`
`
`Exhibit 1001
`
`
`Mako Surgical Corp.
`EX. 1001 Page 1
`
`Mako Surgical Corp.
`Ex. 1001
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`Mako Surgical Corp. Ex. 1001
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`Mako Surgical Corp. Ex. 1001
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`

`

`(12) United States Patent
`(10) Patent N0.:
`US 6,757,582 B2
`
`Brisson et al.
`(45) Date of Patent:
`Jun. 29, 2004
`
`USOO6757582B2
`
`(54) METHODS AND SYSTEMS TO CONTROLA
`SHAPING TOOL
`
`(56)
`
`References Cited
`US. PATENT DOCUMENTS
`
`(75)
`
`Inventors: Gabriel Brisson, Pittsburgh, PA (US);
`Takeo Kanade, Pittsburgh, PA (US);
`Anthony DiGiOia, 111, Pittsburgh, pA
`(US); Branislav Jaramaz, Pittsburgh,
`PA (US)
`
`(73) Assignee: Carnegie Mellon University,
`Pittsburgh, PA (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. N05 10/427’093
`(22)
`Filed:
`Apr. 30, 2003
`
`(65)
`
`Prior Publication Data
`US 2003/0208296 A1 Nov. 6, 2003
`
`(60)
`
`(51)
`Egg
`
`Related US. Application Data
`Provisional application No. 60/377,695, filed on May 3,
`2002.
`
`7
`
`................................................ G06F 19/00
`Int. Cl.
`gfsl'dCIfs""""h"""""""" 700/186; 83973315261162:
`earc
`.................................
`,
`,
`1e
`0
`700/159, 245; 606/128; 318/568.11; 144/31;
`83/768, 367, 370; 451/5
`
`4/1987 Brumbach .................. 606/128
`4,660,573 A *
`
`9/1995 Brust et al. ........... 606/128
`5,449,363 A *
`
`. 318/568.11
`8/2000 Katoh etal.
`6,097,168 A *
`6,501,997 B1 * 12/2002 Kakmo ....................... 700/159
`6,520,228 B1 *
`2/2003 Kennedy et al.
`............. 83/768
`* cited by examiner
`
`Primary Examiner—Albert W. Paladini
`(74) Attorney, Agent, or Firm—Kevin A. Oliver; Foley
`Hoag LLP
`(57)
`
`ABSTRACT
`
`A method and system for providing control that include
`providing a workpiece that includes a target shape, provid-
`ing a cutting tool, providing a 3-D image associated with the
`workpiece, identifying the target shape within the workpiece
`image, providing a 3-D image associated with the cutting
`tool, registering the workpiece with the workpiece image,
`registering the cutting tool with the cutting tool image,
`tracking at least one of the workpiece and the cutting tool,
`transforming the tracking data based on image coordinates
`to determine a relationship between the workpiece and the
`cutting tool, and, based on the relationship, providing a
`control to the cutting tool. In one embodiment, the work-
`piece image can be represented as volume pixels (voxels)
`that can be classified and/or reclassified based on target
`~
`Shape’ waSte’ and/0r workplece'
`65 Claims, 13 Drawing Sheets
`
`CUTTING TOOL
`CUTTING
`
`SENSOR
`COLLECTION
`
`COORDINATE
`xrom
`
`CALIBRATION
`
`COLLISION/
`INTERFERENCE
`DETECTION
`
`PROBE
`
`Mako Surgical Corp. Ex. 1001
`Page 1
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`Page 1
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`

`

`US. Patent
`
`Jun. 29, 2004
`
`Sheet 1 0f 13
`
`US 6,757,582 B2
`
`GENERATE WORKPIECE IMAGE
`
`INTEGRATE TARGET SHAPE INTO WORKPIECE IMAGE
`
`“VOXILLATE” INTEGRATED WORKPIECE IMAGE
`
`GENERATE CUTTING TOOL IMAGE
`
`CALIBRATE POINT PROBE
`
`100
`
`1l2
`
`1l4
`
`1l6
`
`1 I 8
`
`1 0
`
`ASSOCIATE MARKERS WITH CUTTING TOOL AND WORKPIECE
`
`USE POINT PROBE TO REGISTER CUTTING TOOL AND WORKPIECE
`
`1 2
`
`ITERATIVELY:
`TRACK CUTTING TOOL AND WORKPIECE
`
`PROVIDE CONTROL TO CUTTING TOOL
`
`VOXILLATE INTEGRATED WORKPIECE IMAGE
`
`FIGURE 1
`
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`US. Patent
`
`Jun. 29, 2004
`
`Sheet 2 0f 13
`
`US 6,757,582 B2
`
`114
`
`120
`
`TRACK MARKERS ON WORKPIECE AND/OR CUTTING TOOL
`
`(RECEIVE TRACKING DATA)
`
