Granted Patent B2

US 12,274,520 · App. 18/659,045 · Granted Apr 15, 2025

Inventors: David Gene Bowling (Los Ranchos De Albuquerque, NM); John Michael Stuart (Rio Rancho, NM); Jerry A. Culp (Kalamazoo, MI); Donald W. Malackowski (Schoolcraft, MI); José Luis Moctezuma de la Barrera (Freiburg, DE); Patrick Roessler (Merzhausen, DE); Joel N. Beer (Albuquerque, NM)

Assignee: MAKO Surgical Corp.

A61B34/30A61B17/1675A61B34/10A61B34/20A61B34/32A61B34/37A61B34/76A61B90/39A61B2018/00565A61B2018/00601A61B2034/105A61B2034/107A61B2034/2055A61B2034/2059A61B2034/2068A61B2090/3937A61B2090/3975

Abstract

Claims (62)

1. A surgical system configured to manipulate an anatomy, the surgical system comprising:

a surgical tool configured to interact with the anatomy;

a robotic manipulator configured to support and move the surgical tool; and

one or more controllers configured to:

generate a first virtual boundary delineating a first portion of the anatomy allowed to be removed by the surgical tool;

control the robotic manipulator to autonomously move the surgical tool in relation to the first virtual boundary and according to a first feed rate to remove the first portion;

generate a second virtual boundary being spaced apart from the first virtual boundary and delineating a second portion of the anatomy allowed to be removed by the surgical tool; and

control the robotic manipulator to autonomously move the surgical tool in relation to the second virtual boundary and according to a second feed rate to remove the second portion, wherein the first feed rate is different than the second feed rate.

2. The surgical system of claim 1 , wherein the first virtual boundary further delineates the first portion of the anatomy from the second portion of the anatomy such that the first virtual boundary protects the second portion from removal by the surgical tool.

3. The surgical system of claim 1 , wherein the second portion of the anatomy is located between the first virtual boundary and the second virtual boundary.

4. The surgical system of claim 1 , wherein the one or more controllers are configured to generate the first virtual boundary and the second virtual boundary relative to a target surface of the anatomy, wherein the target surface defines a planned surface of the anatomy onto which an implant is to be positioned.

5. The surgical system of claim 4 , wherein the one or more controllers are configured to

generate the first virtual boundary to be spaced apart from the target surface by a first distance; and

generate the second virtual boundary to be:

aligned with the target surface; or

spaced apart from the target surface by a second distance that is less than the first distance.

6. The surgical system of claim 1 , wherein, during removal of the first portion of the anatomy, the one or more controllers are configured to activate the second virtual boundary.

7. The surgical system of claim 1 , wherein, after removal of the first portion of the anatomy, the one or more controllers are configured to:

deactivate the first virtual boundary; and

activate the second virtual boundary.

8. The surgical system of claim 1 , wherein the one or more controllers are configured to:

control the robotic manipulator to autonomously move the surgical tool in relation to the first virtual boundary and according to the first feed rate to bulk cut the first portion; and

control the robotic manipulator to autonomously move the surgical tool in relation to the second virtual boundary and according to the second feed rate to fine cut the second portion, wherein the first feed rate is faster than the second feed rate.

9. The surgical system of claim 8 , wherein the one or more controllers are configured to:

generate a first tool path for the surgical tool to bulk cut the first portion, the first tool path defining a first frequency of path oscillations; and

generate a second tool path for the surgical tool to fine cut the second portion, the second tool path defining a second frequency of path oscillations, wherein the second frequency of path oscillations is greater than the first frequency of path oscillations.

10. The surgical system of claim 1 , wherein the one or more controllers are configured to:

control the robotic manipulator to autonomously move the surgical tool in relation to the first virtual boundary and according to the first feed rate to fine cut the first portion; and

control the robotic manipulator to autonomously move the surgical tool in relation to the second virtual boundary and according to the second feed rate to bulk cut the second portion, wherein the first feed rate is slower than the second feed rate.

