System and method for controlling a surgical manipulator based on implant parameters

• US 9,820,818 B2
• Filed: 09/04/2015
• Issued: 11/21/2017
• Est. Priority Date: 08/03/2012
• Status: Active Grant

• Current Assignee: Stryker Corporation
• Original Assignee: Stryker Corporation
• Inventors: Malackowski, Donald W., Stuart, John Michael, Culp, Jerry A., Bowling, David Gene, Moctezuma de la Barrera, Jos Luis, Roessler, Patrick, Beer, Joel N.
• Primary Examiner(s): Kiswanto, Nicholas
• Assistant Examiner(s): WEBER, TAMARA L
• Application Number:
  US14/845,820
• Publication Number:
  US 20150374446A1
• Time in Patent Office: 809 Days
• Field of Search: None
• 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 2034/107 Visualisation of planned trajectories or target regions
• 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

Abstract

System and method for controlling a surgical manipulator to apply an energy applicator to a patient. The surgical manipulator cooperates with a navigation system to position the energy applicator with respect to a boundary so that the energy applicator is constrained from moving outside the boundary. The boundary is generated based on implant parameters measured after manufacture of the implant.

Claims

1. A robotic system comprising:

a surgical manipulator configured to apply an energy applicator to a patient;

a navigation system configured to cooperate with said surgical manipulator to position the energy applicator with respect to a boundary between tissue of the patient to which the energy applicator should be applied and tissue of the patient to which the energy applicator should not be applied, said navigation system including a navigation processor and a boundary generator module operable on said navigation processor,

wherein said boundary generator module is configured to generate an initial definition of the boundary based on initial implant data including an initial definition of a shape of an implant; and

wherein said boundary generator module is further configured to generate a final definition of the boundary, different than the initial definition of the boundary, based on measurements of the implant made after manufacture and a final definition of the shape of the implant generated from the measurements.

2. The robotic system of claim 1, wherein said boundary generator module is configured to generate the initial definition of the boundary based on a preoperative image of the tissue of the patient to which the energy applicator should be applied.

3. The robotic system of claim 1, wherein said initial implant data comprises an initial map of the implant from an implant database.

4. The robotic system of claim 1, wherein said boundary generator module is configured to generate the initial definition of the boundary based on user settings.

5. The robotic system of claim 1, further comprising a storage device storing the measurements of the implant.

6. The robotic system of claim 5, wherein said storage device comprises one of a memory stick and an RFID tag.

7. The robotic system of claim 1, wherein said navigation system comprises a tool path generator module operable on said navigation processor to generate a tool path for the energy applicator.

8. The robotic system of claim 7, wherein said tool path generator module is configured to generate said tool path based on a geometry of the energy applicator.

9. A method of controlling a surgical manipulator, said method comprising the steps of:

providing the surgical manipulator to apply an energy applicator to a patient;

providing a navigation system to cooperate with the surgical manipulator to position the energy applicator with respect to a boundary between tissue of the patient to which the energy applicator should be applied and tissue of the patient to which the energy applicator should not be applied;

generating an initial definition of the boundary based on initial implant data including an initial definition of a shape of an implant; and

generating a final definition of the boundary, different than the initial definition of the boundary, based on measurements of the implant made after manufacture and a final definition of the shape of the implant generated from the measurements.

10. The method of claim 9, wherein generating the initial definition of the boundary comprises generating the initial definition of the boundary based on a preoperative image of the tissue of the patient to which the energy applicator should be applied.

11. The method of claim 9, wherein generating the initial definition of the boundary based on the initial implant data comprises generating the initial definition of the boundary based on an initial map of the implant from an implant database.

12. The method of claim 9, wherein generating the initial definition of the boundary comprises generating the initial definition of the boundary based on user settings.

13. The method of claim 9, further comprising storing the measurements of the implant on a storage device.

14. The method of claim 9, further comprising generating a tool path for the energy applicator.

15. The method of claim 14, wherein generating the tool path for the energy applicator comprises generating the tool path based on a geometry of the energy applicator.