`TRANSFORM TRACKING DATA TO IMAGE COORDINATES
`
`122
`
`
`
`
`
` 124
`
` 126
`
`
`INTERSECTION DETECTION/COMPUTE CONTROL
`
`TRANSMIT CONTROL TO CUTTING TOOL AND UPDATE
`IIVIAGE/VOXELS BASED ON INTERSECTION DETECTION
`
`FIGURE 2A
`
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`US. Patent
`
`Jun. 29, 2004
`
`Sheet 3 0f 13
`
`US 6,757,582 B2
`
`ESTABLISH GRID OF VOXELS
`
`INCORPORATE WORKPIECE IMAGE DATA TO GRID
`
`CLASSIFY VOXELS
`
`REGISTER WORKPIECE/CUTTING TOOL TO IMAGES
`
`UPDATE WORKPIECE AND/OR CUTTING TOOL IMAGES
`
`
`
`WITH TRACKING DATA
`
`
`
`
`COMPUTE CONTROL
`
`PERFORM COLLISION/INTERSECTION DETECTION/
`
`
`
`
`UPDATE IMAGE/VOXELS (CLASSIFICATION, DIVISION,
`COMBINATION, ...)/TI-U\NSMIT CONTROL
`
`130
`
`132
`
`.
`
`126A
`
`112
`
`120, 122
`
`124
`
`126
`
`FIGURE 2B
`
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`US. Patent
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`Jun. 29, 2004
`
`Sheet 4 0f 13
`
`US 6,757,582 B2
`
`1100
`
`m 1108 1102 1102
`lllm
`VInm-
`
`L
`
`
`
`1 10
`
`FIGURE 3A
`
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`US. Patent
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`Jun. 29, 2004
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`Sheet 5 0f 13
`
`US 6,757,582 B2
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`1100
`
`1102
`
`1102
`
` 1108
`‘22:!
`man
`
`
`
`1104
`
`
`
`1101
`
`FIGURE 3B
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`
`
`
`
`
`
`
`1122 1122
`
`1122 1122
`
`1134 1134
`
`1104
`
`US. Patent
`
`Jun. 29, 2004
`
`Sheet 6 0f 13
`
`US 6,757,582 B2
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`1120
`
`1110 1132
`
`1110 1132
`
`1132
`
`1132 1132 1132
`
`1112
`
`
`
`
`
`
`1122 1132
`
`1122 1132
`
`1132 1132 1132 1132
`
`1134 1134
`
`1134 1134 1134 1134
`
`1104
`
`1104
`
`1104
`
`FIGURE 4A
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`US. Patent
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`Jun. 29, 2004
`
`Sheet 7 0f 13
`
`US 6,757,582 B2
`
`
`
`
`
`
`
`
`1132”1132”
`
`1120
`
`1120’
`
`11029
`
`1132”1122”
`
`1132
`
`1132 1132 1132 1132 1122
`
`1122
`
`1122 1122
`
`1122 1122 1122 1122
`
`1122 1122
`
`1122 1122
`
`1122 1122 1122 1122
`
`1134 1134
`
`1134 1134
`
`1134 1134 1134 1134
`
`1104
`
`1104
`
`1104
`
`1104
`
`FIGURE 4B
`
`
`
`
`
`
`
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`Mako Surgical Corp. Ex. 1001
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`US. Patent
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`Jun. 29, 2004
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`Sheet 8 0f 13
`
`US 6,757,582 B2
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`1132
`
`1132
`
`1122
`
`1132
`
`1122
`
`
`
`1130
`
`
`
`
`
`
`
`1132
`
`1122
`
`1132
`
`1122
`
`1122
`
`1110’1110’ 1110’1110’1132
`
`1122 1122 1122
`
`1134 1134
`
`1134 1134
`
`1134 1134 1134 1134
`
`1104
`
`1104
`
`1104
`
`1104
`
`FIGURE 4C
`
`
`
`
`
`
`
`
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`US. Patent
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`Jun. 29, 2004
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`Sheet 9 0f 13
`
`US 6,757,582 B2
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`CUTTING TOOL
`
`ELEMENT
`
`
`
`
`PROCESSOR
`
`
`
`SENSOR
`
`fl
`
`
`SENS OR
`
`COORDINATE
`
`
`
`
`
`WORKPIECE
`COLLECTION
`XFORM
`
`
`
`MODULE
`MODULE
`
`
`
`
` COLLISION/
`INTERFERENCE
`
`DETECTION
`
` PROBE
`MODULE
`
`CALIBRATION
`
`MODULE
`
`CUTTER
`
`CONTROL ‘
`
`
` IMAGE
`MODULE
`
`
`REGISTRATION
`
`MODULE
`
`
`MODULE
`
`
`
`IMAGE ACQUISITION
`
`
`
`DISPLAY
`
`‘
`
`FIGURE 5
`
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`US. Patent
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`Jun. 29, 2004
`
`Sheet 10 0f 13
`
`US 6,757,582 B2
