Surgical apparatus including a sterile adapter with mechanical lockout

Abstract

The name of the invention is surgical apparatus including a sterile adapter with mechanical lockout. A surgical system includes a pre-load assembly in a surgical instrument manipulator controlled by a controller. The controller is capable of automatically causing the pre-load assembly to engage and disengage pre-load. The surgical apparatus includes a surgical instrument manipulator assembly and a sterile adapter assembly. The sterile adapter assembly is mounted in a distal face of the surgical instrument manipulator assembly. The sterile adapter assembly is removable from the distal face of the surgical instrument manipulator when the pre-load assembly configures the surgical instrument manipulator assembly to apply a pre-load force on the sterile adapter assembly. The sterile adapter assembly includes a mechanical sterile adapter assembly removal lockout and a mechanical surgical instrument removal lockout.

Description

[0001] This application is a divisional application of patent application No. 2017800519814, filed on June 21, 2017, entitled "Surgical device including a sterile adapter with mechanical lock".

[0002] Related applications

[0003] This patent application claims priority and benefit to U.S. Provisional Patent Application 62 / 362,183, filed July 14, 2016, entitled “A SURGICAL APPARATUSINCLUDING A STERILE ADAPTER HAVING MECHANICAL LOCKOUTS,” which is incorporated herein by reference in its entirety. Technical Field

[0004] This invention generally relates to remotely operated instruments and systems, and more particularly to remotely operated instruments and systems utilizing preloaded forces. Background Technology

[0005] Systems such as those used in 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," etc., include aspects of remote operation or remote robotics.) Figure 1A An example of a known robot control system 100 is shown. System 100 may be, for example, a daemon commercially available from Intuitive Surgical. As part of a surgical system (da Vinci Surgical System), system 100 includes a patient-side system 110 having multiple arms 130. Each arm 130 has a docking port with a drive system 140, which typically includes a drive system with a mechanical interface for mounting instruments 150 and providing mechanical power for the operation of the instruments 150. The arms 130 are capable of moving and positioning the various instruments 150 used in the procedure during medical procedures.

[0006] Figure 1BA bottom view of a known instrument 150 is shown. Instrument 150 generally includes a delivery or rear-end mechanism 152, a main tube 154 extending from the rear-end mechanism 152, and a functional tip 156 at the distal end of the main tube 154. Tip 156 generally includes a medical instrument, such as a scalpel, scissors, forceps, or cauterization instrument that can be used during medical procedures. A drive cable or tendon 155 is connected to tip 156 and extends through main tube 154 to rear-end mechanism 152. Rear-end mechanism 152 typically provides a mechanical connection between the drive tendons 155 of instrument 150 and the motorized axis of the mechanical interface of drive system 140. Specifically, gears or discs 153 have features such as protrusions or holes, their position, size, and shape set to engage complementary features on the mechanical interface of drive system 140. In a typical instrument, rotation of disc 153 pulls on individual drive tendons 155 and actuates corresponding mechanical links in tip 156. System 100 is thus able to control the movement and tension of drive tendons 155 as needed for positioning, orientation, and manipulation of tip 156. Further details of known surgical systems are described, for example, in U.S. Patent No. 7,048,745, filed August 13, 2001, by Tierney et al., entitled “Surgical Robotic Tools, Data Architecture, and Use,” which is incorporated herein by reference in its entirety.

[0007] The instruments 150 of system 100 can be exchanged with each other by removing one instrument 150 from drive system 140 and then installing another instrument 150 to replace the removed instrument. The installation process generally requires that features on disc 153 properly engage complementary features of drive system 140. However, the patient-side system 110 generally does not know the orientation of disc 153 on instrument 150 prior to installation.

[0008] Furthermore, due to the difficulty in cleaning and sterilizing complex equipment between medical procedures, equipment such as the patient-side system 110 is typically covered by a sterile barrier (e.g., a plastic sheet drape) during the medical procedure. This sterile barrier can include a sterile adapter positioned between the docking port associated with the drive system 140 and the rear-end mechanism 152 of the instrument. See, for example, U.S. Patent No. 7,048,745 and U.S. Patent No. 7,699,855, entitled “Sterile Surgical Adaptor”, filed by Anderson et al. (March 31, 2006), each of which is incorporated herein by reference in its entirety, and which describe exemplary sterile barrier and adapter systems.

[0009] A typical installation procedure for the device 150 involves installing the rear-end mechanism 152, possibly along with an interventional sterile adapter, regardless of the orientation of the discs 153 on the drive system 140. The drive motor in the drive system 140 can then be rotated back and forth multiple times during the installation procedure to ensure that complementary features mesh with each other and are securely engaged for operation of the newly installed device 150. At some point during the installation process, the drive motor is securely engaged to rotate the individual discs 153. However, the device 150 being installed can sometimes move in unpredictable ways during the installation procedure because the drive motor engages the individual discs 153 of the device 150 at different and unpredictable times. Such unpredictable movement is unacceptable for a particular application. Generally, a defined or limited space is required around the device 150 to accommodate uncontrolled movement of the device tip during the installation procedure. Summary of the Invention

[0010] A computer-aided surgical device includes a preloading component and a controller. The controller is coupled to the preloading component. The preloading component includes a preloading engagement / disengagement mechanism. The controller is configured to move the preloading component until it is fully retracted; if the preloading component is fully retracted, activate the preloading engagement / disengagement mechanism; and after activating the preloading engagement / disengagement mechanism, move the preloading component to its home position.

[0011] The device also includes a surgical instrument manipulator assembly comprising the preloading assembly, a housing, and a motor assembly movably mounted within the housing. The preloading assembly includes a cam follower assembly comprising a wheel and a body. The wheel is configured to ride on a preloading track. The body of the cam follower assembly is rotatably coupled to a first pivot pin. The body includes first and second ends. The second end of the body is coupled to the motor assembly. The first end of the body is coupled to the wheel.

[0012] In one aspect, the preload engagement / disengagement mechanism further includes a preload engagement arm having a first end and a second end. The first end of the preload engagement arm is coupled to a first pivot pin. A rolling pin is mounted in the second end of the preload engagement arm.

[0013] In this respect, the preload engagement / disengagement mechanism further includes a second pivot pin and a preload engagement / disengagement arm rotatably coupled to the second pivot pin. The preload engagement / disengagement arm is engageable and disengageable from the rolling pin. A torsion spring is mounted on the second pivot pin and coupled to the preload engagement / disengagement arm. The torsion spring is configured to provide torque on the preload engagement / disengagement arm to hold the preload engagement / disengagement arm in a disengaged position from the rolling pin.

[0014] The preload engagement / disengagement mechanism further includes an electric actuator coupled to the preload engagement / disengagement arm and the controller. If an engagement command from the controller is received by the electric actuator, the electric actuator provides torque on the preload engagement / disengagement arm to hold the preload engagement / disengagement arm in a position relative to the rolling pin engagement; this is referred to as the preload being engaged. The preload engagement / disengagement mechanism also includes an emergency device release button coupled to the preload engagement / disengagement arm.

[0015] In another aspect, a device includes a surgical instrument manipulator assembly, an insertion assembly, and a controller. The surgical instrument manipulator assembly includes a housing, a motor assembly, and a preloading assembly. The motor assembly is movably mounted within the housing. The preloading assembly includes a preloading engagement / disengagement mechanism. The insertion assembly is coupled to the surgical instrument manipulator assembly. The insertion assembly includes a preloading track. The controller is coupled to the surgical instrument manipulator assembly, the insertion assembly, and the preloading assembly. The controller is configured to command the insertion assembly to move the preloading assembly until the preloading assembly is fully retracted; if the preloading assembly is fully retracted, to command the preloading engagement / disengagement mechanism to engage the preloading; and after engaging the preloading, to command the insertion assembly to move the preloading assembly to its original position. In this device, the preloading engagement / disengagement mechanism is the same as that described above.

[0016] One method involves releasing the preload force on the motor assembly of the surgical instrument manipulator assembly by moving the surgical instrument manipulator assembly to a fully retracted position.

[0017] Another method includes moving the surgical instrument manipulator assembly to a fully retracted position by a controller. The method further includes issuing a command from the controller to a preload assembly of the surgical instrument manipulator assembly to engage a preload. The method further includes moving the surgical instrument manipulator assembly back to its original position by the controller after the preload is engaged. The method can also include moving the surgical instrument manipulator assembly to the fully retracted position by the controller to automatically release the preload.

[0018] A surgical device includes a surgical instrument manipulator assembly and a sterile adapter assembly. The sterile adapter assembly is mounted in the distal side of the surgical instrument manipulator assembly. The sterile adapter assembly is removable from the distal side of the surgical instrument manipulator assembly when the preloading assembly configures the surgical instrument manipulator assembly to apply a preloading force to the sterile adapter assembly.

[0019] In one aspect, the sterile adapter assembly includes a mechanical sterile adapter assembly removal lockout and a mechanical surgical instrument removal lockout. In another aspect, the surgical device further includes a surgical instrument mounted in the sterile adapter assembly. Mounting the surgical instrument in the sterile adapter assembly activates the mechanical sterile adapter assembly removal lockout.

[0020] In another embodiment, the surgical device further includes an insertion assembly connected to the surgical instrument manipulator assembly. If the surgical instrument manipulator assembly is moved a predetermined distance in the distal direction, the surgical instrument manipulator assembly activates the sterile adapter to remove the blockage.

[0021] In this regard, the surgical instrument manipulator assembly also includes a clutch button. The clutch button and the emergency release button are user-only interfaces for the surgical instrument manipulator assembly.

[0022] In one aspect, the sterile adapter assembly includes a frame. In this aspect, the mechanical surgical instrument removal lock includes a movable body movably mounted within the frame of the sterile adapter assembly. In a first position of the movable body, the surgical instrument can be removed from the sterile adapter assembly, while in a second position of the movable body, the surgical instrument is locked in place within the sterile adapter assembly.

[0023] In another aspect, the sterile adapter assembly further includes a crossbeam having a first end and a second end, wherein the first end is opposite to the second end. The crossbeam is pivotally connected to the frame of the sterile adapter assembly. A plurality of hook extensions extend from the second end of the crossbeam. Each of the plurality of hook extensions includes a hook configured to engage a hook receiver in the surgical instrument manipulator assembly. A sterile adapter assembly release button is coupled to the first end of the crossbeam. Pressing the sterile adapter assembly release button in a first direction causes the plurality of hook elements to move in a second direction, disengaging each hook from the hook receiver. The mechanical sterile adapter assembly removal block includes the first end of the crossbeam, wherein if the surgical instrument is mounted in the sterile adapter assembly, the surgical instrument prevents movement of the sterile adapter assembly release button in the first direction and thus disables removal of the sterile adapter assembly from the surgical instrument manipulator assembly.

[0024] In one aspect, a surgical instrument manipulator assembly includes a housing, a clutch button mounted within the housing, and a preload assembly including an emergency instrument release button. The clutch button and the emergency instrument release button are user-only buttons of the surgical instrument manipulator assembly.

[0025] A method includes moving a combination of a surgical instrument manipulator assembly and a sterile adapter assembly from a second position to a first position, wherein in the second position the surgical instrument manipulator assembly applies a second preload force to the sterile adapter assembly, and in the first position the surgical instrument manipulator assembly applies a first preload force to the sterile adapter assembly, wherein the second preload force is greater than the first preload force. The method further includes removing the sterile adapter assembly from the surgical instrument manipulator assembly while the first preload force is applied to the sterile adapter assembly.

[0026] In another aspect, a computer-aided surgical system includes a surgical instrument manipulator assembly and a controller. The surgical instrument manipulator assembly includes a preloading component. The controller is coupled to the preloading component. The controller directly controls the preloading provided by the preloading mechanism via commands to the preloading component.

[0027] In this respect, the surgical instrument manipulator assembly includes a housing and a motor assembly movably mounted within the housing. A preloading assembly is connected to the housing. The preloading assembly is configured to move the motor assembly relative to the housing under the control of the controller.

[0028] The preloading assembly includes a motor and a nut. The motor is coupled to the controller. The nut is coupled to the motor such that the motor moves the nut in a first direction and a second direction. The preloading assembly also includes an arm coupled to the motor assembly and a preloading release lever pivotally mounted on the arm. The preloading release lever is engageable and disengageable from the nut. If the preloading release lever is engaged with the nut, movement of the nut is transmitted to the arm. The preloading assembly also includes an emergency device release button coupled to the preloading release lever.

[0029] In another aspect, a computer-aided surgical system includes a surgical instrument manipulator assembly, an insertion assembly, and a controller. The surgical instrument manipulator assembly includes a housing, a motor assembly, and a preloading assembly. The motor assembly is movably mounted within the housing. The insertion assembly is coupled to the surgical instrument manipulator assembly to move the surgical instrument manipulator assembly. The controller is coupled to the surgical instrument manipulator assembly, the insertion assembly, and the preloading assembly. The controller is configured to command the preloading assembly to change the position of the motor assembly relative to the housing of the motor assembly, independent of the position of the insertion assembly relative to the preloading assembly and independent of whether the insertion assembly is moving or stationary.

[0030] Another method involves controlling the preload force on the motor assembly of the surgical instrument manipulator assembly by sending commands directly to the preload assembly via the controller.

[0031] Another method includes moving the motor assembly of the surgical instrument manipulator assembly from a no-preload position to a low-preload position by a controller relative to the housing of the surgical instrument manipulator assembly while the surgical instrument manipulator assembly is held in a fixed position (such as the original position). The method further includes moving the motor assembly of the surgical instrument manipulator assembly from a high-preload position to a low-preload position by the controller relative to the housing of the surgical instrument manipulator assembly, regardless of the control of the insertion assembly on which the surgical instrument manipulator is mounted. Attached Figure Description

[0032] Figure 1A This is an illustration of a remotely operated minimally invasive surgical system based on existing technology.

[0033] Figure 1B This is an illustration of components of a prior art surgical device.

[0034] Figure 2This is an illustration of a remote operating system including an instrument manipulator assembly with a preloading component, the preloading component including automatic preloading engagement / disengagement and an emergency instrument release button and clutch button only.

[0035] Figure 3A is Figure 2 A more detailed illustration of the configuration of the surgical apparatus components, with all components in their original positions.

[0036] Figure 3B is Figure 2 A more detailed illustration of the configuration of the surgical device components, some of which are in an extended position.

[0037] Figures 4A to 4G are block diagrams illustrating the installation of the sterile adapter assembly and the instrument on the instrument manipulator assembly, the operation of the preloading mechanism, the instrument removal lock, the sterile adapter removal lock, the automatic preloading release, and the automatic preloading reset.

[0038] Figure 5 The image shows a sterile surgical drape.

[0039] Figure 6A It is in a configuration for covering. Figure 2 A diagram of the patient-side support system.

[0040] Figure 6B and Figure 6C The diagram shows the alignment of the cover and the mounting holes on the linkage of the patient-side support system.

[0041] Figure 7A The illustration shows a surgical drape installation kit being moved to a position on a platform at one end of a link for installation on the patient-side support system.

[0042] Figure 7B Showing that it is installed Figure 7A Surgical drape installation kit on the platform.

[0043] Figure 8 This is a state diagram for the instrument manipulator assembly.

[0044] Figure 9A illustrates the component being attached to the insertion component. Figure 2 The instrument manipulator assembly, wherein the insertion assembly is then attached to the insertion axis base assembly.

[0045] Figures 9B to 9F are illustrations of a sterile adapter assembly including a mechanical lock.

[0046] Figures 10A and 10B illustrate the installation of the sterile adapter assembly of Figures 9B to 9F onto another instrument manipulator assembly.

[0047] Figure 10CThis is a partial cross-sectional view illustrating the features of the sterile adapter assembly and the instrument manipulator assembly.

[0048] Figures 11A and 11B are Figure 2 A more detailed illustration of one of the instruments.

[0049] Figures 12 to 14 The illustration shows the device during installation in the sterile adapter assembly.

[0050] Figure 15 The illustrations of the surgical instruments in Figures 11A and 11B are shown in the sterile adapter assemblies of Figures 9B to 9F, which are installed to activate the sealing mechanism of the sterile adapter assembly.

[0051] Figure 16 This is a more detailed illustration of the insertion components in the prior art.

[0052] Figures 17A and 17B illustrate the preloaded components in more detail.

[0053] Figure 17C is a side view of the torsion spring in the preloaded assembly of Figures 17A and 17B.

[0054] Figures 18A to 18E illustrate automatic engagement via preloading by the controller.

[0055] Figures 19A to 19C illustrate automatic unloading via preloading by the controller.

[0056] Figures 20A to 20C illustrate different preload states of an instrument manipulator assembly with a preload component that is directly controlled by a controller.

[0057] Figures 20D and 20E illustrate mechanical device removal blockage assemblies with different mechanical devices that are directly controlled by a controller to remove the blockage.

[0058] Figures 21A to 21C further illustrate one aspect of the preloaded components of Figures 20A to 20C in more detail.

