Curved-Tip Surgical Instrument Calibration for Virtual Accuracy

Solution Overview

Problem

Current methods for instrument calibration in surgical instruments, particularly those with curved distal tips, fail to accurately model distortions and bending over time, leading to inaccurate virtual representations and potential safety risks during computer and robotic-assisted surgery.

Innovation Solution

A calibration system comprising a surgical instrument with a pivot point and a calibration instrument having a predefined geometric structure and reference elements, coupled with a monitoring system that records and calculates deviations from an ideal distal tip, allowing for real-time updates to the virtual representation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If current calibration methods are used for surgical instruments with curved distal tips, then the calibration process is simple, but the virtual representation becomes inaccurate over time due to distortions and bending

Engineering Contradiction:

Improveaccuracy of virtual representationVSAvoidcomplexity of calibration system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The calibration instrument establishes a predefined geometric structure and reference element relationships before surgical use. The monitoring system records the initial positions of multiple reference elements on the surgical instrument relative to the calibration instrument, creating a baseline virtual representation that accounts for the instrument's actual geometry including any distortions or bends

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The monitoring system continuously tracks the positions of reference elements on the surgical instrument during surgery and compares them against the pre-recorded calibration data. When deviations are detected that indicate distortion or bending, the system provides feedback to update the virtual representation, ensuring continued accuracy throughout the procedure

Inventive Principle:

Principle #23Feedback

2Reliability

If traditional calibration approaches are used, then the process is quick, but the instrument tracking accuracy deteriorates due to unmodeled distortions

Engineering Contradiction:

Improvetracking accuracyVSAvoidcalibration time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The calibration instrument establishes a predefined geometric structure and reference element relationships before surgical use. The monitoring system records the initial positions of multiple reference elements on the surgical instrument relative to the calibration instrument, creating a baseline virtual representation that accounts for the instrument's actual geometry including any distortions or bends

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically updates the virtual representation parameters of the surgical instrument based on real-time tracking data. When distortions or bending occur, the monitoring system calculates new positional parameters for the reference elements and adjusts the virtual model accordingly, maintaining accuracy without requiring physical recalibration

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If no calibration update mechanism is implemented, then the system is simple to operate, but the virtual representation becomes outdated and inaccurate

Engineering Contradiction:

Improveaccuracy of virtual representationVSAvoidoperational simplicity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The monitoring system automatically performs calibration updates without requiring manual intervention. The system self-calibrates by continuously monitoring the positions of reference elements on the surgical instrument and autonomously updating the virtual representation to reflect any changes in the instrument's geometry or positioning

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The monitoring system continuously tracks the positions of reference elements on the surgical instrument during surgery and compares them against the pre-recorded calibration data. When deviations are detected that indicate distortion or bending, the system provides feedback to update the virtual representation, ensuring continued accuracy throughout the procedure

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12402957B2Instrument calibration

Publication Date: 2025.09.02 DEPUY SYNTHES PROD INC

AI summary

Surgical instrument calibration methods, systems, and devices are provided that allow a virtual representation of a surgical instrument to be modified to adjust for any variations in a distal tip of a surgical instrument. For example, an instrument calibration system is provided that can have a surgical instrument, a calibration instrument, and a monitoring system. The surgical instrument can have a distal tip and an orientation element thereon, and the calibration instrument can have a pivot point thereon and a calibration reference element attached thereto. The monitoring system can be configured to record movement of the surgical instrument with respect to the calibration instrument when the tip of the surgical instrument is inserted into the pivot point of the calibration instrument, and to calculate a deviation of the tip of the surgical instrument from a predefined ideal tip based on the recorded movement.