Actuator interface to sterile instrument adapter

Abstract

The present invention relates to an actuator interface to an instrument sterile adapter. A surgical system (200) includes a surgical instrument (260) that is sensitive to backlash, which will adversely affect the transmission of controlled torque and position to the surgical instrument. The surgical instrument (260) is coupled to a motor in a surgical instrument manipulator assembly (240) via a mechanical interface. The combination of the mechanical interface and the surgical instrument manipulator assembly (240) has low backlash, for example, less than 0.7 degrees. The backlash is controlled in the surgical instrument manipulator assembly (240). From a drive output disk (545) in the surgical instrument manipulator assembly to a driven disk (964) of the surgical instrument, the mechanical interface has zero backlash for torque levels used in surgery.

Description

[0001] This application is a divisional application of the divisional application 2018115675563, entitled “Actuator interface to sterile adapter for instrument”, filed on August 14, 2014. The divisional application 2018115675563 is a divisional application of Chinese patent application 201480055208.1 (PCT / US2014 / 051001).

[0002] Related Applications

[0003] This application claims priority to and the benefit of the following patent applications:

[0004] U.S. Patent Application No. 61 / 866,115 (filed on August 15, 2013 by Thomas G. Cooper et al., disclosed as “Preloaded Surgical Instrument Interface”);

[0005] U.S. Patent Application No. 61 / 866,117 (filed on August 15, 2013 by Todd R. Solomon et al., disclosed as “Variable Instrument Preloaded Mechanism Controller”);

[0006] U.S. Patent Application No. 61 / 866,118 (filed on August 15, 2013 by Thomas G. Cooper et al., disclosed as “Actuator Interface to Instrument Sterile Adapter”);

[0007] U.S. Patent Application No. 61 / 866,120 (Thomas G. Cooper et al., filed on August 15, 2013, disclosed as “Instrument Sterile Adapter Drive Features”);

[0008] U.S. Patent Application No. 61 / 866,124 (Robert E. Holop et al., filed on August 15, 2013, disclosed as “Instrument Sterile Adapter Drive Interface”); and

[0009] US Patent Application No. 61 / 866,125 (Thomas G. Cooper et al., filed on August 15, 2013, disclosed as “Robotic Instrument Driven Element”), each of which is incorporated herein by reference in its entirety. Technical Field

[0010] The present invention relates generally to surgical instruments and systems and, more particularly, to surgical instruments with low backlash drive systems. Background Art

[0011] Robotically controlled systems, such as those used for minimally invasive medical procedures, can include large and complex equipment to precisely control and drive relatively small tools or instruments. (As used herein, the terms "robot" or "robotically" and the like include teleoperation or tele-operated robotic aspects.) FIG. 1A shows an example of a known robotically controlled system 100. System 100 may be, for example, a da Part of a (da Vinci) surgical system, the system 100 includes a patient side cart 110 having a plurality of arms 130. Each arm 130 has a docking port 140 that generally includes a drive system with a mechanical interface for mounting and providing mechanical power for operation of an instrument 150. The arms 130 can be used during a medical procedure to move and position the various medical instruments 150 for the procedure.

[0012] FIG. 1B shows a bottom view of a known instrument 150. The instrument 150 generally includes a transmission or backend mechanism 152, a main tube 154 extending from the backend mechanism 152, and a functional tip 156 at the distal end of the main tube 154. The tip 156 generally includes a medical tool, such as a scalpel, scissors, forceps, or a cautery instrument that can be used during a medical procedure. A drive cable or tendon 155 is connected to the tip 156 and extends through the main tube 154 to the backend mechanism 152. The backend mechanism 152 generally provides a mechanical coupling between the drive tendons of the instrument 150 and the motorized axis of the mechanical interface of the drive system 140. Specifically, the gear or disk 153 has features such as protrusions or holes, and its position, size, and shape are set to engage complementary features on the mechanical interface of the drive system 140. In a typical instrument, the rotation of the disk 153 pulls each tendon 155 and actuates the corresponding mechanical chain in the tip 156. The system 100 is therefore able to control the movement and tension of the drive tendons 155 required for placement, orientation, and operation of the tip 156. Further details of known surgical systems are described, for example, in U.S. Patent No. 7,048,745, entitled “Surgical Robotic Tools, Data Architecture, and Use,” filed by Tierney et al. on August 13, 2001, which is incorporated herein by reference in its entirety.

[0013] The instruments 150 of the system 100 can be interchanged by removing one instrument 150 from the drive system 140 and then installing another instrument 150 to replace the removed instrument. The installation process generally requires that features on the tray 153 properly engage complementary features of the drive system 140. However, the orientation of the tray 153 on the instrument 150 is generally unknown to the patient side cart 110 prior to installation.

[0014] Further, because it is difficult to clean and sterilize complex equipment between medical procedures, equipment used in medical procedures, such as the patient side cart 110, is often covered with a sterile barrier (e.g., a plastic sheet drape). The sterile barrier can include a sterile adapter that is placed between the docking port 140 and the instrument rear end 152. For example, see U.S. Pat. No. 7,048,745 and U.S. Pat. No. 7,699,855, entitled "Sterile Surgical Adaptor," filed by Anderson et al. on March 31, 2006, which describes some exemplary sterile barriers and adapter systems, which patent applications are incorporated herein by reference in their entirety.

[0015] The typical installation process for the instrument 150 involves installing the rear end mechanism 152 together with the interventional sterile adapter, regardless of the orientation of the disk 153 on the drive system 140. The drive motor in the drive system 140 can then rotate back and forth multiple times during the installation process to ensure that the complementary features meet and firmly engage each other for the operation of the newly installed instrument 150. At a certain moment during the placement process, the drive motor is firmly engaged to rotate each disk 153. However, the instrument 150 being installed can sometimes move in an unpredictable manner during the installation process because the drive motor is at different and unpredictable times to positively engage each disk 153 of the instrument 150. For specific applications, this unpredictable movement is unacceptable. Generally speaking, a clear or limited space is required around the instrument 150 to accommodate the random movement of the instrument tip during the installation process. Summary of the invention

[0016] A surgical system includes a surgical instrument that is sensitive to backlash, which will adversely affect the transmission of controlled torque and position to the surgical instrument. The surgical instrument is coupled to a motor in a surgical instrument manipulator assembly via a mechanical interface. The combination of the mechanical interface and the surgical instrument manipulator assembly has low backlash, for example, less than 0.7 degrees. The mechanical interface couples a drive interface in the surgical instrument manipulator assembly to a driven interface of the surgical instrument. In one aspect, the mechanical interface has zero backlash for torque levels used in surgery.

[0017] Thus, an apparatus includes a surgical instrument manipulator assembly. The surgical instrument manipulator assembly includes a drive unit and a drive output assembly. The drive output assembly is coupled to the drive unit. The drive output assembly includes a low backlash coupler coupled to the drive unit. The drive output disk is coupled to the low backlash coupler. A portion of the surgical instrument manipulator assembly backlash is in the drive unit and in the coupling of the drive output disk to the low backlash coupler.

[0018] In one aspect, the drive output disk is a cylindrical body with a distal surface. A first alignment element extends from the distal surface. A second alignment element also extends from the distal surface. The first alignment element is separate from the second alignment element. When the drive output disk is mated with a disk of another component in the device, the combination of the first and second alignment elements orients the drive output disk to the disk. In one aspect, the first alignment element is a pin and the second alignment element is a tab.

[0019] In this regard, the distal surface of the drive output disk has a center and a circumferential edge. A plurality of drive pawls extend from the distal surface. Each drive pawl includes a first edge surface disposed at a first distance from the center, and a second edge surface disposed approximately adjacent to the circumferential edge. The second edge surface is opposite to the first edge surface. Further, each drive pawl includes: a first portion extending from the distal surface, the first portion being a three-dimensional structure, such as a three-dimensional rectangle; and a second portion extending from the first portion. The second portion has two opposing second portion side surfaces. Each second portion side surface is a curved surface. In one aspect, the curved surface is a portion of a circular cross-section, such as a portion of an outer surface of a cylinder.

[0020] The drive output assembly also includes a shaft. A first preload spring is coupled to the shaft. The first preload spring is also coupled to the drive output disk. The first preload spring is configured to apply a first preload force on the drive output disk when the first preload spring is compressed.

[0021] The drive output assembly also includes a second preload spring coupled to the shaft. The second preload spring combined with the first preload spring is configured to apply a second preload force on the drive output disk when the first and second preload springs are compressed. The second preload force is greater than the first preload force.

[0022] The surgical instrument manipulator assembly includes a motor group, which includes a plurality of drive units. The plurality of drive units include the drive units described above. The motor group is movably mounted in a housing of the surgical instrument manipulator assembly. The motor group also includes a plurality of hard stops. The plurality of hard stops are configured to extend from a distal side of the motor group.

[0023] The surgical instrument manipulator assembly also includes a release latch. The release latch is pivotally mounted in a housing of the surgical instrument manipulator assembly. A pin extends from a proximal portion of the release latch into the housing. In one aspect, the pin is a spring-loaded pin.

[0024] The motor group of the surgical instrument manipulator assembly also includes a release latch inhibition stop. On the one hand, if the motor group is in a fully withdrawn position relative to the housing of the surgical instrument manipulator assembly, operation of the release latch is not inhibited. However, if the motor group is in a first position relative to the housing, the pin contacts the release latch inhibition stop, and if the release latch pin is pressed, rotation of the release latch is inhibited. On the other hand, when the motor group is in the fully withdrawn position while the surgical instrument is installed in the sterile adapter assembly, the release latch inhibition stop inhibits rotation of the release latch.

[0025] In another aspect, an apparatus includes a surgical device assembly, a preload track, and a preload assembly riding on the preload track. The preload assembly is coupled to the surgical device assembly. The insertion assembly includes the preload track.

[0026] When the preload assembly is positioned at a first position on the preload track, the preload assembly applies a first force to the surgical device assembly. When the preload assembly is positioned at a second position on the preload track, the preload assembly applies a second force to the surgical device assembly. The second force is greater than the first force.

[0027] In one aspect, a preload assembly includes a cam follower assembly and an arm. The cam follower assembly rides on a preload track. The arm has a first end and a second end. The first end is coupled to the surgical device assembly. The second end of the arm is coupled to the cam follower assembly. If the cam follower assembly is positioned at a first position on the preload track, the arm is configured to transmit a force proportional to a first force from the cam follower assembly to the surgical device assembly. If the cam follower assembly is positioned at a second position on the preload track, the arm is configured to transmit a force proportional to a second force from the cam follower assembly to the surgical device assembly.

[0028] The surgical device assembly also includes a drive unit housing and a motor pack. The motor pack is movably mounted in the drive unit housing. The first end of the arm is coupled to the motor pack. If the cam follower assembly is positioned at a first position on the preload track, the arm is configured to transmit a force proportional to a first force from the cam follower assembly to the motor pack. If the cam follower assembly is positioned at a second position on the preload track, the arm is configured to transmit a force proportional to a second force from the cam follower assembly to the motor pack.

[0029] In another aspect, an apparatus includes a preload track and a preload assembly configured to ride on the preload track. The preload assembly is configured to couple to a surgical device assembly. If the preload assembly is positioned at a first position on the preload track, the preload assembly is further configured to apply a first force to the surgical device assembly.

[0030] The preload assembly includes a preload reset mechanism. The preload reset mechanism is configured to automatically place the preload assembly at a first position on the preload track.

[0031] In yet another aspect, the apparatus includes a surgical instrument manipulator assembly, an insertion assembly, and a preload assembly. The surgical instrument manipulator assembly includes a housing and a motor group. The motor group is movably mounted in the housing. The insertion assembly is coupled to the surgical instrument manipulator assembly. The insertion assembly also includes a preload track. The preload assembly includes a cam follower assembly, an arm, and a preload reset assembly. The arm includes a first end and a second end. The first end of the arm is rotatably connected to the cam follower assembly. The second end of the arm is coupled to the motor group. The cam follower assembly is configured to ride on the preload track. The preload reset assembly is configured to automatically place the preload assembly at a first position on the preload track. At the first position, the preload assembly applies a first force on the motor group.

[0032] Another apparatus includes an insertion assembly, an instrument manipulator assembly, a surgical device interface, and a surgical instrument. Sometimes, the surgical device interface is referred to as a surgical device interface element. The insertion assembly includes a distal end and a preload track. The instrument manipulator assembly is coupled to the distal end of the insertion assembly. The instrument manipulator assembly includes a drive output disk. The drive output disk has a drive output interface.

[0033] The surgical device interface is mounted on the instrument manipulator assembly. The surgical device interface includes an intermediate disk. The intermediate disk has an intermediate driven interface and an intermediate drive interface. The intermediate driven interface is coupled to the drive output interface.

[0034] The surgical instrument is mounted on the surgical device interface. The surgical instrument includes a driven disk. The driven disk has a driven interface. The driven interface is coupled to the intermediate drive interface.

[0035] If a first force is applied to the coupling between the drive output disk and the intermediate disk, the coupling between the drive output disk and the intermediate disk has non-zero backlash for a torque level used to align the two disks. If a second force is applied to the coupling between the drive output disk and the intermediate disk, the coupling between the drive output disk and the intermediate disk has zero backlash for a torque level used in a surgical procedure. The second force is greater than the first force.

[0036] Thus, the device includes a drive output disk and an intermediate disk. The drive output disk includes a distal surface and a plurality of drive pawls extending from the distal surface. Each of the plurality of drive pawls includes a first portion extending from the distal surface and being a three-dimensional structure (e.g., a three-dimensional rectangle), and a second portion extending from the first portion. The second portion includes two opposing second portion side surfaces. Each second portion side surface is a curved surface. In one aspect, the curved surface is a portion of a circular cross-section, for example, a portion of an outer surface of a cylinder. The intermediate disk includes a proximal surface, and a plurality of drive pawl receptacles extending from the proximal surface into the intermediate disk. Each of the plurality of drive pawl receptacles is configured to receive one of the plurality of drive pawls. Each of the plurality of drive pawl receptacles includes a first portion including opposing side walls extending from the outer surface into the intermediate disk; a second portion being a bottom surface of the drive pawl receptacle; and a third portion extending from the first portion to the second portion. The third portion has two opposing third portion inclined side surfaces.

[0037] The device has a first preload spring coupled to the drive output disk. When the drive output disk is coupled to the intermediate disk, the first preload spring is compressed. The compression of the first preload spring applies a first preload force to the drive output disk. When the preload force is applied to the drive output disk, the coupling between the drive output disk and the intermediate disk has a non-zero backlash for a torque level necessary to align the disks.

[0038] The apparatus also includes a second preload spring coupled to the drive output disk. The preload assembly is coupled to the first and second preload springs. When the preload assembly compresses the first and second preload springs, the compressed second spring in combination with the compressed first spring applies a second preload force to the coupling between the drive output disk and the intermediate disk. When the second preload force is applied to the coupling, the coupling between the drive output disk and the intermediate disk has zero backlash for torque levels used in surgical procedures.

[0039] In still another aspect, an apparatus includes a surgical device interface element. The surgical device interface element includes a plurality of intermediate disks and a first body structure having the plurality of intermediate disks rotatably mounted therein.

[0040] Each intermediate disk includes an intermediate driven interface and an intermediate driving interface. The intermediate driving interface is opposite to the intermediate driven interface.

[0041] The intermediate driven interface includes a first alignment socket and a drive pawl socket. The intermediate drive interface includes a drive pawl and an engagement structure.

[0042] The first alignment receptacle is configured to mate with a first alignment element extending from a drive output disk of the surgical instrument manipulator assembly. The intermediate driven interface also includes a second alignment receptacle. The second alignment receptacle is configured to mate with a second alignment element extending from the drive output disk. The first alignment receptacle is separate from the second alignment receptacle. When the drive output disk and the intermediate disk are coupled, such as mated, the combination of the first and second alignment receptacles directs the drive output disk to the intermediate disk.

[0043] The first body structure includes a plurality of hard stops. Each intermediate disk is associated with one of the hard stops. Each intermediate disk has a hard stop tab extending from an outer side surface of the disk. In a first axial position of the intermediate disk, when the intermediate disk rotates, the hard stop tab contacts the hard stop associated with the intermediate disk. In a second axial position of the intermediate disk, the intermediate disk is free to rotate and the hard stop tab does not contact the hard stop associated with the intermediate disk.

[0044] Each drive pawl receptacle includes a first portion having opposing side walls extending from an outer surface of the intermediate disk into the intermediate disk. The second portion of the drive pawl receptacle is a bottom surface of the drive pawl receptacle. The third portion of the drive pawl receptacle extends from the first portion to the second portion. The third portion includes two opposing third portion side surfaces. Each third portion side surface is an inclined surface. In one aspect, the inclined surface is a portion of a side surface of the wedge-shaped body.

[0045] Each drive pawl of the intermediate disk has a first portion, which is a three-dimensional structure, for example, a three-dimensional rectangle. The second portion of the drive pawl extends from the first portion. The second portion has two opposite second portion side surfaces. Each second portion side surface is a portion of a curved surface. In one aspect, the curved surface is a portion of a circular cross-section, for example, a portion of the outer surface of a cylinder.

[0046] Each drive pawl receptacle of the intermediate disk is arranged so that each drive pawl receptacle is bisected by a first plane. Each drive pawl of the intermediate disk is arranged so that each drive pawl is bisected by a second plane. The first plane is perpendicular to the second plane.

[0047] The surgical device interface element further includes a second main structure. The first main structure is movably mounted in the second main structure. The second main structure includes a slide plate.

[0048] The intermediate disk also has a distal surface. In one aspect, the engagement structure is an open three-dimensional structure extending from the distal surface in a distal direction. The open three-dimensional structure is a generally C-shaped structure. The C-shaped structure has a height, a first end, and a second end. The first end and the second end constrain an opening of the C-shaped structure. A centerline extends through the center of the C-shaped structure. The centerline is equidistant from the first end and the second end.

[0049] The open three-dimensional structure also includes a wall extending from one of the first end and the second end. The wall extends in a direction substantially parallel to the centerline of the C-shaped structure. The wall also extends toward the outer edge of the distal surface of the intermediate disk. The wall has a height less than the height of the C-shaped structure.

[0050] On the other hand, the open three-dimensional structure is a circular track. The circular track includes a first circumferential section having a first height, a first end, and a second end. The circular track also includes a second circumferential section extending between the first end and the second end of the first circumferential section. The second circumferential section has a second height. The second height is less than the first height. The centerline of the circular track extends through the center of the circular track and is equidistant from the first end and the second end. A C-type structure is an example of a circular track. In this regard, the open three-dimensional structure also includes a wall extending from one of the first end and the second end of the first circumferential section in a direction substantially parallel to the centerline of the circular cross-section. The wall extends toward the outer edge of the distal surface of the intermediate disk of the plurality of intermediate disks. The wall has a height. The height of the wall is less than the first height of the first circumferential section.

