Systems and methods for controlling movement of a surgical tool along a predefined path class

Patent metadata

Field	Value
Publication number	US-12178540-B2
Application number	US-202318093384-A
Country	US
Kind code	B2
Filing date	Jan 5, 2023
Priority date	Mar 8, 2019
Publication date	Dec 31, 2024
Grant date	Dec 31, 2024

Abstract

Robotic surgical systems and methods for controlling movement of a tool relative to a tool path. An input is received from a force/torque sensor in response to user forces/torques manually applied to the tool by a user. A component of force is calculated tangential to the path based on the input. An effective feed rate is calculated to advance the tool along the path based on the tangential component. Virtual constraints are defined on movement of the tool along the path with respect to three degrees of freedom and based on the effective feed rate to promote movement of the tool along the path. Dynamics of the tool are virtually simulated based on the virtual constraints and the input from the force/torque sensor. The manipulator is commanded to advance the tool along the path based on the virtual simulation.

First claim

The invention claimed is:

1. A robotic surgical system comprising:
a surgical tool;
a manipulator configured to support the surgical tool, the manipulator comprising a plurality of links;
a force/torque sensor to measure forces and torques applied to the surgical tool; and
a control system configured to:
obtain a tool path for the surgical tool, wherein the tool path is three-dimensional and pre-defined;
receive an input from the force/torque sensor in response to user forces and torques manually applied to the surgical tool by a user;
calculate, based on the input from the force/torque sensor, a tangential component of force that is tangential to the tool path;
calculate an effective feed rate for advancing the surgical tool along the tool path based on the calculated tangential force component and by excluding normal components of force that are normal to the tool path;
define virtual constraints on movement of the surgical tool along the tool path with respect to three degrees of freedom and based on the effective feed rate to promote movement of the surgical tool along the tool path;
simulate dynamics of the surgical tool in a virtual simulation based on the input from the force/torque sensor; and
command the manipulator to advance the surgical tool along the tool path based on the virtual simulation.

2. The robotic surgical system of claim 1 wherein the control system is further configured to simulate dynamics of the surgical tool by representing the surgical tool as a virtual rigid body having a virtual mass and by applying a constraint force to the virtual mass in the virtual simulation to yield a commanded pose, wherein the constraint force is based on the virtual constraints.

3. The robotic surgical system of claim 2 , wherein the control system is configured to determine a target pose on the tool path based on the effective feed rate.

4. The robotic surgical system of claim 3 , wherein the control system is configured to define the virtual constraints with respect to the three degrees of freedom on a distance between the commanded pose and the target pose.

5. The robotic surgical system of claim 1 , wherein the control system is configured to:
define one or more additional constraints associated with constraining an orientation of the surgical tool;
simulate dynamics of the surgical tool in the virtual simulation based on the virtual constraints, the one or more additional constraints, and the input from the force/torque sensor; and
command the manipulator to advance the surgical tool along the tool path based on the virtual simulation.

6. The robotic surgical system of claim 1 , wherein:
the manipulator is operable in a guided-manual mode and a semi-autonomous mode and wherein the control system is further configured to utilize the effective feed rate and define the virtual constraints in the guided-manual mode; and
in response to transitioning to the semi-autonomous mode from the guided-manual mode, the control system is configured to calculate a transition path from a current position of a tool center point of the surgical tool to a last known point of the surgical tool on the tool path before transitioning from the semi-autonomous mode.

7. The robotic surgical system of claim 1 , wherein the control system is configured to:
obtain a virtual boundary for the surgical tool with the virtual boundary being a three-dimensional tube defining the tool path; and
define the virtual constraints on movement of the surgical tool inside the three-dimensional tube and along the tool path, the virtual constraints being defined to constrain movement of the surgical tool to be along the tool path.

8. The robotic surgical system of claim 1 , wherein the virtual constraints are defined as velocity constraints, wherein each of the velocity constraints comprises stiffness and damping parameters and one or more force limits and one or more activation limits.

9. The robotic surgical system of claim 1 , wherein the control system is configured to determine a direction of movement to move the surgical tool along the tool path based on the calculated tangential force component.

10. The robotic surgical system of claim 1 , wherein the control system is configured to:
define an end constraint with respect to one degree of freedom tangential to the tool path to constrain the surgical tool to remain on the tool path by constraining movement beyond an end of the tool path.

11. A method for operating a robotic surgical system, the robotic surgical system comprising a surgical tool, a manipulator configured to support the surgical tool, and a force/torque sensor to measure forces and torques applied to the surgical tool, the method comprising the steps of:
obtaining a tool path for the surgical tool, wherein the tool path is three-dimensional and pre-defined;
receiving input from the force/torque sensor in response to user forces and torques manually applied to the surgical tool by a user;
calculating a tangential component of force that is tangential to the tool path based on the input from the force/torque sensor;
calculating an effective feed rate to advance the surgical tool along the tool path based on the calculated tangential component and by excluding normal components of force that are normal to the tool path;
defining virtual constraints on movement of the surgical tool along the tool path with respect to three degrees of freedom and based on the effective feed rate to promote movement of the surgical tool along the tool path;
simulating dynamics of the surgical tool in a virtual simulation based on the virtual constraints and the input from the force/torque sensor; and
commanding the manipulator to advance the surgical tool along the tool path based on the virtual simulation.

12. The method of claim 11 , wherein simulating dynamics of the surgical tool further comprises representing the surgical tool as a virtual rigid body having a virtual mass and by applying a constraint force to the virtual mass in the virtual simulation to yield a commanded pose, wherein the constraint force is based on the virtual constraints.

13. The method of claim 12 , comprising:
determining a target pose on the tool path based on the effective feed rate.

14. The method of claim 13 , comprising:
defining the virtual constraints with respect to the three degrees of freedom based on a distance between the commanded pose and the target pose.

15. The method of claim 11 , comprising:
defining one or more additional constraints associated with constraining an orientation of the surgical tool;
simulating dynamics of the surgical tool in the virtual simulation based on the virtual constraints, the one or more additional constraints, and the input from the force/torque sensor; and
commanding the manipulator to advance the surgical tool along the tool path based on the virtual simulation.

16. The method of claim 11 , comprising:
operating the manipulator in a guided-manual mode and a semi-autonomous mode;
utilizing the effective feed rate and define the virtual constraints in the guided-manual mode; and
in response to transitioning to the semi-autonomous mode from the guided-manual mode, calculating a transition path from a current position of a tool center point of the surgical tool to a last known point of the surgical tool on the tool path before transitioning from the semi-autonomous mode.

17. The method of claim 11 , comprising:
obtaining a virtual boundary for the surgical tool with the virtual boundary being a three-dimensional tube defining the tool path; and

Assignees

• Mako Surgical Corp

Inventors

• Rohs Helmut
• Dozeman Michael Dale
• Arora Bharat
• Ferko Michael
• Roessler Patrick
• Deluca Richard Thomas
• Bowling David Gene

Classifications

• A61B34/74

  Manipulators with manual electric input means · CPC title

• A61B34/37

  Leader-follower robots (A61B34/35 takes precedence) · CPC title

• A61B2034/2046

  Tracking techniques · CPC title

• A61B34/20

  Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis · CPC title

• A61B2034/108

  Computer aided selection or customisation of medical implants or cutting guides · CPC title