Mounting system

Abstract

A mounting system includes a first mounting portion associated with an arm of a surgical robot, the first mounting portion including a plurality of receptacles, and each of the receptacles including a contact surface; a second mounting portion associated with an end effector for a surgical robot and configured to be releasably coupled to the first mounting portion, the second mounting portion including a plurality of receptacles, and each of the receptacles including a contact surface; and a sterile barrier assembly for establishing a barrier between the first surgical component and the second surgical component, comprising: an interface having a plurality of kinematic couplings configured to engage the contact surfaces of the receptacles of the first mounting portion and the second mounting portion, the system includes a first mounting portion, a second mounting portion, and a kinematic coupling between the first mounting portion and the second mounting portion to constrain six degrees of freedom between the arm and the end effector, and a drape assembly including a ring defining an opening for receiving and attaching to the interface, and a drape material attached to the ring.

Description

[0001] This application is a divisional application of the invention patent application entitled “Installation System”, filed on February 19, 2016, and with application number 202111225396.6. This invention patent application is a divisional application of the invention patent application entitled “Sterile barrier assembly, installation system and method for connecting surgical components”, filed on February 19, 2016, with international application number PCT / US2016 / 018691 and national application number 201680009618.1.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to and the benefit of U.S. Provisional Patent Application Serial No. 62 / 118,737, filed on February 20, 2015, the entire contents of which are hereby incorporated by reference into this application. Technical Field

[0004] The present invention relates to a sterile barrier assembly, a mounting system and a method for coupling surgical components through the sterile barrier assembly. Background Art

[0005] Sterile barrier assemblies such as surgical sterile drapes are known for establishing a barrier between surgical components during surgery. For example, a surgical sterile drape can be used to provide a barrier between a robotic arm and an end effector attached to the robotic arm. During surgery, the robotic arm is not sterile, while the end effector is sterile. The surgical sterile drape forms a barrier between the robotic arm and the end effector to prevent contamination of the sterile field in which the end effector operates.

[0006] Typically, the surgical drape disposed between the robotic arm and the end effector has perforations or other openings through which various connections, e.g., mechanical and / or electrical connections, can be made between the robotic arm and the end effector. As long as the perforations are covered during surgery, these perforations are acceptable. If the end effector fails during surgery and needs to be replaced, or if a different end effector is needed and the perforations become uncovered, standard operating room aseptic procedures may dictate that the surgical drape needs to be replaced before a different end effector can be installed. Because removing the surgical drape and installing a new surgical drape takes up valuable time, replacement is undesirable.

[0007] Other surgical drapes are not intentionally perforated, but instead are compressed between the robotic arm and the end effector. When compressed, if the surgical drape is formed of thin plastic, accidental tearing may occur. Even when the surgical drape does remain intact, the compressibility of the surgical drape makes the positioning of the end effector on the robotic arm imprecise. For example, the surgical drape may compress unevenly. In addition, thick drapes made of conventional drape materials will bend skew under normal end effector loads. Small skew bends are magnified to the tool center point (TCP) of the end effector and can become unacceptable due to positioning accuracy errors of the TCP.

[0008] Therefore, there is a need in the art to address one or more of these deficiencies. Summary of the invention

[0009] In one embodiment, a sterile barrier assembly for establishing a barrier between a first surgical component and a second surgical component during surgery is provided. The assembly includes a protective cover having a plurality of kinematic couplings. The plurality of kinematic couplings provide a kinematic coupling between the first surgical component and the second surgical component through the protective cover.

[0010] In another embodiment, a mounting system for coupling a first surgical component and a second surgical component is provided. The system includes a first mounting portion for the first surgical component and a second mounting portion for the second surgical component. The system also includes a protective cover having a plurality of kinematic couplings to kinematically couple the first mounting portion and the second mounting portion through the protective cover.

[0011] In yet another embodiment, a method for coupling a first surgical component to a second surgical component is provided. The method includes placing a sterile barrier assembly on the first surgical component, the sterile barrier assembly having a plurality of kinematic couplings. The method also includes placing the second surgical component on the sterile barrier assembly. The method also includes preloading a preload element so as to kinematically couple the surgical components together through the sterile barrier assembly via the plurality of kinematic couplings.

[0012] One advantage of the sterile barrier assembly, mounting system, and method is the ability to kinematically couple a first surgical component to a second surgical component via the sterile barrier assembly such that positioning is repeatable and deterministic while at the same time maintaining the integrity of the sterile barrier assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Advantages of the present invention will become apparent and better understood by referring to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0014] Figure 1 is a perspective view of a robotic surgical system including a mounting system and a sterile barrier assembly;

[0015] Figure 2 is a perspective view of the installation system;

[0016] Figure 3 yes Figure 2 A cutaway perspective view of a mounting system;

[0017] Figure 4 yes Figure 2 Another cutaway perspective view of the mounting system;

[0018] Figure 5 is a front perspective view of the first mounting portion;

[0019] Figure 6 is a front perspective view of the second mounting portion;

[0020] Figure 7 is a front perspective view of a sterile barrier assembly;

[0021] Figure 8 is a cutaway perspective view of a sterile barrier assembly;

[0022] Fig. 9 yes Figure 2 A cutaway perspective view of a mounting system;

[0023] Fig.10 yes Figure 5 a cut-away perspective view of a first mounting portion;

[0024] Fig.11 yes Figure 5 a cut-away perspective view of a first mounting portion;

[0025] Fig.12 yes Figure 6 a cut-away perspective view of a second mounting portion;

[0026] Fig.13 is a perspective view of components of a preloading mechanism;

[0027] Fig.14 is with Figure 6 a perspective view of a capture member associated with a second mounting portion;

[0028] Fig.15 is a perspective view of the camshaft of the preload mechanism;

[0029] Fig.16 is a cut-away perspective view illustrating an electrical connection between a first mounting portion and a second mounting portion through a sterile barrier assembly;

[0030] Fig.17 is a perspective view of an alternative mounting system;

[0031] Fig.18 yes Fig.17 A cutaway perspective view of an alternative mounting system;

[0032] Fig.19 yes Fig.17 Another cutaway perspective view of an alternative mounting system;

[0033] Fig. 20 is a front perspective view of the first mounting portion;

[0034] Fig.21 is a front perspective view of the second mounting portion;

[0035] Fig. 22 is a front perspective view of an alternative sterile barrier assembly;

[0036] Fig.23 is a rear perspective view of an alternative sterile barrier assembly;

[0037] Fig.24 is a cutaway perspective view of an alternative sterile barrier assembly (without the drape);

[0038] Fig.25 is a cutaway perspective view of an alternative sterile barrier assembly (without the drape);

[0039] Fig.26 is an exploded perspective view of an alternative sterile barrier assembly (without the drape);

[0040] Fig.26A yes Fig.26 Close-up view of

[0041] Fig. 27 yes Fig.17 A cutaway perspective view of an alternative mounting system;

[0042] Fig.28 is a perspective view of the load-bearing member;

[0043] Fig.29 It is a perspective view of the camshaft;

[0044] Fig.30 is a cutaway perspective view of a first mounting portion;

[0045] Fig.31 is a cut-away perspective view of the second mounting portion; and

[0046] Fig.32 Steps for mounting a replacement sterile barrier assembly onto a robotic arm and end effector are shown.

[0047] Fig.33is another alternative barrier component.

[0048] Fig.34 yes Fig.33 A cross-sectional view of an alternative barrier assembly.

[0049] Fig.35 yes Fig.33 A close up view of the drape of an alternative barrier assembly.

[0050] Fig.36 is included Fig.33 A cross-sectional view of another alternative mounting system for an alternative barrier assembly.

[0051] Fig.37 yes Fig.33 A perspective view of a backplate assembly of an alternative barrier assembly.

[0052] Fig.38 and 39 yes Fig.33 A cross-sectional view of an alternative barrier assembly showing connection to a first mounting portion of a robotic arm.

[0053] Fig.40 and 41 yes Fig.33 A cross-sectional view of an alternative barrier assembly showing connection to a second mounting portion of an end effector.

[0054] Fig.42 and 43 yes Fig.33 An exploded view of the components of the preload mechanism of an alternative barrier assembly.

[0055] Fig.44 yes Fig.33 A partial exploded view of the operating lever of an alternative barrier assembly.

[0056] Fig.45 Is used for preloading Fig.33 Alternative barrier components Fig.44 A view of the joystick;

[0057] Fig.46 is used to release the first mounting part from the robot arm Fig.33 An elevation view of components of an actuator of an alternative barrier assembly;

[0058] Fig.47A and 47B It is used for alignment when installing to the first mounting part. Fig.33 View of the gross error positioning features of an alternative barrier assembly. DETAILED DESCRIPTION

[0059] Reference Figure 1 and 2, a mounting system 20 is shown for kinematically coupling a first surgical component and a second surgical component using a sterile barrier assembly 22. In one embodiment described herein, the first surgical component is a robotic arm R and the second surgical component is an end effector EE for the robotic arm R. It should be understood that the mounting system 20 may be employed to kinematically couple any surgical component using a sterile barrier assembly 22.

[0060] The robotic arm R includes a first mounting portion 24 and the end effector EE includes a second mounting portion 26. The sterile barrier assembly 22 is located between the first mounting portion 24 and the second mounting portion 26 to establish a barrier between the robotic arm R and the end effector EE during surgery. The barrier separates the robotic arm R from the sterile area S in which the end effector EE operates. During surgery, the robotic arm R is considered non-sterile and the barrier reduces the possibility of contaminants migrating from the robotic arm R into the sterile area S.

[0061] The mounting portions 24, 26 are kinematically coupled together using the sterile barrier assembly 22. The kinematic coupling provides a rigid connection between the mounting portions 24, 26 so that the positioning between the mounting portions 24, 26 can be determined and repeatable. Due to this rigid, determined and repeatable connection, errors in positioning the end effector EE that are associated with a more flexible connection can be reduced.

[0062] The kinematic connection constrains just the degrees of freedom to be constrained, i.e., does not over-constrain the degrees of freedom. For example, in one embodiment, there are six degrees of freedom between the mounting portions 24, 26, e.g., three translations and three rotations. Thus, the kinematic connection constrains just these six degrees of freedom.

