We designed a Linear Variable Differential Transformer (LVDT) sensor to deliver precise real-time positional feedback and improved measurement accuracy in surgical applications. Testing and calibration were conducted using a mechanical test rig constructed from 80/20 aluminum rails and 3D-printed parts the team designed. A breadboard circuit solution was implemented to eliminate noise and enhance measurement stability, while an aluminum casing, machined using CAM, ensured compliance with sterilization and performance standards. This approach resulted in a reliable and responsive sensor capable of meeting accuracy requirements provided by the client.
The current surgery system relies on a passive tool guide without depth sensing, forcing surgeons to use hard stops. A depth-sensing tool guide is needed to enhance safety and efficiency by providing real-time, precise feedback on tool position and depth.