[0051] In one aspect, a surgical device interface element is mounted on a surgical instrument manipulator assembly. The surgical instrument manipulator assembly includes a drive output disk having a drive interface. The drive interface is coupled to an intermediate driven interface of an intermediate disk. When a predetermined preload force is applied to the drive output disk, the coupling between the intermediate disk and the drive output disk has zero backlash for torque levels used in surgery.

[0052] In another aspect, a surgical instrument is mounted on a surgical device interface element. The surgical instrument further has a driven disk with a driven interface. The driven interface is coupled to an intermediate drive interface of the intermediate disk. When a predetermined preload force is applied to the intermediate disk, the coupling between the intermediate disk and the driven disk has zero backlash for torque levels used in surgery.

[0053] Therefore, in one aspect, the device comprises an intermediate disk and a driven disk. The intermediate disk comprises an intermediate driven interface and an intermediate driving interface. The intermediate driving interface is opposite to the intermediate driven interface.

[0054] The intermediate driven interface includes an alignment socket and a drive pawl socket. The intermediate drive interface includes a drive pawl and an engagement structure.

[0055] The driven disk includes a driven interface configured to mate with the intermediate drive interface. The driven interface includes an engagement receptacle, a drive dog receptacle, and a rotationally disabling element. The rotationally disabling element includes a rotational locking mechanism that prevents rotation of the driven disk. The engagement receptacle is configured to receive the engagement structure if the engagement structure is aligned with the engagement receptacle.

[0056] In still further aspects, the device includes a surgical instrument. The surgical instrument includes a body having a driven disk receptacle. The proximal end of a shaft in the surgical instrument extends into the driven disk receptacle. The driven disk is mounted on the proximal end of the shaft so that the driven disk is seated in the driven disk receptacle.

[0057] The driven disk includes a driven interface. The driven interface includes an engagement socket, a drive dog socket, and a rotationally disabling element. The rotationally disabling element has a rotational locking mechanism. When the rotationally disabling element is engaged, the rotational locking mechanism engages the driven disk socket and prevents rotation of the driven disk.

[0058] Each drive pawl receptacle includes a first portion, a second portion, and a third portion. The first portion includes opposing side walls extending from the proximal surface of the driven disk into the driven disk. The second portion is the bottom surface of the drive pawl receptacle. The third portion extends from the first portion to the second portion. The third portion has two opposing third portion side surfaces. Each third portion side surface includes an inclined surface. In one aspect, the inclined surface is a portion of a side surface of the wedge-shaped body. In one aspect, each drive pawl receptacle includes a first edge surface disposed at a first distance from the longitudinal axis of the driven disk, and a second opening edge opposite the first edge.

[0059] The engagement receptacle includes a groove extending from a proximal surface of the driven disk into the driven disk. The groove extends from a first end to a second end. The groove has a width and a depth. The first end of the groove is separated from the rotationally disabling element by a first gap. The second end of the groove is separated from the rotationally disabling element by a second gap. The width and depth of the groove are sized to receive an engagement structure of an intermediate drive interface on the intermediate disk.

[0060] In one aspect, the rotationally disabling element is a flexure. The rotational locking mechanism extends from the flexure. In this aspect, the rotational locking mechanism includes a tang.

[0061] The driven disk receptacle has a bottom surface. A plurality of teeth extend from the bottom surface in a proximal direction.

[0062] The apparatus also includes a sterile adapter assembly. The surgical instrument is mounted on the sterile adapter assembly. The sterile adapter assembly includes an intermediate disk having an intermediate drive interface coupled to the drive interface of the driven disk. When a predetermined preload force is applied to the intermediate disk, the coupling between the intermediate disk and the driven disk has zero backlash.

[0063] The apparatus also includes a surgical instrument manipulator assembly. The sterile adapter assembly is mounted on the surgical instrument manipulator assembly. The surgical instrument manipulator assembly further includes a drive output disk having a drive interface coupled to the driven interface of the intermediate disk. When a predetermined preload force is applied to the drive output disk, the coupling between the intermediate disk and the drive output disk has zero backlash for a torque level used in a surgical procedure. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] FIG. 1A is an illustration of a prior art teleoperated minimally invasive surgical system.

[0065] FIG. 1B is an illustration of a prior art surgical device assembly.

[0066] Figure 2 is an illustration of a teleoperated surgical system including a surgical device assembly having low backlash.

[0067] Figure 3A yes Figure 2 A more detailed illustration of the configuration of a surgical device assembly in which the surgical device assembly has a known side clearance.

[0068] Figure 3B yes Figure 2 A more detailed illustration of a configuration of a surgical device assembly in which the surgical device assembly has low backlash.

[0069] FIG. 4A to FIG. 4G is a block diagram illustrating the installation of a sterile adapter assembly and surgical instrument on a surgical instrument manipulator assembly, operation of a preload mechanism to reduce backlash, an instrument removal lockout, a sterile adapter removal lockout, a preload release, and an automatic preload reset.

[0070] Figure 5 Diagram Figure 2 The distal end of the surgical instrument manipulator assembly.

[0071] Figure 6 A surgical instrument manipulator assembly is shown attached to an insertion assembly, which in turn is attached to an insertion axis base assembly.

[0072] Fig. 7A and Figure 7B A first aspect of attaching a sterile adapter assembly to a surgical instrument manipulator assembly is illustrated.

[0073] Fig. 8A Another aspect of the drive output unit and sterile adapter assembly is shown.

[0074] FIG. 8B to FIG. 8D It is a graphic Fig. 8ACross-sectional view of the coupling of the sterile adapter assembly to the drive output unit.

[0075] FIG. 8E to FIG. 8G This diagram is used for Fig. 8A A cross-sectional view of a sterile adapter latch assembly of a sterile adapter assembly.

[0076] Figure 8H yes Fig. 8A Bottom perspective view of the sterile adapter assembly.

[0077] Figure 8I yes Fig. 8A Top perspective view of the sterile adapter assembly.

[0078] Fig. 9A and Fig. 9B yes Figure 2 A more detailed illustration of the surgical instruments.

[0079] Figures 10 to 13 Stages of installation of a surgical instrument in a sterile adapter assembly are shown.

[0080] Fig.14 is a diagram of a disk stack when a drive output disk is coupled to (eg, mated to) an intermediate disk and the intermediate disk is coupled to a driven disk.

[0081] Fig.15A is an illustration of a surgical instrument manipulator assembly with the drive unit assembly housing removed and the housing surrounding the drive output unit removed.

[0082] Fig. 15B It is a side view of the planetary reducer.

[0083] Fig. 15C This is a far side view of the planetary reducer.

[0084] Fig.15D This is a close-up view of a 28:1 planetary reducer.

[0085] Fig.15E This is a close-up side view of a 9:1 planetary reducer.

[0086] Fig.16A is a more detailed illustration of the drive output components.

[0087] Fig. 16B is an end view of a low backlash coupler.

[0088] Fig. 16C is a diagram of the drive interface on the drive output disk.

[0089] Fig.16D is a cross-sectional view of the drive dog.

[0090] Fig.17Ais an illustration of a sterile adapter assembly.

[0091] Fig. 17B is an enlarged illustration of a portion of the movable body showing the socket and the intermediate disk.

[0092] Fig.18A is a diagram of the intermediate driven interface on the proximal end of the intermediate disk.

[0093] Fig.18B is an illustration of the intermediate drive interface on the distal end of the intermediate disk.

[0094] Fig.18C is a cross-sectional view of the drive dog receptacle.

[0095] Fig.18D is a cross-sectional view illustrating a drive dog inserted into a drive dog receptacle under a light preload force after the drive interface on the drive output disk has been partially coupled to the intermediate driven interface on the intermediate disk.

[0096] Fig.19A is a diagram of the driven interface on the proximal end of the driven disk.

[0097] Fig.19B is an illustration of a portion of the body of a driven interface assembly.

[0098] Fig. 20A The figure shows a cross-sectional view when the intermediate plate and the driven plate are in contact, i.e. partially coupled, but not mated.

[0099] Fig. 20B The figure shows a cross-sectional view when the intermediate plate and the driven plate are mated.

[0100] Fig.21 is a more detailed illustration of one aspect of the insert assembly.

[0101] Fig.22A and Fig. 22B The preload assembly is shown in more detail.

[0102] Fig. 22C is a free body diagram of the forces acting on the wheel in the cam follower assembly of the preload assembly.

[0103] Fig.22D and Fig.22E The motor pack is shown having moved an additional distance Δ relative to the top of the drive unit housing which has moved a distance Zload.

[0104] Fig.22F The dimensions of the preload track are illustrated on one hand.

[0105] Figure 22G is a graph of the retraction force of a surgical instrument as a function of insertion distance.

[0106] Fig.23 is a more detailed illustration of the preload component.

[0107] Fig.24A Shown is the release of the cam follower assembly.

[0108] Fig. 24B The automatic preload reset mechanism of the preload assembly is shown.

[0109] Fig.25 is a cross-sectional view of a surgical instrument manipulator assembly, a sterile adapter assembly, and a surgical instrument, with the motor group of the surgical instrument manipulator assembly including a plurality of deployed hard stops.

[0110] Fig.26A and Fig.26B is a diagrammatic representation of a release latch mechanism, and a mechanism for inhibiting operation of the release latch mechanism.

[0111] In the drawings, for single-digit codes, the first digit in the component identification number is the code when the component first appears in the drawings. For double-digit codes, the first two digits in the component identification number are the code when the component first appears in the drawings. DETAILED DESCRIPTION

[0112] In one aspect, the surgical system 200 ( Figure 2 ), for example, a minimally invasive teleoperated surgical system, includes a patient side cart 210 having an arm 220. At one end of the arm 220 is an access catheter manipulator 230. Mounted on the access catheter manipulator 230 is a master instrument manipulator 280, which in turn supports a plurality of surgical device assemblies. In one aspect, the surgical device assemblies include a surgical instrument manipulator assembly 240, an instrument sterile adapter assembly 250, and a surgical instrument 260.

[0113] Surgical instrument manipulator assembly 240 is sometimes referred to as instrument manipulator assembly 240 . Instrument sterile adapter assembly 250 is sometimes referred to as sterile adapter assembly 250 .

[0114] The access catheter manipulator 230 changes the pitch and yaw of the surgical device assembly in a group. The main tube of each surgical instrument 260 extends through a different channel in the single-port access catheter 270. In this regard, the single-port access catheter 270 is installed in a cannula. A single port refers to a single access location (e.g., a single incision, a single natural orifice, etc.) leading to a surgical site in a patient.

[0115] As used herein, a cannula is a tube that passes through the patient's body wall and is in direct contact with the patient. A cannula generally does not slide in or out relative to the patient, but the cannula can tilt and yaw about a point on its axis called the remote center of motion.

[0116] As used herein, a single-port access catheter 270 is a tube through which all surgical instruments and camera instruments must pass to reach locations within a patient. The access catheter 270 has a separate lumen for each instrument. The access catheter 270 passes through the cannula and can be twisted relative to the cannula.

[0117] As used herein, backlash is the maximum angle through which a portion of a mechanical interface can move without moving the connected portion of the mechanical interface. Surgical instrument 260 is sensitive to backlash, which will adversely affect the transmission of controlled torque and position from instrument manipulator assembly 240 to surgical instrument 260. As explained more fully below, surgical instrument 260 is coupled to a motor in instrument manipulator assembly 240 via a mechanical interface. The combination of the mechanical interface and instrument manipulator assembly 240 has low backlash, for example, less than 0.7 degrees. On the one hand, the mechanical interface has zero backlash from the output disk (drive output disk) in instrument manipulator assembly 240 to the input disk (driven disk) of surgical instrument 260.

[0118] In one aspect, the mechanical interface includes a sterile adapter assembly 250. Sterile adapter assembly 250 includes a sterile drape (not shown). The sterile drape is configured in a material equivalent to a configuration known to those skilled in the art. Sterile adapter assembly 250 is a single use product. Therefore, the portion of the mechanical interface implemented in sterile adapter assembly 250 includes a minimal number of parts, as described more fully below.

[0119] The transfer unit of surgical instrument 260 has multiple parallel input shafts. Due to manufacturing variations and tolerances, not all of these input shafts are or can be completely parallel or precisely positioned. To this end, the mechanical interface must accommodate shaft angle and planar misalignment during the process of engaging surgical instrument 260 to instrument manipulator assembly 240. During the instrument engagement process, the mechanical interface couples surgical instrument 260 to the drive motor in mechanical manipulator assembly 240 with very little, effectively zero instrument tip motion. As explained more fully below, instrument tip motion is inhibited until surgical instrument 260 engages the motor in instrument manipulator assembly 240. In addition, the distal end of surgical instrument 260 does not extend beyond the distal end of the cannula until the side play in the mechanical interface has been minimized.

[0120] Controller 290 is coupled to the surgeon's console (not shown) and to the patient side cart 210. Controller 290 represents various controllers in system 200. Controller 290 sends control commands to surgical instruments 260 in response to control commands. The control commands are based on the movement of the master machine in the surgeon's console by the surgeon. As the slave surgical instruments 260 move in response to the control commands, the display module in the system controller 290 also updates the stereoscopic view of the surgical site generated by the display device in the surgeon's console.

[0121] Although described as controller 290, it should be understood that controller 290 may be implemented in practice by any combination of hardware, software executed on a processor, and firmware. Moreover, as described herein, its functions may be performed by one unit or may be divided among different components, each of which in turn may be implemented by any combination of hardware, software executed on a processor, and firmware. When divided among different components, the components may be centralized in one location or may be distributed across system 200 for distributed processing purposes. A processor should be understood to include at least a logic unit and a memory associated with the logic unit.

[0122] Figure 3A and Figure 3B is an illustration of four surgical device assemblies 300 mounted on entry guide manipulator 230. Figure 3A In FIG. 2 , surgical device assembly 300 is positioned in a starting position, such as a first position. As explained more fully below, the mechanical interface includes a disc stack between a motor in instrument manipulator assembly 240 and a shaft in a transport unit of surgical instrument 260. Figure 3A In the configuration, a first preload force is applied to the disc stack, for example, a first predetermined force is applied to the disc stack.

[0123] As for this first preload force, the mechanical interface may have some backlash because the first preload force is not sufficient to clamp the disks in the disk stack together tightly enough to prevent relative movement between the disks in the mechanical interface. However, the design of the disks in the disk stack in the mechanical interface combined with the first preload force ensures that the disks in the disk stack remain engaged, e.g., partially coupled, until the backlash is minimized.

[0124] As for the first preload force, which is a low preload force, assuming a coefficient of friction of 0.1, the disks in the mechanical interface have zero backlash up to a first torque level, e.g., 0.13 N·m (1.17 in-lbf). Above the first torque level, there may be a known small backlash, e.g., 1.13 degrees. As described in more detail below, this force typically provides more than the first torque level because a force sufficient to rotate the disks is used to overcome friction and dynamically mate the disks quickly. In this case, the disks in the mechanical interface have non-zero backlash. Thus, in this case, the mechanical interface is said to have non-zero backlash.

[0125] exist Figure 3B , three of the four surgical device assemblies have been moved distally. Arrow 390 defines a distal direction and a proximal direction. Here, the distal direction is toward the patient 201 and away from the main instrument manipulator 280. The proximal direction is away from the patient 201 and toward the main instrument manipulator 280.

[0126] As surgical device assembly 300 moves distally on insertion assembly 331, the preload force on the disc stack automatically increases from the first preload force to the second preload force. The second preload force is an example of a second predetermined force. The second preload force reduces the backlash of the mechanical interface (i.e., the backlash between the discs in the disc stack) to zero for a torque level used in surgery.

[0127] In one aspect, the second preload force is a high preload force, for example, 10.2309 Newtons (2.3 lbf). As just described, the disk in the mechanical interface, and therefore the mechanical interface, has zero backlash at torque levels used in surgery. In one example, if the coefficient of friction is assumed to be 0.1, the mechanical interface has zero backlash for torque levels up to 0.55 Newton meters (N·m) (4.9 in-lbf). For the surgical instrument 260 to apply a surgically useful force at the end effector, a specific torque must be applied to the disk in the mechanical interface. This is considered a surgically useful torque. In one example, the surgically useful torque may be 0.5 N·m (4.425 in-lbf), and therefore in this regard, the mechanical interface has zero backlash for torque levels used in surgery.

[0128] As explained more fully below, unlike the prior art, control of the backlash is in instrument manipulator assembly 240. Previously, the backlash was controlled in the disposable sterile adapter assembly, which in one example required the sterile adapter assembly to include an injection molded part with elastic properties. Moving the control of the backlash to instrument manipulator assembly 240 allows the use of machined parts and, therefore, allows for reduced backlash.

[0129] FIG. 4A to FIG. 4Gis a block diagram illustrating the installation of a sterile adapter assembly and a surgical instrument on a surgical instrument manipulator assembly. FIG. 4A to FIG. 4G Other aspects illustrated in include operation of the preload mechanism to reduce backlash, instrument removal lockout, sterile adapter removal lockout, preload release, and automatic preload reset. FIG. 4A to FIG. 4G Not drawn to scale. Figure 4A and Figure 4G Arrow 390 in FIG. FIG. 4A to FIG. 4G in a proximal direction and a distal direction in each of the.

[0130] Figure 4A Surgical instrument manipulator assembly 440 is shown attached to insertion assembly 431. Specifically, instrument manipulator assembly housing 448 is fixedly attached to the distal end of insertion assembly 431, and thus instrument manipulator assembly housing 448 moves with the movement of insertion assembly 431. However, motor group 446 within instrument manipulator assembly housing 448 is capable of moving on rails 439. Motor group 446 is capable of moving in a distal direction and a proximal direction relative to instrument manipulator assembly housing 448. Motor group 446 is coupled to instrument manipulator assembly housing 448 by return spring 447.

[0131] The motor pack 446 is movably coupled to the insertion assembly 431 through a preload assembly 480. The preload assembly 480 rides on a preload track in the insertion assembly 431. As explained more fully below, the preload assembly 480 provides a longitudinal force in the distal direction on the motor pack 446 when the preload assembly 480 moves in the distal direction. The preload assembly 480 includes a preload release button 482.

[0132] The motor group 446 includes a plurality of drive units 441. The plurality of drive units 441 include a plurality of drive motors and a plurality of drive output assemblies. Each of the plurality of drive motors is coupled to a corresponding drive output assembly 443 of the plurality of drive output assemblies.

[0133] The drive output assembly 443 includes a preload spring assembly and a drive output disk 445. The drive output assembly 443 also includes a low backlash coupler disposed between the preload spring assembly and the drive output disk 445. The drive output disk 445 is coupled to the low backlash coupler via a set of input pins. As explained more fully below, the drive output disk 445 is a cylindrical disk including a distal surface. The distal end of each drive output disk 445 has a drive interface. The drive interface includes a drive dog and an alignment element.

[0134] The drive pawl extends from the distal surface in a distal direction. Each drive pawl includes a first portion and a second portion extending from the first portion, wherein the first portion includes a three-dimensional structure extending from the distal surface, such as a three-dimensional rectangle. The second portion of the drive pawl includes two opposing second portion side surfaces. And each second portion side surface includes a curved surface. In one aspect, the curved surface is a portion of a circular cross-section, for example, a portion of the outer surface of a cylinder.

