Surgical Rod Bending With Free Rotation and Roller Forming
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Solution Overview
Problem
Current methods for bending surgical rods in spine surgery are manual, time-consuming, prone to metal fatigue, and risk surface damage, with existing automated systems being bulky and restrictive in their bending capabilities.
Innovation Solution
An automated surgical rod bending system that includes a base with a linear movement device, rotational movement device, and a bending device with a roller that allows full rotation of the rod and imposes bending forces perpendicular to its axis, enabling precise curvature without previous bend restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual rod bending is used, then the surgeon can control the bending process, but the procedure is time-consuming and prone to metal fatigue
Solution Approach 1:
The patent replaces manual mechanical bending with an automated motorized rod-bending device that uses computer-controlled mechanics to bend the rod according to pre-calculated coordinates, eliminating manual manipulation and reducing procedure time while maintaining rod integrity
Solution Approach 2:
The system allows the rod to guide its own bending process by following predetermined virtual coordinates that are automatically translated into bending commands, reducing the need for continuous surgeon intervention and minimizing metal fatigue from repeated manual adjustments
2Reliability
If manual rod bending is used, then the surgeon can adjust the rod curvature, but the risk of surface damage from sharp metal tools increases
Solution Approach 1:
The patent replaces sharp metal bending tools with a motorized device that uses controlled mechanical force applied through a roller or similar mechanism, eliminating surface damage from sharp tools while maintaining precise bending control through computer coordination
Solution Approach 2:
The system introduces a computer control system as an intermediary between the surgeon's intent and the physical bending process, translating desired rod curvature into precise motor commands that control the bending mechanism, ensuring surface integrity while maintaining ease of operation
3Manufacturing precision
If automated mapping and bending systems are used, then bending precision is improved, but the systems become bulky and complex
Solution Approach 1:
The patent integrates multiple functions into a single coordinated system where the motorized device performs both positioning and bending operations, and the computer control system handles both mapping and bending command generation, reducing overall system complexity while maintaining high precision
Solution Approach 2:
The system merges the mapping function and bending execution function into an integrated automated process, where virtual coordinates are directly translated into bending commands without requiring separate manual measurement and bending steps, simplifying the system architecture while improving precision
4Force
If force-actuating mechanisms with bulky structures are used, then enough bending force is applied, but the system size increases and rotation freedom is restricted
Solution Approach 1:
The patent replaces bulky mechanical force multiplication mechanisms with a motorized actuator that directly applies controlled bending force through a roller, eliminating the need for complex mechanical advantage systems while maintaining sufficient bending force and preserving full rod rotation capability
Solution Approach 2:
The system transitions from mechanical force application in three-dimensional space to computer-controlled force application, where bending commands are generated based on virtual coordinates, allowing unrestricted rod rotation while maintaining precise force control through digital rather than mechanical means
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for accurate, efficient, and stress-free bending of surgical rods with unlimited rotation, reducing the risk of metal fatigue and surface damage, while enabling precise control over the bending process.
Implementation Method 1
a linear movement device configured to feed the rod in a first direction through the base passage
Implementation Method 2
a rotational movement device configured to rotate the rod as it is fed through the base passage
Implementation Method 3
a bending device configured to impose bending forces against the rod perpendicular to its axis
Data Source
AI summary
System and method for automatically bending a surgical rod are provided. The system includes a linear movement device configured to axially feed the surgical rod, a rotational movement device configured to rotate the surgical rod as it is axially fed, and a bending device including a roller to impose bending forces against the rod. The rod is free from contact with the bending device after it is axially fed past the roller.