Surgical Torque Sensing for Real-Time Plan Deviation Detection

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Solution Overview

Problem

The use of power tools in robot-assisted surgery reduces tactile feedback for surgeons, making it difficult to identify necessary deviations from preoperative plans, which can lead to potentially harmful surgical outcomes.

Innovation Solution

A torque sensor and decision support system that monitors surgical procedures, providing recommendations and adjustments based on torque data to ensure appropriate deviations from preoperative plans, even in the absence of direct human intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If power tools are operated autonomously in robot-assisted surgery, then productivity and precision are improved, but loss of information (tactile feedback) increases, making it difficult to identify necessary deviations from preoperative plans

Engineering Contradiction:
Improvesurgical procedure efficiencyVSAvoidtactile feedback
Core Design Contradiction:
ProductivityVSLoss of information

Solution Approach 1:

The system implements a decision support system that provides real-time feedback to the surgeon by monitoring torque data from the power tool and comparing it against expected values. When deviations are detected, the system alerts the surgeon, effectively restoring the loss of tactile feedback information through electronic monitoring and communication channels.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The decision support system acts as an intermediary between the autonomously operated power tool and the surgeon. It processes torque data, identifies deviations from preoperative plans, and communicates relevant information to the surgeon, bridging the information gap created by autonomous operation.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of operation

If power tools are operated autonomously without human input, then ease of operation is improved, but reliability decreases due to inability to identify necessary deviations from preoperative plans

Engineering Contradiction:
Improveautonomous power tool operationVSAvoidsurgical outcome accuracy
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The system maintains reliability during autonomous operation by continuously monitoring torque data and providing feedback when deviations occur. This allows the autonomous system to operate easily while maintaining surgical outcome accuracy through real-time detection and communication of anomalies.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system replaces the mechanical tactile feedback that would naturally occur during manual operation with an electronic monitoring and communication system. The decision support system substitutes the surgeon's direct tactile sensing with electronic sensors and digital communication channels.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If torque monitoring and decision support systems are implemented, then reliability is improved by enabling necessary adjustments to surgical plans, but device complexity increases

Engineering Contradiction:
Improvesurgical outcome assuranceVSAvoidtorque sensor and decision support system
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The decision support system is designed to be universally applicable across different surgical procedures and power tools. By creating a multi-functional system that can handle various torque patterns and surgical scenarios, the complexity is justified by the broad reliability improvements across multiple applications.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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

Ensures positive surgical outcomes by enabling necessary adjustments to surgical plans, even when power tools are operated autonomously, by utilizing torque data and machine learning to identify and implement changes in real-time.

Implementation Method 1

a torque sensor for measuring a torque characteristic of the power tool... receive torque data from the torque sensor, the torque data corresponding to the measured torque characteristic

Methodology Applied
Scientific EffectTorque measurement: Torque

Data Source

PatentUS12599441B2Torque sensor with decision support and related systems and methods
Publication Date: 2026.04.14 MAZOR ROBOTICS
  • US12599441B2 patent drawing
  • US12599441B2 patent drawing
  • US12599441B2 patent drawing

AI summary

A surgical system includes a power tool that generates torque; a torque sensor for measuring a torque characteristic of the power tool; a user interface; at least one processor; and a memory. The memory stores instructions for execution by the at least one processor that, when executed, cause the at least one processor to: receive torque data from the torque sensor, the torque data corresponding to the measured torque characteristic; evaluate the torque data; and execute a predetermined action based on the evaluation.