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`
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`Mako Surgical Corp. Ex. 1001
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`Page 11
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`U S. Patent
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`Jun. 29, 2004
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`Sheet 11 0f 13
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`US 6,757,582 B2
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`
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`Mako Surgical Corp. Ex. 1001
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`US. Patent
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`Jun. 29, 2004
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`Sheet 12 0f 13
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`US 6,757,582 B2
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`
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`Mako Surgical Corp. Ex. 1001
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`US. Patent
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`Jun. 29, 2004
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`Sheet 13 0f 13
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`US 6,757,582 B2
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`
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`US 6,757,582 B2
`
`1
`METHODS AND SYSTEMS TO CONTROLA
`SHAPING TOOL
`
`CROSS-REFERENCE TO RELATED
`APPLICATION
`
`This application claims benefit of priority to US. Provi-
`sional Patent Application Serial No. 60/377,695, filed May
`3, 2002, the contents of which are herein incorporated by
`reference in their entirety.
`
`FIELD
`
`This disclosure relates generally to controls, and more
`specifically to controlling a tool for shaping a workpiece.
`
`BACKGROUND
`
`A wide variety of applications call for objects to be
`formed from general workpieces, where the object forma-
`tion can include cutting the object from the workpiece. The
`precision required of the cut may depend on the particular
`application.
`One application that can call for high precision is the
`shaping of bone during surgery. For example, in a surgery
`such as a total knee replacement (TKR), the bones to which
`a prosthetic knee may be attached, typically the femur and
`the tibia, can be shaped to facilitate stable and effective
`implantation of the prosthesis.
`Some cutting systems achieve increased accuracy by
`fixating the workpiece, such as bone. Bone fixation can be
`accomplished using a screw(s) and/or a clamp(s) to secure
`the bone to a secure positioning brace. Fixation can be used
`for many robotic orthopedic surgery systems because such
`systems depend on a fixed target and cannot or do not track
`the target. Fixation may be used in robotic systems despite
`the risks to the patient that can include pain, infection, and
`increased recovery and rehabilitation periods caused by the
`invasive nature of fixation.
`
`Robotic and other surgical systems may be susceptible to
`failure that can occur suddenly and can cause damage or
`injury to the subject. Controllable or detectible failure may
`be detected before harm is done. Undetectable failure may
`cause damage when the system appears to be functioning
`normally. If a robot provides power drive or power assis-
`tance to an operator, failure may result when the robot
`malfunctions because the operator may be unable to react in
`time or with sufficient force to prevent the robot components
`from injuring the subject. Robotic systems may also be
`undetectable failures, since the operator may not be in full
`or even partial physical control of the robot.
