Systems and methods for docking surgical robotic arms

Abstract

To provide a method and device for attaching a cannula to a surgical robotic arm.SOLUTION: An attachment device or docking interface 212 located on a distal block of a robotic arm / tool driver is manipulated until the attachment device is aligned with an attachment portion of the cannula (e.g., a cannula lug) exposed outside a patient. Then, the attachment device or interface of the robotic arm / tool driver is latched (or clamped) to the attachment portion of the cannula to provide a rigid mechanical attachment of the robotic arm / tool driver and the cannula.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates generally to the field of robotic surgery, and more particularly to systems and methods for docking surgical arms. [Background technology]

[0002] Minimally invasive surgery (MIS), such as laparoscopic surgery, involves techniques intended to reduce tissue damage during surgical procedures. For example, laparoscopic procedures typically involve making several small incisions in a patient (e.g., within the abdomen) and introducing one or more tools and at least one endoscopic camera into the patient through the incisions. The surgical procedure is then performed using the introduced tools with visualization assistance provided by the camera. Generally, MIS offers several advantages, including smaller scars, less patient pain, shorter patient recovery time, and reduced medical costs associated with patient recovery. In some embodiments, MIS may be performed using a robotic system including one or more robotic arms for manipulating surgical instruments based on commands from an operator.

[0003] During robotic MIS, a surgeon or other operator may use several different surgical instruments to perform a procedure at a surgical site. Often, a surgeon may rely on the use of a trocar or cannula to target a site within a patient's body. The cannula may provide a channel or opening through which additional surgical instruments may be introduced and removed by the surgeon. For example, a cannula may be positioned within a patient's body cavity, and surgical instruments may be inserted into and guided through the cannula into the body cavity. In a robotic system, the cannula may be attached to one or more robotic arms that may be remotely controlled by the surgeon to move the cannula. A cannula attachment may be used to attach the cannula to the robotic arm to ensure proper control and placement of the cannula within the patient. Summary of the Invention [Means for solving the problem]

[0004] In an MIS procedure, once the trocar cannula is properly positioned and inserted through tissue into an interior region of the patient, a robotic arm or tool driver is attached to the cannula to provide a rigid mechanical attachment of the robotic arm and cannula. Such attachment of the robotic arm and cannula can provide stabilization of the cannula, for example, so that one or more surgical tools can be inserted through the lumen of the cannula into an interior region of the patient. In this regard, an attachment device or docking interface located on the distal block of the robotic arm / tool ​​driver is manipulated until the attachment device is aligned with an attachment portion of the cannula (e.g., a cannula lug) exposed outside the patient. The attachment device or interface of the robotic arm / tool ​​driver is then latched (or clamped) to the attachment portion of the cannula, providing a rigid mechanical attachment of the robotic arm / tool ​​driver and cannula.

[0005] A robotic arm (on an operating table or cart) can be manually or autonomously guided by surgical staff or a surgeon toward a cannula within a surgical port (incision). The goal is to “dock” the surgical arm to the cannula / trocar, establish a firm connection, and then deploy a surgical tool through the access channel. Due to the delicate nature of interacting with the surgical incision and the confined space within the operating room, this action must be performed by one person, with one hand on the robot and the other on the cannula. However, the user's ability to grasp the arm is limited by the location of the cannula latch (e.g., a lever or actuator on the attachment device) and the geometry of the arm. For example, the latch may not be accessible in all configurations, and the geometry of the arm may introduce pinch points. In one aspect, an improved scheme for docking the arm is provided, where the method maintains a mechanical connection, allows the user to grasp the arm anywhere they wish, and provides audible, tactile, and visual feedback regarding task success. Typically, a docking interface or attachment device is provided that automatically steps through the three states required during docking of the arm to the cannula. These states are: 1) a locked-out open position that allows the user to signal to the system that "docking mode" is in progress; 2) mechanical detection that the cannula latch is in the correct position for docking; and 3) automatic clamping of the cannula latch and signaling to the user. Typically, the attachment device may include a lever or actuator coupled to the clamp with a lockout mechanism that, when triggered by the user, holds the clamp in an open configuration. This configuration is maintained until the cannula is "mechanically" detected and the mechanism automatically steps through actuation of the clamp.

[0006] In another aspect, the system may include sensing and logic for detecting the docking of a cannula to the surgical robotic arm using the attachment device. Typically, sensors may be incorporated into the attachment device or interface that drive a finite state machine to detect the presence of a cannula, proper latching or clamping to the cannula, the type of cannula docked, and any scenario that may indicate the release of the cannula. Each of these conditions may then be communicated to the user using visual, audio, or other forms of feedback on the robotic arm and via any form of similar feedback on the surgeon bridge. Typically, when the robotic arm is ready to dock to the cannula, a latch, lever, or actuator may be pressed to open the attachment device, allowing the latch, lever, or actuator to seat on a lockout that holds the latch open. This movement of the latch actuator may be sensed by two redundant latch position encoders, and a gravity compensated active back (GCAB) drive mechanism associated with the surgical robotic arm may allow the arm to be positioned in the docking position. Once the arm is positioned and the cannula is pushed into the distal block, the lockout is disengaged and the latch closes, allowing the cannula to be secured to the arm. At this point, the latch position encoder can sense that the attachment device has closed past the mechanical overcenter point, which stops the GCAB and holds the arm in its docked position. The signals from these encoders are actively monitored, and if the lever or latch is accidentally depressed after the cannula is docked, the state machine transitions to an error state where it must stop the procedure and notify the user.

[0007] In another aspect, the present invention provides a cannula sterilization adapter having an overcenter latch mechanism, structural alignment features as part of the attachment device and / or cannula to ensure proper attachment between the attachment device and cannula, and / or both flexible and rigid portions to ensure proper attachment and / or alignment between the cannula and attachment device. Typically, the attachment device may include a lever, actuator, or the like with an overcenter configuration to ensure that forces applied to the cannula cannot backdrive the lever (or latch) to an open position. Once overcenter, any increase in load applied to the cannula causes the latch to gradually close itself. This aspect ensures that the cannula is firmly and securely held to the robotic arm during surgery. In another aspect, the cannula and attachment device interface may have alignment features that mate with each other to ensure proper alignment and attachment of the cannula to the attachment device. In still further aspects, the sterile adapter that seats between the cannula and the attachment device can have both rigidity and structural features that allow the interface surfaces of the alignment features of the cannula and the attachment device to mate with one another to provide a secure attachment between the two structures.

[0008] In another aspect, the mounting device may include a ball bearing trigger mechanism that reduces wear and increases reliability of the mounting device. Typically, the lockout mechanism of the mounting device (which holds the device in the open configuration) may include a trigger hook that interfaces with the ball bearing of the lever or actuator instead of a fixed structure. This, in turn, reduces wear between the interfacing surfaces. Additionally, the geometry of the trigger hook may be configured to have a specific size and shape that allows a desired amount of force to transition the lockout mechanism between a locked-out open position, in which the lockout mechanism engages the bearing, and a closed position, in which the hook disengages the bearing.

[0009] In another aspect, the mounting device can have an adjustment mechanism for adjusting the docking force required to transition the mounting device between a lockout open position (e.g., the lockout mechanism is engaged with the ball bearing) and a closed position (e.g., the lockout mechanism disengages the ball bearing). For example, the mounting device can include a set screw positioned between the lockout mechanism hook and the bearing that, when tightened, biases the lockout toward disengagement. When the lockout adjustment set screw is tightened, it presses against the bearing, shifting the lockout so that it is less engaged with the lockout bearing than it was before the lockout adjustment set screw was tightened. Less force can be achieved by shortening the distance the lockout must travel to disengage. The converse can be achieved by loosening the adjustment screw to allow for tighter engagement. In some aspects, the adjustment mechanism is operable to adjust the force required to disengage the lockout bearing within a range of 3 pounds of force to 14 pounds of force.

