Patent Description:
The invention also concerns a method to produce such a punched component, and the punched component thus obtained.

In general, prosthetic surgery instruments are known which are able to remove bone tissues by milling, cutting, abrasion and shaped to produce coordinated and conjugated bone sites suitable for the arrangement and implantation of relative components of surgical prostheses. Such instruments may be, for example, acetabular cutters, patellar cutters, glenoid cutters, rasps, broaches or similar or comparable instruments.

The aforementioned known instruments generally include an internally hollow cutting body, having a size related to the bone site to be made. On an external surface of the cutting body, a plurality of through holes are made, which are provided with sharp and protruding edges, able to carry out a mechanical excavation on the bone.

Typically, the cutting body is produced starting from an untreated component in metal material, for example, but not only, titanium or steel, which is fed to a production facility of such instruments which comprises in sequence a chip removal machine and/or a laser cutting apparatus, a sharpening machine, a grinding machine, and a punching machine, to then undergo appropriate finishing treatments.

In particular, chip removal machines or laser cutting apparatuses are used at least for the production of the aforementioned through holes and any auxiliary apertures functional for the subsequent workings.

One drawback of current production facilities is that they require manual intervention by an operator in some of the working steps. In particular, in the punching working, an operator manipulates the component to place it in cooperation with a punching press. The need for human intervention makes it impossible to ensure a good repeatability of the working results, as well as a risk to the safety of the operator themself, who necessarily enters the range of action of the machine.

In addition, the required activity is repetitive and tiring, and the operator may need pause intervals close in time, causing a decrease in productivity.

There is therefore a need to improve an automated station for the production of punched components for prosthetic surgery instruments that can overcome at least one of the drawbacks of the prior art.

In particular, an objective of the present invention is to provide an automated punching station able to reduce, as much as possible, the need for intervention by an operator for the execution of the working.

Another objective is to increase the repeatability of the working and the productivity of the process.

A further objective is to develop a method to produce a punched component in the aforementioned automated punching station.

The Applicant has studied, tested and realised the present invention to overcome the drawbacks of the prior art, and to obtain these and further objectives and advantages.

The present invention is expressed and characterised in the independent claims. The dependent claims show other features of the present invention or variants of the main solution idea.

In accordance with the aforementioned objectives, an automated punching station for the production of punched components which exceeds the limits of the prior art and eliminates the defects present therein is disclosed.

The automated punching station in accordance with the present invention may be suitable for insertion into a robotic working line for the automated production of prosthetic surgery instruments.

The punching station is able to produce the aforementioned punched components which are able, once finished, to be used in prosthetic surgery instruments. Such punched components are produced starting from hollow intermediate components which have at least one external surface and an opposite internal surface.

According to embodiments, the intermediate components have through holes having at least a segment of the edge sharp.

The aforementioned punching station comprises:.

In accordance with the aforementioned objectives, a method to produce punched components for prosthetic surgery instruments and a punched component thus made are also disclosed.

These and other aspects, features and advantages of the present invention will become clear from the following embodiment disclosure, given as a non-limiting example, with reference to the attached drawings in which:.

To facilitate understanding, identical reference numbers have been used, where possible, to identify identical common elements in the figures. It is to be understood that elements and features of an embodiment can be conveniently combined or incorporated into other embodiments without further clarification.

Reference will now be made in detail to the possible embodiments of the invention, one or more examples of which are shown in the attached figures by way of non-limiting example. The phraseology and terminology used herein is also for non-limiting exemplary purposes.

Embodiments disclosed using the attached figures refer to an automated punching station <NUM> for the production of punched components <NUM> able, once finished, to be used in prosthetic surgery instruments.

The automated station <NUM> may be suitable for insertion into a robotic working line for the automated production of the aforementioned prosthetic surgery instruments.

The aforementioned punched components <NUM>, once finished, can be used, by way of example, to produce cutting bodies such as acetabular cutters <NUM>, patellar cutters, glenoid cutters, rasps <NUM>, broaches <NUM> (<FIG>) or similar or comparable instruments.

The punched component <NUM> (<FIG>) is obtained starting from a hollow intermediate component <NUM> (<FIG>) which has at least one external surface <NUM> and an opposite internal surface <NUM>.

According to embodiments, said intermediate component <NUM> is obtained from a hollow untreated component on which cutting workings for the production of through holes <NUM>, each defined by a respective edge <NUM> and having at least one segment BB of the edge <NUM> sharp, and any grinding workings for the elimination of residual elements, or burrs, that may have formed during the previous workings have been carried out.