[0059] In the accompanying drawings, for single-digit designations, the first digit of the component's identification number is the designation of the component when it first appears in the drawing. For double-digit designations, the first two digits of the component's identification number are the designation of the component when it first appears in the drawing. Detailed Implementation

[0060] In one aspect, a computer-aided remote operating system 200 (sometimes referred to as System 200) Figure 2For example, a minimally invasive computer-assisted remote operating system includes a patient-side support system 210 with an arm 220. At one end of the arm 220 is an access guide manipulator assembly 230 (also referred to as the access guide manipulator 230). Mounted on the access guide manipulator 230 is a master instrument manipulator 280, which in turn supports multiple surgical device assemblies. In one aspect, the surgical device assembly includes an instrument manipulator assembly 240, an instrument sterile adapter assembly 250, and an instrument 260. In one aspect, the instrument sterile adapter assembly 250 is attached to a sterile drape used to cover the access guide manipulator 230 and each instrument manipulator assembly 240.

[0061] 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.

[0062] The access manipulator 230 alters the pitch and yaw of the surgical instrument components in a group manner. The main tube of each instrument 260 extends through different channels in the single-port access guide 270. In this respect, the single-port access guide 270 is mounted in a cannula. Single-port refers to a single access location to a surgical site within the patient (e.g., a single incision, a single natural orifice, etc.).

[0063] As used in this article, a cannula is a tube that passes through the patient's body wall and is in direct contact with the patient. The cannula generally does not slide in or out relative to the patient, but it can pitch and yaw about a point on its axis (known as a telemotor center).

[0064] As used herein, the single-port access guide 270 is the tube through which all surgical instruments and camera instruments must pass to reach their positions within the patient. The access guide 270 has a separate lumen for each instrument. The access guide 270 passes through the cannula and is tortuous relative to the cannula.

[0065] Controller 290 is coupled to the surgeon's console (not shown) and to the patient-side support system 210. Controller 290 represents various controllers in system 200. Controller 290 sends a second control command to instrument 260 in response to a first control command. The first control command is based on movement of the main device in the surgeon's console next to the surgeon. When instrument 260 moves in response to the second control command, the display control module in system controller 290 also updates the stereoscopic view of the surgical site generated by the display device in the surgeon's console.

[0066] Although described as controller 290, it should be understood that controller 290 can be implemented in practice by any combination of hardware, software executing on a processor, and firmware. Moreover, as described herein, its functionality can be executed by a single unit or distributed to different components, each of which can in turn be implemented by any combination of hardware, software executing on a processor, and firmware. When distributed to different components, the components can be centralized in one location or distributed across system 200 for distributed processing purposes. The processor should be understood to include at least logic units and memory associated with the logic units.

[0067] As explained more fully below, in one aspect, controller 290 releases the preloaded force on the motor assembly of instrument manipulator assembly 240 by moving instrument manipulator assembly 240 to a fully retracted position close to its original position.

[0068] To engage preload, controller 290 moves instrument manipulator assembly 240 to the fully retracted position, and then controller 290 issues a command to engage preload to the preload component of instrument manipulator assembly 240. After preload is engaged, controller 290 moves instrument manipulator assembly 240 back to its original position. Here, when it is in the state of controller 290 performing an action, it means that the controller issues a command or signal to the component to perform that action.

[0069] In another aspect, the controller 290 can change the preload independently of the position of the instrument manipulator assembly 240 and independently of whether the instrument manipulator assembly 240 is moving or stationary. The controller 290 controls a motor within the preload assembly, which in turn determines the preload applied by the preload assembly. In this respect, commands from the controller 290 to move the instrument manipulator assembly 240 of the insertion assembly do not affect the preload. The preload is directly controlled by the controller 290 and can be changed by the controller 290 if necessary.

[0070] As described in more detail below, the computer-aided remote operating system 200 includes some features of previous systems, which are presented below:

[0071] US Patent Application Publication No. US2016 / 0184037A1 (published as "Preloaded Surgical Instrument Interface");

[0072] US Patent Application Publication No. US2016 / 0184036A1 (published as "VARIABLE INSTRUMENTPRELOAD MECHANISM CONTROLLER");

[0073] US Patent Application Publication No. US2016 / 0184035A1 (published as "ACTUATOR INTERFACE TOINSTRUMENT STERILE ADAPTER");

[0074] PCT International Publication No. WO2015 / 023834A1 (published as "Instruction Sterile Adaptor Drive Features");

[0075] PCT International Publication No. WO2015 / 023840A1 (published as "Instrument Sterile Adapter Drive Interface"); and

[0076] PCT International Publication No. WO2015 / 023853A1 (publication entitled "ROBOTIC INSTRUMENT DRIVENELEMENT"), each of which is incorporated herein by reference in its entirety.

[0077] The common features of both the existing system and system 200 are not described in detail herein in order to avoid diminishing the inventive aspects described herein.

[0078] In one aspect of the system described in the disclosure cited above, each instrument manipulator assembly includes a sterile adapter release latch, a clutch button, and a preload release button. As explained more fully, the instrument manipulator assembly in system 200 does not include a sterile adapter release latch or a preload-based sterile adapter release lock.

[0079] The instrument manipulator assembly 240 includes a clutch button and an emergency release button housed within its housing. The clutch button and emergency release button are user-only buttons of the instrument manipulator assembly 240. Therefore, the clutch button and emergency release button constitute the user-only interface of the instrument manipulator assembly 240. Reducing the number of buttons on the instrument manipulator assembly 240 improves the user experience by minimizing the possibility of users accidentally pressing the wrong button or delaying critical moments due to confusion regarding the functions of the various buttons on the instrument manipulator assembly 240.

[0080] In one aspect of the system described in the disclosure cited above, the preload release button has a dual function. The preload release button is actuated to disarm the sterile adapter removal occlusion feature, allowing the sterile adapter to be removed. The preload release button is also used to release the preload in an emergency. In contrast, as explained more fully below, the emergency device release button on each of the plurality of device manipulators in system 200 is used only to release the preload force on the tray stack. Furthermore, to facilitate masking by system 200, the release and activation of the preload are controlled by controller 290, enabling the preload to be released to facilitate the masking process and to be activated after masking is completed.

[0081] Figures 3A and 3B are illustrations of four surgical device assemblies 300 mounted on an access guide manipulator 230. In Figure 3A, the surgical device assembly 300 is positioned in a starting position, such as a first position (sometimes referred to as the "original position"). The mechanical interface includes a stack of discs between a motor in the instrument manipulator assembly 240 and a shaft in the transfer unit of the instrument 260. In the configuration of Figure 3A, after covering, a first preload force is applied to the stack, for example, a first predetermined force is applied to the stack.

[0082] Regarding the first preload force, the mechanical interface may have a certain backlash because the first preload force is insufficient to clamp the disks in the disk stack 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, for example, partially connected, until the backlash is minimized.

[0083] Regarding the first preload force with a low preload force, assuming a coefficient of friction of 0.1, the disk in the mechanical interface has zero backlash up to a first torque level (e.g., 1.17 in-lbs). Above the first torque level, there may be known small backlashes, such as 1.13 degrees. As described in more detail below, this force typically provides more than the first torque level due to the use of a force sufficient to rotate the disk, thereby overcoming friction and dynamically and rapidly mating the disks. In this case, the disk in the mechanical interface has non-zero backlash. Therefore, in this case, the mechanical interface is referred to as having non-zero backlash.

[0084] In Figure 3B, three of the four surgical apparatus components have been moved distally. Arrow 390 defines the distal and proximal directions. 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. The distal direction is an example of the first direction, and the proximal direction is an example of a second direction opposite to the first direction.

[0085] As the surgical device assembly 300 moves distally on the insertion assembly 331, the preload force on the disk stack automatically increases from a first preload force to a 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 disks in the disk stack) to zero for the torque level used in the surgical procedure.

[0086] In one aspect, the second preload force is a high preload force, for example, 2.3 lb. As just described, the disc in the mechanical interface, and therefore the mechanical interface, has zero backlash at the torque level used in surgery. In one example, if the coefficient of friction is assumed to be 0.1, the mechanical interface has zero backlash for a torque level of up to 4.9 in-lb. For the instrument 260 that applies surgically useful forces at the end effector, a specific torque must be applied to the disc in the mechanical interface. This is considered the surgically useful torque. In one example, the surgically useful torque could be 4.425 in-lb, and therefore in this aspect, the mechanical interface has zero backlash for the torque level used in surgery.

[0087] Figures 4A through 4G are block diagrams illustrating the installation of the sterile adapter assembly and the instrument on the instrument manipulator assembly. Other aspects illustrated in Figures 4A through 4G include the operation of the preload engagement / disengagement mechanism to reduce side clearance, instrument assembly removal lock, sterile adapter removal lock, preload release, and automatic preload reset. These mechanical locking features are used to ensure that the system 200 cannot undergo unauthorized transitions between different states of the system 200.

[0088] Figures 4A through 4G are not drawn to scale. Arrow 390 in Figures 4A and 4G indicates the proximal and distal directions in each of Figures 4A through 4G.

[0089] Figure 4A shows an instrument manipulator assembly 440 attached to the insertion assembly 431. The instrument manipulator assembly 440 is an example of the instrument manipulator assembly 240. The insertion assembly 431 is an example of the insertion assembly 331.

[0090] The instrument manipulator assembly housing 448 (sometimes referred to as housing 448) is fixedly attached to the distal end of the insertion assembly 431, and thus the instrument manipulator assembly housing 448 moves with the insertion assembly 431. However, a motor assembly 446 within the instrument manipulator assembly housing 448 is movable on a guide rail 439. The motor assembly 446 is movable in both distal and proximal directions relative to the instrument manipulator assembly housing 448. The motor assembly 446 is coupled to the instrument manipulator assembly housing 448 via a motor assembly return spring 447 (sometimes referred to as return spring 447).

[0091] Motor assembly 446 is movably coupled to insertion assembly 431 via preloading assembly 480. In one aspect, preloading assembly 480 rides on a preloading track in insertion assembly 431. As explained more fully below, preloading assembly 480 provides a longitudinal force in the distal direction on motor assembly 446 when moving in the distal direction. Preloading assembly 480 includes an emergency device release button 482.

[0092] Motor assembly 446 includes multiple drive units 441. Each drive unit 441 includes multiple drive motors and multiple drive output components. Each of the multiple drive motors is connected to a corresponding drive output component 443 among the multiple drive output components.

[0093] The drive output assembly 443 includes a preloaded spring assembly and a drive output disk 445. The drive output assembly 443 also includes a low-backlash connector positioned between the preloaded spring assembly and the drive output disk 445. The drive output disk 445 is connected to the low-backlash connector via a set of input pins.

[0094] Drive output disk 445 is a cylindrical disk including a distal surface. Each drive output disk 445 has a drive interface at its distal end. The drive interface includes a drive claw and an alignment element. The drive claw extends from the distal surface in a distal direction. Examples of motor assemblies and multiple drive units suitable for use as motor assemblies 446 including multiple drive units 441 are described in U.S. Patent Application Publication No. 2016 / 0184037A1 (published as "Preloaded Surgical Instrument Interface"), which is previously incorporated herein by reference.

[0095] Motor assembly 446 includes a plurality of hard stops 437. Each of the plurality of hard stops 437 is configured to extend from the distal side of motor assembly 446 when a high preload is present on motor assembly 446.

[0096] Figure 4A shows the instrument manipulator assembly 440 with motor assembly 446 in the no-preload position 432 (i.e., the preload mechanism is released). In this configuration, if the preload mechanism is not engaged, for example, if the preload is not engaged, there is no preload on motor assembly 446 such that, regardless of the position of instrument manipulator assembly 440 relative to its original position, the plurality of drive output discs, including drive output disc 445, do not extend from the distal side of instrument manipulator assembly housing 448. The distal side of motor assembly 446 is in the no-preload position 432. Conversely, if the preload mechanism is engaged and instrument manipulator assembly 440 is in its original position, there is a first preload force on motor assembly 446 such that the plurality of drive output discs, including drive output disc 445, extend from the distal side of instrument manipulator assembly housing 448. This occurs when the motor assembly is in the low-preload position 433 relative to instrument manipulator assembly housing 448.

[0097] Typically, at least a portion of the patient-side support system 210 is covered with a sterile surgical drape before use of the system 200. It is useful to consider the aspects of the patient-side support system 210 and the sterile surgical drape before considering the mechanical locking safety features of the system 200 as presented in Figures 4B to 4G, because some control states of the instrument manipulator assembly 440 depend on signals provided during the covering process.

[0098] In one aspect, sterile surgical drapes 560 ( Figure 5 (Sometimes referred to as surgical drape 560) is part of a patient-side support system 210 used to cover the patient. In one aspect, the sterile surgical drape 560 includes a first portion 561 and a second portion 562.

[0099] A first portion 561 of a sterile surgical drape 560 is connected to a stationary portion of a rotatable seal 565, and a second portion 562 is connected to a movable portion of the rotatable seal 565. In one aspect, the rotatable seal 565 is a labyrinth seal, wherein the stationary portion is a rolling cover portion of the labyrinth seal, and the movable portion is a base comb-shaped portion of the labyrinth seal.

[0100] In one aspect, the second portion 562 of the sterile surgical drape 560 includes a plurality of drape sleeves 562-1, 562-2, a plurality of boot-shaped elements 563-1, 563-2, and a plurality of mechanical interface elements 564-1, 564-2. Typically, the sterile surgical drape 560 includes a drape sleeve, a boot-shaped element, and a mechanical interface element for each instrument manipulator assembly 240 in system 200.

[0101] Each of a plurality of mechanical interface elements 564-1, 564-2 is coupled to a corresponding boot-shaped element among a plurality of boot-shaped elements 563-1, 563-2. Each of a plurality of boot-shaped elements 563-1, 563-2 is coupled to a corresponding cover sleeve among a plurality of cover sleeves 562-1, 562-2. The opening of each cover sleeve among a plurality of cover sleeves 562-1, 562-2 is connected to a movable portion of a rotatable seal 565, in one aspect of which the movable portion of the rotatable seal 565 is a ribbed disc forming a plurality of wedge-shaped "frames" with orifices, each of the frames being sized to surround an instrument manipulator assembly. The open end of each of a plurality of cover sleeves 562-1, 562-2 is coupled to a different wedge-shaped frame among a plurality of wedge-shaped frames. Each of the multiple boot-shaped objects 563-1, 563-2 is adapted to be connected to the surrounding instrument manipulator assembly via an insertion assembly into the guide manipulator assembly.

[0102] Figure 6A This is an illustration of one aspect of the patient-side support system 210 in its initial coverage configuration. (As shown in...) Figure 2 and Figure 6A As illustrated, the entry guide manipulator assembly 230 (sometimes referred to as entry guide manipulator 230) includes four links 613, 615, 617, and 619 connected via connectors. (As shown in...) Figure 6A As shown, a yaw joint 611 of the control assembly is coupled between one end of the mounting link 606 and a second end (e.g., the proximal end) of the first control link 613. The yaw joint 611 allows the first control link 613 to move about the link 606 in a movement that can be arbitrarily defined as “yaw” about the yaw axis of the control assembly.

[0103] In one embodiment, the mounting link 606 is rotatable in a horizontal or x, y plane, and the yaw joint 611 is configured to allow the first manipulator link 613 entering the guide manipulator 230 to rotate about a yaw axis. The mounting link 606, yaw joint 611, and first manipulator link 613 provide a constant vertical yaw axis for entering the guide manipulator 230.

[0104] The first end of the first actuator link 613 is connected to the second end of the second actuator link 615 via a first active control rotary joint 614. The first end of the second actuator link 615 is connected to the second end of the third actuator link 617 via a second active control rotary joint 616. The first end of the third actuator link 617 is connected to the distal portion of the fourth actuator link 619 via a third active control rotary joint.

[0105] In one embodiment, links 615, 617, and 619 are coupled together to act as a coupled motion mechanism. Coupled motion mechanisms are well-known (e.g., these mechanisms are called parallel motion linkages when the input and output linkage movements are kept parallel to each other). For example, if rotary joint 614 is actively rotated, joints 616 and 618 are also actively rotated, causing link 619 to move in a constant relationship with link 615. Thus, it can be seen that the axes of rotation of joints 614, 616, and 618 are parallel. When these axes are perpendicular to the axis of rotation of joint 611, links 615, 617, and 619 move about link 613 in a motion that can be arbitrarily defined as "pitch" about the pitch axis of the actuator assembly. Since links 615, 617, and 619 move as a single component, the first actuator link 613 can be considered as the active proximal actuator link, and the second through fourth actuator links 615, 617, and 619 can be collectively considered as the active distal actuator links.