[0135] The motor group 446 includes a plurality of hard stops 437 configured to extend from a distal side of the motor group 446, and the motor group 446 also includes a release latch inhibiting stop 438. The release latch inhibiting stop 438 extends in a distal direction from one side of the motor group 446. The release latch 435 is mounted in a wall of the instrument manipulator assembly housing 448. A latch pin 435P is coupled to a proximal portion of the release latch 435.

[0136] Figure 4A Instrument manipulator assembly 440 is shown with preload released, e.g., motor pack 446 in a fully withdrawn position. In this configuration, return spring 447 retracts motor pack 446 within instrument manipulator assembly housing 448 so that a plurality of drive output disks including drive output disk 445 do not extend from a distal face of instrument manipulator assembly housing 448. The distal face of motor pack 446 is at position 432, which is a fully withdrawn position.

[0137] In one aspect, when motor pack 446 is at fully withdrawn position 432, controller 290 causes insertion assembly 431 to move the preload track on which preload assembly 480 rides. Movement of the preload track causes preload assembly 480 to exert a longitudinal force on motor pack 446. The longitudinal force on motor pack 446 causes motor pack 446 to move distally relative to instrument manipulator assembly housing 448 to position 433, such that a plurality of drive output disks including drive output disk 445 extend from a distal side of instrument manipulator assembly housing 448, as shown. Figure 4B As shown. With respect to the motor group 446 at position 433, when the motor group 446 is at position 432, the return spring 447 is stretched from its initial state.

[0138] A surgical device interface component 450, such as a sterile adapter, may be mounted on a Figure 4B 4. However, installing surgical device interface component 450 in this configuration requires compressing multiple preload spring assemblies, including the preload spring assembly in drive output assembly 443, during the installation process.

[0139] Thus, on the one hand, if the motor group 446 is in Figure 4BIn the illustrated position, prior to installing the surgical device interface element 450, the preload release button 482 is activated, causing the first longitudinal force applied by the preload mechanism 408 on the motor group 446 to be released. As a result, the return spring 447 pulls the motor group 446 to the fully withdrawn position 432, as shown. Figure 4A As shown.

[0140] With motor pack 446 in fully retracted position 432, on the one hand, a tongue on one end of surgical device interface element 450 seats in a groove in instrument manipulator assembly housing 448 and the other end of surgical device interface element 450 moves in a proximal direction until the other end engages release latch 435, as shown in FIG4C . Figure 4C In a configuration in which motor pack 446 is fully retracted, if the proximal end of release latch 435 is pushed, release latch 435 releases surgical device interface element 450, and surgical device interface element 450 can be removed from instrument manipulator assembly 440. However, in one aspect, if a surgical instrument is installed in surgical device interface element 450 while motor pack 446 is in fully retracted position 432, operation of release latch 435 is inhibited by release latch inhibit stop 438 until after preload release button 482 is pressed (e.g., activated).

[0141] Thus, in this regard, the surgical device interface element 450 ( Figure 4C ) is mounted on the distal side of the instrument manipulator assembly 440. As explained more fully below, the surgical device interface element 450 includes a frame 451 and a movable body 451C. The movable body 451C is movable within the frame 451 in the proximal direction and the distal direction. A plurality of intermediate disks are mounted in the movable body 451C such that each of the plurality of intermediate disks can rotate relative to the frame 451. In this regard, each of the plurality of disks is identical, and thus the intermediate disk 453 represents each of the plurality of intermediate disks.

[0142] Each intermediate disk 453 of the plurality of intermediate disks includes an intermediate driven interface 455 (a first intermediate disk interface), and an intermediate drive interface 456 (a second intermediate disk interface). The intermediate driven interface 455 is opposite to and removed from the intermediate drive interface 456. In one aspect, as explained more fully below, the intermediate driven interface 455 includes a first alignment receptacle and a drive dog receptacle. The intermediate drive interface 456 includes a drive dog and an engagement structure.

[0143] Each drive dog receptacle of the intermediate driven interface is arranged so that each drive dog receptacle of the intermediate driven interface is bisected by a first plane. Each drive dog of the intermediate drive interface is arranged so that each drive dog of the intermediate drive interface is bisected by a second plane. The first plane is perpendicular to the second plane.

[0144] Each drive dog receptacle of the intermediate driven interface includes: a first portion including opposite side walls extending from the outer surface into the intermediate disk; a second portion including a bottom surface; and a third portion extending from the first portion to the second portion. The third portion includes two opposite third portion side surfaces, wherein each third portion side surface includes an inclined surface.

[0145] Each drive pawl of the intermediate drive interface includes a first portion and a second portion extending from the first portion. The first portion is a three-dimensional structure, such as a three-dimensional rectangle. The second portion includes two opposite second portion side surfaces, wherein each second portion side surface includes a curved surface. The engagement structure includes an open three-dimensional structure extending in the distal direction from the distal surface of the intermediate disk.

[0146] The movable body 451C also includes a plurality of hard stop receptacles 457. The plurality of hard stop receptacles 457 extend in a distal direction from a proximal side of the movable body 451C into the movable body 451C.

[0147] In one aspect, instrument manipulator assembly 440 includes a sensor that sends a signal to controller 290 when surgical device interface element 450 is mounted on instrument manipulator assembly 440. In response to the signal, controller 290 causes insertion assembly 431 to move the preload track on which preload assembly 480 rides, causing preload assembly 480 to reset and causing preload assembly 480 to automatically exert a longitudinal force on motor pack 446. The longitudinal force on motor pack 446 moves motor pack 446 distally relative to instrument manipulator assembly housing 448 to position 433.

[0148] When the motor group 446 moves from the fully withdrawn position 432 to the position 433, the drive interface of each drive output disk 445 of the plurality of drive output disks contacts a corresponding intermediate driven interface 455 of the plurality of intermediate driven interfaces of the plurality of intermediate disks, and in turn each intermediate disk 453 contacts the movable body 451C. When the movable body 451C moves as far distally as possible within the frame 451, further movement of the drive output disk 445 in the distal direction is inhibited.

[0149] As a result, when the motor group 446 continues to move to the position 433, in response to the longitudinal force, the return spring 447 is further stretched, and the preload spring assembly in each drive output assembly 443 of the plurality of drive output assemblies is compressed, so that the preload force is applied to each drive output disk 445 of the plurality of drive output disks. The preload force pushes the drive output disk 445 and pushes the corresponding intermediate driven interface 455, so that the preload force is transmitted to each intermediate disk 453 of the plurality of intermediate disks in the surgical device interface element 450. This configuration is Figure 4D As shown in the figure.

[0150] When external surgical device interface component 450 (sometimes referred to as a surgical device interface) is first installed on instrument manipulator assembly 440, elements of intermediate driven interface 455 may not align with corresponding elements of the drive interface on drive output disk 445. If elements of disks 453 and 445 are not aligned, the two disks are partially coupled together via features in the drive interface and the intermediate driven interface, but the two disks are not coupled to each other, e.g., mated.

[0151] Next, controller 290 sends a signal to instrument manipulator assembly 440 to rotate drive output disk 445. As explained more fully below, rotation of intermediate disk 453 is inhibited and drive output disk 445 is rotated until the drive interface of drive output disk 445 mates with intermediate driven interface 455 of intermediate disk 453. Moreover, as explained more fully below, partial coupling of elements of the drive interface on drive output disk 445 with corresponding elements of intermediate driven interface 455 on intermediate disk 453 ensures that the two disks remain partially coupled under the preload force as the two disks rotate. In one aspect, when the two disks are coupled, another sensor detects a change in the height of the disk stack and sends a signal to controller 290 to stop the rotation of drive output disk 445. An alternative technique for sensing the mating of the two disks is described below. When the two disks are mated, the preload force is reduced because the height of the disk stack is reduced.

[0152] When the motor pack 446 is in position 433, the release latch inhibiting stop 438 extends in front of the latch pin 435P coupled to the release latch 435. Therefore, if someone attempts to release the surgical device interface component 450 by pressing the proximal end of the release latch 435, the latch pin 435P contacts the release latch inhibiting stop 438, which prevents the release of the surgical device interface component 450 because the release latch 435 cannot be rotated sufficiently to release the surgical device interface component 450. Therefore, when there is a preload force on the surgical device interface component 450, the surgical device interface component 450 cannot be removed.

[0153] On the other hand, when surgical device interface element 450 is mounted on instrument manipulator assembly 440, no signal is sent to the controller and thus motor pack 446 remains in fully released position 432, as shown. Figure 4C As shown. Surgical instrument 460 can be coupled to Figure 4B Configuration or Figure 4C For purposes of illustration, the instrument manipulator assembly 440 is used. Figure 4C Configuration.

[0154] In one aspect, the first end of the surgical instrument 460 slides along the ramp in the frame 451 of the surgical device interface element 450 until the surgical instrument 460 is held in place, such as Figure 4E In one aspect, surgical instrument 460 includes a body 465 and a main tube 467. Main tube 467 extends distally from body 465. Body 465 includes driven disk receptacle 463, shaft 466, and driven disk 464. Shaft 466 and driven disk 464 are part of a transmission unit that transmits torque received through the instrument to one or more components of the instrument.

[0155] The proximal end of shaft 466 extends into driven disk receptacle 463, and driven disk 464 is mounted on the proximal end of shaft 466 such that driven disk 464 is seated in driven disk receptacle 463. Driven disk 464 includes a drive interface that interacts with intermediate drive interface 456 of intermediate disk 453.

[0156] The driven interface of the driven disk 464 includes an engagement socket, a drive pawl socket, and a rotationally disabling element. The drive pawl socket is equivalent to those described above. The rotationally disabling element includes a rotational locking mechanism. When the rotationally disabling element is engaged, the rotational locking mechanism engages the driven disk socket 463 and prevents the rotation of the driven disk 464.

[0157] When surgical instrument 460 is coupled to instrument manipulator assembly 440, each driven disk 464 pushes the corresponding intermediate disk 453 in surgical device interface element 450 proximally, allowing intermediate disk 453 to rotate freely. This increases the preload force on the disk stack. However, when surgical instrument 460 is first installed on surgical device interface element 450, the elements of intermediate drive interface 456 may not align with the corresponding elements of the driven interface on driven disk 464. If the elements of the two disks 453 and 464 are not aligned, the two disks are partially coupled together by features in intermediate drive interface 456 and the driven interface, but the two disks are not mated with each other.

[0158] As explained more fully below, when the intermediate drive interface 456 of the intermediate disk 453 is not aligned with the corresponding driven interface of the driven disk 464, the engagement structure on the intermediate drive interface 456 of the intermediate disk 453 engages a rotationally disabling element on the driven disk 464 of the surgical instrument 460. The rotationally disabling element includes a rotational locking mechanism. When the rotationally disabling element is engaged, the rotational locking mechanism engages the driven disk receptacle 463 and prevents rotation of the driven disk 464.

[0159] When surgical instrument 460 is coupled to instrument manipulator assembly 440, instrument manipulator assembly 440 detects the presence of surgical instrument 460 and sends a signal to controller 290. In response to the signal, controller 290 sends a signal to instrument manipulator assembly 440 to rotate drive output disk 445. When intermediate drive interface 456 of intermediate disk 453 rotates with driven disk 464 fixed in the proper position, each element on intermediate drive interface 456 rotates in alignment with and mates with the corresponding element of the driven interface of driven disk 464. The coupling of intermediate drive interface 456 and the driven interface on driven disk 464 releases the rotation lock on driven disk 464. Therefore, the disk stack (disks 445, 453 and 464) rotates as a unit. When disks 453 and 464 are coupled, the sensor again detects the change in the height of the disk stack and sends a signal to controller 290 to stop the rotation of drive output disk 445. When the disc stacks are mated, the preload force applied to the disc stack is referred to as a first longitudinal force, ie, a first preload force.

[0160] The above description assumes that Figure 4D In the illustrated configuration, surgical instrument 460 is mounted with instrument manipulator assembly 440 and surgical device interface element 450. However, in a different aspect, if instrument manipulator assembly 440 and surgical device interface element 450 are mounted in Figure 4C In the illustrated configuration, when surgical instrument 460 is installed, the sensor sends a signal to the controller and, as described above, the controller automatically resets the preload so that disks 445, 453, and 464 are under the preload force. The controller then rotates the drive output disk 445 so that the disk stack is aligned, mated, and rotated as a unit in a manner equivalent to that described above. Thus, when surgical instrument 460 is installed, regardless of the initial position of motor group 446 relative to positions 432 and 433, the resulting configuration is Figure 4E Shown in.

[0161] The first longitudinal force is applied to the motor group 446 Figure 4E In the configuration of , the surgical device interface element 450 cannot be removed without releasing the preload. However, the surgical instrument 460 can still be removed. As explained more fully below, in one aspect, there are release buttons on each side of the surgical instrument 460. Engaging the release buttons causes the mechanism in the surgical instrument 460 to proximally push the movable body 451C in the surgical device interface element 450, causing the intermediate disk 453 and the driven disk 464 to disengage and the surgical instrument 460 can be removed.

[0162] When surgical instrument 460 is inserted into the cannula by moving instrument manipulator assembly 440 along insertion assembly 431, a second preload force is applied by preload assembly 480 to the stack of disks 445, 453, and 464 before the tip assembly coupled to main tube 467 extends from the distal end of the cannula. Specifically, when surgical instrument 460 moves distally, preload assembly 480 moves distally along the preload track. As explained more fully below, when instrument manipulator assembly 440 moves distally a predetermined distance Zload, preload assembly 480 causes motor group 446 to move a predetermined distance Zload plus an additional distance Δ, so that motor group 446 is at position 434. The movement of motor group 446 by the additional distance Δ compresses the preload spring assembly in each drive output assembly 443 of the plurality of drive output assemblies, so that a second preload force is applied to each drive output disk 545 of the plurality of drive output disks. The second preload force reduces any backlash between rotation of the motor shaft in the drive unit 441 and rotation of the shaft 467 in the surgical instrument 460 to less than 0.7 degrees before the distal end of the surgical instrument 260 exits the cannula.

[0163] The movement of the motor group 446 an additional distance Δ also further stretches the return spring 447, and furthermore inserts each of the plurality of hard stops 437 into a corresponding hard stop receptacle in the plurality of hard stop receptacles 457. The plurality of hard stops 437 prevent any proximal movement of the movable body 451C in the surgical device interface element 450. The combination of the plurality of hard stops 437 and the plurality of hard stop receptacles 457 form a surgical instrument removal interlock and prevent removal of the surgical instrument 460. If someone attempts to engage the release button on the surgical instrument 460, the mechanism in the surgical instrument 460 cannot proximally push the movable body 451C in the surgical device interface element 450 because the plurality of hard stops 437 prevent any proximal movement of the movable body 451C, and therefore the intermediate disk 453 and the driven disk 464 cannot disengage.

[0164] The use of multiple hard stop receptacles 457 is illustrative only and not limiting. In another aspect, multiple hard stop receptacles 457 are not used. Instead, multiple hard stops 437 contact the proximal surface of movable body 451C and prevent movement of movable body 451C in the proximal direction.

[0165] If for some reason it is necessary to remove the surgical instrument 460 while the distal tip of the surgical instrument 460 extends beyond the distal end of the cannula, one pushes the preload release button 482. When pushed, the preload release button 482 causes the longitudinal force on the motor pack 446 to be released. As a result, the return spring 447 pulls the motor pack 446 to the fully withdrawn position 432.

[0166] With motor pack 446 fully withdrawn, multiple hard stop receptacles 457 in movable body 451C of surgical device interface element 450 are retracted and disks 453 and 464 are no longer subject to any preload force. Thus, a release button on surgical instrument 460 can be used to remove surgical instrument 460 in surgical device interface element 450 at any position of insertion assembly 431. Additionally, release latch inhibit stop 438 is withdrawn and release latch 435 can be used to disengage surgical device interface element 450 from instrument manipulator assembly 440 at any position of insertion device 431. In one aspect, release of surgical device interface element 450 is inhibited until preload release button 482 is pressed, e.g., release latch inhibit stop 438 inhibits operation of release latch 435 until preload release button 482 is pressed. The preload is automatically reset, as described above, and next surgical device interface element 450 is installed and insertion assembly 431 is moved to the fully retracted position.

[0167] Figures 5 to 13 The parts of the surgical device assembly 300 are shown assembled to obtain Figure 3A One aspect of the illustrated configuration. Figure 5 The distal end of the instrument manipulator assembly 240 is shown. The instrument manipulator assembly 240 includes a drive unit assembly 541 and a drive output unit 542. In this regard, the drive output unit 542 includes a plurality of drive output assemblies 543P, for example, eight drive output assemblies. Herein, the drive output assembly 543 refers to any one of the eight drive output assemblies. In one aspect, only six of the eight drive output assemblies are used. The drive output assembly 543 includes a low backlash coupler 544 (sometimes referred to as a coupler 544) and a drive output disk 545. See also Fig.16A In one aspect, a coupler having a backlash of less than 0.3 degrees is considered a low backlash coupler.

[0168] Drive output disks 545 are coupled to low backlash coupler 544 via a set of output pins. As explained more fully below, drive output disks 545 are cylindrical disks that include a distal surface. The distal end of each drive output disk 545 has a drive interface 557. Drive interface 557 includes a drive dog and an alignment element. Figure 5 , the drive dog and the first and second alignment elements are moved in the distal direction from the distal end surface of the drive output disk 545 (see Fig. 16C )extend.

[0169] Figure 6 The instrument manipulator assembly 240 is shown attached to the insertion assembly 331, which in turn is attached to the insertion axis base assembly 632. The insertion axis base assembly 632 includes a motor and power electronics to move the insertion assembly 331.

[0170] Sterile adapter assembly 250 includes sterile adapter frame 651 and sterile drape (not shown). Sterile drape is fixedly attached to sterile adapter frame 651. Sterile adapter assembly 250 is an example of a surgical device interface element. Sterile adapter frame 651 is an example of a surgical device interface element body. More broadly, a surgical device interface element is a structure that includes a mechanical interface between a drive interface of a drive system and a driven interface of a surgical instrument.

[0171] A plurality of tongues 652A, 652B extend from a first end 651A of sterile adapter frame 651. First end 651A is sometimes referred to as a closed end of sterile adapter assembly 250 and a closed end of sterile adapter frame 651. Each tongue 652A, 652B is configured to mate with a corresponding groove 647A, 647B of a plurality of grooves in drive output unit 542. A second end 651B of sterile adapter frame 651 includes a lip 654 that is engaged by a sterile adapter release latch 635 of drive output unit 542 when sterile adapter frame 651 is mounted on drive output unit 542. Second end 651B is sometimes referred to as an open end of sterile adapter assembly 250 and an open end of sterile adapter frame 651.

[0172] As explained more fully below, sterile adapter frame 651 includes movable body 651C. Movable body 651C is movable within sterile adapter frame 651 in a proximal direction and a distal direction.

