Robotic Surgical Rod Bending Without Surface Notching
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Solution Overview
Problem
Current manual devices for bending surgical rods in spinal fusion surgery are cumbersome and can introduce notches, reducing the rod's fatigue life.
Innovation Solution
A robotic system comprising a robot base, rod feeding, brake, and bending subassemblies, with actuators to automatically bend surgical rods with precision, preventing notching through the use of roller bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual bending devices (French bender, power bender) are used to bend surgical rods, then the rods can be bent to desired curvature, but notches are introduced on the rod which decreases the rod's fatigue life
Solution Approach 1:
The patent replaces manual mechanical bending devices with an automated robotic system that uses controlled mechanical forces through a bending element. The robotic system precisely controls the bending process to apply force without creating notches, thereby maintaining rod fatigue life while achieving the desired curvature. The automated control eliminates the variability and excessive force application inherent in manual operations.
Solution Approach 2:
The patent changes the parameters of the bending process by using a robotic system that precisely controls bending force, speed, and positioning. The robotic controller adjusts these parameters to optimize the bending operation, applying minimal necessary force over a controlled duration to avoid notch formation while achieving the target rod curvature. This precise parameter control prevents the harmful effects of manual bending.
2Ease of operation
If manual bending devices are used to bend surgical rods, then bending can be performed, but the process is cumbersome and requires manual operation
Solution Approach 1:
The patent replaces cumbersome manual bending devices with an automated robotic system that simplifies the operator's task to programming and monitoring. The robotic system handles all complex mechanical operations automatically, reducing the skill and effort required while improving precision. The trade-off of increased device complexity is justified by the significant improvement in operational ease and rod integrity.
Solution Approach 2:
The robotic bending system performs the bending operation autonomously once programmed with the desired rod curvature parameters. The system self-regulates the bending process, automatically adjusting forces and positioning without continuous manual intervention. This self-service capability eliminates the cumbersome manual operations while maintaining device functionality.
3Extent of automation
If automated robotic bending is implemented, then precision and automation are improved, but device complexity increases
Solution Approach 1:
The robotic bending system is designed as a multi-functional platform that can perform rod bending, positioning, and curvature adjustment through a single integrated system. The robotic arm and bending mechanism can be programmed to handle various rod types and bending requirements, reducing the need for multiple specialized devices. This universality justifies the initial complexity investment by providing versatile automated functionality.
Solution Approach 2:
The robotic system uses programmable parameters to control the bending process, allowing precise adjustment of force, speed, and positioning without physical device modifications. This software-based parameter control reduces mechanical complexity compared to hardware-based adjustment mechanisms while maintaining high automation levels and precision.
Data Source
AI summary
A robotic system may include a robot base and a rod feeding subassembly coupled to the robot base that includes a feeding actuator configured to selectively move a surgical rod. The robotic system may include a brake subassembly coupled to the robot base that includes a brake actuator configured to receive the surgical rod from the rod feeding subassembly, and selectively fix a first portion of the surgical rod with respect to the brake subassembly. The robotic system may include a bending subassembly coupled to the robot base that includes a bending actuator configured to selectively rotate to engage a second portion of the surgical rod and bend the second portion of the surgical rod with respect to the first portion of the surgical rod so that the first portion and the second portion of the surgical rod define a first bend angle.