Granted Patent B2

US 12,558,132 · App. 17/214,392 · Granted Feb 24, 2026

Inventors: David Gene Bowling (Los Ranchos De Albuquerque, NM); Bojan Gospavic (Boca Raton, FL); Christopher W. Jones (Kokomo, IN); Greg McEwan (Mattawan, MI); Lucas Gsellman (Kalamazoo, MI); Kana Nishimura (Baden-Baden, DE); Weiyi Ding (Northville, MI)

Assignee: MAKO Surgical Corp.

A61B17/7082A61B34/10A61B34/25A61B34/30A61B34/76A61B2034/104A61B2034/107

Abstract

Claims (121)

1 . A robotic surgical system comprising:

a robotic manipulator;

a surgical tool coupled to the robotic manipulator and configured to interface with a screw and to rotate the screw about a rotational axis;

a hand-held pendant remotely spaced apart from the robotic manipulator and the surgical tool and comprising an actuator and a rotational interface coupled to the actuator and the rotational interface being configured to be manually manipulatable by a hand of an operator;

a navigation system configured to track a position of a target site;

a memory comprising computer-readable instructions; and

one or more controllers coupled to the memory, the robotic manipulator, the hand-held pendant and the navigation system, and the one or more controllers configured to implement the computer-readable instructions to:

control movement of the robotic manipulator to maintain the rotational axis of the surgical tool along a planned trajectory with respect to the target site based on the tracked position of the target site;

obtain a known thread geometry of the screw;

autonomously control the surgical tool to rotate the screw at a rotational rate about the rotational axis and to linearly advance the screw at an advancement rate along the planned trajectory, wherein the rotational rate and the advancement rate are predetermined and proportional to the known thread geometry of the screw;

obtain a measurement indicative of a present interaction between the screw and the target site; and

based on the obtained measurement, control the actuator of the hand-held pendant to enable the rotational interface to emulate the present interaction between the screw and the target site.

2 . The robotic surgical system of claim 1 , wherein the one or more controllers further emulate the present interaction between the screw and the target site by being configured to provide a resistive force to the actuator to adjust a force required to rotate the rotational interface by the hand of the operator, wherein the force required to rotate the rotational interface reflects a present force required to rotate the screw relative to the target site.

3 . The robotic surgical system of claim 2 , wherein the one or more controllers are further configured to initiate an autonomous check mode, wherein the rotational interface is manually manipulatable:

according to the adjusted force to provide the operator with haptic feedback reflecting the present force required to rotate the screw relative to the target site; and

without an ability to control the surgical tool to rotate the screw; and

wherein, in response to a condition or a command, the one or more controllers are further configured to:

initiate the autonomous check mode concurrent to autonomously controlling the surgical tool;

initiate the autonomous check mode after stopping or pausing autonomously controlling the surgical tool to stop rotation of the screw; and

resume autonomously controlling the surgical tool to rotate the screw after autonomous control of the surgical tool is stopped or paused to stop rotation of the screw.

4 . The robotic surgical system of claim 2 , wherein:

the one or more controllers are further configured to initiate a manual control mode, wherein the rotational interface is manually manipulatable with an ability to control one of the rotational rate of the screw or the advancement rate of the screw based on the operator manually manipulating the rotational interface;

the one or more controllers are configured to control the surgical tool to rotate the screw at the rotational rate about the rotational axis and to linearly advance the screw at the advancement rate along the planned trajectory in response to the rotational interface being manually manipulated to control one of the rotational rate of the screw or the advancement rate of the screw; and

the rotational interface is manually manipulatable according to the adjusted force to provide the operator with haptic feedback reflecting the present force required to rotate the screw relative to the target site; and

wherein, in response to a condition or a command, the one or more controllers are further configured to:

initiate the manual control mode after stopping or pausing autonomously controlling the surgical tool to stop rotation of the screw; and

switch from the manual control mode to resuming autonomously controlling the surgical tool to rotate the screw.

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

determine that a condition exists during control of the screw; and

in response to determining that the condition exists, provide the operator with haptic feedback regarding the condition by controlling the actuator of the hand-held pendant to prevent an ability to rotate the rotational interface.

