Methods, devices and systems for computer-assisted robotic surgery

Abstract

Methods, devices and systems for the planning and execution of computer-assisted robotic surgery are provided. The methods include methods to collect information about bones and prostheses, use the information to create virtual models and simulations, optionally receive input based on user discretion in generating the cut file, and to generate instruction for the execution of cut paths during the surgery. The system and devices include computers and peripherals and set-ups to link the components together into functional systems.

1 . A method for generating a user-specified cut-file for execution by a surgical robot, the method comprising:
 providing a computer system comprising one or more central processing units (CPUs) and storage of machine-readable information;   storing a cut-file as part of the machine-readable information, said cut file comprising instructions for execution by the surgical robot, the instructions specifying at least one cut path configured to remove a volume of material to receive at least a portion of a prosthesis;   providing display data on a display device, the display data including portions of said machine readable information of at least one of: image data of a bone, a model of the bone, a model of the prosthesis, a model of the volume of material to be removed from the bone, a simulation of the model of the bone with the model of the prosthesis, a simulation of the model of the bone with the model of the volume of the-material to be removed, or a simulation of the model of the volume of the material to be removed with the model of the prosthesis;   receiving a user-specified input entered via a user interface device to modify said cut-file to create a user-specified cut file, wherein the user-specified input modifies the instructions contained in the cut file to at least one of: a depth of a cut path, a length of a cut path, a diameter of a cut path, a region of bone to be cut, a number of cut paths, or a shape of a cut path; and   providing at least one safety control that limits the user-specified input to modify the instructions in the cut-file.   
     
     
         2 . The method of  claim 1  wherein the surgical robot executes at least one modified instruction in the user-specified cut-file to remove the material and wherein said computer system is further configured to pause the surgical robot to permit the user to further modify the input to modify the user-specified cut-file. 
     
     
         3 . The method of  claim 1  wherein the safety control comprises generating a bounding volume as the limit and based on the model of the prosthesis, comparing: (i) the bounding volume; and (ii) the volume of the material is bone to be removed as specified by modify the user-specified cut file; and warning a user if (ii) exceeds (i). 
     
     
         4 . The method of  claim 1  wherein the one or more CPUs are further configured to receive information from the surgical robot. 
     
     
         5 . A method of  claim 1  wherein the safety control limits the user-specified input to a pre-populated library of options. 
     
     
         6 . The method of  claim 1  wherein the cut-file is a pre-existing cut file generated from one or more of a model of the bone and a model of the prosthesis. 
     
     
         7 . The method of  claim 1  further comprising robotically removing a portion of the material prior to the receiving a user-specified input step. 
     
     
         8 . The method of  claim 7  further comprising pausing the surgical robot before the receiving a user-specified input step. 
     
     
         9 . The method of  claim 5  wherein the pre-populated library of options is a drop-down menu. 
     
     
         10 . The method of  claim 5  wherein the safety control warns the user if a proposed modification to the cut-files exceeds a predefined safety limit. 
     
     
         11 . The method of  claim 1  further comprising execution by the surgical robot of the modified instructions in the user-specified cut-file to remove material from the bone. 
     
     
         12 . The method of  claim 1  wherein the user-specified input to modify said cut-file is received pre-operatively. 
     
     
         13 . The method of  claim 12  wherein the safety control is provided pre-operatively. 
     
     
         14 . A surgical system to prepare a bone according to a user-specified cut-file to receive a prosthesis according to the method of  claim 1 , the system comprising:
 a planning computer comprising:
 an input device to receive image data of the bone; 
 a display device to provide data for at least one of: a model of the bone, a model of a prosthesis, a model of a volume of material to be removed from the bone, a simulation of the model of the bone with the model of the prosthesis, a simulation of the model of the bone with the model of the volume of bone to be removed, and a simulation of the model of the volume of bone to be removed with the model of the prosthesis; 
 a user-interface to receive user-specified input to modify a cut-file according to  claim 1  or to make modifications thereto of at least one of: precut, depth of cut, length of cut, diameter of cut path, regions to be cut, number of cut paths, shapes of cut paths, and types and sizes of cutters to be used so as to create a user-specified cut-file; and 
 an output device to provide said user-specified cut-file to a surgical robot; and 
   said robot to remove material from the bone according to said user-specified cut-file.   
     
     
         15 . The system of  claim 14  wherein said user-interface further comprises a stop control for said robot to pause removal of the material while said user-specified cut-file is generated. 
     
     
         16 . The system of  claim 14  wherein said user-interface further comprises a warning triggered when a volume of bone to be removed as specified by said user-specified cut-file exceeds a preselected bounding volume. 
     
     
         17 . The system of  claim 14  wherein said user-interface further comprises a phone line or Internet service for input from an off-site user.