Abstract: Surgical systems involve a robotic manipulator that moves a surgical tool to remove material from a workpiece and a navigation system to track a pose of the surgical tool relative to the workpiece. A control system determines a non-homogenous density distribution of the workpiece. The control system generates a tool path based on the density distribution. The control system controls the robotic manipulator to move the surgical tool along the tool path to remove the material from the workpiece while accounting for the density distribution. As the surgical tool moves along the tool path, the control system adjusts one or more operating parameters of the surgical tool to account for the density distribution, such as by adjusting the feed rate of the surgical tool, the cutting speed of the surgical tool, and/or the cutting depth of the surgical tool.

Abstract: Surgical systems and methods for manipulating an anatomy includes a surgical tool, a robotic manipulator configured to support and move the surgical tool, and controller(s) that generate a virtual boundaries delineating a portions of the anatomy allowed to be removed by the surgical tool. The controller(s) control the robotic manipulator to autonomously move the surgical tool in relation to a first virtual boundary and according to a first feed rate or first frequency of path oscillations to remove a first portion. The controller(s) control the robotic manipulator to autonomously move the surgical tool in relation to a second virtual boundary that is spaced from the first virtual boundary, and according to a different feed rate or different frequency of path oscillations, to remove a second portion.

Abstract: Surgical systems, computer-implemented methods, and software programs for generating a milling path for a bone. The implementations involve obtaining a virtual model of the bone, a resection volume defined relative to the virtual model of the bone, and a reference guide defined with respect to the resection volume. Section planes are successively arranged along the reference guide, and each section plane intersects the reference guide and intersects the resection volume. A section path is generated within each section plane and is defined relative to the resection volume. Transition segments are generated to connect section paths of section planes. The milling path is then generated by combining the section paths and the transition segments.

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: Robotic surgical systems and methods for controlling movement of a tool relative to a tool path. An input is received from a force/torque sensor in response to user forces/torques manually applied to the tool by a user. A component of force is calculated tangential to the path based on the input. An effective feed rate is calculated to advance the tool along the path based on the tangential component. Virtual constraints are defined on movement of the tool along the path with respect to three degrees of freedom and based on the effective feed rate to promote movement of the tool along the path. Dynamics of the tool are virtually simulated based on the virtual constraints and the input from the force/torque sensor. The manipulator is commanded to advance the tool along the path based on the virtual simulation.

Abstract: Surgical systems and methods involve a surgical manipulator with a plurality of links and joints that is configured to support and move a surgical instrument for manipulation of an anatomy. A controller is coupled to the surgical manipulator and is configured to measure an actual torque for at least one active joint and calculate an expected torque for the at least one active joint. The controller compares the actual torque and the expected torque to estimate an external force. The controller determines, based on the external force, that the surgical manipulator and/or the surgical instrument has collided with an object.

Abstract: Surgical systems, computer-implemented methods, and software programs for producing a patient-specific virtual boundary. Controller(s) obtain a virtual tibial model specific to a patient and identify an outer edge contour of the virtual tibial model. The controller(s) generate an offset contour being spaced apart from the outer edge contour by an offset distance that is based on a geometric feature of a surgical tool and generate a face extending perpendicularly from, and along, the offset contour. The controller(s) produce a patient-specific virtual boundary by merger of the virtual tibial model, the offset contour and the face and configure the patient-specific virtual boundary to provide a constraint on movement and/or operation of the surgical tool.

Abstract: A surgical navigation system and method of operating the same involve a pointer tool and a localizer configured to track the pointer tool. Controller(s) is/are coupled to the localizer and are configured to generate a virtual boundary relative to a bone at a surgical site. The virtual boundary has a shape that delineates a region of the bone to be removed from a region to be avoided. The controller(s) identify, with the localizer, a position of one or more landmarks at the surgical site in response to the pointer tool touching the one or more landmarks at the surgical site. The controller(s) revise the shape of the virtual boundary based on the position of the one or more landmarks.

Abstract: Surgical systems and methods for manipulating an anatomy includes a surgical tool, a robotic manipulator configured to support and move the surgical tool, and controller(s) that generate a virtual boundaries delineating a portions of the anatomy allowed to be removed by the surgical tool. The controller(s) control the robotic manipulator to autonomously move the surgical tool in relation to a first virtual boundary and according to a first feed rate or first frequency of path oscillations to remove a first portion. The controller(s) control the robotic manipulator to autonomously move the surgical tool in relation to a second virtual boundary that is spaced from the first virtual boundary, and according to a different feed rate or different frequency of path oscillations, to remove a second portion.

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: Surgical systems, computer-implemented methods, and software programs for producing a patient-specific virtual boundary configured to constrain movement and/or operation of a surgical tool in response to the surgical tool interacting with the patient-specific virtual boundary. The implementations include obtaining a generic virtual boundary including a generic surface with a generic edge, and positioning the generic virtual boundary relative to a virtual anatomical model such that the generic surface intersects the virtual anatomical model. The implementations include computing an intersection of the generic surface and the virtual anatomical model to define a cross-sectional contour of the virtual anatomical model, and morphing the generic edge to the cross-sectional contour to produce a customized surface with a patient-specific edge.

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 involve a manipulator that supports a tool and a control system to control operation of the manipulator and movement of the tool based on a relationship between the tool and a first virtual boundary. The control system operates to maintain compliance of the tool with the first virtual boundary. While maintaining compliance of the tool with the first virtual boundary, the control system enables a user to select a second virtual boundary. In response to user selection of the second virtual boundary, the control system determines whether the tool is in compliance with the second virtual boundary.

Abstract: Surgical systems and methods for preventing collision of a cutting instrument with a retractor. A robotic device includes a robotic arm to support and move the cutting instrument. A vision device is attached to the robotic device or the cutting instrument such that the vision device is movable by the robotic device. A control system controls the robotic device to move the cutting instrument along a tool path to remove material from a bone. The control system acquires vision data sets from the vision device in response to movement of the cutting instrument along the tool path and detects the retractor from the vision data sets. The control system generates an output to prevent collision of the cutting instrument with the retractor, such as, for example, defining a “no-fly” zone for the retractor and controlling the robotic device to avoid the cutting instrument from contacting the “no-fly” zone.

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: Systems and methods are provided for controlling robotic movement of a tool based on one or more virtual boundaries. The system comprises a tool and a manipulator to support the tool. A control system controls operation of the manipulator and movement of the tool based on a relationship between the tool and the one or more virtual boundaries associated with a target site. The control system includes a boundary handler to determine whether the tool is in compliance with the one or more virtual boundaries or is in violation of the one or more virtual boundaries.

Abstract: Systems and methods are disclosed comprising a robotic device, an instrument attachable to the robotic device to treat tissue, a vision device attached to the robotic device or instrument, and one or more controllers. The vision device generates vision data sets captured from multiple perspectives of the physical object enabled by the vision device moving in a plurality of degrees of freedom during movement of the robotic device. The controller(s) have at least one processor and are in communication with the vision device. The controller(s) associate a virtual object with the physical object based on one or more features of the physical object identifiable in the vision data sets. The virtual object at least partially defines a virtual boundary defining a constraint on movement of the robotic device relative to the physical object. In some cases, movement of the robotic device is actively constrained by using the virtual boundary.

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 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.