Systems and methods for controlling robotic movement of a tool based on a virtual boundary

Patent metadata

Field	Value
Publication number	US-12564455-B2
Application number	US-202418589509-A
Country	US
Kind code	B2
Filing date	Feb 28, 2024
Priority date	Mar 27, 2020
Publication date	Mar 3, 2026
Grant date	Mar 3, 2026

Abstract

Surgical systems and methods involve a manipulator that supports a tool and a control system to control operation of the manipulator and movement of the tool based on a relationship between the tool and a first virtual boundary. The control system operates to maintain compliance of the tool with the first virtual boundary. While maintaining compliance of the tool with the first virtual boundary, the control system enables a user to select a second virtual boundary. In response to user selection of the second virtual boundary, the control system determines whether the tool is in compliance with the second virtual boundary.

First claim

What is claimed is:

1 . A surgical system comprising:
a tool; a manipulator to support the tool; a virtual boundary selector comprising a user input; and a control system to control operation of the manipulator and movement of the tool based on a relationship between the tool and a first virtual boundary, wherein the control system is configured to:
operate to maintain compliance of the tool with the first virtual boundary;
while maintaining compliance of the tool with the first virtual boundary, enable a user to manually select a second virtual boundary with the user input of the virtual boundary selector, wherein the second virtual boundary is further defined as a keep-in boundary that defines a volume within which the tool should be kept;
in response to user selection of the second virtual boundary, evaluate whether activation of the second virtual boundary would cause the tool to be positioned outside the volume of the second virtual boundary; and
generate feedback to the user in response to determination that activation of the second virtual boundary would cause the tool to be positioned outside the volume of the second virtual boundary.

2 . The surgical system of claim 1 , wherein, in response to determination that activation of the second virtual boundary would cause the tool to be positioned outside the volume of the second virtual boundary, the control system is configured to:
maintain the first virtual boundary as being active; and continue to control operation of the manipulator and movement of the tool based on the relationship between the tool and the first virtual boundary.

3 . The surgical system of claim 2 , wherein the control system is configured to generate user feedback using one or more of: audible feedback, visual feedback, and haptic feedback boundary.

4 . The surgical system of claim 1 , wherein the user input has a first input state and a second input state, wherein the control system is configured to enable the user to manually select the second virtual boundary in response to the user input being in the first input state.

5 . The surgical system of claim 2 , wherein the user input is located on the tool and configured such that the user input is actuated by the user to place the user input in the first input state and the user input is released by the user to place the user input in the second input state.

6 . The surgical system of claim 4 , wherein:
in response to the user input being in the first input state and the first virtual boundary being active, the control system is configured to generate first boundary constraints to limit relative movement between the tool and the first virtual boundary.

7 . The surgical system of claim 6 , wherein the control system is configured to:
calculate a constraint force adapted to maintain the tool in compliance with the first virtual boundary based on the first boundary constraints; simulate dynamics of the tool in a virtual simulation based on the constraint force, and to output a commanded pose; and command the manipulator to move the tool based on the commanded pose.

8 . The surgical system of claim 1 , wherein the control system is configured to enable the user to toggle between the first and second virtual boundaries, toggle sequentially from among a plurality of virtual boundaries, or select from a list of virtual boundaries.

9 . The surgical system of claim 1 , wherein the tool includes a tool drive and the control system is configured to continue operation of the tool drive in response to user selection of the second virtual boundary.

10 . The surgical system of claim 1 , wherein one or both of the first virtual boundary and second virtual boundary are associated with a target site.

11 . The surgical system of claim 1 , wherein the first virtual boundary is further defined as a keep-in boundary that defines a volume within which the tool should be kept.

12 . The surgical system of claim 11 , wherein a portion of the volume defined by the first virtual boundary overlaps a portion of the volume defined by the second virtual boundary.

13 . A method of operating a surgical system including a tool, a manipulator to support the tool, a virtual boundary selector including a user input, and a control system to control operation of the manipulator and movement of the tool based on a relationship between the tool and a first virtual boundary, the method comprising the control system;
operating to maintain compliance of the tool with the first virtual boundary; while maintaining compliance of the tool with the first virtual boundary, enabling a user to manually select a second virtual boundary with the user input of the virtual boundary selector, wherein the second virtual boundary is further defined as a keep-in boundary that defines a volume within which the tool should be kept; in response to user selecting the second virtual boundary, evaluating whether activation of the second virtual boundary would cause the tool to be positioned outside the volume of the second virtual boundary; and generating feedback to the user in response to determining that activation of the second virtual boundary would cause the tool to be positioned outside the volume of the second virtual boundary.

14 . The method of claim 13 , wherein, in response to determining that activation of the second virtual boundary would cause the tool to be positioned outside the volume of the second virtual boundary, the method comprises the control system:
maintaining the first virtual boundary as being active; and continuing to control operation of the manipulator and movement of the tool based on the relationship between the tool and the first virtual boundary.

15 . The method of claim 14 , comprising the control system:
generating user feedback using one or more of: audible feedback, visual feedback, and haptic feedback.

16 . The method of claim 13 , wherein the user input has a first input state and a second input state, the method comprising the control system:
enabling the user to select the second virtual boundary in response to the user input being in the first input state.

17 . The method of claim 16 , comprising the control system:
in response to the user input being in the first input state and the first virtual boundary being active, generating first boundary constraints to limit relative movement between the tool and the first virtual boundary.

18 . The method of claim 17 , comprising the control system:
calculating a constraint force for maintaining the tool in compliance with the first virtual boundary based on the first boundary constraints; simulating dynamics of the tool in a virtual simulation based on the constraint force, and for outputting a commanded pose; and commanding the manipulator to move the tool based on the commanded pose.

19 . The method of claim 13 , comprising the control system enabling the user to:
toggle between the first and second virtual boundaries, toggle sequentially from among a plurality of virtual boundaries, or select from a list of virtual boundaries.

20 . A method of controlling a surgical manipulator that supports a tool, method comprising:
controlling the surgical manipulator and movement of the tool for maintaining compliance of the tool with a first virtual boundary based on a relationship between the tool and the first virtual boundary; while maintaining compliance of the tool with the first virtual boundary, enabling a user to manually select a second vi

Assignees

• Mako Surgical Corp

Inventors

• Dozeman Michael Dale
• Roessler Patrick
• Garcia Gregory
• Dunn Jeremy L

Classifications

• A61B34/76

  Manipulators having means for providing feel, e.g. force or tactile feedback · CPC title

• A61B34/32 Primary

  operating autonomously · CPC title

• A61B34/20

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

• A61B2090/064

  for measuring force, pressure or mechanical tension · CPC title

• A61B2034/2055

  Optical tracking systems · CPC title