Surgical Manipulator And Method For Resuming Semi-Autonomous Tool Path Position

• US 20190192249A1
• Filed: 01/30/2019
• Published: 06/27/2019
• Est. Priority Date: 08/03/2012
• Status: Active Grant

• Current Assignee: Stryker Corporation
• Original Assignee: Stryker Corporation
• Inventors: Bowling, David Gene, Roessler, Patrick, Beer, Joel N.
• Granted Patent: US 10,463,440 B2
• Time in Patent Office: Days
• 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

Surgical manipulators and methods disclosed comprise an energy applicator extending from an instrument and actuators to move links to position the energy applicator. A force/torque sensor sense forces/torques applied to the instrument. Controller(s) control operation of the manipulator in a semi-autonomous mode wherein the manipulator moves the energy applicator along a tool path comprising a target position and advances the energy applicator along the tool path by moving the energy applicator to the target position. The controller(s) transition from the semi-autonomous mode to a manual mode wherein operation of the manipulator is controlled in response to forces/torques applied to the instrument. In the manual mode, the controller(s) enable movement of the energy applicator to one or more positions different from the target position. The controller(s) transition from the manual mode back to the semi-autonomous mode by moving the energy applicator back to the target position on the tool path.

Claims

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

a plurality of links and a plurality of actuators configured to move the plurality of links to position the energy applicator;

a force/torque sensor configured to sense forces and torques applied to the instrument; and

at least one controller configured to;

control operation of the surgical manipulator in a semi-autonomous mode wherein the surgical manipulator is configured to move the energy applicator along a tool path comprising a target position and to advance the energy applicator along the tool path by moving the energy applicator to the target position;

transition from the semi-autonomous mode to a manual mode wherein operation of the surgical manipulator is controlled in response to forces and torques applied to the instrument;

in the manual mode, enable movement of the energy applicator to one or more positions different from the target position; and

transition from the manual mode back to the semi-autonomous mode by moving the energy applicator back to the target position on the tool path.

2. The surgical manipulator of claim 1, wherein the at least one controller is configured to model the instrument and the energy applicator as a virtual rigid body.

3. The surgical manipulator of claim 2, wherein in response to transitioning from the semi-autonomous mode to the manual mode, the at least one controller is configured to apply force and torques to the virtual rigid body to hold the instrument in a static pose at the target position.

4. The surgical manipulator of claim 2, wherein, in the semi-autonomous mode, the at least one controller is configured to determine forces to apply to the virtual rigid body to advance the energy applicator from the target position to a subsequent target position on the tool path.

5. The surgical manipulator of claim 1, wherein, in response to moving the energy applicator back to the target position on the tool path, the at least one controller controls the surgical manipulator in the semi-autonomous mode to resume movement of the energy applicator along the tool path by being configured to advance the energy applicator along the tool path by moving the energy applicator from the target position to a subsequent target position on the tool path.

6. The surgical manipulator of claim 1, wherein in response to transitioning from the manual mode back to the semi-autonomous mode, the at least one controller is configured to generate a new tool path.

7. The surgical manipulator of claim 1, wherein the tool path comprises a plurality of path segments and the at least one controller is configured to compute the target position for one path segment of the plurality based on one or more of the following:

a feed rate of the instrument;

a relationship between an initial position of a coordinate system of the energy applicator and starting and ending points of the one path segment; and

geometric characteristics of the one path segment.

8. The surgical manipulator of claim 1, wherein the instrument further comprises a switch, and wherein the at least one controller is configured to transition from the semi-autonomous mode to the manual mode in response to detecting actuation of the switch.

9. The surgical manipulator of claim 1, further comprising a hand held pendant comprising a trigger and being configured to regulate operation of the surgical manipulator in the semi-autonomous mode, and wherein the at least one controller is configured to transition from the semi-autonomous mode to the manual mode in response to detecting release of the trigger.

10. The surgical manipulator of claim 1, further comprising a hand held pendant comprising a trigger and wherein the at least one controller is configured to control operation of the surgical manipulator in a semi-autonomous mode in response to detecting actuation of the trigger.

11. A method of operating a surgical manipulator, the surgical manipulator configured to manipulate an instrument and an energy applicator extending from the instrument, the surgical manipulator comprising a plurality of links and a plurality of actuators configured to move the plurality of links to position the energy applicator, a force/torque sensor configured to sense forces and torques applied to the instrument, and at least one controller being configured to perform the steps of:

controlling operation of the surgical manipulator in a semi-autonomous mode wherein the surgical manipulator moves the energy applicator along a tool path comprising a target position and advances the energy applicator along the tool path by moving the energy applicator to the target position;

transitioning from the semi-autonomous mode to a manual mode wherein operation of the surgical manipulator is controlled in response to forces and torques applied to the instrument;

in the manual mode, enabling movement of the energy applicator to one or more positions different from the target position; and

transitioning from the manual mode back to the semi-autonomous mode by moving the energy applicator back to the target position on the tool path.

12. The method of claim 11, further comprising the at least one controller modeling the instrument and the energy applicator as a virtual rigid body.

13. The method of claim 12, wherein in response to transitioning from the semi-autonomous mode to the manual mode, the at least one controller applies force and torques to the virtual rigid body for holding the instrument in a static pose at the target position.

14. The method of claim 12, wherein, in the semi-autonomous mode, the at least one controller determines forces to apply to the virtual rigid body for advancing the energy applicator from the target position to a subsequent target position on the tool path.

15. The method of claim 11, wherein, in response to moving the energy applicator back to the target position on the tool path, the at least one controller controls the surgical manipulator in the semi-autonomous mode for resuming movement of the energy applicator along the tool path by advancing the energy applicator along the tool path by moving the energy applicator from the target position to a subsequent target position on the tool path.

16. The method of claim 11, wherein, in response to transitioning from the manual mode back to the semi-autonomous mode, the at least one controller generates a new tool path.

17. The method of claim 11, wherein the tool path comprises a plurality of path segments and the at least one controller computes the target position for one path segment of the plurality based on one or more of the following:

a feed rate of the instrument;

a relationship between an initial position of a coordinate system of the energy applicator and starting and ending points of the one path segment; and

geometric characteristics of the one path segment.

18. The method of claim 11, wherein the instrument further comprises a switch, and wherein the at least one controller transitions from the semi-autonomous mode to the manual mode in response to detecting actuation of the switch.

19. The method of claim 11, further comprising a hand held pendant comprising a trigger and being configured to regulate operation of the surgical manipulator in the semi-autonomous mode, and wherein the at least one controller transitions from the semi-autonomous mode to the manual mode in response to detecting release of the trigger.

20. The method of claim 11, further comprising a hand held pendant comprising a trigger and wherein the at least one controller controls operation of the surgical manipulator in a semi-autonomous mode in response to detecting actuation of the trigger.