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Automated Manufacture of Spinal Instrumentation
By
Richard Ryan Pilson
Thesis submitted to the Faculty of Virginia Polytechnic Institute & State
University in partial fulfillment of the requirements for the degree of
MASTERS OF SCIENCE
In
Mechanical Engineering
Harry Dankowicz, Ph.D., co-chair
Alfred Wicks, Ph.D., co-chair
Donald Leo, Ph.D.
February 6, 2006
Blacksburg, Virginia
Keywords: Scoliosis, Spinal Instrumentation, Rod, Bend
Contents
1 Introduction 1
1.1 Scoliosis Surgery . 1
1.2 Surgical echniques . 1
1.2.1 Harrington Rod Instrumentation Technique . 2
1.2.2 Bilateral Sublaminar Segmental Instrumentation Technique 2
1.2.3 Interspinous Process Segmental Instrumentation Technique 2
1.2.4 Galveston and Dunn-McCarthy Pelvic Fixation Technique .2
1.2.5 Segmental Hook and Pedicle Screw Instrumentation Technique .3
1.3 Spinal Rod Contouring Methods 3
1.4 General Rod Bending Devices 3
2 Proposed Solution 5
2.1 Spinal Instrumentation Bending Prototype .5
2.2 Challenges .6
2.3 Design Concepts 6
2.4 Design and Analysis Tools 7
3 Hardware 8
3.1 Overview .8
3.2 Feeding Mechanism 8
3.2.1 Linear Actuator and Step Motor . 9
3.2.2 Limit Switches 10
3.2.3 Support Brackets .10
3.3 Rotating Mechanism . 10
3.3.1 Step Motor and Gear Reducer .11
3.3.2 Keyless Chuck 12
3.3.3 Mounting Bracket . 12
3.4 Bending Mechanism . 12
3.4.1 Drive Assembly 13
3.4.2 Bending Assembly 16
3.4.3 Feedback Assembly 20
3.5 Frame 22
3.6 Electrical System 23
3.6.1 SIBP Power Supply and Bus Wiring 25
3.6.2 Emergency Stop Circuit 25
3.6.3 Control Panel 25
4 Software 27
4.1 Overview .27
4.2 National Instruments LabVIEW . 27
4.3 Feeding & Rotating Open Loop Control 28v
4.4 Open & Closed Loop Bending Control .29
4.4.1 Open Loop Bending Control .29
4.4.2 Closed Loop Bending Control 30
4.5 Integrated Control Application . 31
4.5.1 Control Application Flow . 31
4.5.2 Setup Application 31
4.5.3 Input 33
4.6 Manufacturing Flow . 34
4.7 Software Based Emergency Stop 36
5 Results 37
5.1 Testing Methods 37
5.2 Test Results .37
5.2.1 Local Accuracy Test Results 37
5.2.2 Global Accuracy Test Results .38
5.3 Data Analysis 44
5.3.1 Local Accuracy Comparison .44
5.3.2 Global Accuracy Data Analysis 46
6 Conclusion 49
6.1 Conclusion 49
6.2 Future Opportunities . 49
Glossary 50
Bibliography 51
Appendix A Test Data 53
Appendix B SIBP Drawings 63
Appendix C SIBP Software 85vi
List of Figures
3.1 Feeding Mechanism Components 9
3.2 Rotating Mechanism Components .11
3.3 Bending Mechanism Components . 13
3.4 Drive Assembly Components 14
3.5 Bending System Free Body Diagram 15
3.6 Bending Assembly Drawing 17
3.7 Inside and Outside Bending Assembly 18
3.8 Fulcrum Assembly Drawing 19
3.9 Feedback Assembly Drawing 21
3.10 Frame Components 22
3.11 Electrical System Components 1 . 24
3.12 Electrical System Components 2 . 24
4.1 Feeding Control VI 29
4.2 Open Loop Bending Control VI 30
4.3 Closed Loop Bending Control VI 31
4.4 Setup Application Interface . 32
