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: A method of operating a robotic system to efficiently remove material from a workpiece based on a density distribution of the material of the workpiece. The density distribution of the material of the workpiece is determined from a three-dimensional representation and evaluated by classifying the plurality of points or voxels into a first density classification and a second density classification. A navigation computer generates a first tool path and a second tool path for the tool based on the evaluated density distribution. The first tool path is associated with the first density classification, and the second tool path is associated with the second density classification. The position of the tool relative to the workpiece is tracked with a navigation computer and controlled with a manipulator controller based on the generated tool path to remove material along the first tool path, and remove material along the second tool path.

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 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 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: 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: A system includes a robotic manipulator and an end effector coupled to the robotic manipulator and being moveable for interacting with a target site in a manual mode and an autonomous mode of operation. A navigation system is configured to track a position of the end effector and the target site. One or more controllers are configured to define a virtual boundary relative to the target site, prevent the end effector from penetrating the virtual boundary in the autonomous mode, and allow the end effector to penetrate the virtual boundary in the manual mode.

Abstract: A system includes a robotic manipulator and an end effector coupled to the robotic manipulator and being moveable for interacting with a target site in a manual mode and an autonomous mode of operation. A navigation system is configured to track a position of the end effector and the target site. One or more controllers are configured to define a virtual boundary relative to the target site, prevent the end effector from penetrating the virtual boundary in the autonomous mode, and allow the end effector to penetrate the virtual boundary in the manual mode.

Abstract: A robotic surgical system comprises a surgical tool, a manipulator configured to support the surgical tool, a force/torque sensor to measure forces and torques applied to the surgical tool, and a control system. The control system obtains a three-dimensional milling path for the surgical tool. The control system also receives one or more signals from the force/torque sensor in response to a user manually applying user forces and torques to the surgical tool. The control system determines a commanded pose to which to command the manipulator to advance the surgical tool along the milling path based on a tangential component of the user forces and torques, based on a virtual simulation using virtual constraints, and/or based on other suitable factors to promote guided, manual movement of the surgical tool along the milling path.

Abstract: A system includes a robotic manipulator comprising an arm and an end effector coupled to the arm and being moveable by the arm for interacting with a target site in a manual mode and an autonomous mode of operation. A navigation system is configured to track a position of the end effector and the target site. One or more controllers are configured to define a first virtual boundary relative to the target site, prevent the end effector from penetrating the first virtual boundary in the manual mode, and allow the end effector to penetrate the first virtual boundary in the autonomous mode.

Abstract: An injection unit for an injection molding machine includes a cylindrical body rotatably supported in a housing interior for rotational coupling with a plasticizing screw. The cylindrical body is fixed to rotate with the plasticizing screw about an injection axis. A gear train in the housing includes a central gear mounted about, and fixed to rotate with, the cylindrical body, the central gear having an uppermost extent vertically above the injection axis and opposed first and second lateral extents on horizontally opposed sides of the injection axis. A rotary drive for powering rotation of the plasticizing screw includes a first motor having a first motor shaft rotatable about a first motor axis, the first motor axis parallel to the injection axis, the first motor axis at a first elevation below the uppermost extent of the central gear, and laterally outboard of the first lateral extent of the central gear.

Abstract: Systems, methods, software and techniques are disclosed for morphing a generic virtual boundary into a patient-specific virtual boundary for an anatomical model. The generic virtual boundary comprises one or more morphable faces. An intersection of the generic virtual boundary and the anatomical model is computed to define a cross-sectional contour of the anatomical model. One or more faces of the generic virtual boundary are morphed to conform to the cross-sectional contour of the anatomical model to produce the patient-specific virtual boundary. In some cases, the morphed faces are spaced apart from the cross-sectional contour by an offset distance that accounts for a geometric feature of a surgical tool.

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: Systems and methods are disclosed involving an instrument, an instrument tracking device for tracking movement of the instrument, a first boundary tracking device for tracking movement of a first virtual boundary associated with an anatomy of a patient to be treated by the instrument, and a second boundary tracking device for tracking movement of a second virtual boundary associated with a periphery of an opening in the patient to be avoided by the instrument. One or more controllers receive information associated with the tracking devices including positions of the instrument relative to the first and second virtual boundaries, detect movement of the first and second virtual boundaries relative to one another, and generate a response upon detecting movement of the first and second virtual boundaries relative to one another.

Abstract: Navigation systems and methods for tracking physical objects near a target site during a surgical procedure. The navigation system comprises a robotic device and an instrument attached to the robotic device. A vision device is attached to the robotic device or the instrument and generates vision data sets. The vision data sets are captured from multiple perspectives of the physical object. A computing system associates 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 for the instrument.

Abstract: Systems and methods for establishing and tracking virtual boundaries. The virtual boundaries can delineate zones in which an instrument is not permitted during a surgical procedure. The virtual boundaries can also delineate zones in which the surgical instrument is permitted during the surgical procedure. The virtual boundaries can also identify objects or structures to be treated by the instrument or to be avoided by the instrument during the surgical procedure.

Abstract: Systems, methods, software and techniques for generating a milling path for a tool of a surgical system are provided. The milling path is designed to remove a resection volume associated with an anatomical volume. A reference guide is defined with respect to the resection volume. Sections are defined along the reference guide in succession. Each section intersects the reference guide at a different intersection point and is at a specified orientation relative to the reference guide at the intersection point. Each section further intersects the resection volume. A section path is generated to be bounded within each section and defined relative to the resection volume. A plurality of transition segments are generated and each transition segment connects section paths of successive sections along the reference guide.

Abstract: Surgical manipulators and methods disclosed comprise an energy applicator extending from an instrument and actuators to move links to position the energy applicator. A force/torque sensor sense forces/torques applied to the instrument. Controller(s) control operation of the manipulator in a semi-autonomous mode wherein the manipulator moves the energy applicator along a tool path comprising a target position and advances the energy applicator along the tool path by moving the energy applicator to the target position. The controller(s) transition from the semi-autonomous mode to a manual mode wherein operation of the manipulator is controlled in response to forces/torques applied to the instrument. In the manual mode, the controller(s) enable movement of the energy applicator to one or more positions different from the target position. The controller(s) transition from the manual mode back to the semi-autonomous mode by moving the energy applicator back to the target position on the tool path.

Abstract: Surgical manipulators and methods disclosed comprise an energy applicator extending from an instrument and actuators to move links to position the energy applicator. A force/torque sensor sense forces/torques applied to the instrument. Controller(s) control operation of the manipulator in a semi-autonomous mode wherein the manipulator moves the energy applicator along a tool path comprising a target position and advances the energy applicator along the tool path by moving the energy applicator to the target position. The controller(s) transition from the semi-autonomous mode to a manual mode wherein operation of the manipulator is controlled in response to forces/torques applied to the instrument. In the manual mode, the controller(s) enable movement of the energy applicator to one or more positions different from the target position. The controller(s) transition from the manual mode back to the semi-autonomous mode by moving the energy applicator back to the target position on the tool path.

Abstract: A surgical robotic system and method for controlling an instrument feed rate. The surgical robotic system comprises a surgical manipulator for manipulating a surgical instrument and an energy applicator extending from the surgical instrument. At least one controller includes a feed rate calculator configured to calculate the instrument feed rate. A hand held pendant is operable by a user to adjust a defined feed rate of the surgical manipulator in the semi-autonomous mode.