Abstract: Surgical systems and methods of operating the same involve controlling a robotic manipulator to move a cutting instrument to cut away material from a bone at a surgical site. A machine vision system uses a vision camera to detect an object at, or in proximity to, the surgical site. A control system associates a virtual boundary with the detected object and controls the robotic manipulator to move the cutting instrument based on the virtual boundary such that the cutting instrument avoids the detected object. In one example, the control system modifies a tool path of the cutting instrument based on the virtual boundary to avoid the detected object. Additionally, or alternatively, the control system can automatically adjust an orientation of the cutting instrument based on the virtual boundary to avoid the detected object.

Abstract: A surgical system, method, and non-transitory computer readable medium involving a robotic manipulator configured to move a surgical instrument relative to virtual boundaries. A navigation system tracks each of a first object, a second object, and the surgical instrument. The first object is moveable relative to the second object. One or more controllers associate a first virtual boundary with the first object and associate a second virtual boundary with the second object. The first virtual boundary is moveable in relation to the second virtual boundary. The controller(s) control the robotic manipulator in relation to the first virtual boundary to facilitate interaction of the surgical instrument with the first object. The controller(s) control the robotic manipulator in relation to the second virtual boundary to avoid interaction of the surgical instrument with the second object.

Abstract: A surgical system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. A navigation system includes a localizer, a first tracker coupled to the robotic manipulator or the tool, and a second tracker coupled to a workpiece. Controller(s) determine, from the navigation system, a pose of the tool relative to the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a first portion from the workpiece with the tool and sense interaction between the tool and the workpiece during removal of the first portion to detect a density of the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a second portion from the workpiece with the tool, wherein a cutting depth for the second portion is based, at least in part, on the detected density.

Abstract: A sterile drape assembly for a surgical robot including a robotic arm with a plurality of links and a plurality of joints. The sterile drape assembly includes a surgical drape adapted to be disposed over the robotic arm and a drape belt configured to be secured to the surgical drape. The drape belt has at least one optical tracking element that moves with the drape belt as the drape belt is secured to the surgical drape.

Abstract: A surgical robotic system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. Controller(s) generate a first tool path to remove a first portion of material from the bone and control the manipulator to position the tool for movement along the first tool path to remove the first portion. The controller(s) sense interaction between the tool and the bone during movement of the tool along the first tool path and generate a second tool path to remove a second portion of material from the bone. Generation of the second tool path is based, at least in part, on the sensed interaction between the tool and the bone during movement along the first tool path. The controller(s) control the manipulator to position the tool for movement along the second tool path to remove the second portion.

Abstract: Surgical systems, methods and non-transitory computer readable medium for comparing localizer and image data to identify a region, such as an avoidance region or object. A localizer generates the localizer data associated with a surgical object. A vision device generates image data associated with the surgical object and an environment of the surgical object within a field-of-view of the vision device. Controller(s) associate a first virtual object with the surgical object and determine a pose of the first virtual object based on the localizer data. The controller(s) compare the image data and the localizer data to identify a region in the image data located outside of the first virtual object. The controller(s) associate a second virtual object with the identified region.

Abstract: A sterile drape assembly is disclosed for a surgical robot. The surgical robot has a robotic arm including a plurality of links and a plurality of motorized joints for moving the plurality of links. At least one optical tracking element is located on one or more the links of the robotic arm. The sterile drape assembly has a surgical drape with an arm drape portion adapted to be disposed over the robotic arm and the one or more the links of the robotic arm. A drape belt cooperates with the arm drape portion to cover the at least one optical tracking element located on the one or more the links of the robotic arm.

Abstract: Surgical systems and methods are described in which a localizer generates localizer data associated with a bone. A vision device generates, in a coordinate system of the vision device, image data associated with the bone and an environment of the bone within a field-of-view of the vision device. A robotic manipulator supports and moves a surgical instrument. Controller(s) associate a virtual object with the bone and determine a position and orientation of the virtual object based on the localizer data. Controller(s) merge the image data and the localizer data associated with the bone into a common coordinate system and control the robotic manipulator based on an output of merging the image data and the localizer data.

Abstract: A surgical system for manipulating an anatomy includes a surgical tool, a robotic manipulator configured to support and move the surgical tool, and one or more controllers that activate a first virtual boundary delineating a first portion of the anatomy that is allowed to be removed by the surgical tool from a second portion of the anatomy that is protected from removal by the surgical tool. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform fine cutting of the first portion in relation to the first virtual boundary. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform bulk cutting of the second portion of the anatomy.

Abstract: Surgical systems and methods for generating a tool path. A manipulator is configured to support and move a surgical instrument. Controller(s) obtain data that defines a volume of tissue to be removed from a surgical site. The controller(s) operate the manipulator to move the surgical instrument to remove first portions of the volume and acquire data defining the first portions removed from the volume. The controller(s) identify, based on the volume and the acquired data, additional portions of the volume of tissue that require removal. The controller(s) generate a tool path that passes through the additional portions and operate the manipulator to move the surgical instrument along the tool path to remove the additional portions.

Abstract: A surgical system for manipulating an anatomy includes a surgical tool, a robotic manipulator configured to support and move the surgical tool, and one or more controllers that activate a first virtual boundary delineating a first portion of the anatomy that is allowed to be removed by the surgical tool from a second portion of the anatomy that is protected from removal by the surgical tool. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform bulk cutting of the first portion in relation to the first virtual boundary. The one or more controllers control the robotic manipulator for enabling the surgical tool to perform fine cutting of the second portion of the anatomy.

