Surgical manipulator having a feed rate calculator

• US 9,566,125 B2
• Filed: 08/31/2015
• Issued: 02/14/2017
• Est. Priority Date: 08/03/2012
• Status: Active Grant

• Current Assignee: Stryker Corporation
• Original Assignee: Stryker Corporation
• Inventors: Bowling, David Gene, Stuart, John Michael, Culp, Jerry A., Malackowski, Donald W., Moctezuma de la Barrera, Jos Luis, Roessler, Patrick, Beer, Joel N.
• Primary Examiner(s): Edwards, Jerrah
• Assistant Examiner(s): WEBER, TAMARA L
• Application Number:
  US14/841,062
• Publication Number:
  US 20150366629A1
• Time in Patent Office: 533 Days
• US Class Current: 1/1
• CPC Class Codes: A61B 17/16 Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans arthroscopic bone cutters A61B17/320016; dental implant drills potentially for other surgical use A61C8/0089; bone grinders A61F2/4644, A22C17/06; A61B17/1662 takes precedence over all other subgroups except A61B17/17
• CPC Class Codes: A61B 18/148 having a short, rigid shaft for accessing the inner body transcutaneously, e.g. for neurosurgery or arthroscopy
• CPC Class Codes: A61B 2018/00565 Bone
• CPC Class Codes: A61B 2018/00601 Cutting
• CPC Class Codes: A61B 2034/104 Modelling the effect of the tool, e.g. the effect of an implanted prosthesis or for predicting the effect of ablation or burring
• CPC Class Codes: A61B 2034/107 Visualisation of planned trajectories or target regions
• CPC Class Codes: A61B 2034/2046 Tracking techniques
• CPC Class Codes: A61B 2034/2055 Optical tracking systems
• CPC Class Codes: A61B 2034/2059 Mechanical position encoders
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• 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 34/32 operating autonomously
• CPC Class Codes: A61B 34/37 Master-slave robots A61B34/35 takes precedence
• CPC Class Codes: A61B 34/70 Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 34/74 Manipulators with manual electric input means
• CPC Class Codes: A61B 34/76 Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: B25J 13/00 Controls for manipulators programme controls B25J9/16; control in general G05
• CPC Class Codes: B25J 9/161 Hardware, e.g. neural networks, fuzzy logic, interfaces, processor
• CPC Class Codes: B25J 9/1633 compliant, force, torque control, e.g. combined with position control
• CPC Class Codes: Y10S 901/09 : Closed loop, sensor feedback controls arm movement

Abstract

A surgical manipulator for manipulating a surgical instrument and an energy applicator extending from the surgical instrument. The surgical manipulator further includes at least one controller configured to operate the surgical manipulator in a manual mode or a semi-autonomous mode. The at least one controller including a feed rate calculator configured to calculate an instrument feed rate. The instrument feed rate is a velocity at which a distal end of the energy applicator advances along a path segment of a tool path in the semi-autonomous mode.

Claims

1. A surgical manipulator for manipulating a surgical instrument and an energy applicator extending from the surgical instrument, said surgical manipulator comprising:

at least one controller configured to operate said surgical manipulator in a manual mode or a semi-autonomous mode, said at least one controller including a feed rate calculator configured to calculate an instrument feed rate,

wherein said instrument feed rate is a velocity at which a distal end of the energy applicator advances along a path segment of a tool path in said semi-autonomous mode and wherein said feed rate calculator calculates said instrument feed rate by adjusting a defined feed rate based on a plurality of variables,

wherein said at least one controller is configured to model the surgical instrument and the energy applicator as a virtual rigid body and said feed rate calculator is configured to adjust said defined feed rate based on a virtual force applied to said virtual rigid body.

2. The surgical manipulator of claim 1, wherein said defined feed rate is based on one or more of:

a shape of a space to which the energy applicator is applied, a type of energy applicator, patient health, nature of tissue to which the energy applicator is applied, and geometry of said path segment.

3. The surgical manipulator of claim 1, wherein said feed rate calculator is configured to adjust said defined feed rate by multiplying said defined feed rate by a plurality of coefficients associated with said plurality of variables.

4. The surgical manipulator of claim 1 wherein said feed rate calculator is configured to adjust said defined feed rate based on user adjustment of said defined feed rate.

5. The surgical manipulator of claim 4 including a pendant having a feed rate adjustment button operable by a user to adjust said defined feed rate.

6. The surgical manipulator of claim 1 wherein said feed rate calculator is configured to adjust said defined feed rate based on forces and torques to which the energy applicator is exposed.

7. The surgical manipulator of claim 1 wherein said feed rate calculator is configured to adjust said defined feed rate based on curvature of said path segment.

8. The surgical manipulator of claim 1 wherein said feed rate calculator is configured to adjust said defined feed rate based on instrument power.

9. The surgical manipulator of claim 1 wherein said feed rate calculator is configured to adjust said defined feed rate based on tissue temperature.

10. The surgical manipulator of claim 1 wherein said feed rate calculator is configured to adjust said defined feed rate based on a signal from a force overrider module so that said instrument feed rate is zero, said force overrider module configured to be run by said at least one controller to compare forces and torques to one or more limit values and generate said signal when said one or more limit values are exceeded.

11. The surgical manipulator of claim 10 wherein said force overrider module is configured to output said signal to transition said surgical manipulator from said semi-autonomous mode to said manual mode.