[0106] In one aspect, the first actuator link 613 includes a first end 613-1 ( Figure 6B ) and the second end 613-2 ( Figure 6C The first end 613-1 includes an alignment socket 613C, and the second end 613-2 includes two alignment sockets 613A and 613B. An attachment device (one for each of the alignment sockets) is attached to the surgical drape 560. In one aspect, each of the alignment sockets 613A, 613B, and 613C includes a magnet, and the attachment device attached to the surgical drape 560 is shaped to fit into the alignment sockets 613A, 613B, and 613C, and is made of metal that is attracted to and connected to the magnet.

[0107] In one aspect, each of the alignment sockets 613A, 613B, and 613C includes an attachment sensor, or has an attachment sensor associated with the alignment socket. When the attachment sensor detects that the surgical drape 560 has been attached to the patient-side support system 210, a signal indicating that the drape has been attached is sent to the controller 290, indicating the attachment of the surgical drape 560. Specifically, the attachment sensor detects the presence of the attachment device when the attachment device attached to the surgical drape 560 engages with the corresponding alignment socket to attach the surgical drape 560 to a portion of the patient-side support system 210.

[0108] The sensor configured to detect the presence of a cover attachment can be, for example, an inductive sensor. An inductive sensor emits a magnetic field sensed by the sensor via an inductor coil. When a metal component (i.e., the attachment) is near the sensor, the metal component changes its inductance, which is detected by the sensor to indicate the presence of the attachment. The use of an inductive sensor is illustrative only and is not intended to be limiting.

[0109] The sensor for detecting the attachment of the surgical drape 560 can be, for example, an optical sensor. The optical sensor can detect when the surgical drape 560 has been attached, for example, by light reflected from the drape attachment device or by light reflected from the drape 560 itself. In another example, the optical sensor can be a sensor that emits and receives a light beam but senses the presence of the surgical drape 560 when the light beam is interrupted by the surgical drape 560 or the attachment device. The sensor can also be a capacitive sensor that senses a change in capacitance that occurs when the surgical drape 560 has been attached. In another example, the sensor can be a switch that is mechanically pressed down or otherwise toggled by the drape attachment device or the surgical drape 560 when the surgical drape 560 is attached to the linkage 613 of the patient-side support system 210.

[0110] Figure 7A The illustration shows a surgical drape mounting kit 770 being moved to a position for mounting on a platform 632 at one end of a link 619. The surgical drape mounting kit 770 includes a surgical drape mounting aid on which a sterile surgical drape 560 is mounted.

[0111] Figure 7B A surgical drape installation kit 770 is shown mounted on a platform 632. Specifically, each of the plurality of latches in the rotatable seal 565 is engaged in a corresponding latch socket in the platform 632. An example of a surgical drape installation kit is presented in commonly assigned and commonly filed U.S. Patent Application No. 62 / 362,190 (published July 14, 2016, entitled "Surgical Drape Installation Aid"), which is incorporated herein by reference in its entirety.

[0112] When the surgical drape installation kit 770 is mounted on the platform 632, the drape installation sensor sends a drape installation signal to the controller 290, instructing the installation of the surgical drape installation kit 770. In one aspect, the drape installation sensor includes a mechanical switch, such as a plunger, activated by the installation of the stationary portion of the rotatable seal 565. Alternatively, instead of a mechanical sensor, the drape installation sensor may be an inductive sensor, a capacitive sensor, or an optical sensor similar to those described above.

[0113] Returning to the considerations in Figures 4B through 4G, these figures combine a state workflow diagram 800 of the instrument manipulator assembly 240 and the instrument manipulator assembly 440. Figure 8 This will be described using [the appropriate method / method]. Figure 8 In the workflow diagram 800, the different states are divided into normal mode 891 and illegal state mode 892. The normal path between states is... Figure 8 The middle part is indicated by a thick solid line.

[0114] In the start state 801 of the instrument manipulator assembly 440 of the computer-aided remote operating system 200, the preload engagement / disengagement mechanism of the preload assembly 480 is disengaged. Therefore, there is no preload force on the drive disc of the motor assembly 446; for example, the motor assembly 446 is in the unpreloaded position 432 relative to the instrument manipulator housing 448. Furthermore, in the start state 801, if the instrument manipulator assembly 440 is not in its original position, the instrument manipulator assembly 440 (FIG. 4A) is moved to its original position. Therefore, in the start state 801, the preload engagement / disengagement mechanism is not activated, and thus no preload force is generated when the instrument manipulator assembly 440 is moved by the insertion assembly 431.

[0115] In response to a command from the user interface regarding mask deployment, the install drag action 815 begins. During the install drag action 815, the entry guide manipulator 230 is moved by the controller 290 to the... Figure 6A The positions shown are such that the main instrument manipulator 280 moves multiple instrument manipulator assemblies as far apart as possible to facilitate covering. Next, a surgical drape installation package 770 is installed on the access guide manipulator assembly platform 632, and in response to the installation of the package 770, a signal indicating that the drape has been installed is sent to the controller 290.

[0116] The first portion 561 of the sterile surgical drape 560 extends over the links 619, 617, and 615 of the access guide manipulator 230. Finally, the first portion 561 is attached to the alignment sockets 613A, 613B, and 613C of the link 613. As explained above, the attachment of the sterile drape 560 to the link 613 causes a signal indicating that the drape is attached to be sent to the controller 290. After completing the covering of the links of the access guide manipulator 230, the user typically removes the access guide manipulator 230 from the... Figure 7A and Figure 7B The tilted position shown in the image is moved back to the vertical position.

[0117] When controller 290 receives a drape attachment signal after receiving a drape installation signal, the state of instrument manipulator assembly 440 transitions from start state 801 to drape-mounted state 811 during the draping process 810, sometimes referred to as state 811. Upon entering state 811, instrument manipulator assembly 440 is configured such that if the user pushes instrument manipulator assembly 440, it automatically moves in the direction of the force applied by the user. This helps the user position the sleeve of sterile drape 560 around insertion assembly 431 and instrument manipulator assembly 440.

[0118] Therefore, in the extended insertion action 816, the user pushes the instrument manipulator assembly 440 in the distal direction. In response to the force supplied by the user, the controller 290 causes the insertion assembly 430 to move the instrument manipulator assembly 440 in the distal direction. An example of a controller that moves the instrument manipulator in response to a user tap is described in commonly assigned and co-filed U.S. Patent Application No. 62 / 362,192 (published July 14, 2016, entitled "Automatic Manipulator Assembly Deployment for Draping"), which is incorporated herein by reference in its entirety. After the insertion assembly 431 is extended, the covered drape installation state 811 transitions to the extended insertion state 812. Even though the insertion assembly 431 is extended, there is no preloading action because the preloading engagement / disengagement mechanism of the preloading assembly 480 is disengaged.

[0119] With the instrument manipulator assembly 440 in the inserted extended state 812, during the INSTALLSTERILE ADAPTER action 817, the surgical device interface element 450 (e.g., the sterile adapter assembly) is mounted on the instrument manipulator assembly 440 to obtain the configuration shown in FIG. 4B. The surgical device interface element 450 is an example of the sterile adapter assembly 250. Because the preload engagement / disengagement mechanism is not engaged, the motor assembly 446 is not displaced distally relative to the housing 448, and therefore, mounting the surgical device interface element 450 in this configuration does not require compression of multiple preload spring assemblies (including the preload spring assemblies in the drive output assembly 443) during the mounting of the surgical device interface element 450.

[0120] Without preload on the motor assembly 446, the surgical device interface element 450 is mounted by moving the surgical device interface element 450 proximally until the hook on the surgical device interface element 450 engages the hook receiver in the instrument manipulator assembly 440. Unlike prior art surgical device interfaces that require one end to be placed in the instrument manipulator assembly and the opposite end to be pivoted until it is locked, the surgical device interface element 450 is moved in a direction perpendicular to the distal side of the instrument manipulator assembly 440. The mounting of the surgical device interface element 450 causes a sensor to send a signal to the controller 290 that the sterile adapter has been mounted, resulting in a transition to the sterile adapter mounted state 813. In one aspect, the sensor is a mechanical switch that changes the state when the surgical device interface element 450 is mounted. Alternatively, the sensor can be an optical sensor, an inductive sensor, or a capacitive sensor as described above.

[0121] Therefore, when the user performs the sterile adapter installation action 817, the state of the instrument manipulator assembly 440 changes from the insertion extended state 812 to the sterile adapter installed state 813, as shown in Figure 4B. In the sterile adapter installed state 813, the insertion assembly 431 is extended, and the preload engagement / disengagement mechanism is not engaged.

[0122] The covering process 810 is completed when the surgical instrument interface element 450 is installed on each of the instrument manipulator assemblies. After the covering process 810 is completed, the user manually moves the instrument manipulator assembly 440 to its original position using the clutch button on the instrument manipulator assembly 440.

[0123] During the retraction insertion action 818, each of the instrument manipulator assemblies is retracted and returned to its original position. After the retraction insertion action 818 is completed, each of the instrument manipulator assemblies is in the sterile adapter installed, insertion retracted state 820, sometimes referred to as state 820. In state 820, there is no preload force on the surgical device interface element 450 because the preload engagement / disengagement mechanism is still disengaged.

[0124] Before considering further operation of the instrument manipulator assembly 440, the structure of the surgical instrument interface element 450 is first described. In this respect, the surgical instrument interface element 450 includes a frame 451 and a movable manipulator-instrument interface plate 451C. The movable manipulator-instrument interface plate 451C (sometimes referred to as the movable body 451C) is mounted in the frame 451, such that the movable body 451C is movable within the frame 451 in both proximal and distal directions. A plurality of intermediate discs are mounted in the manipulator-instrument interface plate 451C, such that each of the plurality of intermediate discs is rotatable relative to the frame 451.

[0125] In this respect, each of the multiple disks is identical, and therefore intermediate disk 453 represents each of the multiple intermediate disks. Each intermediate disk 453 includes an intermediate slave interface 455 (sometimes referred to as a first intermediate disk interface) and an intermediate drive interface 456 (sometimes referred to as a second intermediate disk interface). The intermediate slave interface 455 is opposite to and removed from the intermediate drive interface 456. In one aspect, the intermediate slave interface 455 includes a first alignment socket and a drive claw socket. The intermediate drive interface 456 includes a drive claw and an engagement structure. Examples of movable manipulator-device interface boards and multiple intermediate disks suitable for use as movable manipulator-device interface boards 451C and multiple intermediate disks in Figures 4A to 4G are presented in U.S. Patent Application Publication No. US2016 / 0184035A1, PCT International Publication No. WO2015 / 023834A1 and PCT International Publication No. WO2015 / 023840A1, each of which is previously incorporated herein by reference.

[0126] The movable body 451C also includes a plurality of hard stop recesses 457. The plurality of hard stop recesses 457 extend from the proximal side of the movable body 451C into the movable body 451C in a distal direction.

[0127] When the instrument manipulator assembly 440 is retracted to its original position, placing it in state 820, the controller 290 initiates a sterile adapter engagement sequence 821. In one aspect of this sterile adapter engagement sequence 821, the controller 290 commands the insertion assembly 431 to move the instrument manipulator assembly 440 to a first predetermined position (fully retracted position) close to its original position.

[0128] When the instrument manipulator assembly 440 is in the fully retracted position, in one aspect, the controller 290 sends an ACTIVATE PRELOAD signal 486 to the preload engagement / disengagement mechanism 485 in the preload assembly 480. In response to the ACTIVATE PRELOAD signal 486, the preload engagement / disengagement mechanism 485 engages the preload, and then the controller 290 causes the insertion assembly 431 to return to its original position (FIG. 4C). As the insertion assembly 431 moves the instrument manipulator assembly 440 from the fully retracted position to its original position, the motor assembly 446 is displaced distally relative to the housing 448 of the instrument manipulator assembly 440 from a no-preload position 432 to a low-preload position 433. This displacement causes the motor assembly return spring 447 to extend. The engagement of the preload engagement / disengagement mechanism holds the motor assembly 446 in the distally displaced position relative to the housing 448, resulting in a distal preload force on the motor assembly 446.

[0129] Therefore, when the instrument manipulator assembly 440 is moved to its original position, the displacement of the motor assembly 446 relative to the housing 448 from the no-preload position 432 to the low-preload position 433 causes the drive interface of each of the plurality of drive output discs 445 to contact the corresponding intermediate driven interface 455 of the plurality of intermediate discs. Thus, the movement of the instrument manipulator assembly 440 causes each intermediate disc 453 to contact the movable body 451C and move the movable body 451C in the distal direction. Further movement of the drive output discs 445 in the distal direction is suppressed as the movable body 451C moves as distally as possible within the frame 451.

[0130] Therefore, as the instrument manipulator assembly 440 continues to move to its original position, the preload spring assembly in each of the plurality of drive output assemblies 443 is compressed, such that a preload force is applied to each of the plurality of drive output discs 445. This preload force is sometimes referred to as the first preload force or the low preload force. The preload force pushes the drive output discs 445 and the corresponding intermediate driven interfaces 455, such that the preload force is transmitted to each of the plurality of intermediate discs 453 in the surgical device interface element 450. This configuration is illustrated in FIG4C.

[0131] When the external surgical device interface element 450 (sometimes referred to as the surgical device interface) is first mounted on the instrument manipulator assembly 440, the elements of the intermediate slave interface 455 may not be aligned with the corresponding elements of the drive interface on the drive output disk 445. If the elements of disks 453 and 445 are not aligned, the two disks are partially connected together by features in the drive interface and the intermediate slave interface, but the two disks are not connected to each other, for example, mated.

[0132] Next, in the sterile adapter engagement sequence action 821, controller 290 sends a signal to instrument manipulator assembly 440 to rotate drive output disk 445. Rotation of intermediate disk 453 is suppressed and drive output disk 445 is rotated until the drive interface of drive output disk 445 mates with the intermediate driven interface 455 of intermediate disk 453. Partial engagement of elements of the drive interface on drive output disk 445 with corresponding elements of the intermediate driven interface 455 on intermediate disk 453 ensures that the two disks remain partially engaged under a preload force when both disks rotate. In one aspect, when the two disks are engaged, 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. When the two disks are engaged, a first preload force is applied to the disks. The engagement of drive output disk 445 and intermediate disk 453 is the same as the engagement of the corresponding disks as described in U.S. Patent Application Publication No. US2016 / 0184035A1.

[0133] After each drive output disc in the instrument manipulator assembly 440 is paired with the corresponding intermediate disc of the surgical device interface element 450, the sterile adapter engagement action 821 is completed. The instrument manipulator assembly 440 is then in a low preload set, discs engaged state 831 during the normal use process 830.

[0134] When the instrument manipulator assembly 440 is in the low preload setting and disc engaged state 831, several actions are possible. For example, the user can install the instrument and continue the surgical procedure. After the surgical procedure is completed, as described more fully below, the normal use process 830 returns to the low preload setting and disc engaged state 831, and then the user releases the patient-side support system 210. Alternatively, the user can press the emergency instrument release button. Thus, each of these actions is considered.

[0135] When the instrument manipulator assembly 440 is in the low preload set and disc engaged state 831, the user can press the Emergency Instrument Release (EIR) button 482 during Emergency Instrument Release (EIR) action 822. Activating the Emergency Instrument Release button 482 (e.g., pressing button 482) causes the preload engagement / disengagement mechanism 485 to disengage from the preload engagement / disengagement mechanism of the preload assembly 480, and thus the low preload force on the disc stack is released. This returns the instrument manipulator assembly 440 to the sterile adapter installed and insertion retracted state 820.

[0136] Alternatively, when the instrument manipulator assembly 440 is in a low preload setting and the discs are engaged 831, the user can install the instrument into the surgical device interface element 450. Therefore, during the instrument installation action 835, the first end of the instrument 460 slides along the ramp in the frame 451 of the surgical device interface element 450 until the instrument 460 is held in place, as shown in Figure 4E. With the instrument manipulator assembly 440 in this low preload state, the movable manipulator-instrument interface plate 451C is not locked in place and can be moved proximally. Therefore, as the instrument 460 slides along the ramp, the movable manipulator-instrument interface plate 451C is displaced proximally, which further compresses the first preload spring assembly, and thus the preload force on the disc stack formed by discs 445, 453, and 463 is considered approximately the first preload.

[0137] After the instrument installation action 835 is completed, the instrument manipulator assembly 440 is in the instrument installed state 832, sometimes referred to as state 832. In state 832, the preload on the disk stack consisting of disks 445, 453, and 463 is approximately the first preload, and the driven interface of the driven disk 464 may not be paired with the intermediate drive interface 456 of the intermediate disk 453.

[0138] Before considering the instrument engagement sequence action 836, the features of the instrument 460 are briefly considered, which changes the state of the instrument manipulator assembly 440 from the instrument installed state 832 to the instrument engaged state 833. In one aspect, the instrument 460 is identical to the surgical instrument described in U.S. Patent Application Publication No. US2016 / 0184037A1.

