Computer controlled surgical rotary tool
Inventors
Assignees
Smith and Nephew Orthopaedics AG • Smith and Nephew Asia Pacific Pte Ltd • Smith and Nephew Inc
Publication Number
US-12310671-B2
Publication Date
2025-05-27
Expiration Date
2040-06-18
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Abstract
A rotary tool includes a tool body and a powered rotary cutting tooltip that is oriented and positioned relative to the tool body by a plurality of processor-controlled actuators that provide degrees of freedom. The processor uses a surgical tracking system to identify the pose of the tool body and the tooltip relative to a patient's anatomy and controls the actuators to maintain the tooltip within a predetermined cutting plan to compensate for deviation of a surgeon's hand or a robotic arm controlling the tool body during a cutting operation.
Core Innovation
The invention provides a system for resecting bone that combines a rotary surgical tool having a powered rotary cutting tip, a tracking array with multiple fiducial markers, and processor-controlled linear actuators that adjust the cutting tip's position and pitch. The system integrates a surgical tracking device to identify the position of these fiducial markers relative to patient anatomy, enabling real-time tracking of the tool's pose, and a processor that maintains the cutting tip on a predetermined virtual cutting plane by actively controlling the actuators based on tracking feedback and a surgical plan.
This tool is equipped with a tool rest that maintains contact with the portion of bone to be resected and is configured to compensate for deviations in the movement of either a surgeon’s hand or a robotic arm during a bone cutting operation. The processor receives a surgical plan specifying one or more virtual cutting planes, monitors the pose of the cutting tip, and automatically adjusts the vertical position and pitch of the cutting tip to keep it aligned with the prescribed plane, thus delivering refined, precise, and consistent cuts even when the tool is moved freely or by a robotic system.
The problem addressed is the limitations of conventional systems in achieving both the speed and accuracy of bone resection during procedures such as knee arthroplasty. Prior solutions, such as the use of oscillating saws with cutting guides, hybrid approaches combining burrs and saws, and fully-constrained robotic arms, suffer from drawbacks including complex workflows, additional sources of error, cumbersome manual steps, and increased equipment cost and complexity. This invention overcomes those limitations by enabling processor-augmented, real-time compensation of hand or robotic deviations, reducing error while increasing operational simplicity and efficiency.
Claims Coverage
The patent includes three independent claims, each detailing core inventive features relating to processor-controlled, tracked rotary surgical tools for precise bone resection.
Processor-controlled tracked rotary tool for bone resection with real-time compensation
A system comprising: - A rotary tool including a tool body, a tracking array with three or more fiducial markers, a powered rotary cutting tip rotatable about its longitudinal axis, first and second linear actuators for adjusting vertical and pitch position of the cutting tip, and a tool rest that maintains contact with the bone throughout the procedure. - A surgical tracking device that identifies the positions of the fiducial markers relative to the bone. - A processor that: - Receives a surgical plan with at least one virtual cutting plane. - Receives fiducial marker position data from the surgical tracking device. - Determines real-time pose of the cutting tip with respect to the virtual cutting plane(s). - Controls the linear actuators to maintain the powered rotary cutting tip on at least one virtual cutting plane by adjusting its vertical and pitch position relative to the tool body.
Rotary cutting tool with actuators for positioning on a virtual cutting plane
A rotary cutting tool including: - A tool body with a tracking array (one or more fiducial markers) tracked by a surgical tracking system. - A powered rotary cutting tip (with longitudinal axis) attached and rotatable by a motor. - First and second linear actuators for adjusting vertical and pitch position of the cutting tip relative to the tool body to maintain position on at least one virtual cutting plane. - A tool rest extending from the tool body and configured to maintain contact with the bone as the tool body is moved during a portion of a surgical procedure.
Bone resection system with non-transitory instructions for actuator and tool tip control
A system comprising: - A rotary tool having a tool body, a tracking array (at least three fiducial markers), a powered rotary cutting tip rotatable about its axis, first and second linear actuators for adjusting vertical and pitch tip position, and a tool rest maintaining bone contact. - A surgical tracking device that identifies the fiducial marker positions with respect to the bone. - A processor and a non-transitory, computer-readable medium storing instructions that cause the system to: 1. Receive a surgical plan comprising at least one virtual cutting plane. 2. Receive marker position data from the tracking device. 3. Determine real-time pose of the cutting tip relative to the virtual cutting plane(s). 4. Control the linear actuators, based on the real-time pose, to adjust position and pitch of the rotary cutting tip relative to the tool body to maintain it on the virtual cutting plane.
The inventive features focus on integrated systems where a processor, using real-time tracking of fiducial markers, controls linear actuators to actively maintain a rotary cutting tip precisely within at least one virtual cutting plane during bone resection procedures. The coverage extends to both system and tool claims, as well as implementation through software instructions.
Stated Advantages
Improves accuracy and repeatability of implant placement by maintaining the cutting tip on a virtual cutting plane using processor control.
Compensates in real time for deviations of a surgeon’s hand or robotic arm, resulting in smoother, straighter, and more consistent bone resections.
Allows for precise bone cuts with minimal post-cut surface preparation, increasing workflow efficiency.
Reduces potential errors introduced by manual placement of cutting guides, traditional saws, or transferring jigs.
Documented Applications
Shoulder, hip, and knee surgical procedures involving bone resection.
Other surgical interventions such as arthroscopic procedures, spinal procedures, maxillofacial procedures, rotator cuff procedures, ligament repair and replacement procedures.
Partial or total arthroplasty, including total knee and hip replacement surgeries.
Processing both femoral and tibial cuts, including vertical, horizontal, and chamfer cuts during orthopedic operations.
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