Abstract: A system and process is provided for dynamically positioning or repositioning a robot in a surgical context based on workspace and task requirements, manipulator requirements, or user preferences to execute a surgical plan. The system and method accurately determines and indicates an optimal position for a robot with respect to a patient's anatomy before or during a surgical procedure. Optimal positions for a robot are intuitively indicated to a user. surgical procedures can illustratively include surgery to the knee joint, hip joint, spine, shoulder joint, elbow joint, ankle joint, jaw, a tumor site, joints of the hand or foot, and other appropriate surgical sites.

Abstract: A computer-assisted surgery system for guiding alterations to a bone, comprises a trackable member secured to the bone. The trackable member has a first inertial sensor unit producing orientation-based data. A positioning block is secured to the bone, and is adjustable once the positioning block is secured to the bone to be used to guide tools in altering the bone. The positioning block has a second inertial sensor unit producing orientation-based data. A processing system providing an orientation reference associating the bone to the trackable member comprises a signal interpreter for determining an orientation of the trackable member and of the positioning block. A parameter calculator calculates alteration parameters related to an actual orientation of the positioning block with respect to the bone.

Abstract: A system for confirming registration of a bone involved in a joint replacement procedure is provided. The system includes a three-dimensional (3-D) bone model of the bone registered to a bone location, a visible light camera, and a display. The visible light camera captures images of the bone in the camera’s field-of-view (FOV). The display is configured to display the captured images of the FOV and an image of the 3-D bone model, where the displayed location of the image of the 3-D bone model corresponds to the location of the 3-D bone model registered to the bone location. The registration may be confirmed if the displayed location of the image of the bone as captured by the visible light camera corresponds to the displayed location of the 3-D bone model.

Abstract: A system and process for performing orthopedic surgery is provided that uses a tibial trial system in total knee arthroplasty for assessing optimal internal-external rotation and posterior tibial slope, and for measuring the rotation of a tibial trial throughout flexion-extension to determine and mark the best position for the final tibial component. The tibial trial system determines the internal-external location on a patient specific basis with improved component placement well within the present manual methods. One particular advantage to the tibial trial system is to assess the natural internal-external rotation that the tibial component will experience relative to the femoral component during flexion-extension as opposed to simply recording and balancing forces on a static tibial trial. The invention disclosed herein may also be adapted to be used with a computer assisted surgical device. Such surgical devices include active, semi-active, and haptic devices as well as articulating drill and saw systems.

Abstract: A process for confirming registration of bones involved in a joint replacement procedure is provided that includes a three dimensional (3-D) models of the bones being generated. The bones are tracked with a tracking device attached to each of the bones to allow 6-degrees of freedom (DOF) tracking during the joint replacement procedure. The 3-D models to the bones are registered and the bones having the tracking device are moved. A corresponding motion in the 3-D models with the moving of the bones is then observed. The registration of the 3-D models to the bone when the observations of the 3-D models move in correspondence with the actual bones is then confirmed or an alarm when an algorithm detects the 3-D bone models move unexpectedly during the movement of the bones. A system for confirming registration of bones involved in the joint replacement procedure is also provided.

Abstract: A system for determining an orientation of a tool axis with respect to a coordinate frame of a robot is described herein. The robot includes a tool holder and a plurality of fiducial markers for defining a first coordinate frame of the robot. A calibration device is provided having a second fiducial marker for a tracking system to track positions and configured to couple to the tool holder; and rotate relative to the tool holder when coupled to the tool holder. A computer having a processor is configured to fit a circle or arc to recorded positions of the calibration device. The recorded positions of the calibration device are recorded when coupled to the tool holder, is rotated relative to the tool holder. A vector normal to the fitted circle or arc is calculated to determine an orientation of the tool axis. A method of use is also provided.

Abstract: A calibration device is provided having a body with an exterior surface configured for placement about a tool such that the body rotates about a tool axis. One or more fiducial marker is positioned on the exterior surface and in communication with a tracking system. A fixed fiducial marker array is provided that is also in communication with the tracking system. A calibration tool defines the tool axis relative to the fiducial marker array. A surgical system is also provided with a tracking module that calculates a center point of the rotation or a normal vector to the circular path to define a tool axis orientation. A method of using the surgical system and defining a tool axis relative to a fiducial marker array is provided. A system for defining a robot link orientation or tracking a tool a medical procedure and a fiducial marker array are provided.

Abstract: A method and system to align a pin or drill a tunnel along a single line in space with a two degree of freedom (2-DOF) surgical device in a patient is provided. A plane is defined relative to a desired location for an implant or tunnel on a bone, where the implant or tunnel has an axis. An end-effector of the 2-DOF surgical device is aligned coincident with the plane, and the 2-DOF surgical device is moved side-to until a first indicator signals when the end-effector aligns with an entry point for the desired location for the implant or tunnel on the bone. A tip of the end-effector is anchored into the bone at the entry point; and the 2-DOF surgical device is rotated about the anchored tip until a second indicator signals when the end-effector aligns with the axis of the implant or tunnel at the desired location.

Abstract: A method and system are provided to assist in positioning the field-of-view (FOV) of an optical tracking system during a computer-assisted surgical procedure. The method includes displaying a view from a visible light detector on a display, and generating an outline as an overlay on the display of a FOV of two or more optical tracking detectors on the displayed view from the visible light detector. A user then positions at least one of: a) the two or more optical tracking detectors, or b) a tracked object based on the displayed view from the visible light detector and the generated outline.

Abstract: A surgical device is provided includes a hand-held portion with a working portion movably coupled to the hand-held portion for driving a tool. Actuators are provided for moving the working portion with each of the actuators having a travel range. An indicator notices a user when at least one of actuators is: (i) within the travel range; (ii) approaching a travel limit of the travel range; or (iii) outside the travel range. A surgical system is also provided inclusive the surgical device and a computing system configured to activate the indicator.