[0063] Reference Figure 3 and 4 , the mounting portions 24, 26 are kinematically coupled using a plurality of kinematic couplings (also referred to as kinematic elements) of the sterile barrier assembly 22. In the illustrated embodiment, the kinematic coupling is a spherical ball 28. During use, the ball 28 is located in a first plurality of receiving portions 30, 32, 34 and a second plurality of receiving portions 36, 38, 40 of the mounting portions 24, 26. The receiving portions 30, 32, 34, 36, 38, 40 are appropriately sized and shaped to receive the ball 28. In the illustrated embodiment, the first mounting portion 24 includes a first body 42 and a first cover plate 44, which is fixed to the first body 42. The first plurality of receiving portions 30, 32, 34 are fixed in the first cover plate 44. The second mounting portion 26 includes a second body 46 and a second cover plate 48, which are fixed to the second body 46. The second plurality of receiving portions 36, 38, 40 are fixed in the second cover plate 48.

[0064] Reference Figure 5 and 6 , the first plurality of receiving portions 30, 32, 34 includes one receiving portion 30 having a contact surface 50, the contact surface having a conical configuration (also referred to as a conical receiving portion). Another receiving portion 32 has a pair of contact surfaces 52 provided by a V-shaped groove (also referred to as a V-groove receiving portion). Yet another receiving portion 34 has a contact surface including a flat portion 54 (also referred to as a planar receiving portion). The second plurality of receiving portions 36, 38, 40 includes three receiving portions having a contact surface 56, the contact surface having a conical configuration (i.e., conical receiving portions). Three balls 28 are trapped between corresponding aligned pairs of receiving portions, i.e., receiving portion 30 and receiving portion 36, receiving portion 32 and receiving portion 38, and receiving portion 34 and receiving portion 40, as shown Figure 3 and 4 The contact surfaces 50, 52, 54, 56 of the receiving parts 30, 32, 34, 36, 38, 40 serve as constraining surfaces for the kinematic coupling described herein.

[0065] The receiving portions 30, 32, 34, 36, 38, 40 may be formed of steel or other suitably rigid material and may be separate components rigidly connected to the cover plates 44, 48, or may be integral with the cover plates 44, 48. The receiving portions 30, 32, 34, 36, 38, 40 may be integrated into the mounting portions 24, 26, in which case the receiving portions 30, 32, 34, 36, 38, 40 merely include a restraining surface that is integral with the mounting portions 24, 26 for securing the ball 28, or the receiving portions 30, 32, 34, 36, 38, 40 may be attached to the mounting portions 24, 26 in a variety of ways via a variety of structures.

[0066] When the mounting portions 24, 26 are brought together in an approximate final orientation (with the sterile barrier assembly 22 positioned between the mounting portions), the ball 28 of the sterile barrier assembly 22 seats itself into the receiving portions 30, 32, 34, 36, 38, 40. The conical receiving portion, the V-groove receiving portion, and the planar receiving portion of the first mounting portion 24 remove three degrees of freedom, two degrees of freedom, and one degree of freedom via three points, two points, and one point of contact with the ball 28, respectively. Thus, exactly six degrees of freedom are constrained. In other embodiments, as further described below, each of the first plurality of receiving portions 30, 32, 34 of the first mounting portion 24 can remove two degrees of freedom via two points of contact with the ball 28. In any of these cases, exactly six degrees of freedom are constrained via exactly six points of contact (e.g., one point of contact for each degree of freedom).

[0067] Reference Figure 7 and 8, the sterile barrier assembly 22 includes a protective cover 58. The protective cover 58 includes an interface 60 and a drape 62 attached to the interface 60. The drape 62 has an inner surface and an outer surface. The inner surface is placed adjacent to the robotic arm R during surgery. In the illustrated embodiment, the drape 62 is assembled to the robotic arm R so as to enclose the robotic arm R as a whole. The drape 62 is formed of at least one of polyethylene, polypropylene, and polycarbonate. The drape 62 can be attached to the interface 60 by ultrasonic welding, tape, adhesive, etc. The drape 62 is attached to the interface 60 so that there are no perforations, that is, the drape forms a continuous barrier that is continuous with the interface 60.

[0068] In the illustrated embodiment, the interface 60 is formed of a molded plastic material. The interface 60 may be formed of rubber, silicone, urethane, or other suitable materials. The interface 60 includes a main wall 64 having a perimeter and a peripheral wall 66 joining the main wall 64 at the perimeter. The peripheral wall 66 may be generally perpendicular to the main wall 64, but preferably flares slightly outward from the perpendicular to define a cavity 68 for receiving the first mounting portion 24. The drape 62 is attached to the peripheral wall 66 of the interface 60 (see Figure 8 ). Figure 2-4 , 9 and 16, the curtain 62 is not shown in order to better illustrate other components.

[0069] The main wall 64 has a plurality of separate support portions 70, 72, 74, 76 having a greater thickness. The main wall 64 has a width between about 0.050 inches and about 0.150 inches between the support portions 70, 72, 74, 76, and a width between about 0.150 inches and about 0.250 inches at the support portions 70, 72, 74, 76. The main wall 64 has a Shore A hardness of 80 degrees.

[0070] The interface 60 includes a ball 28 integrated therein. In one embodiment, the ball 28 is insert molded into the three supports 70, 72, 74. As described above, the ball 28 is arranged to be received in the first plurality of receiving portions 30, 32, 34 and the second plurality of receiving portions 36, 38, 40 so as to kinematically couple the first mounting portion 24 and the second mounting portion 26. The ball 28 is positioned so that the barrier remains unbroken between the supports 70, 72, 74 and the ball 28 so as to reduce the possibility of contaminants migrating through the interface 60. Therefore, the drape 62 and the interface 60 provide a continuous barrier that hinders the migration of contaminants from the robotic arm R into the sterile area S.

[0071] In one embodiment, the ball 28 has a polished, corrosion-resistant surface that enables sub-micron repeatability in positioning the mounting portions 24, 26 under certain load conditions. The ball 28 may be formed of ceramic, stainless steel, or other suitable materials. The ball 28 may be formed of silicon carbide or tungsten carbide. The ball 28 may be precision machined to very tight tolerances, for example, less than 50 millionths of an inch.

[0072] The interface 60 includes a plurality of electrical terminals. In the illustrated embodiment, the electrical terminals are pins 78 that may be insert molded into the main wall 64. The pins 78 are positioned so that the barrier remains unbroken between the main wall 64 and the pins 78 to reduce the likelihood of contaminants migrating through the interface 60. The pins 78 transmit power / signals across the sterile barrier assembly 22.

[0073] The interface 60 includes a preload element. In the illustrated embodiment, the preload element is an elongated load bar 80. The load bar 80 may be insert molded into one of the supports. The load bar 80 is formed with a rounded recess on its side to facilitate embedding in the support so that the load bar 80 remains fixed to the interface 60 during use. The load bar 80 is positioned so that the barrier remains unbroken between the support and the load bar 80 to reduce the possibility of contaminants migrating through the interface 60. Thus, the drape 62 and the interface 60 provide a continuous barrier to prevent contaminants from migrating from the robotic arm R into the sterile zone S.

[0074] The load bar 80 has a first end and a second end. The load bar 80 can be formed of stainless steel, Kevlar composite, or other suitable rigid material. The load bar 80 defines a hole 82 near each of the ends. An insert 84 is located in the hole 82. The insert 84 is in the form of a cylindrical bushing. The insert 84 is formed of stainless steel or silicon nitride. In some embodiments, the load bar 80 is used without using an insert.

[0075] Reference Figure 9-11 Once the mounting portions 24, 26 are brought together in an approximately final orientation, the preload mechanism 86 clamps the mounting portions in place. In the illustrated embodiment, the load bar 80 forms part of the preload mechanism 86 and also serves as an initial support member to hold the protective cover 58 on the robot arm R. A preload force is applied to the load bar 80. The magnitude of the preload force exceeds the expected loading through the kinematic coupling so that the kinematic coupling and related performance are maintained.

[0076] The preload mechanism 86 also includes a first catch 88. The first catch 88 is slidably disposed in a catch guide 90 so as to move from an unlocked position to a locked position. The catch guide 90 is retained in a first inner cavity 92 (see Figure 4), the first inner cavity is defined in the first body 42. The capture member guide 90 defines an oblong through-passage 94 in which the first capture member 88 slides.

[0077] like Fig.11 As shown in the figure, the first spring 96 biases the first catch 88 laterally into the locked position from the side wall 98 of the first body 42. A first release button (not shown) can be slidably arranged in the first body 42 to release the first catch 88. The first release button can be simply pressed to slide the first catch 88 from the locked position to the unlocked position.

[0078] The load bar receiver 100 defines another oblong passage 102. The oblong passages 94, 102 of the catch guide 90 and the receiver 100 are aligned with each other so that the first catch 88 can slide therein to move from the unlocked position to the locked position. The receiver 100 is cylindrical. The receiver 100 also defines a load bar slot 104 therethrough. The load bar slot 104 is arranged perpendicular to the oblong passage 102 in the receiver 100 so as to receive the first end of the load bar 80.

[0079] During use, the first end of the load bar 80 is inserted into the load bar slot 104 until one of the holes 82 in the load bar 80 is engaged by the first catch 88 (see FIG. Figure 4 and 9 Once the load bar 80 is fully engaged by the first catch 88, the sterile barrier assembly 22 is substantially supported on the first mounting portion 24 for further manipulation. Thus, the load bar 80 and the first catch 88 serve as an initial support mechanism for the sterile barrier assembly 22.

[0080] Reference Fig. 9 and 12 -15, the preloading mechanism 86 further includes a second capture member 106. The second capture member 106 is slidably disposed in the second body 46. More specifically, the second mounting portion 26 defines a second inner cavity 108, in which the second capture member 106 can slide between an unlocked position and a locked position.

[0081] The second spring 110 biases the second catch 106 laterally into the locked position from the side wall 112 of the second body 46. Like the first release button, the second release button 114 can be slidably disposed in the second body 46 to release the second lock 106. The second release button 114 can be simply pressed to move the second catch 106 from the locked position to the unlocked position.

[0082] The second cover plate 48 fixed to the second body 46 has an elongated slot 116 (see Figure 6), the elongated slot being appropriately sized to receive the second end of the load bar 80, the second end being opposite to the first end inserted into the receiving member 100.

