Surgical Robotic Systems with Manual and Haptic and/or Active Control Modes

• US 20130006267A1
• Filed: 06/30/2011
• Published: 01/03/2013
• Est. Priority Date: 06/30/2011
• Status: Active Grant

• Current Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Original Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Inventors: Odermatt, Daniel, Bassik, Renen, Wu, Chunyan, Landeck, Danielle, Wojcik, Jason
• Granted Patent: US 8,498,744 B2
• Time in Patent Office: Days
• US Class Current: 606/130
• CPC Class Codes: A61B 2034/742 Joysticks
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: B25J 9/1628 characterised by the control loop
• CPC Class Codes: G05B 2219/39439 Joystick, handle, lever controls manipulator directly, manually by operator
• CPC Class Codes: G05B 2219/40415 Semi active robot, cobot, guides surgeon, operator to planned trajectory, constraint
• CPC Class Codes: G05B 2219/45117 Medical, radio surgery manipulator

Abstract

A surgical robotic system is disclosed that provides a combination of a programmed control, such as active control or passive control, when a high degree of accuracy is required and manual control when a high degree of accuracy is not required, such as during the removal of osteophytes, irregular bone growth and/or soft tissue. Manual resection may be completed by switching from the programmed control mode to the manual control mode and allowing the surgeon free control of the cutting tool. The manual resection may be carried out using some navigational features of the robotic system such as allowing the surgeon to visualize the position of the cutting tool thereby allowing accurate resection of osteophytes, irregular bone and tissue while having the unrestricted freedom to move the cutting tool. The programmed control mode may be reserved for procedures that require a high degree of accuracy, for example, the reaming of a bone and placement of an implant onto the bone.

Claims

1. A surgical robotic system for modifying a bone of a patient, the system comprising:

a robotic arm;

a tool coupled to the robotic arm;

a controller programmed to be switchable between an at least partial manual control mode and an at least partial programmed control mode;

in the at least partial programmed control mode, the controller is programmed to generate control signals that will limit movement or operation of the tool away from a programmed course;

in the at least partial manual control mode, the controller is programmed to allow the tool to move and operate away from the programmed course without imposing resistance to movement or operation of the tool.

2. The system of claim 1 wherein the at least partial programmed control mode is selected from the group consisting of passive control, active control, and combinations thereof.

3. The system of claim 1 wherein the at least partially manual control provides unrestricted freedom to move and operate the tool.

4. The system of claim 1 wherein the at least partial programmed control mode is a haptic control mode and the programmed course is a virtual cutting boundary, wherein, in the haptic control mode, the controller is programmed to:

compare an intended modification to the bone and a position of the tool; and

generate control signals that will at least assist in directing the tool along or within the virtual cutting boundary and constrain movement of the tool away or outside of the virtual cutting boundary.

5. The system of claim 1 wherein movement of the robotic arm in the at least partial manual control mode is performed using a joystick.

6. The system of claim 1 wherein, in the at least partial programmed control mode, movement of the robotic arm by a surgeon is performed using a joystick, and any resistance to movement or operation of the tool away from the programmed course is provided through the joystick.

7. The system of claim 1 wherein the tool is selected from the group consisting of reamers, saws, drills, burrs and combinations thereof.

8. The system of claim 1 wherein the programmed course is a virtual cutting boundary that is selected from the group consisting of a haptic volume, a haptic path, a planned trajectory, a planned plane and a planned depth.

9. The system of claim 1 wherein the controller is further programmed to allow limitless switching between the at least partial manual control mode and the at least partial programmed control mode.

10. The system of claim 1 wherein both the at least partial manual control mode and the at least partial programmed control mode includes use of an image of the patient'"'"'s anatomy for navigational purposes.

11. The system of claim 10 wherein the controller is further programmed to track at least a portion of a tool and display the portion of the tool on the image of the patient.

12. A method for modifying a bone of a patient, the method comprising:

registering a location of a planned modification of the bone with a surgical robotic system equipped with a controller programmed with an at least partial manual control mode and an at least partial programmed control mode, the system further including a robotic arm and a tool coupled to the robotic arm;

modifying the bone under the at least partial programmed control mode using the robotic arm and the tool;

deactivating the at least partial programmed control mode and activating the at least partial manual control mode;

resecting at least one of tissue, osteophytes and irregular bone near the location of the modification of the bone in the at least partial manual control mode.

13. The method of claim 12 wherein the resecting of at least one of tissue, osteophytes and irregular bone may be performed before or after the modifying of the bone.

14. The method of claim 12 wherein the modifying of the bone and the resecting of at least one of tissue, osteophytes and irregular bone is performed at least in part using a joystick.

