of the one of the plurality of pails with the camera device based upon the inspection instructions including: operating the camera device to capture an image of the one of the plurality of parts at each of the plurality of poses; detecting a flaw in the one of the plurality of parts in the image; classifying the one of the plurality of parts based upon the detected flaw; and generating an output for the one of the plurality of parts based upon the classifying.XXX. The method of clause XXIX, wherein the one of the plurality of pails defines a lumen extending along a longitudinal axis; and further comprising utilizing a robotic manipulator to manipulate the camera device or the one of the plurality of parts to capture an image down the longitudinal axis of the lumen.XXXI. The method of clause XXX, wherein detecting the flaw in the one of the plurality of parts in the image includes analyzing the image down the longitudinal axis of the lumen.XXXIT. The method of any of clauses XXX-XXXI, wherein detecting the flaw in the one of the plurality of parts in the image includes detecting bioburden upon the one of the plurality of parts.XXXIII. The method of clause XXXII, wherein classifying the one of the plurality of parts based upon the detected flaw includes classifying the one of the plurality of pails as contaminated based upon the detected bioburden.XXXIV. The method of any of clauses XXIX -XXXIII, further comprising: within the one or more controllers: capturing one or more images of the plurality of parts; analyzing the one or more images to identify each of the plurality of parts as a respective identified part; obtaining part-specific inspection instructions for inspection of each of the plurality of pails; and commanding inspection of each of the plurality of parts in sequence based upon the part- specific inspection instructions.

Claims

CLAIMS1. A surgical kit inspection system for inspecting a surgical kit including a plurality of parts, the surgical kit inspection system comprising: a camera device; a workpiece support device configured to position one of the plurality of parts relative to the camera device; and one or more controllers being configured to: obtain inspection instructions; and command inspection of the one of the plurality of parts with the camera device based upon the inspection instructions including: operating the camera device to capture an image of the one of the plurality of pails; detecting a flaw in the one of the plurality of parts in the image; classifying the one of the plurality of parts based upon the detected flaw; and generating an output for the one of the plurality of parts based upon the classifying.

2. The surgical kit inspection system of claim 1, wherein the workpiece support device is further defined as a robotic manipulator configured to automatically arrange the one of the plurality of parts in a predetermined pose relative to the camera device.

3. The surgical kit inspection system of claim 2, wherein the robotic manipulator is further configured to acquire the one of the plurality of parts.

4. The surgical kit inspection system of claim 2, wherein the one of the plurality of parts defines a lumen extending along a longitudinal axis; and wherein the predetermined pose relative to the camera device is defined with the camera device disposed along the longitudinal axis of the lumen.

5. The surgical kit inspection system of claim 4, further comprising a light source arranged to at least partially illuminate the lumen.

6. The surgical kit inspection system of claim 2, wherein the robotic manipulator is further configured to selectively position the one of the plurality of pails at a plurality of poses relative to the camera device.

7. The surgical kit inspection system of claim 1 , wherein the workpiece support device is further defined as a part holder including a working end to receive the one of the plurality of parts in a predetermined pose relative to the camera device.

8. The surgical kit inspection system of claim 7, wherein the part holder is a stationary part holder.

9. The surgical kit inspection system of claim 7, wherein the one of the plurality of parts defines a lumen extending along a longitudinal axis; and wherein the predetermined pose relative to the camera device is defined with the camera device disposed along the longitudinal axis of the lumen.

10. The surgical kit inspection system of claim 9, further comprising a light source arranged to at least partially illuminate the lumen.

11. The surgical kit inspection system of claim 1, wherein the camera device is configured to obtain images of unique geometric features of the one of the plurality of parts.

12. The surgical kit inspection system of claim 1, wherein the camera device is configured to obtain images of characters on the one of the plurality of parts.

13. The surgical kit inspection system of claim 1, wherein the camera device includes: a first camera having a first lens to obtain images of unique geometric features of a first type on the one of the plurality of parts; and a second camera having a second lens, different than the first lens, to obtain images of unique geometric features of a second type on the one of the plurality of parts.

14. The surgical kit inspection system of claim 13, further comprising a robotic camera manipulator supporting the first and second cameras such that the first and second cameras are capable of being moved by the robotic camera manipulator relative to the one of the plurality of parts.

15. The surgical kit inspection system of claim 14, wherein the one or more controllers are further configured to command inspection of the one of the plurality of parts with the first camera and the second camera; and wherein the inspection instructions include: positioning the robotic camera manipulator to dispose the first camera and the second camera at a plurality of poses relative to the one of the plurality of parts in accordance with the inspection instructions;operating one or both of the first camera and the second camera at each of the plurality of poses to capture images of the one of the plurality of parts at each of the plurality of poses; and detecting the flaw in the one of the plurality of parts in the images captured at each of the plurality of poses using a first identification method when utilizing the images captured by the first camera and using a second identification method when utilizing the images captured by the second camera.

