Navigation System For And Method Of Tracking The Position Of A Work Target

Abstract

Navigation system and method for tracking movement of a patient during surgery. Image data is acquired by imaging the patient with a base layer of a skin-based patient tracking apparatus secured to the patient's skin. The skin-based patient tracking apparatus includes a plurality of optical surgical tracking elements. A computer processor arrangement is adapted to implement a navigation routine. The patient position is registered to the image data. The movement of the patient is tracked based on movement of the plurality of optical surgical tracking elements. The movement of the patient's skin is tracked by determining positions of the optical surgical tracking elements both before and after a deformation of the skin-based patient tracking apparatus. Movement of the patient's skin results in corresponding movement of the surgical tracking elements to provide a dynamic reference frame for use in continuously tracking movement of a patient's skin during surgery.

Claims

1. A surgical navigation system for tracking a position of a work target located inside a patient's body in a surgical operating room, wherein the body is compressible and has a distortable outer surface, the navigation system comprising: a trackable device comprising a plurality of tracking points configured to be secured to the outer surface of skin of the patient's body, wherein the tracking points are configured to be moveable relative to each other when secured to the outer surface of the body; and a computer-implemented tracking system that is adapted to remotely track the positions of each tracking point of the trackable device relative to a coordinate system, the tracking system including a computer processor arrangement adapted to implement a navigation routine that includes the steps of: accessing an initial model of the trackable device, the initial model having an initial shape based on initial locations of a set of the tracking points of the trackable device; registering the initial model with an initial position of the work target in an image of the work target; sensing a deformation of the trackable device with the tracking system after registering the initial model; creating a refined model of the trackable device that compensates for the deformation; and calculating a current position of the work target from the refined model, wherein the trackable device is adapted to be attached to the outer surface of the skin of the patient's body so as to extend around a surgical area on the patient without covering the surgical area.

2. The navigation system of claim 1, wherein the step of creating a refined model includes at least one of the following steps: removing at least one of the tracking points of the set that is deformed more than a deviation threshold from the initial shape; and adjusting a sensed location of a tracking point relative to sensed locations of the other tracking points in the set as a function of the relative positions of the tracking points to each other and spatial deviations of these relative positions.

3. The navigation system of claim 2, wherein the step of creating a refined model includes the step of removing at least one of the tracking points of the set that is deformed more than a deviation threshold from the initial shape, and wherein the refined model is based on a reduced set of the sensed tracking points not including the removed tracking point(s).

4. The navigation system of claim 1, wherein the step of sensing the deformation comprises: tracking subsequent locations of the tracking points of the set after the initial model is registered, the subsequent locations defining a deformed shape; and identifying the deformation of the trackable device based on a difference between the deformed shape and the initial shape.

5. The navigation system of claim 4, wherein the step of identifying the deformation comprises: matching the initial shape to the deformed shape; and calculating a spatial deviation of a tracking point of the set.

6. The navigation system of claim 5, wherein the step of creating a refined model comprises removing the tracking point from the set when the spatial deviation for that tracking point exceeds a deviation threshold and is the largest spatial deviation of all the tracking points in the set, thereby basing the refined model on a reduced set of tracking points without the subsequent location of the removed tracking point.

7. The navigation system of claim 6, wherein, prior to calculating the position of the work target, the steps of matching the initial shape to the deformed shape, calculating a spatial deviation, and removing the tracking point are iteratively repeated until at least one of: no further tracking points are removed from the set of tracking points; and the set of tracking points includes fewer than a pre-defined minimum number of tracking points.

8. The navigation system of claim 1, wherein the navigation routine further includes the steps of: estimating an expected error of the current position of the work target calculated from the initial model and the deformation of the trackable device; and providing an indication to a user when the expected error exceeds a pre-defined maximum error threshold for the work target.

9. The navigation system of claim 1, wherein the navigation routine further includes the steps of: sensing the initial locations of the tracking points of the set of tracking points with a navigation sensor configured to measure a position of the tracking points relative to the navigation sensor; and creating the initial model of the trackable device from the initial locations of the set of tracking points.

10. The navigation system of claim 1, wherein the trackable device comprises a flexible substrate configured to be secured to the outer surface of the skin of the patient's body, wherein the plurality of the tracking points is carried by the flexible substrate.

11. The navigation system of claim 10, wherein the flexible substrate is in the shape of a frame surrounding a window through a central portion of the trackable device.

12. The navigation system of claim 1, wherein the trackable device comprises a plurality of separate substrates, each substrate configured to be secured to the outer surface of the skin of the patient's body spaced apart from the other substrates, wherein each substrate carries at least one of the tracking points.

13. The navigation system of claim 1, wherein the tracking points include at least one of an LED, a reflective surface, a reflective pattern, a magnetic coil, and an optically identifiable geometric shape that uniquely defines position and orientation.

