System and method for surgical tool insertion using multiaxis force and moment feedback

1. A method for detecting expected movement of a surgical instrument of a surgical robot system having at least one arm and an end effector adapted to attach to the arm, the end effector having a guide tube through which the surgical instrument is inserted, said method comprising:

monitoring one or more forces associated with an insertion force applied to the surgical instrument relative to the arm through one or more sensors;

comparing the monitored forces to a predetermined range or threshold expected for the surgical procedure;

providing a notification, via the robot system, upon detecting that the monitored forces fall outside of the predetermined range or threshold;

monitoring a bone movement of the patient caused by a lateral force of the surgical instrument through a dynamic reference array attached to the patient; and

automatically adjusting the guide tube by the arm to offset the bone movement based on the monitoring of the bone movement.

2. The method of claim 1 , wherein the surgical instrument is configured with a cutting tip.

3. The method of claim 1 , wherein the one or more sensors are positioned on the surgical instrument for determining forces applied on the surgical instrument when the surgical instrument contacts bone.

4. The method of claim 1 , wherein the sensors measure deflection of the surgical instrument when the surgical instrument contacts bone.

5. The method of claim 1 , wherein the robot system determines whether skiving has occurred based on the forces applied on the surgical instrument.

6. The method of claim 1 , wherein the step of monitoring includes monitoring the one or more forces through the sensors positioned on the arm or end effector.

7. The method of claim 1 , wherein the one or more forces are measured in at least one of an x, y, or z direction relative to the arm.

8. The method of claim 1 , wherein the surgical instrument is a cutting tool.

9. The method of claim 1 , wherein the measured force is a lateral force applied on the surgical instrument.

10. A surgical robot system for detecting the expected movement of a surgical instrument associated with the robot system, said robot system comprising:

a robot base;

a robot arm connected to and in electronic communication with the robot base;

an end-effector adapted to connect to the robot arm and be in electronic communication with the robot base, wherein the end-effector includes a guide tube, and

wherein one or more sensors are positioned on a surgical instrument coupled to the end-effector, the one or more sensors are configured to measure forces associated with the insertion force of the surgical instrument disposed in the guide tube relative to the robot arm,

wherein the robot base is configured to receive the measured forces and indicate when the measured forces are outside of an expected range for the measured forces,

wherein the robot base is configured to monitor a bone movement of the patient caused by a lateral force of the surgical instrument through a dynamic reference array attached to the patient and

wherein the robot base is configured to automatically adjust the guide tube by the arm to offset the bone movement based on the monitoring of the bone movement.

11. The system of claim 10 , wherein the robot system is configured to provide a notification on a display associated with the robot system indicating skiving forces applied on the surgical instrument.

12. The system of claim 11 , wherein the skiving force is a lateral force applied to the surgical instrument.

13. The system of claim 12 , wherein the surgical instrument includes a tapered tip for cutting into bone.

14. The system of claim 10 , wherein the one or more sensors are positioned on the surgical instrument and the sensors monitor a deflection of the tip of the surgical instrument.

15. The system of claim 10 , wherein the robot is configured to use a neural network for calculating the deflection of the surgical instrument.

16. The system of claim 10 , wherein the notification indicates that the surgical instrument has reached a maximum depth based on the position of the surgical instrument inside the patient.

17. The system of claim 10 , wherein the surgical instrument is one of a drill, an awl, a tap, and a screwdriver.

18. A surgical robot system for detecting the expected movement of a surgical instrument associated with the robot system, said robot system comprising:

a robot base;

a robot arm connected to and in electronic communication with the robot base;

an end-effector connected to the robot arm and in electronic communication with the robot base, wherein the end-effector comprises a guide tube and is configured to receive a surgical instrument, and

wherein one or more sensors are positioned on the surgical instrument coupled to the end-effector, the one or more sensors configured to measure forces associated with the insertion force of a surgical instrument disposed in the guide tube relative to the robot arm,

wherein the one or more sensors measure skiving forces applied to the surgical instrument,

wherein the robot base is configured to monitor a bone movement of the patient caused by a lateral force of the surgical instrument through a dynamic reference array attached to the patient; and

wherein the robot base is configured to automatically adjust the guide tube by the arm to offset the bone movement based on the monitoring of the bone movement.

19. The method of claim 1 , prior to the step of monitoring, further comprising automatically orienting the guide tube by the arm to allow the surgical instrument to reach a desired anatomical target within a patient body.