`SUMMARY
`
`The disclosed methods and systems include a control
`method that includes providing a workpiece that includes a
`target shape, providing a cutting tool, providing a 3-D image
`associated with the workpiece, identifying the target shape
`within the workpiece image, providing a 3-D image asso-
`ciated with the cutting tool, registering the workpiece with
`the workpiece image, registering the cutting tool with the
`cutting tool image, tracking the workpiece and/or the cutting
`tool, transforming the tracking data based on image coor-
`dinates to determine a relationship between the workpiece
`and the cutting tool, and based on the relationship, providing
`a control to the cutting tool. The control can include an
`analog signal, a digital signal, a control to at least partially
`retract a cutting element associated with the cutting tool, a
`control to reduce the speed of a cutting element associated
`
`10
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`15
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`25
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`60
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`65
`
`2
`with the cutting tool, a control to stop a cutting element
`associated with a cutting tool, or another control.
`The methods and systems can include representing the
`workpiece image using volume pixels (voxels), and classi-
`fying the workpiece image voxels based on the target shape.
`Accordingly, based on the relationship between the cutting
`tool and the workpiece, the methods and systems can include
`re-classifying the voxels based on the relationship.
`The methods and systems can include providing an image
`based on CT scan data, X-ray data, MRI data, fiuoroscopy
`data, and/or ultrasound data. The methods and systems can
`also include classifying such image data, represented as
`three dimensional volume pixels or “voxels,” where classi-
`fying the image voxels based on the target shape includes
`distinguishing target shape voxels and workpiece voxels. In
`an embodiment, distinguishing target and workpiece voxels
`includes associating target shape voxels with the target
`shape and associating non-target shape voxels as waste.
`Color-coding voxels, such as target shape voxels associated
`with the target shape, can also be performed to distinguish
`voxels. The images and/or voxels can be displayed to a user
`to enable a user to view relative positions of the cutting tool
`and workpiece and/or target shape. In one embodiment, the
`methods and systems can include re-classifying the voxels
`based on the relationship.
`Classifying and/or re-classifying voxels can include iden-
`tifying mixture voxels that include part workpiece and part
`target shape, subdividing the mixture voxels, and iteratively
`identifying and subdividing mixture voxels to a predeter-
`mined voxel resolution. In one embodiment, mixture voxels
`can be understood to be voxels that can be associated with
`
`more than one classification, where exemplary voxel clas-
`sifications can include target, workpiece, waste, empty,
`cutting tool, cutting element, or other classifications. Sub-
`dividing the mixture voxels can be performed based on an
`octree data structure. Further, the methods and systems can
`include recombining voxels having the same classification,
`where such recombining can generally be performed based
`on neighboring voxels of the same classification.
`The methods and systems can also include a probe that
`can be calibrated and employed to register the workpiece
`and/or the cutting tool to the workpiece image and the
`cutting tool image, respectively. The disclosed tracker can
`include a tracking method and system based on providing
`one or more markers on or otherwise associated with the
`
`workpiece and/or the cutting tool. The tracker can measure
`and/or determine at least one position and at least one angle
`associated with the workpiece and/or the cutting tool, where
`in one embodiment, the tracker can track in three positions
`and three angles to provide six degrees of freedom. The
`tracked data can thus be transformed to an image coordinate
`system to allow an updating of the respective image
`positions, angles, etc.
`The image updating can also include (re)classifying vox-
`els associated with the workpiece, where the reclassification
`can be based on the tracking data associated with the
`workpiece and/or the cutting tool. Such classifying and/or
`reclassifying can include identifying voxels associated with
`the workpiece that are eliminated by the cutting tool. The
`classifying and/or reclassifying can also include identifying
`mixture voxels, subdividing the mixture voxels, and, itera-
`tively identifying and subdividing mixture voxels until
`reaching a predetermined voxel resolution. As provided
`previously, identifying mixture voxels includes identifying
`voxels having more than one classification. The subdividing
`can be based on an octree data structure. Voxel recombina-
`
`tion of voxels having the same classification can also be
`performed.