[0010] Typically, in one embodiment, an apparatus for attaching a cannula to a robotic surgical system includes a first clamp component configured to transition between an open position and a closed position, a second clamp component spaced from the first clamp component, the first clamp component and the second clamp component defining an area, the area configured to receive a portion of a cannula and to retain the portion of the cannula within the area when the first clamp component is in the closed position, and a locking component configured to lock the first clamp component in the open position and enable the first clamp component to automatically transition to the closed position based on the position of the portion of the cannula within the area. In one embodiment, the locking component locks the first component in the open position when the portion of the cannula is misaligned within the area. In another embodiment, the first clamp component automatically transitions from the open position to the closed position when the portion of the cannula is aligned within the area. In another aspect, the cannula contacts a portion of the locking component when aligned within the region, disengaging the locking component from the first clamp component and allowing the first clamp component to transition from the open position to the closed position. Still further, the locking component may mechanically detect whether a portion of the cannula is aligned or misaligned within the region. The device may further include one or more processors configured to signal to the robotic surgical system that a user is attaching a cannula to the robotic surgical system when the first clamp component is in the open position and a portion of the cannula is within the region.

[0011] In another aspect, a system for attaching a cannula to a robotic surgical system includes: a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a locking assembly coupled to the clamp assembly configured to lock the clamp assembly in the open position and allow the clamp assembly to automatically transition to the closed position based on the position of the cannula within the clamping assembly; and one or more processors configured to signal to the robotic surgical system whether the clamp assembly is in a docking mode when the clamping assembly is locked in the open position or a clamping mode when the clamping assembly is locked in the closed position. In some aspects, in the docking mode, the clamping assembly remains locked in the open position until the detected position of the cannula is suitable for attachment to the surgical robotic system. In the clamping mode, the surgical robotic system can notify a user that the cannula is attached to the robotic surgical system. In another aspect, the locking assembly can lock the clamp assembly in the open position when the detected position of the cannula is misaligned. In some aspects, the locking assembly is further configured to transition the clamping assembly from the open position to the closed position when the detected position of the cannula is aligned. The locking assembly may include a lever coupled to a lockout mechanism that locks or unlocks the clamping assembly based on the position of the cannula.

[0012] In another aspect, a system for detecting cannula attachment to a robotic surgical system may include a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach a cannula to a robotic arm of the robotic surgical system; a sensor assembly operable to sense a characteristic of the clamp assembly; and one or more processors configured to determine a state of the clamp assembly based on the characteristic sensed by the one or more sensors and provide feedback to a user regarding the state of the clamp assembly. The clamp assembly may include a lever operable to transition the clamp assembly between the open and closed positions, the sensor assembly comprising a position sensor coupled to the lever. In some aspects, the characteristic sensed by the position sensor is an angle of the lever. In some aspects, the state of the clamp assembly determined by the one or more processors is an open or closed position and is determined based on the angle of the lever. In some aspects, a visual or audio feedback mechanism may be provided to indicate to a user that the state of the clamp assembly is (1) a cannula is present in the clamp assembly or (2) the cannula has been released from the clamp assembly.

[0013] In another aspect, a system for detecting cannula attachment to a robotic surgical system includes a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a sensor assembly operable to sense a characteristic of the cannula when received by the clamp assembly; and one or more processors configured to determine a status of the cannula based on the characteristic sensed by the one or more sensors and provide feedback to a user regarding the status of the cannula. In some aspects, the position sensor is a magnetic encoder, and the cannula includes a magnet that is sensed by the magnetic encoder to sense the characteristic of the cannula. In another aspect, the characteristic of the cannula includes the presence of the cannula in a receiving portion of the clamp assembly. In some aspects, the condition of the cannula determined based on the characteristic is whether the cannula is properly attached to the robotic arm or whether the cannula is released from the robotic arm. In another aspect, the characteristic of the cannula is the type of cannula in the receiving portion of the clamp assembly. In some aspects, the type of cannula in the receiving portion of the clamping assembly is determined based on the angle of the magnet coupled to the cannula. In another aspect, the system includes a visual or audio feedback mechanism.

[0014] In another aspect, a method for controlling attachment of a cannula to a robotic surgical system may include a clamp assembly configured to attach a cannula to the robotic surgical system, the clamp assembly operable to transition between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system, a sensor assembly operable to detect whether the clamp assembly is in the open position or the closed position or the presence of a cannula received by the clamp assembly, and one or more processors configured to control attachment of the cannula to the robotic surgical system based on detection by the sensor assembly. In some aspects, when the sensor assembly detects that the clamp assembly is in the open position, the one or more processors cause the surgical robotic system to engage and disengage a brake assembly associated with a surgical robotic arm coupled to the clamp assembly and engage a gravity-compensated active back-drive mechanism associated with the surgical robotic arm to enable positioning of the cannula within the clamp assembly. In another aspect, when the sensor assembly detects a transition of the clamp assembly to the closed position, the one or more processors cause the surgical robotic system to engage a brake assembly associated with the surgical robotic arm and disengage a gravity compensated active back drive mechanism associated with the surgical robotic arm such that a current position of the cannula relative to the clamp assembly is maintained. In another aspect, when the sensor assembly detects a transition of the clamp assembly to the closed position, the one or more processors cause the surgical robotic system to engage a brake assembly associated with the surgical robotic arm coupled to the cannula and disengage a gravity compensated active back drive mechanism associated with the surgical robotic arm.In another aspect, the sensor assembly further detects the presence of a cannula in the clamp assembly, and upon detecting the presence of the cannula, the one or more processors cause the surgical robotic system to notify a user that a cannula has been attached to the surgical robotic system. In another aspect, the sensor assembly further detects the presence of a cannula in the clamp assembly, and upon detecting the presence of the cannula, the one or more processors cause the surgical robotic system to determine the type of cannula and notify a user of the cannula type. In another aspect, when the sensor assembly detects a transition of the clamp assembly to an open position, when it detects that a cannula is not present in the clamp assembly, or when it does not sense a cannula identifier (ID), the one or more processors cause the surgical robotic system to engage a brake assembly associated with the surgical robotic arm and notify a user that the surgical robotic system is ready to attach a cannula.

[0015] In another aspect, an apparatus for attaching a cannula to a robotic surgical system may include a clamp operable to transition between an open position configured to receive a cannula and a closed position for attaching the cannula to the robotic surgical system, an actuator operable to transition the clamp between the open and closed positions, and a link member pivotally coupled to the clamp at a first pivot point and to the actuator at a second pivot point, wherein in the closed position the second pivot point is over-centered relative to the first pivot point. In some aspects, in the closed position the second pivot point is over-centered relative to the first pivot point by an angle of 1 degree or less. In another aspect, having the second pivot point over-centered relative to the first pivot point causes any increase in load applied to a cannula attached to the robotic surgical system to cause the clamp to progressively close itself to the closed position. In another embodiment, the clamp has a second pivot point that is overcenter relative to the first pivot point to prevent the clamp from transitioning to the open position when a force is applied to a cannula attached to a robotic surgical system. In another embodiment, the clamp can include a first end rotatably coupled to the base member at a third pivot point and a second end that rotates to an advanced position to attach the cannula to the robotic surgical system. The second end can include a cannula-engaging feature configured to reinforce the attachment of the cannula to the robotic surgical system. In some embodiments, the actuator is coupled to the base member at a fourth pivot point to form a four-bar linkage mechanism. In some embodiments, the actuator includes a first end configured to allow a user to manually cause the actuator to transition the clamp to the open position and a second end proximate a lockout mechanism that engages the actuator to lock the clamp in the open position and disengages from the actuator to allow the clamp to transition to the closed position upon contact with a cannula.In another aspect, the device may further include a base member having a cannula receiving chamber in which the cannula is positioned when attached to the robotic surgical system by the clamp, the receiving chamber including a cannula mating feature to guide the cannula into the receiving chamber and prevent displacement of the cannula.