4.5 Setup Application Block Diagram .33
4.6 SIBP Manufacture Control Flow Overview 35
5.1 Global Accuracy Test Rod 1 Overlay 40
5.2 Global Accuracy Test Rod 2 Overlay 41
5.3 Global Accuracy Test Rod 3 Overlay 42
5.4 Global Accuracy Test Rod 4 Overlay 43
5.5 Global Accuracy Test Rod 5 Overlay 44
B.1 Complete Assembly .65
B.2 Bending Assembly Sheet 1 66
B.3 Bending Assembly Sheet 2 67
B.4 Bending Assembly Sheet 3 68
B.5 Bending Assembly Sheet 4 69
B.6 Bending Assembly Sheet 5 70
B.7 Feedback Assembly Sheet 1 71
B.8 Feedback Assembly Sheet 2 72
B.9 Feedback Assembly Sheet 3 73
B.10 Feedback Assembly Sheet 4 74
B.11 Fulcrum Assembly Sheet 1 75
B.12 Fulcrum Assembly Sheet 2 76
B.13 Fulcrum Assembly Sheet 3 77
B.14 Bending Plate Support Bracket Assembly Sheet 1 78
B.15 Bending Plate Support Bracket Assembly Sheet 2 79vii
B.16 Gearbox Bushing . 80
B.17 Electrical Layout 81
B.18 Electrical Wiring Sheet 1 .82
B.19 Electrical Wiring Sheet 2 .83
B.20 Electrical Wiring Sheet 3 .84
C.1 Setup Application Front Panel .87
C.2 Setup Application Block Diagram . 88
C.3 Bending Open Loop Control Block Diagram. . 89
C.4 Bending Closed Loop Control Block Diagram . .90
C.5 Feeding Open Loop Control Block Diagram .91
C.6 Rotating Open Loop Control Block Diagram. .92
C.7 Main Control Application Front Panel . . 93
C.8 Main Control Application Block Diagram View 1. .94
C.9 Main Control Application Block Diagram View 2. .95
C.10 To Angles Block Diagram View 1 . . 96
C.11 To Angles Block Diagram View 2 . . 97
C.12 To Points Block Diagram View 1 . .98
C.13 To Points Block Diagram View 2 . .99
C.14 Cross Product Block Diagram . . . 100
C.15 Dot Product Block Diagram . . 101
C.16 Normalize Block Diagram . . . 102
C.17 Rotmatrix1 Block Diagram . .103
C.18 Rotmatrix3 Block Diagram . .104
C.19 Vector Length Block Diagram . . .105viii
List of Tables
3.1 Feeding Mechanism Components 9
3.2 Rotating Mechanism Components .11
3.3 Bending Mechanism Components . 13
3.4 Drive Assembly Components 13
3.5 Frame Components 22
3.6 Electrical System Components 23
5.1 SIBP Local Accuracy Test Results 38
5.2 Dr. Shilt’s Local Accuracy Test Results 38
5.3 Global Accuracy Test Results 39
5.4 Local Accuracy Descriptive Statistics . 45
5.5 Local Accuracy Two Sample T-Test . 45
5.6 Control Point Difference 47
5.7 Control Point Difference Descriptive Statistics. 48
5.8 Control Point Difference Descriptive Statistics Without Rod 4 .48
A.1 15 Degree Bend Local Accuracy Test Results 54
A.2 30 Degree Bend Local Accuracy Test Results 55
A.3 45 Degree Bend Local Accuracy Test Results 56
A.4 60 Degree Bend Local Accuracy Test Results 57
A.5 75 Degree Bend Local Accuracy Test Results 58
A.6 90 Degree Bend Local Accuracy Test Results 59
A.7 Dr. Shilt’s Local Accuracy Test Results 60
A.8 Global Accuracy Test Data 1 .61
A.9 Global Accuracy Test Data 2 .62
B.1 SIBP Drawing List .64
C.1 SIBP Control Application File List .
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