Abstract: A plate for attaching to an anatomic structure with fasteners. The plate has a body with a top surface and a bottom surface opposite the top surface. The body defines one or more openings to receive a respective one of the one or more fasteners. The bottom surface is concave to define a space to accommodate a portion of the anatomic structure. A bone pad surface extends from the bottom surface. A spike extends away from the bone pad surface. An extension arm can be coupled to the plate and the extension arm can support a tracking head to implement a surgical tracking assembly.

Abstract: A tool path generator utilizes a solid body model of a volume to generate a tool path for a manipulator to remove material of the volume with an energy applicator in a semi-autonomous mode. A material logger monitors movement of the energy applicator according to a cutting path taken by a practitioner in the manual mode, identifies material of the volume to which the energy applicator has been applied in the manual mode, and updates the solid body model based on the identified material. The tool path generator modifies the tool path based on the updated solid body model such that, for the semi-autonomous mode, the modified tool path accounts for the identified material of the volume to which the energy applicator has been applied in the manual mode.

Abstract: A surgical system including a surgical tool and a navigation system for tracking the position of the surgical tool. The surgical tool comprising a housing including a variable speed motor and control module disposed within the housing. The navigation system comprising a navigation console in communication with the control module of the surgical tool, the navigation console may be configured to communicate instructions to the control module of the surgical tool based on the position of the surgical tool relative to a defined zone. The navigation console may be configured to deactivate the surgical tool based on the position of the surgical tool relative to the defined zone. The navigation console may also be configured to provide a user-selectable override option to allow continued operation of the surgical tool within the defined zone.

Abstract: A robotic system and methods are disclosed. A common axis is defined for an instrument and an energy applicator extending from the instrument. A manipulator has a plurality of links and actuators configured to move the links to position the instrument and energy applicator. A force/torque sensor coupled to the manipulator generates an output in response to forces/torques applied to the instrument. Controller(s) defines a centering point that intersects the common axis. Controller(s) model the instrument and the energy applicator as a virtual rigid body and determine forces/torques to apply to the virtual rigid body, which are determined, in part, based on the output of the force/torque sensor. Controller(s) control the manipulator to advance the energy applicator based on the determined forces/torques applied to the virtual rigid body and reorient the instrument such that the common axis pivots about the centering point during advancement of the energy applicator.

Abstract: A plate for attaching to an anatomic structure with fasteners. A body defines openings for receiving the fasteners, and includes a bottom surface that is concave. The plate includes bone pad surface, and a spike extends away from the bone pad surface. The bone pad surface is oriented at an angle relative to the bottom surface to prevent further penetration of the spike into the anatomic structure beyond a predetermined depth. The bone pad surface may be oriented at an obtuse angle relative to the bottom surface. The bone pad surfaces may be planar or concave, or contoured to a corresponding profile of the anatomic structure. The spikes may be pyramidal or conical. At least one side of the spike may be integral and continuous with the bottom surface. The side may have a radius of curvature equal to that of the bottom surface.

Abstract: A user control device for a surgical system. The surgical system includes a robotic manipulator to support and move a surgical instrument that has an energy applicator. One or more controllers operate the robotic manipulator in a semi-autonomous mode and calculate an instrument feed rate, which is the velocity at which the energy applicator advances along a tool path in the semi-autonomous mode. The user control device includes a housing configured as a pendant configured to be held in one hand of a user. A first control member is mounted to the housing and can be depressed to initiate operation of the robotic manipulator in the semi-autonomous mode. A second control member is mounted to the housing and can be depressed to modify the instrument feed rate in the semi-autonomous mode.

Abstract: Systems and methods are disclosed involving a navigation system including a localizer and a tracker detected within a field-of-view of the localizer. In one example, a virtual line-of-sight boundary is generated based on a line-of-sight relationship between the tracker and localizer. Additionally, or alternatively, a virtual field-of-view boundary is generated based on the field-of-view of the localizer. A virtual object is associated with a physical object and/or the tracker. Controller(s) detect whether a virtual collision occurs between the virtual object and the virtual line-of-sight boundary and/or virtual field-of-view boundary. The controller(s) enable a response based on detecting the virtual collision.

Abstract: A surgical system, method, and non-transitory computer readable medium involving a robotic manipulator configured to move a surgical instrument relative to virtual boundaries. A navigation system tracks each of a first object, a second object, and the surgical instrument. The first object is moveable relative to the second object. One or more controllers associate a first virtual boundary with the first object and associate a second virtual boundary with the second object. The first virtual boundary is moveable in relation to the second virtual boundary. The controller(s) control the robotic manipulator in relation to the first virtual boundary to facilitate interaction of the surgical instrument with the first object. The controller(s) control the robotic manipulator in relation to the second virtual boundary to avoid interaction of the surgical instrument with the second object.

Abstract: Systems and methods are disclosed wherein a tracker is detected within a field-of-view of a localizer. In one example, a virtual line-of-sight boundary is generated based on the line-of-sight relationship between the tracker and localizer. Additionally or alternatively, a virtual field-of-view boundary is generated based on the field-of-view of the localizer. A virtual object is associated with a manipulator, a surgical tool coupled to the manipulator, or the tracker when coupled to manipulator and/or surgical tool. Controller(s) predictively determine whether a planned movement of the manipulator will cause a virtual collision between the virtual object and the virtual line-of-sight boundary and/or virtual field-of-view boundary. The controller(s) enable a response based on an outcome of predictively determining whether the planned movement will cause the virtual collision.