[0016] In another aspect, a sterile adapter for attaching a cannula to a robotic surgical system includes: a rigid barrier portion having a cannula interface defining an opening dimensioned to receive a cannula lug, a first cannula interface structure extending from the cannula interface, and a second cannula interface, the first cannula interface and the second cannula interface dimensioned to interface with the alignment structure of the cannula lug; and a flexible barrier portion molded into the rigid barrier portion, the flexible barrier portion defining a cavity around the opening of the rigid barrier portion dimensioned to receive the cannula lug inserted therein, the cavity having a first side defined by the first cannula interface structure and a second side along which the second cannula interface structure lies, the second cannula interface structure being generally surrounded by the flexible barrier portion. In some aspects, the cannula interface includes a plate having an arm side facing a robotic surgical arm of a robotic surgical system and a cannula side facing the cannula lug, with the first cannula interface structure extending from the arm side toward the robotic surgical arm. The flexible barrier portion may be molded into the arm side of the plate and define at least three sides of a cavity. In some aspects, the first cannula interface structure may include a keel-shaped structure dimensioned to interface with a complementary recessed region of the cannula lug. In some aspects, the rigid clamp interface portion may include a plate molded into the second side. In some aspects, the angle of the plate is modifiable to the angle of the cannula lug alignment structure. In some aspects, a retention bump is coupled to the second side of the flexible barrier portion, the retention bump being dimensioned to retain the cannula sterilization adapter within the clamp assembly during insertion and removal of the cannula lug within the clamp assembly.Additionally, a mating datum can be coupled to a third side of the flexible barrier portion and configured to maintain alignment of a cannula lug inserted therein with an axis of an associated tool. In some embodiments, the rigid barrier portion is formed from a plastic material. In some embodiments, the flexible barrier portion is formed from a flexible elastomeric material overmolded onto the rigid barrier portion. In some embodiments, the flexible barrier portion comprises a thermoplastic polyurethane.

[0017] In another aspect, an apparatus for attaching a cannula to a robotic surgical system may include a clamp assembly configured to attach a cannula to the robotic surgical system, the clamp assembly including an actuator coupled to the clamp to transition the clamp between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system; and a lockout assembly coupled to the clamp assembly to control transition of the clamp, the lockout assembly having a hook dimensioned to engage a bearing coupled to the actuator when the clamp is in the open position and to disengage the bearing to allow the clamp to automatically transition to the closed position. In some aspects, the hook may include a tip that extends beyond a contact point on the bearing to engage the bearing, such that when the tip is aligned with the contact point, the hook disengages the bearing and allows the clamp to transition to the closed position. In some aspects, alignment of the tip with the contact point causes rotation of the bearing, which allows the hook to disengage the bearing. In some aspects, the hook is coupled to a spring to bias the hook into engagement with the bearing. In some aspects, engagement or disengagement of the hook and bearing provides audible or tactile feedback notifying the user of the engaged state of the lockout assembly. The lockout assembly may be disengaged from the bearing upon contact with a cannula inserted into the clamp assembly. The device may further include an adjustment mechanism operable to adjust the force required to engage or disengage the hook from the bearing. The adjustment mechanism may include a set screw adjustable between a first position that increases the spacing between the hook and the bearing and a second position that decreases the spacing between the hook and the bearing. In some aspects, in the first position, the force required to disengage the bearing from the hook is reduced. In some aspects, in the second position, the force required to disengage the bearing from the hook is increased.

[0018] In another aspect, an apparatus for attaching a cannula to a robotic surgical system may include a clamp operable to transition between an open position configured to receive a cannula and a closed position for attaching the cannula to the robotic surgical system; a locking assembly coupled to the clamp assembly to hold the clamp in the open position and release the clamp to the closed position upon application of force by the cannula, the locking assembly having a lockout hook that engages a lockout bearing of the clamp in the open position and disengages the lockout bearing to release the clamp to the closed position; and an adjustment member operable to adjust the force required to disengage the lockout bearing. In some aspects, the lockout hook is biased toward engagement of the lockout bearing by a spring. In another aspect, the adjustment member shifts the position of the lockout hook away from the lockout bearing to reduce the force required to disengage the lockout bearing. In another aspect, the adjustment member shifts the position of the lockout hook toward the lockout bearing to increase the force required to disengage the lockout bearing. In some embodiments, the adjustment member includes a set screw that extends through the lockout hook to an interface between the lockout hook and the lockout bearing. In one embodiment, tightening the set screw shifts the position of the lockout hook away from the lockout bearing. In another embodiment, loosening the set screw shifts the position of the lockout hook toward the lockout bearing. In some embodiments, the lockout bearing is a ball bearing. In another embodiment, the clamp may include an actuator coupled to a first clamp component of the clamp and operable to move the first clamp component between an open position and a closed position, the ball bearing being coupled to the actuator.