Abstract: A surgical device is provided includes a hand-held portion with a working portion movably coupled to the hand-held portion for driving a tool. Actuators are provided for moving the working portion with each of the actuators having a travel range. An indicator notices a user when at least one of actuators is: (i) within the travel range; (ii) approaching a travel limit of the travel range; or (iii) outside the travel range. A surgical system is also provided inclusive the surgical device and a computing system configured to activate the indicator.

Abstract: Systems and methods for creating planar cuts on a bone are provided utilizing one or more cutting guides assembled to a plurality of bone pins, where the bone pins are inserted on the bone coincident with one or more virtual pin planes defined relative to one or more of the planar cuts. Alignment guides are also disclosed herein that aid in the creation of pilot holes for receiving a cutting block in a desired position and orientation (POSE). An articulating surgical device actively positions the bone pins coincident with the virtual plane to ensure the cutting guides, when assembled to the pins, aligns one or more guide slots in the desired POSE to create the planar cuts.

Abstract: A system for improved surgical cutting in the presence of surgical debris, the system comprising: a surgical cutter comprising a distal end and a proximal end, the distal end of the surgical cutter being configured to cut bone; a debris detection system mounted to the surgical cutter, the debris detection system comprising: a light source for emitting light; a receiver for receiving light emitted from the light source; and a microprocessor for determining a change in a characteristic of the light emitted by the light source and received by the receiver, and for determining the presence and/or amount of surgical debris present at a surgical site using a change in a characteristic of the light emitted by the light source and received by the receiver; and a controller for varying, based on the presence and/or amount of surgical debris present at the surgical site, at least one of (i) an amount of irrigation supplied to the surgical site, (ii) the feed rate of the surgical cutter, (iii) the direction of the surgi

Abstract: Systems and methods for creating cuts on a bone are provided utilizing one or more cutting guides assembled to a plurality of bone pins, where the bone pins are inserted on the bone coincident with one or more virtual pin planes defined relative to one or more of the cuts. Alignment guides are also disclosed herein that aid in the creation of pilot holes for receiving a cutting block in a desired position and orientation (POSE). An articulating surgical device actively positions the bone pins coincident with the virtual plane to ensure the cutting guides, when assembled to the pins, aligns one or more guide slots in the desired POSE to create the cuts.

Abstract: Systems and methods for creating cuts on a bone are provided utilizing one or more cutting guides assembled to a plurality of bone pins, where the bone pins are inserted on the bone coincident with one or more virtual pin planes defined relative to one or more of the cuts. Alignment guides are also disclosed herein that aid in the creation of pilot holes for receiving a cutting block in a desired position and orientation (POSE). An articulating surgical device actively positions the bone pins coincident with the virtual plane to ensure the cutting guides, when assembled to the pins, aligns one or more guide slots in the desired POSE to create the cuts.

Abstract: Systems and methods for creating cuts on a bone are provided utilizing one or more cutting guides assembled to a plurality of bone pins, where the bone pins are inserted on the bone coincident with one or more virtual pin planes defined relative to one or more of the cuts. Alignment guides are also disclosed herein that aid in the creation of pilot holes for receiving a cutting block in a desired position and orientation (POSE). An articulating surgical device actively positions the bone pins coincident with the virtual plane to ensure the cutting guides, when assembled to the pins, aligns one or more guide slots in the desired POSE to create the cuts.

Abstract: A device for checking post cut plane accuracy and alignment following bone removal in a bone of a patient during a computer-assisted surgical procedure to create a bone surface is provided. The device includes a body having an axis and adapted to contact the bone surface. One or more alignment features are associated with the body and are accessible when the body is in contact with the bone surface. Each of the one or more alignment features has a known orientation and position relative to the axis. A method for checking post cut plane accuracy and alignment following removal of bone from a patient to create a bone surface during a computer-assisted surgical procedure is also provided. A computer-assisted surgical system is provided that includes a tracking system, a tracked digitizer probe, the aforementioned device, a tracked surgical device, and one or more computers with software for determining the orientation.

Abstract: A protective drape for a robotic arm is provided. The protective drape may be used with robotic arm that are required to operate in varied environments that illustratively include industrial applications, a sterile surgical suite for patient care, and a clean room for manufacturing sensitive electronic components. In each of these applications, there is a need to prevent contaminants from infiltrating from the environment to the robot and affecting operation of the robot itself or the robotic system, as well to prevent contaminants from the robot from infecting a patient or contaminating an assembly or process product.

Abstract: A surgical device for pin insertion in a bone of a subject to aid in performing a bone cutting procedure is provided that includes a drive portion configured to drive a pin for insertion into the bone. The drive portion has a pin drive assembly with a shaft having a shaft proximal end. At least one magnet is associated with the shaft proximal end adapted for attraction and retention of the pin in the shaft proximal end. A spindle assembly is adapted to drive the shaft so as to rotate the pin into the bone to a degree of bone retention that overcomes the attraction and the retention of the pin in the shaft proximal end. An alignment system for surgical bone cutting procedures inclusive of the same is also provided along with a method for aligning a cutting guide on a subject's bone.

Abstract: An optical tracking system includes at least one tracking array for generating and optically transmitting data between 1 and 2,000 MB/s. At least one tracker for optically receiving the optically transmitted data between 1 and 2,000 MB/s is also provided. The tracking system is used not only for tracking objects and sending tracking information quickly but also providing the user or other components in an operating room with additional data relevant to an external device such as a computer assisted device. Orthopedic surgical procedures such as total knee arthroplasty (TKA) are performed more efficiently and with better result with the optical tracking system.