Trackable protective packaging for tools and methods for calibrating tool installation using the same

A method for operating a system comprising a surgical device and a tool for mounting to the surgical device, the tool including a working portion having a tool center point, a protective packaging for retaining the working portion, the protective packaging comprising trackable features having a predetermined state defined relative to an actual state of the tool center point, one or more controllers configured to store the predetermined states of the trackable features and to store an expected state of the tool center point based on an expected condition in which the tool is properly mounted to the surgical device, and a localizer, the method comprising:

• detecting, with the localizer, actual states of the trackable features in a coordinate system;
• determining, with the one or more controllers, the actual state of the tool center point in the coordinate system based on the actual states of the trackable features detected by the localizer and the predetermined state of the trackable features defined relative to the actual state of the tool center point;
• comparing, with the one or more controllers, the actual state and expected state of the tool center point;
• evaluating, with the one or more controllers, whether the tool is properly mounted to the surgical device based on comparing the actual state and expected state of the tool center point;
• and
• instructing, with the one or more controllers, generation of at least one of a haptic, audible, and visual alert in response to evaluating whether the tool is properly mounted to the surgical device.

A system comprising:

• a surgical device;
• a tool configured to mount to the surgical device and comprising a working portion having a tool center point;
• a protective packaging configured to retain the working portion of the tool, the protective packaging comprising trackable features having a predetermined state defined relative to an actual state of the tool center point;
• one or more controllers coupled to the surgical device and configured to store the predetermined states of the trackable features and to store an expected state of the tool center point based on an expected condition in which the tool is properly mounted to the surgical device;
• and
• a localizer coupled to the one or more controllers and being configured to detect actual states of the trackable features in a coordinate system;
• and wherein the one or more controllers are configured to:
• determine the actual state of the tool center point in the coordinate system based on the actual states of the trackable features detected by the localizer and the predetermined state of the trackable features defined relative to the actual state of the tool center point;
• compare the actual state and expected state of the tool center point;
• and
• evaluate whether the tool is properly mounted to the surgical device based on comparing the actual state and expected state of the tool center point.

A system comprising:

• a surgical device;
• a tool configured to mount to the surgical device and comprising a working portion having a tool center point;
• a protective packaging configured to retain the working portion of the tool, the protective packaging comprising trackable features having a predetermined state defined relative to an actual state of the tool center point;
• one or more controllers coupled to the surgical device and configured to store the predetermined states of the trackable features and to store an expected state of the tool center point based on an expected condition in which the tool is properly mounted to the surgical device;
• and
• a localizer coupled to the one or more controllers and being configured to detect actual states of the trackable features in a coordinate system;
• and wherein the one or more controllers are configured to:
• determine the actual state of the tool center point in the coordinate system based on the actual states of the trackable features detected by the localizer and the predetermined state of the trackable features defined relative to the actual state of the tool center point;
• compare the actual state and expected state of the tool center point;
• evaluate whether the tool is properly mounted to the surgical device based on comparing the actual state and expected state of the tool center point;
• and
• instruct generation of at least one of a haptic, audible, and visual alert in response to evaluating whether the tool is properly mounted to the surgical device.