6 . The robotic surgical system of claim 1 , wherein the navigation system is further configured to:

determine a position of the screw relative to an anatomical model of the target site that is registered to the target site, the navigation system including predetermined data indicative of expected interactions between the screw and the anatomical model at a plurality of positions of the screw relative to the anatomical model; and

obtain the measurement indicative of the present interaction between the screw and the target site based on the determined position of the screw relative to the anatomical model and the predetermined data.

7 . The robotic surgical system of claim 1 , wherein the rotational rate and the advancement rate are proportional to the known thread geometry according to a relationship

δθ

δ

⁢

t

=

δ

⁢

D

δ

⁢

t

⋆

Pitch

2

⁢

π

,

wherein

δθ

δ

⁢

t

is the rotational rate,

δ

⁢

D

δ

⁢

t

is the advancement rate, and Pitch is a number of threads per unit length of the screw.

8 . The robotic surgical system of claim 1 , wherein the one or more controllers are further configured to receive an input from the operator to selectively adjust one or more of:

a resistive force provided to the actuator; and

a sensitivity of the rotational interface's ability to control the surgical tool to rotate the screw.

9 . The robotic surgical system of claim 1 , wherein the robotic surgical system further comprises a display, and wherein the one or more controllers are further configured to initiate a simulated autonomous check mode, wherein the one or more controllers are configured to:

simulate autonomously controlling the surgical tool by rotating the screw at the rotational rate about the rotational axis and linearly advancing the screw at the advancement rate along the planned trajectory;

display the simulated autonomous control of the surgical tool on the display;

obtain a simulated present interaction between the screw and the target site; and

based on the simulated present interaction, control the actuator of the hand-held pendant to enable the rotational interface to emulate the simulated present interaction between the screw and the target site; and

wherein the one or more controllers are further configured to initiate the simulated autonomous check mode prior to autonomously controlling the surgical tool.

10 . The robotic surgical system of claim 1 , wherein the robotic surgical system further comprises a display, and wherein the one or more controllers are further configured to initiate a simulated manual control mode, wherein the one or more controllers are configured to:

receive control input in response to the rotational interface being manually manipulated to control one of the rotational rate of the screw or the advancement rate of the screw;

simulate manually controlling the surgical tool by rotating the screw at the rotational rate about the rotational axis and linearly advancing the screw at the advancement rate along the planned trajectory in response to the control input;

display the simulated manual control of the surgical tool on the display;

obtain a simulated present interaction between the screw and the target site; and

based on the simulated present interaction, control the actuator of the hand-held pendant to enable the rotational interface to emulate the simulated present interaction between the screw and the target site; and

wherein, in response to a condition or a command, the one or more controllers are further configured to initiate the simulated manual control mode after stopping or pausing autonomously controlling the surgical tool to stop rotation of the screw.

11 . A method of controlling a robotic surgical system, the robotic surgical system including a robotic manipulator, a surgical tool coupled to the robotic manipulator and configured to interface with a screw and to rotate the screw about a rotational axis, a hand-held pendant remotely spaced apart from the robotic manipulator and the surgical tool and including an actuator and a rotational interface coupled to the actuator and configured to be manually manipulatable by a hand of an operator, a navigation system configured to track a position of a target site, a memory including computer-readable instructions, and one or more controllers coupled to the memory, the robotic manipulator, the hand-held pendant, and the navigation system, the method comprising:

controlling, with the one or more controllers, movement of the robotic manipulator to maintain the rotational axis of the surgical tool along a planned trajectory with respect to the target site based on the tracked position of the target site;

implementing, with the one or more controllers, the computer-readable instructions to obtain a known thread geometry of the screw;

autonomously controlling, with the one or more controllers, the surgical tool to rotate the screw at a rotational rate about the rotational axis and to linearly advance the screw at an advancement rate along the planned trajectory, wherein the rotational rate and the advancement rate are predetermined and proportional to the known thread geometry of the screw;

obtaining, with the one or more controllers, a measurement indicative of a present interaction between the screw and the target site; and

controlling, with the one or more controllers and based on the obtained measurement, the actuator of the hand-held pendant to enable the rotational interface to emulate the present interaction between the screw and the target site.

