Robotic Tool Virtual Boundary Control for Predictable Surgical Motion

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Solution Overview

Problem

Surgical robotic systems face challenges in maintaining compliance with virtual boundaries when patient anatomy moves, leading to unexpected tool movement that users may find undesirable, and there is a need for user-controlled or semi-autonomous modes to manage these movements.

Innovation Solution

A surgical system with a control system that enables user-input-controlled autonomous or semi-autonomous tool movement, allowing users to select virtual boundaries and includes a boundary handler to ensure compliance with predefined boundaries, and provides feedback to guide the user into compliance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the surgical system commands the manipulator to move the tool autonomously to compensate for patient anatomy movement, then compliance with the virtual boundary is maintained, but unexpected tool movement occurs that users may find undesirable

Engineering Contradiction:
Improveboundary complianceVSAvoiduser control
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The system dynamically switches between autonomous and manual control modes based on user input state. When the user input device indicates autonomous mode, the control system automatically moves the tool to maintain boundary compliance. When the user input device indicates manual mode, the control system disables autonomous movement and allows direct user control, thus adapting the control behavior to user needs in real-time

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control system changes the autonomy parameter of the manipulator based on user input state. By detecting the state of the user input device, the system transitions between different levels of autonomous control, enabling users to adjust the degree of automation according to their preference and situational requirements

Inventive Principle:
Principle #35Parameter changes

2Reliability

If autonomous movement is always enabled to maintain boundary compliance, then safety is improved, but users cannot perform manual positioning or adjustments

Engineering Contradiction:
ImprovesafetyVSAvoidoperational flexibility
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The control system provides dynamic adaptability by allowing users to switch between autonomous and manual modes through the user input device. This enables the system to be safe and compliant when autonomous mode is active, while also being flexible and controllable when manual mode is selected, thus serving multiple operational needs

Inventive Principle:
Principle #15Dynamics

3Reliability

If the control system continuously monitors and adjusts tool position to maintain boundary compliance, then boundary compliance is ensured, but system complexity increases

Engineering Contradiction:
Improveboundary complianceVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The control system extracts the boundary compliance monitoring and adjustment functionality as a separate autonomous control module that operates independently when enabled. This modular approach allows the system to maintain simplicity in manual mode while providing advanced compliance features when autonomous mode is active, reducing the perceived complexity for users who only need manual control

Inventive Principle:
Principle #2Taking out (Extraction)

Data Source

PatentUS12564455B2Systems and methods for controlling robotic movement of a tool based on a virtual boundary
Publication Date: 2026.03.03 MAKO SURGICAL CORP
  • US12564455B2 patent drawing
  • US12564455B2 patent drawing
  • US12564455B2 patent drawing

AI summary

Surgical systems and methods involve a manipulator that supports a tool and a control system to control operation of the manipulator and movement of the tool based on a relationship between the tool and a first virtual boundary. The control system operates to maintain compliance of the tool with the first virtual boundary. While maintaining compliance of the tool with the first virtual boundary, the control system enables a user to select a second virtual boundary. In response to user selection of the second virtual boundary, the control system determines whether the tool is in compliance with the second virtual boundary.