12. A surgical manipulator for manipulating a surgical instrument and an energy applicator extending from the surgical instrument, said surgical manipulator comprising:

at least one controller configured to operate said surgical manipulator in a manual mode or a semi-autonomous mode, said at least one controller including a feed rate calculator configured to calculate an instrument feed rate,

wherein said instrument feed rate is a velocity at which a distal end of the energy applicator advances along a path segment of a tool path in said semi-autonomous mode and wherein said feed rate calculator calculates said instrument feed rate by adjusting a defined feed rate based on a plurality of variables,

wherein said feed rate calculator is configured to adjust said defined feed rate based on a signal from a force overrider module so that said instrument feed rate is zero, said force overrider module configured to be run by said at least one controller to compare forces and torques to one or more limit values and generate said signal when said one or more limit values are exceeded,

wherein said force overrider module is configured to output said signal to transition said surgical manipulator from said semi-autonomous mode to said manual mode.

13. The surgical manipulator of claim 12, wherein said defined feed rate is based on one or more of:

a shape of a space to which the energy applicator is applied, a type of energy applicator, patient health, nature of tissue to which the energy applicator is applied, and geometry of said path segment.

14. The surgical manipulator of claim 12, wherein said feed rate calculator is configured to adjust said defined feed rate by multiplying said defined feed rate by a plurality of coefficients associated with said plurality of variables.

15. The surgical manipulator of claim 12 wherein said feed rate calculator is configured to adjust said defined feed rate based on user adjustment of said defined feed rate.

16. The surgical manipulator of claim 15 including a pendant having a feed rate adjustment button operable by a user to adjust said defined feed rate.

17. The surgical manipulator of claim 12 wherein said feed rate calculator is configured to adjust said defined feed rate based on forces and torques to which the energy applicator is exposed.

18. The surgical manipulator of claim 12 wherein said feed rate calculator is configured to adjust said defined feed rate based on curvature of said path segment.

19. The surgical manipulator of claim 12 wherein said feed rate calculator is configured to adjust said defined feed rate based on instrument power.

20. The surgical manipulator of claim 12 wherein said feed rate calculator is configured to adjust said defined feed rate based on tissue temperature.

21. A method for controlling a surgical manipulator to manipulate a surgical instrument and an energy applicator extending from the surgical instrument, the surgical manipulator comprising at least one controller configured to operate the surgical manipulator in a manual mode or a semi-autonomous mode and the at least one controller including a feed rate calculator, said method comprising the steps of:

calculating an instrument feed rate with the feed rate calculator, wherein the instrument feed rate is a velocity at which a distal end of the energy applicator advances along a path segment of a tool path in the semi-autonomous mode and wherein the feed rate calculator calculates the instrument feed rate by adjusting a defined feed rate based on a plurality of variables;

modeling the surgical instrument and the energy applicator as a virtual rigid body; and

adjusting the feed rate based on a virtual force applied to the virtual rigid body.

22. The method of claim 21, wherein the defined feed rate is based on one or more of:

a shape of a space to which the energy applicator is applied, a type of energy applicator, patient health, nature of tissue to which the energy applicator is applied, and geometry of the path segment.

23. The method of claim 21, including adjusting the defined feed rate by multiplying the defined feed rate by a plurality of coefficients associated with the plurality of variables.

24. The method of claim 21, including adjusting the defined feed rate based on user adjustment of the defined feed rate.

25. The method of claim 24, including adjusting the defined feed rate based on operation by a user of a feed rate adjustment button of a pendant.

26. The method of claim 21, including adjusting the defined feed rate based on forces and torques to which the energy applicator is exposed.

27. The method of claim 21, including adjusting the defined feed rate based on curvature of the path segment.

28. The method of claim 21, including adjusting the defined feed rate based on instrument power.

29. The method of claim 21, including adjusting the defined feed rate based on tissue temperature.

30. The method of claim 21, including adjusting the defined feed rate based on a signal from a force overrider module so that the instrument feed rate is zero, the force overrider module configured to be run by the at least one controller to compare forces and torques to one or more limit values and generate the signal when the one or more limit values are exceeded.

31. The method of claim 30, including outputting the signal to transition the surgical manipulator from the semi-autonomous mode to the manual mode.

32. A method for controlling a surgical manipulator to manipulate a surgical instrument and an energy applicator extending from the surgical instrument, the surgical manipulator comprising at least one controller configured to operate the surgical manipulator in a manual mode or a semi-autonomous mode and the at least one controller including a feed rate calculator, said method comprising the steps of:

calculating an instrument feed rate with the feed rate calculator, wherein the instrument feed rate is a velocity at which a distal end of the energy applicator advances along a path segment of a tool path in the semi-autonomous mode and wherein the feed rate calculator calculates the instrument feed rate by adjusting a defined feed rate based on a plurality of variables;

adjusting the defined feed rate based on a signal from a force overrider module so that the instrument feed rate is zero, the force overrider module configured to be run by the at least one controller to compare forces and torques to one or more limit values and generate the signal when the one or more limit values are exceeded; and

outputting the signal to transition the surgical manipulator from the semi-autonomous mode to the manual mode.

33. The method of claim 32, wherein the defined feed rate is based on one or more of:

a shape of a space to which the energy applicator is applied, a type of energy applicator, patient health, nature of tissue to which the energy applicator is applied, and geometry of the path segment.

34. The method of claim 32, including adjusting the defined feed rate by multiplying the defined feed rate by a plurality of coefficients associated with the plurality of variables.

35. The method of claim 32, including adjusting the defined feed rate based on user adjustment of the defined feed rate.

36. The method of claim 35, including adjusting the defined feed rate based on operation by a user of a feed rate adjustment button of a pendant.

37. The method of claim 32, including adjusting the defined feed rate based on forces and torques to which the energy applicator is exposed.

38. The method of claim 32, including adjusting the defined feed rate based on curvature of the path segment.

39. The method of claim 32, including adjusting the defined feed rate based on instrument power.

40. The method of claim 32, including adjusting the defined feed rate based on tissue temperature.