[0083] During use, the second end of the load bar 80 is inserted into the elongated slot 116 until the other hole 82 in the load bar 80 is engaged by the second catch 106. Once the load bar 80 is fully engaged by the second catch 106, the sterile barrier assembly 22 and the second mounting portion 26 are generally supported on the first mounting portion 24 for further installation. Thus, the load bar 80, the first catch 88 and the second catch 106 also serve as a support mechanism for the sterile barrier assembly 22 and the second mounting portion 26.

[0084] like Fig. 9 , the preload mechanism further includes a tensioner 118 operably coupled to the load bar 80. The tensioner 118 applies a tensioning force to the load bar 80 and clamps the first mounting portion 24 and the second mounting portion 26 together using the preload force so that the ball 28 is seated in the first plurality of receiving portions 30, 32, 34 and the second plurality of receiving portions 36, 38, 40.

[0085] Reference Fig.12 and 13 , the tensioner 118 applies a tensioning force to the load bar 80 by moving the second catch 106 relative to the first catch 88. The second catch 106 is pivotally supported in the second body 46 about a pivot 120 while being able to slide between an unlocked position and a locked position in the second body 46. The pivot 120 is located in a pair of support holes 122, 124 in the second body 46. The second catch 106 defines a pivot hole 126 therethrough (see Fig.14 ), in order to receive the pivot 120. As a result, the second capture member 106 can pivot around the pivot 120.

[0086] The tensioner 118 includes a camshaft 128. The camshaft 128 is rotatable between a tensioned position and a relaxed position. The camshaft 128 is rotatably supported in a pair of support holes 130, 132 in the second body 46. The camshaft 128 has a first cylindrical shaft section 134 and a second cylindrical shaft section 136, which are rotatably supported in the support holes 130, 132 by a bushing 138.

[0087] The camshaft 128 includes a cam segment 140 located between the first shaft segment 134 and the second shaft segment 136 (see Fig. 9 and 15The cam segment 140 is offset relative to the first shaft segment 134 and the second shaft segment 136. The cam segment 140 is disposed in a cam channel 142 defined in the second capture member 106 (see Fig.14 ). The cam channel 142 is rectangular and extends through the second capture member 106 near one end of the second capture member 106, while the pivot hole 126 extends through the second capture member 106 near the opposite end. When the cam shaft 128 begins to rotate toward the tensioning position, the cam segment 140 contacts the inner surface 144 that defines the cam channel 142. Further rotation of the cam shaft 128 causes the cam segment 140 to abut against the inner surface 144 for additional camming action, which causes the second capture member 106 to pivot about the pivot 120 so that a tensioning force is applied to the load bar 80.

[0088] The tensioner 118 also includes an operating lever 146 that is rotatably fixed to the cam shaft 128 via an operating lever attachment 148. The operating lever attachment 148 has a geometry that conforms to the shape of a cavity (not shown) in the operating lever 146, so that actuation of the operating lever 146 causes rotation of the cam shaft 128. The cam shaft 128 rotates at least ninety degrees to move between a relaxed position and a tensioned position. Of course, other positions between the relaxed position and the tensioned position can apply a tensioning force on the load bar 80 and can be adapted to apply a desired preload force.

[0089] When the cam shaft 128 is positioned in a desired position (e.g., a tensioning position), the operating lever 146 is locked. In the tensioning position, a preload tensioning force is applied to the load bar 80. By locking the operating lever 146 after the preload force is applied, the preload force is continuously applied during use of the robot arm R and the end effector EE so as to maintain the kinematic connection. The preload mechanism 86 transmits the preload force across the sterile barrier assembly 22 without piercing the barrier.

[0090] When the tensioner 118 applies a preload force to the load bar 80, the coil spring 150 applies a compressive force equal to the preload force to the load bar 80. The coil spring 150 is housed between two spring washers 152. The coil spring 150 biases the catch guide 90, the receiver 100, and the first catch 88 toward the rear wall 154 of the first body 42. The coil spring 150 biases the load bar 80 by virtue of the load bar 80 being locked to the first catch 88.

[0091] When the balls 28 are aligned within the first plurality of receiving portions 30, 32, 34 and the second plurality of receiving portions 36, 38, 40 and a preload force is applied, the interface 60 is capable of a certain degree of stretching and / or bending between the balls 28 so that the balls 28 are properly seated in the receiving portions 30, 32, 34, 36, 38, 40, particularly when the second plurality of receiving portions 36, 38, 40 have a conical configuration (which engages each of the balls 28 at three contact points). This stretching and / or bending occurs without destroying the barrier. Therefore, the balls 28 are able to move into the receiving portions 30, 32, 34, 36, 38, 40 when preloaded. These properties of the interface 60 allow for manufacturing tolerances. In other words, the interface 60 is able to stretch and / or bend without destroying the contact or seal with the balls 28, such as the contact or seal formed during molding.

[0092] Once in place, the position of the ball 28 is fixed relative to the first plurality of receiving portions 30, 32, 34 and the second plurality of receiving portions 36, 38, 40. As a result, the first mounting portion 24 and the second mounting portion 26 are kinematically coupled together without piercing the sterile barrier assembly 22. The kinematic coupling allows the end effector EE to be easily released from the robot arm R and attached to the robot arm R again at the same position. The kinematic coupling also allows the end effector EE to be easily released from the robot arm R, so that a different end effector having a similar mounting portion can be kinematically coupled to the robot arm R.

[0093] Fig.16 Shown are power and / or other signal connections that can be made through the sterile barrier assembly 22. These connections employ pins 78. These pins 78 electrically interconnect the electrical connectors attached to the first mounting portion 24 and the second mounting portion 26.

[0094] exist Figure 5 , 6 In the embodiment of the present invention, the first mounting portion 24 includes a first electrical connector base 156. The first electrical connector base 156 is fixed in a communication cavity 158 defined in the first body 42. The first cover plate 44 defines an opening 160 into the communication cavity 158. A wire channel 162 is also defined in the first body 42 to carry wires that exit the first electrical connector base 156. A plurality of probe-type connectors 164 (e.g., spring-loaded electrical connectors) are movably supported by the first electrical connector base 156.

[0095] The second mounting portion 26 includes a second electrical connector base 166. The second electrical connector base 166 is fixed in an opening 168 in the second cover plate 48. A plurality of electrical receiver terminals 170 are supported by the second electrical connector base 166. When the first mounting portion 24 and the second mounting portion 26 are kinematically coupled together and preloaded, the electrical receiver terminals 170 receive the pins 78 of the interface 60. Likewise, the probe connector 164 contacts the pins 78 of the interface 60 so that power or other electrical signals can flow through the pins 78. Thus, power, communication signals, or other signals can reach the end effector EE from the robot arm R and vice versa.

[0096] Reference Figure 17-32 , shows an alternative mounting system 220 that uses a sterile barrier assembly 222 to kinematically couple a first surgical component and a second surgical component (eg, a robotic arm R and an end effector EE).

[0097] In this embodiment, the robotic arm R includes a first mounting portion 224 and the end effector EE includes a second mounting portion 226. A sterile barrier assembly 222 is located between the first mounting portion 224 and the second mounting portion 226 to establish a barrier between the robotic arm R and the end effector EE during surgery.

[0098] Reference Fig.18 and 19 , a first mounting portion 224 and a second mounting portion 226 are kinematically coupled using a plurality of kinematic couplings. In this embodiment, the kinematic coupling is a spherical ball 228. The ball 228 is located in the first plurality of receiving portions 230, 232, 234 and the second plurality of receiving portions 236, 238, 240. The receiving portions 230, 232, 234, 236, 238, 240 are appropriately sized and shaped to receive the ball 228. The first mounting portion 224 includes a first body 242 and a first cover plate 248 fixed to the first body 242. The first plurality of receiving portions 230, 232, 234 are fixed in the first body 242. The second mounting portion 226 includes a second body 246. The second plurality of receiving portions 236, 238, 240 are fixed in the second body 246.

[0099] Reference Fig. 20, the first plurality of receiving portions 230, 232, 234 includes one receiving portion 230 having a contact surface 250 having a conical configuration (also referred to as a conical receiving portion). Another receiving portion 232 has a pair of contact surfaces 252 provided by a V-shaped groove (also referred to as a V-groove receiving portion). Another receiving portion 234 has a contact surface 254 including a flat portion (also referred to as a planar receiving portion). The contact surface 252 of the V-groove receiving portion or the contact surface 254 of the planar receiving portion can be generally flat, or can be concave, wherein the concavity of the surface 252, 254 causes only a single point to contact the ball 228. In some variations, the contact surface 252 of the V-groove receiving portion is in the shape of a Gothic arch.

[0100] The second plurality of receivers 236, 238, 240 includes three receivers having contact surfaces 256 having a conical configuration (i.e., conical receivers). The three balls 228 are trapped between corresponding aligned pairs of receivers, i.e., receivers 230 and 236, receivers 232 and 238, and receivers 234 and 240, as shown in FIG. Fig. 20 and 21 as shown in .

[0101] The receiving portions 230, 232, 234, 236, 238, 240 may be formed of steel or other suitably rigid material and may be separate components rigidly connected to the body 243, 246, or may be integral with the body 242, 246. The receiving portions 230, 232, 234, 236, 238, 240 may be integrated into the mounting portions 224, 226, or may be attached to the mounting portions 224, 226 in a variety of ways.

[0102] When the mounting portions 224, 226 are brought together in an approximate final orientation (wherein the sterile barrier assembly 222 is positioned between the mounting portions), the ball 228 of the sterile barrier assembly 222 seats itself into the receiving portions 230, 232, 234, 236, 238, 240. The conical receiving portion, the V-groove receiving portion, and the planar receiving portion of the first mounting portion 224 remove three degrees of freedom, two degrees of freedom, and one degree of freedom, respectively. Thus, exactly six degrees of freedom are constrained. In other embodiments, as further described below, each of the first plurality of receiving portions 230, 232, 234 of the first mounting portion 224 can remove two degrees of freedom via two points of contact with the ball 228. In any of these cases, exactly six degrees of freedom are constrained via exactly six points of contact (e.g., one point of contact for each degree of freedom).

