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 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 manipulation of an anatomy that includes cortical and cancellous bone. A surgical manipulator has a robotic arm to move an instrument with an energy applicator. A sensor senses forces/torques applied to the energy applicator. Controller(s) obtain a tool path for the energy applicator to traverse. A segment of the tool path transitions into, or between, cortical bone and cancellous bone. The controller(s) control the manipulator to advance the energy applicator along the tool path according to a first feed rate to manipulate the cortical or cancellous bone and detect, with the sensor, a change in the forces/torques being indicative of the transition. In response to detection of this change, the controller(s) control the manipulator to advance the energy applicator along the tool path according to a second feed rate, greater/less than the first feed rate.

Abstract: A manipulator supports a tool and operates in a first mode to move the tool along a tool path and a second mode to move the tool in response to user forces/torques applied to the tool. Sensor(s) measure forces/torques applied to the tool. Controller(s) generate virtual constraints based on a target state and a current state of the tool. The controller(s) calculate constraint forces to attract the tool toward the target state from the current state based on the virtual constraints. A virtual simulator simulates dynamics of the tool in a virtual simulation based on input from the sensor(s) and the constraint forces to output commanded poses. The controller(s) command the manipulator to move the tool in the second mode based on the commanded poses to thereby provide haptic feedback to the user that guides the user toward placing the tool at the target state.

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: Systems and methods are provided for guiding movement of a tool. The system includes a tool and a manipulator. A guide handler obtains a target state for the tool and generates virtual constraints based on the target state and a current state of the tool. A constraint solver calculates a constraint force adapted to attract the tool toward the target state or repel the tool away from the target state based on the virtual constraints. A virtual simulator simulates dynamics of the tool in a virtual simulation based on the constraint force and input from one or more sensors, to output a commanded pose. The control system commands the manipulator to move the tool based on the commanded pose to thereby provide haptic feedback to the user that guides the user toward placing the tool at the target state or away from the target state.

Abstract: Surgical systems and methods of operating the same involve controlling a robotic manipulator to move a cutting instrument to manipulate a bone at a surgical site. A navigation system has a localizer to track poses of a tracker coupled to a bone at a surgical site. A machine vision system has a vision camera. A control system is coupled to the robotic manipulator, the navigation system, and the machine vision system. The control system detects, with the machine vision system, an object at, or in proximity to, the surgical site and associate a virtual boundary with the detected object. The control system controls the robotic manipulator to move the cutting instrument to manipulate the bone based on the tracked poses of bone. The control system controls the robotic manipulator to constrain movement of the cutting instrument based on the virtual boundary such that the cutting instrument avoids the object.

Abstract: A surgical system and method involve a robotic manipulator with a plurality of links and actuators and an end effector supporting a surgical instrument. A sensor is coupled to the robotic manipulator and is configured to sense forces/torques applied to the surgical instrument. The surgical system includes controller(s) to operate the robotic manipulator in a semi-autonomous mode, and in the semi-autonomous mode, the robotic manipulator is controlled to advance the surgical instrument along a cutting path to remove material from a target site. During advancement of the surgical instrument along the cutting path in the semi-autonomous mode, the controller(s) evaluate forces/torques sensed by the sensor to detect an obstruction to the surgical instrument. In response to detection of the obstruction, the controller(s) perform an action to address the obstruction.

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 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: Generating a milling path to enable a tool to remove material from bone. An allowed volume is intersected with a virtual bone model. An offset boundary is spaced inward from the allowed volume. Intersection between the allowed volume and the virtual bone model defines a resection volume. An outer portion of the resection volume is defined between the allowed volume and offset boundary. An inner portion of the resection volume is defined within the offset boundary. Section planes are defined to successively intersect the resection volume. Section paths are bounded within each section plane and are defined relative to the resection volume. One or more sections plane includes a section path with a path segment enabling the tool to remove only the outer portion of the resection volume. Transition segments connect section paths of successive section planes. The section paths and transition segments are combined to generate the milling path.

Abstract: Surgical systems and methods for manipulating an anatomy involve a surgical tool, a robotic manipulator configured to support and move the surgical tool, and controller(s) that generate first and second virtual boundaries associated with the anatomy. The second virtual boundary is spaced apart from the first virtual boundary. The controller(s) control movement of the surgical tool in a first mode wherein the first boundary is activated. In the first mode, the controller(s) produce a first alert to inform that constraint of the surgical tool is occurring in relation to the first boundary. The controller(s) control movement of the surgical tool in a second mode wherein the first boundary is deactivated, and the surgical tool is constrained in relation to the second boundary. In the second mode, the controller(s) produce a second alert to inform that constraint of the surgical tool is occurring in relation to the second boundary.

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.