[0173] A plurality of intermediate disks 653P are mounted in a plurality of intermediate disk receptacles of movable body 651C such that each intermediate disk can rotate relative to sterile adapter frame 651 and relative to movable body 651C. Thus, a plurality of intermediate disks 653P are rotatably mounted in sterile adapter frame 651. Intermediate disk 653 represents each intermediate disk in plurality of intermediate disks 653P. Intermediate disk 653 is a representative intermediate disk.

[0174] Each intermediate disk 653 includes an intermediate driven interface 655 on a first side of the intermediate disk 653 and an intermediate drive interface 756 ( FIG. 7 ) on a second side of the intermediate disk 653. The first side is opposite to and removed from the second side. The intermediate driven interface 655 of each intermediate disk 653 is located at a position corresponding to the intermediate driven interface 655 of the intermediate disk 653. Figure 6 651C, and the intermediate disk 653 is mounted in the intermediate disk receptacle of the movable body 651C. The intermediate driven interface 655 is configured to mate with the drive interface 557 on the drive output disk 545 in the drive output unit 542.

[0175] To install sterile adapter assembly 250 on instrument manipulator assembly 240, each tongue 652A, 652B is inserted into a corresponding groove 647A, 647B in drive output unit 542. Fig. 7A Sterile adapter frame 651 is then rotated until lip 654 is engaged by sterile adapter release latch 635. Referring to elements 652A, 652B as tongues and elements 647A, 647B as grooves is illustrative only and not limiting. Alternatively, elements 652A, 652B may be described as tenons or protrusions and elements 647A, 647B may be described as mortises or cavities.

[0176] When sterile adapter frame 651 is locked to drive output unit 542, as shown in FIG. Figure 7B As shown, plunger 546 of instrument manipulator assembly 240 is depressed. When plunger 546 is depressed, a signal is generated that indicates to controller 290 the presence of sterile adapter assembly 250. In response to the signal, controller 290 in surgical system 200 first causes a preload force ( 546 ) to be generated on each of drive output disks 545P of a plurality of drive output disks 545P. Figure 5 ) automatic preload reset mechanism (see Fig. 24B ) is powered on, and the controller then sends a signal to instrument manipulator assembly 240 to rotate each drive output disk 545 of plurality of drive output disks 545P.

[0177] As explained more fully below, each drive output assembly 543 in drive output unit 542 is spring loaded and automatically positioned so that a preload force is applied to each drive output disk 545 after sterile adapter assembly 250 is installed on instrument manipulator assembly 240. The preload force pushes against drive output disk 545 and pushes against a corresponding intermediate driven interface 655 of intermediate disk 653 in sterile adapter frame 651.

[0178] However, in Figure 7B , when sterile adapter frame 651 is first installed on instrument manipulator assembly 240, elements of intermediate driven interface 655 may not align with corresponding elements of drive interface 557 on drive output disk 545. If elements of two disks 653 and 545 are not aligned, the two disks are partially coupled, but the two disks are not paired with each other. Therefore, the disk stack including partially coupled disks 545 and 653 (i.e., the first disk and the second disk) has a first height. After the preload force is applied to the disk stack, the controller rotates drive output disk 545.

[0179] As explained more fully below, rotation of intermediate disk 653 is inhibited while drive output disk 545 is rotated until the two disks mate. Moreover, as explained more fully below, coupling of elements of drive interface 557 on drive output disk 545 with corresponding elements of intermediate driven interface 655 on intermediate disk 653 ensures that the two disks remain partially coupled under a preload force while drive output disk 545 is rotated. When the two disks mate, in one aspect, the height of the disk stack has a second height that is less than the first height, and a sensor in instrument manipulator assembly 240 detects this change in height and sends a signal to controller 290 to stop rotation of drive output disk 545. Alternative ways of detecting the mating of the drive output disk and the intermediate disk are described below.

[0180] Figure 7B Also shown is a preload assembly 780 coupled to the motor pack in drive unit assembly 541. Preload assembly 780 is a more detailed example of an aspect of preload assembly 480.

[0181] Preload assembly 780 rides on a preload track in insert assembly 331 (see Fig.22A Instrument manipulator assembly housing 741 and instrument sterile adapter assembly 250 are fixedly attached to the distal end of insertion assembly 331 and move with the distal end of insertion assembly 331 as a unit.

[0182] However, the motor assembly within the instrument manipulator assembly housing 741 (see FIG. 22A to FIG. 22B ) is capable of moving in the distal and proximal directions relative to the instrument manipulator assembly housing 741. As explained more fully, when the preload assembly 780 moves in the distal direction, the preload assembly 780 provides a longitudinal force in the distal direction on the motor group. The longitudinal force causes the spring in the drive output assembly 543 to compress, which generates the second preload force. The second preload force reduces any backlash to less than 0.7 degrees before the distal end of the surgical instrument 260 leaves the cannula.

[0183] Return to Fig. 7A , the intermediate drive interface 756 on the far side of the intermediate disk 653 of the plurality of intermediate disks 653P is visible. Fig. 7A and Figure 7B Also visible in FIG. 6 is an instrument insertion slide 755B extending from the inside surface of sterile adapter frame 651. There is a similar instrument insertion slide 755A extending from the inside surface on the opposite side of sterile adapter frame 651. Fig. 7A and Figure 7B , side 751B (sometimes referred to as lip 751B of movable body 651C) is also visible. Fig.11 Side 751A is shown.

[0184] FIG. 8A to FIG. 8I An alternative example of surgical device interface element 450 and an alternative example of sterile adapter assembly 250 are shown, sterile adapter assembly 250A. Sterile adapter assembly 250A includes a sterile adapter frame 851 and a sterile drape (not shown). The sterile drape is fixedly attached to sterile adapter frame 851. Sterile adapter frame 851 is an example of a surgical device interface element body.

[0185] A plurality of grooves 852A, 852B ( Figure 8H and Figure 8I ) extends into first end 851A of sterile adapter frame 851 to form first and second lips 852A1, 852B1. First end 851A is sometimes referred to as the closed end of sterile adapter assembly 250A and the closed end of sterile adapter frame 851. The depth and size of each groove 852A, 852B is configured to allow the surface of the corresponding hook 847A, 847B on the distal end of ventral latch assembly 847 to engage the corresponding lip 852A1, 852B1.

[0186] Each of the first and second lips 852A1, 852B1 includes a first surface and a second surface. The second surface is opposite to the first surface, for example, the first surface is a proximal surface and the second surface is a distal surface. The second surface of the lip is longer than the first surface of the lip in a direction perpendicular to the axis 890. The third surface of the lip extends between the first surface and the second surface and gradually decreases in view of the different lengths of the first surface and the second surface. In one aspect, the third surface is a bevel surface.

[0187] Second end 851B of sterile adapter frame 851 includes lip 854 engaged by lip 835L that extends inwardly toward axis 890 from a distal portion of sterile adapter release latch 835 of drive output unit 542A when sterile adapter assembly 250A is mounted on drive output unit 542A. Second end 851B is sometimes referred to as the open end of sterile adapter assembly 250A and the open end of sterile adapter frame 851.

[0188] The lip 854 includes a first surface and a second surface. The second surface is opposite to the first surface, for example, the first surface is a proximal surface and the second surface is a distal surface. The second surface of the lip 854 is longer than the first surface of the lip 854 in a direction perpendicular to the axis 890. The third surface of the lip 854 extends between the first surface and the second surface and gradually decreases in view of the different lengths of the first surface and the second surface. In one aspect, the third surface is a bevel surface.

[0189] As explained more fully below, sterile adapter frame 851 includes movable body 851C. Movable body 851C is capable of moving in the proximal and distal directions within sterile adapter frame 851. An instrument insertion slide 855A extends from the inside surface of sterile adapter frame 851. There is a similar instrument insertion slide 855B extending from the inside surface on the opposite side of sterile adapter frame 851. Fig. 8A , the side 851C1 (sometimes referred to as the lip 851C1 of the movable body 851C) is also visible.

[0190] The features and operation of movable body 851C are the same as those of movable body 651C, and thus the description of the features and operation of movable body 651C is not repeated herein for movable body 851C. Furthermore, the mounting of the surgical instrument on sterile adapter assembly 250A is the same as described with respect to sterile adapter assembly 250, and thus the description for sterile adapter assembly 250A is not repeated.

[0191] To install sterile adapter assembly 250A on instrument manipulator assembly 240, sterile adapter assembly 250A is moved axially in a proximal direction along longitudinal axis 890, i.e., as indicated by arrow 891 ( Fig. 8A and Figure 8B ) until the sterile adapter assembly engages via features of drive output unit 542A, as explained more fully below. FIG. 8B to FIG. 8D is a cross-sectional view illustrating the components used to mount sterile adapter assembly 250A to drive output unit 542A. Drive output unit 542A is similar to drive output unit 542, except for latching mechanism 860 for sterile adapter assembly 250A included in drive output unit 542A.

[0192] Frame 842F of drive output unit 542A includes a first sterile adapter alignment element 845A (sometimes referred to as a first alignment element) extending from a distal surface of frame 842F and a second sterile adapter alignment element 845B (sometimes referred to as a second alignment element) also extending from a distal surface of frame 842F. Sterile adapter alignment element 845A is adjacent to ventral latch assembly 847 but on the inside of ventral latch assembly 847, while sterile adapter alignment element 845B is adjacent to sterile adapter release latch 835 but on the inside of sterile adapter release latch 835.

[0193] When sterile adapter assembly 250A moves axially to the vicinity of the distal surface of drive output unit 542A, first sterile adapter alignment element 845A enters, for example, engages, first sterile adapter alignment receptacle 853A ( Figure 8H and Figure 8I). Similarly, second sterile adapter alignment element 845B enters, e.g., engages, second sterile adapter alignment receptacle 853B in sterile adapter frame 851. The alignment element and receptacle are configured to align sterile adapter assembly 250A such that further movement of sterile adapter assembly 250A in the proximal direction causes latch mechanism 860 to engage sterile adapter assembly 250A.

[0194] First and second alignment elements 845A, 845B are examples of multiple sterile adapter alignment elements. First and second alignment receptacles 853A, 853B are examples of multiple alignment receptacles. Thus, in this regard, drive output unit 542A, and therefore instrument manipulator assembly 240, includes multiple sterile adapter alignment elements, and sterile adapter assembly 250A includes multiple alignment receptacles. Alternatively, multiple receptacles may be formed in drive output unit 542A, and multiple alignment elements may extend from the proximal side of sterile adapter frame 851.

[0195] As sterile adapter assembly 250A moves further in the proximal direction, the tapered surface of hook 847A contacts the tapered surface of lip 852A1 of sterile adapter assembly 250A, and the tapered surface of hook 847B contacts the tapered surface of lip 852B1 of sterile adapter assembly 250A. Similarly, the tapered surface of lip 835L of sterile adapter release latch 835 contacts the tapered surface of lip 854 of sterile adapter assembly 250A.

[0196] Further movement of sterile adapter assembly 250A in the proximal direction causes the distal portion of sterile adapter release latch 835 to pivot outwardly away from axis 890 of drive output unit 542A and causes hooks 847A, 847B of ventral latch assembly 847 to pivot outwardly away from axis 890 of drive output unit 542A. After hooks 847A and 847B and lip 835L move distally beyond lip 852A1 and lip 852B1, and after lip 835L moves distally beyond lip 854, hooks 847A and 847B and lip 835L pivot inwardly toward axis 890 such that lip 835L engages lip 854, hook 847A engages lip 852A1, and hook 847B engages lip 852B1. Specifically, the proximal surface of each hook contacts the second surface of the corresponding lip. Thus, as shown in FIG. Fig.8D As illustrated, sterile adapter assembly 250A is installed on drive output unit 542A by simply moving sterile adapter assembly 250 along axis 890 toward the distal side of drive output unit 542A.

[0197] FIG. 8E to FIG. 8G 860 is a cross-sectional view illustrating sterile adapter latch mechanism 860. Components not necessary to understand sterile adapter latch mechanism 860 are not included. FIG. 8E to FIG. 8G . Sterile adapter latch mechanism 860 is movably coupled to frame 842F of drive output unit 542A. Sterile adapter latch mechanism 860 includes sterile adapter release latch 835, push rod 844, and ventral latch assembly 847. Push rod 844 couples sterile adapter release latch 835 to ventral latch assembly 847 so that the movement of latch 835 is transmitted to ventral latch assembly 847. Therefore, sterile adapter latch mechanism includes a first latch assembly, a second latch assembly, and a push rod that couples the first latch assembly to the second latch assembly.

[0198] Sterile adapter release latch 835 (sometimes referred to as latch 835) includes a proximal portion (an example of a first end portion) and a distal portion (an example of a second end portion opposite the first end portion). Latch pin 835P ( Figure 8B ) is coupled to the inner surface of the proximal portion of latch 835. Latch pin 835P extends inwardly from the inner surface of latch 835. Latch pin 835P is equal to latch pin 435P and latch pin 2635P, and therefore the description of those latch pins is directly applicable to latch pin 835P, and vice versa. Lip 835L extends inwardly from the distal portion of latch 835. In this regard, sterile adapter release latch 835 is pivotally connected to frame 842F. The pivot connection is spring loaded to maintain latch 835 in a state of engagement referred to as an engagement position, or in an engagement state in which there is no force causing latch 835 to pivot. The first end of push rod 844 is pivotally connected to the proximal portion of latch 835 so that when the proximal portion of latch 835 is pushed inwardly, for example, in a first direction, motion is transmitted to push rod 844.

[0199] In this regard, a proximal portion of the ventral latch assembly 847, such as a first end portion, is pivotally connected to the frame 842F. In one aspect, the connection to the frame 842F is spring loaded to maintain the ventral latch assembly 847 in what is referred to as an engaged position, or an engaged state in which there is no force causing the ventral latch assembly 847 to pivot. Two feet are distally extended from the proximal portion of the ventral latch assembly 847. At the distal end of each foot, such as at the distal end of the ventral latch assembly 847, is a hook, namely one of the hook 847A and the hook 847B. The push rod 844 is pivotally connected to one foot of the ventral latch assembly 847 between the proximal portion of the latch assembly 847 and the distal end of the foot.

[0200] In this regard, ventral latch assembly 847 is implemented as a level 3 lever, with the force being between the fulcrum (pivot connection to the frame) and the load (hook 847A and hook 847B). The use of a level 3 lever is illustrative only and not limiting. In other aspects, a level 1 lever or a level 2 lever may be used. For a level 2 lever, the load is between the fulcrum and the force, and for a level 1 lever, the fulcrum is between the force and the load.

[0201] like Fig.8F As shown, in a first state in which no external force is applied to sterile adapter release latch 835, sterile adapter release latch 835 and ventral latch assembly 847 are both in a stable state position (engaged position), and the longitudinal axis of each is aligned with longitudinal axis 890, i.e., substantially parallel to axis 890. Here, substantially parallel means parallel within manufacturing tolerances. In a second state, in which external force 892 is applied to the proximal end ( Figure 8G ), or alternatively, a force is applied to the lip 835L, the proximal portion of the latch 835 pivots inwardly toward the axis 890 and the distal portion of the latch 835 pivots outwardly. In response to the movement of the latch 835, the distal portion of the ventral latch assembly 847 pivots outwardly. Thus, the external force 892 causes the two latch assemblies to move to a disengaged position, e.g., to a second state different from the first state.

[0202] Figure 8H is a bottom perspective view of sterile adapter assembly 250A. Figure 8I is a top perspective view of sterile adapter assembly 250A. Figure 8H and Figure 8I 851C, but the intermediate disk 653 is mounted in each of the plurality of intermediate disk receptacles in the movable body 851C. Figure 6 ), the plurality of intermediate disks are mounted in the plurality of intermediate disk receptacles of the movable body 851C so that each intermediate disk can rotate relative to the sterile adapter frame 851 and the movable body 851C. Therefore, the plurality of intermediate disks are rotatably mounted in the sterile adapter frame 851. The plurality of intermediate disks are the same as the plurality of intermediate disks 653P, and therefore the features of the plurality of intermediate disks are not repeated here. Moreover, each of the plurality of disks mounted in the movable body 851C is rotatable with respect to the intermediate disk 653 (see Fig. 17B ) are the same as those of sterile adapter assembly 250A, and therefore the description of intermediate disk 653 is not repeated with respect to sterile adapter assembly 250A.

[0203] Multiple hard stop receptacles 857 of sterile adapter assembly 250A are identical to multiple hard stop receptacles 1757 and operate in the same manner as described for multiple hard stop receptacles 1757, and therefore that description is not repeated here. Sterile adapter assembly 250A has an intermediate disk hard stop 861 associated with each intermediate disk. Each intermediate disk hard stop 861 of sterile adapter assembly 250A is mutually adjacent to intermediate disk hard stop 1761 ( Fig. 17B ) and operates in the same manner as described for the intermediate disk hard stop 1761, and therefore that description is not repeated here.

[0204] On the one hand, Fig. 9Ais a more detailed illustration of the surgical instrument 260. In this regard, the surgical instrument 260 includes a driven interface assembly 961, a transmission unit 965, a main tube 967, a parallel motion mechanism 968, a wrist joint 969, and an end effector 970. The wrist joint 969 is described, for example, in U.S. Patent Application No. US 2003 / 0036748A1 (disclosed as "Surgical Tool Having Positively Positionable Tendon-Activated Multi-Disk Wrist Joint" filed on June 28, 2002), which is incorporated herein by reference. The parallel motion mechanism 968 is described, for example, in U.S. Patent No. US7,942,868 B2 (disclosed as "Surgical Instrument With Parallel Motion Mechanism" filed on June 13, 2007).

[0205] like Fig. 9B As shown, the driven interface assembly 961 includes a plurality of driven disks 964P. The plurality of driven disks 964P are examples of driven interface elements. Driven disk 964 represents each of the plurality of driven disks 964P. The driven disk 964 is mounted on the shaft of the transmission unit 965. Moreover, each driven disk 964 is mounted in a socket in the body of the driven interface assembly 961 (see Fig.19B ).

[0206] Mechanical components (e.g., gears, levers, gimbals, cables, etc.) in the transmission unit 965 transmit torque from a plurality of driven disks 964P to a number of cables, wires, and / or combinations of cables, wires, and hypotubes that run through the main tube 967 to control the movement of the parallel motion mechanism 968, wrist joint 969, and end effector 970. Although the main tube 967 is generally rigid, the main tube 967 is able to bend slightly between the transmission unit 965 and the access conduit 270. This bend allows the instrument body tube holes in the access conduit 270 to be spaced more closely than the size of the transmission unit would otherwise allow. The bend is resilient so that when the surgical instrument 260 is withdrawn from the access conduit 270 (the main tube may be formed with a permanent bend that will prevent the instrument body from rolling), the main tube 967 assumes its straight shape.

[0207] The driven interface assembly 961 has a pair of mounting wings (962A1, 962B1) and (962A2, 962B2) on each side. Also, on each side of the transmission unit 965 are release buttons 963A, 963B. The mounting wings 962B2 and the release buttons 963B are located on the Fig.10 Shown in.