`
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`US 6,757,582 B2
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`3
`Accordingly, the methods and systems include providing
`a control based on determining a distance between the
`cutting tool image and the voxels classified based on the
`target shape. In one embodiment, the control can be based on
`increasing the size of the cutting tool image to determine
`whether the increased size cutting tool intersects with the
`target image. The cutting tool image can be increased by a
`fixed amount, and/or based on tracking data associated with
`the cutting tool. The control provided to the cutting tool can
`thus be based on the relationship between a cutting element
`associated with the cutting tool image, and voxels classified
`based on the target shape.
`In an embodiment, the control provided to the cutting tool
`can be based on the relationship between the cutting tool
`image and the voxels classified and/or associated with the
`target shape, where the relationship can be based on colli-
`sion detection and/or intersection detection between at least
`part of the cutting tool and voxels associated with the target
`shape.
`In one embodiment, the workpiece image can be under-
`stood to be associated with voxels that can be further
`
`associated with a three-dimensional grid of voxels, where an
`image associated with the workpiece can be incorporated
`into the grid, and grid voxels can be identified as being
`associated with the workpiece. Some of the workpiece
`voxels can thus further be associated with the target shape.
`The methods and systems include providing a control to
`the cutting tool by performing at least one of collision
`detection and intersection detection. Such control can per-
`forming at least one of collision detection and intersection
`detection between at least part of the cutting tool and the
`target shape of the workpiece image.
`In the disclosed methods and systems, identifying the
`target shape includes classifying voxels associated with the
`workpiece image as at least one of workpiece and target
`shape. Accordingly, providing control to the cutting tool can
`include performing at least one of collision detection and
`intersection detection between at least part of the cutting tool
`and the target shape voxels. Providing control can also
`include providing a control based on a threshold distance
`between the workpiece image and the cutting tool image.
`Also disclosed is a system that includes a cutting tool, a
`workpiece that includes a target shape, a tracker to provide
`tracking data associated with the cutting tool and the
`workpiece, and a controller to control the cutting tool based
`on the tracking data associated with the cutting tool and the
`tracking data associated with the workpiece. The cutting tool
`can include one or more cutting elements that can include
`one or more blade(s), one or more rotatable blade(s), one or
`more retractable blade(s), one or more water jet(s), one or
`more particulate jet(s), one or more lithotriptor(s) and/or one
`or more ultrasonic lithotriptor(s). The controller can control
`the cutting tool by providing a control to at least partially
`retract the cutting element(s), and/or at least partially reduce
`a rotation rate and/or change a cutting rate of the cutting
`element(s). The controller can transmit a control signal to
`the cutting tool, where the control signal includes an analog
`signal, a digital signal, and no signal.
`The systems can include a tracker that includes or other-
`wise provides tracking data based on at least three positions
`and at least three angles. The tracker can include one or more
`first markers associated with the workpiece, and one or more
`second markers associated with the cutting tool. The mark-
`ers or some of the markers can be one or more infrared
`
`sources, Radio Frequency (RF) sources, ultrasound sources,
`and/or transmitters. The tracker can thus be an infrared
`
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`
`4
`tracking system, an optical tracking system, an ultrasound
`tracking system, an inertial tracking system, a wired system,
`and/or a RF tracking system.
`The systems also include one or more images associated
`with the workpiece and at least one image associated with
`the cutting tool. The workpiece image(s) can be registered to
`the workpiece, and the cutting tool image(s) can be regis-
`tered to the cutting tool. Accordingly, the systems include a
`means to register the workpiece to the image(s) associated
`with the workpiece, and a means to register the cutting tool
`to the image(s) associated with the cutting tool. The regis-
`tration means can include a probe that can be calibrated prior
`to registration. Registration can be performed by contacting
`locations on the workpiece and/or cutting tool with the
`calibrated probe.
`The systems thus also include means to provide at least
`one image associated with the workpiece, and means to
`provide at least one image associated with the cutting tool.
