Methods, devices and systems for computer-assisted robotic surgery

Abstract

Methods, devices and systems for the planning and execution of computer-assisted robotic surgery are provided. The methods include methods to collect information about bones and prostheses, use the information to create virtual models and simulations, optionally receive input based on user discretion in generating the cut file, and to generate instruction for the execution of cut paths during the surgery. The system and devices include computers and peripherals and set-ups to link the components together into functional systems.

What is claimed is: 
     
         1 . A method to prepare a bone according to a user-specified cut-file to receive a prosthesis, the method comprising:
 generating a pre-existing cut-file for a robot to follow in removing material from the bone;   modifying the pre-existing cut-file based on user-specified discretionary input to a user interface so as to generate a user-specified cut-file, where the user-specified input is limited to a pre-populated library of options; and   robotically removing the material from the bone according to the user-specified cut-file to receive the prosthesis.   
     
     
         2 . The method of  claim 1  wherein the pre-existing cut file is computational generated from one or more a model of the bone and a model of the prosthesis. 
     
     
         3 . The method of  claim 1  further comprising robotically removing a portion of the material prior to the modifying step. 
     
     
         4 . The method of  claim 3  further comprising pausing the robot during the modifying step. 
     
     
         5 . The method of  claim 1  wherein the modifying step varies an instruction for one or more of precut, depth of cut, length of cut, diameter of cut path, regions to be cut, number of cut paths, dimensions of planes, shapes of cut paths, or types and sizes of cutters to be used. 
     
     
         6 . The method of  claim 1  wherein the pre-populated library of options is a drop-down menu. 
     
     
         7 . The method of  claim 1  further comprising warning the user if a proposed user-specified cut-file exceeds a predefined safety limit. 
     
     
         8 . The method of  claim 1  wherein the modifying step occurs in real time or with minimal delay. 
     
     
         9 . A surgical system to prepare a bone according to a user-specified cut-file to receive a prosthesis, the system comprising:
 a planning computer comprising:   an input device to receive image data of the bone;   a display device to provide data for at least one of: a model of the bone, a model of a prosthesis, a model of a volume of material to be removed from the bone, a simulation of the model of the bone with the model of the prosthesis, a simulation of the model of the bone with the model of the volume of bone to be removed, and a simulation of the model of the volume of bone to be removed with the model of the prosthesis;   a user-interface to receive user-specified input to modify a pre-existing cut-file according to  claim 1  or to make modifications thereto of at least one of: precut, depth of cut, length of cut, diameter of cut path, regions to be cut, number of cut paths, shapes of cut paths, and types and sizes of cutters to be used so as to create a user-specified cut-file;   an output device to provide said user-specified cut-file to a surgical robot; and   said robot to remove material from the bone according said user-specified cut-file.   
     
     
         10 . The system of  claim 9  wherein said user-interface further comprises a stop control for said robot to pause removal of the material while said user-specified cut-file is generated. 
     
     
         11 . The system of  claim 9  wherein said user-interface further comprises a warning triggered when said user-specified cut-file exceeds a preselected bounding volume. 
     
     
         12 . The system of  claim 9  wherein said user-interface further comprises a phone line or Internet service for input from an off-site user.