11. A method of operating a surgical system for manipulating an anatomy, the surgical system including a surgical tool configured to interact with the anatomy, a robotic manipulator configured to support and move the surgical tool, and one or more controllers, the method comprising the one or more controllers performing the following:

generating a first virtual boundary delineating a first portion of the anatomy allowed to be removed by the surgical tool;

controlling the robotic manipulator for autonomously moving the surgical tool in relation to the first virtual boundary and according to a first feed rate for removing the first portion;

generating a second virtual boundary being spaced apart from the first virtual boundary and delineating a second portion of the anatomy allowed to be removed by the surgical tool; and

controlling the robotic manipulator for autonomously moving the surgical tool in relation to the second virtual boundary and according to a second feed rate for removing the second portion, wherein the first feed rate is different than the second feed rate.

12. A surgical system configured to manipulate an anatomy, the surgical system comprising:

a surgical tool configured to interact with the anatomy;

a robotic manipulator configured to support and move the surgical tool; and

one or more controllers configured to:

generate a first virtual boundary delineating a first portion of the anatomy allowed to be removed by the surgical tool;

control the robotic manipulator to autonomously move the surgical tool in relation to the first virtual boundary and according to a first tool path defining a first frequency of path oscillations to remove the first portion;

generate a second virtual boundary being spaced apart from the first virtual boundary and delineating a second portion of the anatomy allowed to be removed by the surgical tool; and

control the robotic manipulator to autonomously move the surgical tool in relation to the second virtual boundary and according to a second tool path defining a second frequency of path oscillations to remove the second portion, wherein the first frequency of path oscillations is different than the second frequency of path oscillations.

13. The surgical system of claim 12 , wherein the first virtual boundary further delineates the first portion of the anatomy from the second portion of the anatomy such that the first virtual boundary protects the second portion from removal by the surgical tool.

14. The surgical system of claim 12 , wherein the second portion of the anatomy is located between the first virtual boundary and the second virtual boundary.

15. The surgical system of claim 12 , wherein the one or more controllers are configured to concurrently activate the first virtual boundary and the second virtual boundary during removal of the first portion of the anatomy.

16. The surgical system of claim 12 , wherein the one or more controllers are configured to generate the first virtual boundary and the second virtual boundary relative to a target surface of the anatomy, wherein the target surface defines a planned surface of the anatomy onto which an implant is to be positioned.

17. The surgical system of claim 16 , wherein the one or more controllers are configured to

generate the first virtual boundary to be spaced apart from the target surface by a first distance; and

generate the second virtual boundary to be:

aligned with the target surface; or

spaced apart from the target surface by a second distance that is less than the first distance.

18. The surgical system of claim 17 , wherein the one or more controllers are configured to:

control the robotic manipulator to autonomously move the surgical tool in relation to the first virtual boundary and according to the first tool path defining the first frequency of path oscillations to bulk cut the first portion; and

control the robotic manipulator to autonomously move the surgical tool in relation to the second virtual boundary and according to the second tool path defining the second frequency of path oscillations to fine cut the second portion, wherein the first frequency of path oscillations is less than the second frequency of path oscillations.

19. The surgical system of claim 17 , wherein the one or more controllers are configured to:

control the robotic manipulator to autonomously move the surgical tool in relation to the first virtual boundary and according to the first tool path defining the first frequency of path oscillations to fine cut the first portion; and

control the robotic manipulator to autonomously move the surgical tool in relation to the second virtual boundary and according to the second tool path defining the second frequency of path oscillations to bulk cut the second portion, wherein the first frequency of path oscillations is greater than the second frequency of path oscillations.

20. A method of operating a surgical system for manipulating an anatomy, the surgical system including a surgical tool configured to interact with the anatomy, a robotic manipulator configured to support and move the surgical tool, and one or more controllers, the method comprising the one or more controllers performing the following:

generating a first virtual boundary delineating a first portion of the anatomy allowed to be removed by the surgical tool;

controlling the robotic manipulator for autonomously moving the surgical tool in relation to the first virtual boundary and according to a first tool path defining a first frequency of path oscillations for removing the first portion;

generating a second virtual boundary being spaced apart from the first virtual boundary and delineating a second portion of the anatomy allowed to be removed by the surgical tool; and

controlling the robotic manipulator for autonomously moving the surgical tool in relation to the second virtual boundary and according to a second tool path defining a second frequency of path oscillations for removing the second portion, wherein the first frequency of path oscillations is different than the second frequency of path oscillations.

Assignments (3)

Continuity (7)

References Cited (72)