`Such means can include Computer Aided Design (CAD), CT
`scan, MRI data, X-ray,
`fluoroscopy, and/or ultrasound,
`although other means can be used. The systems can update
`the images with tracking data using means to transform the
`tracking data between different coordinate systems. Such
`transformations can be mathematically effectuated.
`The systems and methods can be applied to a workpiece
`that
`includes bone, cartilage,
`tendon,
`ligament, muscle,
`connective tissue, fat, neuron, hair, skin, a tumor, and an
`organ. The cutting tool can include an endoscopic instru-
`ment.
`The controller can also include a collision detection
`module and/or an intersection detection module that can
`determine a relationship between the cutting tool and at least
`part of the workpiece.
`Disclosed is a system that includes a workpiece having a
`target shape included therein, a tracker to track at least one
`of a cutting tool and the workpiece, and, a control system,
`the control system including instructions to cause a proces-
`sor to track the cutting tool and the workpiece, to determine
`a relationship between the cutting tool and at least one of the
`workpiece and the target shape, and to provide a control to
`the cutting tool based on at least one of the relationship of
`the cutting tool and the workpiece, and the relationship of
`the cutting tool and the target shape. The control system can
`also include an image associated with the workpiece and an
`image associated with the cutting tool. The image associated
`with the workpiece can includes an image associated with
`the target shape, and/or at least part of the workpiece image
`can be designated and/or otherwise classified as being
`associated with the target shape.
`The system also includes an image registration means,
`where the image registration means registers the workpiece
`to an image associated with the workpiece, and the image
`registration means registers the cutting tool to an image
`associated with the cutting tool, and wherein the control
`system includes instructions to update at least positions of
`the workpiece image and the cutting tool image based on
`data from the tracker; and, where at
`least one of the
`relationship of the cutting tool and the workpiece, and the
`relationship of the cutting tool and the target shape, are
`based on the updated image positions.
`In the disclosed systems,
`the relationship between the
`cutting tool and the workpiece can be based on position data
`and/or angle data associated with the cutting tool(s) and/or
`the workpiece, where the position data and angle data can be
`based on the tracker. The relationship between the cutting
`tool and the target shape can thus be based on position data
`
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`US 6,757,582 B2
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`5
`and/or angle data associated with the cutting tool and/or the
`target shape, where the position data and angle data are
`based on the tracker. The instructions to determine a rela-
`
`tionship between the cutting tool and the target shape and/or
`workpiece can also include instructions to represent
`the
`workpiece as a group of volume pixels (voxels), classify
`voxels corresponding to the target shape, represent
`the
`cutting tool as a group of voxels, a surface model, and/or
`using constructive solid geometry or other geometric
`modeling, and, based on the tracker data, classify and/or
`update the voxels. The instructions to classify voxels cor-
`responding to the target shape can include classifying voxels
`as target shape and classifying voxels as waste, and/or
`instructions to color-code voxels corresponding to the target
`shape. In an embodiment, the workpiece can be represented
`as a surface model
`
`The disclosed methods and systems can include a control
`for a shaping tool that can be referred to herein as a cutting
`tool, and in one embodiment, is a freehand shape cutter, but
`can be understood to be a tool that can cut, shave, and/or
`grind. References herein to a shaping tool or cutting tool can
`accordingly be understood to represent a tool that can cut,
`shave, and/or grind.
`The disclosed methods and systems include a freehand
`shape cutter that includes a handheld cutting tool having a
`cutting element and a first marker. A second marker can be
`affixable to a workpiece that includes a target shape. A
`tracker can track a position of the cutting tool based on a
`position of the first marker, and also track a position of the
`workpiece based on a position of the second marker. A
`controller can control
`the cutting element based on the
`position of the cutting tool and the position of the workpiece
`to prevent
`the cutting element from invading the target
`shape.
`In one exemplary embodiment, the methods and systems
`include a method of shaping a bone by determining a target
`shape of the bone, aligning the target shape with the bone,
`providing a handheld cutting tool having a cutting element,
`tracking the bone and the cutting tool, cutting the bone with
`the cutting tool, and controlling the cutting element
`to
`prevent invasion of the cutting tool on the target shape. In
`such an embodiment, the target shape of the bone can be
`determined by creating a bone model based on geometrical
`data of the bone, and establishing the target shape based on
`the bone model.