[0019] The above summary does not include an exhaustive list of all aspects of the present invention. The present invention is intended to include all systems and methods that can be implemented from all suitable combinations of the various aspects summarized above, as well as those disclosed in the following detailed description and particularly those pointed out in the claims filed with this application. Such combinations have certain advantages not specifically described in the above summary. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is a schematic diagram of an operating room layout with a surgical robotic system. [Figure 2] FIG. 1 is a perspective view of a portion of a robotic arm according to one aspect of the present disclosure. [Figure 3] FIG. 3 is a schematic perspective view of a mounting device for the robot arm of FIG. 2. [Figure 4A] FIG. 3 is a side cross-sectional view of the mounting device of the robotic arm of FIG. 2 in an open position. [Figure 4B] FIG. 3 is a side cross-sectional view of the mounting device of the robotic arm of FIG. 2 in a closed position. [Figure 5] FIG. 3 is a process flow diagram of a method for providing user feedback regarding the mounting device of the robotic arm of FIG. [Figure 6] FIG. 4C is a cross-sectional side view of a sensor assembly associated with the mounting device of FIGS. 4A-4B. [Figure 7] FIG. 3 is a process flow diagram of a method for detecting docking using the attachment device of the robotic arm of FIG. 2. [Figure 8A] FIG. 4C is a cross-sectional side view of another embodiment of the attachment device of FIGS. 4A-4B in an open position. [Figure 8B] 4B-4C are side cross-sectional views of another embodiment of the attachment device of FIG. 4B. [Figure 9A] FIG. 4C is a side cross-sectional view of another embodiment of the attachment device of FIGS. 4A-4B. [Figure 9B]FIG. 9B is an enlarged cross-sectional side view of a portion of the attachment device of FIG. 9A. [Figure 9C] FIG. 4C is a side cross-sectional view of another embodiment of the attachment device of FIGS. 4A-4B. [Figure 9D] 4B-4C are side cross-sectional views of another embodiment of the attachment device of FIG. 4B. [Figure 10A] FIG. 4C is a side cross-sectional view of another embodiment of the attachment device of FIGS. 4A-4B. [Figure 10B] FIG. 4C is a bottom side perspective view of a portion of the mounting device of FIGS. 4A-4B. [Figure 10C] FIG. 4C is a top perspective view of a portion of the attachment device of FIGS. 4A-4B. [Figure 11A] FIG. 4C is a bottom perspective view of a sterilization adapter of the mounting device of FIGS. 4A-4B. [Figure 11B] FIG. 11B is a top perspective view of the sterile adapter of FIG. 11A. [Figure 11C] FIG. 11B is a cross-sectional side view of the sterile adapter of FIG. 11A with the attachment device in an open position. [Figure 11D] FIG. 11B is a side cross-sectional view of the sterile adapter of FIG. 11A with the attachment device in a closed position. [Figure 12] FIG. 1 is a block diagram of a computer portion of a user console for a surgical robotic system including a robotic arm and attachment mechanism, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0021] In various embodiments, the description is provided with reference to figures. However, certain embodiments may be practiced without one or more of these specific details or in combination with other known methods and configurations. In the following description, numerous specific details are set forth, such as specific configurations, dimensions, and processes, to provide a thorough understanding of the embodiments. In other instances, well-known processes and manufacturing techniques have not been described in particular detail in order to avoid unnecessarily obscuring the description. Throughout this specification, references to “one embodiment,” “an embodiment,” etc. mean that a particular feature, structure, configuration, or characteristic being described is included in at least one embodiment. Thus, the appearances of the phrases “one embodiment,” “an embodiment,” etc. in various places throughout this specification do not necessarily refer to the same embodiment. Furthermore, particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments.

[0022] Additionally, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. Spatially relative terms, such as "beneath," "below," "lower," "above," and "upper," may be used herein to facilitate the description of the relationship of one element or feature to another element or feature illustrated in the figures. It will be understood that these spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the figures. For example, if the device in the figures were turned upside down, elements described as "below" or "below" other elements or features would be oriented "above" the other elements or features. Thus, the exemplary term "below" can encompass both an upper and lower orientation. The device may be oriented differently (e.g., rotated 90 degrees or to another orientation), and the spatially relative descriptors used herein would be interpreted accordingly.

[0023] As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising" specify the presence of stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0024] As used herein, the terms "or" and "and / or" should be construed as being inclusive or meaning any one or any combination. Thus, "A, B, or C" or "A, B, and / or C" means any of the following: "A; B; C; A and B; A and C; B and C; A, B and C." Exceptions to this definition will occur only where combinations of elements, features, steps, or acts are in some way inherently mutually exclusive.

[0025] Additionally, use of relative terms throughout the description may represent relative positions or directions. For example, "distal" may refer to a first direction away from a reference point, e.g., away from the user. Similarly, "proximal" may refer to a location in a second direction opposite the first direction, e.g., toward the user. However, such terms are provided to establish a relative frame of reference and are not intended to limit the use or orientation of any particular surgical robotic component to the specific configurations described in the various embodiments below.

[0026] Referring to FIG. 1 , this figure is a pictorial representation of an exemplary surgical robotic system 100 in an operating room. The surgical robotic system 100 includes a user console 102, a control tower 103, and one or more surgical robots 120 including a robotic arm 104 that reside on a surgical robotic platform 105, e.g., an operating table, bed, etc. The system 100 can incorporate any number of devices, tools, or accessories used to perform surgery on a patient 106. For example, the system 100 can include one or more surgical tools 107 used to perform the surgery. The surgical tool 107 can be an end effector attached to the distal end of the surgical arm 104 for performing the surgical procedure.

[0027] Each surgical tool 107 may be manipulated manually, robotically, or both during surgery. For example, the surgical tool 107 may be a tool used to enter, view, or manipulate the internal anatomical structures of the patient 106. In one embodiment, the surgical tool 107 is a grasping instrument capable of grasping patient tissue. The surgical tool 107 may be controlled manually by a bedside operator 108 or robotically via actuation movement of a surgical robotic arm 104 to which the surgical tool is attached. While the robotic arm 104 is shown as a table-mounted system, in other configurations, the arm 104 may be mounted to a cart, ceiling, or sidewall, or another suitable structural support.

[0028] Generally, a teleoperator 109, such as a surgeon or other operator, can use the user console 102 to remotely, e.g., teleoperate, the arm 104 and / or the attached surgical tool 107. Teleoperation can be engaged or disengaged based on a user action. It should be understood that “engaging” a teleoperation mode is intended to refer to an action in which, for example, a UID or foot pedal that is prevented from controlling a surgical instrument is transitioned to a mode in which it can currently control the surgical instrument (e.g., a teleoperation mode). Disengaging teleoperation mode, on the other hand, is intended to refer to an action that occurs when the system is in teleoperation mode and then transitions to a mode in which the UID or foot pedal can no longer control the surgical instrument (a non-teleoperation mode). For example, teleoperation mode can be disengaged when the system determines that a detected movement is an unexpected action or movement by the user, or the user engages in any other action that suggests teleoperation mode should no longer be engaged.

[0029] 1, the user console 102 may be located in the same operating room as the rest of the system 100. However, in other environments, the user console 102 may be located in an adjacent or nearby room, or may be in a remote location, e.g., a different building, city, or country. The user console 102 may include a seat 110, one or more user interface devices, e.g., a foot control 113 or a handheld user input device (UID) 114, and at least one user display 115 configured, for example, to display a view of a surgical site inside the patient 106. In the exemplary user console 102, a remote operator 109 sits in the seat 110 and views the user display 115 while operating the foot control 113 and the handheld UID 114 to remotely control the arm 104 and the surgical tool 107 (mounted at the distal end of the arm 104).

[0030] In some variations, the bedside operator 108 may also operate the system 100 in a "bed-facing" mode, in which the bedside operator 108 (user) is present near the patient 106 and manipulates a robotically driven tool (an end effector attached to the arm 104) simultaneously with a manual laparoscopic tool, e.g., while holding a handheld UID 114 in one hand. For example, the bedside operator's left hand may operate a handheld user input device to control the robotic components, while the bedside operator's right hand may operate a manual laparoscopic tool. Thus, in these variations, the bedside operator 108 may perform both robotically-assisted minimally invasive surgery and manual laparoscopic surgery on the patient 106.

[0031] During an exemplary procedure (surgery), the patient 106 is sterilized, prepped, and draped to achieve anesthesia. Initial access to the surgical site may be performed manually while the arms of the robotic system 100 are in a stowed or retracted configuration (to facilitate access to the surgical site). A trocar assembly may be at least partially inserted into the patient through an incision or entry point in the patient (e.g., in the abdominal wall) to create a port to allow for the introduction of surgical instruments into the patient 106. The trocar assembly may include a cannula or trocar, an obturator, and / or a seal. In some variations, the trocar assembly may include an obturator, such as a needle with a sharp tip for penetrating the patient's skin. The obturator may be disposed within the lumen of the cannula when inserted into the patient 106 and then removed from the cannula so that surgical instruments can be inserted through the lumen of the cannula. As described further herein, when positioned within the patient 106, the cannula may provide a channel for accessing a body cavity or other site within the patient 106, for example, to allow one or more surgical instruments or tools to be inserted into the body cavity of the patient 106. It will be understood that the cannulas described herein may be part of a trocar and may optionally include an obturator or other components.