Untreated component means an unfinished component obtained by a drawing, bending or similar operation to obtain an internal cavity identified by said internal surface <NUM>. For example, the untreated component can be drawn starting from a flat metal sheet and, as a result, have a concave shape, more or less complex.

For example, the residual elements, or burrs, may comprise molten material formed during laser cutting of the holes. The solidified material, harder than the non-molten material, can damage or otherwise reduce the service life of punches <NUM> included in the punching station <NUM>, and should preferably be removed. As a further example, the residual elements may comprise trimmings formed during a turning operation.

Each hole <NUM> (<FIG>) can be peripherally defined by an edge <NUM>, which comprises a segment BB and a complementary segment AA.

The segment AA may have a surface inclined by a cutting angle α1, with respect to a reference plane P tangent to the external surface <NUM> passing through the centre C of the hole <NUM> (<FIG>). The segment BB may have a surface inclined by a cutting angle α2, with respect to said reference plane P.

According to embodiments, the angle α2 is different from the angle α1, in particular is smaller, so as to make the edge BB sharp. This edge BB, or cutting edge, after a punching operation that will make it protruding (<FIG>), will be able to carry out a mechanical excavation on the bone. In a preferred form, the hole <NUM> may only be sharpened in the segment BB. Alternatively, it may be sharpened both on the segment BB and on the segment AA.

The segment BB may have an internal perimeter B1, lying on the external surface <NUM>, and an external perimeter B2, lying on the internal surface <NUM>.

The intermediate component <NUM> may comprise both the through holes <NUM>, able to define a cutting part <NUM> of said cutting body <NUM>, <NUM>, <NUM> and optional auxiliary apertures functional for workings only. The auxiliary apertures may be centring notches <NUM>, perimeter slits <NUM> which define a pre-cut circumference, gripping holes <NUM> or the like, and may be comprised in correspondence with an auxiliary band <NUM> (<FIG>).

The punching station <NUM> comprises at least one automated operator <NUM>, a press device <NUM>, and a control unit <NUM> (<FIG>, <FIG>). The punching station <NUM> further comprises a transport support <NUM>, <NUM> able to receive and position a plurality of intermediate components <NUM>.

The at least one automated operator <NUM> is configured to pick up and move, one at a time, the intermediate components <NUM> from the transport support <NUM>, <NUM>, and to place them in cooperation with the press device <NUM>.

The press device <NUM> is able to cooperate with the automated operator <NUM> to carry out a punching operation, on each occasion, on the segment BB of the edge <NUM> of the hole <NUM> of the intermediate component <NUM>, for the production of a cutting part <NUM> of the prosthetic surgery instrument.

According to the invention, the press device <NUM> comprises at least one aforementioned punch <NUM> and a counter-punch <NUM>, the punch <NUM> being fixed and the counter-punch <NUM> being able to move toward the punch <NUM> during the punching working.

The control unit <NUM> is configured at least to command the automated operator <NUM> to place in cooperation, one at a time, the intermediate components <NUM> with the press device <NUM>, and to maintain each intermediate component <NUM> in a grip once placed in cooperation with the press device <NUM>, and to move in a coordinated manner the automated operator <NUM> and the press device <NUM>.

Within the present disclosure, the term "to place in cooperation" means that the automated operator <NUM> is able at least to rest the intermediate component <NUM> on the punch <NUM> in correspondence with the segment BB of the edge <NUM>, and to accompany the intermediate component <NUM> in the movement direction of the counter-punch <NUM>, or punching direction P, when the counter-punch <NUM> engages the intermediate component <NUM>.

By the term "in a coordinated manner" it is meant at least that, during the punching operation, the automated operator <NUM> moves synchronously and in the same punching direction P with the counter-punch <NUM>, toward the punch <NUM>. The punching operation is intended as the working part in which the counter-punch <NUM> engages, or contacts, the intermediate component <NUM> disposed on the punch <NUM> and moves toward the punch <NUM> to produce a protruding part of the edge <NUM> of the hole <NUM> with respect to the external surface <NUM>, from the moment in which the counter-punch <NUM> engages the intermediate component <NUM> until the instant in which the counter-punch ends its movement toward the punch <NUM>.

Within the present disclosure, the term "synchronous" means that the aforementioned automated operator <NUM> is able to move together with the counter-punch <NUM> and with the same speed thereof. According to embodiments, the synchronous movement occurs at least during the punching operation.