14. The navigation system of claim 1, comprising a work piece adapted to be tracked by the tracking system, wherein the tracking system is adapted to track the position of the work piece relative to the coordinate system, and wherein the navigation routine further comprises the step of calculating the position of the work piece relative to the position of the work target based on the tracked position of the work piece and the calculated position of the work target.

15. A non-transitory computer readable storage medium having computer-executable instructions stored thereon that, upon execution by a computer processor arrangement, cause the computer processor arrangement to implement a method of tracking a position of a work target located inside a patient's body with a surgical navigation system in a surgical operating room, wherein the body is compressible and has a distortable outer surface, the navigation system comprising a trackable device and a computer-implemented tracking system, the trackable device comprising a plurality of tracking points configured to be secured to the outer surface of skin of the patient's body, wherein the tracking points are configured to be moveable relative to each other when secured to the outer surface of the skin of the patient's body, and the computer-implemented tracking system is configured to remotely track the positions of the tracking points of the trackable device relative to a coordinate system, and wherein the trackable device is adapted to be attached to the outer surface of the skin of the patient's body so as to extend around a surgical area on the patient without covering the surgical area, the method comprising the steps of: accessing an initial model of the trackable device when secured to the outer surface of the skin of the patient's body, the initial model having an initial shape based on initial locations of a set of the tracking points; registering the initial model with an initial position of the work target in an image of the work target; sensing a deformation of the trackable device with the tracking system after registering the initial model; creating a refined model of the trackable device that compensates for the deformations; and calculating a current position of the work target from the refined model.

16. A trackable device for a surgical navigation system for tracking a position of a work target located inside a patient's body in a surgical operating room, wherein the patient's body is compressible and has a distortable outer surface, the trackable device comprising a plurality of tracking points configured to be secured to the outer surface of skin of the patient's body and configured to be remotely tracked by a computer-implemented tracking system of the surgical navigation system, wherein the tracking points are configured to be moveable relative to each other when secured to the outer surface of the body and wherein the trackable device is adapted to be attached to the outer surface of the skin of the patient's body so as to extend around a surgical area on the patient without covering the surgical area.

17. The trackable device of claim 16, comprising a flexible substrate configured to be secured to the outer surface of the skin of the patient's body, wherein the plurality of the tracking points is carried by the flexible substrate.

18. The trackable device of claim 17, wherein the flexible substrate is in the shape of a frame surrounding a window through a central portion of the trackable device.

19. The trackable device of claim 16, comprising a plurality of separate substrates, each substrate configured to be secured to the outer surface of the skin of the patient's body spaced apart from the other substrates, wherein each substrate carries at least one of the tracking points.

20. The trackable device of claim 16, wherein the tracking points include at least one of an LED, a reflective surface, a reflective pattern, a magnetic coil, and an optically identifiable geometric shape that uniquely defines position and orientation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The above and other aspects and features of the navigation system and method presented herein may be understood further with reference to the following description and drawings of exemplary arrangements.

[0030] FIG. 1 is a schematic diagram of a navigation system according to an exemplary arrangement of the present disclosure;

[0031] FIG. 2 is a logic flow diagram of a navigation routine implemented by the navigation system of FIG. 1 according to an exemplary method;

[0032] FIG. 3 is a schematic representation of an initial model of an exemplary trackable device in in the navigation system of FIG. 1;

[0033] FIG. 4 is a schematic representation of registering the initial model of FIG. 3 with image data of the work target;

[0034] FIG. 5 is a schematic representation of sensing deformations of the trackable device in FIG. 1;

[0035] FIG. 6 is a schematic representation of a refined model of the trackable device in FIG. 1;

[0036] FIG. 7 is a logic flow diagram depicting some optional arrangements of the navigation routine of FIG. 2.

[0037] FIG. 8 is an isometric view of the exemplary trackable device shown in FIG. 1;

[0038] FIG. 9 is an isometric view of another exemplary trackable device usable in the navigation system of FIG. 1 according to additional aspects of the present disclosure;

[0039] FIG. 10 is an isometric view of a further exemplary trackable device usable in the navigation system of FIG. 1 according to aspects of the present disclosure; and

[0040] FIG. 11 is an isometric view of still a further exemplary trackable device usable in the navigation system of FIG. 1 according to aspects of the present disclosure.