[0032] Once access is complete, initial positioning or preparation of the robotic system 100, including its arm 104, may occur. The teleoperator 109 of the user console 102 then proceeds with the procedure by utilizing the foot controls 113 and UID 114 to operate the various end effectors and possibly the imaging system to perform the procedure. Manual assistance may also be provided at the procedure bed or table by sterile, gowned bedside personnel, such as the bedside operator 108, who may perform tasks such as retracting tissue, performing manual repositioning, and replacing one or more tools on the robotic arm 104. Non-sterile personnel may also be present to assist the teleoperator 109 of the user console 102. Once the procedure or surgery is complete, the system 100 and user console 102 may be configured or set to a state to facilitate post-operative procedures, such as cleaning or sterilization and entering or printing medical records via the user console 102.

[0033] In one embodiment, the teleoperator 109 holds and moves the UID 114 to provide input commands for moving the robotic arm actuator 117 of the robotic system 100. The UID 114 may be communicatively coupled to the rest of the robotic system 100, for example, via the console computer system 116. Typically, in some embodiments, the UID 114 may be a portable handheld user input device or controller that is not grounded relative to other components of the surgical robotic system. For example, the UID 114 may be ungrounded while either tethered or untethered to a user console. The term “ungrounded” is intended to refer to implementations in which, for example, both UIDs are not mechanically or kinematically constrained relative to the user console. For example, a user may hold the UID 114 in their hand and move it freely to any possible position and orientation within a space limited only by, for example, the tracking mechanism of the user console. The UID 114 can generate spatial state signals corresponding to the movement of the UID 114, e.g., the position and orientation of the UID's handheld housing, which can be input signals for controlling the movement of the robotic arm actuator 117. The robotic system 100 can use control signals derived from the spatial state signals to control the proportional movement of the actuator 117. In one embodiment, a console processor in the console computer system 116 receives the spatial state signals and generates corresponding control signals. Based on these control signals, which control how the actuator 117 is energized to move segments or links of the arm 104, the movement of a corresponding surgical tool attached to the arm can mimic the movement of the UID 114. Similarly, interaction between the teleoperator 109 and the UID 114 can generate, for example, a grasping control signal that causes the jaws of a grasping instrument of the surgical tool 107 to close to grasp tissue of the patient 106.

[0034] The surgical robotic system 100 may include several UIDs 114, with a separate control signal generated for each UID controlling the actuators and surgical tools (end effectors) of each arm 104. For example, a teleoperator 109 may move a first UID 114 to control the movement of an actuator 117 in a left robotic arm, which responds by moving linkages, gears, etc. within that arm 104. Similarly, movement of a second UID 114 by the teleoperator 109 controls the movement of another actuator 117, which in turn moves other linkages, gears, etc. in the robotic system 100. The robotic system 100 may include a right arm 104 on the right side of a patient immobilized on a bed or table, and a left arm 104 on the left side of the patient. The actuators 117 may include one or more motors that are controlled to drive the rotation of the joints of the arms 104 to, for example, change the orientation of an endoscope or grasping instrument of a surgical tool 107 attached to that arm relative to the patient. The movement of several actuators 117 within the same arm 104 can be controlled by spatial state signals generated from a particular UID 114. The UID 114 can also control the movement of a respective surgical tool grasper. For example, each UID 114 can generate a respective grasp signal to control the movement of an actuator, e.g., a linear actuator, that opens or closes the jaws of the grasper at the distal end of the surgical tool 107 to grasp tissue within the patient 106. When the user is finished controlling the surgical tool with the UID 114, the user can dock (i.e., store) the UID 114 via a docking station or UID holder located on the console 102. For example, the console 102 can include a docking station 130 on each of the left and right armrests of the chair 110. To dock the UIDs 114, the user may move the left UID 114 to the left docking station 130 and the right UID 114 to the right docking station 130 and place each UID in their respective docking station holders.

[0035] In some embodiments, communication between the platform 105 and the user console 102 may be through a control tower 103, which may translate user commands received from the user console 102 (particularly from the console computer system 116) into robotic control commands sent to the arm 104 on the robotic platform 105. The control tower 103 may also transmit status and feedback from the platform 105 back to the user console 102. The communication connections between the robotic platform 105, the user console 102, and the control tower 103 may be via wired and / or wireless links using any suitable of a variety of data communication protocols. Any wired connections may optionally be integrated into the floor and / or walls or ceiling of the operating room. The robotic system 100 may provide video output to one or more displays, including displays in the operating room and remote displays accessible via the Internet or other network. The video output or feed may also be encrypted to ensure privacy, and all or a portion of the video output may be stored on a server or electronic health care record system. It will be understood that the operating room scene of FIG. 1 is illustrative and may not accurately represent a particular medical procedure.

[0036] Referring to Figure 2, a portion of a robotic arm 200 (e.g., robotic arm 104) is illustrated according to one aspect of the present disclosure. The robotic arm 200 and related components described herein can form a surgical robotic system according to one embodiment of the present disclosure. The robotic arm 200 can be incorporated into the surgical robotic system 100 described with reference to Figure 1 or can form part of a different system. While a single robotic arm 200 is illustrated, it will be understood that the robotic arm 200 can include additional arm portions or can be a component of a multi-arm arrangement without departing from the present disclosure.

[0037] The robotic arm 200 may include multiple links (e.g., links 202A-202E) and multiple joint modules (e.g., joints 204A-204E) for actuating the multiple links relative to one another. The joint modules may include various joint types, such as pitch joints or roll joints, any of which may be actuated manually or by a robotic arm actuator (e.g., actuator 117), and any of which may substantially constrain movement of adjacent links about a particular axis relative to another axis. Also shown, a tool driver 206 is attached to the distal end of the robotic arm 200. As described herein, the tool driver 206 may be configured with an attachment device or docking interface 212 to receive an attachment portion (e.g., a mating interface or cannula lug) of a cannula and attach the cannula to the robotic arm so that one or more surgical instruments (e.g., an endoscope, a stapler, etc.) can be guided through the lumen of a trocar cannula. For example, the tool driver 206 may include an elongated base (or "stage") 208 and a tool carriage 210 slidingly engaged with the elongated base or stage 208. The stage 208 may be configured to couple to a distal end of the robotic arm 200, such that articulation of the robotic arm 200 positions and / or orients the tool driver 206 in space. The tool carriage 210 may be configured to receive a tool for extension through an associated cannula of a trocar. Additionally, the tool carriage 210 may actuate a set of articulation movements through a cable system or wires operated and controlled by an actuation drive (the terms "cable" and "wire" are used interchangeably throughout this application). The tool carriage 210 may include different configurations of actuation drives, such as mechanical transmissions. Multiple joint modules 204A-204E of the robotic arm 200 may be actuated to position and orient the tool driver 206 for robotic surgery.

[0038] With additional reference to FIG. 3, FIG. 3 illustrates an enlarged perspective view of an attachment device associated with a robotic arm (e.g., docking interface 212 of robotic arm 200). As described in more detail with reference to FIGS. 4A-4B, a cannula can be coupled to tool driver 206 or another component of surgical robotic system 100 at attachment device or docking interface 212 located on a distal block of elongated base 208. Attachment device or docking interface 212 is configured to receive a portion of the cannula (e.g., a cannula lug). Attached device or docking interface 212 may be referred to interchangeably herein as a cannula or trocar docking interface, attachment device, or mounting device. Docking interface 212 can provide a reliable and rapid method for attaching a cannula to surgical robotic system 100.