According to the present disclosure, therefore, the control unit <NUM> is configured to move said automated operator <NUM> synchronously, and in the same punching direction P, with respect to said counter-punch <NUM>, so as to accompany the intermediate component <NUM>, maintained in a grip by the automated operator <NUM>, in said punching direction P when said counter-punch <NUM> engages said intermediate component <NUM> in the punching operation. In fact, the automated operator <NUM>, while maintaining in a grip the intermediate component <NUM>, moves in a coordinated manner with the movement of the counter-punch <NUM>, in particular when the counter-punch <NUM> engages the intermediate component <NUM> and throughout the stroke made by the mobile counter-punch <NUM> during punching.

Advantageously, in this way it is avoided that the intermediate component <NUM> undergoes an undesired deformation in the area surrounding the hole <NUM> during punching, thus clearly, cleanly and precisely defining the cutting part <NUM>. Indeed, during the punching operation the internal perimeter B1 of the segment BB of the hole <NUM>, resting on a central and protruding part of the punch <NUM>, remains stationary, while the external perimeter B2 of the segment BB is pushed by the counter-punch <NUM> toward a peripheral part of the punch, not protruding (<FIG>, <FIG>). If the intermediate component <NUM> were maintained fixed while the external perimeter B2 deforms under the action of the counter-punch, in the surrounding area a consequent deformation would result such as to compensate for the movement of the external perimeter B2 of the segment BB.

According to embodiments, the automated operator <NUM> comprises a fixed base platform <NUM> on which a robotic articulated arm <NUM> is rotatably associated.

The robotic articulated arm <NUM> may comprise a plurality of elements <NUM> rotatably articulated with respect to each other in succession, so as to allow movement of the robotic articulated arm <NUM> according to a number of degrees of freedom sufficient to allow the robotic articulated arm <NUM> to carry out all necessary manipulations and positioning.

In the present case, the robotic articulated arm <NUM> may be moved according to six degrees of freedom. This allows picking and/or positioning from/on the transport support <NUM>, <NUM> respectively of the intermediate component <NUM> or the punched component <NUM> and subsequent manipulating operations without the intervention of an operator.

The automated operator <NUM>, controlled by the control unit <NUM>, can therefore allow the movement of the intermediate component <NUM> to obtain the desired working without the intervention of an operator.

The robotic articulated arm <NUM> may be provided with a manipulation head <NUM> for picking up and positioning the components <NUM>, <NUM> in a desired manner.

According to embodiments, the robotic articulated arm may comprise, in correspondence with the manipulation head <NUM>, a gripping device <NUM> for gripping the aforementioned components <NUM>, <NUM>.

The gripping device <NUM> may comprise gripping elements <NUM>, in particular hooks <NUM>, with reference to <FIG>, and, by way of example, two hooks <NUM>. In variations not shown, the gripping elements <NUM> can be ring-shaped bands, magnetic elements or the like.

According to embodiments and as shown in <FIG>, the gripping elements <NUM> can have coupling elements <NUM>, able to cooperate with the gripping holes <NUM>.

In this way it is possible for the automated operator <NUM> to grip the components <NUM>, <NUM> firmly.

It is also possible for the automated operator <NUM> to grip the components <NUM>, <NUM> in known positions, so as to know a priori the positioning of the holes <NUM> on the component <NUM>.

The press device <NUM> may further comprise a device body <NUM>.

The device body <NUM> may be able to support the punch <NUM> and the counter-punch <NUM>.

The device body <NUM> may comprise a body base <NUM>, a support element <NUM> for the punch <NUM>, and a movement element <NUM> of the counter-punch <NUM>.

According to embodiments, the body base <NUM> and the support element <NUM> are fixed, the movement element <NUM> is mobile.

As shown by way of example in <FIG>, the movement element <NUM> may comprise a mobile support <NUM> of the counter-punch <NUM>, and a shaft <NUM>, able to fit into a hollow structure <NUM> of the body base <NUM>.

The press device <NUM> can comprise actuating members, not shown in the figures, for example an electric, hydraulic motor and the like, able to move the movement element <NUM>.

The control unit <NUM> comprises at least one electronic memory, and a data processing unit.

The electronic memory may be connected to the processing unit and may be one or more of those commercially available, such as random access memory (RAM), read-only memory (ROM), floppy disk, hard disk, mass memory, or any other form of digital storage, local or remote.

The electronic memory may be able to contain software instructions and data executable by the at least one processing unit to command at least the automated operator <NUM> and the press device <NUM> to carry out the punching working.

The automated station <NUM> can also comprise a rotation tray <NUM>, on which the automated operator <NUM> can temporarily deposit the intermediate component <NUM>, while the manipulation head <NUM> rotates around its own axis Y, so as to grip the component <NUM> in a different working position.