DETAILED DESCRIPTION

[0041] Turning now to FIGS. 1 and 2, a navigation system 20 is arranged for tracking the position of a work target 22 located near a body 24. The work target 22 may be located inside the body 24, on the outer surface of the body 24, and/or even spaced from the body 24. The navigation system 20 includes a trackable device 26 that is adapted to be secured on the exterior of the body 24, and a computer implemented tracking system 28 which is adapted to track the position of the trackable device 26 during a navigation procedure and to detect and compensate for some deformations of the trackable device 26 during a navigation procedure. The navigation system 20 is particularly well suited for tracking the position of the work target 22 wherein the body 24 is compressible and/or has a distortable outer surface. However, the navigation system 20 is suitable for use with a body 24 that has any shape and figuration, including having a fixed shape. In the depicted example, the navigation system 20 is a surgical navigation system adapted and arranged for tracking the position of a work target inside of a patient's body, and preferably relative to one or more working tools, such as at 40, and/or operative plans. In the depicted example, the navigation system 20 is particularly adapted for surgical navigation on a human. However, the navigation system 20 may be used for surgery on other animals, and/or may be adapted for tracking the position of the work target in other types of bodies that are not humans or animals. The surgical navigation system 20 is adapted to track the position of a bone and/or an organ disposed inside of the patient 24. Thus, the work target 22 may include bones of a spine, a lung, a liver, a femur, a pelvis, an orthopedic implant, or any other object disposed inside the body. However, the navigation system 20 may also be used to track the position of work targets disposed outside of the body, such as on the skin of the patient 24. In the description of this particular exemplary arrangement, the work target 22 may be a vertebrae or a portion of the patient's spine, it being understood that other work targets are also contemplated.

[0042] The trackable device 26 includes a plurality of tracking points 30 that are configured to be secured to the outer surface of the body 24, such as the outer surface of the skin of a patient. The tracking points 30 are moveable relative to each other, such as by deforming relative to each other, when secured to the skin of the patient. The trackable device 26 is not limited to a particular shape or form, and may be rigid, flexible, and/or have multiple separate sections. Some exemplary shapes and forms of the trackable device 26 suitable for use in the navigation system 20 are discussed in detail hereinafter with reference to the trackable devices 26a-d shown in FIGS. 8 to 11. For purposes of example only, the trackable device 26 in FIG. 1 has a plurality of tracking points 30, such as LED's, disposed on a flexible substrate having the shape of a generally rectangular frame with an open window there through that can be removably secured to the patient's skin with adhesive, generally similar to the trackable device 26a shown and described hereinafter with respect to FIG. 8. However, the tracking device 26 is not limited to this particular arrangement.

[0043] The computer-implemented tracking system 28 is adapted to remotely track the position of one or more of the tracking points 30 relative to a coordinate system 32. The coordinate system 32 may be any coordinate system suitable for use with the tracking system 28, such as a global coordinate system, a local coordinate system relative to the patient 24, and/or a local coordinate system relative to some portion of the tracking system 28, such as the working tool 40 or the trackable device 26. The tracking system 28 includes a computer processor arrangement 34 adapted to implement a navigation routine 36 that is capable of detecting deformations of the trackable device 26 and compensating for at least some detected deformations during a navigation procedure implemented with the navigation system 20, as described in further detail hereinafter.

[0044] The computer-implemented tracking system 28 may take a variety of different forms, wherein a computer processor arrangement preferably is adapted to receive data from one or more sensors 38 relative to the locations of the tracking points 30, track the positions of the tracking points 30 relative to at least one coordinate system, and correlate the tracked positions to the positions of one or more additional features, such as a portion of the patient 24, the work tool 40, and/or virtual work plan information, such as a proposed osteotomy, suture, and the like. In the exemplary form shown in FIG. 1, the tracking system 28 includes the computer processor arrangement 34 and one or more sensors 38 adapted to sense the positions of the tracking points 30 remotely. The sensors 38 may include cameras, such as CCD cameras, CMOS cameras, and/or optical image cameras, magnetic sensors, radio frequency sensors, or any other sensor adapted to sufficiently sense the position of the tracking points 30. In the present exemplary arrangement, the sensors are in the form of cameras, which may be, for example, carried by a stand, secured to a wall of an operating room, and/or may be secured to the working tool 40 in a manner well understood in the art. However, other arrangements of the sensors 38 are also possible. Each of the cameras 38 is adapted to capture a view of the tracking points from a different position, and the computer processor arrangement 34 includes software and/or hardware having computing instructions adapted to calculate the location of each tracking point 30 relative to the coordinate system 32 by triangulation of the different views of the same tracking points. Optionally, one or more cameras may be carried by the surgical tool 40, and the computer processor arrangement 34 may include computing instructions adapted to calculate the pose of a tool 40 relative to a pose of the work target 22 based on images of the trackable device 26 and/or the tracking points 30 captured by the one or more cameras 38 on the tool 40. The computer processor arrangement 34 includes hardware and/or software arrangement to implement the various routines and/or methods disclosed herein. In the exemplary arrangement of FIG. 1, the computer processor arrangement also includes input output/devices, such as a keyboard 42 and a display monitor 44, and one or more data communication devices, such as data communication cables 46 and/or wireless communication devices 48. The computer processor arrangement 34 further has access to one or more databases 47 for storing various data. Optionally, the computer processor arrangement includes a data connection to a larger computer network 49 such as via the internet, wide area network, local area network, or other computer networking means. Additional and/or alternative and/or fewer hardware and programming components may also be implemented as part of the computer processor arrangement 34 as would be understood in the art.

