Apparatus and method for forming support device for effecting orthopedic stabilization

Patent metadata

Field	Value
Publication number	US-10405908-B2
Application number	US-201414574595-A
Country	US
Kind code	B2
Filing date	Dec 18, 2014
Priority date	Dec 18, 2014
Publication date	Sep 10, 2019
Grant date	Sep 10, 2019

Abstract

A forming apparatus and method for forming a workpiece used a medical procedure is provided. A controllable bending machine for bending the workpiece is provided. A template is manually formable. The template has a shape sensor so as to sense a shape of the template. A controller receives template shape data from the shape sensor and operates the bending machine in accordance with the template shape data. The bending of the workpiece includes a spring back compensating operation which performs a first bending operation on the workpiece in accordance with the template shape data, acquires workpiece shape data from one of the shape sensor re-disposed associated with the workpiece, or another shape sensor associated with the workpiece, and performs a second bending operation compensating for spring back. A method employs the template for workpiece measurements and the forming apparatus using the measurements for forming the workpiece.

First claim

What is claimed is:

1. A forming apparatus for forming a workpiece for use in a medical procedure wherein the workpiece is to be fitted to a patient by bending, comprising:
a bending machine comprising a shaft defining an axis, the shaft being connected to a motor, the workpiece being coupled to the shaft such that motor rotates the workpiece about the axis;
a fiber optic shape sensor which is manually formable, said forming apparatus being configured to sense a shape of the shape sensor such that a relative position of at least two portions of the shape sensor relative to each other are measurable, wherein said shape sensor is disposed in a sensor channel of the workpiece; and
a controller configured to receive template shape data from said shape sensor and operate said bending machine to effect bending of the workpiece in accordance with the template shape data, wherein said bending of said workpiece includes a spring back compensating operation comprising one of an iterative bending operation or a material characteristic data calculated bend amount.

2. A forming apparatus according to claim 1 , wherein said spring back compensating operation is an iterative bending operation comprising:
performing a first bending operation on said workpiece in accordance with said template shape data;
acquiring workpiece shape data from said shape sensor so as to provide workpiece shape data, representative of said workpiece, to said controller; and
performing a second bending operation compensating for spring back due to elastic deformation during said first bending operation based on said template shape data and said workpiece shape data.

3. A forming apparatus according to claim 2 , wherein
the sensor channel is a bore.

4. A forming apparatus according to claim 1 , wherein:
said controller is configured to accept linear identifier coordinates identifying target positions along the shape sensor;
said shape sensor includes indicia identifying linear positions along said shape sensor; and
said controller is configured to effect minimum bend bending via said bender wherein a number of bends, between the target positions, are minimized and bends are affected outside of defined areas including said target positions.

5. A forming apparatus according to claim 4 , wherein said controller is configured to accept linear identifier coordinates identifying said defined areas.

6. A forming apparatus according to claim 1 , wherein:
said shape sensor includes a linear touch sensor for accepting contact at a position to effect input of coordinates of the position of the contact;
said controller is configured to accept input from said linear touch sensor as linear identifier coordinates identifying target positions along the shape sensor; and
said controller is configured to effect minimum bend bending via said bender wherein a number of bends, between the target positions, are minimized and bends are affected outside of defined areas including said target positions.

7. A forming apparatus according to claim 6 , wherein said controller is configured to accept input from said linear touch sensor as linear identifier coordinates identifying said defined areas.

8. A forming apparatus according to claim 1 , further comprising an interrogator that is connected to the shape sensor, the interrogator being configured to analyze reflections from a laser signal applied to the shape sensor using optical frequency domain reflectometry to determine a shape imposed on the shape sensor when the laser signal is applied to the shape sensor.

9. A forming apparatus according to claim 1 , wherein the fiber optic shape sensor comprises optical fiber cores.

10. A forming apparatus for forming a spinal rod, the apparatus comprising:
a bending machine comprising a shaft defining an axis, the shaft being connected to a motor, the spinal rod being positioned between a mandrel member of the bending machine and a bending member of the bending machine, the spinal rod being coupled to the shaft such that motor rotates the spinal rod about the axis;
a fiber optic shape sensor which is manually formable, the shape sensor being positioned in a sensor channel of the spinal rod;
an interrogator that is connected to the shape sensor, the interrogator being configured to analyze reflections from a laser signal applied to the shape sensor using optical frequency domain reflectometry to determine a shape imposed on the shape sensor when the laser signal is applied to the shape sensor; and
a controller configured to receive template shape data from the shape sensor and operate the bending machine to effect bending of the spinal rod in accordance with the template shape data.

11. A forming apparatus for forming a workpiece, the forming apparatus comprising:
a bending machine comprising a shaft defining an axis, the shaft being connected to a motor, the workpiece being coupled to the shaft such that motor rotates the workpiece about the axis;
a fiber optic shape sensor disposed in a sensor channel of the workpiece;
an interrogator configured to sense a shape of the shape sensor; and
a controller configured to receive data regarding the shape of the shape sensor from the interrogator and operate the bending machine to effect bending of the workpiece in accordance with the data.

12. A forming apparatus according to claim 11 , wherein bending of the workpiece includes a spring back compensating operation comprising a material characteristic data calculated bend amount.

13. A method for forming a workpiece for use in a medical procedure wherein the workpiece is to be fitted to a patient by bending, comprising:
providing said forming apparatus of claim 1 ;
manually shaping said shape sensor to fit the patient; and
operating said controller to effect bending of said workpiece based on said template shape data using said spring back compensating operation.

14. A method for forming a workpiece for use in a medical procedure wherein the workpiece is to be fitted to a patient by bending, comprising:
providing said forming apparatus of claim 1 ;
manually shaping said shape sensor to fit the patient by placing said shape sensor in-situ;
positioning the shape sensor in the sensor channel; and
operating said controller to effect bending of said workpiece based on said template shape data using said spring back compensating operation.

15. A method according to claim 14 wherein said shape sensor is limp and said manually forming comprises laying said shape sensor in-situ and acquiring said template shape data with said shape sensor laying in-situ.

16. A method according to claim 15 , wherein said workpiece is a spinal rod.

17. A method for forming a workpiece for use in a medical procedure wherein the workpiece is to be fitted to a patient by bending, comprising:
providing said forming apparatus of claim 4 ;
manually shaping said shape sensor to fit the patient;
inputting linear identifier coordinates of at least one of said target positions or said defined areas;
positioning the shape sensor in the sensor channel; and
operating said controller to effect said minimum bend bending of said workpiece based on said template shape data, and said linear identifier coordinates of at least one of said target positions or said defined areas, using said spring back compensating operation.

18. A method according to claim 17 , wherein said workpiece is a spinal rod.

19. A method for forming a workpiece for use in a medical procedure wherein the workpiece is to be fitted to a patient by be

Assignees

• Warsaw Orthopedic Inc

Inventors

• Redmond Jerald L

Classifications

• A61B17/8863 Primary

  Apparatus for shaping or cutting osteosynthesis equipment by medical personnel · CPC title

• B21D7/14

  combined with measuring of bends or lengths · CPC title

• B21D7/12

  with program control · CPC title