Surgical manipulator capable of controlling a surgical instrument in multiple modes

• US 9,119,655 B2
• Filed: 08/02/2013
• Issued: 09/01/2015
• 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, Jose Luis, Roessler, Patrick, Beer, Joel N., Ketchel, John
• Primary Examiner(s): Edwards, Jerrah
• Assistant Examiner(s): WEBER, TAMARA L
• Application Number:
  US13/958,070
• Publication Number:
  US 20140039681A1
• Time in Patent Office: 760 Days
• Field of Search: 700/261
• 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 2017/2908 Multiple segments connected by articulations
• 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 2090/066 for measuring torque
• 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 a switch and at least one controller configured to control operation of the surgical manipulator in a first operating mode or a second operating mode. The at least one controller is also configured to determine a commanded pose to which the energy applicator is advanced based on a summation of a plurality of input forces and torques and transition between the operating modes by adjusting the plurality of input forces and torques in response to actuation of the switch.

Claims

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

a switch; and

at least one controller configured to;

control operation of said surgical manipulator in a first operating mode or a second operating mode;

determine a commanded pose to which the energy applicator is advanced based on a summation of a plurality of input forces and torques; and

transition between said operating modes by adjusting said plurality of input forces and torques in response to actuation of said switch.

2. The surgical manipulator of claim 1, wherein said at least one controller is further configured to determine a commanded velocity at which the energy applicator is advanced based on said summation of said plurality of input forces and torques.

3. The surgical manipulator of claim 1, wherein said first operating mode is a manual mode to advance the energy applicator based on forces and torques applied to the surgical instrument by a user and said second operating mode is a semi-autonomous mode to advance the energy applicator along a tool path.

4. The surgical manipulator of claim 3, wherein said at least one controller is configured to reorient the surgical instrument in said semi-autonomous mode as the energy applicator advances along the tool path in response to reorientation forces and torques applied to the surgical instrument by the user while in said semi-autonomous mode.

5. The surgical manipulator of claim 3, wherein said at least one controller is configured to reorient the surgical instrument in said semi-autonomous mode as the energy applicator advances along the tool path in response to reorientation forces and torques applied to the surgical instrument by obstructions.

6. The surgical manipulator of claim 3, wherein said at least one controller is configured to transition from said semi-autonomous mode to said manual mode by adjusting two of said plurality of input forces and torques to zero.

7. The surgical manipulator of claim 1, including a plurality of links wherein a connection between two links forms a joint and wherein an angle between two links forms a joint angle.

8. The surgical manipulator of claim 7, wherein said at least one controller includes a plurality of modules, and wherein at least one of said plurality of modules is a behavior control module configured to determine said commanded pose, and wherein at least another of said plurality of modules is a motion control module configured to determine joint angles that position the energy applicator according to said commanded pose.

9. The surgical manipulator of claim 8, wherein said behavior control module is configured to model the surgical instrument and the energy applicator as a virtual rigid body having virtual mass and virtual inertia.

10. The surgical manipulator of claim 9, wherein said behavior control module is configured to selectively apply said plurality of input forces and torques to said virtual rigid body to emulate orientation and movement of the energy applicator.

11. The surgical manipulator of claim 9, wherein said behavior control module is further configured to determine a total force and a total torque, wherein said total force and total torque are applied to a center of gravity of said virtual rigid body.

12. The surgical manipulator of claim 11, wherein said behavior control module includes a total force summer module configured to calculate said total force and said total torque based on said plurality of input forces and torques.

13. The surgical manipulator of claim 11, wherein said total force and said total torque are a sum of an instrument force vector, an orientation force vector, and an environmental force.

14. The surgical manipulator of claim 13, wherein said instrument force vector is a vector having three distinct forces and three distinct torques, said instrument force vector being selectively applied to said virtual rigid body to emulate advancement of the energy applicator at a particular velocity, and wherein said orientation force vector is a force and torque vector selectively applied to said virtual rigid body to emulate repositioning of an axis of the surgical instrument towards a centering point, and wherein said environmental force is a weighted sum.

15. The surgical manipulator of claim 14, wherein said behavior control module further includes a tool path force calculator module configured to determine said instrument force vector and said orientation force vector.

16. The surgical manipulator of claim 14, wherein said behavior control module further includes an environmental force summer configured to determine said environmental force.

17. The surgical manipulator of claim 16, wherein said environmental force summer is configured to receive a plurality of force inputs that include one or more of:

a joint limit force, an interference limit force, a workspace boundary force, an external force and a damping force.

18. The surgical manipulator of claim 17, wherein said environmental force is determined by summing said plurality of force inputs.

19. The surgical manipulator of claim 18, wherein said environmental force summer is configured to selectively balance a relative contribution of each force input by applying coefficients to each of said plurality of force inputs.

20. The surgical manipulator of claim 19, wherein said first mode is a manual mode and said second mode is a semi-autonomous mode and said coefficients vary as a function of a transition between said manual mode and said semi-autonomous mode such that said coefficients are increased or decreased over a time interval following said transition.