[0039] The attachment device or docking interface 212 can define a chamber 302 that is accessible through a mouth or front opening 304 of the docking interface 212, and the chamber 302 can include a first clamp component 306 and a second clamp component 308 (e.g., arms, plates, levers, members) arranged about a receiver 310 that defines a receiving space 312 for receiving a portion of a trocar or cannula (e.g., a cannula lug of a proximal portion of the cannula). At least one of the clamp components 306, 308 can be pivotable between an open position and a closed position such that the attachment portion of the cannula (e.g., a cannula lug) can be inserted into the receiving space 312 between the clamp components 306, 308, such that the portion of the cannula is held in place at least partially by the first clamp component 306 and the second clamp component 308.

[0040] In one variation, the mounting device or docking interface 212 may include an overcenter mechanism, such as an actuator, latch, or lever 314, or other suitable locking component, that mechanically cooperates with the clamp component 306, for example, through a pin and slot arrangement or through another pivotable or movable connection, between an open position and a closed position. The lever 314 may be coupled to or otherwise assist in locking the device in the open or closed position and, therefore, may be referred to as or considered part of a locking assembly or component herein. The actuator or lever 314 may be movable between a forward, locked position (e.g., a locked, overcenter position) and a rearward, unlocked position. When the actuator or lever 314 is moved toward the locked position, the lever 314 may urge the clamp component 306 downward toward the receiving space 312, locking the clamp component 306 in the closed position, thereby securely holding a portion of the cannula (e.g., the cannula lug) between the first clamp component 306 and the second clamp component 308. In some variations, the second clamp component 308 may be stationary or fixed. In one variation, the actuator or lever 314 may be controlled and / or actuated manually, automatically, or a combination of manually and automatically. Typically, in some embodiments, the attachment device may include a fully mechanical locking assembly that locks the clamp in an open position (e.g., a locked position) and then automatically transitions to a closed position (e.g., a locked position) upon detecting that the cannula has been properly inserted into the clamp. The specific configuration of the locking component and its operation are described in more detail with reference to FIGS. 4A-4B.

[0041] In some variations, the attachment device or docking interface 212 may also provide a sterile barrier between sterile components, such as between the cannula and non-sterile components such as the first and second clamp components 306 and 308 (or other non-sterile components of the surgical system). The sterile barrier may be provided, for example, by a sterile adapter interposed between the cannula and the first and second clamp components 306 and 308 (as described in more detail with reference to FIGS. 11A-11D).

[0042] In some embodiments, the attachment device or docking interface 212 may also include a sensor system 316. The sensor system 316 may be used, for example, to detect characteristics of a cannula positioned within the docking interface 212, as described in more detail with reference to FIGS. 6-7 and / or 10A-10B. The sensor system 316 may include a motherboard or first sensor board 318 in a first location in the docking interface 212 and a daughterboard or second sensor board 320 in a second location in the docking interface 212 and in electrical communication with the first sensor board 318 via a cable 322 or other conductive connection. In one variation, communication between the sensor boards 318, 320 may use a multi-slave and multi-master inter-integrated circuit communication computer bus. One or both of the sensor boards 318, 320 may include a microprocessor or other associated processor, for example, to control and / or read out the sensors of the sensor boards 318, 320 and to facilitate communication between the sensor boards 318, 320, for example, to enable temporal synchronization between the sensor boards 318, 320. As shown, the first sensor board 318 and the second sensor board 320 are positioned parallel but spaced apart from each other, for example, facing each other on opposite sides of the chamber 302 of the docking interface 212. The first sensor board 318 may include a first plurality of sensors 324, and the second sensor board 320 may include a second plurality of sensors 326. For example, the sensors 324, 326 may be embedded in or otherwise coupled to the robotic arm 200 or the tool driver 212. Each of the plurality of sensors 324, 326 may be arranged such that at least one sensor 324, 326 is disposed rearward relative to another respective sensor 324, 326, for example, at a depth measured from the front opening 304 of the docking interface 212. Although the sensors 324, 326 are described in a grid-like column configuration, it will be understood that one or both of the plurality of sensors 324, 326 may have a different arrangement without departing from this disclosure.

[0043] As described further herein, sensors 324, 326 may be operable to sense or measure a magnetic field associated with a cannula inserted therein and generate a respective corresponding electrical signal. In this regard, sensors 324, 326 may be configured as magnetometers, e.g., sensors that receive at least a portion of a magnetic field as an input and generate an output electrical signal corresponding to the strength or other characteristic of the magnetic field, thereby making sensors 324, 326 transducers. Any of sensors 324, 326 may be configured to receive a different physical input and generate a corresponding electrical signal, e.g., an inertial measurement unit, an accelerometer, or the like. In this regard, as described further herein, sensors 324, 326 generate output electrical signals that may be electrically communicated to a processor or controller associated with a control tower to provide force or velocity commands to command movement of a robotic arm (e.g., robotic arm 200) via a robotic arm actuator (e.g., actuator 117). It will be understood that processors can be incorporated into additional or alternative portions of the surgical robotic system 100, and that the sensor system 316 can be in electrical communication with one or more different processors. For example, as described further herein, a switch 328 or other control is mounted on or near the docking interface 212, e.g., on the backside of the actuator or lever 314, in a location that can bias the actuator or lever 314 into contact with the switch 328. The switch 328 can be in electrical communication with a processor in the control tower and signal the processor to energize or activate one or both of the sensor boards 318, 320, activate the sensor system 316, sense or measure magnetic fields, and guide the robotic arm toward the cannula according to an algorithm, as described further herein.In one variation, system 316 can be activated by a processor prior to or independent of activation of switch 328, which signals the processor to initiate calculations based on signals received from sensor system 316 to determine an estimated pose of the cannula, which can then be used to guide robotic arm 200 and its coupled tool driver 206. Switch 328 can have one of several different configurations; for example, a combination of a mechanical button and mechanical switch may be preferred, although another form of tactile interface or touch screen that can be activated by a user is also possible.

[0044] Although the sensor boards 318, 320 are generally described as first and second printed circuit boards (PCBs) including respective sensors 324, 326 embedded therein or thereon, it will be understood that the sensor system 316 may be provided in different arrangements, for example, as separate components, without departing from this disclosure. Additionally, it will be understood that any of the components described herein may communicate via wired and / or wireless links using any suitable of a variety of data communication protocols.

[0045] Aspects of the attachment device or docking interface and its operation are described in more detail below with reference to FIGS. 4A-4B. Typically, as seen in FIGS. 4A-4B, the attachment device or docking interface 212 may include a first clamp component 306 and a second clamp component 308 that define an opening 304 (e.g., a receiving space or chamber) for receiving a cannula 404. A latch, actuator, or lever 314 is also provided for transitioning the first clamp component 306 and the second clamp component 308 between an open position (allowing insertion of the cannula 300 between the clamp components 306, 308) and a closed position (locking or clamping the cannula 300 between the clamp components 306, 308). Typically, the first clamp component 306 may be movable or pivotable about a clamp pivot point 402 by the lever 314 between an open position as shown in FIG. 4A and a closed position as shown in FIG. 4B. In some variations, the second clamp component 308 may be fixed or stationary. In other variations, the second clamp component 308 may be pivotable similar to the first clamp component. The second clamp component 308 may be spaced from the first clamp component 306 to form an opening 304 configured to receive a portion of the cannula 404, such as the mounting portion or cannula lug 406 of the cannula 404.

