Robotic systems and methods for controlling a tool to remove material from a workpiece

Patent metadata

Field	Value
Publication number	US-12220192-B2
Application number	US-202318385994-A
Country	US
Kind code	B2
Filing date	Nov 1, 2023
Priority date	Jul 1, 2015
Publication date	Feb 11, 2025
Grant date	Feb 11, 2025

Abstract

A surgical system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. A navigation system includes a localizer, a first tracker coupled to the robotic manipulator or the tool, and a second tracker coupled to a workpiece. Controller(s) determine, from the navigation system, a pose of the tool relative to the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a first portion from the workpiece with the tool and sense interaction between the tool and the workpiece during removal of the first portion to detect a density of the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a second portion from the workpiece with the tool, wherein a cutting depth for the second portion is based, at least in part, on the detected density.

First claim

What is claimed is:

1. A surgical system comprising:
a robotic manipulator including a plurality of links and joints;
a tool coupled to the robotic manipulator and the tool being configured to remove material from a workpiece;
a navigation system comprising a localizer, a first tracker coupled to the robotic manipulator or the tool, and a second tracker coupled to the workpiece, and wherein the localizer is configured to detect the first and second trackers; and
one or more controllers coupled to the robotic manipulator and the navigation system, the one or more controllers configured to:
determine, from the navigation system, a pose of the tool relative to the workpiece;
control the robotic manipulator to facilitate removal of a first portion from the workpiece with the tool at a first cutting depth;
sense interaction between the tool and the workpiece during removal of the first portion to detect a density of the workpiece;
control the robotic manipulator to facilitate removal of a second portion from the workpiece with the tool at a second cutting depth, wherein the second cutting depth is based, at least in part, on the detected density and is different from the first cutting depth; and
modify operation of the tool based, at least in part, on the detected density.

2. The surgical system of claim 1 , wherein the one or more controllers modify operation of the tool by being configured to modify one or both of: a feed rate of the tool and a cutting speed of the tool.

3. The surgical system of claim 1 , wherein:
the robotic manipulator comprises a force/torque sensor to detect forces/torques experienced by the tool; and
the one or more controllers further sense interaction between the tool and the workpiece by being configured to determine forces/torques experienced by the tool during interaction with the workpiece.

4. The surgical system of claim 1 , wherein the one or more controllers are configured to:
obtain a density distribution of the workpiece from a pre-operative model of the workpiece;
evaluate the density distribution of the workpiece to identify a first density classification for the first portion of the workpiece; and
control the robotic manipulator to facilitate removal of the first portion from the workpiece based, at least in part, on the first density classification.

5. The surgical system of claim 1 , wherein the one or more controllers are configured to control the robotic manipulator in a manual mode of operation to guide a user to facilitate removal of the first portion with the tool.

6. The surgical system of claim 1 , wherein the tool is further defined as a saw blade.

7. The surgical system of claim 1 , wherein the first portion and the second portion are removed to receive an implant.

8. The surgical system of claim 1 , wherein the density is indictive of a bone mineral density.

9. A method of operating a surgical system, the surgical system including a robotic manipulator including a plurality of links and joints, a tool coupled to the robotic manipulator and the tool being configured to remove material from a workpiece, a navigation system comprising a localizer, a first tracker coupled to the robotic manipulator or the tool, and a second tracker coupled to the workpiece, and wherein the localizer is configured to detect the first and second trackers, and one or more controllers coupled to the robotic manipulator and the navigation system, the method comprising the one or more controllers performing the following:
determining, from the navigation system, a pose of the tool relative to the workpiece;
controlling the robotic manipulator to facilitate removing of a first portion from the workpiece with the tool at a first cutting depth;
sensing interaction between the tool and the workpiece during removal of the first portion for detecting a density of the workpiece;
controlling the robotic manipulator to facilitate removing of a second portion from the workpiece with the tool at a second cutting depth, wherein the second cutting depth, is based, at least in part, on the detected density and is different from the first cutting depth; and
modifying operation of the tool based, at least in part, on the detected density.

10. The method of claim 9 , comprising the one or more controllers modifying operation of the tool by further modify one or both of: a feed rate of the tool and a cutting speed of the tool.

11. The method of claim 9 , wherein the robotic manipulator comprises a force/torque sensor to detect forces/torques experienced by the tool, and comprising the one or more controllers:
sensing interaction between the tool and the workpiece by determining forces/torques experienced by the tool interacting with the workpiece.

12. The method of claim 9 , comprising the one or more controllers:
obtaining a density distribution of the workpiece from a pre-operative model of the workpiece;
evaluating the density distribution of the workpiece for identifying a first density classification for the first portion of the workpiece; and
controlling the robotic manipulator to facilitate removing of the first portion from the workpiece based, at least in part, on the first density classification.

13. The method of claim 9 , comprising the one or more controllers controlling the robotic manipulator in a manual mode of operation to guide a user to facilitate removal of the first portion with the tool.

14. The method of claim 9 , wherein the tool is further defined as a saw blade.

15. The method of claim 9 , wherein the first portion and the second portion are removed to receive an implant.

16. The method of claim 9 , wherein the density is indictive of a bone mineral density.

Assignees

• Mako Surgical Corp

Inventors

• Moctezuma De La Barrera José Luis
• Bowling David Gene
• Malackowski Donald W
• Roessler Patrick
• Beer Joel N

Classifications

• A61B2090/3945

  Active visible markers, e.g. light emitting diodes · CPC title

• A61B90/39

  Markers, e.g. radio-opaque or breast lesions markers · CPC title

• A61B34/32

  operating autonomously · CPC title

• A61B2034/2063

  Acoustic tracking systems, e.g. using ultrasound · CPC title

• A61B2034/2057

  Details of tracking cameras · CPC title