[0045] As illustrated in FIG. 2, the navigation routine 36 implements a plurality of method steps that, when suitably implemented together with other components of the navigation system 20, enable the navigation system to track the position of the work target 22, and optionally additional components such as the tool 40, relative to at least one coordinate system. The navigation routine 36 may be implemented in software programming code accessed and/or implemented by the computer processor 34, for example from the database 47 and/or from a remote source such as via the internet at 49, and/or may include one or more ASIC configurations, in a manner that would be understood in the computer programming and control arts.

[0046] A block 50 accesses an initial model of the trackable device, such as the model 51 shown schematically in FIG. 3. The initial model 51 defines an initial shape based on the initial locations 53 of a set of the tracking points 30 from the trackable device 26 after it has been secured to the skin of the patient. The initial model 51 may be formed separately from the navigation routine 36 or it may optionally be obtained and/or formed as part of the navigation routine 36. If formed separately from the navigation routine 36, the initial model 51 may for example be stored in the database 47 or accessed via a data communication connection from a remote source such as at 49.

[0047] In one optional arrangement where the initial model 51 is formed as part of the navigation routine 36, a block 52 obtains the initial locations 53 of the tracking points 30 after the trackable device 26 has been secured to the patient 24, and a block 54 creates the initial model 51 of the trackable device 26 from the initial locations 53 of the tracking points 30. The initial locations 53 may be in the form of coordinates relative to the coordinate system 32 or some other arbitrary coordinate system, for example, defined relative to the trackable device 26. In some arrangements, the initial locations 53 are obtained with one or more of the navigation sensors 38. In some arrangements, the initial locations 53 are obtained from image data, such as a pre-operative scan. For example, the trackable device 26 and the patient 24 may be scanned together after the trackable device 26 is attached to the patient 24. The initial model 51 is created based on the coordinates of the initial locations 53 of the tracking points 30, and may be the point cloud defined by the coordinates of the initial locations 53. However, other modeling techniques for creating the initial model 51 may be used. For example, a surface mesh may be generated based on the point cloud and apriori knowledge of the trackable device 26. In some arrangements the navigation routine 36 may create the initial model 51 of the trackable device at block 54 from the locations of the set of tracking points 30 obtained from a scan data set, such as a preoperative or intraoperative MRI, x-ray, or other type of scan, without obtaining the initial locations 53 with the sensors 38 at block 52.

[0048] A block 56 registers the pose of the initial model 51 with an initial position of the work target 22 in an image data set, such as a pre-operative scan image of the patient, as shown schematically in FIG. 4. The step of registering may be performed in any manner understood in the art, such as with a point cloud matching technique, a point to point registration technique, and/or any other technique sufficient to register the pose of the initial model 51 as secured to the patient to the initial position of the work target 22 in image data set of the patient. In one arrangement, the registration may include identifying an initial pose of the initial model 51 relative to the coordinate system 32, such as a global coordinate system, from the initial locations 53 of the set of tracking points 30. Thereafter, the initial pose of the initial model 51 is registered to the initial pose of the work target 22 in a pre- or intra-operative scan image of the patient, such as an MRI, CT, X-ray, ultrasound, optical image, and the like.

[0049] After registering, a block 58 senses deformation of the trackable device 26 while tracking the locations of the tracking points 30 during a navigation procedure, as depicted schematically in FIG. 5 and discussed in further detail hereinafter. For example, as seen in FIG. 5, the sensed locations 66′ of the tracking points 30 in the upper right corner of the trackable device 26 have been deformed downwardly substantially from initial locations 53′ of the same tracking points 30 as represented in the initial model 51 of the tracking device. The sensed locations 66 of the remaining tracking points around the upper, lower, and lower left corners, however, correspond closely to the initial locations 53 of the corresponding tracking points 30. This deformation could be caused, for example, by excessive pressure against the nearby area of the skin of the patient near the upper right corner of the trackable device 26.

[0050] At a block 60, a refined model 62 of the trackable device 26 that compensates for the deformations sensed in block 58 is created, an example of which is shown schematically in FIG. 6. The refined model 62 is a model that based on a modification of the sensed locations of the tracking points after the initial model 51 has been registered to the image of the work target 22. The step of creating the refined model 62 may include excluding some tracking points that are deformed more than a selected deviation threshold from the initial shape of the trackable device 26 and/or may include adjusting a sensed location of a deformed tracking point relative to sensed locations of one or more of the other tracking points, as is explained in further detail hereinafter. In the example of FIG. 6, the refined model 62 is based on a set of the sensed locations of the tracking points that excludes the locations of tracking points that have been deformed beyond the deviation threshold. Thus, continuing with the example started above regarding FIG. 5, the refined model 62 in FIG. 6 excludes the tracking points of the upper right corner of the device, as shown schematically in the region 63 of the refined model 62 where no tracking points are shown. In this way, the refined model 62 is based on the sensed locations 66 of the tracking points 30 that have not been deformed excessively, while removing the excessively deformed tracking points from the refined model 62. This can improve the accuracy of the pose of the refined model 62 relative to the position of the work target 22 without necessitating interrupting the navigation procedure to re-register the trackable device 26 or otherwise re-set the entire setup.