[0139] In this respect, the instrument 460 (FIG. 4E) includes a body 465 and a main tube 467. The main tube 467 extends distally from the body 465. The body 465 includes a driven disc socket 463, a shaft 466, and a driven disc 464. The shaft 466 and the driven disc 464 are part of a transmission unit that transmits received torque to one or more components of the instrument.

[0140] The proximal end of shaft 466 extends into driven disk socket 463, and driven disk 464 is mounted on the proximal end of shaft 466 such that driven disk 464 is positioned in driven disk socket 463. Driven disk 464 includes a drive interface that engages with intermediate drive interface 456 of intermediate disk 453.

[0141] The driven interface of the driven disk 464 includes an engagement socket, a drive claw socket, and a rotationally deactivated element. The rotationally deactivated element includes a rotation locking mechanism. When the rotationally deactivated element is engaged, the rotation locking mechanism engages the driven disk socket 464 and prevents rotation of the driven disk 464.

[0142] When the surgical instrument 460 is coupled to the instrument manipulator assembly 440, each driven disc 464 pushes the corresponding intermediate disc 453 in the surgical device interface element 450 proximally, allowing the intermediate disc 453 to rotate freely. This increases the preload force on the disc stack. However, when the instrument 460 is first mounted on the surgical device interface element 450, the elements of the intermediate drive interface 456 may not be aligned with the corresponding elements of the driven interfaces on the driven discs 464. If the elements of the two discs 453 and 464 are not aligned, the two discs are partially coupled together by features in the intermediate drive interface 456 and the driven interfaces, but the two discs are not mated to each other.

[0143] 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 the rotationally disable element on the driven disk 464 of the device 460. The rotationally disable element includes a rotation locking mechanism. When the rotationally disable element is engaged, the rotation locking mechanism engages the driven disk socket 464 and prevents the rotation of the driven disk 464.

[0144] When instrument 460 is engaged with instrument manipulator assembly 440, instrument manipulator assembly 440 detects the presence of instrument 460 and sends a signal to controller 290. In response to this signal, controller 290 sends a signal to instrument manipulator assembly 440 to execute instrument engagement sequence action 836 (sometimes referred to as action 836).

[0145] In response to a signal from controller 290, the instrument manipulator assembly 440 rotates the drive output disk 445, which in turn rotates the intermediate disk 453. As the intermediate drive interface 456 of the intermediate disk 453 rotates together with the driven disk 464, which is fixed in place, each element on the intermediate drive interface 456 aligns and rotates with the corresponding element on the driven interface of the driven disk 464, mating with the corresponding element. The connection between the intermediate drive interface 456 and the driven interface on the driven disk 464 releases the rotation lock on the 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 the drive output disk 445. The preload force applied to the disk stack when the disk stack is mated is referred to as the first longitudinal force, i.e., the first preload force.

[0146] After the intermediate disc of the surgical instrument interface element 450 is paired with the disc of the instrument 460, the instrument manipulator assembly 440 is in the instrument engaged state 833 of normal use process 830, sometimes referred to as state 833. In state 833, the instrument 460 is mounted, the preload is low, and the instrument 460 can be removed from the surgical instrument interface element 450. The instrument 460 can be removed because, under low preload, the movable manipulator-instrument interface plate 451C is not locked in place and can therefore be displaced in the proximal direction.

[0147] In the configuration of Figure 4E, the surgical device interface element 450 cannot be removed without removing the instrument 460. The installation of the instrument 460 prevents the use of the release button on the side of the surgical device interface element 450. Therefore, the surgical device interface element 450 includes a mechanical sterile adapter assembly removal lock such that when the instrument 460 is installed in the surgical device interface element 450, the instrument 460 activates the mechanical sterile adapter assembly removal lock.

[0148] Unlike existing systems that prevent operation of the mechanical release button for the surgical device interface element whenever a preload force is present, there is no preload-based interlock on the surgical device interface element 450. The only interlock on the surgical device interface element 450 is a mechanical interlock based on whether the instrument 460 is installed in the surgical device interface element 450.

[0149] However, in the configuration of Figure 4E, the instrument 460 can still be removed. As explained more fully in U.S. Patent Application Publication No. US2016 / 0184036A1, in one aspect, the instrument 460 has a release button on each side. Engaging the release button causes a mechanism in the instrument 460 to proximal push the movable body 451C in the surgical device interface element 450, thereby disengaging the intermediate disc 453 and the driven disc 464 and allowing the instrument 460 to be removed.

[0150] Therefore, in the instrument removal action 838, the user manipulates the release buttons on each side of the instrument 460, which disengages the intermediate plate 453 and the driven plate 464, and the user then slides the instrument 460 out of the surgical device interface element 450. The removal of the instrument 460 changes the state of the instrument manipulator assembly 440 from the instrument engaged state 833 back to the low preload set, plate engaged state 831 of the normal use process 830.

[0151] The extended insertion action 837 changes the state of the instrument manipulator assembly 440 from the instrument engaged state 833 to the instrument in use high preload state 834, sometimes referred to as state 834. State 834 exists in both normal use 830 and instrument tip beyond cannula state 850.

[0152] In the extended insertion action 837, the distal end of the instrument 460 is moved into and through the cannula by moving the instrument manipulator assembly 440 in the distal direction via the insertion assembly 431. As the distal instrument 460 is inserted into the cannula by moving the instrument manipulator assembly 440 via the insertion assembly 431, a second preload force is applied to the stack of disks 445, 453, and 464 by the preload assembly 480 before the distal part connected to the main tube 467 protrudes from the distal end of the cannula.

[0153] Specifically, when the instrument 460 moves distally, the preload assembly 480 moves distally along the preload track. In one aspect, when the instrument manipulator assembly 440 moves distally by a predetermined distance Zload, the preload assembly 480 causes the motor assembly 446 to move the predetermined distance Zload plus an additional distance Δ. In another aspect, regardless of whether the instrument manipulator assembly 440 moves by the insertion assembly 431 or in combination with the movement of the instrument manipulator assembly 440 by the insertion assembly 431, the motor controller causes the motor assembly 446 to move a distance Δ relative to the housing 448.

[0154] In both aspects, the motor assembly 446 moves an additional distance Δ relative to the housing 448, compressing the preloaded spring assembly in each of the plurality of drive output assemblies 443, such that a second preload force is applied to each of the plurality of drive output discs 545. Before the distal end of the instrument 260 exits the cannula, the second preload force reduces any backlash between the rotation of the motor shaft in the drive unit 441 and the rotation of the shaft 466 in the instrument 460 to less than 0.7 degrees.

[0155] The additional distance Δ that the motor assembly 446 travels further stretches the return spring 447, and in addition, each of the plurality of hard stops 437 is inserted into a corresponding hard stop socket in the plurality of hard stop sockets 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 sockets 457 forms an instrument removal interlock and prevents the removal of the instrument 460. If someone attempts to engage the release button on the instrument 460, the mechanism in the instrument 460 will not push the movable body 451C in the surgical device interface element 450 proximally because the plurality of hard stops 437 prevent any proximal movement of the movable body 451C, and therefore the intermediate plate 453 and the driven plate 464 cannot disengage.

[0156] The use of multiple hard stop sockets 457 is illustrative only and not intended to be limiting. In another embodiment, the multiple hard stop sockets 457 are not used. Instead, multiple hard stops 437 contact the proximal surface of the movable body 451C and prevent movement of the movable body 451C in the proximal direction. After the extension insertion action 837 is completed, the instrument manipulator assembly 440 is in a high preload state 834 for instrument use. In state 834, all discs in the disc stack of discs 445, 453, and 464 are engaged, and a second preload force is present on the disc stack. In state 834, neither the surgical device interface element 450 nor the instrument 460 can be removed.

[0157] The retraction insertion action 839 changes the state of the instrument manipulator assembly 440 from the high preload state 834 (in use) to the engaged state 833. During the retraction insertion action 839, the instrument manipulator assembly 440 is moved by the user along the insertion assembly 431 to its original position. When the instrument manipulator assembly 440 is moved to its original position, the distal end of the instrument 460 no longer extends through the cannula, and the second preload force is changed to the first preload force by the preload engagement / disengagement mechanism 485 of the preload assembly 480; that is, when the instrument manipulator assembly 440 is retracted, the motor assembly 446 moves relative to the housing 448 from the high preload position 434 to the low preload position 433.

[0158] If, for some reason, the distal tip of the instrument 460 needs to be removed when it extends beyond the distal end of the cannula in state 834, a person pushes the Emergency Instrument Release Button 482 to perform the Emergency Instrument Release Button action 851. The Emergency Instrument Release (EIR) button action 851 changes the state of the instrument manipulator assembly 440 from the high-preload state 834 (instrument in use) to the no-preload state 861 (user interface (UI)-guided recovery process 860). The state of the user interface-guided recovery process 860 is the illegal instrument state.

[0159] In the emergency device release button action 851, activating the emergency device release button 482 causes the longitudinal force on the motor assembly 446 to be released. Therefore, the return spring 447 pulls the motor assembly 446 back to the fully retracted position within the housing 448.

[0160] With the motor assembly 446 fully retracted, the plurality of hard stops 437 are retracted from the plurality of hard stop sockets 457 in the movable body 451C of the surgical instrument interface element 450, and the discs 453 and 464 are no longer subjected to any preload force. Therefore, the release button on the instrument 460 can be used to remove the instrument 460 from the surgical instrument interface element 450 at any position of the insertion assembly 431.

[0161] However, in order to remove the instrument 460 from the cannula, a retraction insertion action 865 is performed. The retraction insertion action 865 changes the state of the instrument manipulator assembly 440 from a no-preload state 861 to a no-preload insertion home state 862 of the user-interface-guided retraction process 860. During the retraction insertion action 865, the user engages the clutch button on the instrument manipulator assembly 440 and moves the instrument manipulator assembly 440 to its original position along the insertion assembly 431.

[0162] If the instrument manipulator assembly 440 is in the instrument engaged state 833, and the instrument 460 is installed with low preload, the emergency instrument release button action 867 can be executed. In the emergency instrument release button action 867, activating the emergency instrument release button 482 causes the longitudinal force on the motor assembly 446 to be released. Therefore, the return spring 447 pulls the motor assembly 446 back to the fully retracted position within the housing 448, so that there is no preload. The execution of the emergency instrument release button action 867 changes the state of the instrument manipulator assembly 440 from the instrument engaged state 833 to the unloaded insertion original state 862.

[0163] In the unloaded insertion state 862, instrument 460 is withdrawn from the cannula, and there is no preload force on the tray stack. Therefore, it is safe and possible to remove instrument 460 from the surgical device interface element 450.

[0164] In the removal instrument action 866, the user manipulates the release buttons on each side of the instrument 460, disengaging the intermediate plate 453 and the driven plate 464, and then the user slides the instrument 460 out of the surgical device interface element 450. The completion of the removal instrument action 866 changes the state of the instrument manipulator assembly 440 from the unloaded insertion state 862 to the sterile adapter installed and the insertion retracted state 820.

[0165] During a normal surgical procedure, an instrument retraction action 839 is performed to change the state of the instrument manipulator assembly 440 from a high preload state 834 (instrument in use) to an engaged state 833. Then, an instrument removal action 838 is performed to change the state of the instrument manipulator assembly 440 from the engaged state 833 to a low preload set, disc engaged state 831.

[0166] As the surgical procedure is completed, the drape needs to be removed from the patient-side support system 210. To facilitate the unveiling process 840, during the extended insertion action 841, the user uses a clutch button on the instrument manipulator assembly 440 to move the instrument manipulator assembly 440 distally. As the instrument manipulator assembly 440 moves distally, the preload assembly 480 moves distally along a preload track. In one aspect, when the instrument manipulator assembly 440 moves distally a predetermined distance Zload, the preload assembly 480 causes the motor assembly 446 to move relative to the housing 448 a predetermined distance Zload plus an additional distance Δ to reach a high preload position 434. The additional distance Δ of the motor assembly 446 compresses the preload spring assembly in each of the plurality of drive output assemblies 443, such that a second preload force is applied to each of the plurality of drive output discs 545. This second preload force is sometimes referred to as a high preload force relative to the low preload force described above.

[0167] The additional distance Δ traveled by the motor assembly 446 also causes the return spring 447 to extend further, and further inserts each of the plurality of hard stops 437 into a corresponding hard stop socket in the plurality of hard stop sockets 457. The plurality of hard stops 437 prevent proximal movement of the movable body 451C in the surgical device interface element 450. This configuration is illustrated in Figure 4D. Thus, the extended insertion action 841 changes the state of the instrument manipulator assembly 440 from a low preload setting and sterile drape engagement state in the normal use process 830 to a high preload state 842 in the undoing process 840 where the sterile adapter is installed. In the high preload state 842 where the sterile adapter is installed, a second preload is applied to the engaged discs (drive output disc 445 and intermediate disc 453), where the surgical device interface element 450 is mounted on the instrument manipulator assembly 440.

[0168] In existing systems, for either the first or second preloaded state, removal of the sterile adapter requires first pressing the preload release button on the instrument manipulator assembly to release the preloaded state and disabling the lock on the sterile adapter release button on the instrument manipulator assembly. The sterile adapter release button on the instrument manipulator assembly is then used to remove the sterile adapter. For further details on existing systems, see U.S. Patent Application Publication No. 2016 / 0184037A1.

[0169] In contrast, during the removal of the sterile adapter / drape (REMOVE STERILE ADAPTER / DRAPE) action 843, the user squeezes the release button on the side of the surgical device interface element 450 and moves the surgical device interface element 450 distally away from the distal side of the instrument manipulator assembly 440, regardless of whether the second preload condition is activated. In the second preload condition, there is no need to manipulate any buttons on the instrument manipulator assembly 440 to remove the surgical device interface element 450. This makes the removal of the surgical device interface element 450 more intuitive, as the only feature of the surgical device interface element 450 is used for its removal. Furthermore, it reduces confusion, as the emergency instrument release button 482 is not used or needed for the removal of the surgical device interface element 450 in any preload condition. After the removal of the surgical device interface element 450, the user removes the surgical drape from the patient-side support system 210.

[0170] After the removal of the sterile adapter is completed (action 843), the instrument manipulator assembly 440 is in the INSERTION EXTENDED state (action 844). The user performs a RETRACT INSERTION action (action 845) to change the state of the instrument manipulator assembly 440 from the INSERTION EXTENDED state (action 844) to the INSERTION HOME state (action 846).

[0171] In the retraction insertion action 845, the user moves the instrument manipulator assembly 440 to its original position using the clutch button on the instrument manipulator assembly 440, and each of the instrument manipulator assemblies is retracted and returned to its original position.

[0172] Since the instrument manipulator assembly 440 is in its original position, the controller 290 performs a preload release action 847 to change the state of the instrument manipulator assembly 440 to the start state 801. In one aspect, the controller commands the insertion assembly 431 to move the instrument manipulator assembly 440 closer to its original position, which automatically releases the preload, as described more fully below. In another aspect, the controller 290 commands the motor to move the motor assembly 446 to a position without preload.

[0173] Figure 9A illustrates an example of an instrument manipulator assembly 940 attached to an insertion assembly 931, which is further attached to an insertion axis base assembly 932. The insertion axis base assembly 932 includes a motor and power electronics for moving the insertion assembly 931. The instrument manipulator assembly 940 is an example of instrument manipulator assembly 240 and instrument manipulator assembly 440. The insertion assembly 931 is an example of insertion assembly 331 and insertion assembly 431.

[0174] The instrument manipulator assembly 940 includes two buttons—a clutch button 944 and an invisible emergency instrument release button. The emergency instrument release button is an example of emergency instrument release button 482. If the user presses (i.e., activates) the clutch button 944, the user can manually move the instrument manipulator assembly 940 in both proximal and distal directions along the insertion assembly 931. The emergency instrument release button is used to release preload, as per [the relevant information]. Figure 8 Described.

[0175] The instrument manipulator assembly 940 also includes a drive unit assembly 941 and a drive output unit 942. In this respect, the drive output unit 942 includes a plurality of drive output components, for example, eight drive output components. Here, drive output component 943 refers to any one of the eight drive output components. In one aspect, only six of the eight drive output components are used. Drive output component 943 includes a low-backlash connector and a drive output disk. The drive unit assembly, drive output unit 942, and drive output component 943 are equivalent to those described in U.S. Patent Application Publication No. US 2016 / 0184035A1.

[0176] The sterile adapter assembly 250 (Figures 9B to 9F) includes a sterile adapter frame 951 and a sterile drape (not shown). The sterile drape is fixedly attached to the sterile adapter frame 951. The sterile adapter assembly 250 is an example of a surgical device interface element. The sterile adapter frame 951 is an example of the body of a surgical device interface element. 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 an instrument (such as a surgical instrument or a camera instrument).

[0177] The frame 951 of the sterile adapter assembly 250 has a front end 951FE (i.e., the first end), a rear end 951RE (i.e., the second end), a first side 951S1, and a second side 951S2. The second end 951RE is sometimes referred to as the open end of the sterile adapter assembly 250 and the sterile adapter frame 951 because the second end 951RE is the end in which the instrument is inserted and is therefore open to receive the instrument.