[0208] To install surgical instrument 260 in sterile adapter frame 651, first mounting wings 962A1, 962A2 are placed on slide plates 755A, 755B at the open end of sterile adapter frame 651. Fig.10 and Fig.11 )superior. Fig.11 The outer surface of the sterile adapter frame 651 is removed. Fig.10 sectional view of .

[0209] Mounting wings 962A1 rest on slide plates 755A extending from a first side wall of sterile adapter frame 651. When surgical instrument 260 is slid on slide plates 755A toward resting slots 1155A, the top surfaces of first mounting wings 962A1, 962A2 contact the bottom edges of lips 751A, 751B at opposite ends of slide plates 755A ( Fig.11 ), the lips 751A, 751B move the movable body 651C in the proximal direction ( Fig.12 ). The proximal movement of movable body 651C depresses plunger 1246 of instrument manipulator assembly 240 in the proximal direction, which in turn generates a signal to controller 290 that surgical instrument 260 is being loaded onto sterile adapter assembly 250.

[0210] When mounting wing 962A1 reaches docking slot 1155A at the closed end of sterile adapter frame 651 ( Fig.13 ), the top surfaces of the first mounting wings 962A1, 962A2 no longer contact the bottom edges of the lips 751A, 751B. As a result, the preload force on the movable body 651C moves the body 651C in the distal direction ( Fig.13 ) and locks first mounting wing 962A1 in the proper position. When first mounting wing 962A1 reaches the closed end of sterile adapter frame 651, second mounting wing 962B1 rests on the flat portion of slide plate 755A near the open end of sterile adapter frame 651.

[0211] Each intermediate disk 653 in sterile adapter frame 651 is axially urged in the distal direction by the preload force on multiple drive output disks 545P. Thus, when surgical instrument 260 is mounted in sterile adapter frame 651, multiple intermediate disks 653P transmit a first preload force to movable body 651C so that the preload force is applied to mounting wings 962A1. The preload force is selected so that surgical instrument 260 can be easily slid into sterile adapter frame 651 and so that a small preload force is maintained on all disks.

[0212] When surgical instrument 260 is installed in sterile adapter assembly 250, instrument manipulator assembly 240 detects the presence of surgical instrument 260 and sends a signal to controller 290 indicating the presence of surgical instrument 260. In response to the signal, controller 290 in surgical system 200 sends a signal to instrument manipulator assembly 240 to rotate each drive output disk 545 of plurality of drive output disks 545P.

[0213] As explained more fully below, each drive output assembly 543 in drive output unit 542 is spring loaded and automatically positioned so that a preload force is applied to each drive output disk 545 after sterile adapter assembly 250 is installed on instrument manipulator assembly 240. The preload force pushes against drive output disk 545 and pushes against a corresponding intermediate driven interface 655 of intermediate disk 653 in sterile adapter frame 651.

[0214] However, in Figure 7B , when surgical instrument 260 is first mounted on sterile adapter assembly 250, elements of intermediate drive interface 765 of intermediate disk 653 may not align with corresponding elements of driven interface 980 on driven disk 964. If elements of two disks 653 and 964 are not aligned, the two disks are partially coupled, but the two disks are not mated with each other. Therefore, the disk stack including partially coupled disks 964, 653 and 545, i.e., the third disk, the second disk and the first disk, has a third height.

[0215] When surgical instrument 260 is installed in sterile adapter frame 651, each driven disk 964 in driven interface assembly 961 pushes the corresponding intermediate disk 653 in sterile adapter assembly 250 proximally, allowing intermediate disk 653 to rotate freely. As explained more fully below, when intermediate drive interface 756 of intermediate disk 653 in sterile adapter assembly 250 is not aligned with corresponding driven interface 980 of driven disk 964 in driven interface assembly 961, the engagement structure on intermediate drive interface 756 of intermediate disk 653 engages rotationally disabling element 1980 (see FIG. 1 ) on driven disk 964 of surgical instrument 260. Fig.19A ), the rotation disabling element 1980 prevents the rotation of the driven disk 964 in the driven interface assembly 961.

[0216] When the intermediate drive interface 756 of the intermediate disk 653 rotates with the driven disk 964 fixed in place, each element on the intermediate drive interface 756 rotates in alignment with the corresponding element of the driven interface 980 of the driven disk 964 and is paired with the corresponding element. The coupling of the intermediate drive interface 756 and the driven interface 980 releases the rotation lock on the driven disk 964. Therefore, the disk stack rotates as a unit. When all three disks are paired, the height of the disk stack has a fourth height, and the fourth height is less than the third height. The sensor in the instrument manipulator assembly 240 detects this change in height and sends a signal to the controller to stop the rotation of the drive output disk 545. The sensor in the instrument manipulator assembly 240 that detects the change in the height of the disk stack can be a mechanical sensor, an optical sensor, an inductive sensor, a capacitive sensor, etc.

[0217] Fig.14 14 is a diagram of the disk stack 1400 when the drive output disk 545 is coupled to the intermediate disk 653, and the intermediate disk 653 is coupled to the driven disk 964. In this article, coupling means that all alignment features on the two interface disks are aligned so that the two disks are mated, i.e., fully coupled. As described above, the two interface disks are partially coupled when some alignment features on the two interface disks are aligned, but other alignment features on the two interface disks are not aligned. The preload force is selected so that despite some side play, the two partially coupled disks remain in contact so that all alignment features can be aligned and mated.

[0218] The disk stack 1400 refers to the above Figure 3A and Figure 3B The drive interface 557 of the drive output disk 545 is mated to the intermediate driven interface 655 of the intermediate disk 653, and the intermediate drive interface 756 of the intermediate disk 653 is mated to the driven interface 980 of the driven disk 964. As explained more fully below, when there is a high preload force (i.e., a second preload force) on the disk stack 1400, there is zero backlash between the disks in the disk stack 1400 for torque levels used in surgical procedures, even though the shaft 1466 may not be precisely aligned with the shaft coupled to the drive output disk 545. When the disks 545, 653, and 964 in the disk stack 1400 are mated under the second preload force, there is zero backlash in the coupling between the disks for torque levels used in surgical procedures. The low backlash coupler 544 compensates for spatial misalignment and transmits motion and torque to the disk stack 1400. As explained more fully below, the design of the drive dogs compensates for angular misalignment of the drive output disk 445 and the driven disk 964.

[0219] Fig.15A7 is an illustration of the instrument manipulator assembly 240 with the instrument manipulator assembly housing 741 removed. Also, there is a vertical cutaway view showing the components in the drive output assembly 541. The instrument manipulator assembly 240 includes a motor group 1541, which in turn includes a plurality of drive units 1500P and a plurality of drive output assemblies 543P. Each drive unit 1500 of the plurality of drive units 1500P includes an encoder 1501, a slotless brushless servo motor 1502, a compact Hall effect sensor 1503, and a planetary reducer 1504.

[0220] In one aspect, the slotless brushless servo motor 1502 has a very high motor constant, and thus the servo motor 1502 is very efficient. The use of a slotless brushless servo motor is merely illustrative and is not intended to limit the motors in the plurality of drive units 1500P to this particular type of motor. A variety of motors can be used including brushed motors, stepper motors, etc. In view of the compact configuration of the eight servo motors in the motor group 1541, each servo motor 1502 includes a magnetic shield to prevent torque fluctuations to adjacent servo motors.

[0221] A compact Hall Effect sensor 1503 is used to detect the position of the permanent magnet in the servo motor 1502. The Hall Effect sensor 1503 acts as a second encoder. The encoder to Hall check compares the rotational position reported by the encoder 1501 and the Hall Effect sensor 1503. If the rotational position is significantly different, there is a problem with the encoder 1501, the Hall Effect sensor 1503, or the mechanism between them. When this check fails, the executive software in the controller immediately shuts down the motor.

[0222] The planetary reducer 1504 is heavy duty and efficient (greater than 90%) and is therefore easier to backdrive than a typical reducer. By backdriveable, it is meant that the output shaft of the reducer can be rotated at a relatively low torque compared to a typical reducer.

[0223] The planetary reducer 1504 has a backlash of less than 1 degree on the one hand, and a low backlash of, for example, 0.4 degrees on the other hand. On the one hand, the four planetary reducers have an input-output ratio of 28:1 and are referred to as standard planetary reducers. In this regard, the four planetary reducers have an input-output ratio of 9:1 and are referred to as high-speed reducers. Similarly, the drive unit 1500 with a standard planetary reducer is referred to as a standard drive unit. The drive unit 1500 with a high-speed planetary reducer is referred to as a high-speed drive unit.

[0224] FIG. 15B to FIG. 15E is an illustration of an example of a planetary reducer suitable for use in motor assembly 1541. Fig. 15B It is a side view of the planetary reducer 1504. Fig. 15C It is a far side view of the planetary reducer 1504. Fig.15D This is a close-up view of a 28:1 planetary reducer. Fig.15E This is a close-up view of a 9:1 planetary reducer. Table 1 gives FIG. 15B to FIG. 15E An example of the dimensions of a reducer.

[0225] Table 1

[0226]

[0227] FIG. 16A to FIG. 16D is a more detailed illustration of a drive output assembly 543 that represents each of the plurality of drive output assemblies 543P in this regard. Drive output assembly 543 includes a ball spline 1603. A light preload spring 1601, such as a first preload spring, is mounted in a central lumen of ball spline 1603 and affixed at one end to a proximal side of drive output disk 545. When spring 1601 is compressed, light preload spring 1601 applies a first preload force to drive output disk 545. In one aspect, the first preload force is 2.22 Newtons (0.5 pounds force (Lbf)).

[0228] The ball spline nut 1604 is mounted on the ball spline 1603. The ball spline nut 1604 slides proximally and distally along the ball spline 1603, i.e., in a first direction and in a second direction opposite to the first direction, while transmitting torque / motion from the ball spline 1603. Therefore, the torque / motion is transmitted through the ball spline 1603 to the low backlash coupler 544 (sometimes referred to as the flexure 544). The ball spline 1603 transmits torque / motion while allowing the drive output assembly 543 to move along the longitudinal axis of the ball spline 1603. When the disk is engaged or disengaged in the disk stack 1400, the drive output assembly 543 moves in and out of the ball spline 1603 to facilitate engagement or disengagement. The ball spline 1603 has zero backlash for torque levels used in surgical procedures.

[0229] Ball spline nut 1604 is inserted into housing 1605, and heavy preload spring 1602 (second preload spring) is mounted on housing 1605. When both springs are compressed, heavy preload spring 1602 combines with light preload spring 1601 to apply a second preload force to drive output disk 545. In one aspect, the second preload force is 10.2 Newtons (2.3 pounds force (Lbf)).

[0230] Flexure 544 is coupled to the drive unit through two pins that transmit torque from the drive unit to flexure 544. Flexure 544 is also coupled to drive output disk 545 through two pins. Therefore, flexure 544 transmits torque from the drive unit to drive output disk 545. Fig. 16B is an end view of the flexure 544.

[0231] The flexure 544 has a Fig.14 and Fig.16A ) on the central lumen 1640, the cylinder 1445C extending proximally from the proximal surface of the drive output disk 545. The flexure has four beams 1641A, 1641B, 1641C and 1641D. The first end of each of the four beams 1641A, 1641B, 1641C and 1641D is connected to the body 1642 of the flexure 544. The second end of each of the four beams 1641A, 1641B, 1641C and 1641D is connected to the cylinder 1643A, 1643B, 1643C and 1643D having a central hole, respectively. The beams 1641A, 1641B, 1641C and 1641D are rigid in torsion about an axis passing through the central lumen 1640, but are bendable about lateral displacement.

[0232] The output pin driven by the drive unit is installed in the center hole of the cylinder 1643A, 1643B. The input pin of the drive output disk 545 is installed in the center hole of the cylinder 1643C, 1643D.

[0233] On the one hand, flexure 544 is a precision machined one-piece part made of precipitation hardened stainless steel 17-4HI 150. The side clearance of flexure 544 is determined by the mounting pin clearance between the center hole of the cylinder and the outer diameter of the input pin or output pin. In this regard, the side clearance of surgical device assembly 300 is controlled only by instrument manipulator assembly 240. This is in contrast to previous systems, in which the side clearance is caused by the Oldham coupling in the sterile adapter of the prior art. The parts in the sterile adapter of the prior art are injection molded and therefore cannot be made to the same precision as flexure 544. Controlling the side clearance of the reusable parts (e.g., instrument manipulator assembly 240) of surgical device assembly 300 means that the side clearance is consistent for each use of surgical device assembly 300 and does not depend on the manufacturing tolerances of the injection molded parts in the single-use disposable assembly such as the sterile adapter of the prior art.

[0234] Flexure 544 accommodates two degrees of freedom motion in a plane orthogonal to the axis of central lumen 1640. Output pins coupled to beams 1641A, 1641B are capable of moving along axis 1690. The range of motion is limited by the gap between the outer surface of cylinders 1643A, 1643B and the outer surface of body 1642. Similarly, input pins coupled to beams 1641C, 1641D are capable of moving along axis 1691 perpendicular to axis 1690. The range of motion is limited by the gap between the outer surface of cylinders 1643C, 1643D and the outer surface of body 1642. In one aspect, to displace a beam along one of axes 1690, 1691 by 0.254 mm (0.010 in), 2.94 N (0.66 Lbf) is taken and a stress of 199.95 MPa (29,000 lbs per square inch) is generated. The peak stress is 262.00 MPa (38,000 psi) at an applied torque of 11.3 N·m (100 in-Lbf).

[0235] The two degrees of freedom of flexure 544 accommodate shaft misalignment. Specifically, drive unit assembly 541 is able to tolerate misalignment of the drive shaft in motor pack 1541 with the shaft in transmission unit 965 because each flexure 544 transmits torque to drive output disk 545 while flexing to compensate for shaft 1466 (which is not completely coaxial with the corresponding drive shaft of drive unit 1500) Fig.14 ).

[0236] Fig. 16C 545 is a more detailed illustration of one aspect of drive interface 557 of drive output disk 545 (eg, a distal portion of drive output disk 545). Drive output disk 545 has a cylindrical body. Fig.16D is a cross-sectional view of drive output disk 545 with drive dog 1652A.

[0237] Two holes 1651A, 1651B extend through drive output disk 545. An input pin is mounted in each hole 1651A, 1651B and in a corresponding hole in cylinder 1643A, 1643B of flexure 544.

[0238] Two drive dogs 1652A, 1652B, a first alignment element (center post 1653 and tab 1654), and a second alignment element (pin 1655) extend distally from a distal end surface 1656 of drive output disk 545. The height of center post 1653 is greater than the height of tab 1654 and thus helps center drive output disk 545 about a corresponding alignment receptacle in intermediate driven interface 655 of intermediate disk 653. Tab 1654 extends from center post 1653 toward the circumferential edge of distal end surface 1656. Center lines 1670 and 1671 extend through the center of center post 1653 and intersect at the center. Center post 1653 and tab 1654 help align drive output disk 545 to intermediate disk 653. Center post 653 and tab 1654 also provide stability to a pair of mated disks.

[0239] In this regard, pin 1655 is also centered on centerline 1670 and disposed between the center post 1653 and the edge of distal surface 1656. Pin 1655 is a segment of a cylinder, e.g., a cylinder that has been cut vertically by a plane, such that a portion of the outer surface of pin 1655 is flat and not cylindrical. In one aspect, pin 1655 has a generally three-dimensional D-shape. Here, generally three-dimensional D-shape means a shape that is sufficiently similar to a three-dimensional D-shape to be considered a three-dimensional D-shape, e.g., the shape of pin 1655. Pin 1655 is configured to mate with an alignment receptacle in intermediate disk 653.

[0240] The shapes and orientations of the first and second alignment elements are illustrative only and not limiting. Other shapes of alignment elements and other orientations between alignment elements may be used as long as no backlash is introduced under the second preload force, no binding occurs when the elements are engaged and disengaged, and the elements provide stability to a pair of mating disks.

[0241] The drive interface 557 includes two drive dogs 1652A, 1652B. Each drive dog 1652A, 1652B extends distally from the distal surface 1656. Each drive dog 1652A, 1652B is the same radial distance Rdog from the longitudinal axis of the drive output disk 545. The longitudinal axis of the drive output disk 545 runs through the center of the center pillar 1653. Moreover, each drive dog 1652A, 1652B is close to the circumferential edge of the distal surface 1656. The combination of the radially equidistant drive dogs 1652A, 1652B and the placement of the drive dogs 1652A, 1652B adjacent to the circumferential edge allows the drive dogs 1652A, 1652B to effectively transmit torque / motion to the intermediate disk 653.

[0242] The position of the drive pawls 1652A, 1652B relative to the circumferential edge of the distal end surface 1656 is determined by the position of the drive pawl receptacles on the intermediate disk 653 (see Fig.18A). The diameter of intermediate disk 653 is determined in part by the number of intermediate disks 653 that can be installed in movable body 651C of sterile adapter assembly 250. Drive dogs 1652A, 1652B are sized and positioned so that, as explained more fully below, drive dogs 1652A, 1652B engage drive dog receptacles in intermediate disk 653 and so that drive dogs 1652A, 1652B do not contact the side walls of movable body 651C.

[0243] like Fig. 16C As illustrated, drive dogs 1652A, 1652B have mirror symmetry about a plane including y-axis 1670 and a longitudinal axis (not shown) of drive output disk 545. The longitudinal axis of drive output disk 545 is perpendicular to axis 1670 and axis 1671 at the center of center post 1653.

[0244] Each drive dog 1652A, 1652B has mirror symmetry about a plane that includes x-axis 1671 and the longitudinal axis of drive output disk 545. The plane bisects each of drive dogs 1652A, 1652B.

[0245] The size of the drive dogs 1652A, 1652B is selected based on strength requirements. In this application, the length of the drive dogs 1652A, 1652B (radially from the center to the edge) is determined by the size constraints of the alignment features / anti-rotation features in the center of the disk 545, and the height of the drive dogs 1652A, 1652B is minimized to reduce the size and weight of the mechanism while ensuring proper engagement with the intermediate disk 653 under the first and second preload forces.

[0246] Drive dog 1652A is identical to drive dog 1652B and therefore only the features of drive dog 1652A will be considered in further detail. The description of drive dog 1652A is directly applicable to drive dog 1652B and therefore the description for drive dog 1652B is not repeated.

[0247] Drive dog 1652A has a first portion 1652A1 and a second portion 1652A2. First portion 1652A1 extends distally from distal end surface 1656 to second portion 1652A2. Second portion 1652A2 extends in a distal direction from first portion 1652A1.

[0248] The first portion 1652A1 of the drive dog 1652A is a three-dimensional rectangle and thus has four straight sides extending from the distal surface 1656, e.g. Fig.16DIn this context, straight means substantially parallel to a plane including the longitudinal axis of drive dog 1652A and one of x-axis 1671 and y-axis 1670. The selected axis depends on the sides considered as a three-dimensional rectangle. Substantially parallel means parallel within manufacturing tolerances.