[0051] Thereafter, a block 64 calculates the current position of the work target 22 from the refined model 68 in any suitable manner. Of course, it is understood that, if the sensed locations 66 of the tracking points 30 are not deformed beyond the acceptable limit, the navigation routine 36 may skip the block 60 and calculate the current position of the work target 22 directly from the model defined by the sensed locations 66 without performing further refinements to the model.

[0052] During a normal surgical navigation procedure, the blocks 50 and 56, and optionally the blocks 52 and 54, are normally performed a single time during a setup of the navigation procedure, and the blocks 58, 60, and 64 are normally iteratively repeated during the remaining course or some period of the navigation procedure until the navigation procedure is interrupted or ended for some reason. However, the iteration of the blocks 58, 60 and 64 is optional and may be performed only once and/or may include additional method steps interspersed therein.

[0053] The steps of sensing the deformations of the trackable device 26 and refining the model, as performed in the blocks 58 and 60 of the navigation routine 36 may be performed according to various different specific methods. In one exemplary method, the step of sensing deformations at block 58 includes tracking the subsequent locations 66 of the tracking points 30 after the initial model 51 has been registered to the initial location of the target 22 in the scan image. The subsequent locations 66 define a deformed model 68 having a deformed shape, which may be simply the shape of the point cloud defined by the sensed locations 66, as shown schematically in FIG. 5. Thereafter, the deformation of the trackable device 26 is identified based on one or more differences between the deformed shape 68 and the initial shape 51.

[0054] In the exemplary arrangement of FIG. 7, these steps are performed as part of the block 58. After the trackable device 26 has been registered to the work target 22 in the scan image, a block 70 obtains the subsequent location a set of the tracking points 30, for example with the sensors 38 of the tracking system 28. A block 72 identifies one or more deformations of the trackable device 26 based on one or more differences between the deformed shape 68 and the initial shape 51. With reference again to FIG. 5, in one method, the block 72 matches the initial shape 51 to the deformed shape 68. This matching may be performed by transforming the coordinates of the initial locations 55 of the tracking points 30 to the subsequent locations 66 of the tracking points 30 as sensed by the sensors 38. For example, the transformation may include an orthogonal transformation that is a result of a least squares match of the point cloud formed by the initial locations 55 with the point cloud formed by the subsequent locations 66. Alternatively, the coordinates of the subsequent locations could be transformed to match the coordinates of the initial locations, or both the initial and subsequent locations could be transformed to be based on a further coordinate system. The initial and deformed shapes 51 and 68 are matched by any suitable algorithm. One exemplary method includes performing a least squares analysis to find a best fit between the initial shape 51 and the deformed shape 68. However, other methods of matching the initial and deformed shapes may also be used.

[0055] After matching the best fit between the initial shape 51 and the deformed shape 68, a block 74 calculates a spatial deviation of one or more of the tracking points 30 of the set. As shown schematically in FIG. 5, the spatial deviation 76 may include the distance and/or direction between the subsequent location 66 of a particular tracking point and the transformed initial location 53 of the same tracking point. For example, the same tracking point 30 may have a coordinate 53′ corresponding to the transformed initial location of the tracking point and a coordinate 66′ corresponding to the subsequent location of the same tracking point. The spatial deviation 76′ in this example is equal to absolute value of the distance between the coordinate 53′ and the coordinate 66′. In some arrangement, the spatial deviation 76 may include both distance and direction between the coordinate 53′ and the coordinate 66′. However, other methods of calculating the spatial deviation 76′ may also be used. This calculation may be performed, such as iteratively, on all of the tracking points 30 in the set that define the deformed model 68 and/or can be performed on selected tracking points within the set.

