The treatment of joint-fractures is a common task in orthopaedic surgery causing considerable health costs and patient disabilities. Percutaneous techniques have been developed to mitigate the problems related to open surgery (e.g. soft tissue damage), although their application to joint-fractures is limited by the sub-optimal intra-operative imaging (2D- fluoroscopy) and by the high forces involved. Our earlier research toward improving percutaneous reduction of intra-articular fractures has resulted in the creation of a robotic system prototype, i.e. RAFS (Robot-Assisted Fracture Surgery) system.

We propose a robot-bone attachment device for percutaneous bone manipulation, which can be anchored to the bone fragment through one small incision, ensuring the required stability and reducing the “biological cost” of the procedure. It consists of a custom-designed orthopaedic pin, an anchoring system (AS secures the pin to the bone), and a gripping system (GS connects the pin and the robot). This configuration ensures that the force/torque applied by the robot is fully transferred to the bone fragment to achieve the desired anatomical reduction.

The device has been evaluated through the reduction of 9 distal femur fractures on human cadavers using the RAFS system. The devices allowed the reduction of 7 fractures with clinical acceptable accuracy. 2 fractures were not reduced: in one case the GS failed and was not able to keep the pin stationary inside the robot (pin rotates inside the GS). The other fracture was too dislocated (beyond the operational workspace capability of the robot). A more stable GS will be designed to avoid displacements between the pin and the robot.

One of the more difficult tasks in surgery is to apply the optimal instrument forces and torques necessary to conduct an operation without damaging the tissue of the patient. This is especially problematic in surgical robotics, where force-feedback is totally eliminated. Thus, force sensing instruments emerge as a critical need for improving safety and surgical outcome. We propose a new measurement system that can be used in real fracture surgeries to generate quantitative knowledge of forces/torques applied by surgeon on tissues.

We instrumented a periosteal elevator with a 6-DOF load-cell in order to measure forces/torques applied by the surgeons on live tissues during fracture surgeries. Acquisition software was developed in LabView to acquire force/torque data together with synchronised visual information (USB camera) of the tip interacting with the tissue, and surgeon voice recording (microphone) describing the actual procedure. Measurement system and surgical protocol were designed according to patient safety and sterilisation standards.

The developed technology was tested in a pilot study during real orthopaedic surgery (consisting of removing a metal plate from the femur shaft of a patient) resulting reliable and usable. As demonstrated by subsequent data analysis, coupling force/torque data with video and audio information produced quantitative knowledge of forces/torques applied by the surgeon during the surgery. The outlined approach will be used to perform intensive force measurements during orthopaedic surgeries. The generated quantitative knowledge will be used to design a force controller and optimised actuators for a robot-assisted fracture surgery system under development at the Bristol Robotics Laboratory.