[0178] A first crossbeam 955 (sometimes referred to as crossbeam 955) is movably attached to the inside of a first side 951S1 of the sterile adapter frame 951, such that when the distal end (first end) of crossbeam 955 moves in a first direction (inward), the proximal end (second end) of crossbeam 955 moves in a second direction opposite to the first direction (outward). A second crossbeam 956 (sometimes referred to as crossbeam 956) is movably attached to the inside of a second side 951S2 of the sterile adapter frame 951, such that when the distal end (first end) of crossbeam 956 moves in a first direction (inward), the proximal end (second end) of crossbeam 956 moves in a second direction opposite to the first direction (outward). Crossbeams 955 and 956 have identical structures and each crossbeam has the same characteristics.

[0179] In one aspect, a crossbeam 955 is attached to the inside of a first side 951S1 via a first flexure, such that when the distal end of the crossbeam 955 is moved inward, the proximal end of the crossbeam 955 moves outward. A crossbeam 956 is attached to the inside of a second side 951S2 via a second flexure, such that when the first end of the crossbeam 956 is moved inward, the proximal end of the crossbeam 956 moves outward.

[0180] In another embodiment, a crossbeam 955 is pivotally attached to the inside of a first side 951S1 and includes a spring that holds the proximal end of the crossbeam 955 in an engaged position. When a force is applied to the distal end of the crossbeam 955, the proximal end of the crossbeam 955 pivots to a disengaged position. Similarly, a crossbeam 956 is pivotally attached to the inside of a second side 951S3 and includes a spring that holds the proximal end of the crossbeam 956 in an engaged position. When a force is applied to the distal end of the crossbeam 956, the proximal end of the crossbeam 955 pivots to a disengaged position.

[0181] A first hook extension 955HE1 extends from the crossbeam 955 in a proximal direction. The first hook extension 955HE1 is adjacent to the third end of the crossbeam 955. A second hook extension 955HE2 extends from the crossbeam 955 in a proximal direction. The second hook extension 955HE2 is adjacent to the fourth end of the crossbeam 955, wherein the third end of the crossbeam 955 is removed from the fourth end of the crossbeam 955 and does not intersect with the fourth end of the crossbeam 955.

[0182] The first hook extension 956HE1 extends from the crossbeam 956 in a proximal direction. The first hook extension 956HE1 is adjacent to the third end of the crossbeam 956. The second hook extension 956HE2 extends from the crossbeam 956 in a proximal direction. The second hook extension 956HE2 is adjacent to the fourth end of the crossbeam 956, from which the third end of the crossbeam 956 is removed and does not intersect with the fourth end of the crossbeam 956.

[0183] Side 951S1 includes a through opening 959 extending from the proximal edge of side 951S1 (Figures 9B, 9C, and 9D). A sterile adapter release button 961 (sometimes referred to as release button 961) is positioned in the through opening 959. The sterile adapter release button 961 is attached to the outer side of the crossbeam 955.

[0184] The second side 951S2 includes a through opening 960 extending from the proximal edge of the second side 951S2 (Figures 9E and 9F). A sterile adapter release button 962 (sometimes referred to as release button 962) is positioned in the through opening 960. The sterile adapter release button 962 is attached to the outer surface of the crossbeam 956.

[0185] The inner sides of each of crossbeams 955 and 956 respectively include instrument insertion slides 963 and 964 terminating in a docking slot. Instrument insertion slide 963 is formed on the inner side of crossbeam 955. Instrument insertion slide 963 extends from the fourth end of crossbeam 955 to docking slot 965, adjacent to the third end of crossbeam 955. Instrument insertion slide 964 is formed on the inner side of crossbeam 956. Instrument insertion slide 964 extends from the fourth end of crossbeam 956 to docking slot 966, adjacent to the third end of crossbeam 956.

[0186] The sterile adapter frame 951 includes a movable manipulator-device interface plate 951C, sometimes referred to as a movable body 951C. The movable manipulator-device interface plate 951C is movable within the sterile adapter frame 951 in distal and proximal directions (e.g., in the first and second directions).

[0187] The movable manipulator-instrument interface board 951C includes a socket for each of the plurality of intermediate disks 953P. The movable body 951C also includes a plurality of hard stop sockets 957 (FIG. 9C), which are optional.

[0188] Each intermediate disc has a cylindrical body. Each of the plurality of intermediate discs 953P is mounted in a corresponding intermediate disc socket of a plurality of intermediate disc sockets of a movable body 951C, such that each intermediate disc is rotatable relative to the sterile adapter frame 951 and relative to the movable body 951C. Thus, the plurality of intermediate discs 953P are rotatably mounted in the sterile adapter frame 951. Moreover, each intermediate disc is movable distally and proximally within the intermediate disc socket.

[0189] Each intermediate disk includes an intermediate slave interface on a first side of the intermediate disk and an intermediate drive interface on a second side of the intermediate disk. The intermediate slave interface is configured to mate with the drive interface on the drive output disk in the drive output unit 942. The movable body 951C and the plurality of intermediate disks 953P correspond to the movable body and plurality of intermediate disks of the sterile adapter described in PCT International Publication No. WO2015 / 023840A1, which is previously incorporated herein by reference.

[0190] Figures 10A and 10B illustrate the movements and forces required to attach the sterile adapter assembly 250 to the instrument manipulator assembly 1040 connected to the insertion assembly 1031 (Figure 10A) and to disconnect the sterile adapter assembly 250 from the instrument manipulator assembly 1040 (Figure 10B). The instrument manipulator assembly 1040 also includes a drive unit assembly and a drive output unit. In this respect, the drive output unit includes multiple drive output assemblies, for example, eight drive output assemblies. Each drive output assembly includes a low-backlash connector and a drive output disc. The drive unit assembly, drive output unit, and drive output assemblies are equivalent to those described in U.S. Patent Application Publication No. 2016 / 0184035A1.

[0191] Instrument manipulator assembly 1040 is another example of instrument manipulator assembly 240 and instrument manipulator assembly 440. Insertion assembly 1031 is another example of insertion assembly 331 and insertion assembly 431. Instrument manipulator assembly 1040 includes two buttons—clutch button 1044 and emergency instrument release button 1082. Emergency instrument release button 1082 is an example of emergency release button 482.

[0192] Clutch button 1044 is installed in the housing of instrument manipulator assembly 1040. If the user presses (i.e. activates) clutch button 1044, the user can manually move instrument manipulator assembly 1040 in both proximal and distal directions along insertion assembly 1031.

[0193] An emergency device release button 1082 is installed in the preload assembly 1080 of the device manipulator assembly 1040. The emergency device release button is used to release the preload, as per [specific instructions / requirements]. Figure 8 Described.

[0194] To mount the sterile adapter assembly 250 onto the instrument manipulator assembly 1040, the user moves the sterile adapter assembly 250 in direction 1091 (proximal direction) and presses the sterile adapter assembly 250 into the distal side of the instrument manipulator assembly 1040. The hook extensions of the sterile adapter assembly 250 are movable, allowing each hook in the hook extensions to engage with the distal side of the instrument manipulator assembly 1040 to securely attach the sterile adapter assembly 250 to the instrument manipulator assembly 1040.

[0195] When the sterile adapter assembly 250 is attached to the instrument manipulator assembly 1040, as illustrated in Figure 10A, the plunger of the instrument manipulator assembly 1040 is depressed and breaks the light crossbeam, which in turn generates a signal to the controller 290 indicating the presence of the sterile adapter assembly 250. Alternatively, one of the other sensors described above can be used to detect the presence or absence of the sterile adapter assembly 250.

[0196] To remove the sterile adapter assembly 250, regardless of whether a preload force is present on the sterile adapter assembly 250, the user applies inward forces 1092A and 1092B respectively to press the sterile adapter release buttons 961 and 962 in an inward direction. The inward force on buttons 961 and 962 causes the crossbeam to pivot, which releases the hooks, including hooks 1071 and 1072 ( Figure 10C This retains the sterile adapter assembly 250 to the instrument manipulator assembly 1040, and thus allows for easy removal of the sterile adapter assembly 250. When the sterile adapter assembly 250 is removed from the instrument manipulator assembly 1040, the plunger of the instrument manipulator assembly 240 is no longer pressed, which in turn generates a signal to the controller 290 indicating the absence of the sterile adapter assembly 250.

[0197] Figure 10C This is an illustration of a sterile adapter assembly 250 installed within an instrument manipulator assembly 1040, wherein multiple portions of the sterile adapter assembly 250 and the instrument manipulator assembly 1040 are removed to show hooks and hook receiver locking mechanisms used to mount and retain the sterile adapter assembly 250 in the distal side of the instrument manipulator assembly 1040. Regarding the sterile adapter assembly 250 and the instrument manipulator assembly 1040... Figure 10C In the following description, the left-hand and right-hand configurations of the sterile adapter assembly 250 and the instrument manipulator assembly 1040 are identical. Therefore, the following is described... Figure 10C On the left-hand side, and each reference number is... Figure 10C The reference numerals for the corresponding features on the right-hand side follow to avoid repeating this description in the case of different reference numerals for the left-hand and right-hand sides of the sterile adapter assembly 250 and the instrument manipulator assembly 1040.

[0198] The instrument manipulator assembly 1040 includes a first side member 1073 and a second side member 1074. The side member 1073 (1074) includes a ramp side surface 1075 (1076) that forms part of a hook receiver 1077 (1078) of the side member 1073 (1074). The hook receiver 1077 (1078) is shaped to engage a hook 1071 (1072) formed in a hook extension 955HE2 (956HE2) of a crossbeam 955 (956), for example, the hook receiver fitting into the hook of the hook extension.

[0199] In the sterile adapter assembly 250, a crossbeam 955 (956) is movably connected to the sidewall of the sterile adapter assembly 250 via a flexure 1083 (1084). In this respect, the crossbeam 955 (956) and the flexure 1083 (1084) are formed as a single part. More generally, a first end of the flexure 1083 (1084) is connected to the crossbeam 955 at a location between the distal and proximal ends of the crossbeam 955 (956). This location is chosen to allow the flexure to engage and disengage the hook 1071 (1072) formed in the hook extension 955HE2 (956HE2) of the crossbeam 955 (956) with the hook receiver 1077 (1078) of the side crossbeam 1073 (1074). A second end of the flexure 1083 (1084) is connected to the sidewall of the sterile adapter assembly 250. More generally, the beam 955 (956) is pivotally connected to the sidewall at a location between the distal and proximal ends of the beam 955 (956).

[0200] To remove the sterile adapter assembly 250 from the instrument manipulator assembly 1040, the user presses each of the release buttons 961 and 962 toward the interior of the sterile adapter assembly, i.e., applying force 1092A to release button 961 and force 1092B to release button 962. Forces 1092A and 1092B on release buttons 961 and 962 are applied to the distal ends of crossbeams 955 and 956.

[0201] Forces at the distal ends of crossbeams 955 and 956 cause flexures 1083 and 1084 to bend, causing the hooks in hook extensions 955HE1 and 956HE2 to rotate outward away from the plane that bisects and includes the longitudinal axis of the instrument manipulator assembly 1040. This outward rotation of the hooks disengages them from the hook receiver, which in turn allows the sterile adapter assembly 250 to be displaced distally from the instrument manipulator assembly 1040.

[0202] Figure 11A is a more detailed illustration of a prior art surgical instrument that can be mounted in a sterile adapter assembly 250. In this respect, the instrument 260 includes a driven interface assembly 1161, a delivery unit 1165, a main tube 1167, a parallel motion mechanism 1168, a wrist joint 1169, and an end effector 1170. The wrist joint 1169 is described, for example, in U.S. Patent Publication No. US2003 / 0036748A1 (published as “Surgical Tool Having Positively Positionable Tendon-Activated Multi-Disk Wrist Joint”), which is incorporated herein by reference. The parallel motion mechanism 1168 is described, for example, in U.S. Patent No. US7,942,868B2 (filed June 13, 2007, published as “Surgical Instrument With Parallel Motion Mechanism”).

[0203] As shown in Figure 11B, the slave interface assembly 1161 includes a plurality of slave disks 1164P. The plurality of slave disks 1164P are examples of slave interface elements. Each slave disk 1164 represents one of the plurality of slave disks 1164P. The slave disks 1164 are mounted on the shaft of the transfer unit 1165. Furthermore, each slave disk 1164 is mounted in a socket in the body of the slave interface assembly 1161.

[0204] Mechanical components in the transfer unit 1165 (e.g., gears, levers, balance rings, cables, etc.) transmit torque from multiple driven discs 1164P to a combination of cables, wires, and tubes running through the main pipe 1167 to control the movement of the parallel motion mechanism 1168, the wrist joint 1169, and the end effector 1170. While the main pipe 1167 is generally rigid, it is capable of slight bending between the transfer unit 1167 and the entry guide 270. This bending allows the instrument body tube openings in the entry guide 270 to be spaced more closely than the dimensions of the transfer unit would otherwise allow. The bending is elastic, such that when the instrument 260 is withdrawn from the entry guide 270 (the main pipe may have a permanent bend that would prevent the instrument body from rolling), the main pipe 1167 retains its straight shape.

[0205] The driven interface assembly 1161 has a pair of mounting wings (1162A1, 1162B1) and (1162A2, 1162B2) on each side. Furthermore, each side of the transfer unit 1165 has release buttons 1163A and 1163B. Mounting wings 1162B2 and release buttons 1163B are shown in FIG. 10.

[0206] To install the instrument 260 into the sterile adapter frame 951, the mounting wings 1162A1 and 1162A2 are first installed on the slide plates 963 and 964 placed at the open end 951RE of the sterile adapter frame 951 (Figures 9E, 9F, and 964). Figures 12 to 14 )superior. Figures 12 to 14 This is a cross-sectional view of the outer surface of the sterile adapter frame 951 and the crossbeam 956 after they have been removed.

[0207] Mounting wing 1162A1 rests on a sliding plate 964 extending from the inner wall of crossbeam 956. When device 260 slides on sliding plate 964 toward docking slot 966, the docking slot 966 is located at the opposite end of sliding plate 964. Figure 12 The top surfaces of the first mounting wings 1162A1 and 1162A2 contact the bottom edge of the lip 1251A of the movable body 951C, causing the movable body 951C to move in the proximal direction. Figure 12 and Figure 13 The proximal movement of the movable body 951C presses down the plunger 1246 of the instrument manipulator assembly 1040 in the proximal direction, which in turn generates a signal to the controller 290 that the instrument 260 is being loaded onto the sterile adapter assembly 250.

[0208] When the mounting wing 1162A1 reaches the docking slot 966 ( Figure 14 The top surfaces of the first mounting wings 1162A1 and 1162A2 no longer contact the bottom edge of the lip 1251A of the movable body 951C. As a result, the preload force on the movable body 951C moves the body 951C in the distal direction. Figure 13 And lock the first mounting wing 1162A1 in place. When the first mounting wing 1162A1 reaches the end of the sterile adapter frame 951, the second mounting wing 1162B1 rests on the flat portion of the slide plate 964 near the open end of the sterile adapter frame 951. Figure 14 ).

[0209] Each intermediate disc 953 in the sterile adapter frame 951 is axially propelled in the distal direction by preload forces on multiple drive output discs of the instrument manipulator assembly. Therefore, when the instrument 260 is mounted in the sterile adapter frame 951, the multiple intermediate discs 953P transmit a first preload force to the movable body 951C, such that the preload force is applied to the mounting wing 1162A1. This preload force is selected to allow the instrument 260 to be easily slid into the sterile adapter frame 951 and to maintain a small preload force on all discs.

[0210] When instrument 260 is installed in sterile adapter assembly 250, instrument manipulator assembly 1040 detects the presence of instrument 260 and sends a signal to controller 290 indicating the presence of instrument 260. In response to this signal, controller 290 in system 200 sends a signal to instrument manipulator assembly 1040 to rotate each of the plurality of drive output discs.

[0211] As explained more fully in U.S. Patent Application Publication No. 2016 / 0184037A1, each drive output assembly 943 in drive output unit 942 is spring-loaded and automatically positioned such that a preload force is applied to each drive output disc after the sterile adapter assembly 250 is mounted on the instrument manipulator assembly 1040. The preload force pushes the drive output disc and pushes the corresponding intermediate driven interface of the intermediate disc 953 in the sterile adapter frame 951.

[0212] However, when the instrument 260 is first mounted on the sterile adapter assembly 250, the elements of the intermediate drive interface of the intermediate disk 953 may not align with the corresponding elements of the driven interface 1180 on the driven disk 1164. If the elements of the two disks 953 and 1164 are not aligned, the two disks are partially connected, but not mated with each other. Therefore, the disk stack including the drive disk, intermediate disk, and driven disk is partially connected. To mate the disks, the instrument engagement sequence action 836 is performed.

