SURGICAL SYSTEM FOR POSITIONING PROSTHETIC COMPONENT AND/OR FOR CONSTRAINING MOVEMENT OF SURGICAL TOOL

• US 20110082468A1
• Filed: 09/29/2010
• Published: 04/07/2011
• Est. Priority Date: 10/01/2009
• Status: Active Grant

• Current Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Original Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Inventors: Odermatt, Daniel, HAGAG, Benny, Mozes, Alon, Schmitz, Brian D., Kang, Hyosig
• Granted Patent: US 8,992,542 B2
• Time in Patent Office: Days
• US Class Current: 606/130
• CPC Class Codes: A61B 17/1617 with mobile or detachable parts
• CPC Class Codes: A61B 17/162 Chucks or tool parts which are to be held in a chuck
• CPC Class Codes: A61B 17/1631 Special drive shafts, e.g. flexible shafts A61B17/1642, A61B17/164 take precedence
• CPC Class Codes: A61B 17/1655 for tapping
• CPC Class Codes: A61B 17/1659 Surgical rasps, files, planes, or scrapers
• CPC Class Codes: A61B 17/1664 for the hip
• CPC Class Codes: A61B 17/1666 for the acetabulum
• CPC Class Codes: A61B 17/1684 for the shoulder
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/2051 Electromagnetic tracking systems
• CPC Class Codes: A61B 2090/062 penetration depth
• CPC Class Codes: A61B 2090/08021 of the patient or his organs
• 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 34/74 Manipulators with manual electric input means
• CPC Class Codes: A61B 90/03 Automatic limiting or abutting means, e.g. for safety
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2/36 Femoral heads ; Femoral endoprostheses
• CPC Class Codes: A61F 2/4607 : of hip femoral endoprostheses
• CPC Class Codes: A61F 2/4609 : of acetabular cups
• CPC Class Codes: Y10T 74/20305 : Robotic arm

Abstract

A surgical system for positioning a prosthetic component on an anatomy of a patient includes a surgical tool configured to engage the prosthetic component, a force system configured to provide at least some force to the surgical tool, and a controller programmed to compare a target pose of the prosthetic component and an actual pose of the prosthetic component engaged by the surgical tool and generate control signals that cause the force system to allow movement of the surgical tool within a range of movement and provide haptic feedback to constrain a user'"'"'s ability to manually move the surgical tool beyond the range of movement. The haptic feedback resists movement of the surgical tool by the user that would cause substantial deviation between at least one aspect of the actual pose of the prosthetic component and a corresponding aspect of the target pose of the prosthetic component. The controller is programmed to generate control signals that cause the force system to maintain the haptic feedback as the user implants the prosthetic component on the anatomy.

Claims

1. A surgical system for positioning a prosthetic component on an anatomy of a patient, comprising:

a surgical tool configured to engage the prosthetic component;

a force system configured to provide at least some force to the surgical tool; and

a controller programmed to;

compare a target pose of the prosthetic component and an actual pose of the prosthetic component engaged by the surgical tool; and

generate control signals that cause the force system to allow movement of the surgical tool within a range of movement and provide haptic feedback to constrain a user'"'"'s ability to manually move the surgical tool beyond the range of movement, wherein the haptic feedback resists movement of the surgical tool by the user that would cause substantial deviation between at least one aspect of the actual pose of the prosthetic component and a corresponding aspect of the target pose of the prosthetic component;

wherein the controller is programmed to generate control signals that cause the force system to maintain the haptic feedback as the user implants the prosthetic component on the anatomy.

2. The surgical system of claim 1, wherein the at least one aspect of the actual pose and the corresponding aspect of the target pose include at least one of an angle, an axis, an orientation, a center of rotation, a boundary, and a depth.

3. The surgical system of claim 1, wherein the target pose includes a planned pose of the prosthetic component implanted on the anatomy and an activation region.

4. The surgical system of claim 3, wherein the activation region extends beyond a boundary of the planned pose.

5. The surgical system of claim 3, wherein at least a portion of the planned pose and at least a portion of the activation region coincide.

6. The surgical system of claim 3, wherein the activation region includes a cylindrical volume coaxial with an axis of the planned pose.

7. The surgical system of claim 3, wherein the controller is further programmed to:

generate signals to activate the haptic feedback when at least a portion of the actual pose of the prosthetic component coincides with at least a portion of the activation region of the target pose.