[0249] Part II 1652A2( Fig.16D ) includes two opposing side surfaces 1652cyl2, 1652cyl4, the two opposing side surfaces 1652cyl2, 1652cyl4 being curved surfaces. In one aspect, the curved surface is a portion of a circular cross-section, for example, a portion of the outer surface of a cylinder 1658. The side surfaces 1652cyl2, 1652cyl4 are the outer surfaces of a cross-section of a cylinder intersected by two parallel planes, the two parallel planes including the edges 1652e1, 1652e2, and extending outwardly from the sides of the cylinder. Fig.16D Therefore, the side surfaces 1652cyl2 and 1652cyl4 are curved surfaces.

[0250] In one aspect, cylinder 1658 has a diameter of 3.175 mm (0.125 in). The axis of cylinder 1658 extends out Fig.16D In this regard, the other two side walls of the second portion 1652A2 are straight sides.

[0251] In one aspect, drive output disk 545 is an injection molded disk. Drive output disk 545 can be made of polycarbonate, polyphenylsulfone (PPSU), polyethyleneimine (PEI), or the like.

[0252] Fig.17A 1751 . A sterile drape (not shown) is fixedly attached to rim 1751, for example, by double-sided tape. Sterile drapes are well known and therefore not described in further detail. See, for example, U.S. Patent No. US 7,666,191 B2 (filed December 20, 2005), U.S. Patent No. 7,699,855 B2 (filed March 31, 2006), U.S. Patent Application Publication No. US 2011 / 0277775 A1 (filed August 12, 2010), and U.S. Patent Application Publication No. US 2011 / 0277776 A1 (filed August 1, 2010), all of which are incorporated herein by reference. A sterile drape covers at least a portion of system 200 to maintain a sterile field during a surgical procedure, while sterile adapter assembly 250 also provides for efficient and easy instrument exchange along with a precise mechanical interface between surgical instrument 260 and its associated instrument manipulator assembly 240 .

[0253] As noted above, movable body 651C is mounted in sterile adapter frame 651 such that movable body 651C is movable in the proximal direction and the distal direction, i.e., in a first direction relative to the sterile adapter frame and in a second direction opposite to the first direction. Fig.17A 651C is in the most distal position. The movable body 651C includes a socket for each intermediate disk 653 in the plurality of intermediate disks 653P. The movable body 651C also includes a plurality of hard stop sockets 1757. Each intermediate disk 653 has a cylindrical body.

[0254] In one aspect, each of sterile adapter frame 651, removable body 651C and multiple intermediate disks 653P is made by injection molding. Suitable materials for sterile adapter frame 651, removable body 651C and multiple intermediate disks 653P include polycarbonate, polyphenylsulfone (PPSU), polyethyleneimine (PEI) and the like.

[0255] Each intermediate disk 653 is mounted in a corresponding socket of the movable body 651C. Each intermediate disk 653 is rotatable within the socket and is movable distally and proximally within the socket. Fig.17A , the middle disk 653 is at the farthest position. Fig. 17B 17 is an enlarged view showing a portion of the intermediate disk receptacle 1766 and the movable body 651C of the intermediate disk 653. The intermediate disk 653 has a tab 1767 extending from the outer side surface of the disk 653 and extending from the proximal end surface of the disk 653 (see FIG. Fig.18A ). Intermediate disk 653 is said to be associated with intermediate disk hard stop 1761. This means that tab 1767 is able to contact hard stop 1761 and when contacted, rotation of intermediate disk 653 is stopped.

[0256] When surgical instrument 260 is mounted on sterile adapter assembly 250, intermediate disk 653 is displaced proximally relative to movable body 651C. In this position, the most distal portion of tab 1767 (the bottom of tab 1767) is on the most proximal portion of hard stop 1761 (the top of stop 1761), allowing intermediate disk 653 to rotate freely and not contact hard stop 1761.

[0257] Fig.18A and Fig.18B It is the intermediate driven interface 655 of the intermediate disk 653 ( Fig.18A ) and intermediate drive interface 756 ( Fig.18B ) is a diagram of the intermediate slave interface 655 ( Fig.18A) on the proximal end of the intermediate disk 653. The intermediate driven interface 655 includes a first alignment socket and a second alignment socket. In this regard, the first alignment socket is a combination of the center pillar socket 1853 and the tab socket 1854. The second alignment socket is a pin socket 1855.

[0258] The combination of center post receptacle 1853 and tab receptacle 1854 is configured to mate with the combination of center post 1653 and tab 1654 when post 1653 and tab 1654 are aligned with receptacle 1853 and receptacle 1854, respectively. Similarly, pin receptacle 1855 is configured to mate with pin 1655 when pin receptacle 1855 and pin 1655 are aligned. Thus, drive output disk 545 can only mate with intermediate disk 653 in one orientation when the alignment elements of disk 545 are aligned with the alignment receptacles of intermediate disk 653.

[0259] The intermediate driven interface 655 also includes two drive claw receptacles 1852A, 1852B. Fig.18A As illustrated, drive dog receptacles 1852A, 1852B have mirror symmetry about a plane including y-axis 1870 and the longitudinal axis (not shown) of intermediate disk 653. The longitudinal axis of intermediate disk 653 is perpendicular to both axis 1870 and axis 1871.

[0260] Each drive dog receptacle 1852A, 1852B has mirror symmetry about a plane that includes x-axis 1671 and the longitudinal axis of intermediate disk 653. The plane bisects each of drive dog receptacles 1852A, 1852B.

[0261] Each drive dog receptacle has an inner edge surface that is the same distance Rrcpt from the longitudinal axis of the intermediate disk 653. The inner edge surface forms a third side of the drive dog receptacle, as explained more fully below. Since the drive dog receptacle 1852A is the same as the drive dog receptacle 1852B, only the features of the drive dog receptacle 1852A will be considered in further detail. The description of the drive dog 1852A is directly applicable to the drive dog receptacle 1852B and therefore the description for the drive dog receptacle 1852B is not repeated.

[0262] The drive pawl receptacle 1852A can be surrounded by four sides. In one aspect, the first side does not appear, and therefore the first side is referred to as open. The use of the open sidewall is only illustrative and not restrictive. In some aspects, the first sidewall can be a solid sidewall. The second side and the fourth side are walls perpendicular to the first side. The third side is a wall perpendicular to the second side and the fourth side. Therefore, in this regard, the drive pawl receptacle 1852A is surrounded by three walls extending from the outer proximal edge surface 1856 of the intermediate disk 653 distally to the bottom surface 1857 of the drive pawl receptacle 1852A. The third wall opposite to the open side is a straight wall extending from the outer proximal edge surface 1856 to the bottom surface 1857. As described below, the two opposite walls (the second wall and the fourth wall) have two parts (a straight wall part and an inclined wall part).

[0263] Fig.18C 1871 is a cross-sectional view of the drive dog receptacle 1852A cut along a centerline perpendicular to the x-axis 1871. The drive dog receptacle 1852A is divided into a first portion 1852A1 and a second portion 1852A2. The first portion 1852A1 extends from the outer proximal surface 1856 into the intermediate disk 653 and then to the second portion 1852A2. The second portion 1852A2 further extends from the first portion 1852A1 into the intermediate disk 653 and then to the bottom surface 1857 of the drive dog receptacle 1852A.

[0264] The opposing walls of first portion 1852A1 surrounding drive dog receptacle 1852A are straight walls 1852s2, 1852s4. Typically, the height of first portion 1852A1 is less than the height of portion 1652A1 of drive dog 1652A, so that there is some space between the distal edge surface of drive output disk 545 and the proximal edge surface of intermediate disk 653.

[0265] Part II 1852A2( Fig.18C ) is surrounded by two opposing side walls 1852w2, 1852w4, which are part of the outer side surface of the wedge shape, that is, the side walls 1852w2, 1852w4 are inclined flat surfaces. The side walls 1852w2, 1852w4 subtend an angle α. The side surfaces 1852w1, 1852w2 are surface portions of the wedge that are intersected by two parallel planes (e.g., a plane including line 1852e1 and a plane including bottom surface 1857). Both planes extend outward. Fig.18C .

[0266] In one aspect, the wedge-shaped portion is selected so that when the distal end of drive dog 1652A is fully inserted into receptacle 1852, the distal end surface of drive dog 1652A does not contact bottom surface 1857, and the cylindrical sidewall portion of cylinder 1658 contacts the angled sidewalls 1852w2, 1852w4. In one aspect, for a 0.125 diameter of cylinder 1658, angle α is 30 degrees, so sidewalls 1852w2, 1852w4 are portions of the sides of a 30 degree wedge shape.

[0267] When sterile adapter assembly 250 is mounted on instrument manipulator assembly 240, the orientation of drive interface 557 on drive output disk 545 is unknown with respect to the orientation of intermediate driven interface 655 on intermediate disk 653. However, regardless of the relative orientation of the two interfaces, the preload force on drive output disk 545 pushes intermediate disk 653 distally so that intermediate disk 653 seats within receptacle 1766 ( Fig. 17B ) in the most distal position, for example, intermediate disk 653 is in the first axial position. As explained more fully below, when surgical instrument 260 is installed in sterile adapter assembly 250, intermediate disk 653 is proximally displaced to the second axial position.

[0268] As described above, after plunger 546 is depressed by attaching sterile adapter assembly 250 to instrument manipulator assembly 240, drive output disk 545 is rotated. Since drive output disk 545 and intermediate disk 653 are in contact and partially coupled, the rotation of drive output disk 545 causes intermediate disk 653 to rotate. Therefore, interfaces 557 and 655 are aligned and mated, or tabs 1767 on intermediate disk 653 contact hard stop 1761. When tabs 1767 contact hard stop 1761, the rotation of intermediate disk 653 is stopped. When interfaces 557 and 655 are not mated and the rotation of intermediate disk 653 is stopped, drive output disk 545 continues to rotate until the two interfaces are mated. Therefore, the result is that disks 545 and 653 are coupled and the rotation of drive output disk 545 stops at hard stop 1761. The control system uses the stop of the rotation of drive output disk 545 to determine the orientation of drive output disk 545. Note that if two disks are mated before reaching hard stop 1761, the rotation of the two mated disks is stopped when hard stop 1761 is reached.

[0269] Fig.18Dis a cross-sectional view of drive dog 1652 inserted into drive dog receptacle 1852A under a light preload force after drive interface 557 on drive output disk 545 has been partially coupled with intermediate driven interface 655 on intermediate disk 653. As described above, drive dog 1652A has a first portion 1652A1 with straight sides. The straight sides of first portion 1652A1 merge into second portion 1652A2 (cylindrical tip) as described above. Drive dog receptacle 1852A also has a first portion 1852A1 with a straight inner sidewall. First portion 1852A1 merges into second portion 1852A2 with a tapered inner wall, also as described above.

[0270] The curved surfaces on both sides of the distal portion of drive dog 1652A and the corresponding inclined side walls on both sides of the distal portion of drive dog receptacle 1852A, where the inclined side walls are tangential to the curved side surfaces, are merely illustrative and non-limiting. Other surfaces on the distal portion of drive dog 1652A and other surfaces on the corresponding distal end wall portions of drive dog receptacle 1852A may be used as long as there is zero backlash in the rotational direction between drive output disk 545 and intermediate disk 653 at a torque level used in surgical procedures under a high preload force (second preload force), and as long as the interface between the two disks compensates for angular misalignment.

[0271] Due to the tapered walls of receptacle 1852A and the cylindrical surface on second portion 1652A2 of drive dog 1652A, a suitable force is required to hold drive output disk 545 and intermediate disk 653 in place so that the two disks function properly while the two disks are partially coupled when torque / motion is applied through drive output disk 545. In the absence of this force, drive output disk 545 and intermediate disk 653 can separate because the applied torque can drive them apart.

[0272] To prevent this separation under light preload forces, both drive dog 1652A and drive dog receptacle 1852A have first portions with straight walls, as described above. When drive dog 1652A and drive dog receptacle 1852A begin to separate under torque, the straight wall portions contact each other, as shown in FIG. Fig.18C 1852A. At this point, drive dog 1652A and drive dog receptacle 1852A are no longer able to drive themselves apart, and motion can continue with a known or controlled level of backlash, and drive dog 1652A is not fully inserted and coupled to drive dog receptacle 1852A. In one aspect, under light preload forces, the known level of backlash is 1.13 degrees. Thus, the partial coupling between drive output disk 545 and intermediate disk 653 has a known level of backlash under light preload forces.

[0273] Moreover, if Fig.18DAs shown, a small amount of misalignment between the shaft of the drive disk 545 and the shaft driven by the intermediate disk 653 can be tolerated. In addition, angular misalignment can be tolerated in a direction defined by the axis of the curved cylinder 1658, the axis of the curved cylinder 1658 being in the Fig.18D Inside and outside the page.

[0274] When drive dog 1652A and drive dog receptacle 1852A are mated together under a high preload force (e.g., a second preload force), as explained more fully below, there is no backlash in the interface between the two disks. When torque / motion is applied, the second preload force is sufficient to prevent drive dog 1652A and drive dog receptacle 1852A from physically moving back apart and separating. Thus, this combination is able to transmit torque / motion without backlash. Under the second preload force, the coupling between drive output disk 545 and intermediate disk 653 has zero backlash for torque levels used in surgical procedures.

[0275] Fig.18B 653. is a more detailed illustration of intermediate drive interface 756 on the distal end of intermediate disk 653. Intermediate drive interface 756 includes drive dogs 1862A, 1862B, and engagement structure 1863C.

[0276] Each of the drive pawls 1862A and 1862B is a structure equivalent to each of the drive pawls 1652A and 1652B. Specifically, each of the drive pawls 1862A, 1862B extends distally from the distal surface 1866. The inner edge of each of the drive pawls 1862A, 11862B is at the same radial distance from the longitudinal axis of the distal surface 1866. Moreover, each of the drive pawls 1862A, 1862B is adjacent to the circumferential edge of the distal surface 1866. The combination of the drive pawls 1862A, 1862B being equidistant in the radial direction and the arrangement of the drive pawls 1862A, 1862B adjacent to the circumferential edge allows the drive pawls 1862A, 1862B to effectively transmit torque / motion to the driven disk 964.

[0277] like Fig.18B As illustrated, drive dogs 1862A, 1862B have mirror symmetry about a plane including x-axis 1871 and the longitudinal axis (not shown) of intermediate disk 653. The longitudinal axis of intermediate disk 653 is perpendicular to both axes 1870 and 1871 at their intersection.

[0278] Each of drive dogs 1862A, 1862B has mirror symmetry about a plane that includes y-axis 1870 and a longitudinal axis (not shown). The plane bisects the drive dogs.

[0279] Drive dog 1862A is identical to drive dog 1862B and therefore only the features of drive dog 1862A will be considered in further detail. The description of drive dog 1862A is directly applicable to drive dog 1862B and therefore the description for drive dog 1862B is not repeated.

[0280] The cylindrical side wall portion of drive dog 1862A and the straight wall portion of drive dog 1862B are identical to the corresponding portions of drive dog 1652A, and therefore a description of these portions will not be repeated herein. Fig.18B As shown, lip 1862L extends radially outward from the distal end of the second portion of drive dog 1862A. Two side walls 1862s2, 1862s4 are perpendicular to side wall 1862s1, and lip 1862A1 extends radially outward from side wall 1862s1. Lip 1862L is a retention feature that retains the intermediate disk 653 in the movable body 651C.

[0281] In this regard, the engagement structure 1863C is an open three-dimensional structure. In this regard, the open three-dimensional structure has a mirror symmetry about a plane including the longitudinal axis of the intermediate disk 653 and the axis 1871. Here, an open three-dimensional structure means a three-dimensional structure without a closed perimeter, i.e., an opening where the outer surface meets the inner surface. Fig.18D In the example of the invention, the open three-dimensional structure includes two parts, namely a substantially three-dimensional letter C-shaped structure 1863C and two walls 1863A, 1863B. Furthermore, the substantially three-dimensional letter C-shaped structure is a three-dimensional structure that is viewed as a three-dimensional letter C-shaped structure by a person observing the structure.

[0282] The three-dimensional letter C-shaped structure 1863C has a height, a first end 1863C1, and a second end 1863C2. The height of the structure 1863C extends distally from the distal surface 1866 of the intermediate disk 653, which may be referred to as the distal side of the intermediate disk 653, to the distalmost surface or distalmost edge of the structure 1863C. The first end 1863C1 and the second end 1863C2 surround the opening of the C-shaped structure 1863C. In this regard, the axis 1871 is equidistant from the first end 1863C1 and from the second end 1863C2, and is the centerline of the C-shaped structure 1863C.

[0283] C-shaped structure 1863C is an example of an open three-dimensional structure of a circular track. The circular track includes a first circumferential section having a first height, a first end, and a second end, such as the body of the C-shaped structure. The circular track also includes a second circumferential section extending between the first end and the second end of the first circumferential section, such as a gap between the ends of the C-shaped structure. The second circumferential section has a second height. The second height is less than the first height. The centerline of the circular track extends through the center of the circular track and is equidistant from the first end and the second end.

[0284] Wall 1863A is adjacent to first end 1863C1 and extends toward the circumferential edge of distal surface 1866. Wall 1863B is adjacent to second end 1863C2 and extends toward the circumferential edge of distal surface 1866. Wall 1863A and wall 1863B have the same height. The height of wall 1863A and the height of wall 1863B extend from the distal side of distal surface 1866 of intermediate disk 653 to the distalmost surface or distalmost edge of wall 1863A and the distalmost surface or distalmost edge of wall 1863B. The height of wall 1863A and wall 1863B is less than the height of C-shaped structure 1863C.

[0285] like Fig.18A and Fig.18B As shown, the axis bisecting the drive dog receptacles 1852A, 1852B (i.e., the x-axis 1871) is perpendicular to the axis bisecting the drive dogs 1862A, 1862B. When all disks are mated as in the disk stack 1400, the allowed rotation axis for the intermediate disk 653 and the driven disk 964 is 90 degrees from the allowed rotation axis for the intermediate disk 653 and the drive output disk 545. In other words, each drive dog receptacle 1852A, 1852B of the intermediate disk 653 is arranged so that each of the drive dog receptacles 1852A, 1852B is bisected by a first plane. Each of the drive dogs 1862A, 1862B of the intermediate disk 653 is arranged so that each of the drive dogs 1862A and the drive dogs 1862B are bisected by a second plane. The first plane is perpendicular to the second plane.

[0286] The coupling of the interface between the intermediate disk 653 and the drive output disk 545 forms a first joint, while the coupling of the interface between the intermediate disk 653 and the driven disk 964 forms a second joint. These two working joints together accommodate angular misalignment as the system rotates and transmits motion / torque. The two joints act like a set of U-joints.

[0287] Fig.19A 964. The driven interface 980 includes an engagement receptacle, drive dog receptacles 1952A, 1952B, and a rotationally disabling element 1980. The rotationally disabling element 1980 includes a rotational locking mechanism 1981 as explained more fully below.