[0213] In one aspect, each of the aseptic adapter frame 951, the movable body 951C, and the multiple intermediate discs 953P is manufactured by injection molding. Suitable materials for the aseptic adapter frame 951, the movable body 951C, and the multiple intermediate discs 953P include polycarbonate, polyphenylene sulfone (PPSU), polyethyleneimine (PEI), etc.

[0214] The crossbeams 955 and 956 of the sterile adapter assembly 250 are included in a mechanical instrument removal lock, which is activated by mounting the instrument 260 in the sterile adapter assembly 250. Specifically, if the proximal ends of the crossbeams 955 and 956 cannot be moved inward by pressing release buttons 961 and 962, the hook of the sterile adapter assembly 250 cannot disengage from the hook receiver of the instrument manipulator assembly 1040. When the instrument 260 is mounted in the sterile adapter assembly 250, the body of the instrument prevents the inward movement of the crossbeams 955 and 956, and therefore the instrument 260 is considered to have activated the mechanical instrument lock, which is the crossbeams 955 and 956.

[0215] More specifically, such as in Figure 15 As shown, the distance 1501 between crossbeams 955 and 956 is selected based on the dimensions of the body of instrument 260. Distance 1501 is selected such that any movement of the proximal ends of crossbeams 955 and 956 when instrument 260 is installed in the sterile adapter assembly 250 is insufficient to disengage the hooks of the sterile adapter assembly 250 from the hook receiver of the instrument manipulator assembly 1040. Therefore, to prevent accidental release of the sterile adapter assembly 250, the body of instrument 260 physically prevents movement of crossbeams 955 and 956, thereby preventing removal of the sterile adapter assembly 250 when instrument 260 is present. This blocking is independent of any preload force that may be present.

[0216] Figure 16 This is a more detailed illustration of one aspect of the insertion assembly 331. The insertion assembly 331 includes a frame 1610, an intermediate bracket 1620, and a distal bracket 1630. The intermediate bracket 1620 rides on a ball screw 1611 in the frame 1610. In one aspect, the ball screw 1611 has a 6 mm pitch, and therefore the intermediate bracket 1620 is rearwardly driven. The intermediate bracket 1620 includes a metal band 1621 that drives the distal bracket 1630. The distal bracket 1630 is attached to the instrument manipulator assembly housing of the instrument manipulator assembly 240. In one aspect, the distal bracket 1630 travels twice as far as the intermediate bracket 1620.

[0217] Figures 17A and 17B illustrate the operation of the preloading assembly 1080. In one aspect, the structure and operation of preloading assemblies 480 and 980 are the same as those illustrated in Figures 17A and 17B. For ease of illustration, the housings of the instrument 260, sterile adapter assembly 250, instrument manipulator assembly 1040, and insertion assembly 331 are not shown in Figures 17A and 17B. When the preloading assembly 1080 is in the configuration shown in Figure 17A, the distal end of the instrument 260 is positioned, for example, at the entrance to the channel in the access guide 270. Similarly, in Figures 18A-18E and 19A-19C, only elements necessary for understanding the preloading assembly are illustrated. The actual configurations associated with Figures 17A, 17B, 18A-18E, and 19A-19C include those with respect to Figures 9A-9E, 10A-19C, and 19A-19C. Figure 10C All the elements shown and described in Figures 11A and 11B.

[0218] Before considering the operation of the preloading component 1080, the elements in the preloading component 1080 are described. Unlike the preloading component described in U.S. Patent Application Publication No. 2016 / 0184036A1, the preload supplied by the preloading component 980 can be automatically released by the controller 290 and can be manually released by the user. The preload supplied by the preloading component described in U.S. Patent Application Publication No. 2016 / 0184036A1 can only be manually released by the user.

[0219] In Figures 17A, 17B, 18A-18E, and 19A-19C, a preload track 1725 is mounted on an intermediate bracket 1620. A recess is located at the proximal end of the preload track 1725. A ramp 1725R in the preload track 1725 connects the recess to the flat portion of the preload track 1725. A preload engagement ridge 1726 extends distally from the preload track 1725 to the ramp 1725R. A description of a preload track suitable for use as preload track 1725 is presented in U.S. Patent Application Publication No. US 2016 / 0184036A1, which is incorporated herein by reference in its entirety.

[0220] Wheel 1783W is rotatably attached to the first end of cam follower assembly 1783. Wheel 1783W rides on preload rail 1725. (In some of Figures 17A, 17B, 18A-18E, and 19A-19C, wheel 1783W appears to be displaced from preload rail 1725. This is merely for illustration purposes. In all cases shown in Figures 17A, 17B, 18A-18E, and 19A-19C, wheel 1783W is in contact with and rides on preload rail 1725.)

[0221] Cam follower assembly 1783 pivots about pivot pin 1784 (first pivot pin). Cam follower assembly 1783 is rotatably connected to a first end of arm 1782 in preload assembly 1080. The first end (e.g., distal end) of arm 1782 is connected to motor assembly bracket 1781. A description of a cam follower assembly suitable for use as cam follower assembly 1783 is presented in U.S. Patent Application Publication No. 2016 / 0184036A1.

[0222] Motor assembly bracket 1781 is attached to motor assembly 1746. Therefore, arm 1782 is coupled to motor assembly 1746. As indicated above, the instrument manipulator assembly housing is attached to distal bracket 1630. An example of motor assembly 1746 is presented in U.S. Patent Application Publication No. US 2016 / 0184036A1.

[0223] The second end (proximal end) of the preloaded engagement arm 1786 is rotatably connected to the pivot pin 1784. The pivot pin 1784 is slidably connected to the housing of the instrument manipulator assembly 1040.

[0224] A rolling pin 1786P is installed in the first (far end) of the preload engagement arm 1786. Adjacent to the rolling pin 1786P in the first end of the preload engagement arm 1786 is the preload engagement surface 1786S, sometimes referred to as surface 1786S. In this respect, the preload engagement surface 1786S is perpendicular to the flat portion of the preload rail 1725. The preload engagement arm 1786 is coupled to the linear guide rail 1787. A description of a preload engagement arm and linear guide rail suitable for use as the preload engagement arm 1786 and the linear guide rail 1787 is presented in U.S. Patent Application Publication No. US 2016 / 0184036A1.

[0225] In this respect, the preload engagement / disengagement arm 1785 (sometimes referred to as arm 1785) is a T-shaped structure with a crossbar and legs. The T-shaped structure is rotated ninety degrees relative to the vertical direction, such that the legs of the T-shaped structure are horizontal, or more generally, perpendicular to the crossbar. The use of the T-shaped structure is optional. Any shape of preload engagement / disengagement arm 1785 capable of performing the actions described below can be used.

[0226] The crossbar of the preload engagement / disengagement arm 1785 acts as a lever and is therefore sometimes referred to as the lever or lever section of the preload engagement / disengagement arm 1785. When preload is enabled, a hook on the second end (proximal end) of the crossbar of the preload engagement / disengagement arm 1785 engages with a rolling pin 1786P in the second end of the arm 1785, and disengages from the rolling pin 1786P when preload is disabled. An emergency device release button 1082 is attached to the first end (distal end) of the crossbar of the preload engagement / disengagement arm 1785, for example, in contact with the first end (distal end) of the crossbar of the preload engagement / disengagement arm 1785. Emergency device release button 1082 is an example of emergency device release button 482 and emergency device release button 982.

[0227] Between the first and second ends of the crossbar of the preload engagement / disengagement arm 1785, the preload engagement / disengagement arm 1785 is rotatably mounted on another pivot pin 1788 (second pivot pin), which acts as a fulcrum for the lever action of the preload engagement / disengagement arm 1785. A T-shaped support leg extends from the lever portion of the arm 1785, such that the pivot pin 1788 is centered relative to the T-shaped support leg. Thus, the support leg of the preload engagement / disengagement arm 1785 has a first end and a second end, wherein the first end is connected to the crossbar of the preload engagement / disengagement arm 1785.

[0228] A torsion spring 1789 (Fig. 17C), co-centered with pivot pin 1788, applies a counterclockwise torque to the preload engagement / disengagement arm 1785 (counterclockwise relative to Figs. 17A, 17B, 18A-18E, and 19A-19C). The torsion spring 1789 provides force on the preload engagement / disengagement arm 1785, moving the hook of the preload engagement / disengagement arm 1785 away from the axis extending through pivot pins 1784 and 1788. The axis extending through pivot pins 1784 and 1788 is perpendicular to the longitudinal axis of pivot pins 1784 and 1788. The torsion spring 1789 rotates the preload engagement / disengagement arm 1785 in the preload disengagement direction, which is necessary to hold the preload engagement / disengagement arm 1785 in the release position shown in Figures 18A, 18B, 18C, 19B and 19C.

[0229] In one aspect, regarding the emergency device release button 1082, the lever portion of the preloaded engagement / disengagement arm 1785 is a Class 1 lever because the fulcrum is between the force (the force supplied by the emergency device release button 1082) and the load (the connection between the hook and the rolling pin 1786P). Although the preloaded engagement / disengagement arm 1785 is implemented as a Class 1 lever in this example, this is merely illustrative and not intended to be limiting. In other aspects, Class 2 or Class 3 levers may be used. For a Class 2 lever, the load is between the fulcrum and the force, and for a Class 3 lever, the force is between the fulcrum and the load.

[0230] The second end of the outrigger of the preloaded engagement / disengagement arm 1785 is connected to the second end of the link 1723. The first end of the link 1723 is connected to an electric actuator, which in this embodiment is implemented as a solenoid 1720 with a plunger 1721. In this respect, the first end of the link 1723 is connected to the plunger 1721. The electric actuator is connected to a controller 290. In response to commands from the controller 290, the electric actuator is enabled and disabled.

[0231] The emergency device release button 1082, preload engagement / disengagement arm 1785, preload engagement arm 1786, torsion spring 1789, electric actuator, and linkage 1723 form the preload engagement / disengagement mechanism of the preload assembly 1080. Therefore, both the preload engagement / disengagement mechanism and the preload assembly 1080 are mechanical structures connected to the controller.

[0232] A preload engagement / disengagement arm 1785 is rotatably coupled to a second pivot pin 1788. The preload engagement / disengagement arm 1785 can be engaged and disengaged from the rolling pin 1786P of the preload engagement arm 1786. A torsion spring 1789 is mounted on the second pivot pin 1788 and coupled to the preload engagement / disengagement arm 1785. The torsion spring 1789 is configured to provide torque on the preload engagement / disengagement arm 1785 to hold the preload engagement / disengagement arm 1785 in the disengaged position from the rolling pin 1786P. See Figures 18A and 18B.

[0233] Initially, as shown in Figure 17A, the cam follower assembly 1783 in the preload assembly 1080 is positioned in a recess in the preload track 1725 on the intermediate bracket 1620, for example, at a first position (original position) on the preload track 1725. At the first position, a light preload spring in each drive output assembly of the motor assembly 1746 is compressed, and a first preload force is applied to each disc in the disc stack (see Figure 4E). As the surgical device assembly 300 moves distally a distance Zload from the first position to the second position via the insertion assembly 331, the instrument manipulator assembly housing moves a distance Zload.

[0234] A pivot pin 1784, rotatably mounted on the cam follower assembly 1783, is coupled to the instrument manipulator assembly housing of the instrument manipulator assembly 1040. Therefore, when the insertion assembly 331 moves the instrument manipulator assembly housing 741 distally by a distance Zload, the pivot pin 1784 moves the cam follower assembly 1783 by the same distance Zload. In one respect, the distance Zload is 3.85 inches.

[0235] As described above, wheel 1783W is rotatably attached to the first end of cam follower assembly 1783, and wheel 1783W rides on preload track 1725. Therefore, as cam follower assembly 1783 moves distally, wheel 1783W follows the contour of preload track 1725. However, as cam follower assembly 1783 moves distally, the distance between preload track 1725 and pivot pin 1784 decreases. As a result, when cam follower assembly 1783 rides on ramp 1725R in preload track 1725, cam follower assembly 1783 rotates from the first position illustrated in FIG. 17A to the second position illustrated in FIG. 17B, moving motor assembly 1746 a distance greater than the distance traveled by the instrument manipulator assembly housing. Therefore, the rotation of cam follower assembly 1783 displaces motor assembly 1746 distally relative to instrument manipulator assembly housing by a predetermined distance Δ.

[0236] As the cam follower assembly 1783 travels along the preload track 1725, two actions are performed via the cam follower assembly 1782. When the cam follower assembly 1783 moves up the ramp 1725R and rotates, the rotation of the cam follower assembly 1783 pushes the motor assembly further away than the distance Zload, for example, the motor assembly 1746 moves a distance (Zload + Δ). Furthermore, as the cam follower assembly 1783 moves up the ramp 1725R, it transmits force to the motor assembly 1746, which in turn compresses both the light preload spring and the high preload spring in each drive output assembly, such that a second preload force (high preload force) is applied to each drive output disc of the instrument manipulator assembly 1040. This is true only when the instrument is mounted, as otherwise the springs are not compressed.

[0237] Figures 18A to 18E illustrate one embodiment of the actions performed by the preloading component 1080 in the automatic preloading setup. In one aspect, the operation of the preloading components 480 and 980 is the same as illustrated in Figures 18A to 18E.

[0238] When the sterile adapter assembly 250 is installed on the instrument manipulator assembly 1040 during the sterile adapter installation action 817, the instrument manipulator assembly 1040 sends a signal to the controller 290 indicating the presence of the sterile adapter assembly 250.

[0239] When the user presses the clutch button 1044 and moves the instrument manipulator assembly 1040 proximally, the instrument manipulator assembly housing moves proximally as fast as the preload engagement ridge 1726 on the preload track 1725. This is because the distal bracket 1630 to which the instrument manipulator assembly 1040 is attached moves as far as the intermediate bracket 1620 to which the preload track 1725 is attached. In this respect, the preload engagement ridge 1726 extends from the distal portion of the preload track 1725.

[0240] Initially, when the instrument manipulator assembly 1040 is in its original position, a gap 1801 exists between the preload engagement ridge 1726 on the preload track 1725 and the preload engagement surface 1786S of the preload engagement arm 1786. The controller 290 commands the insertion assembly to move the instrument manipulator assembly from its original position in a proximal direction. As the instrument manipulator assembly housing moves proximally, the preload engagement ridge 1726 moves proximally at half the speed of the preload engagement arm 1786 and the instrument manipulator assembly housing, and the insertion assembly 331 shortens. Consequently, the intermediate bracket 1620 and the distal bracket 1630 move closer together, closing the gap 1801 between the preload engagement ridge 1726 on the preload track 1725 and the surface 1786S of the preload engagement arm 1786.

[0241] When gap 1801 closes (Fig. 18B), surface 1786S of the preload engagement arm 1786 engages the preload engagement ridge 1726 on the preload track 1725. As the proximal movement of the preload engagement arm 1786 is constrained to move proximally with the preload track 1725, the instrument manipulator assembly 1040 continues to move proximally with the distal bracket 1630, and the linear guide 1787 slides relative to a guide rail within the instrument manipulator housing. As the instrument manipulator housing continues to move proximally (which extends the motor assembly return spring), arm 1782 holds the motor assembly 1746 in place.

[0242] When the instrument manipulator assembly 1040 is at a predetermined distance (e.g., 2 mm) from its original position, a hook on the second end of the lever included in the preload engagement / disengagement arm 1785 is adjacent to the rolling pin 1786P in the first end of the preload engagement arm 1786 (FIG. 18C). However, a torsion spring 1789 around the pivot pin 1788 prevents the preload engagement / disengagement arm 1785 from rotating clockwise to engage the rolling pin 1786P.

[0243] When the instrument manipulator assembly reaches the fully retracted position (third position), the controller 290 actuates the solenoid 1720, which moves the plunger 1721 in the proximal direction. The proximal movement of the plunger 1721 moves the linkage 1723 in the proximal direction, which in turn causes the hook on the preload engagement / disengagement arm 1785 to rotate clockwise until the hook on the preload engagement / disengagement arm 1785 engages the rolling pin 1786P (Figure 18D).

[0244] After the hook on the preload engagement / disengagement arm 1785 engages with the rolling pin 1786P, the controller 290 causes the instrument manipulator assembly 1040 to move distally to its original position, creating a gap between the preload engagement ridge 1726 on the preload track 1725 and the surface 1786S of the preload engagement preload engagement arm 1786 (FIG. 18E). In this position, the motor assembly return spring in the instrument manipulator assembly pulls the motor assembly 1746 distally. The force supplied by the motor assembly return spring is sufficient to keep the hook of the preload engagement / disengagement arm 1785 engaged with the rolling pin 1786P. This places the hook under tension, preventing the torsion spring 1789 from rotating the preload engagement / disengagement arm 1785 counterclockwise. Therefore, the controller 290 removes the firing command to the solenoid 1720. As illustrated in Figures 18A to 18E, the instrument manipulator assembly 1040 is automatically configured under the control of the controller 290 to set a first preload on the motor assembly 1746.