[0046] The two clamping components 306, 308 may be supported on a support component 420, such as, for example, a plate, bar, beam, or other suitable surface of a tool driver of a robotic surgical system. The first clamping component 306 may be supported on the support component 420 at a first location via a first pivot point 402 (e.g., a pin joint, hinge, etc.), and the second clamping component 308 may be supported on the support component 420 at a second location spaced apart from the first clamping component 306. In some variations, the first clamping component 306 may be attached to a pivot structure that allows the first clamping component 306 to rotate about the pivot point 402, and the pivot structure may be attached to the support component 420. In such variations, the first clamp component 230 can be attached to the pivot structure via fasteners (e.g., bolts, nails, screws, pins, etc.) or adhesives (e.g., epoxy, polyurethane, polyimide, etc.), and / or other fastening techniques including, for example, crimping, welding, brazing, etc. In other variations, the first clamp component 306 can be integrally formed with the pivot structure, such as, for example, a living hinge. In some variations, the second clamp component 308 can be attached directly to the support component 420 via fasteners (e.g., bolts, nails, screws, pins, etc.), adhesives (e.g., epoxy, polyurethane, polyimide, etc.), and / or other fastening techniques (e.g., crimping, welding, brazing, etc.). In other variations, the second clamp component 308 can be integrally formed with the support component 420. In some variations, the two clamp components 306, 308 can be formed of plastic, metal, or a composite material. In some variations, the two clamping components 306, 308 may be formed via machining, molding, or other manufacturing techniques. While the variations shown generally depict two opposing clamping components, it should be understood that in other variations, the mounting device may include more than two clamping components.

[0047] In some embodiments, the two clamp components 306, 308 may be non-sterile, and the cannula 404 may be sterile. Accordingly, a sterile adapter 450 may be provided that separates the non-sterile clamp components 306, 308 from the sterile cannula 404. As depicted in FIGS. 4A-4B , the sterile adapter 450 may form a sterile barrier between the non-sterile clamp components 306, 308 and the sterile cannula 404. The sterile adapter 404 may be a cover having an opening 452 for receiving the attachment portion 406 of the cannula 404 such that the attachment portion 406 is covered or surrounded by the sterile adapter 450 when received within the sterile adapter 450. The sterile adapter 450 may be sufficiently flexible so that certain portions can deform (e.g., to receive the mounting portion 406 when it is inserted through the opening), while other portions may be sufficiently rigid to retain an undeformed or resting shape that generally corresponds to the shape of the mounting portion 406 of the cannula 404. Particular configurations of the sterile adapter 450, including both flexible and rigid portions, are described in more detail with reference to Figures 11A-11D.

[0048] The sterilization adapter 450 may be removably attached to the base member 420 so that it can be replaced as needed. For example, the sterilization adapter 450 may include an engagement mechanism that latches onto an edge or ridge of the base member 420 (or other support member coupled to the base member 420).

[0049] As further shown, the cannula 404 can have a proximal portion 416, such as a hub, fitting, connector, or the like. The proximal portion 416 of the cannula 404 can include an attachment portion 406. The attachment portion 406 can extend from a side of the proximal portion 416 and can be configured for insertion into the opening 304 of the attachment device or docking interface 212. The cannula 404 can also have a shaft 418 (partially depicted in FIGS. 4A-4B ) extending from the proximal portion 416. The shaft 418 can have a lumen through which one or more surgical instruments can be inserted. When the cannula 404 is disposed within a patient, the distal end of the shaft can be positioned within the patient's body, such as, for example, a body cavity.

[0050] To allow a robotic surgical procedure to begin, the surgical robotic arm must be docked to a cannula. Therefore, at some point in the workflow, surgical staff place the surgical robotic arm in the sterile field to gain access to the surgical field. During this operation, the robotic arm (on a surgical table or cart) is manually or autonomously guided by surgical staff or a surgeon toward a surgical port (incision). The goal is to "dock" the surgical arm to the cannula, establish a firm connection, and then deploy a surgical tool through the access channel. Due to the delicate nature of interacting with the surgical incision and the confined space within the operating room, this operation is typically performed by one person, with one hand on the robot and one hand on the cannula. This can be problematic because the user's ability to grasp the arm is limited by the position of the cannula and the geometry of the arm. For example, the locking component (e.g., a lever or actuator) for locking the cannula to the arm may not be accessible in all configurations, and the geometry of the arm may present pinch points. The attachment device or docking interface 212 addresses some of these issues by providing an improved configuration for attaching (e.g., docking) the cannula to the surgical robotic arm, allowing the user to grasp the arm anywhere they wish, and providing audible, tactile, and visual feedback regarding task success.

[0051] Typically, as discussed above, the attachment device or docking interface 212 may include a fully mechanical locking assembly that locks the device (e.g., lever 314 and / or first clamp component 306) in an open position (e.g., a locked position) and then allows the device 212 to automatically transition to a closed position (e.g., a locked position) upon detecting that a cannula has been properly inserted into the clamp. For example, the assembly may automatically transition through three states during docking of the cannula to the robotic arm. Typically, these states may include: 1) a locked-out open position that allows the user to signal to the system that "docking mode" is in progress; 2) mechanical detection that the cannula is in the correct position for docking; and 3) automatic clamping of the cannula and signaling to the user that the cannula is attached.

[0052] To transition the attachment device 212 through these states, the device may include a lever 314, as discussed above, which may also be interchangeably referred to herein as a locking component or actuator. The lever or locking component 314 may be movably coupled to a base 420 and the first clamp component 306. For example, the lever or locking component 314 may be coupled to the base 420 and move relative to the base at a pivot point 422. The lever or locking component 314 may further be coupled to the first clamp component 306 by a link 424 that includes pivot points 426, 428 that allow the locking component 314 and the first clamp component 306 to move relative to one another. For example, as shown in FIG. 4A , when in an open position (e.g., a locked-out open position), the lever or locking component 314 is pivoted about the pivot point 422 to a rearward position (e.g., away from the base 420). Due to the coupling of locking component 314 to first clamping component 306 by link 424, this movement in turn causes first clamping component 306 to pivot upward (e.g., away from opening 304) about pivot point 402. In this embodiment, locking component 314 and / or first clamping component 306 are in the open position and cannula 404 can be inserted into opening 304.

[0053] As discussed above, locking component 314 and first clamping component 306 are held (or locked) in this open position (e.g., a locked out open position) until cannula 404 is properly inserted into opening 304. In this aspect, the device may further include a lockout mechanism 430 to hold or lock locking component 314 and first clamping component 306 in this open position (e.g., a locked out open position) until proper insertion of the cannula is mechanically detected. For example, lockout mechanism 430 may be a trigger-like mechanism including hooks 432 on one end and the other end pivotally coupled to base 420 at pivot point 434. Hook 432 is configured to hook around or otherwise engage with a bearing 436 attached to lever or locking component 314 when locking component 314 is in the open position to hold lever or locking component 314 (and first clamping component 306) in the locked out open position. Lockout mechanism 430 may further include a protruding member 438, which disengages lockout mechanism 430 from lock component 314 upon contact with a cannula properly inserted and / or aligned within opening 304. This, in turn, allows lock component 314 to automatically transition to the closed position. For example, protruding member 438 may reside between hook 432 and pivot point 434 and extend into opening 304 when lockout mechanism 430 engages with lever or lock component 314 (e.g., hook 432 is around bearing 436). When cannula lug 406 is inserted into opening 304 as shown in FIG. 4B , cannula lug 406 contacts protruding member 436 and pushes it away from opening 304. This, in turn, pivots lockout mechanism 430 rearward, causing hook 432 to disengage or otherwise release lock component bearing 436. The locking component or lever 314 may be biased toward a closed position (e.g., a forward position) by a spring 440 so that when released from the lockout mechanism 430, it automatically pivots forward (e.g., closer to the base 420) to the closed position to attach the cannula 404 to the robotic arm.

