Automated Spinal Rod Bending Device with Sensor Feedback
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Solution Overview
Problem
Current spinal implant systems face challenges in accurately bending spinal rods intra-operatively to achieve the desired corrective configuration, particularly in complex spinal disorders like scoliosis, due to limitations in precision and flexibility during surgical procedures.
Innovation Solution
An automated spinal implant bending device that uses a digitizer to identify bone fastener coordinates, communicating with a computer to display graphical indicia for precise manipulation of spinal implants to a selected configuration, incorporating a displacement module and bending module with linear actuators and sensors for accurate rod bending within a sterile field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual bending methods are used for spinal rods, then device complexity is reduced, but manufacturing precision and measurement precision deteriorate
Solution Approach 1:
The patent replaces manual mechanical bending with an automated bending device that uses computer-controlled actuators and sensors. The system substitutes human skill and manual manipulation with an automated mechanism that precisely controls bending parameters, thereby improving manufacturing precision while accepting increased device complexity.
Solution Approach 2:
The bending device incorporates sensors that automatically detect bone fastener positions and implant configuration, eliminating the need for manual measurement and marking. The system self-calibrates and self-adjusts during the bending process, improving precision without requiring extensive operator expertise.
2Productivity
If intra-operative bending is performed, then productivity is improved, but measurement precision and manufacturing precision deteriorate
Solution Approach 1:
The patent employs sensors that continuously monitor the bending process and provide real-time feedback to the control system. The system adjusts bending parameters based on actual sensor readings, ensuring measurement precision is maintained even during rapid intra-operative bending operations.
Solution Approach 2:
The system creates a digital model or copy of the bone fastener positions and implant configuration before bending begins. This digital replica allows the system to perform precise measurements and calculations without physical contact or time-consuming manual measurement during the surgical procedure.
3Manufacturing precision
If automated bending device is used, then manufacturing precision is improved, but ease of operation deteriorates
Solution Approach 1:
The bending device is divided into modular components including separate modules for coordinate detection, bending control, and sensor feedback. This segmentation allows each module to perform its specific function independently, making the overall system easier to operate while maintaining high manufacturing precision through specialized functionality.
Data Source
AI summary
A spinal implant system includes a spinal implant template having a base connected to vertebral tissue and a member movable relative to the base. The member includes a sensor configured to identify coordinates of one or more bone fasteners connected with the vertebral tissue. An implant bending device includes work surfaces engageable with a spinal implant to manipulate the spinal implant to a selected implant configuration based on the coordinates. Surgical instruments, spinal constructs, implants and methods are disclosed.