[0245] In one aspect, Figures 19A to 19C illustrate one embodiment of the actions performed by the preloading component 1080 during the automatic release of preloading. The operation of the preloading components 480 and 980 is the same as that illustrated in Figures 19A to 19C.

[0246] As the instrument manipulator assembly 1040 and preloading assembly 1080 move proximally, the cam follower assembly 1783 (FIG. 17B) moves proximally, with wheel 1783W following the contour of preloading track 1725. However, the distance between preloading track 1725 and pivot pin 1784 increases as the cam follower assembly 1783 moves proximally. Therefore, as the cam follower assembly 1783 rides down ramp 1725R in preloading track 1725, it rotates from the second position illustrated in FIG. 17B to the position illustrated in FIG. 17A. This releases the second preload, such that when preloading assembly 1080 is in its original position, as shown in FIG. 19A, only the first preload force is activated. This also retracts the hard stop from sterile adapter assembly 250, allowing instrument 260 to be removed, as the movable manipulator-instrument interface plate can move proximally when the hard stop is retracted.

[0247] Regarding Figure 19A, controller 290 activates the motor that moves the instrument manipulator assembly 1040 proximally. The instrument manipulator assembly housing moves proximally as fast as the preload engagement ridge 1726 on the preload track 1725. This is because the distal bracket 1630 to which the instrument manipulator assembly 1040 is attached moves as far as the intermediate bracket 1620 to which the preload track 1725 is attached.

[0248] Initially, a gap exists between the preload engagement ridge 1726 on the preload track 1725 and the preload engagement surface 1786S of the preload engagement arm 1786 (Fig. 19A). As the instrument manipulator assembly housing moves proximally, the preload engagement ridge 1726 moves proximally at half the speed of the preload engagement arm 1786 and the instrument manipulator assembly housing, and the insertion assembly 331 shortens. Consequently, the intermediate bracket 1620 and the distal bracket 1630 move closer together, closing the gap between the preload engagement ridge 1726 on the preload track 1725 and the surface 1786S of the preload engagement arm 1786.

[0249] When the gap closes (Fig. 19B), the surface 1786S of the preload engagement arm 1786 engages the preload engagement ridge 1726 on the preload track 1725. As the proximal movement of the preload engagement arm 1786 is constrained to move proximally with the preload track 1725, the instrument manipulator assembly 1040 continues to move proximally with the distal bracket 1630, and the linear guide 1787 slides relative to the guide rail in the instrument manipulator housing.

[0250] When the instrument manipulator assembly 1040 is at a predetermined distance (e.g., 2 mm) from its original position, a hook on the second end of the lever included in the preload engagement / disengagement arm 1785 is adjacent to the rolling pin 1786P in the first end of the preload engagement arm 1786 (FIG. 18C). Since the solenoid 1720 is not activated, the torsion spring 1789 around the pivot pin 1788 rotates the preload engagement / disengagement arm 1785 counterclockwise to disengage the hook from the rolling pin 1786P.

[0251] After the hook on the preload engagement / disengagement arm 1785 disengages from the rolling pin 1786P, the controller 290 causes the instrument manipulator assembly 1040 to move distally to its original position. Since the hook on the preload engagement / disengagement arm 1785 disengages from the preload engagement arm 1786, there is no force in the distal direction on the motor assembly 1746. The motor assembly does not shift distally relative to the instrument manipulator housing, and therefore, there is no preload force when the instrument manipulator assembly 1040 moves distally. Thus, as illustrated in Figures 19A to 19C, the instrument manipulator assembly 1040 is automatically configured under the control of the controller 290 to reset the first preload on the motor assembly 1746, and prevents the application of any preload force when the instrument manipulator assembly 1040 moves distally from the fully withdrawn position to its original position and beyond.

[0252] If the insertion component 331 is stuck in the extended position, the high preload force must be released to allow the device 260 to be removed. To remove the device 260, the user pushes the emergency device release button 1082 (FIG. 10A). In response to the force provided by the user, the emergency device release button 1082 applies force to the first end of the preload engagement / disengagement arm 1785. The force on the first end of the preload engagement / disengagement arm 1785 causes the preload engagement / disengagement arm 1785 to rotate about the pivot pin 1788 and disengages the hook on the second end of the preload engagement / disengagement arm 1785 from the rolling pin 1786P mounted in the second end of the preload engagement arm 1786.

[0253] It should be noted that the motor assembly return spring is installed between the instrument manipulator assembly housing and the motor assembly 1746 and is extended when a high preload force is applied. Therefore, when the preload engagement / disengagement arm 1785 disengages from the preload engagement arm 1786, the motor assembly return spring retracts the motor assembly 1746 back to the fully retracted position.

[0254] At the fully retracted position, there is no preload force, and therefore the drive output disc disengages from the intermediate disc. Furthermore, multiple hard stops are retracted, allowing both the instrument sterile adapter assembly 250 and the instrument 260 to be disassembled. If the distal end of the instrument 260 is not straight, the cannula forces the distal end of the instrument 260 to straighten when the instrument is withdrawn, because the disc stack is retractable without preload force and without the drive output disc being engaged.

[0255] Figure 20A shows an instrument manipulator assembly 2040 attached to an insertion assembly 2031 (also referred to as insertion mechanism 2031). Instrument manipulator assembly 2040 is another example of each of instrument manipulator assemblies 240, 440, and 1040. Insertion assembly 2031 is an example of insertion assembly 331. The position of instrument manipulator assembly 2040 is determined by insertion assembly 2031 and changes from an initial position to a fully extended position. In the fully extended position, insertion assembly 2031 is fully extended.

[0256] The instrument manipulator assembly housing 2048 (sometimes referred to as housing 2048) is fixedly attached to the distal end of the insertion assembly 2031, and thus the instrument manipulator assembly housing 2048 moves from the original position to the fully extended position as the insertion assembly 2031 moves.

[0257] A motor assembly 2046 within the instrument manipulator assembly housing 2048 is movable on a guide rail 2039. The motor assembly 2046 is movable relative to the instrument manipulator assembly housing 2048 in both distal and proximal directions. The motor assembly 2046 is coupled to the instrument manipulator assembly housing 2048 via a motor assembly return spring 2047 (sometimes referred to as return spring 2047). In one aspect, the elements included with the motor assembly 2046 are the same as those described above with respect to motor assembly 446. The motor assembly return spring 2047 corresponds to the motor assembly return spring 447.

[0258] The preloading assembly 2080 is mounted to the instrument manipulator assembly housing 2048 and thus moves with the housing 2048. The preloading assembly 2080 is connected to the motor assembly 2046 via the arm 2088. The preloading assembly 2080 includes an emergency instrument release button 2082.

[0259] Unlike the motor assembly 446, which is movably coupled to the insertion assembly 431 via the preloading assembly 480, the motor assembly 2046 is not movably coupled to the insertion assembly 2031 via the preloading assembly 2080. However, the preloading assembly 2080 has the ability to move the motor assembly 2046 relative to the housing 2048 regardless of the position of the instrument manipulator assembly 2040 relative to its original position. Therefore, compared to the aspects in Figures 18A-18E and 19A-19C, where the preloading assembly moves along a track and increases the preload from a first preload to a second preload as the instrument manipulator assembly moves from its original position, the preloading assembly 2080 is under the direct control of the controller 290 (e.g., the motor controller in the controller 290), and therefore the preload can be increased or decreased regardless of the position of the instrument manipulator assembly 2040 relative to its original position and regardless of whether the instrument manipulator assembly 2040 is being moved or stationary by the insertion assembly 2031.

[0260] When no preload is desired and when the motor assembly 2046 is not displaced in the distal direction relative to the instrument manipulator assembly housing 2048, the controller 290 takes no action. (Note that, in one aspect, the desired preload is determined by the state of the instrument manipulator assembly 2040, as described above regarding...) Figure 8 (Described.) In this case, regardless of where the manipulator assembly is positioned between the original position and the fully extended position of the instrument, the motor assembly 2046 is in the unloaded position 2032 relative to the instrument manipulator housing 2048.

[0261] Movement of the instrument manipulator assembly 2040 from its original position to its fully extended position or from its fully retracted position to its original position does not change the preload. Preload is only changed when the controller 290 sends a command to the preload assembly 2080 to change it, or only when the emergency instrument release button 2082 is activated. Since the motor assembly 2046 is in the no-preload position 2032, no preload force exists on the intermediate disc of the sterile adapter assembly if the sterile adapter assembly is mounted on the distal side of the instrument manipulator assembly 2040.

[0262] If low preload is desired and if motor assembly 2046 is not displaced distally relative to instrument manipulator housing 2048, i.e., the motor assembly is in the no-preload position 2032, controller 290 commands preload assembly 2080 to move arm 2088 distally to move motor assembly 2046 to low preload position 2033. As motor assembly 2046 moves distally relative to instrument manipulator housing 2048, motor assembly return spring 2047 is extended.

[0263] If the sterile adapter assembly is mounted in the distal side of the instrument manipulator assembly 2040, with the motor assembly 2046 in the low preload position 2033, a low preload force (e.g., a first preload force) will be present on the intermediate disc of the sterile adapter assembly. In the examples of Figures 20A and 20B, the preload force is increased by the controller 290, but the instrument manipulator assembly 2040 is not moved by the insertion assembly 2031. Alternatively, the preload force can be increased by the controller 290 when the instrument manipulator assembly is moved by the insertion assembly 290. If the emergency instrument release button 2082 is activated when the motor assembly 2046 is in the low preload position 2033, the preload mechanism in the preload assembly 2080 is disengaged, and the motor assembly return spring 2047 retracts the motor assembly 2046 proximally back to the no-preload position 2032.

[0264] If a low preload is desired and if the motor assembly 2046 is in a high preload position 2034 relative to the instrument manipulator assembly housing 2048, i.e., the motor assembly is in a high preload position 2034, the controller 290 commands the preload assembly 2080 to move the arm 2088 in the proximal direction to move the motor assembly 2046 to a low preload position 2033. As the motor assembly 2046 moves proximally relative to the instrument manipulator housing 2048, the motor assembly return spring 2047 retracts. Furthermore, this can be accomplished even when the insertion mechanism is not moving the instrument manipulator assembly 2040, because the preload force supplied by the preload assembly 2080 can be changed independently of the position of the preload assembly relative to its original position and independently of whether the insertion assembly 2031 is moving the instrument manipulator assembly 2040. The change in preload is independent of commands from the controller 290 to the insertion mechanism 2031 to change the position of the instrument manipulator assembly 2040, which differs from the embodiments described with respect to Figures 19A to 19C.

[0265] Preloading is controlled by controller 290 regardless of the control of the insertion assembly 2031 on which the instrument manipulator assembly 2040 is mounted. This means that, unlike the aspects described previously, commands from controller 290 to the insertion assembly 2031 to change the position of the instrument manipulator assembly 2040 cannot alter the preloading. Instead, controller 290 directly commands the preloading assembly 2080 to change the preloading. It should be understood that controller 290 can command the preloading assembly 2080 to change the preloading based on the position of the instrument manipulator assembly 2040. Therefore, commands to the preloading assembly 2080 can be coupled to commands to the insertion assembly 2031, but in this respect, commands to the insertion assembly 2031 cannot change the preloading, and thus the control of preloading by controller 290 is considered independent of the control of the insertion assembly 2031 on which the instrument manipulator assembly 2040 is mounted.

[0266] If no preload is desired and if motor assembly 2046 is in a low preload position 2033 relative to the instrument manipulator assembly housing 2048, i.e., motor assembly 2046 is in the low preload position 2033, controller 290 commands preload assembly 2080 to move arm 2088 in the proximal direction to move motor assembly 2046 to the no preload position 2032. As motor assembly 2046 moves proximally relative to instrument manipulator housing 2048, motor assembly return spring 2047 retracts. Furthermore, this can be accomplished even when insertion mechanism 2031 is not moving instrument manipulator assembly 2040, because the preload force supplied by preload assembly 2080 can be changed by controller 290 independently of the position of preload assembly 2080 relative to insertion assembly 2031 and independently of the position of instrument manipulator assembly 2040 relative to its original position. Of course, this can also be accomplished when insertion assembly 2031 moves instrument manipulator assembly 2040.

[0267] If high preload is desired, controller 290 commands preload assembly 2080 to move arm 2088 in the distal direction to move motor assembly 2046 to high preload position 2034. As motor assembly 2046 moves distally relative to instrument manipulator housing 2048, motor assembly return spring 2047 is extended.

[0268] If the sterile adapter assembly is installed in the distal part of the instrument manipulator assembly 2040, with the motor assembly 2046 in the high preload position 2034, a high preload force (e.g., a second preload force) will exist on the intermediate disc of the sterile adapter assembly. If the emergency instrument release button 2082 is activated when the motor assembly 2046 is in the high preload position 2034, the preload mechanism in the preload assembly 2080 is disengaged, and the motor assembly return spring 2047 retracts the motor assembly 2046 proximally back to the no-preload position 2032, thus removing the high preload force.

[0269] If the motor assembly 2046 is in a high preload position 2033 relative to the instrument manipulator assembly housing 2048, the controller 290 can command the preload assembly 2080 to move the motor assembly 2046 proximally to a low preload position 2033 or a no-preload position 2032. In the examples of Figures 20A, 20B, and 20C, the preload force is increased by the controller 290, but the insertion assembly 2031 does not move the instrument manipulator assembly 2040. In each of these examples, the preload force can also be changed by the controller 290 when the insertion assembly 2031 moves the instrument manipulator assembly 2040.

[0270] In the examples discussed below with respect to Figures 21A to 21C and illustrated in Figures 4A to 4G, the mechanical instrument removal block (prevention of proximal movement of the movable body in the sterile adapter assembly) is activated by a motor assembly in the moving instrument manipulator assembly. In another aspect illustrated in Figures 20D and 20E, the mechanical instrument removal block is independent of movement of any part of the instrument manipulator assembly 2040. In this respect, the mechanical instrument removal block assembly 2090 is mounted to the housing 2048 of the instrument manipulator assembly 2040. The mechanical instrument removal block assembly 2090 is connected to a blocking arm 2091, sometimes referred to as arm 2091, which includes multiple stops at its proximal end. These multiple stops are optional and are examples used for engagement with the previously described sterile adapter assembly. More generally, the distal side of arm 2091 engages, for example, the proximal side of the movable body of the sterile adapter assembly. In this respect, the emergency instrument release button 2082A is shared between the preload assembly 2080 and the mechanical instrument removal blocking assembly 2090. In one aspect, the blocking reset spring 2047A is connected between the proximal end of the blocking arm 2091 and the housing 2048.

[0271] A sterile adapter assembly 2050 (Figure 20D) is mounted in the distal side of the instrument manipulator assembly 2040. The sterile adapter assembly 2050 includes a movable manipulator-instrument interface plate 2051C, sometimes referred to as a movable body 2051C, which is movable relative to the frame of the sterile adapter assembly 2050 in both proximal and distal directions. A sterile adapter assembly 250 is an example of a sterile adapter assembly 2050, and therefore the sterile adapter assembly 2050 is not described in further detail.

[0272] As previously explained, when the device is installed or removed from the sterile adapter assembly 2050, the movable body 2051C is moved in the proximal direction. To prevent removal of the device, the movable body 2051C is locked in place by the mechanical instrument removal locking assembly 2090 to prevent movement of the movable body 2051C in the proximal direction.

[0273] The optional mechanical instrument removal lock assembly 2090 (FIG. 20D) is directly controlled by a controller 290 (e.g., a motor controller within the controller 290). The mechanical instrument removal lock can be activated or deactivated regardless of the position of the instrument manipulator assembly 2040 relative to its original position, whether the instrument manipulator assembly 2040 is being moved or stationary by the insertion assembly 2031, and the position of the motor assembly 2046 relative to the housing 2048. The movement of the arm 2091 is independent of the movement of the instrument manipulator assembly 2040 and the movement of the motor assembly 2046. The arm 2091 moves only when the controller 290 commands the mechanical instrument removal lock assembly 2090 to move the arm 2091, or when the arm 2091 is in the extended position and the emergency instrument release button 2082A is activated by the user.

[0274] In this respect, arm 2091 has a proximal position illustrated in Figure 20D and a distal position illustrated in Figure 20E. In the proximal position (second position), the portion of arm 2091 not in contact with the movable body 2051C of the sterile adapter assembly 2050. If the mechanical instrument removal locking assembly 2090 receives an engagement locking command from the controller 290, the mechanical instrument removal locking assembly 2090 moves arm 2091 to the distal position (Figure 20E), which locks the movable body 2051C in the distal position within the sterile adapter assembly 2050. With the movable body 2051C locked in the distal position, the instrument mounted in the sterile adapter assembly cannot be removed.