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

a switch;

at least one arm for connecting to the surgical instrument, said at least one arm having a plurality of links, wherein an angle between two links forms a joint angle; and

at least one controller configured to;

control operation of said surgical manipulator in a first operating mode or a second operating mode;

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

determine a commanded pose of the energy applicator based on a summation of a plurality of input forces and torques, wherein said plurality of input forces and torques are applied to said virtual rigid body to emulate orientation and movement of the energy applicator;

determine commanded joint angles that position the energy applicator according to said commanded pose; and

transition between said operating modes by adjusting said plurality of input forces and torques in response to actuation of said switch.

22. The surgical manipulator of claim 21, wherein said first operating mode is a manual mode to advance the energy applicator based on forces and torques applied to the surgical instrument by a user and said second operating mode is a semi-autonomous mode to advance the energy applicator along a tool path.

23. The surgical manipulator of claim 22, wherein said at least one controller is configured to transition from said semi-autonomous mode to said manual mode by adjusting two of said plurality of input forces and torques to zero.

24. The surgical manipulator of claim 22, wherein in said manual mode, said forces and torques applied by the user indicate the user'"'"'s desired positioning of the surgical instrument, and wherein said at least one controller emulates the user'"'"'s desired positioning of the surgical instrument by positioning the surgical instrument according to said commanded pose.

25. The surgical manipulator of claim 22, wherein in said semi-autonomous mode, said plurality of input forces and torques include forces and torques directed to advancing and maintaining an orientation of the surgical instrument along the tool path.

26. The surgical manipulator of claim 21, wherein said at least one controller is configured to selectively balance a relative contribution of each of said summed plurality of input forces and torques by applying coefficients to each of said plurality of input forces and torques.

27. A method for controlling a surgical manipulator, wherein the surgical manipulator includes a switch and at least one arm connected to a surgical instrument, and wherein the at least one arm includes a plurality of links, and wherein an angle between two links forms a joint angle, and wherein an energy applicator extends from the surgical instrument, said method comprising the steps of:

controlling operation of the surgical manipulator in a first operating mode or a second operating mode;

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

determining a commanded pose for the energy applicator based on a summation of a plurality of input forces and torques, wherein the plurality of input forces and torques are selectively applied to the virtual rigid body to emulate orientation and movement of the energy applicator;

determining commanded joint angles that position the energy applicator according to the commanded pose; and

transitioning between the operating modes by adjusting the plurality of input forces and torques in response to actuation of the switch.

28. The method of claim 27, further including determining a commanded velocity at which the energy applicator is advanced based on the summation of the plurality of input forces and torques.

29. The method of claim 27, wherein controlling operation of the surgical manipulator in the first operating mode or the second operating mode includes:

controlling operation of the surgical manipulator in a manual mode to advance the energy applicator based on forces and torques applied by a user on the surgical instrument;

or

controlling operation of the surgical manipulator in a semi-autonomous mode to advance the energy applicator along a tool path.

30. The method of claim 29, further including transitioning from the semi-autonomous mode to the manual mode by adjusting two of the plurality of input forces and torques to zero.

31. The method of claim 27, further including computing a total force and a total torque, wherein the total force and the total torque are applied to a center of gravity of the virtual rigid body.

32. The method of claim 31, wherein the total force and the total torque are a sum of an instrument force vector, an orientation force vector, and an environmental force.

33. The method of claim 32, wherein the instrument force vector is a vector having three distinct forces and three distinct torques, the instrument force vector being selectively applied to the virtual rigid body to emulate advancement of the energy applicator at a particular velocity, and wherein the orientation force vector is a force and torque vector selectively applied to the virtual rigid body to emulate repositioning of an axis of the surgical instrument towards a centering point, and wherein the environmental force is a weighted sum.

34. The method of claim 32, wherein the environmental force includes a plurality of force inputs that include one or more of:

a joint limit force, an interference limit force, a workspace boundary force, an external force and a damping force.

35. The method of claim 34, wherein determining the environmental force includes summing the plurality of force inputs.

36. The method of claim 35, further including selectively balancing a relative contribution of each force input by applying coefficients to each of the plurality of force inputs.

37. The method of claim 36, wherein the first operating mode is a manual mode and the second operating mode is a semi-autonomous mode and further including varying the coefficients as a function of a transition between the manual mode and the semi-autonomous mode such that the coefficients are increased or decreased over a time interval following the transition.

38. The method of claim 29, further including reorienting the surgical instrument in the semi-autonomous mode as the energy applicator advances along the tool path in response to reorientation forces and torques applied to the surgical instrument by the user while in the semi-autonomous mode.

39. The method of claim 29, further including reorienting the surgical instrument in the semi-autonomous mode as the energy applicator advances along the tool path in response to reorientation forces and torques applied to the surgical instrument by obstructions.