Computer-Controlled Surgical Rod Bending System

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Solution Overview

Problem

Current methods for bending surgical rods in spinal fusion surgeries are time-consuming, inaccurate, and can compromise the material properties of the rods, leading to potential stress on pedicle screws and vertebrae, resulting in complications such as premature loosening.

Innovation Solution

A system comprising a linear actuator, rotational actuator, and bending mechanism, controlled by a controller, which moves and rotates the surgical rod to accurately bend it into a desired three-dimensional shape, allowing for precise matching of the rod to the contours of the vertebrae.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual iterative trial and error process is used to bend rods, then flexibility in shaping is maintained, but operative time increases and manufacturing precision deteriorates

Engineering Contradiction:

Improveflexibility in shapingVSAvoidoperative time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical bending with a computer-controlled mechanical bending system. The rod bending device uses automated actuators and computer control to perform bending operations, eliminating the need for manual iterative trial and error while maintaining shaping flexibility through programmable control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the control parameter from manual surgeon manipulation to computer-controlled parameters including bend location, bend angle, and bending force. This allows precise control over the bending process while reducing operative time through automated execution of pre-planned bending sequences.

Inventive Principle:

Principle #35Parameter changes

2Shape

If iterative manual manipulations are performed on rods, then shape adjustments are possible, but material strength deteriorates

Engineering Contradiction:

Improverod shapeVSAvoidrod strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The patent performs preliminary planning of the rod shape based on preoperative imaging and pedicle screw positioning. The computer-controlled bending device executes pre-calculated bend sequences, minimizing the number of manipulations required and reducing cumulative damage to the rod material strength while achieving the desired shape.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces repeated manual manipulations with a single automated bending process. The computer-controlled device applies precise controlled forces in one or few steps rather than multiple manual adjustments, preserving rod strength by minimizing plastic deformation cycles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If manual rod bending is performed, then adaptability to patient anatomy is achieved, but manufacturing precision deteriorates

Engineering Contradiction:

Improveadaptability to patient anatomyVSAvoidrod shape accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent incorporates feedback from preoperative imaging (CT or MRI scans) and intraoperative pedicle screw positioning data. The computer-controlled bending device uses this information to calculate and execute precise bend parameters, ensuring the rod accurately matches the patient's anatomy while maintaining high manufacturing precision through automated control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent creates a digital copy or model of the patient's spinal anatomy from imaging data. The rod bending process replicates this digital model by calculating bend parameters that will produce a rod shape matching the scanned anatomy, ensuring precision while maintaining adaptability to individual patient variations.

Inventive Principle:

Principle #26Copying

4Productivity

If inaccurate rod shaping occurs, then surgical completion is achieved, but harmful factors increase due to stress on pedicle screws and vertebrae

Engineering Contradiction:

Improvesurgical completionVSAvoidstress on pedicle screws and vertebrae

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual rod shaping with computer-controlled bending that precisely achieves the desired rod contour in fewer steps. This eliminates inaccurate shaping while maintaining surgical productivity, and by doing so prevents excessive stress on pedicle screws and vertebrae that would result from poor rod fit.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9999460B2Surgical rod bending

Publication Date: 2018.06.19 UNIVERSITY OF SOUTH CAROLINA

AI summary

A system for bending a surgical rod including a linear actuator and a rotational actuator is provided. The linear actuator is configured for moving the surgical rod along a linear direction of the system, and the rotational actuator is configured for rotating the surgical rod about the linear direction. A bending mechanism is also provided positioned downstream of the linear and rotational actuators configured for bending the surgical rod. A controller is operably connected to the linear and rotational actuators and the bending mechanism, the controller configured to activate the various components and bend the surgical rod into a desired three-dimensional shape.