15. The method of claim 12 wherein the resecting at least one of tissue, osteophytes and irregular bone near the location of the modification of the bone may be carried out multiple times and before or after the modification of the bone.

16. The method of claim 12 wherein the at least partial programmed control mode is selected from the group consisting of haptic control, active control, haptic control using a joystick and combinations thereof.

17. The method of claim 12 wherein the at least partial programmed control mode is a haptic control mode, and in the haptic control mode, the method further including:

comparing an intended modification to the bone and a position of the tool;

generating a virtual cutting boundary; and

generating control signals that will at least assist in moving the tool along or within the virtual cutting boundary and constraining movement of the tool away or outside of the virtual cutting boundary.

18. The method of claim 17 wherein the moving of the tool along or within the virtual cutting boundary is carried out using a joystick and the constraining of movement of the tool is felt through the joystick.

19. The method of claim 12 wherein both the at least partial manual control mode and the at least partial programmed control mode includes use of an image of the patient for navigational purposes.

20. The method of claim 19 wherein the controller is further programmed to track a portion of a tool and display the portion of the tool on the image in both the at least partial manual control mode and the at least partial programmed control mode.

21. The method of claim 12 wherein the modifying of the bone is selected from the group consisting of bone preparation for joint restorations, skeletal corrections, corrective bone applications, osteotomies, revisions of previous interventions, preparation and placement of temporary structures, preparation and placement of permanent structures and combinations thereof.

22. A surgical robotic system for performing hip arthroplasties, the system comprising:

a robotic arm coupled to a cutting tool and a handle;

a controller linked to the robotic arm and the handle, the controller programmed to be switchable between a programmed control mode and a manual control mode;

in the programmed control mode, the controller programmed to;

compare an intended indentation in an acetabulum and a position of the cutting tool;

generate a course through which the controller allows the cutting tool to move;

imposing resistance to movement of the tool away from the course;

in the manual control mode, the controller programmed to;

allow the cutting tool to move and operate away from the course without imposing resistance to movement or operation of the cutting tool.

23. The system of claim 22 wherein the manual control mode allows the cutting tool and robotic arm to be manipulated freely.

24. The system of claim 22 wherein the handle is a joystick and resistance to movement of the cutting tool is applied through the joystick.

25. The system of claim 22 wherein the cutting tool is a semi-spherical reamer.

26. The system of claim 22 wherein the controller is further programmed to allow limitless switching between the manual control mode and the programmed control mode.

27. The system of claim 22 wherein the manual control mode and the programmed control mode includes use of an image of a patient for navigational purposes.

28. The system of claim 22 wherein the controller is further programmed to track a cutting tool center point and display the cutting tool center point on a visual display of the image.

29. The system of claim 22 wherein the programmed control mode is selected from the group consisting of passive control, active control, and combinations thereof.

30. The system of claim 29 wherein the programmed control mode is a haptic control mode and the programmed course is a virtual cutting boundary, wherein in the haptic control mode, the controller is programmed to:

compare an intended modification to the bone and a position of the tool; and

generate control signals that will at least assist in moving the tool along or within the virtual cutting boundary and constrain movement of the tool away or outside of the virtual cutting boundary.

31. A method for resecting an acetabulum, osteophytes, irregular bone growth and soft tissue surrounding the acetabulum of a patient, the method comprising:

registering a location of a planned resection of the acetabulum with a surgical robotic system including controller programmed with an at least partial programmed control mode selected from the group consisting of a haptic control mode, an active control mode and a combination thereof, the controller also programmed with a manual control mode, the system also including a robotic arm and a reamer coupled to the robotic arm;

turning off the at least partial programmed control mode and turning on the manual control mode;

resecting at least one of osteophytes, irregular bone growth and soft tissue that at least partially surround the acetabulum in the manual control mode;

turning on the at least partial programmed control mode;

resecting the acetabulum under at least partial programmed control mode using the robotic arm and the reamer.

32. The method of claim 31 wherein the reamer includes a center point and the resecting of at least one of osteophytes, irregular bone growth and tissue around the acetabulum in the manual control mode further includes

tracking a location of the center point of the reamer.

33. The method of claim 31 wherein the resecting at least one of osteophytes, irregular bone growth and tissue around the acetabulum in the manual control mode may be carried out before and/or after the resecting of the acetabulum under the at least partial programmed control mode.

34. The method of claim 31 wherein the resecting at least one of osteophytes, irregular bone growth and tissue around acetabulum in the manual control mode may be carried out multiple times and before and/or after the resecting of the acetabulum under the at least partial control mode.