[0103] Reference Figure 22-26, the sterile barrier assembly 222 includes a protective cover 258. The protective cover 258 includes an interface 260 and a drape 262 attached to the interface 60. The drape 262 has an inner surface and an outer surface. The inner surface is placed adjacent to the robotic arm R during surgery. In this embodiment, the drape 262 is assembled to the robotic arm R so as to encapsulate the robotic arm R as a whole. The drape 262 is formed of at least one of polyethylene, polypropylene, and polycarbonate. The drape 262 can be attached to the interface 260 by ultrasonic welding, tape, adhesive, etc. The drape 262 is attached to the interface 260 so that there are no perforations or a seal is made, that is, the drape forms a continuous barrier continuous with the interface 260. In Figure 17-19 The curtain 62 is not shown in Figures 24-27 in order to better illustrate other components.

[0104] Reference Fig.25 and 26 In the illustrated embodiment, the interface 260 includes a locking member bracket 263 formed of a rigid material, such as aluminum or stainless steel. The locking member bracket 263 includes a main wall 264 (see Fig.26 ), the main wall having an outer periphery and an inner wall 266, the inner wall extending from the main wall 264. The inner wall 266 can be substantially perpendicular to the main wall 264. The locking member bracket 263 includes a pair of locking members 265 (see also Fig.23 ), the pair of locking members extend from the main wall 264 in a direction opposite to the inner wall 266. The locking member 265 can be in the form of a locking hook. The locking member 265 interacts with and engages with the first locking member 288 of the first mounting portion 224, as described below.

[0105] The interface 260 also includes a cover 269 having an outer peripheral edge 271. The cover 269 can be formed of injection molded plastic. The outer peripheral edge 271 snap fits on the main wall 264 so that the cover 269 is fixed to the locking member bracket 263. When fixed, the cover 269 includes an outer wall 273, which surrounds the inner wall 266 of the locking member bracket 263. The cover 269 also includes a wall 275. The wall 275 extends from the base of the outer wall 273 to the outer peripheral edge 271. In addition to the snap-fit ​​connection, the cover 269 can be fixed to the locking member bracket 263 by an adhesive between the wall 275 and the main wall 264 of the locking member bracket 263. A seal (not shown) can be located between the edge of the main wall 264 and the inner edge of the outer peripheral edge 271 to further enhance the barrier.

[0106] The peripheral edge 271 defines an attachment slot 277 in which the drape 262 is attached to the interface 260. The attachment slot 277 may receive, for example, an elastic band of the drape 262, a strap for the drape 262, a snap ring of the drape 262, or the like.

[0107] The interface 260 includes a ball 228 integrated therein. In this embodiment, the ball 228 is located in a ball opening defined in the main wall 264 of the locking member bracket 263. The ball openings are appropriately sized so that a portion of each of the balls 228 protrudes on either side of the main wall 264. The main wall 264 includes a stop 279 in each of the ball openings. In the illustrated embodiment, the stop 279 is a radially inwardly directed tapered surface of the main wall 264. The tapered surface defines an opening having a diameter slightly smaller than the diameter of the ball 228 to prevent the ball 228 from completely passing through the main wall 264 (see Fig.18 ).

[0108] During assembly, the ball 228 is dropped into the ball opening in the main wall 264. The stop 279 prevents the ball 228 from passing completely through the ball opening while still allowing a portion of the ball 228 to protrude beyond the main wall 264. The cover 269 is then snap-fitted onto the latch bracket 263 to hold the ball 228 in place in the ball opening. The wall 275 of the cover 269 defines a plurality of auxiliary ball openings 267 that are co-linear with the ball opening in the main wall 264 but are sized slightly smaller than the diameter of the ball 228. As a result, the ball 228 is able to protrude beyond the wall 275 but remain located between the wall 275 and the main wall 264.

[0109] The main wall 264 has a plurality of countersunk holes 284 that further define ball openings. The diameter of the countersunk holes 284 is slightly larger than the diameter of each of the balls 228 so that the balls 228 can be seated in the ball openings. The countersunk holes 284 are also appropriately sized so that seals 281 (e.g., O-rings) can be seated in the countersunk holes 284 to seal around the balls 228 and relative to the main wall 264. As shown, two seals 281 are located in each of the countersunk holes 284 (see also FIG. 2 ). Fig.18 ). The seal 281 is held in place by virtue of the wall 275 being positioned on the seal 281. The wall 275 engages one of each pair of seals 28 to further enhance the barrier.

[0110] The seal 281 is resilient so that the ball 228 can move slightly laterally in the ball opening, e.g., the lateral movement of the ball 228 in the ball opening is not constrained. As a result, the distance between the balls 228 can be adjusted (e.g., increased or decreased) so that the balls 228 are properly seated in the receiving portions 230, 232, 234, 236, 238, 240, especially in the case where each of the second plurality of receiving portions 236, 238, 240 has a conical configuration and the conical configurations are rigidly fixed in position relative to each other. Due to the ability of the ball 228 to adjust laterally, the ball 228 can be properly fitted into the conical receiving portion so that three points are in contact with the ball 228.

[0111] As described above, the ball 228 is arranged to be received in the first receiving portion 230, 232, 234 and the second plurality of receiving portions 236, 238, 240 to kinematically couple the first mounting portion 224 and the second mounting portion 226. The ball 228 is positioned so that the barrier remains unbroken between the main wall 264 and the ball 228 to reduce the possibility of contaminants migrating through the interface 260. Thus, the drape 262 and the interface 260 provide a continuous barrier that prevents contaminants from migrating from the robotic arm R into the sterile zone S.

[0112] In this embodiment, the ball 228 has a polished, corrosion-resistant surface that enables sub-micron repeatability in positioning the mounting portions 224, 226 under certain load conditions. The ball 228 can be formed of ceramic, stainless steel, or other suitable materials. The ball 228 can be formed of silicon carbide or tungsten carbide. The ball 228 can be precision machined to very tight tolerances, for example, less than 50 millionths of an inch.

[0113] like Fig.24 , the interface 260 includes a plurality of electrical terminals embedded in a cover 269. In this embodiment, the electrical terminals are pins 278 that can be insert molded into the cover 269 of the interface 260. The pins 278 are located in the connector portion 274 of the cover 269. The connector portion 274 partially passes through the hole 276 of the locking member bracket 263. The connector portion 274 can be press-fit into the hole 276 to reduce the possibility of contaminants migrating through the interface 260. A peripheral seal (not shown) can also be present to seal in the hole 276 relative to the connector portion 274 and the main wall 264 to further reduce the possibility of contaminants migrating through the interface 260. The pins 278 transmit power / signals across the sterile barrier assembly 222.

[0114] Reference Figure 18-20 , the first mounting portion 224 includes a first capture member 288. In this embodiment, the first capture member 288 is a sliding capture plate. The first capture member 288 defines a pair of spaced apart holes 289 ( Fig. 20 ). The first catch piece 288 is slidably disposed in the first body 242. The first body 242 includes a front wall 285. The cover plate 293 is mounted to the front wall 285 to define a catch piece guide recess 287. The first catch piece 288 slides in the catch piece guide recess 287.

[0115] One or more compression springs 291 bias the first catch 288 upward so that the upper edge of the first catch 288 contacts the downward facing edge of the front wall 285 defining the catch guide recess 287. The compression spring 291 acts between the lower edge of the first catch 288 and the upward facing opposite edge of the front wall 285 defining the catch guide recess 287.

[0116] The front wall 285 also defines a latch hole 295 through which the latch 286 can engage the first catch 288. In a normal state, the hole 289 is only partially aligned with the latch hole 295. Fig. 20 Also, a sufficiently large portion of the hole 289 is exposed through the locking member hole 295 so that the locking member 265 engages the first capture member 288 .

[0117] Each of the locking members 265 has a head 297 that tapers toward the front surface and is appropriately sized to fit in the exposed portion of the hole 289. As the front surface of each head 297 moves into and through the exposed portion of the hole 289, the tapered surface of the head 297 cams downward against the bias of the compression spring 291.

[0118] The first catch 288 is moved until the head 297 is completely moved through the hole 289. Once the head 297 has completely passed through the hole 289, the first catch 288 slides upward under the bias of the compression spring 291 into the latch recess 299 defined by each of the heads 297. This holds the latch bracket 263 and, in turn, the entire sterile barrier assembly 222 to the first body 242.

[0119] This locking / capturing arrangement allows the interface 260 to engage the first body 242 without requiring any tilting therebetween. In other words, the interface 260 can be pressed into engagement with the first body 242 by merely translating or linearly moving the interface 260. This also facilitates the engagement of the pins 278 into the corresponding electrical connectors 251, 257 on the first and second bodies 242, 246. It should be understood that the locking member 265 and the first capturing member 288 can be reversed or the locking member 265 and the first capturing member 288 can be referred to as the capturing member 265 and the first locking member 288.

[0120] The actuator 301 is used to release the locking member bracket 263 from the first body. The actuator 301 is fixed to the first catch 288. In this embodiment, the actuator 301 is U-shaped and can be actuated by pressing the actuator 301 downward to move the first catch 288 downward against the bias of the compression spring 291, so that the head 297 of the locking member 265 can be pulled back through the hole 289 and the locking member hole 295.

[0121] Reference Fig.19 , with the interface 260 supported by the first body 242, the second body 246 is ready to engage the interface 260. The locking member hole 283 is positioned to easily engage the second capture member 306 (or can be referred to as the capture hook 283 and the second locking member 306) fixed to the second body 246. The locking hook 283 is pivotally supported by the locking member bracket 263. The torsion spring ( Fig.26 (not shown) biases the locking hook 283 into engagement with the second capture member 306.

[0122] The second catch 306 is a D-shaped rod that is fixed to the second body 246 and is shaped to engage the locking hook 283. The second body 246 is simply pressed onto the interface 260 until the locking hook 283 engages the second catch 306. More specifically, as the second body 246 is pressed onto the interface 260, the second catch 306 presses against the tapered surface of the locking hook 283, thereby pushing the locking hook 283 to pivot upward against the bias of the torsion spring until the recess in the locking hook 283 is aligned with the second catch 306, at which point the torsion spring pushes the locking hook 283 onto the second catch 306, as shown in FIG. Fig.19 . Now, the mounting system 220 is ready to be preloaded and ready for use. In this state, the mounting system 220 acts as a support mechanism to support the end effector EE on the robot arm R before preloading.