`
`In one embodiment, the cutting tool can have six degrees
`of freedom, and the tracker can track with six degrees of
`freedom.
`
`The cutting element can include at least one of a blade, a
`rotatable blade, a retractable blade, a water jet, a particulate
`jet, a lithotriptor, and an ultrasonic lithotriptor. The control-
`ler can control the cutting element by at least one of stopping
`the cutting element, retracting the cutting element, progres-
`sively retracting the cutting element, switching off the
`cutting element, and interrupting power to the cutting ele-
`ment. The tracked and/or determined positions can be three-
`dimensional positions that can be tracked substantially
`simultaneously. Additionally and optionally,
`the positions
`can be tracked continuously.
`The target shape may be represented in the controller as
`a virtual template. The workpiece can include, for example,
`at least one of bone, cartilage, tendon, ligament, muscle,
`connective tissue, fat, neuron, hair, skin, tumor, and an organ
`that can include skin, brain, meninges, palate,
`tongue,
`esophagus, stomach, duodenum,
`jejunum,
`ileum, colon,
`liver, kidney, spleen, pancreas, ganglion, heart, artery, vein,
`
`5
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`10
`
`15
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`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6
`trachea, bronchus,
`lung,
`arteriole, venule, capillary,
`bronchiole, alveolus, blood, extremity, and a reproductive
`organ. A tumor can include a neoplasm, a benign tumor, a
`hyperplasia, a hypertropy, a dysplasia, an anaplasia, a
`metaplasia, a metastasis, and a malignant tumor.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`FIG. 1 is a block diagram of one embodiment;
`FIGS. 2A and 2B illustrate embodiments of the disclosed
`
`methods and systems;
`FIGS. 3A—3B provide schematic diagrams of embodi-
`ments of voxellation;
`FIGS. 4A—4C provide schematic diagrams of embodi-
`ments of voxellation;
`FIG. 5 is an architectural block diagram of one embodi-
`ment;
`
`FIGS. 6 and 7 depict embodiments of cutting systems;
`FIGS. 8 depicts an embodiment of a handheld cutting
`tool;
`FIGS. 9A and 9B depict an embodiment of a cutting tool
`with a retractable head;
`FIGS. 10A and 10B illustrate an exemplary cutting head;
`FIGS. 11A and 11B also illustrate an exemplary cutting
`head;
`FIG. 12 provides a cutting tool for endoscopic use; and
`FIG. 13 shows a cross-section of the FIG. 12 tool.
`
`DETAILED DESCRIPTION
`
`To provide an overall understanding, certain illustrative
`embodiments will now be described; however, it will be
`understood by one of ordinary skill in the art that the systems
`and methods described herein can be adapted and modified
`to provide systems and methods for other suitable applica-
`tions and that other additions and modifications can be made
`
`without departing from the scope of the systems and meth-
`ods described herein.
`
`Unless otherwise specified, the illustrated embodiments
`can be understood as providing exemplary features of vary-
`ing detail of certain embodiments, and therefore, unless
`otherwise specified, features, components, modules, and/or
`aspects of the illustrations can be otherwise combined,
`separated, interchanged, and/or rearranged without depart-
`ing from the disclosed systems or methods.
`The disclosed systems and methods include a methods
`and systems for controlling a cutting tool.
`In one
`embodiment, the cutting tool can be controlled relative to a
`workpiece and/or an object (target) that can be derived from
`the workpiece. Although the illustrated embodiments and
`other examples provided herein relate to surgical applica-
`tions where the workpiece can be, for example, a bone, those
`of ordinary skill in the art will recognize that the disclosed
`methods and systems relate to a system and method where
`a target shape can be developed from other workpieces,
`where the workpiece can include a material including, for
`example, wood, plastic, living tissue, ceramic, plaster, or
`other non-living materials. For surgical applications, work-
`pieces can include, for example,
`living tissue including
`bone, cadaveric grafts, or engineered tissue grafts.