[0056] A block 78 thereafter determines if one or more of the tracking points 30 is deformed (beyond an acceptable amount). In some arrangements, a tracking point 30 is considered to be deformed if it has a spatial deviation 76 that exceeds a selected deviation threshold and/or is larger than the spatial deviation of one or more of the other tracking points 30. The deviation threshold may be selected and/or defined as a static value and/or as a dynamic value. A static value may include an unchanging value, for example, a specific preselected distance above which the spatial deviation is considered to be too large and thereby considered an error. A dynamic value may change as a function of one or more selected parameters, for example, by being based on a comparison of the spatial deviation for a particular tracking point 30 in comparison to the spatial deviations of one or more other tracking points 30 in the set defining the models 51 and/or 68. However, other methods of selecting the deviation threshold may also be used. This determination may be performed individually on a point by point basis, such as by comparing each spatial deviation 76 with the deviation threshold, and/or or may be based on an agglomeration of a larger set of the tracking points, such as by comparing an averaged or composite spatial deviation of two or more of the tracking points 30 to the deviation threshold. In one exemplary arrangement, the spatial deviation of a particular tracking point 30 is compared with a pre-defined static deviation threshold. In addition, the difference of the spatial deviations of the tracking points with respect to each other is also considered. The tracking point 30 that exceeds a static pre-defined deviation threshold, for example about 2 mm, and that has the largest spatial deviation relative to the other tracking points is removed from the initial model. Then the iterative process starts with the refined model (less one tracking point) being matched with the initial model. Only one point, such as the worst tracking point (i.e., the tracking point with the largest spatial deviation), is excluded per iterative step. If there is still a second tracking point that both exceeds the deviation threshold and has the greatest deviation with respect to the other tracking points, then the iterative process repeats, and so on, until no further tracking points are removed from the model or the model does not have enough tracking points for suitable navigation. However, if all the remaining tracking points of the deformed model are not above the deviation threshold, then the target position is calculated. Similarly, if all the tracking points would have the same deviation value/vector above the deviation threshold, the model may not be altered because this deformation can be assumed to be a uniform movement of the patient 24 and/or trackable device 26 (e.g., translation of the entire patient) rather than a deformation of the trackable device 26. If one or more of the tracking points 30 has a spatial deviation greater than the deviation threshold and has the greatest spatial deviation of all the tracking points, then the navigation routine 36 advances to block 60 to refine the model before calculating the target position at block 64. Of course, if the tracking points of the deformed model 68 are not considered to be deformed, then the navigation routine 36 may optionally advance directly to block 64 to calculate the target position based on the deformed model itself.

[0057] In some arrangements, block 60 includes refining the model by removing, such as by excluding, one or more tracking points 30 from the refined model 62 when the tracking point has a spatial deviation above the deviation threshold. In this arrangement, the refined model 62 thereby has fewer tracking points than the initial model of the trackable device, as illustrated by way of example in FIG. 6. Thus, the refined model 62 is based on a reduced set of tracking points without the subsequent location of the removed tracking point. Optionally, the deformed tracking point is removed from the refined model 62 without modifying the shape of remaining portions of the deformed model 68. In another arrangement, the block 60 may refine the model by adjusting the subsequent location of one or more of the tracking points 30 without removing the tracking point from the set. In this arrangement, when the position 66′ of a sensed tracking point is considered to be deformed, the location of the deformed tracking point in the deformed model 68 may be adjusted into a corrected position in the refined model. The sensed location of a tracking point may be adjusted relative to the sensed locations of the other tracking points in the set as a function of the relative positions of the tracking points to each other and the spatial deviations of these relative positions and/or relative distances. This adjustment may be performed based on a finite element method analysis, for example based on a force spring model assumption of movements of the skin of the patient 24. In this method, the spatial deviation 76′ of a deformed tracking point 30 may be equated to a resultant force. A set of forces applied to the spring model may be calculated to shift the deformed tracking point back toward the original or initial position 53′ in the initial model. The shift may result in the shifting of one or more of the remaining tracking points 30 in the refined model. However, other tracking points 30 in the refined model may be assumed to remain static relative to the position of the work target 22. In this way, the corrected position of the deformed tracking point may be retained in the refined model rather than omitted from the refined model. In addition, the block 60 may apply both of these methods of refining the model and/or other methods of refining the model so as to compensate for deformations of the tracking points 30 after the initial positions of the tracking points have been registered to the initial position of the work target 22 in the image data set.

[0058] After refining the model at block 60, the navigation routine 36 may optionally include one or more sufficiency checks such as at blocks 80 and 82 as shown in FIG. 7. The optional block 80 determines whether the refined model 62 is still sufficient for use in the navigation procedure. In one exemplary arrangement, if the step of refining the model includes removing one or more deformed tracking points from the refined model 62, the block 80 determines if the remaining set of tracking points in the refined model includes at least some predefined minimum number of tracking points that are considered to be acceptable for reasons of accuracy or otherwise. If not, then the refined model 62 is considered to be insufficient, and a block 84 provides a notification to a user that the model is no longer sufficient for navigation, such as by ending the navigation routine 36 and/or providing a warning signal. If the refined model 62 includes the minimum number of tracking points such that the model is considered sufficient, then the navigation routine may continue. In some arrangements, the steps of matching the initial and deformed shapes, calculating spatial deviations, and refining the model may be iteratively repeated after the block 80 until either no further tracking points are removed from the set of tracking points forming the refined model 62 or the refined model includes fewer than the predefined minimum number considered acceptable. Optionally, the block 80 may calculate an averaged spatial deviation of up to all of the tracking points in the set of tracking points defining the deformed model from the spatial deviations, and the navigation routine is ended at block 84 when the averaged spatial deviation exceeds a selected value.