A plurality of modular positioning elements <NUM> may be present on the tray <NUM>. Each of the modular positioning elements <NUM> may be associated with the tray <NUM> by means of appropriate positioning holes defined on the latter, not shown in the figure.

Each modular positioning element <NUM> is able to receive in a desired position a respective component <NUM>. The modular positioning elements <NUM> may comprise adaptor elements, to support components <NUM> of different sizes.

The components <NUM>, <NUM> may be fed to/from the automated station <NUM> by an operator in a manual mode.

According to embodiments not shown, the automated station <NUM> comprises at least one storage space able to accommodate a plurality of the aforementioned components <NUM>, <NUM>.

According to embodiments, the storage space comprises at least one tray <NUM>, or transport support <NUM>, for the components <NUM>, <NUM>. The tray <NUM> can be disposed in support, i.e. associated above, to a support structure that can comprise vertical and horizontal support elements, so as to define a shape that resembles that of the frame of a table.

On the tray <NUM> there can be a plurality of modular positioning elements <NUM>, each of which is associated with the tray <NUM> by means of appropriate positioning holes <NUM> defined on the latter.

Each modular positioning element <NUM> is able to position in a desired manner a respective component <NUM>, <NUM>. The modular positioning elements <NUM> may include adaptor elements <NUM>.

For example, in the case of components <NUM>, <NUM> having a spherical cap shape intended for the production of acetabular cutters <NUM>, the modular positioning elements <NUM> may comprise a cylindrical-shaped central body projecting from the tray <NUM>, with which a plurality of rings <NUM> having a gradually decreasing diameter may be associated.

The components <NUM>, <NUM> may be positioned on said modular positioning elements <NUM> at random or in a predefined position, for example in reference to a centring notch <NUM>.

According to embodiments, the tray <NUM> may be associated with an RFID radio frequency type identification label <NUM>, on which information relating to the components <NUM>, <NUM> supported by it is stored. The aforementioned information may relate to the type, dimension or size of the components <NUM>, <NUM>, as well as to an identifier of completed working or similar information.

According to possible embodiments, a respective identification label <NUM> may be associated with each position defined on the tray <NUM>. A respective identification label <NUM> may also be associated with the modular positioning elements <NUM> and/or the adaptor elements <NUM>.

According to embodiments, the manipulation head <NUM> may comprise devices interfacing with the aforementioned identification labels <NUM>, for reading/writing information from/on the same, for managing the punching working and any subsequent finishing workings.

In an embodiment, as shown in <FIG> and <FIG>, the punching station <NUM> may be connected to other stations of the robotic working line in an automatic mode, by means of a transport line <NUM> which comprises one or more conveying devices, for example belt, strap conveyors, or the like.

The transport line <NUM> can cooperate with the trays <NUM>, for the containment of the components <NUM>, <NUM>. The trays <NUM> may have, for example on their sides, specific gripping elements in order to be manipulated and moved in an automated manner.

In an alternative embodiment not shown in the figures, the transport line <NUM> may be able to operate as a transport support for the components <NUM>, <NUM>. The transport line <NUM> may, in this case, comprise a plurality of modular positioning elements to which adaptor elements may possibly be associated, similarly to what is disclosed above.

In an alternative embodiment not shown, the punching station <NUM> may be connected to other stations of the robotic working line in a semi-automatic mode, for example by means of robotic devices for the transport of the components from one station to the next.

Embodiments disclosed herein also relate to a method to produce punched components <NUM> for prosthetic surgery instruments, starting from hollow intermediate components <NUM> provided with through holes <NUM> defined by a respective edge <NUM>.

According to embodiments, the method provides to:.

According to embodiments, the method provides to control the automated operator <NUM> and the press device <NUM> by means of a control unit <NUM>.

The method may provide to detect the moment in which the counter-punch <NUM> engages the intermediate component <NUM> by directly or indirectly detecting parameters of the press device <NUM>. For example, it may provide to detect the electric current required by the actuating members to move the counter-punch <NUM>, for example by detecting the moment of engagement by means of the increase of the electric current required by the actuating member. For example, it may provide to detect by means of sensors the pressure of a fluid in the control circuits of the actuating members. According to an alternative embodiment, the method may provide to estimate the time required for the counter-punch <NUM> to engage the intermediate component <NUM>, based on the distance to be travelled.

The method may provide to repeat the steps disclosed above for the other holes <NUM>.