[0288] Drive pawl receptacles 1952A, 1952B have mirror symmetry about a plane including x-axis 1971 and the longitudinal axis (not shown) of driven disk 964. The longitudinal axis of driven disk 964 is perpendicular to the intersection of axis 1970 and axis 1971. Each of drive pawl receptacles 1952A, 1952B has mirror symmetry about a plane including y-axis 1970 and the longitudinal axis of driven disk 964. The plane bisects the drive pawl receptacles. Each drive pawl receptacle has an inner edge surface that is the same distance Rrcpt2 from the longitudinal axis of driven disk 964. Since drive pawl 1952A is identical to drive pawl 1952B, only the features of drive pawl receptacle 1952B are considered in further detail. The description of drive pawl receptacle 1952B is directly applicable to drive pawl receptacle 1952A and therefore the description for drive pawl receptacle 1952A is not repeated.

[0289] The drive claw receptacle 1952B can be surrounded by four sides. The second side and the fourth side are walls perpendicular to the first side. The third side is a wall perpendicular to the second side and the fourth side. However, in this regard, the first side of the four sides is missing and is therefore referred to as an open first side. The use of an open sidewall is only illustrative and not restrictive. In some aspects, the first sidewall can be a solid sidewall.

[0290] Thus, in this regard, the drive dog receptacle 1952B is surrounded by three walls, each extending from the outer proximal edge surface 1956 of the driven disk 964 to the bottom surface 1957 of the drive dog receptacle 1952B. The third wall opposite to the open side is a straight wall 1952s3 extending from the outer proximal edge surface 1956 to the bottom surface 1957. The two opposing walls (the second wall and the fourth wall) have two portions, namely, straight wall portions 1952s2, 1952s4 and inclined wall portions 1952w2, 1952w4.

[0291] Thus, drive dog receptacle 1952B is divided into a first portion 1952B1 and a second portion 1952B2. First portion 1952B1 extends from outer proximal edge surface 1956 into driven disk 964 and then to second portion 1952B2. Second portion 1952B2 further extends from first portion 1952B1 into driven disk 964 and then to bottom surface 1957 of drive dog receptacle 1952B. Other features of drive dog receptacle 1952B are the same as those of drive dog receptacle 1852A described above, and therefore the description is applicable to drive dog receptacle 1953B and is not repeated here.

[0292] In this regard, the engagement receptacle comprises an open three-dimensional groove formed in the proximal end of the driven disk 964. The open three-dimensional groove extends distally from the outer proximal edge surface 1956 into the driven disk 964. Here, the open three-dimensional groove means a three-dimensional groove without a closed inner periphery and outer periphery. Fig.19A In the example of FIG. 1 , the open three-dimensional groove is a substantially three-dimensional letter C-shaped groove 1963C having a width and a depth.

[0293] The three-dimensional letter C-shaped groove 1963C has a first end 1963C1 and a second end 1963C2. The first end 1963C1 and the second end 1963C2 are separated from the rotation disabling element 1980 by a first gap 1963A and a second gap 1963B, respectively.

[0294] In this regard, the rotationally disabling element 1980 includes a flexure 1980F having a rotational locking mechanism 1981 at one end. In this regard, the flexure 1980F extends radially outward from a central region of the proximal end of the driven disk 964 toward the sidewall of the driven disk 964. The central region is surrounded by a C-shaped groove 1963C. The rotational locking mechanism 1981 extends in a distal direction from the end of the flexure 1980F. The rotational locking mechanism 1981 forms part of the sidewall of the disk 964. In this regard, the distal end of the rotational locking mechanism 1981 is a tang.

[0295] Fig.19B is an illustration of a portion of a body 1985 of a driven interface assembly 961. The body 1985 includes a driven disk receptacle 1986. A plurality of gear teeth 1987 extend in a proximal direction from a bottom surface of the driven disk receptacle 1986. The body 1985 includes a driven disk receptacle 1986 for each driven disk 964 of a plurality of driven disks 964P.

[0296] The shaft 1466 of the transmission unit 965 has a proximal end extending into the driven disk receptacle 1986. The driven disk 964 is mounted on the proximal end of the shaft 1466 so that the driven disk 964 is seated in the driven disk receptacle 1986 and can rotate therein.

[0297] When surgical instrument 260 is first installed in sterile adapter assembly 250, driven disk 964 in driven interface assembly 961 pushes intermediate disk 653 in sterile adapter assembly 250 proximally relative to movable body 651C, allowing intermediate disk 653 to rotate freely, e.g., tab 1767 on intermediate disk 653 moves proximally so that tab 1767 no longer contacts hard stop 1761 when intermediate disk 653 rotates. Typically, when surgical instrument 260 is first installed in sterile adapter assembly 250, intermediate drive interface 756 of intermediate disk 653 in sterile adapter assembly 250 is not aligned with driven interface 980 of driven disk 964. Therefore, intermediate disk 653 and driven disk 964 are not mated. Fig. 20A The cross-sectional view is shown when the intermediate disk 653 and the driven disk 964 are partially in contact (ie, partially coupled).

[0298] When the intermediate disk 653 and the driven disk 964 are in contact and partially coupled, the C-shaped structure 1863C is partially inserted into the C-shaped groove 1963C. However, the wall 1863A is not aligned with the gap 1963A and the wall 1863B is not aligned with the gap 1963B. Therefore, the C-shaped structure 1863C only enters the C-shaped groove 1963C until the walls 1863A, 1863B contact the proximal outer edge surface 1956 of the driven disk 964.

[0299] A portion of the C-shaped structure 1863C rests on the flexure 1980F and deflects the flexure 1980F in the distal direction. The deflection of the flexure 1980F moves the rotation locking mechanism 1981 distally, causing the tang 1981T to engage the teeth 1987 on the bottom surface of the driven disk receptacle 1986. The engagement of the tang 1981T with the teeth 1987 prevents the driven disk 964 from rotating.

[0300] Thus, when driven disk 964 remains stationary and intermediate disk 653 rotates, walls 1863A and 1863B are aligned with gaps 1963A and 1963B, respectively, and the preload force causes C-shaped structure 1863C to be fully inserted into C-shaped groove 1963C and causes walls 1863A and 1863B to be inserted into gaps 1963A and 1963B, respectively. Furthermore, each drive dog is inserted into a corresponding drive dog receptacle. Since C-shaped structure 1863C no longer pushes flexure 1980F, flexure 1980F returns to an undeflected state ( Fig. 20B ). This disengages the tang 1981T from the teeth 1987 and thus the driven disk 964 can rotate. Thus, the driven disk 964 has been coupled to the intermediate disk 653 so that torque is transmitted to the shaft 1466.

[0301] Flexure 1980F is illustrative only and not limiting. For example, a spring loaded pin may be included in the driven disk 964 so that the C-shaped structure 1863C depresses the pin until the intermediate disk 653 and the driven disk 964 are coupled. The depressed pin may push a flexure in the distal end of the driven disk 964, which includes a tang on one end. The tang will engage the teeth 1987 until the force on the flexure is removed. Alternatively, the spring loaded pin may engage the teeth 1987 to prevent rotation.

[0302] After surgical instrument 260 is mounted on sterile adapter assembly 250 and the intermediate disk is coupled to the driven disk, motion / torque can be transmitted from drive unit assembly 541 to the transfer unit in surgical instrument 260. However, as described above, under the first preload force supplied by the compression of spring 1601, there is some side play in disk stack 1400.

[0303] At the first preload force, the coupling between the intermediate disk 653 and the driven disk 964 and the coupling between the drive output disk 545 and the intermediate disk 653 have known non-zero backlash for the torque levels necessary to align the two disks. However, for lower torque levels, a portion of the coupling between the drive output disk 545 and the intermediate disk 653 has zero backlash. In order to reduce the backlash of the coupling between the intermediate disk 653 and the driven disk 964 and the coupling between the drive output disk 545 and the intermediate disk 653 to zero for the torque levels used in the surgical procedure, the preload force is varied from the first preload force to the second preload force using the preload assembly 780.

[0304] Fig.21 is a more detailed illustration of one aspect of the insertion assembly 331. The insertion assembly 331 includes a frame 2110, an intermediate bracket 2120, and a distal bracket 2130. The intermediate bracket 2120 rides on a ball screw 2111 in the frame 2110. In one aspect, the ball screw 2111 has a 6 mm pitch and is therefore rearwardly drivable. The intermediate bracket 2120 includes a metal band 2121 that drives the distal bracket 2130. The distal bracket 2130 is attached to the instrument manipulator assembly housing 741 of the instrument manipulator assembly 240. In one aspect, the distal bracket 2130 moves twice as far as the intermediate bracket 2120.

[0305] Fig.22A and Fig. 22B The preload assembly 780 is shown in greater detail. Fig.22A and Fig. 22B , surgical instrument 260 is installed in sterile adapter assembly 250. However, for ease of description, Fig.22A and Fig. 22B The surgical instrument 260 is not shown. The distal end of the surgical instrument is disposed, for example, at the entrance of a passageway leading into the access conduit 270.

[0306] First, if Fig.22A As shown, the cam follower assembly 2283 in the preload assembly 780 is disposed in a valley in the preload track 2225 on the intermediate bracket 2120, for example, at a first position on the preload track 2225. The preload track 2225 is mounted on the intermediate bracket 2120. The valley is located at the proximal end of the preload track 2225. The cam follower assembly 2283 is rotatably connected to a first end of an arm 2282 in the preload assembly 780. A second end of the arm 2282 is connected to a motor group bracket 2281. The motor group bracket 2281 is attached to the motor group 1541. Therefore, the arm 2282 is coupled to the motor group 1541. Fig.22A and Fig. 22B In FIG. 7 , instrument manipulator assembly housing 741 is transparent so that features and elements within instrument manipulator assembly housing 741 are visible. As noted above, instrument manipulator assembly housing 741 is attached to distal bracket 2130 .

[0307] In the first position, the light preload spring 1601 in each drive output assembly 543 has been compressed, and a first preload force is applied to each disk in the disk stack 1400. When the surgical device assembly 300 is inserted from the first position ( Fig.22A ) to the second position ( Fig. 22B ) When the distal side moves a distance Zload, the instrument manipulator assembly housing 741 moves a distance Zload.

[0308] The pivot pin 2284 on which the cam follower assembly 2283 is rotatably mounted is coupled to the instrument manipulator assembly housing 741 of the instrument manipulator assembly 240. Thus, when the insertion assembly 331 moves the instrument manipulator assembly housing 741 distally by a distance Zload, the pivot pin 2284 moves the cam follower assembly 2283 by the same distance Zload. In one aspect, the distance Zload is 9.779 centimeters (3.85 inches).

[0309] The wheel 2283W is rotatably attached to the first end of the cam follower assembly 2283, and the wheel 2283W rides on the preload track. Therefore, when the cam follower assembly 2283 moves distally, the wheel 2283W follows the contour of the preload track 2225. However, when the cam follower assembly 2283 moves distally, the distance between the preload track 2225 and the pivot pin 2284 decreases. As a result, when the cam follower assembly 2283 rides on the ramp 2225R in the preload track 2225, the cam follower assembly 2283 moves from the preload track 2225. Fig.22A The first position shown is rotated to Fig. 22BThe illustrated second position moves motor pack 1541 a distance greater than the distance traveled by instrument manipulator assembly housing 741. Thus, rotation of cam follower assembly 2283 displaces motor pack 1541 distally relative to instrument manipulator assembly housing 741 a predetermined distance.

[0310] To understand the forces acting on the cam follower assembly 2283, consider Fig. 22C Free body force diagram in . Fig. 22C A portion of the cam follower assembly 2283 and a portion of the preload track 2225 are shown. When the cam follower assembly 2283 moves the wheel 2283W up the ramp 2225R of the preload track 2225, the preload track 2225 applies a wheel force F_WHEEL on the preload track 2225. The wheel force F_WHEEL is perpendicular to the preload track 2225. The force F_WHEEL is composed of two perpendicular forces - the retraction force F_RETRACTION and the longitudinal force F_LONGITUDINALLY. The retraction force F_RETRACTION is the force that the user will apply in the distal direction to move the surgical instrument assembly 300 distally. Alternatively, part or all of this force can be applied by a motor so that the user does not need to apply all of the force.

[0311] When the cam follower assembly 2283 moves from the first position to the second position, a force proportional to the longitudinal force F_longitudinal is transmitted to the arm 2282 through the cam follower assembly 2283. The force proportional to the longitudinal force F_longitudinal is applied to the motor group 1541 through the arm 2282 and the motor group bracket 2281.

[0312] Thus, when cam follower assembly 2283 travels along track 2225, two actions are performed by cam follower assembly 2282. When cam follower assembly 2283 moves up ramp 2225R and rotates, the rotation of cam follower assembly 2283 pushes the motor group distally by a distance greater than the distance Zload, for example, motor group 1541 moves a distance (Zload+Δ). In addition, when cam follower assembly 2283 moves up ramp 2283W, cam follower assembly 2283 transmits a force proportional to the longitudinal force F_longitudinal to motor group 1541, which in turn compresses first and second springs 1601, 1602, so that a second preload force is applied to drive output disk 545. The second preload force is a combination of the forces provided by compression springs 1601, 1602. The force provided by compression spring 1602 is greater than the force provided by compression spring 1601. The second preload force applied to drive output disk 545 is applied to each of the other disks in disk stack 1400. As described above, in one aspect, the second preload force is 13.3 Newtons (3.0 Lbf). Of course, this is only true when the surgical instrument is installed, because otherwise the spring is not compressed.

[0313] Fig.22D and Fig.22E Motor pack 1541 is shown having moved an additional distance Δ relative to the top of instrument manipulator assembly housing 741 moving distance Zload. In one aspect, distance Δ is 0.538 cm (0.212 in). In this regard, Fig.22D and Fig.22E The distance that the proximal end of the arm 2282 moves when the cam follower assembly 2283 is rotated is shown as a distance Δ. This is illustrative only and not limiting.

[0314] In other embodiments, the cam follower assembly 2283 may have different lengths of the lever arm 2283M1 and the lever arm 2283M2 (see FIG. Fig.23 ), so that when the wheel 2283W passes through the ramp 2225R having a height Δ, the arm 2282 and therefore the motor group 1541 moves a distance greater than the distance Δ, or alternatively have the force arm 2283M1 and the force arm 2283M2 of different lengths (see Fig.23 ), so that when wheel 2283W passes through ramp 2225R having height Δ, arm 2282 and therefore motor group 1541 moves a distance less than distance Δ. Finally, Fig.22D Ramp 2225R is shown having a height Δ, for example, when wheel 2283W moves from a first position to a second position, wheel 2283W shifts a distance Δ in a direction perpendicular to track 2225 .

[0315] Fig.22F is an illustration of one aspect of the preload track 2225. Table 2 gives an example of the dimensions of the preload track 2225.

[0316] Table 2

[0317]

[0318]

[0319] The preload track 2225 is configured to smoothly ramp the preload force from a first preload force to a second preload force. Figure 22G is a graph of the retraction force when the preload force assembly 780 is moved distally from a first position to a second position on the preload track 2225. Curve 2280 generates a retraction force at each insertion distance. The retraction force acts on the instrument manipulator assembly housing 741 in the proximal direction.

[0320] In this example, the first position is 0.0 cm (0.0 inch) of insertion distance and the second position is 9.78 cm (3.85 inches) of insertion distance. The contraction force increases approximately linearly from 0.0 cm (0.0 inch) to approximately 1.52 cm (0.6 inches), and then continues to increase linearly from approximately 1.52 cm (0.6 inches) to 5.59 cm (2.2 inches) with a descending slope. From approximately 5.59 cm (2.2 inches) to 6.60 cm (2.6 inches), the force increases and reaches a peak value, and then gradually decreases to zero force at approximately 9.78 cm (3.85 inches). At 9.78 cm (3.85 inches) of insertion distance, the second preload force reaches 10.2 cattle (2.3 Lbf). At 9.78 cm (3.85 inches) of insertion distance, the second preload spring is compressed to its maximum value in the design, and therefore does not provide additional resistance to distal motion. In this example, the instrument tip protrudes from the cannula at an insertion depth of 12.19 centimeters (4.8 inches) or greater. Thus, the disc stack 1400 is fully preloaded and the backlash is effectively reduced to zero before the instrument tip exits the cannula.

[0321] As for curve 2280, a track is machined that provides this variation of retraction force with insertion profile. Machining establishes a preload track profile that smoothly ramps up the preload force according to curve 2280. Curve 2280 is illustrative only and not limiting. Given this disclosure, one skilled in the art will be able to establish the variation of retraction force with insertion distance for a particular preload spring assembly and a particular cannula and surgical instrument.

[0322] Fig.23 is a more detailed illustration of the preload assembly 780. The arm 2282 has a first end 2882A rotatably connected to a first end 2283A of an L-shaped body 2283B of the cam follower assembly 2283. The second end 2282B of the arm 2282 is connected to the motor pack bracket 2281. The motor pack bracket 2281 is attached to the motor pack 1541.

[0323] In this aspect, the first lever arm 2283M1 is perpendicular to the second lever arm 2283M2 at the pivot pin 2284 and has the same length. Thus, in this aspect, a longitudinal force F_longitudinal is applied to the motor group 1541. However, in other aspects, the two lever arms may not be perpendicular. If the lever arms are not perpendicular, or if the lever arms have different lengths, the force applied to the motor group 1541 is proportional to the longitudinal force F_longitudinal. In each aspect, the shape of the body 2283B is selected to accommodate the two lever arms and provide the necessary strength to rotate and transmit the longitudinal force to the motor group.

[0324] The second end 2283C of the L-shaped body 2283B is rotatably connected to the wheel 2283W. The wheel 2283W rides on the preload track. The apex of the L-shaped body 2283B is rotatably connected to the pivot pin 2284. The pivot pin 2284 is fixedly attached to the instrument manipulator assembly housing 741 of the instrument manipulator assembly 240. The first moment arm 2283M1 of the preload assembly 740 extends from the rotation center of the wheel 2283W to the rotation center of the apex of the L-shaped body 2283B. The second moment arm 2283M2 of the preload assembly 740 extends from the rotation center of the first end 2282A of the arm 2282 to the rotation center of the apex of the L-shaped body 2283B. Because the distance between the pivot pin 2284 and the track 2225 is fixed, when the wheel 2283W moves distally up the ramp, the cam follower assembly 2283 as Fig. 22B The indicated rotation, and therefore displacement of motor pack 1541 relative to instrument manipulator assembly housing 741 and resulting longitudinal force F_Longitudinal is exerted on the spring assembly in motor pack 1541.

[0325] exist Fig.23 In the embodiment, the preload assembly 780 also includes a preload release mechanism. The preload release mechanism includes a preload release button 2382, a preload release lever 2385, a preload engagement arm 2386 and a return spring (not shown, but see FIG. 4A to FIG. 4G ). The preload release button 2382 is an example of the preload release button 482. And Fig.23 Not shown is a torsion spring concentric with pin 2388, which applies a clockwise torque (relative to the rotation of the preload lever 2385) Fig.23 Clockwise). It is necessary to keep the preload release lever 2385 and preload release button 2382 in the unreleased position (shown) unless the release button 2382 is pressed.