[0059] Optional block 82 determines whether an estimated error in the calculated location of the work target will be within an acceptable error range. In one arrangement, this is performed by estimating an expected error of the calculated current position of the work target 22 based on the initial model 51 and the deformation of the trackable device 26. Such estimation may be performed according to any desired method and/or based on any desired set of parameters. If the estimated error in the calculated position of the work target is considered to be unacceptable, for example by exceeding a predefined maximum error threshold for the work target, block 86 provides a notification to the user, such as with a warning message, error message, and/or ending the navigation routine 36. If, however, the estimated error is considered to be acceptable, such as by being within the predefined maximum error threshold, block 64 then calculates the current position of the work target 22 based on the refined model 62.

[0060] Turning now to FIGS. 8 to 11, the trackable device 26, unlike trackable devices in many previous systems, does not need to have a rigid or even fixed shape, although a rigid or fixed shape trackable device 26 may be used with the tracking system 28 if desired. Rather, due to the capabilities of the navigation routine 36 to sense and compensate for deformations of the trackable device 26, it may be formed so as to allow one or more of the various tracking points 30 to shift, such as by deforming, relative to other ones of the tracking points 30 during a navigation procedure. Thus, any one of the following exemplary trackable devices 26a-d may be used as part of the navigation system 20.

[0061] In FIG. 8, a trackable device 26a is secured to the skin of a patient 24. The trackable device 26a includes a flexible substrate 90 configured to be secure to the skin of the patient, for example with adhesive or straps. The flexible substrate 90 is in the form of a sheet having a relatively thin thickness that has unlimited flexibility, although in some arrangement it may have limited flexibility, such as by being flexible in only a limited number of directions. The tracking points 30 are carried by the flexible substrate 90. The tracking points 30 are in the form of optical tracking points, such as LEDs or passive optical marks that are visible to sensors 38 in the form of cameras. Although the following description refers to the use of LEDs for exemplary purposes, tracking systems that use passive visual markers may also be used with the systems and methods described herein. The tracking points 30 are disposed on one side of the substrate 90, and optionally an adhesive is disposed on the opposite side of the substrate for attaching the substrate 90 to the skin of the patient 24. The flexible substrate 90 is in the shape of a frame surrounding a central window 92 through a central portion of the trackable device 26a. The frame is shaped and sized such that the window 92 is large enough to encompass the area of the patient above the work target 22 and provide a surgeon with sufficient room to access the work target through the window 92 without excessively disturbing the shape of the frame. The frame is illustrated as being rectangular; however, other shapes are also possible. The number of tracking points 30 carried by the flexible substrate 90 is preferably between 20 and 40 optical emitters disposed at regular intervals around the entire circumference of the frame. However, fewer or more tracking points 30 may be disposed on the flexible substrate 90 and may be grouped in different arrangements. The trackable device 26a optionally includes a data communication link 94 suitable for sending and/or receiving data to and/or from the tracking system 28. The data communication link 94 may include a wireless communication link, for example capable of communicating with the wireless communicator 48 of the computer processor 34. The data communication link 94 may include a hard-wired communication link, for example for connection with the cable 46 to the computer processor 34. Further optionally, the tracking points 30, if optical emitters such as LEDs, may be selectively activated in response to command signals received from the tracking system 28 through the data communication link 94. Also optionally, information regarding any physical constraints of how the tracking points 30 can move relative to each other may be communicated to the tracking system 28 with the data communication link 94. Such information may include information relative to the flexibility of the substrate 90, rigidity of the substrate 90, and/or the type of connection between tracking points 30 associated with the trackable device 26a. The information may be contained in one or more memory devices associated with the trackable device 26a, such as a non-volatile memory also carried with the substrate 90.

[0062] FIG. 9 shows another form of a trackable device 26b suitable for use with the navigation system 20. Similar to the trackable device 26a, a plurality of tracking points 30, in the form of optical emitters such as LEDs, are disposed on one side of a flexible substrate 90 which is adapted to be secured to the skin of a patient with for example adhesive disposed on the opposite side of the flexible substrate. The trackable device 26b also includes a data communication link 94 and optionally a memory as described with regard to the trackable device 26a. The difference, is that the arrangement of the tracking points 30 is not necessarily in a square or rectangle as in FIG. 3. Rather, while the flexible substrate 90 forms generally the shape of a rectangular or square frame surrounding a central window 92, the tracking points 30 are arranged in clusters 95, here generally cross- or star-shaped clusters of four LEDs each, around the circumference of the frame shape of the flexible substrate 90. This may allow the individual clusters 95 of tracking points to be recognized individually as separate uniquely shaped tracking points 30 collectively. However, remaining portions of the trackable device 26b are substantially functionally the same as described with respect to the trackable device 26a.