[0123] Reference Figure 25-27 Once the mounting portions 224, 226 are brought together in an approximately final orientation, a preload mechanism 286 clamps the mounting portions together in place. A preload element is located in the interface 260. In this embodiment, the preload element is an elongated load member 280. The load member 280 is movably supported in the interface 260. The load member 280 has a first end and a second end. The load member 280 can be formed of stainless steel, Kevlar composite, or other suitable rigid material. The load member 280 defines a hole 282 located near one end and a locking hook 283 adjacent to the opposite end.

[0124] A preload force is applied to the load member 280. The magnitude of the preload force exceeds the expected loading through the kinematic connection so that the kinematic connection and associated performance is maintained.

[0125] The load member 280 is movably supported by the latch bracket 263. In particular, the load member 280 is movable from an unloading position to a loading position relative to the latch bracket 263. In the unloading position, the locking hook 283 is positioned to engage the second catch 306. In the loading position, the load member 280 is urged toward the latch bracket 263 in order to load the mounting system 220.

[0126] The preload mechanism 286 also includes a tensioner 318 ( Fig.26 ) and a spring cup 305, which is coupled to a tensioner 318. The tensioner 318 includes a cam shaft 328, which fits inside a pair of concentric inner and outer tubes 307, 309. The tubes 307, 309 are hollow and cylindrical. The tubes 307, 309 are fixed to prevent translation relative to the spring cup 305, so that as the tubes 307, 309 move in translation, the spring cup 305 also moves in translation.

[0127] The spring cup 305 defines a first cup opening 311 ( Fig.25 ), the first cup opening is appropriately sized to receive the outer tube 309. Opposite the first cup opening 311, the spring cup 305 defines a spring cup counterbore 315 ( Fig.25 ), the spring cup counterbore being appropriately sized to receive the outer tube 309. The outer tube 309 may be press fit into the first cup opening 311 and the spring cup counterbore 315 so that the outer tube 309 cannot rotate relative to the spring cup 305, or the outer tube 309 may be allowed to rotate therein but secured against translational movement relative to the spring cup 305. The outer tube 309 passes through the hole 282 in the load member 280.

[0128] The locking hook 283 protrudes beyond the central opening in the spring cup 305. The locking hook 283 also protrudes beyond the central opening in the top of the outer wall 273 so as to reach the second catch 306 of the second body 246. The size of the spring cup 305 is such that the spring cup 305 cannot pass through the central opening in the top of the outer wall 273. The spring cup 305 and the outer wall 273 have chamfered surfaces that are configured to be spaced apart from each other in an unloaded state when the locking hook 283 is released, as further described below.

[0129] The cam shaft 328 is supported for rotation by the inner wall 266 of the locking member bracket 263. The inner wall 266 defines a pair of through holes 301 ( Fig.26). A pair of bushings 338 are press-fitted into the through hole 301 and rotatably support the outer cylindrical section 334 of the cam shaft 328. As a result, the cam shaft 328 can rotate between a tensioned position and a relaxed position relative to the lock bracket 263. The cam shaft 328 includes a pair of cam sections 340 separated by an intermediate cylindrical section 336. The cam sections 340 have an outer diameter that is slightly smaller than the inner diameter of the inner tube 307. The diameter of the cylindrical section 336 of the cam shaft 328 is smaller than the diameter of the cam sections 340, thereby generating a cam action as the cam shaft 328 rotates.

[0130] The inner tube 307 and the outer tube 309 each have a length that is less than the length spanned by the opposing portions of the inner wall 266 between the through holes 301. As a result, the inner tube 307 and the outer tube 309 are able to move in translation relative to the inner wall 266. As the cam shaft 328 rotates, the inner tube 307 and the outer tube 309 move toward and away from the main wall 264 under the cam action of the cam shaft 328. This movement provides the preload required to load the load member 280 after the locking hook 283 has engaged the second catch 306.

[0131] The tensioner 318 also includes an operating rod 346 that is rotatably fixed to the cam shaft 328. The operating rod 346 includes a sleeve 348 having a D-shaped hole to receive the D-shaped portion of the cam shaft 328 so that the cam shaft 328 rotates as the operating rod 346 rotates. A fastener (not labeled) engages the threaded end of the cam shaft 328 to secure the operating rod 346 to the cam shaft 328. The cam shaft 328 rotates at least ninety degrees to move between an unloaded position and a loaded position. Of course, other positions therebetween can apply tensioning force to the load member 280 and can be adapted to apply a desired preload force.

[0132] The operating lever 346 can be locked when the cam shaft 328 is positioned in a desired position (e.g., a loading position). In the loading position, a preload tensioning force is applied to the load member 280. By locking the operating lever 346 after the preload force is applied, the preload force is continuously applied during use of the robot arm R and the end effector EE to maintain the kinematic connection. The preload mechanism 286 transmits the preload force across the sterile barrier assembly 222 without piercing the barrier.

[0133] The tensioner 318 applies a preload force to the load member 280 via a conical disc spring 350 (e.g., a disk spring). The disc spring 350 applies a force equal to the preload force to the load member 280. The disc spring 350 acts between the spring cup 305 and the shoulder 317 of the load member 280. In particular, as the operating lever 346 rotates, the cam shaft 328 rotates and the cam segment 340 causes the inner tube 307 and the outer tube 309 and, in turn, the spring cup 305 to move away from the locking hook 283 (now engaging the second catch 306). The inner tube 307 and the outer tube 309 are also able to move relative to the load member 280 by moving within the hole 282, which is elongated to accommodate such movement. The movement of the spring cup 305 relative to the load member 280 compresses the disc spring 350 and applies a preload force to the load member 280 via the shoulder 317.

[0134] Because the ball 228 is aligned with the first plurality of receiving portions 230, 232, 234 and the second plurality of receiving portions 236, 238, 240, once the preload force is applied, the ball 228 is seated in the receiving portions 230, 232, 234, 236, 238, 240. Once in place, the position of the ball 228 is fixed and the positions of the first plurality of receiving portions 230, 232, 234 and the second plurality of receiving portions 236, 238, 240 are fixed relative to each other. As a result, the first mounting portion 224 and the second mounting portion 226 are kinematically coupled together without piercing the sterile barrier assembly 222.

[0135] The release of the locking hook 283 is facilitated by pushing the locking hook 283 upward away from the second catch 306. This is achieved by further rotating the operating lever 346 counterclockwise when in the unloaded position. This movement causes the cam shaft 328 to interact with the second cup opening 313 defined in the spring cup 305 so as to pivot the spring cup 305 and the locking hook 283 to release the locking hook 283 from the second catch 306.

[0136] The second cup opening 313 is smaller than the outer tube 309, but is large enough to accommodate the eccentric portion 325 of the camshaft 328. The second cup opening 313 has a Fig.26A and is appropriately sized so that in the unloaded position, the eccentric portion 325 rests on Fig.26A From this position, when the eccentric portion 325 is further rotated counterclockwise via the operating rod 346, the eccentric portion 325 engages the spring cup 305 in a manner that causes the spring cup 305 to pivot. More specifically, because the eccentric portion 325 is constrained from further counterclockwise rotation (eg, Fig.26A), so further counterclockwise movement of the operating rod 346 causes the spring cup 305 to pivot relative to the outer wall 273, and thereby causes the locking hook 283 to move upward away from the second capture member 306. In the loaded position, the eccentric portion 325 rests on the Fig.26A The dotted line in the figure shows the position.

[0137] Fig.19 Shown are power and / or other signal connections that can pass through the sterile barrier assembly 222. These connections employ pins 278 embedded in the interface 260. These pins 278 electrically interconnect the electrical connectors 251, 257 attached to the first mounting portion 224 and the second mounting portion 226.

[0138] In this embodiment, the first mounting portion 224 includes a first electrical connector 251. The first electrical connector 251 is capable of floating relative to the first body 242. The second mounting portion 226 includes a second electrical connector 257. The second electrical connector 257 also floats relative to the second body 246. When the first mounting portion 224 and the second mounting portion 226 are kinematically coupled together and preloaded, the electrical connectors 251, 257 receive pins 278 so that power or other electrical signals can flow through the pins 278. Therefore, power, communication signals or other signals can reach the end effector EE from the robot arm R and vice versa.

[0139] Fig.32 The following steps are shown: first, attaching the sterile barrier assembly 222 to the first mounting portion 224 (which is fixed to the robot arm R); then, attaching the second mounting portion 226 (shown as a dotted line integrated into the end effector EE) to the sterile barrier assembly 222; and subsequently pivoting the operating lever 346 downward so as to load the mounting system 220 and apply the preload force required to maintain the positioning between the first mounting portion 224 and the second mounting portion 226.

[0140] Reference Figure 33-47B , shows another alternative mounting system that uses a sterile barrier assembly 422 to kinematically couple a first surgical component and a second surgical component (eg, a robotic arm R and an end effector EE).

[0141] Reference Figure 33-36 A plurality of kinematic couplings similar to the plurality of kinematic couplings in the previous embodiment are used to kinematically couple the end effector EE to the robot arm R. In this embodiment, the kinematic coupling is a spherical ball 428. The ball 428 is located in the first plurality of receiving portions 432 and the second plurality of receiving portions 438 ( Fig.364. The receiving portions 432, 438 are appropriately sized and shaped to receive the ball 428, as previously described. The first plurality of receiving portions 432 are fixed to the first mounting portion 424 of the robot arm R and the second plurality of receiving portions 438 are fixed to the second mounting portion 426 of the end effector EE.

[0142] The first plurality of receiving parts 432 includes three receiving parts (in Fig.36 Each of the first plurality of receiving portions 432 has a pair of contact surfaces 452 provided by a V-shaped groove or a Gothic arch (also referred to as a V-groove receiving portion). The second plurality of receiving portions 438 includes three receiving portions (in Fig.36 Only one is shown in FIG. 1 .) Each of the second plurality of receiving portions has a contact surface 456 having a conical configuration (ie, a conical receiving portion). Three balls 428 are trapped between corresponding aligned pairs of receiving portions 432 , 438 .

[0143] When the mounting portion 424 of the robot arm R and the mounting portion 426 of the end effector EE are brought together in an approximate final orientation, with the sterile barrier assembly 422 positioned between the mounting portions, the ball 428 of the sterile barrier assembly 422 seats itself into the receiving portions 432, 438 so that exactly six degrees of freedom are constrained, as described in the previous embodiment.