[0275] When arm 2091 moves to the distal position, return spring 2047A is extended. If emergency device release button 2082A is activated, arm 2091 disengages from mechanical device removal locking assembly 2090, and return spring 2047A pulls arm 2091 to its proximal position (Figure 20D). Therefore, movable body 2051C can be moved in the proximal direction, and the device can be removed.

[0276] Alternatively, controller 290 can send an unblocking command to mechanical instrument removal block assembly 2090. When mechanical instrument removal block assembly 2090 receives the unblocking command from controller 290, mechanical instrument removal block assembly 2090 moves arm 2091 from the distal position in FIG. 20E to the proximal position in FIG. 20D, which unlocks the movable body 2051C in sterile adapter assembly 2050 and allows movement of movable body 2051C.

[0277] Figures 21A to 21C are examples of one aspect of the instrument manipulator assembly 2040 and preloading assembly 2080 in Figures 20A to 20C. The elements in the instrument manipulator assembly 2040 in Figures 21A to 21C, which have the same reference numerals as in Figure 4A, are equivalent to those in Figure 4A, and therefore the description of the elements in Figure 4A is not repeated here.

[0278] In this respect, the preloaded component 2080 includes a motor 2181, for example, a servo motor, which is connected to the controller 290. The motor 2181 is mounted to the housing 2048. The motor 2181 drives a screw 2183. A nut 2184 is mounted on the screw 2183 and moves proximally or distally as the motor 2181 rotates the screw 2183. In one aspect, the screw 2183 is the threaded shaft of the motor 2181. The rotation of the shaft of the motor 2181, and therefore the distal or proximal movement of the nut 2184, is controlled by the controller 290. The combination of motor, screw, and nut is an example of a movable assembly whose position along its axis is directly controlled by the controller 290.

[0279] A preload tab 2184T extends from the outer surface of the nut 2184 adjacent to the distal end of the nut 2184. The preload tab 2184T has a first flat surface on the distal side and a second flat surface on the proximal side. The first flat surface extends further from the outer surface of the nut 2184 than the second flat surface. Therefore, the surface that joins the first flat surface to the second flat surface is a beveled surface.

[0280] A preload release lever 2186 is mounted on a pivot pin 2187. A torsion spring is mounted around the pivot pin and attached to the preload release lever 2186 to hold the preload release lever 2186 in the preload engaged position if the emergency device release button 2082 is not engaged. The pivot pin 2187 is mounted on an arm 2088, which is connected to a motor assembly 2046. In this example, the arm 2088 moves proximally and distally relative to the housing 2048 on a guide rail 2139. The guide rail 2139 is optional.

[0281] The distal end (i.e., the first end) of the preload release lever 2186 includes a hook 2186A that engages and disengages from the preload tab 2184T. In this example, the hook 2186A has a flat surface extending from the side surface of the preload release lever 2186. The flat surface of the hook 2186A is configured to contact the first flat surface of the preload tab 2184T such that distal movement of the preload tab 2184T causes the preload release lever 2186 to move distally together with the preload tab 2184T.

[0282] The inclined surface extends from the end of the flat surface of the preload release lever 2186, which is removed from the side surface of the preload release lever 2186, to the distal end of the preload release lever 2186. The slope of the inclined surface at the distal end of the preload release lever 2186 is opposite to the slope of the inclined surface on the tab 2184T, such that when the preload is released, the hook 2186A and the tab 2184T can move past each other in the proximal direction.

[0283] Emergency device release button 2082 is mounted to apply a force to the proximal end (second end) of preload release lever 2186. In the examples of Figures 21B and 21C, if emergency device release button 2082 is activated, it applies a preload release force to the proximal end of preload release lever 2186, causing preload release lever 2186 to pivot about pivot pin 2187 in the preload release direction (clockwise in Figures 20B and 20C).

[0284] The pivoting of the preload release lever 2186 about the pivot pin 2187 in the preload release direction causes the hook 2186A to disengage from the tab 2184T of the nut 2184. Therefore, the motor assembly return spring 2047 moves the motor assembly 2046 to the unpreloaded position 2032 in the proximal direction relative to the instrument manipulator assembly housing 2048.

[0285] To engage the preload, controller 290 commands motor 2181 to move nut 2184 proximally from the position in Figure 20B or Figure 20C to the position in Figure 20A. Since tab 2184T is distal to hook 2186A, as nut 2184 moves tab 2184T proximally, the inclined surface of tab 2184T contacts the inclined surface of hook 2186A of preload release lever 2186. As tab 2184T continues to move proximally, the inclined surface of tab 2184T pivots preload release lever 2186 until the first flat surface (distal flat surface) clears the first flat surface of hook 2186A, and then a torsion spring around pivot pin 2187 rotates hook 2186A in the preload engagement direction, causing the first flat surface of hook 2186A to contact the first flat surface of tab 2184T. This engages the preload mechanism because now when the tab 2184T moves, the hook 2186A moves, which in turn moves the motor assembly 2046.

[0286] Specifically, as shown in Figures 21A and 21B, when the preloading mechanism is engaged and motor assembly 2046 is in the no-preload position 2032, and controller 290 commands preloading assembly 2080 to move motor assembly 2046 to the low-preload position 2033, motor 2181 moves nut 2184 in the distal direction. This distal movement of nut 2184 causes tab 2184T to apply a force in the distal direction to hook 2186A. The force on hook 2186A moves arm 2088 in the distal direction, which, relative to instrument manipulator housing 2048, moves motor assembly 2046 to the low-preload position 2033.

[0287] As shown in Figures 21B and 21C, when the preloading mechanism is engaged and motor assembly 2046 is in the low preload position 2033, and controller 290 commands preloading assembly 2080 to move motor assembly 2046 to the high preload position 2034, motor 2181 moves nut 2184 in the distal direction. This distal movement of nut 2184 causes tab 2184T to apply a force in the distal direction to hook 2186A. The force on hook 2186A moves arm 2088 in the distal direction, which moves motor assembly 2046 relative to instrument manipulator housing 2048 to the high preload position 2034.

[0288] In the aspects illustrated in Figures 21A to 21C, with respect to the emergency device release button 2082, the preload release lever 2186 is a Class 1 lever because the fulcrum (pivot pin 2187) lies between the force (the force supplied via the preload release button 3082) and the load (the connection between the hook 2186A and the tab 2184T). Although the preload release lever 2186 is implemented as a Class 1 lever in this example, this is merely illustrative and not intended to be limiting. In other aspects, Class 2 or Class 3 levers may be used. For a Class 2 lever, the load lies between the fulcrum and the force, and for a Class 3 lever, the force lies between the fulcrum and the load.

[0289] Figure 8 All states and all actions can be achieved using the machine manipulator component 2040, which includes the preloaded component 2080. Therefore, Figure 8 The description does not repeat aspects of the instrument manipulator assembly 2040, which includes the preloading component 2080. Here, the controller 290 directly controls the preloading, and the preloading is independent of the movement of the instrument manipulator assembly 2040 via the insertion mechanism 2031. Therefore, using Figure 8 The actions in which the controller 290 does not need to move the instrument manipulator assembly to set or reset the preloading mechanism when the instrument manipulator assembly 2040 includes the preloading assembly 2080.

[0290] Therefore, in one aspect, if the sterile adapter assembly 2050 is not mounted on the instrument manipulator assembly 2040, the controller 290 maintains no preload force on the motor assembly 2046 of the instrument manipulator assembly 2040. The controller directly commands the preload assembly 2080 to increase the preload force on the motor assembly 2046 of the instrument manipulator assembly 240 from no preload force to a first preload force after the sterile adapter assembly 2050 is mounted on the instrument manipulator assembly 2040. The controller directly commands the preload assembly 2080 to increase the preload force on the motor assembly 2046 of the instrument manipulator assembly 240 from the first preload force to a second preload force after the instrument is mounted on the sterile adapter assembly 2050.

[0291] In one aspect, the mechanical device removal lock assembly 2090 is implemented using elements equivalent to those shown for the preloading assembly 2080 in FIG. 21A, and the description is not repeated for the mechanical device removal lock assembly 2090. In another aspect, assemblies 2080 and 2090 are combined in a single assembly that performs both the preloading function and the mechanical device removal lock function, wherein the two functions are independent of each other.

[0292] In some of the examples above, the terms "proximal" or "towards proximal" are generally used to describe objects or elements whose kinematic chains moving along the system are closer to the manipulator arm base or whose kinematic chains moving along the system are farther from the remote center of motion (or surgical site). Similarly, the terms "distal" or "towards distal" are generally used to describe objects or elements whose kinematic chains moving along the system are farther from the manipulator arm base or whose kinematic chains moving along the system are closer to the remote center of motion (or surgical site).

[0293] As used in this article, "first," "second," "third," "fourth," etc., are adjectives used to distinguish different parts or components. Therefore, "first," "second," "third," "fourth," etc., are not intended to imply any ordering of parts or components.

[0294] The above description and accompanying drawings, illustrating aspects and embodiments of the invention, should not be considered limiting; the claims define the protected invention. Various mechanical, compositional, structural, electrical, and operational variations may be made without departing from the spirit and scope of this 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.

[0295] Furthermore, the terminology used in this specification is not intended to limit the invention. For example, spatially relative terms, such as “below,” “under,” “below,” “above,” “over,” “near,” “far,” etc., are used to describe the relationship of one element or feature to another element or feature illustrated in the figures. These spatially relative terms are intended to cover different positions (i.e., locations) and orientations (i.e., rotational positioning) of the device in use or operation, other than those shown in the figures. For example, if the device in the figures is flipped, an element described as being “below” or “under” other elements or features would then be “above” or “above” other element or feature. Thus, the exemplary term “below” can cover both above and below positions and orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations) and the spatially relative descriptive symbols used herein are therefore interpreted accordingly. Similarly, descriptions of movement along or around different axes include various specific device positions and orientations.

[0296] The singular forms “a,” “an,” and “the” are also intended to include the plural forms, unless the context otherwise requires. The terms “comprising,” “including,” “comprise,” etc., define the presence of the stated feature, step, operation, element, and / or component, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups. Components described as connected may be directly electrically or mechanically connected, or they may be indirectly connected via one or more intermediate components.

[0297] All examples and illustrative references are non-limiting and should not be used to limit the claims to the specific embodiments and examples 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 be cross-referenced or applied 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 surgical device comprising: Sterile adapter assembly, comprising: Mechanical surgical instruments were removed from the blockage; Mechanical aseptic adapter assembly removal lock; and A driven interface configured to engage with the surgical instrument manipulator assembly in the mounted state of the sterile adapter assembly on the surgical instrument manipulator assembly; and When the surgical instrument is mounted on the sterile adapter assembly, the mechanical sterile adapter assembly removal lock is activated; and The mechanical surgical instrument removal lock is configured to be activated such that, in the installed state of the sterile adapter assembly on the surgical instrument manipulator assembly and in the installed state of the surgical instrument on the sterile adapter assembly, the motor assembly of the surgical instrument manipulator assembly moves a predetermined distance in the direction toward the driven interface of the sterile adapter assembly.

2. The surgical device according to claim 1: The sterile adapter assembly includes a frame; and The mechanical surgical instrument removal block includes a body that is movably mounted within the frame of the sterile adapter assembly.

3. The surgical device according to claim 2, wherein: In the first position of the main body, the surgical instrument can be removed from its mounted state on the sterile adapter assembly; and In the second position of the main body, the surgical instrument is locked into the mounting state on the sterile adapter assembly.

4. The surgical device according to claim 2: The sterile adapter assembly further includes: A crossbeam having a first end and a second end opposite to the first end, the crossbeam being pivotally connected to the frame between the first end and the second end of the crossbeam; A plurality of hook extensions extending from the second end of the crossbeam, each of the plurality of hook extensions including a hook configured to engage a hook receiver in the surgical instrument manipulator assembly; and A sterile adapter assembly release button, which is coupled to the first end of the crossbeam, wherein pressing the sterile adapter assembly release button in a first direction causes the plurality of hook extensions to move in a second direction, so that each hook disengages from the hook receiver.

5. The surgical device of claim 4, wherein the mechanical sterile adapter assembly removes the occlusion including the first end of the beam.

6. The surgical device of claim 4, wherein when the surgical instrument is in the mounted state on the sterile adapter assembly and the sterile adapter assembly is in the mounted state on the surgical instrument manipulator assembly, the surgical instrument prevents movement of the sterile adapter assembly release button in the first direction to disable removal of the sterile adapter assembly from the mounted state on the surgical instrument manipulator assembly.

7. The surgical device according to claim 1, further comprising: The surgical instrument manipulator assembly, wherein the surgical instrument manipulator assembly includes: Far side, and Preloaded components, including an emergency device release button; The sterile adapter assembly is configured to be removably mounted to the distal side of the surgical instrument manipulator assembly; and The sterile adapter assembly is removable from the distal side of the surgical instrument manipulator assembly independently of the actuation of the emergency instrument release button.

8. The surgical device according to claim 1, wherein: The sterile adapter assembly includes a frame; and The mechanical surgical instrument removal block includes a body movably mounted in the frame of the sterile adapter assembly, the body having a first position and a second position independent of the position of any part of the surgical instrument manipulator assembly to which the sterile adapter assembly is attached; In the first position of the main body, the surgical instrument in the installed state on the sterile adapter assembly can be removed from the sterile adapter assembly; and In the second position of the main body, the surgical instrument is locked into the mounting state on the sterile adapter assembly.

9. A medical device comprising: Sterile adapter assembly, comprising: A first mechanical barrier is configured to prevent the medical device from being removed from its mounted state on the sterile adapter assembly when activated. A second mechanical lock, configured to prevent the sterile adapter assembly from being removed from its mounted position on the surgical instrument manipulator assembly when activated; and A driven interface is configured to engage with the surgical instrument manipulator assembly in the installed state of the sterile adapter assembly on the surgical instrument manipulator assembly. The second mechanical lock is activated by the medical device being present on the sterile adapter assembly in the installed state; and In the installed state of the sterile adapter assembly on the surgical instrument manipulator assembly, the first mechanical lock is activated by the movement of a component mounted to the housing of the surgical instrument manipulator assembly in the direction toward the driven interface of the sterile adapter assembly and relative to the housing from a first position to a second position.

10. The medical device according to claim 9, wherein: The component includes a motor assembly operatively coupled to the preload assembly; The first position corresponds to the position where the preloading component is configured to supply a first preloading force to the sterile adapter component; and The second position corresponds to the position where the preloading component is configured to supply a second preloading force to the sterile adapter component, wherein the second preloading force is greater than the first preloading force.

11. The medical device of claim 9, wherein the component includes a locking arm movable between the first position and the second position.

12. The medical device according to claim 9, wherein: The sterile adapter assembly includes a manipulator latch mechanism capable of engaging with the surgical instrument manipulator assembly, wherein, in the engaged state with the surgical instrument manipulator assembly, the manipulator latch mechanism holds the sterile adapter assembly in the mounted state on the surgical instrument manipulator assembly; and The second mechanical lock is configured to prevent the manipulator latch mechanism from disengaging from the surgical instrument manipulator assembly when the medical device is in the installed state on the sterile adapter assembly.

13. The medical device according to claim 12, wherein: The sterile adapter assembly includes a release element actuable to disengage the manipulator latch mechanism from the engaged state; and The second mechanical lock, when activated, prevents the actuation of the release element.

14. The medical device according to claim 13, wherein: The release element is actuated in response to movement of the second mechanical blockage along a first direction; and When the second mechanical block is activated by the medical device in the installed state, the medical device engages with the second mechanical block and prevents the second mechanical block from moving along the first direction.

15. The medical device of claim 14, wherein the manipulator latching mechanism includes a latching element and a beam connecting the latching element to the release element, and the second mechanical lock includes a portion of the beam.

16. The medical device according to claim 9, wherein: The sterile adapter assembly includes a device latching mechanism capable of engaging with the medical device, wherein, in the engaged state with the medical device, the device latching mechanism holds the medical device in the mounted state on the sterile adapter assembly. and When the first mechanical lock is activated, the first mechanical lock prevents the device latch mechanism from disengaging from the medical device.

17. The medical device according to claim 16, wherein: The sterile adapter assembly includes a frame; The instrument latching mechanism includes a movable body mounted in the frame and capable of moving between a first position and a second position; At the first position of the movable body, the medical device can be removed from the installed state on the sterile adapter assembly; and In the second position of the movable body, the medical device is locked into the mounting state on the sterile adapter assembly.

18. The medical device of claim 17, wherein the first mechanical lock, when activated, prevents movement of the movable body from the second position to the first position.

19. The medical device according to claim 18, wherein: The first mechanical block includes a portion of the movable body that is configured to engage with a portion of the component when activated to prevent movement of the movable body from the second position to the first position.

20. The medical device of claim 19, wherein said portion of said component includes one or more rigid stops, and The portion of the movable body includes one or more hard stop recesses configured to engage with the one or more hard stops to prevent movement of the movable body from the second position to the first position.

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