[0326] The first end (proximal end) of the preload engagement arm 2386 is rotatably coupled to the pivot pin 2284. A rolling pin 2386P is mounted in the second end (distal end of the preload engagement arm 2386). Proximal to the rolling pin 2386P in the second end of the preload engagement arm 2386 is a preload engagement surface 2386S. In this regard, the preload engagement surface 2386S is perpendicular to the flat portion of the preload track 2225. The preload engagement arm 2386 is coupled to the linear rail.

[0327] The hook on the first end (proximal end) of the preload release lever 2385 engages with the rolling pin 2386P in the second end of the engagement arm 2386. The preload release button 2382 is coupled to the second end (distal end) of the preload release lever 2385, for example, in contact with the second end. Between the first end and the second end of the preload release lever 2385, the preload release lever is rotatably mounted on another pivot pin 2388, which acts as a fulcrum for the preload release lever 2385.

[0328] In this example, the preload release lever 2385 is a level 1 lever because the fulcrum is between the applied force (the force supplied by the preload release button 2382) and the load (the coupling between the hook and the rolling pin 2386P). Although in this example, the preload release lever 2385 is implemented as a level 1 lever, this is merely illustrative and not limiting. In other aspects, a level 2 lever or a level 3 lever may be used. For a level 2 lever, the load is between the fulcrum and the applied force, and for a level 3 lever, the applied force is between the fulcrum and the load.

[0329] If the insertion assembly 331 becomes stuck, the high preload force must be released so that the surgical instrument 260 can be removed. To remove the surgical instrument 260, the user pushes the preload release button 2382 ( Fig.24A ). In response to the force provided by the user, the preload release button 2382 applies a force to the second end of the preload release lever 2385. The force on the second end of the preload release lever 2385 causes the preload release lever 2385 to rotate about the pivot pin 2388 and disengage the hook on the second end of the preload release lever 2385 from the rolling pin 2386P installed in the second end of the preload engagement arm 2386.

[0330] As mentioned above, the return spring is installed between the instrument manipulator assembly housing 741 and the motor group 1541 and stretches when a high preload force is applied. As a result, when the preload release lever 2385 is disengaged from the preload engagement arm 2386, the return spring retracts the motor group 1541 to the fully withdrawn position.

[0331] In the fully withdrawn position, there is no preload force, and drive output disk 545 is disengaged from intermediate disk 553. In addition, release latch inhibits stop and plurality of hard stops 2437 are withdrawn, allowing both instrument sterile adapter assembly 250 and surgical instrument 260 to be disassembled. If the distal end of surgical instrument 260 is not straight, when one withdraws the surgical instrument, the cannula forces the distal end of surgical instrument 260 to straighten because there is no preload force and no engaged stack of drive output disks 545 can be driven backwards.

[0332] Fig. 24Bis an illustration of one embodiment of an automatic preload reset mechanism in preload assembly 780. When sterile adapter assembly 250 is mounted on instrument manipulator assembly 240, instrument manipulator assembly 240 sends a signal to controller 290 indicating the presence of sterile adapter assembly 250. In response to the signal, controller 290 activates a motor that moves instrument manipulator assembly 240 proximally.

[0333] The instrument manipulator assembly housing 741 moves proximally twice as fast as the preload engagement ridge 2326 on the preload track 2225. This is because the distal bracket 2130 moves twice as far as the intermediate bracket 2120. In this regard, the preload engagement ridge 2326 extends from the distal portion of the preload track 2225.

[0334] Thus, as instrument manipulator assembly housing 741 moves proximally, preload engagement ridge 2326 moves proximally at half the speed of preload engagement arm 2386 and instrument manipulator assembly housing 741. Thus, as instrument manipulator assembly housing 741 moves proximally, surface 2386S of preload engagement arm 2386 engages preload engagement ridge 2326 on preload track 2225. As instrument manipulator assembly housing 741 continues to move proximally, preload engagement ridge 2326 exerts a longitudinal force on surface 2386S of preload engagement arm 2386 in the proximal direction. This causes cam follower assembly 2283 to exert a longitudinal force on motor group 1541 as described above. When motor group 1541 moves in the proximal direction past position Preload_1 by the longitudinal force, preload release lever 2385 ( Fig. 24B 2386P. After the hook on the preload release lever 2385 on rolling pin 2386P engages, instrument manipulator assembly housing 741 moves distally so that motor group 1541 is at position preload_1. In this regard, the application of the preload force is automatic when sterile adapter assembly 250 is installed, and thus the preload force is maintained on drive output disk 545 after sterile adapter assembly 250 is installed.

[0335] Note that Fig.23 , Fig.24A and Fig. 24B Only the components necessary to understand the release mechanism are shown. Fig.23 , Fig.24A and Fig. 24B The actual configuration associated with Fig.22A All elements shown and described.

[0336] Fig.25is a cross-sectional view of a portion of surgical device assembly 300 illustrating a surgical instrument removal lockout device. The surgical instrument removal lockout device includes a preload mechanism that applies a preload force on tray stack 1400, a plurality of hard stops 2437, and a plurality of hard stop receptacles 1757. The plurality of hard stops 2437 are examples of the plurality of hard stops 437.

[0337] Each of the plurality of hard stops 2437 extends in a distal direction from a distal surface of the motor assembly 1541. Fig.17A As illustrated, each of plurality of hard stop receptacles 1757 extends in a distal direction from a proximal side of movable body 651C of sterile adapter assembly 250 into movable body 651C.

[0338] When sterile adapter assembly 250 is installed on surgical instrument manipulator assembly 240 and the preload force is automatically engaged as described above, movable body 251 is at the distal-most position within sterile adapter frame 651 of sterile adapter assembly 250. In this position, multiple hard stops 2437 are not in multiple hard stop receptacles 1757, and movable body 651C is free to move within sterile adapter frame 651.

[0339] Thus, as described above, surgical instrument 260 can be installed in sterile adapter assembly 250. However, when the second preload force is applied to output drive assembly 543 and the spring assembly is fully compressed, multiple hard stops 2437 extend into multiple hard stop receptacles 1757, and multiple hard stops 2437 prevent movable body 651C from moving in the proximal direction. Removal of surgical instrument 260 moves movable body 651C in the proximal direction. Therefore, if the second preload force is applied to motor group 1541, multiple hard stops 2437 prevent movable body 651C from moving in the proximal direction, and as a result, removal of surgical instrument 260 is inhibited.

[0340] The use of multiple hard stop receptacles 1757 is illustrative only and not limiting. In another aspect, multiple hard stop receptacles 1757 are not used. Instead, multiple hard stops 2437 contact the proximal surface of the movable body 651C and prevent the movable body 651C from moving in the proximal direction.

[0341] Thus, surgical instrument manipulator assembly 240 includes instrument manipulator assembly housing 741 (sometimes referred to as housing 741), and motor group 1541. Motor group 1541 is movably coupled to housing 741. A plurality of hard stops 2437 are mounted in a distal end of motor group 1541. The plurality of hard stops 2437 are positionable in at least a first position and a second position relative to housing 741 of surgical instrument manipulator assembly 240. When the plurality of hard stops 2437 are in the first position, surgical instrument 260 is capable of being coupled to and decoupled from instrument manipulator assembly 240. When the plurality of hard stops 2437 are in the second position, surgical instrument 260 cannot be decoupled from instrument manipulator assembly 240.

[0342] Fig.26A 635 is a more detailed cross-sectional view of sterile adapter release latch 2635. Sterile adapter release latch 2635 is an example of one aspect of release latch 435. Lip 654 on one end of sterile adapter frame 651 is engaged by lip 2635L extending from the distal end of sterile adapter release latch 2635. Sterile adapter release latch 2635 is mounted to the wall of instrument manipulator assembly housing 741 so that sterile adapter release latch 2635 can pivot to engage with and disengage from sterile adapter frame 651 of sterile adapter assembly 250. In one aspect, the pivotal connection of sterile adapter release latch 2635 to the frame is spring loaded so that the stable position of latch 2635 is in the engaged position. Latch pin 2635P is coupled to the proximal portion of sterile adapter release latch 2635. When motor pack 1541 is fully retracted in position home, eg, when no preload force is applied to motor pack 1541 , latch pin 2635P does not prevent sterile adapter release latch 2635 from pivoting to engage with and disengage from sterile adapter frame 651 .

[0343] When sterile adapter assembly 250 is mounted on instrument manipulator assembly 240, as described above, the automatic preload reset mechanism applies a preload force, such as a light preload force, on motor group 1541 when motor group 1541 is moved to position Preload_1 by the preload engagement mechanism. When motor group 1541 is moved to position Preload_1, release latch inhibition stop 2638 mounted to motor group 1541 also moves distally.

[0344] When motor pack 1541 is in position preload_1, if the proximal end of sterile adapter release latch 2635 is pushed, latch pin 2635P contacts release latch inhibition stop 2638, which prevents sterile adapter release latch 2635 from pivoting to disengage from sterile adapter frame 651. Thus, when a light preload force is applied to motor pack 1541, removal of sterile adapter assembly 250 is inhibited.

[0345] Fig.26A The illustration shows a potential problem if the automatic preload reset mechanism is energized while sterile adapter release latch 2635 is depressed. When release latch inhibition stop 2638 moves distally, if sterile adapter release latch 2635 is not released, release latch inhibition stop 2638 will hit latch pin 2635P. This can potentially damage latch pin 2635P, for example, causing latch pin 2635P to bend, such that the sterile adapter removal inhibition mechanism will not function properly. Therefore, in one aspect, latch pin 2636P ( Fig.26B ) is pivotally connected to the proximal portion of sterile adapter release latch 2635, and the connection is spring loaded by spring 2634. Thus, if sterile adapter release latch 2635 is depressed and the automatic preload reset mechanism is energized, when latch inhibiting stop 2638 strikes latch pin 2635P, latch pin 2635P pivots and is therefore not damaged. When sterile adapter release latch 2635 is released, spring 2634 causes latch pin 2633P to return to its initial position.

[0346] In some of the above examples, the terms "proximal" or "proximally" are generally used to describe an object or element that is closer to the manipulator arm base along a kinematic chain moving along the system or farther away from a remote center of motion (or surgical site) along a kinematic chain moving along the system. Similarly, the terms "distal" or "distally" are generally used to describe an object or element that is farther away from the manipulator arm base along a kinematic chain moving along the system or closer to a remote center of motion (or surgical site) along a kinematic chain moving along the system.

[0347] As used herein, “first”, “second”, “third”, “fourth”, etc. are adjectives used to distinguish different components or elements. Therefore, “first”, “second”, “third”, “fourth”, etc. are not intended to imply any ordering of components or elements.

[0348] The above description and accompanying drawings, which illustrate aspects and embodiments of the invention, should not be construed as limiting - the claims define the protected invention. Various mechanical, component, structural, electrical, and operational changes may be made without departing from the spirit and scope of the description and claims. In some cases, well-known circuits, structures, and techniques have not been shown or described in detail to avoid obscuring the invention.

[0349] Further, the terms of this description are not intended to limit the present invention. For example, spatial relative terms, such as "below", "below", "below", "above", "proximal", "distal", etc., can be used to describe the relationship between an element or feature and another element or feature illustrated in the figure. These spatial relative terms are intended to cover the different positions (i.e., places) and orientations (i.e., rotational placement) of the equipment in use or in operation other than the positions and orientations shown in the figure. For example, if the equipment in the figure is flipped, the element described as being "below" other elements or features, or "below" other elements or features will then be "above" or "on" other element features. Therefore, the exemplary term "below" can cover the position and orientation above and below. Equipment can be oriented (rotated 90 degrees or in other orientations) in other ways and the spatially relative descriptive symbols used herein are therefore interpreted. Similarly, the description of the motion along different axes or around different axes includes various special equipment positions and orientations.

[0350] The singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context indicates otherwise. The terms "comprising", "including", "including", etc. qualify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups. Components described as coupled may be directly electrically or mechanically coupled, or they may be indirectly coupled via one or more intermediate components.

[0351] All examples and illustrative references are non-limiting and may not be used to limit the claims to the specific implementations and embodiments described herein and their equivalents. Any headings are for formatting purposes only and should not be used to limit the subject matter in any way, as text under one heading may cross-reference or apply to text under one or more headings. Finally, in view of this disclosure, specific features described with respect to one aspect or embodiment may be applied to other disclosed aspects or embodiments of the invention, even if not specifically shown in the figures or described in the text.

Claims

1. A device comprising: a drive output disk of an instrument manipulator assembly, the drive output disk comprising a distal surface, a first alignment element and a second alignment element, each of the first alignment element and the second alignment element extending from the distal surface, the first alignment element comprising a pin having a three-dimensional structure, the second alignment element comprising a post and a tab extending from the post toward a circumferential edge of the distal surface; and an intermediate disk of a surgical device interface element, the intermediate disk comprising an outer proximal surface, a first alignment receptacle extending within the outer proximal surface into the intermediate disk, and a second alignment receptacle extending within the outer proximal surface into the intermediate disk, the intermediate disk being configured to interface with the drive output disk and a driven disk of an instrument; The combination of the first and second alignment elements of the drive output disk is configured to mate with the combination of the first and second alignment receptacles of the intermediate disk such that the drive output disk mates only with the intermediate disk in one orientation.

2. The device according to claim 1, wherein: The pin of the first alignment element of the drive output disk includes a three-dimensional D-shape.

3. The device according to claim 1, wherein: The drive output disk further includes a plurality of drive dogs extending from the distal end surface. Each of the plurality of drive dogs comprises a first portion and a second portion, The first portion of each drive dog comprises a three-dimensional structure, the second portion of each drive dog extending from the first portion of each drive dog, The second portion of each drive dog includes two opposing drive dog second portion side surfaces, and Each of the two opposing drive dog second portion side surfaces comprises a curved surface; and The intermediate disk also includes a plurality of drive claw sockets, Each of the plurality of drive dog receptacles is configured to receive a corresponding one of the plurality of drive dogs of the drive output disk, Each of the plurality of drive dog receptacles includes a first portion, a second portion, and a bottom surface, said first portion of each drive dog receptacle including opposed side walls extending from said outer proximal surface into said intermediate disk; The second portion of each drive dog receptacle extends from the first portion of the drive dog receptacle to the bottom surface, and The second portion of each drive dog receptacle includes two opposing drive dog receptacle inclined side surfaces.

4. The device according to claim 3, wherein: The curved surfaces of the side surfaces of the two opposing drive dog second portions include a portion of a circular cross-section.

5. The device according to claim 3, wherein: Each of the two opposing drive dog second portion inclined side surfaces includes a portion of a side surface of the wedge-shaped body.

6. The device according to claim 3, wherein: Each of the plurality of drive dog receptacles includes a first edge surface and a second edge surface; The first edge surface is positioned a first distance from a longitudinal axis of the intermediate disk; and The second edge surface is opposite to the first edge surface.

7. The device according to claim 6, wherein: The second edge surface of each drive dog receptacle includes an open edge surface.

8. The device according to claim 3, wherein: the distal surface of the drive output disk includes a center; and Each drive dog of the plurality of drive dogs includes a first edge positioned a first distance from the center of the distal surface.

9. The device according to claim 3, wherein: Each drive dog receptacle of the plurality of drive dog receptacles includes a first edge positioned a first distance from a longitudinal axis of the intermediate disk.

10. The device according to claim 1, wherein: The intermediate disk also includes an outer side surface and a hard stop tab extending from the outer side surface.

11. The device according to claim 1, further comprising: A first preload spring of the instrument manipulator assembly is coupled to the drive output disk.

12. The device according to claim 11, further comprising: a preload assembly coupled to the first preload spring, in: Under the condition that the first preload spring is compressed, a first preload force is applied to the coupling between the drive output disk and the intermediate disk, and Under a condition in which the first preload force is applied to the coupling between the drive output disk and the intermediate disk, the coupling between the drive output disk and the intermediate disk has a non-zero backlash.

13. The apparatus according to claim 11, further comprising: A second preload spring of the instrument manipulator assembly is coupled to the drive output disk.

14. The apparatus according to claim 13, further comprising: a preload assembly coupled to both the first preload spring and the second preload spring, in: Under the condition that the first preload spring and the second preload spring are compressed by the preload assembly, a second preload force is applied to the coupling between the drive output disk and the intermediate disk, and Under a condition in which the second preload force is applied to the coupling between the drive output disk and the intermediate disk, the coupling between the drive output disk and the intermediate disk has zero backlash.

15. The apparatus according to claim 1, further comprising: a first preload spring coupled to the drive output disk; a second preload spring coupled to the drive output disk; and a preload assembly coupled to both the first preload spring and the second preload spring; in: Under the condition that the first preload spring is compressed by the preload assembly, a first preload force is applied to the coupling between the drive output disk and the intermediate disk, and The coupling between the drive output disk and the intermediate disk has a non-zero backlash under a condition where the first preload force is applied to the coupling between the drive output disk and the intermediate disk; and in: Under the condition that the first preload spring and the second preload spring are compressed by the preload assembly, a second preload force greater than the first preload force is applied to the coupling between the drive output disk and the intermediate disk, and Under a condition in which the second preload force is applied to the coupling between the drive output disk and the intermediate disk, the coupling between the drive output disk and the intermediate disk has zero backlash.

16. An apparatus comprising: a surgical device interface element comprising a first body structure and a plurality of intermediate disks mounted in the first body structure; Each intermediate disk of the plurality of intermediate disks is configured to interface with a drive output disk of the instrument manipulator assembly and a driven disk of the instrument; Each of the plurality of intermediate disks comprises a driven interface and a driving interface; The driving interface is opposite to the driven interface, and the driving interface includes a coupling structure; as well as the driven interface comprising a first alignment receptacle and a second alignment receptacle, the combination of the first alignment receptacle and the second alignment receptacle being configured to mate with a combination of a first alignment element and a second alignment element extending from the drive output disk of the instrument manipulator assembly, the second alignment element comprising a post and a tab extending from the post toward a circumferential edge of the drive output disk; When the drive output disk is mated with the intermediate disk, the first and second alignment receptacles of the intermediate disk mate with the first and second alignment elements of the drive output disk such that the drive output disk only mates with the intermediate disk in one orientation.

17. The device according to claim 16, wherein: The alignment element of the drive output disk includes a pin having a three-dimensional D-shape.

18. The apparatus of claim 16, wherein: Each intermediate disk of the plurality of intermediate disks includes an outer side surface and a hard stop tab extending from the outer side surface.

19. The device according to claim 18, wherein: The first body structure further includes a plurality of hard stops; and The hard stop tab of each intermediate disk of the plurality of intermediate disks is associated with a different hard stop of the plurality of hard stops.

20. The apparatus of claim 19, wherein: in a first axial position of each intermediate disk relative to the first body structure, the hard stop tab of each intermediate disk contacts a corresponding hard stop of the plurality of hard stops of the first body structure and prevents free rotation of each intermediate disk relative to the first body structure; and In a second axial position of each intermediate disk relative to the first body structure, the hard stop tab of each intermediate disk does not contact a corresponding hard stop of the plurality of hard stops of the first body structure and each intermediate disk is free to rotate relative to the first body structure.

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