[0063] FIG. 10 shows another exemplary trackable device 26c including a number of different and separate substrates 90a, 90b, etc., for example in the form of patches. Each substrate 90a, 90b is configured to be secured to the outer surface of the patient spaced apart from the other substrates if desired. Each substrate 90a, 90b carries at least one of the tracking points 30. In some arrangements, one or more of the substrates 90a and 90b may carry multiple tracking points 30, for example, similar to the clusters 95 shown in the arrangement of FIG. 9. Although any number of separate substrates 90a, 90b may be used to form a trackable device 26c, preferably between 10 and 40 separate substrates are provided. In the exemplary form shown in FIG. 10, twenty four separate substrates 90a, 90b, etc. are attached to the skin of the patient 24. The trackable device 26c also includes a data communication link 94 and may also include a memory as described with regard to the trackable devices 26a and 26b. With the trackable device 26c, the substrates 90a, 90b may be selectively secured to the skin of the patient in almost any conceivable arrangement desired, such as in a grid as shown in the example of FIG. 5. In such a configuration, the trackable device 26c may use passive visual patches used in combination with a camera, such as a webcam, carried by the surgical instrument 40 to track the positions. Once secured to the skin of the patient 24, the trackable device 26c performs functionally similar or the same as the trackable devices 26a or 26b.

[0064] FIG. 11 shows another exemplary trackable device 26d, in which the substrate 90 is shaped in the form of an H or I, and the tracking points 30 are spaced apart relatively evenly across the shape of the flexible substrate 90. The remaining portions of the trackable device 26d are functionally similar or identical to the corresponding components of the trackable devices 26a through 26c.

[0065] The tracking points 30 are selected to be sensed by the sensors 38 of the tracking system 28. Thus, depending on the type of sensor 38 used by the tracking system 28, the tracking points 30 may include LEDs, reflective surfaces, such as metal spheres, a reflective pattern, a magnetic coil, and/or an optically identifiable geometric shape that uniquely defines position and/or orientation of the tracking point 30. In some arrangements, at least one of the tracking points 30 may be an optical target that uniquely defines a unique pose, and the tracking system 28 includes a camera such as an optical video camera adapted to capture the image of the optical target. In this arrangement, the computer processor arrangement 34 is adapted to implement a tracking routine that calculates the pose of the optical target from the captured optical image of a single tracking point 30.

[0066] Next, an anticipated exemplary method of using the navigation system 20 is described when it is adapted for use as a surgical navigation system as shown schematically in FIG. 1. In a spinal procedure, for exemplary purposes, the trackable device 26 is secured to the skin of the patient 24 in the area of the work target 22, such as a specific target vertebrae. If the trackable device 26a is used, for example, the flexible substrate 90 is located to surround the target vertebrae so that the surgeon can gain access to the target vertebrae through the window 92. Thus, a mathematically strong distribution of tracking points 30 is provided around the work target 22 to provide a high accuracy, low error position calculation during the navigation procedure.

[0067] After the trackable device 26a is secured to the patient 24, it is registered to a pre-operative image of the patient that includes an image of the target vertebrae. In one arrangement, the initial locations 53 of the tracking points 30 are gathered by the tracking system 28 with the sensors 38. Thereafter, the navigation routine 36 creates the initial model 51 from the initial locations 53, and registers the initial model 51 to the pre-operative scan image so that the actual position of the trackable device 26a is registered with the position of the actual target vertebrae and the image of the target vertebrae in the pre-operative scan image. Alternatively, a pre-operative image of the patient 24 with the trackable device 26a already attached may be obtained.

[0068] After registration is completed, the surgical procedure advances with the aid of the navigation system in a manner generally understood in the art. If the trackable device 26a is distorted during the navigated portion of the surgical procedure, the navigation system 20 can detect, and in some cases compensate for the distortions, so as to allow the surgical procedure to proceed without having to reset system, for example by having to re-register the trackable device 26a to the patient or the pre-operative image.

[0069] In general, use of a non-rigid trackable device secured directly to the skin of the patient 24, such as the trackable device 26a, can improve accuracy of the navigation procedure by reducing the possibility of being bumped or sagging. The present navigation system improves on previous systems that used non-rigid trackable devices by being able to detect and, in some circumstances, compensate for potential distortions of the trackable device 26a during the navigated surgical procedure.

[0070] The features described in relation to the exemplary arrangements shown in the drawings can be readily combined to result in different embodiments, as suggested previously above. It is apparent, therefore, that the present disclosure may be varied in many ways. Such variations are not to be regarded as a departure from the scope of the invention, and all modifications within the scope of the appended claims are expressly included therein.