8. The surgical system of claim 1, wherein the controller is further programmed to:

initiate automatic control of the prosthetic component to substantially align the at least one aspect of the actual pose with the corresponding aspect of the target pose when the user moves the prosthetic component to override the haptic feedback.

9. The surgical system of claim 1, wherein the tool comprises an end effector configured to be coupled to a robotic arm and including a first portion configured to engage the prosthetic component and a second portion configured to receive an impact force for implanting the prosthetic component on the anatomy of the patient.

10. The surgical system of claim 9, wherein the end effector comprises:

a mounting portion configured to be coupled to a corresponding mounting portion of the robotic arm such that the mounting portions are fixed relative to one another; and

an operating member configured to translate relative to the coupled mounting portions when the user applies the impact force to the second portion of the end effector.

11. The surgical system of claim 10, wherein the operating member is configured to translate in a region of constraint that includes a first location and a second location.

12. The surgical system of claim 11, wherein the first and second locations are defined at least in part by a recess disposed on the operating member.

13. The surgical system of claim 11, wherein the first location is defined at least in part by a recess disposed on the operating member and the second location is defined at least in part by a protrusion disposed on the operating member.

14. The surgical system of claim 13, wherein the protrusion is disposed remotely from the recess.

15. The surgical system of claim 9, wherein the first and second portions of the end effector comprise a distal end and a proximal end of an operating member, respectively.

16. A surgical system, comprising:

a surgical tool configured to be coupled to a cutting element;

a force system configured to provide at least some force to the surgical tool; and

a controller programmed to generate control signals that cause the force system to;

provide a first constraint on a user'"'"'s manual movement of the surgical tool when the cutting element is a first cutting element; and

provide a second constraint, different from the first constraint, on a user'"'"'s manual movement of the surgical tool when the cutting element is a second cutting element.

17. The surgical system of claim 16, wherein a diameter of the first cutting element is different from a diameter of the second cutting element.

18. The surgical system of claim 16, wherein the first and second cutting elements are each configured to cut a bone to receive a prosthetic component, and

wherein a diameter of the first cutting element is less than a diameter of the prosthetic component by a predetermined amount and a diameter of the second cutting element is greater than the diameter of the first cutting element.

19. The surgical system of claim 18, wherein the predetermined amount is five millimeters less than the diameter of the prosthetic component.

20. The surgical system of claim 16, wherein the first constraint is configured to constrain, along a reference axis, at least one point associated with the cutting element.

21. The surgical system of claim 20, wherein the reference axis is a desired axis of a prosthetic component when the prosthetic component is implanted on an anatomy of a patient.

22. The surgical system of claim 20, wherein the at least one point is a point on a central axis of the cutting element.

23. The surgical system of claim 20, wherein the at least one point is disposed on the cutting element.

24. The surgical system of claim 16, wherein the second constraint is configured to constrain an orientation of the surgical tool relative to a reference axis.

25. The surgical system of claim 24, wherein the reference axis is a desired axis of a prosthetic component when the prosthetic component is implanted on an anatomy of a patient.

26. The surgical system of claim 24, wherein the second constraint is configured to constrain the surgical tool to maintain an axis of the surgical tool within a predefined angular distance from the reference axis.

27. The surgical system of claim 26, wherein the axis of the surgical tool is at least one of an axis of a shaft of the surgical tool and a central axis of the cutting element.

28. The surgical system of claim 16, wherein the controller is further programmed to generate control signals that cause the force system to provide at least one of the first constraint and the second constraint when a portion of at least one of the first cutting element and the second cutting element coincides with an activation region.

29. The surgical system of claim 28, wherein the activation region is defined relative to a planned pose of a prosthetic component implanted on an anatomy of a patient.

30. The surgical system of claim 29, wherein at least a portion of the activation region at least one of extends beyond a boundary of the planned pose and coincides with at least a portion of the planned pose.

31. The surgical system of claim 16, wherein the controller is further programmed to automatically control at least one aspect of a pose of the surgical tool if the user manually overrides at least one of the first constraint and the second constraint.

32. The surgical system of claim 16, wherein the first constraint is configured to constrain the user'"'"'s manual movement of the surgical tool as the user makes a preliminary cut with the first cutting element and the second constraint is configured to constrain the user'"'"'s manual movement of the surgical tool as the user makes a final cut with the second cutting element.

33. The surgical system of claim 32, wherein the controller is programmed to deactivate the second cutting element when a shape of the final cut substantially corresponds to a desired shape of the final cut.