12 . The method of claim 11 , wherein controlling the actuator of the hand-held pendant to enable the rotational interface to emulate the present interaction between the screw and the target site based on the obtained measurement includes providing, with the one or more controllers, a resistive force to the actuator to adjust a force required to rotate the rotational interface by the hand of the operator, wherein the force required to rotate the rotational interface reflects a present force required to rotate the screw relative to the target site.

13 . The method of claim 12 , further comprising:

initiating, with the one or more controllers, an autonomous check mode, wherein the rotational interface is manually manipulatable:

according to the adjusted force to provide the operator with haptic feedback reflecting the present force required to rotate the screw relative to the target site; and

without an ability to control the surgical tool to rotate the screw; and

initiating, with the one or more controllers, the autonomous check mode concurrent to autonomously controlling the surgical tool in response to a condition or a command;

initiating, with the one or more controllers, the autonomous check mode after stopping or pausing autonomously controlling the surgical tool to stop rotation of the screw in response to a condition or a command; and

resuming, with the one or more controllers, autonomously controlling the surgical tool to rotate the screw after autonomous control of the surgical tool is stopped or paused to stop rotation of the screw and in response to a condition or a command.

14 . The method of claim 12 , further comprising:

initiating, with the one or more controllers, a manual control mode, wherein the rotational interface is manually manipulatable with an ability to control one of the rotational rate of the screw or the advancement rate of the screw based on the operator manually manipulating the rotational interface; and

controlling, with the one or more controllers, the surgical tool to rotate the screw at the rotational rate about the rotational axis and to linearly advance the screw at the advancement rate along the planned trajectory in response to the rotational interface being manually manipulated to control one of the rotational rate of the screw or the advancement rate of the screw; and

wherein the rotational interface is manually manipulatable according to the adjusted force to provide the operator with haptic feedback reflecting the present force required to rotate the screw relative to the target site.

15 . The method of claim 14 , further comprising:

initiating, with the one or more controllers, the manual control mode after stopping or pausing autonomously controlling the surgical tool to stop rotation of the screw in response to a condition or a command; and

switching, with the one or more controllers, from the manual control mode to resuming autonomously controlling the surgical tool to rotate the screw in response to a condition or a command.

16 . The method of claim 14 , further comprising:

determining, with the one or more controllers, that a condition exists during control of the screw; and

providing, with the one or more controllers, haptic feedback regarding the condition by controlling the actuator of the hand-held pendant to prevent an ability to rotate the rotational interface in response to determining that the condition exists.

17 . The method of claim 11 , further comprising receiving, with the one or more controllers, an input from the operator to selectively adjust one or more of:

a resistive force provided to the actuator; and

a sensitivity of the rotational interface's ability to control the surgical tool to rotate the screw.

18 . The method of claim 11 , wherein the robotic surgical system further includes a display, the method further comprising:

initiating, with the one or more controllers, a simulated autonomous check mode comprising the one or more controllers:

simulating autonomously controlling the surgical tool by rotating the screw at the rotational rate about the rotational axis and linearly advancing the screw at the advancement rate along the planned trajectory;

displaying the simulated autonomous control of the surgical tool on the display;

obtaining a simulated present interaction between the screw and the target site; and

based on the simulated present interaction, controlling the actuator of the hand-held pendant to enable the rotational interface to emulate the simulated present interaction between the screw and the target site; and

initiating, with the one or more controllers, the simulated autonomous check mode prior to autonomously controlling the surgical tool.

19 . The method of claim 11 , wherein the robotic surgical system further includes a display, the method further comprising initiating, with the one or more controllers, a simulated manual control mode comprising the one or more controllers:

receiving control input in response to the rotational interface being manually manipulated to control one of the rotational rate of the screw or the advancement rate of the screw;

simulating manually controlling the surgical tool by rotating the screw at the rotational rate about the rotational axis and linearly advancing the screw at the advancement rate along the planned trajectory in response to the control input;

displaying the simulated manual control of the surgical tool on the display;

obtaining a simulated present interaction between the screw and the target site;

based on the simulated present interaction, controlling the actuator of the hand-held pendant to enable the rotational interface to emulate the simulated present interaction between the screw and the target site; and

initiating, with the one or more controllers, the simulated manual control mode after stopping or pausing autonomously controlling the surgical tool to stop rotation of the screw in response to a condition or a command.

Assignments (3)

Continuity (2)

References Cited (400)