According to embodiments, the method may provide to divide the cutting part <NUM> into multiple working areas, for example into four working areas, or quadrants Q1, Q2, Q3, Q4, in case the cutting body to be obtained is an acetabular cutter <NUM>.

The method may provide to carry out the punching working on the holes <NUM> of a first working area Q1. The method may then provide to rotate the intermediate component <NUM> around an axis X thereof to repeat the same working on the holes <NUM> of one or more other working areas Q3.

As an example, the intermediate component <NUM> may be worked initially on the working area Q1 (<FIG>, c-d). It may then be rotated by an angle of <NUM>° to repeat the same working on the holes <NUM> of the working area Q3 in case the cutting body is an acetabular cutter <NUM>.

In this way, it is also possible to carry out the working on any areas temporarily covered by the gripping device <NUM>.

According to embodiments, the method may provide, once the working has been carried out on all the holes <NUM>, to deposit the punched component <NUM> on the transport support <NUM>, <NUM>.

In the exemplary case of an acetabular cutter <NUM>, the method may provide to:.

According to one embodiment, the method therefore provides to send the punched component <NUM> to subsequent finishing workings, such as manual removal of the auxiliary band <NUM>, for example along the pre-cut circumference defined by the perimeter slits <NUM>, medical type finishing, such as polishing, washing, sterilisation or the like, and control workings to obtain a finished cutting body <NUM>, <NUM>, <NUM> (<FIG>).

According to a preferred embodiment, the method provides that the intermediate components <NUM> are positioned on the transport support <NUM>, <NUM>, in correspondence with the modular positioning elements <NUM>, with an orientation known to the punching station, for example in reference to a centring notch <NUM>.

According to an alternative variant not shown in the figures, the intermediate components <NUM> are randomly oriented, and the orientation is recognised by a system recognising the position assumed by the intermediate component <NUM>, such as for example a system comprising optical devices, cameras, sensors or the like, for example by means of the recognition of the position of the centring notch <NUM>.

Advantageously, it is thus possible to know the position and orientation of the holes <NUM> for the punching working.

Embodiments disclosed herein relate to a punched component <NUM> produced by means of an automated station <NUM> and in accordance with the production method according to the invention, having at least a cutting part <NUM> delimited by an external surface <NUM> and an opposite internal surface <NUM>.

According to embodiments, the cutting part <NUM> is provided with a plurality of through holes <NUM> passing from the external surface <NUM> to the internal surface <NUM>, wherein each hole <NUM> has a segment AA and a complementary segment BB of the edge <NUM> that define it peripherally. The segment AA and the complementary segment BB may have different inclinations.

The segment AA may have an inclination of an angle α1 with respect to a reference plane P tangent to the external surface <NUM> passing through the centre C of the hole <NUM>. The segment BB may have an inclination of an angle α2 with respect to the reference plane P. The angle α2 is preferably smaller than the angle α1.

The segment BB is able, by means of a punching operation, to assume a protruding shape suitable for the production of the cutting part <NUM> (<FIG>, <FIG>).

It is clear that modifications and/or additions of parts or steps can be made to the automated station <NUM>, the production method, and the punched component <NUM> disclosed so far, without departing from the scope of the present invention as defined by the claims.

Claim 1:
Automated punching station (<NUM>) for producing punched components (<NUM>) for prosthetic surgery instruments, characterized in that said station comprises:
- a transport support (<NUM>, <NUM>) able to receive and position a plurality of hollow intermediate components (<NUM>), each provided with through holes (<NUM>) defined by a respective edge (<NUM>);
- a press device (<NUM>) comprising at least one fixed punch (<NUM>) and a counter-punch (<NUM>) mobile in a punching direction (P) with respect to said fixed punch (<NUM>) for punching each of said edges (<NUM>) for the purpose of producing a cutting part (<NUM>) of the prosthetic surgery instrument;
- at least one automated operator (<NUM>) configured to pick up, and move one at a time, said intermediate components (<NUM>) from said transport support (<NUM>, <NUM>), so as to place each intermediate component (<NUM>) in cooperation on each occasion with said press device (<NUM>) in order to punch a respective edge (<NUM>); and
- a control unit (<NUM>) configured at least to command the automated operator (<NUM>) to maintain each intermediate component (<NUM>) in a grip once placed in cooperation with the press device (<NUM>) and move said automated operator (<NUM>) synchronously, and in the same punching direction (P), with respect to said counter-punch (<NUM>), so as to accompany said intermediate component (<NUM>) in said punching direction (P) when said counter-punch (<NUM>) engages said intermediate component (<NUM>) in the punching operation.