16. The surgical kit inspection system of claim 1, further comprising a light source arranged to at least partially illuminate the one of the plurality of parts.

17. The surgical kit inspection system of claim 16, wherein the light source is further defined as a light table, a light container, or a light box.

18. The surgical kit inspection system of claim 1, wherein generating the output for the one of the plurality of parts based upon the classifying includes designating the one of the plurality of parts for disposal.

19. The surgical kit inspection system of claim 1, wherein generating the output for the one of the plurality of parts based upon the classifying includes designating the one of the plurality of parts for reconditioning.

20. The surgical kit inspection system of claim 1, wherein detecting the flaw in the one of the plurality of parts includes detecting bioburden upon the one of the plurality of parts.

21. The surgical kit inspection system of claim 20, wherein classifying the one of the plurality of pails includes classifying the one of the plurality of parts as contaminated.

22. The surgical kit inspection system of claim 20, wherein the one of the plurality of pails defines a lumen extending along a longitudinal axis; wherein the camera device is arranged to capture an image along a longitudinal axis of the lumen; and wherein detecting bioburden upon the one of the plurality of parts includes analyzing the image along the longitudinal axis of the lumen.

23. The surgical kit inspection system of claim 22, wherein the one or more controllers are further configured to: receive a first image of the one of the plurality of parts;analyze the first image to identify the one of the plurality of parts as an identified part; reference a part-specific instruction for capturing images of the identified part; operate the camera device to capture at least one additional image of the one of the plurality of pails; detect bioburden upon the one of the plurality of parts in the at least one additional image; and classify the one of the plurality of parts as contaminated based upon the detected bioburden.

24. The surgical kit inspection system of claim 23, further comprising a robotic camera manipulator supporting the camera device such that the camera device is capable of being moved by the robotic camera manipulator relative to the one of the plurality of parts.

25. The surgical kit inspection system of claim 24, wherein the one or more controllers are further configured to control the robotic camera manipulator based upon the part-specific instruction to selectively orient the camera device relative to the one of the plurality of parts to capture the at least one additional image of the one of the plurality of parts.

26. The surgical kit inspection system of claim 24, wherein the at least one additional image is further defined as a plurality of additional images; and wherein the one or more controllers are further configured to control the robotic camera manipulator based upon the part-specific instruction to selectively orient the camera device relative to the one of the plurality of parts to capture the plurality of additional images of the one of the plurality of parts at a plurality of poses.

27. The surgical kit inspection system of claim 23, wherein the workpiece support device is further defined as a robotic manipulator configured to automatically arrange the one of the plurality of parts in a predetermined pose relative to the camera device; and wherein the one or more controllers are further configured to control the robotic manipulator based upon the part-specific instruction to selectively orient the one of the plurality of parts relative to the camera device to capture the at least one additional image of the one of the plurality of parts.

28. The surgical kit inspection system of claim 27, wherein the at least one additional image is further defined as a plurality of additional images; andwherein the one or more controllers are further configured to control the robotic manipulator based upon the part-specific instruction to selectively orient the one of the plurality of parts relative to the camera device to capture the plurality of additional images of the one of the plurality of parts at a plurality of poses.

29. A method for inspecting surgical kits having a plurality of parts using a camera device, the method comprising the steps of: within one or more controllers, obtaining inspection instructions; and commanding inspection of the one of the plurality of pails with the camera device based upon the inspection instructions including: operating the camera device to capture an image of the one of the plurality of parts at each of the plurality of poses; detecting a flaw in the one of the plurality of parts in the image; classifying the one of the plurality of parts based upon the detected flaw; and generating an output for the one of the plurality of pails based upon the classifying.

30. The method of claim 29, wherein the one of the plurality of parts defines a lumen extending along a longitudinal axis; and further comprising utilizing a robotic manipulator to manipulate the camera device or the one of the plurality of parts to capture an image down the longitudinal axis of the lumen.

31. The method of claim 30, wherein detecting the flaw in the one of the plurality of pails in the image includes analyzing the image down the longitudinal axis of the lumen.

32. The method of claim 29, wherein detecting the flaw in the one of the plurality of parts in the image includes detecting bioburden upon the one of the plurality of pails.

33. The method of claim 32, wherein classifying the one of the plurality of parts based upon the detected flaw includes classifying the one of the plurality of pails as contaminated based upon the detected bioburden.

34. The method of claim 29, further comprising: within the one or more controllers: capturing one or more images of the plurality of parts;analyzing the one or more images to identify each of the plurality of parts as a respective identified part; obtaining part-specific inspection instructions for inspection of each of the plurality of pails; and commanding inspection of each of the plurality of pails in sequence based upon the part- specific inspection instructions.

Images