[0144] The sterile barrier assembly 422 includes a protective cover 458. The protective cover 458 includes an interface 460 and a drape 462 attached to the interface 460. The drape 462 has an inner surface and an outer surface. The inner surface is placed adjacent to the robot arm R during surgery. The drape 462 is formed of at least one of polyethylene, polypropylene, polycarbonate or other suitable materials. The drape 462 can be directly attached to the interface 460 by ultrasonic welding, tape, adhesive, etc.

[0145] In the illustrated embodiment, the drape 462 includes a ring 468 that engages the interface 460. The ring 468 defines an opening. In the illustrated embodiment, the ring 468 is a snap ring. The loose portion of the drape 462 is attached to the snap ring 468 by ultrasonic welding, a tape, an adhesive, etc., so as to surround the opening. When the robot arm R is draped with the drape, the snap ring 468 (to which the loose portion is attached) is first snap-fitted to the interface 460 before the interface 460 is mounted to the first mounting portion 424 of the robot arm R. The interface 460 is assembled into the opening in the snap ring 468. Once the snap ring 468 is snap-fitted to the interface 460, the interface 460 is mounted to the first mounting portion 424 of the robot arm R. The drape 462 is attached to the interface 460 so that there are no perforations or a seal is made, that is, the drape 462 forms a continuous barrier connected to the interface 460 through the snap ring 468 or other similar attachment mechanism. The drape 462 is not shown in several of the figures in order to better illustrate other components.

[0146] Reference Fig.36 and 37 In the illustrated embodiment, the interface 460 includes a back plate assembly 459 that is secured to a cover 469. The back plate assembly 459 is formed of two separate components: a back ring plate 461 that is mounted to the cover 469 by fasteners; and a back cover plate 467 that is captured between the back ring plate 461 and the cover 469.

[0147] Reference Fig.38 and 39 The interface 460 also includes a latch assembly 463. The latch assembly 463 includes a latch bracket 464 having spaced apart inner walls 466. A pair of latches 465 are retained within a travel channel defined in the latch bracket 464 by the spaced apart inner walls 466.

[0148] The back cover plate 467 is fixed to the locking member bracket 464 (e.g., via fasteners) and is spaced apart from the locking member bracket 464 to further define a travel channel for the locking members 465. Each of the locking members 465 is captured in the travel channel. A pair of biasing members B (e.g., springs) bias the locking members 465 toward each other. The biasing members B act between the inner wall 466 and the locking members 465. In this embodiment, the locking members 465 are in the form of a locking plate with an arcuate recess (see Fig.46 ) in order to engage the first capture member 488 of the first mounting portion 424, as described below.

[0149] The cover 469 has an outer peripheral edge 471. The cover 469 can be formed of injection molded plastic or metal. The outer peripheral edge 471 is fixed around the back plate assembly 459. The cover 469 includes an outer wall 473 and a wall 475. The wall 475 extends from the base of the outer wall 473 to the outer peripheral edge 471. A seal (not shown) can be located between the cover 469 and the back plate assembly 459 to further enhance the barrier.

[0150] The interface 460 includes a ball 428 integrated therein. In this embodiment, the ball 428 is located in a ball opening defined in the cover 469 and the back ring plate 461. The ball opening is appropriately sized so that a portion of each of the balls 428 protrudes from the wall 475 of the back ring plate 461 and the cover 469 to engage the receiving portions 432, 438. The seal, which is X-shaped in cross section, retains the ball 428 in the ball opening and provides a sterile barrier around the ball 428, while at the same time still allowing the ball 428 to move laterally within the ball opening.

[0151] As described above, the ball 428 is arranged to be received in the receiving portion 432, 438 to kinematically couple the mounting portions 424, 426. The ball 428 is positioned so that the barrier remains unbroken between the back ring plate 461 and the ball 428 to reduce the possibility of contaminants migrating through the interface 460. Thus, the drape 462 and the interface 460 provide a continuous barrier to prevent contaminants from migrating from the robotic arm R into the sterile zone S.

[0152] In this embodiment, the ball 428 has a polished, corrosion-resistant surface that enables sub-micron repeatability in positioning the mounting portions 424, 426 under certain load conditions. The ball 428 can be formed of ceramic, stainless steel, or other suitable materials. The ball 428 can be formed of silicon carbide or tungsten carbide. The ball 428 can be precision machined to very tight tolerances, for example, less than 50 millionths of an inch.

[0153] The first mounting portion 424 includes a first capture member 488. In this embodiment, the first capture member 488 is a capture post having a head 497 and a slot 498, the slot being located proximal to the head 497. The locking member 465 engages the first capture member 488 in the slot 498. The back cover plate 467 defines a locking member hole 495 through which the head 497 can engage the locking member 465. The head 497 is tapered to engage the locking member 465. More specifically, the head 497 is tapered to separate the locking members 465 from their normal position (see Fig.38). As the head 497 moves between the locking members 465, the tapered surface of the head 497 causes the locking members 465 to separate against the bias of the biasing member B until the head 497 moves completely over the locking members 465. Once the head 497 passes over the locking members 465, the locking members 465 slide into the groove 498 to retain the sterile barrier assembly 422 to the first mounting portion 424. Fig.38 and 39 The gradual engagement of the first pair of locking members 465 with the first capture member 488 is shown in FIG.

[0154] This locking member / capturing member arrangement allows the interface 460 to engage the first mounting portion 424 without requiring any tilting therebetween. In other words, the interface 460 can be pressed into engagement with the first mounting portion 424 by only longitudinal or linear movement of the interface 460.

[0155] Reference Fig.40 and 41 , with the interface 460 supported by the first mounting portion 424, the end effector EE is now able to engage the interface 460. A second capture member 483, similar in shape to the first capture member 488, is positioned to facilitate engagement with a second pair of locking members 506, which is secured to the second mounting portion 426. The operation and function of the second capture member 483 and the second pair of locking members 506 are similar to those of the first capture member 488 and the first pair of locking members 465 and will not be described in detail, but will be described in detail ... Fig.40 and 41 The second mounting portion 426 attached to the end effector EE is simply pressed onto the interface 460 until the second capture member 483 engages the second pair of locking members 506, as shown in FIG. Fig.41 . Now, the mounting system is ready to be preloaded and ready for use. In this state, the mounting system acts as a support mechanism to support the end effector EE on the robot arm R before preloading.

[0156] Reference Fig.36 and 42 -45, once the mounting portions 424, 426 are brought together in an approximately final orientation, a preload mechanism 486 clamps the mounting portions together in place. A preload element is located in the interface 460. In this embodiment, the preload element is an elongated load member 480. The load member 480 is movably supported in the interface 460. The load member 480 has a first end and a second end. The load member 480 can be formed of stainless steel, Kevlar composite, or other suitable rigid material. The load member 480 includes a flange 482 located near one end and a second capture member 483 adjacent to the opposite end.

[0157] A preload force is applied to the load member 480. The magnitude of the preload force exceeds the expected loading through the kinematic connection so that the kinematic connection and associated performance is maintained.

[0158] The load member 480 is movably captured between the cover 469 and the back plate assembly 459. In particular, the load member 480 is movable from an unloaded position to a loaded position relative to the cover 469 and the back plate assembly 459. In the unloaded position, the second catch 483 is engageable with the second pair of latches 506. In the loaded position, the load member 480 is urged toward the back plate assembly 459 to load the mounting system.

[0159] The guide block 455 interconnects the cover plate 453 and the latch bracket 464. More specifically, the guide block 455 defines a hole through which a fastener passes to engage the latch bracket 464. The guide block 455 is arranged so that the cover plate 453 is spaced apart from the latch bracket 464. As a result, an interior space is provided in the interface 460 in which the load member 480 can move during preloading.

[0160] The preload mechanism 486 also includes a spring plate 505 and a conical disc spring 550 (eg, a disc spring) disposed between the flange 482 of the load member 480 and the spring plate 505. The spring plate 505 defines a first opening 511 (see Fig.42 ), the first opening being appropriately sized to receive the load member 480. The coil spring 550 defines a second opening 513, which is also appropriately sized to receive the load member 480. A snap ring secures the spring plate 505 and the coil spring 550 to the load member 480.

[0161] The preload mechanism 486 also includes a tensioner configured to push the load member 480 toward the back plate assembly 459 when actuated so as to load the mounting system. The tensioner includes a cam shaft 528 supported for rotation relative to the cover 469 (see Fig.44 ). The tensioner also includes a pair of tension members 551 (also referred to as lifters). The tension members 551 are located between the cover plate 453 and the spring plate 505. The cover plate 453 is fastened to the locking member bracket 464 via fasteners.

[0162] The cam shaft 528 is supported for rotation by the guide block 455. As a result, the cam shaft 528 can rotate between a tensioned position and a relaxed position. The cam shaft 528 includes a pair of cam segments 540 separated by an intermediate cylindrical segment 536. The cylindrical segment 536 of the cam shaft 528 has a smaller diameter than the cam segment 540. The cam segment 540 generates a cam action as the cam shaft 528 rotates.

[0163] like Fig.45As shown in FIG. 4 , the tensioning member 551 (two in the illustrated embodiment) has a first end engaged by the cam shaft 528 and a second end engaging the spring plate 505. The second end has a rounded engagement portion 557 that is located in a slot 559 in the spring plate 505. As the cam shaft 528 rotates about the pivot axis P1, the tensioning member 551 pivots about the pivot axis P2 while abutting the cover plate 453. This action causes the second end of the tensioning member to pivot into the spring plate 505 so as to push the spring plate 505 away from the cover plate 453. Since the cover plate 453 is rigidly connected to the lock bracket 464 and the lock bracket 464 is rigidly connected to the back cover plate 467, the load member 480 moves toward the first capture member 488 (which pulls the second capture member 483 toward the first capture member 488), thereby providing the preload required to properly secure the end effector EE to the robot arm R.

[0164] like Fig.44 and 45 As shown in , the tensioner also includes an operating rod 546 that is rotatably fixed to the cam shaft 528. The operating rod 546 can be rotatably fixed to the cam shaft 528 by various types of engagement, such as: a D-shaped hole to receive the D-shaped portion of the cam shaft 528; a coupling having a geometric feature that allows the cam shaft 528 to rotate as the operating rod 546 rotates; etc. In the illustrated embodiment, a fastener (not labeled) secures the operating rod 546 to the cam shaft 528 via the coupling. The cam shaft 528 rotates at least ninety degrees to move between the unloaded position and the loaded position. Of course, other positions therebetween can apply tensioning force to the load member 480 and can be adapted to apply the desired preload force.

