Surgical Manipulator Virtual Boundaries for Bulk and Fine Cutting
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Solution Overview
Problem
Conventional robotic surgical systems lack dynamic control of surgical tools, allowing unintended movement beyond virtual boundaries due to excessive operator force, leading to deviations from the desired surgical target.
Innovation Solution
A system with a manipulator and controller that generates and activates/deactivates intermediate and target virtual boundaries in different modes, constraining tool movement based on the mode, allowing for manual or autonomous control with enhanced precision and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single virtual boundary is used to constrain tool movement in both manual and autonomous modes, then the system maintains simplicity in boundary management, but the operator may inadvertently apply excessive force causing the tool to move beyond the boundary and deviate from the desired surgical target
Solution Approach 1:
The virtual boundary is segmented into mode-specific boundaries: a first virtual boundary for manual mode and a second virtual boundary for autonomous mode. This segmentation allows each boundary to be optimized for its specific operational context, preventing the tool from exceeding appropriate limits in each mode while maintaining clear, manageable boundary definitions.
Solution Approach 2:
The virtual boundary configuration is made dynamic by automatically switching between the first and second virtual boundaries based on the operational mode. The system dynamically adapts the boundary constraints to match the current mode (manual or autonomous), ensuring appropriate level of constraint without requiring manual reconfiguration.
2Manufacturing precision
If the manipulator applies strong constraint forces to prevent tool movement beyond the virtual boundary in manual mode, then cutting precision is maintained, but the operator loses the ability to perform bulk cutting with manual force
Solution Approach 1:
The cutting process is segmented into two phases with different boundary constraints: bulk cutting phase using the first virtual boundary that allows greater freedom for efficient material removal, and precision finishing phase using the second virtual boundary that provides stricter constraints for accurate cutting near the final target surface.
Solution Approach 2:
In manual mode, the system allows partial action by permitting the tool to operate with more freedom within the first virtual boundary during bulk cutting, accepting some excess material removal that can be corrected later, rather than completely preventing all potential boundary violations during aggressive cutting operations.
3Productivity
If the system allows manual control for bulk cutting operations, then productivity and efficiency are improved, but the risk of operator error and inadvertent boundary violation increases
Solution Approach 1:
The system performs preliminary action by establishing the first virtual boundary before manual bulk cutting operations begin. This pre-configured boundary provides a safety net that guides the operator's manual control, allowing efficient bulk cutting while preemptively preventing deviations beyond the acceptable range.
Solution Approach 2:
The navigation system provides continuous feedback by tracking the tool's position relative to the first virtual boundary during manual operations. This real-time feedback allows the operator to maintain awareness of boundary proximity, enabling productive manual cutting while maintaining reliable boundary adherence through constant monitoring.
4Manufacturing precision
If the system uses a fixed virtual boundary configuration for autonomous mode, then cutting precision is maximized, but the system lacks adaptability for different cutting stages and modes
Solution Approach 1:
The virtual boundary configuration is made dynamic and adaptive to the operational mode. The system automatically selects and activates the appropriate virtual boundary (first or second) based on whether the current mode is manual or autonomous, providing mode-specific optimization without requiring manual reconfiguration, thereby achieving both precision and adaptability.
Solution Approach 2:
The virtual boundary system serves multiple functions by implementing different boundary configurations for different modes: the first virtual boundary serves manual bulk cutting operations, while the second virtual boundary serves autonomous precision operations. This multi-functionality allows a single boundary management system to adapt to diverse operational requirements.
Data Source
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AI summary
A surgical system for manipulating an anatomy is provided. The surgical system comprises a manipulator having a base and a linkage, a tool coupled to the manipulator and movable relative to the base to interact with the anatomy, and a controller. The controller is configured to generate a first virtual boundary associated with the anatomy, generate a second virtual boundary associated with the anatomy and being spaced apart from the first virtual boundary, control movement of the tool in a first mode wherein the first virtual boundary is activated to constrain the tool in relation to the first virtual boundary, and control movement of the tool in a second mode, wherein the first virtual boundary is deactivated and the tool is constrained in relation to the second virtual boundary. The controller is further configured to, in the first mode, produce an alert to inform that constraint of the tool is occurring in relation to the first virtual boundary, and in the second mode, produce an alert to inform that constraint of the tool is occurring in relation to the second virtual boundary.