Surgical tool systems and methods

• US 10,653,497 B2
• Filed: 06/10/2016
• Issued: 05/19/2020
• Est. Priority Date: 02/16/2006
• Status: Active Grant

• Current Assignee: Globus Medical, Inc.
• Original Assignee: Globus Medical, Inc.
• Inventors: Crawford, Neil R., Major, Chris, Bartelme, Michael, Johnson, Nobert, Cicchini, Stephen
• Primary Examiner(s): Hoffa, Angela M
• Application Number:
  US15/178,706
• Publication Number:
  US 20160278875A1
• Time in Patent Office: 1,439 Days
• CPC Class Codes: A61B 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00876 magnetic
• CPC Class Codes: A61B 2034/2051 Electromagnetic tracking systems
• CPC Class Codes: A61B 2034/2055 Optical tracking systems
• CPC Class Codes: A61B 2034/2072 Reference field transducer attached to an instrument or patient
• CPC Class Codes: A61B 2034/2074 Interface software
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2090/034 abutting on parts of the device itself
• CPC Class Codes: A61B 2090/0811 for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument
• CPC Class Codes: A61B 2090/3937 Visible markers
• CPC Class Codes: A61B 2090/3945 Active visible markers, e.g. light emitting diodes
• CPC Class Codes: A61B 2090/3966 Radiopaque markers visible in an X-ray image
• CPC Class Codes: A61B 2090/3983 Reference marker arrangements for use with image guided surgery
• CPC Class Codes: A61B 2560/0437 Trolley or cart-type apparatus
• CPC Class Codes: A61B 34/20 Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis
• CPC Class Codes: A61B 34/25 User interfaces for surgical systems
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 5/0059 using light, e.g. diagnosis by transillumination, diascopy, fluorescence A61B5/0093, A61B5/1455, A61B5/02416 and A61B5/0261 take precedence
• CPC Class Codes: A61B 5/064 : using markers A61B5/062 takes precedence
• CPC Class Codes: A61B 90/11 : with guides for needles or instruments, e.g. arcuate slides or ball joints
• CPC Class Codes: A61B 90/37 : Surgical systems with images on a monitor during operation
• CPC Class Codes: A61B 90/39 : Markers, e.g. radio-opaque or breast lesions markers
• CPC Class Codes: A61B 90/96 : using barcodes
• CPC Class Codes: A61B 90/98 : using electromagnetic means, e.g. transponders

Abstract

Embodiments of the present disclosure provide a surgical robot system may include an end-effector element configured for controlled movement and positioning and tracking of surgical instruments and objects relative to an image of a patient'"'"'s anatomical structure. In some embodiments the end-effector and instruments may be tracked by surgical robot system and displayed to a user. In some embodiments, tracking of a target anatomical structure and objects, both in a navigation space and an image space, may be provided by a dynamic reference base located at a position away from the target anatomical structure.

Claims

1. A surgical robot system comprising:

a dynamic reference base adapted to attach to a patient fixture instrument, wherein the dynamic reference base has reference retroreflective markers, which are configured to be tracked by a camera system, indicating a position of the patient fixture instrument in a camera coordinate system associated with the camera system;

a temporary registration fixture device adapted to be temporarily attached to the patient and having;

temporary retroreflective markers trackable by the camera system, indicating a location of a target anatomical structure in the camera coordinate system and

radiopaque markers indicating a location of the target anatomical structure in an image coordinate system defined by an imaging system, the temporary retroreflective markers being in a fixed position relative to the radiopaque markers;

wherein the surgical robot system has a processor configured to perform an initial registration of the target anatomical structure from the imaging coordinate system to the camera coordinate system by associating a spatial location of the radiopaque markers of the temporary registration fixture device in the image coordinate system to a spatial location of the retroreflective markers of the temporary registration fixture device in the camera coordinate system based on the fixed position relationship of the temporary retroreflective markers relative to the radiopaque markers;

wherein the processor of the surgical robot system is configured to transfer the initial registration of the target anatomical structure relative to the temporary registration fixture device to a subsequent registration of the target anatomical structure relative to the dynamic reference base based on a relative position relationship between the temporary retroreflective markers and the reference retroreflective markers; and

wherein the dynamic reference base is configured to track the target anatomical structure in the camera coordinate system after the subsequent registration occurs.

2. The surgical robot system of claim 1, wherein the temporary registration fixture device is adapted to removably attach to the patient in proximity to the target anatomical structure.

3. The surgical robot system of claim 2, wherein the temporary registration fixture device is adapted to removably attach to the skin of the patient.

4. The surgical robot system of claim 2, wherein the temporary registration fixture device is configured to hover or rest on the patient by being removably attachable to the patient fixture instrument to provide the fixed position relationship between the temporary retroreflective markers and the reference retroreflective markers.

5. The surgical robot system of claim 2, wherein the temporary registration fixture device is removed from the patient after the initial registration of the target anatomical structure is transferred to the subsequent registration relative to the dynamic reference base.

6. The surgical robot system of claim 1, wherein the camera system has one or more infrared cameras configured to track the location of the reference retroreflective markers of the dynamic reference base and the temporary retroreflective markers of the temporary registration fixture device.

7. The surgical robot system of claim 1, wherein the temporary registration fixture device comprises a non-co-planar arrangement of the temporary radiopaque markers.

8. The surgical robot system of claim 1, wherein the processor is further configured to indicate through a display that registration of the target anatomical structure has been transferred from the temporary registration fixture device to the dynamic reference base.

9. The surgical robot system of claim 1, wherein the transfer of registration of the target anatomical structure is based upon a geometric relationship of the temporary retroreflective markers of the registration fixture device to the reference retroreflective markers of the dynamic reference base.

10. The surgical robot system of claim 1, wherein the dynamic reference base is positioned in a location different from the target anatomical structure.

11. The surgical robot system of claim 1, wherein the dynamic reference base is adapted to attach to the patient at a location different from the target anatomical structure.

12. A surgical robot system comprising:

a temporary registration fixture adapted to be temporarily attached to a patient and having initial optical markers trackable by a camera system and radiopaque markers detectable by image analysis and at a fixed position from the initial optical markers;

a dynamic reference base adapted to attach to a patient fixture and having reference optical markers trackable by the camera system;

a processor configured to perform an initial registration of a target anatomical structure from an imaging coordinate system to a camera coordinate system based on;

detection of the radiopaque markers contained in an image of the anatomical structure taken by an imaging system;

detection of the initial optical markers by the camera system; and

the fixed position relationship between the radiopaque markers and the initial optical markers;

wherein the processor is further configured to transfer the initial registration to a subsequent registration of the target anatomical structure relative to the dynamic reference base based on a relative position relationship between the initial optical markers and the reference optical markers.

13. The surgical robot system of claim 12, wherein:

the processor performs the initial registration from a 3-dimensional CT image containing the temporary registration fixture;

the processor performs the subsequent registration based on relative positions of the temporary optical markers and the reference optical markers simultaneously tracked by the camera system.

14. The surgical robot system of claim 12, wherein the temporary registration fixture is adapted to be temporarily to the patient fixture of the dynamic reference base during the process of transferring the initial registration to the subsequent registration.

15. The surgical robot system of claim 12, wherein the temporary registration fixture has a plurality of holes through which the radiopaque markers are inserted.

16. The surgical robot system of claim 15, wherein the radiopaque markers are positioned in a non-coplanar manner.