[0165] When the cam shaft 528 is positioned in a desired position (e.g., a tensioning position), the operating lever 546 can be locked. In the tensioning position, a preload tensioning force is applied to the load member 480. By locking the operating lever 546 after the preload force is applied, the preload force is continuously applied during use of the robot arm R and the end effector EE so as to maintain the kinematic connection. The preload mechanism 486 transmits the preload force across the sterile barrier assembly 422 without piercing the barrier.

[0166] The tensioner applies a preload force to the load member 480 via the coil spring 550. The coil spring 550 applies a force equal to the preload force to the load member 480. The coil spring 550 acts between the spring plate 505 and the flange 482 of the load member 480. In particular, as the operating lever 546 rotates, the cam shaft 528 rotates and the cam segment 540 causes the tensioning member 551 to pivot about the pivot axis P2 and thereby causes the spring plate 505 to move longitudinally away from the second catch 483 (which engages the second pair of locking members 506). The movement of the spring plate 505 compresses the coil spring 550 and applies a preload force to the load member 480 via the flange 482.

[0167] Because the ball 428 is already substantially aligned with the receiving portions 432, 438 before preloading, once the preloading force is applied, the ball 428 becomes seated in the receiving portions 432, 438. Once in place, the position of the ball 428 is fixed and the positions of the receiving portions 432, 438 are fixed relative to each other. As a result, the mounting portions 424, 426 are kinematically coupled together without piercing the sterile barrier assembly 422.

[0168] For example Fig.46 The actuator of the button actuator 501 shown in the figure is used to manually separate the locking members 465, 506 and release the capture members 488, 483, so that the end effector EE can be removed from the interface 460 and the interface 460 can be removed from the robot arm R. Only the actuator 501 for separating the first pair of locking members 465 and releasing the first capture member 488 will be shown and described in detail.

[0169] In the illustrated embodiment, the actuator 501 has a button 560 fixed to a release frame 561. The release frame 561 is arranged to have an inclined engagement surface 562 that engages a pin 563 fixed to each of the first pair of locking members 465. The pin 563 extends away from the locking member 465 into an opening 564 in the release frame 561. The opening 564 is partially defined by the inclined engagement surface 562. The pin 563 extends on either side of the locking member bracket 464 (see Fig.46 ) so that the locking member 465 is guided to move along the locking member bracket 464 via the pin 563.

[0170] In a normal, unactuated state, the pins 563 are located and restrained at one end of the opening 564 by virtue of the locking members 465 being biased toward each other by the biasing member B. The actuator 501 can be actuated by pressing the button 560, which causes the release frame 561 to move laterally across the locking members 465, as shown by arrow A1. The release frame 561 is restrained to this lateral movement by being captured in a sliding recess in the locking member bracket 464. Due to this lateral movement of the release frame 561 and the pins 563 restricting the locking members 465 from similar lateral movement, the inclined surface 562 pushes the pins 563 of each of the locking members 465 away from each other, thereby separating the locking members 465 against the bias of the biasing member B in the direction shown by arrow A2. As a result, the locking members 465 are separated from the first capture member 488 ( Fig.46 4 (not shown) and is able to be disengaged from the first mounting portion 424 and remove the interface 460.

[0171] Figure 38-41 Power and other signal connections are shown that can pass through the sterile barrier assembly 422. In this embodiment, the interface 460 includes a plurality of electrical terminals embedded in a carrier 600 that is centrally disposed in the cover 469. In this embodiment, the electrical terminals are pins 478 that can be insert molded into the carrier 600 of the interface 460. The pins 478 transmit power / signals across the sterile barrier assembly 422. These pins 478 electrically interconnect the electrical connectors 451, 457 attached to the mounting portions 424, 426.

[0172] In this embodiment, the first mounting portion 424 includes a first electrical connector 451. The second mounting portion 426 includes a second electrical connector 457. When the mounting portions 424, 426 are coupled together and preloaded, the electrical connectors 451, 457 receive pins 478 so that power and other electrical signals can flow through the pins 478. Thus, power, communication signals, or other signals can reach the end effector EE from the robot arm R and vice versa. The electrical connectors 451, 457 can be inserted into the carrier 600 via a key / channel type interface or can be appropriately oriented by any appropriate feature.

[0173] In the illustrated embodiment, the carrier 600 includes a flange 602 (see Fig.43) and a cylindrical body 604 extending from the flange 602 to support the pin 478. The cylindrical body 604 is appropriately sized to fit within the cylindrical passage through the load member 480. A wave spring 606 is located between the flange 602 of the carrier 600 and the flange 482 of the load member 480. The wave spring 606 helps to maintain the position of the carrier 600 relative to the electrical connectors 451, 457, i.e., by preventing the carrier 600 from moving when the load member 480 moves to the unloaded position, which may otherwise occur due to frictional engagement between the cylindrical body 604 and the cylindrical passage of the load member 480. The wave spring 606 also assists in returning the load member 480 to its unloaded position to engage the end effector EE. The wave spring 606 also serves to retain the tensioning member 551 in the slot in the cover plate 453 and in the slot 559 in the spring plate 505.

[0174] Reference Fig.47A and 47B , the back ring plate 461 of the interface 460 also includes a gross alignment feature for aligning the interface 460 with the first mounting portion 424. In particular, the first mounting portion 424 defines a corresponding matching feature for receiving the alignment feature. In the illustrated embodiment, the alignment feature includes columns 700, 702, which extend backward from the rear surface of the back ring plate 462 to engage the openings 704, 706 in the first mounting portion 424. The columns 700, 702 include a first pair of columns 700 and a second pair of columns 702, which are arranged on the back ring plate 461 and opposite to the first pair of columns 700. The first pair of columns 700 are aligned in a plane, while the second pair of columns 702 are angled relative to each other, for example, they are not aligned. The second pair of columns 702 is also wider than the first pair of columns 700.

[0175] The openings 704, 706 include a first pair of openings 704 and a second pair of openings 706, wherein the first pair of openings are appropriately sized and shaped to receive the first pair of posts 700 and the second pair of openings are appropriately sized and shaped to receive the second pair of posts 702. The openings 704, 706 are appropriately sized and spaced apart to receive the corresponding posts 700, 702 with a small tolerance, for example, to facilitate rough positioning. Moreover, the second pair of posts 702 are appropriately sized so that they cannot fit in the first pair of openings 704, and the first pair of posts 700 are aligned so that they cannot fit in the second pair of openings 706. Due to the spacing / arrangement of the posts 700, 702 and the openings 704, 706, the interface 460 can only be roughly assembled to the first mounting portion 424 along one orientation. The rough positioning also helps to align the above-mentioned electrical connections before the first capture member 488 is fully engaged with the locking member 465.

[0176] When the ball 28, 228, 428 is made of an electrically insulating material (eg, ceramic), the sterile barrier assembly 22, 222, 422 can function as an electrical insulator as required to comply with electrical safety requirements.

[0177] If balls 28, 228, 428 are made of conductive material, they can provide three electrical contacts or terminals. In this case, if the interface features of the kinematic coupling are made of electrically insulating material, the sterile barrier assembly can still be used as an electrical insulator.

[0178] One or more of the balls 28, 228, 428 may have a light-transmitting portion defined through the ball for transmitting data. The light-transmitting portion may include a through hole filled with a transparent plastic material or other material to maintain a barrier.

[0179] In other embodiments, the kinematic coupling may have spherical and / or cylindrical segments.

[0180] The first mounting portion 24, 224, 424 may be a separate component that is rigidly connected to the link L1 of the robot arm R. The second mounting portion 26, 226, 426 may be a separate component that is rigidly connected to the handheld portion H of the end effector EE. In other embodiments, the first mounting portion 24, 224, 424 may be integrated into one or more links of the robot arm R, and the second mounting portion 26, 226, 426 may be integrated into the handheld portion of the end effector EE. The mounting portions 24, 224, 424, 26, 226, 426 may be formed of hardened steel, stainless steel, or other rigid materials.

[0181] The robotic arm R may move the end effector EE in one or more degrees of freedom, including 5 or 6 degrees of freedom. The end effector EE may include a surgical tool for milling tissue (eg, a milling drill for milling bone to receive an implant).

[0182] Examples of robotic arms and end effectors that can be configured with a first mounting portion 24, 224, 424 and a second mounting portion 26, 226, 426 are described in U.S. patent application serial number 13 / 958,070, filed on August 2, 2013, entitled “Surgical Manipulator Capable of Multi-Mode Control of Surgical Instruments,” the entire contents of which are incorporated herein by reference.

[0183] The first plurality of receiving portions may include three V-groove receiving portions. The three balls 28, 228, 428 then center themselves in the three V-grooves of the three V-groove receiving portions, so that each ball 28, 228, 428 contacts two surfaces of the V-groove at two contact points. As a result, the balls 28, 228, 428 contact the three V-groove receiving portions at a total of six contact points to constrain six degrees of freedom, i.e., each V-groove constrains two degrees of freedom, thereby deterministically orienting all six degrees of freedom between the first mounting portion and the second mounting portion. The first mounting portion and the second mounting portion are then clamped in this position by the preload mechanism as described above.

[0184] The first plurality of receiving portions and the second plurality of receiving portions may each include three V-grooves or Gothic arch-shaped receiving portions, so that exactly six contact points are formed between the contact surfaces of the first plurality of receiving portions and the kinematic coupling and between the contact surfaces of the second plurality of receiving portions and the kinematic coupling.

[0185] The conical receiving portion can be simplified by replacing it with three blocks having flat surfaces that are equally spaced from each other along the circumference and arranged at angles that approximate the cone angle. In this embodiment, the ball 28, 228, 428 is located in the three flat surfaces, just like it is located in a cone, but contacts the three flat surfaces at three contact points.

[0186] One or more of the first plurality of receiving portions and / or the second plurality of receiving portions may include a magnet to magnetically engage a ball in the receiving portion. For example, the first plurality of receiving portions may include a magnet to hold a ball to the first mounting portion until the second mounting portion is clamped to the first mounting portion. Similarly, the first mounting portion can include a magnet to hold a ball against a contact surface in the first mounting portion until the second mounting portion engages the first mounting portion, the first mounting portion having a contact surface of the receiving portion integrated therein for kinematic coupling.

