System for image-based robotic surgery

• US 9,259,278 B2
• Filed: 12/27/2012
• Issued: 02/16/2016
• Est. Priority Date: 12/30/2011
• Status: Active Grant

• Current Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Original Assignee: MAKO Surgical Corporation (Stryker Corporation)
• Inventors: Jensen, Vernon
• Primary Examiner(s): Cattungal, Sanjay
• Application Number:
  US13/728,756
• Publication Number:
  US 20130211419A1
• Time in Patent Office: 1,146 Days
• Field of Search: 600407-424
• US Class Current: 1/1
• CPC Class Codes: A61B 2034/2051 Electromagnetic tracking systems
• CPC Class Codes: A61B 2034/2055 Optical tracking systems
• CPC Class Codes: A61B 2034/2059 Mechanical position encoders
• CPC Class Codes: A61B 2034/2061 using shape-sensors, e.g. fiber shape sensors with Bragg gratings
• CPC Class Codes: A61B 2090/371 with simultaneous use of two cameras
• CPC Class Codes: A61B 2090/376 using X-rays, e.g. fluoroscopy
• CPC Class Codes: A61B 34/00 Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
• 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 34/30 Surgical robots
• CPC Class Codes: A61B 6/12 Arrangements for detecting or locating foreign bodies
• CPC Class Codes: A61B 6/4405 the apparatus being movable or portable, e.g. handheld or mounted on a trolley
• CPC Class Codes: A61B 6/4441 the rigid structure being a C-arm or U-arm
• CPC Class Codes: A61B 6/4452 the source unit and the detector unit being able to move relative to each other
• CPC Class Codes: A61B 6/4458 the source unit or the detector unit being attached to robotic arms
• CPC Class Codes: A61B 6/4464 the source unit or the detector unit being mounted to ceiling
• CPC Class Codes: A61B 6/487 involving fluoroscopy
• CPC Class Codes: A61B 90/37 Surgical systems with images on a monitor during operation

Abstract

A robotic surgery system includes a mobile base configured to be movably coupled to the operating room; a first robotic arm coupled to the mobile base and comprising a mounting fixture configured to be interchangeably coupled to a surgical tool and a first element of a fluoroscopic imaging system comprising a source element and a detector element; a second element configured to be repositionable relative to a patient tissue structure that may be placed between the first and second elements; and a controller operatively coupled to the first robotic arm, the controller configured to receive signals from a sensing system operatively coupled to the controller, the sensing system configured to detect motion of one or more sensor elements coupled to each of the first and second elements of the fluoroscopic imaging system and determine a relative spatial positioning between each of the first and second elements.

Claims

1. A robotic surgery system, comprising:

a mobile base configured to be movable into and out of an operating room when in a freewheeling mode, and fixed relative to the operating room when in a braked mode;

a first robotic arm coupled to the mobile base and comprising a mounting fixture configured to be interchangeably coupled to a surgical tool and a first element of a fluoroscopic imaging system comprising a source element and a detector element wherein the first element is one of the source element and the detector element;

a second element of the fluoroscopic imaging system, wherein the second element is the other of the source element and the detector element, the second element configured to be repositionable relative to the first element of the fluoroscopic imaging system and relative to a patient tissue structure such that the patient tissue structure may be positioned between the first and second elements of the fluoroscopic imaging system; and

a controller operatively coupled to the first robotic arm, the controller configured to receive signals from a sensing system operatively coupled to the controller, the sensing system configured to detect motion of one or more sensor elements coupled to each of the first and second elements of the fluoroscopic imaging system and determine a relative spatial positioning between each of the first and second elements of the fluoroscopic imaging system.

2. The system of claim 1, wherein the first robotic arm comprises one or more joints and one or more motors configured to controllably regulate motion at the one or more joints.

3. The system of claim 1, further comprising at least one sensor configured to monitor a position of at least a portion of the first robotic arm.

4. The system of claim 3, wherein the at least one sensor is selected from the group consisting of:

an encoder, a potentiometer, an optical position tracker, an electromagnetic position tracker, and a fiber bragg deflection sensor.

5. The system of claim 1, wherein the first element is the source element and the second element is the detector element.

6. The system of claim 1, wherein the first element is the detector element and the second element is the source element.

7. The system of claim 1, wherein the source element is configured to produce a collimated beam having a cross-sectional shape selected from the group consisting of:

a circle, an ellipse, a square, and a rectangle.

8. The system of claim 1, wherein the detector element is a flat panel detector.

9. The system of claim 8, wherein the flat panel detector is an amorphous silicon panel detector.

10. The system of claim 8, wherein the flat panel detector is a CMOS fluoroscopy panel.

11. The system of claim 8, wherein the flat panel detector has an effective image area having a shape selected from the group consisting of:

a circle, an ellipse, a square, and a rectangle.

12. The system of claim 11, wherein the flat panel detector comprises a rectangular CMOS active fluoroscopy panel having dimensions of about 5 inches by about 6inches.

13. The system of claim 1, wherein the surgical tool comprises a bone cutting tool.

14. The system of claim 13, wherein the bone cutting tool comprises motor.

15. The system of claim 13, wherein the bone cutting cool comprises a bone cutting element selected from the group consisting of:

a rotary cutting burr, an insertion/retraction motion reciprocal cutting saw, and a lateral reciprocal motion cutting saw.

16. The system of claim 1, wherein the mounting feature comprises a tool chuck configured for manually-facilitated removable coupling of the first element of the fluoroscopic imaging system and the surgical tool.

17. The system of claim 1, wherein the second element of the fluoroscopic imaging system is coupled to a movable stand.

18. The system of claim 17, wherein the movable stand is electromechanically movable in response to commands input by an operator.

19. The system of claim 17, wherein the movable stand is manually movable in response to loads applied by an operator.

20. The system of claim 17, wherein the movable stand is mounted to the operating room.

21. The system of claim 17, wherein the movable stand is coupled to the mobile base.

22. The system of claim 1, wherein the sensing system is selected from the group consisting of:

an optical sensing system, an electromagnetic sensing system, a joint rotation sensing system, and an elongate member deflection-sensing system.

23. The system of claim 1, wherein the one or more sensor elements are selected from the group consisting of:

a reflective marker, an electromagnetic localization sensor, a Bragg grating on an optical fiber, a strain gauge, a joint rotation encoder, and a joint rotation potentiometer.

24. The system of claim 1, wherein the controller is configured such that repositioning of the second element causes the robotic arm to reposition the first element to maintain a desired positional alignment between the first and second elements.

25. The system of claim 1, wherein the controller is configured such that reorientation of the second element causes the robotic arm to reorient the first element to maintain a desired rotational alignment between the first and second elements.

26. The system of claim 1, further comprising a user interface configured to allow for an operator to select a desired geometric relationship between the first and second elements relative to the patient tissue structure.

27. The system of claim 1, further comprising a registration probe that may be removably coupled to the mounting fixture and used to register structures within reach of the probe to the coordinate system of the robotic arm.