`The disclosed methods and systems thus include and/or
`can be associated with a workpiece from which a target
`shape can be formed using a cutting tool to cut, grind away,
`or otherwise eliminate pieces or portions of the workpiece.
`When appropriate cuts are made and pieces or portions
`appropriately eliminated, the remaining workpiece can be
`
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`US 6,757,582 B2
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`7
`to the desired target shape.
`substantially similar
`Accordingly, the workpiece can be understood to include a
`target shape and waste, wherein the cutting tool can be used
`to eliminate the waste from the workpiece to leave the target
`shape. The disclosed methods and systems can thus include
`generating one or more computer models and/or a workpiece
`image that includes the target shape and a cutting tool image,
`registering the workpiece and the cutting tool to the respec-
`tive computer models and/or images, and facilitating target
`shape formation by tracking the cutting tool (and/or the
`cutting element) and the workpiece relative to the computer
`models and/or images to enable the cutting tool (and/or
`cutting element) to cut and/or eliminate those portions of the
`workpiece that are not part of the target shape. A 2D
`representation of the 3D images can be provided on a
`display.
`Ablock diagram describing the features of a method and
`system as disclosed herein can be as provided in FIG. 1. As
`previously provided, the features of FIG. 1 are not provided
`in particular order, include varying levels of detail for certain
`embodiments, and such features are presented for illustrative
`purposes. Accordingly, the illustrated features of FIG. 1 can
`be rearranged in terms of order, and as described herein,
`some features can be further detailed and/or eliminated in
`some embodiments.
`
`As FIG. 1 indicates, a workpiece image can be provided
`or otherwise generated 100 for
`input
`to a processor-
`controlled device that can include, and can be referred to
`herein, as a computer. In some embodiments, the workpiece
`image can be a three-dimensional (3-D) image and/or can be
`translated to a 3-D image for presentation. Some embodi-
`ments allow the workpiece image to be manipulated on the
`display screen by a computer user using keyboard, joystick,
`mouse, audio, and/or other commands. For example,
`in
`medical applications, the 3-D image can be provided by a
`Computer Aided Design (CAD), Computed Tomography
`(CT) Scan, Medical Resonance Imaging (MRI), and/or
`combinations of such data and/or other data that can include
`X-Ray, digital image, or other data and/or data formats. In
`an embodiment, a 3-D image can be provided by a 3-D wire
`model derived from orthogonal projections of an object, as
`described for example in Zdravkovic and Bilic, “Computer-
`assisted preoperative planning (CAPP)
`in orthopedic
`surgery,” Computer Methods and Programs in Biomedicine,
`32 (1990) 141—146. The computer can include a display and
`instructions for the processor that can cause a 2-D repre-
`sentation of the workpiece image to be presented on the
`display.
`Once the workpiece image is provided 100, a target shape
`can be integrated into the workpiece image 102. In some
`embodiments, the target shape can also be a 3-D image that
`can be integrated with the workpiece image, or the work-
`piece image may merely be modified to include designations
`of those image portions that are target shape, and those
`portions which are not target shape. For the purposes of the
`present disclosure, non-target shape areas of the workpiece
`can be referred to herein as “waste.” One method of gen-
`erating an integrated workpiece/target shape is provided in
`US. Pat. No. 6,205,411, the contents of which are herein
`incorporated by reference.
`Once the integrated workpiece/target image exists 102,
`the integrated image can be “voxellated.” The term “voxel-
`lated” as provided herein, can include a method for subdi-
`viding an image into three-dimensional (3-D) pixels, or
`“voxels,” where initially,
`the integrated image can be
`divided into voxels having resolution of, for example, 0.3
`millimeters in each of three dimensions, although such
`
`8
`resolution is merely for illustration and not limitation, and
`voxel resolution can depend on the embodiment and can
`depend, for example, on resolutions provided by a tracker
`for the disclosed methods and systems.
`In some embodiments, the voxel size and/or dimensions
`can match the cutting tool tracking system accuracy, while
`in other embodiments, the voxel size can be an integer or
`fractional multiple of the tracking system accuracy and/or
`resolution. Accordingly, workpiece image data may be resa-
`mpled to provide voxels having a desired