[0187] Sterile barrier assembly 22,222,422 can be disposable. In other embodiments, interface 60,260,460 can include independent area sterilizable assembly and can be reused. In this variant, only curtain 62,262,462 is disposable. In this case, tape, elastic seal, snap ring or mechanical clamping area of ​​curtain 62,262,462 can be set to seal to interface 60,260,460, or design features can be provided on interface 60,260,460 to seal / clamp to curtain 62,262,462. Forming ball 28,228,428 from hard ceramic such as silicon carbide can minimize the wear problem associated with reusing ball 28,228,428.

[0188] The protective cover 58, 258, 458 may include a drape 62, 262, 462 without an interface 60, 260, 460, in which case the ball 28, 228, 428 will be seated in an opening in the drape 62, 262, 462, wherein the drape 62, 262, 462 is sealed to the ball 28, 228, 428. In other words, the ball 28, 228, 428 will be directly integrated into the drape 62, 262, 462. In this case, the robotic arm R can be configured to position the first plurality of receiving portions 30, 32, 34, 230, 234, 432 so that they are located in a generally horizontal plane so that the ball 28, 228, 428 can be seated in the first plurality of receiving portions 30, 32, 34, 230, 234, 432 and held there by gravity until installation of the sterile barrier assembly is completed.

[0189] Additional elastic bands or bungee cords may be attached to the interface and configured to releasably engage a post or other feature on the first mounting portion to further initially support the sterile barrier assembly when initially attaching the sterile barrier assembly to the first mounting portion (e.g., after the load bar 80 is inserted into the load bar slot 104 of the receiving member 100).

[0190] Several embodiments have been discussed in the foregoing description. However, the embodiments discussed herein are not exhaustive or intended to limit the invention to any particular form. The terms used are intended to be descriptive rather than limiting in nature. In light of the above teachings, a variety of modifications and variations are possible, and the invention may be practiced in other ways than those specifically described.

Claims

1. A mounting system, comprising: a first mounting portion coupled to an arm of the surgical robot, the first mounting portion comprising a plurality of receiving portions, and each receiving portion comprising a contact surface; a second mounting portion associated with an end effector for the surgical robot and configured to releasably couple to the first mounting portion, the second mounting portion including a plurality of receiving portions, and each receiving portion including a contact surface; as well as A sterile barrier assembly for establishing a barrier between the arm and the end effector, the sterile barrier assembly comprising: an interface having a plurality of kinematic couplings configured to engage the contact surfaces of the receiving portions of the first and second mounting portions and to provide a kinematic coupling between the first and second mounting portions to constrain six degrees of freedom between the arm and the end effector, and A drape assembly includes a ring defining an opening for receiving and attaching to the interface and a drape material attached to the ring.

2. The mounting system of claim 1, wherein the plurality of receiving portions is further defined as three receiving portions, and wherein the plurality of kinematic couplings is further defined as three kinematic couplings.

3. The mounting system of claim 1, wherein each of the plurality of kinematic couplings is further defined as a ball.

4. The mounting system of claim 1, wherein at least one receiving portion includes a magnet to magnetically engage one of the kinematic couplings.

5. The mounting system of claim 1, wherein the contact surface of at least one receiving portion has a conical configuration.

6. The mounting system of claim 1, wherein the contact surfaces of the plurality of receiving portions are configured to provide only six points of contact with the plurality of kinematic couplings.

7. The mounting system of claim 1, wherein the plurality of kinematic couplings provide a kinematic coupling between the first mounting portion and the second mounting portion through the interface of the sterile barrier.

8. The mounting system according to claim 1 further includes a preloading mechanism, which is operably connected to one of the first mounting part or the second mounting part, and the preloading mechanism includes a tensioner rod, which is capable of rotating between a tensioned position and a relaxed position to clamp the first mounting part and the second mounting part together.

9. The mounting system of claim 8, wherein the tensioner is coupled to a spring, the spring being configured to be compressed to apply a preload force when the tensioner is in the tensioning position.

10. The mounting system of any one of claims 8 and 9, wherein the tensioner is coupled to a second mounting portion.

11. The mounting system of claim 8, wherein the preload mechanism comprises one of a first capture member or a first locking member coupled to the first mounting portion, and one of a second capture member or a second locking member coupled to the second mounting portion.

12. The mounting system of claim 8, wherein the preload mechanism is configured to clamp the first mounting portion and the second mounting portion together through the interface of the sterile barrier.

13. The mounting system of claim 1, wherein the first mounting portion is rigidly connected to a link of the surgical robot, and wherein the second mounting portion is rigidly connected to the end effector.

14. A sterile barrier assembly for establishing a barrier between a first mounting portion and a second mounting portion, the first mounting portion being coupled to an arm of a surgical robot, the second mounting portion being coupled to an end effector for the surgical robot, the first mounting portion and the second mounting portion each comprising a plurality of receiving portions, and each receiving portion comprising a contact surface, the sterile barrier assembly comprising: an interface having a plurality of kinematic couplings configured to engage the contact surfaces of the receiving portions of the first and second mounting portions and to provide a kinematic coupling between the first and second mounting portions to constrain six degrees of freedom between the arm and the end effector; as well as A curtain assembly, the curtain assembly comprising: a ring defining an opening for receiving and attaching to the interface, and A drape material is attached to the ring.

15. The sterile barrier assembly of claim 14, wherein the plurality of kinematic couplings are further defined as three kinematic couplings.

16. The sterile barrier assembly of claim 14, wherein each of the plurality of kinematic couplings is further defined as a ball.

17. The sterile barrier assembly of claim 14, wherein at least one of the kinematic couplings is configured to magnetically engage at least one of the receiving portions.

18. The sterile barrier assembly of claim 14, wherein the plurality of kinematic couplings are configured to contact the contact surfaces of the plurality of receiving portions at only six contact points.

19. A surgical robot system, comprising: A surgical robot comprising an arm and comprising a first mounting portion coupled to the arm, the first mounting portion comprising a plurality of receiving portions, and each receiving portion comprising a contact surface; an end effector configured to be coupled to the arm and including a second mounting portion configured to releasably couple to the first mounting portion, the second mounting portion including a plurality of receiving portions, and each receiving portion including a contact surface; as well as A sterile barrier assembly for establishing a barrier between the arm and the end effector, the sterile barrier assembly comprising: an interface having a plurality of kinematic couplings configured to engage the contact surfaces of the receiving portions of the first and second mounting portions and to provide a kinematic coupling between the first and second mounting portions to constrain six degrees of freedom between the arm and the end effector, and A drape assembly includes a ring defining an opening for receiving and attaching to the interface and a drape material attached to the ring.

20. A sterile barrier assembly for establishing a barrier between a first surgical component and a second surgical component, the sterile barrier assembly comprising: A protective cover having a plurality of kinematic linkages configured to provide a kinematic linkage between the first surgical component and the second surgical component through the protective cover to constrain six degrees of freedom of movement between the first surgical component and the second surgical component.

21. A mounting system for coupling a first surgical component and a second surgical component, the mounting system comprising: a first mounting portion coupled to the first surgical component; a second mounting portion coupled to the second surgical component; and and a protective cover having a plurality of kinematic linkages configured to engage the first mounting portion and the second mounting portion and provide a kinematic linkage between the first mounting portion and the second mounting portion through the protective cover to constrain six degrees of freedom of movement between the first surgical component and the second surgical component.

22. A method for coupling a first surgical component to a second surgical component, the method comprising the steps of: placing a sterile barrier assembly on the first surgical component, the sterile barrier assembly having: a plurality of kinematic linkages, and a drape; placing the second surgical component on the sterile barrier assembly; and A preload element is preloaded to kinematically couple the first surgical component and the second surgical component together through the sterile barrier assembly using the plurality of kinematic couplings.

23. A sterile barrier assembly for establishing a barrier between a first surgical component and a second surgical component, the sterile barrier assembly comprising: A protective cover, comprising: an interface having a plurality of kinematic linkages integrated therein, the plurality of kinematic linkages configured to provide a kinematic linkage between the first surgical component and the second surgical component through the protective cover to constrain six degrees of freedom of movement between the first surgical component and the second surgical component, wherein each of the plurality of kinematic linkages are arranged to move laterally relative to each other; and A drape is attachable to the interface.

24. A sterile barrier assembly for establishing a barrier between a first surgical component and a second surgical component, the sterile barrier assembly comprising: A protective cover, comprising: an interface having a plurality of kinematic linkages integrated therein, the plurality of kinematic linkages configured to provide a kinematic linkage between the first surgical component and the second surgical component through the protective cover to constrain six degrees of freedom of movement between the first surgical component and the second surgical component, wherein the interface includes a preload element for preloading the kinematic linkage between the first surgical component and the second surgical component; and A drape is attachable to the interface.

25. A sterile barrier assembly for establishing a barrier between a first surgical component and a second surgical component, the sterile barrier assembly comprising: A protective cover having a plurality of kinematic linkages configured to provide a kinematic linkage between the first surgical component and the second surgical component through the protective cover so as to constrain six degrees of freedom of movement between the first surgical component and the second surgical component.

26. A surgical robot, comprising: an arm comprising a plurality of links, one of the links being a distal link; a mounting portion rigidly coupled to the distal link; Preloading mechanism; and A sterile barrier assembly that is installable and removable relative to the mounting portion, wherein: The preload mechanism has a disengaged position and an engaged position, wherein in the engaged position the preload mechanism is coupled to the first mounting portion to exert a preload force on the sterile barrier assembly.

27. A system comprising: A robotic arm including an installation portion; a surgical drape shaped to cover the robotic arm, the surgical drape comprising an outer surface and an inner surface positioned adjacent to the robotic arm; an interface coupled to the surgical drape, wherein the interface is configured to couple to the mounting portion; and An end effector is configured to be coupled to the mounting portion through the interface.

28. A mounting system for coupling a first surgical component to a second surgical component, the mounting system comprising: a first mounting portion coupled to the first surgical component; a second mounting portion coupled to the second surgical component; and and a protective cover having a plurality of kinematic linkages configured to engage the first mounting portion and the second mounting portion and provide a kinematic linkage between the first mounting portion and the second mounting portion through the protective cover so as to constrain six degrees of freedom of movement between the first surgical component and the second surgical component.

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