[0054] In some aspects, proper docking or alignment of the cannula 404 (e.g., cannula lug 406) relative to the attachment device or interface 212 must cause or otherwise detect an automatic transition of the locking component 314 and / or clamping components 306, 308 from a locked open position to a closed position. A proper docking or alignment position means that the cannula is in a position within the opening that is suitable for attachment to a surgical robotic system. An improper or misaligned position means that the cannula is in a position within the opening that is not suitable for attachment to a surgical robotic system. For example, as discussed above, the cannula 404 must be in a proper docking or alignment position within the opening 304 such that the cannula end 412 is inserted sufficiently into the opening 304 to contact the lockout mechanism 430 and disengage from the lever 314. If the cannula 404 is not in the proper docking position or is misaligned, the lockout mechanism 430 will not disengage, and the locking component 314 and / or clamping component 306 will remain in the locked position until the proper alignment or docking position is detected. Thus, the proper docking or alignment position of the cannula may be considered to be mechanically detected by the system (e.g., as detected by the attachment device or interface 212) when the cannula lugs 406 contact the lockout mechanism 430 or otherwise disengage from the lever 314. For example, in some aspects, the attachment device or interface 212 may include specific shapes and / or surface features that only engage with the cannula 404, allowing the cannula 404 to disengage the lockout mechanism 430 from the lever 314 when the cannula is in the docked position or otherwise properly aligned within the opening 304.In a further aspect, cannula 404, and more specifically cannula lug 406, may be considered to have a particular shape and / or surface features that mate only with attachment device or interface 212, allowing cannula 404 to disengage lockout mechanism 430 from lever 314 when cannula lug 406 is in a docking position or otherwise properly aligned within opening 304.

[0055] Typically, in some embodiments, second clamp component 308 may have alignment structure 444 in the form of a beveled surface. Alignment structure 442 may be capable of mating with or otherwise being aligned with a complementarily shaped alignment structure 414 (e.g., a beveled surface) on the bottom side of cannula lug 406. Alignment structures 444, 414 are described in more detail with reference to Figures 10B-10C.

[0056] In still further aspects, the first clamp component 306 may include an alignment structure 442 forming a triangular protrusion. The alignment structure 442 may be capable of engaging or otherwise aligning with a complementary shaped alignment structure 408 (e.g., a recessed area) on the top side of the cannula lug 406. For example, the cannula 404 may be moved in the direction of the arrow such that the attachment portion 406 of the cannula 404 is inserted into the area between the two clamp components 306, 308, or more specifically, through an opening 304 located in the area between the two clamp components 306, 308. In some variations, a surface of the first clamp component 306 may be configured to help guide and orient the attachment portion 406 when it is inserted into the area between the two clamp components 306, 308. For example, the surface of the first clamp component 306 may be angled to smoothly receive the mounting portion 406 when it is inserted into the area between the two clamp components 306, 308 in the predefined orientation shown in FIG. 4A (e.g., an orientation that allows engagement between the interfacing surfaces, with structure 408 facing structure 442). When the mounting portion 406 is inserted into the area between the two clamp components 306, 308 in a different orientation, structure 442 may push against or otherwise interfere with the mounting portion 406, indicating that the mounting portion 406 is not properly oriented relative to the two clamp components 306, 308. For example, when the mounting portion 406 is not inserted into the area between the two clamp components 306, 308 in a predefined orientation, the structure 442 may prevent the mounting portion 406 from being inserted into the area between the two clamp components 306, 308 (e.g., by creating a gap that is too small for the mounting portion 406 to be inserted into the area). In some variations, to help guide the mounting portion 406 into the opening 304 between the two clamp components 306, 308, the structures 442, 408 may have complementary angles that mate with each other only when the mounting structure 406 is inserted into the opening 304 in a single orientation (e.g., in the proper docking and / or alignment position).

[0057] In some embodiments, the alignment features 408, 414 of the cannula lugs 406 may differ such that the lugs 406 are considered to have an asymmetrical shape that allows them to fit within the attachment device 212 in only one position. In this embodiment, when the cannula lugs 406 are detected to be in the proper docked or aligned position within the opening 304 (as shown in FIG. 4B ), the device 212 automatically closes and clamps onto the cannula 404. This, in turn, solves an important surgical workflow problem by providing a fully mechanical and safe solution for docking a cannula to a robotic arm when access to a mechanical lever is difficult or impossible. Additional alignment features and configurations are described in more detail with reference to FIGS. 10A-10C .

[0058] In some embodiments, upon mechanically detecting that the cannula 404 is in the proper docking position and / or that the device 212 has transitioned to the closed position, the system may further signal to the user that the cannula is in the docking position and / or that the cannula is attached. For example, one or more of the sensors discussed above (e.g., sensor system 316 or switch 328) may detect that the device 212 is in the closed position and signal the user that the cannula is attached. Additionally, the system may signal to the user whether the device 212 is in docking mode or clamping mode based on whether the device 212 is in the locked-out open position or the closed position. The signal may be in the form of a message or indicator on a system display, audio feedback, tactile feedback, or any other suitable notification to indicate the system state or mode (or change in system state or mode) to the user. FIG. 5 illustrates an example process flow for indicating the state or mode of the device 212 to the user. Typically, process 500 may include providing a cannula attachment device (e.g., 212) in operation 502, then determining whether the device is in an open position in operation 504. For example, device 212 may be determined to be in the open position if, for example, lever 314 or first clamp component 306 is in the open position. If the device is determined to be in the open position, the user is notified in operation 506 that the device is in a docking mode. In other words, the user may still be positioning the cannula within the device opening, and / or the cannula may be in the opening but not yet properly aligned. If the device is not in the open position, the process continues by determining whether the device is in a closed position in operation 506. For example, device 212 may be determined to be in the closed position if, for example, lever 314 or first clamp component 306 is in the closed position. If the device is determined to be in the closed position, the user is notified in operation 508 that the device is in a clamp mode or that a cannula has been attached.If operation 506 has not yet determined that the device is in the closed position, this may mean that the user is still attempting to properly position the cannula on the device, and therefore the process returns to operation 506 to inform the user that the device is in docking mode.

[0059] In still further aspects, the attachment device or docking interface may include additional features that enable detection of any scenario that may indicate the presence of a cannula, proper latching engagement with the cannula, the angle of the lever, the type of cannula attached or docked, and / or release of the cannula. For example, sensors driving finite state machines to detect any one or more of the aforementioned scenarios or characteristics may be integrated into device 212 and / or cannula 404. Each of these conditions can then be communicated to the user using visual, audio, or other forms of feedback on the robotic arm and via any form of similar feedback on the surgeon bridge. By way of background, it should be understood that when docking a surgical robotic arm to a cannula, a precise scheme is needed to sense that the cannula (1) is properly docked to the arm with the attachment device fully closed, (2) detect what type of cannula (e.g., standard / bariatric, 8mm / 12mm) is docked and communicate that to the system, and (3) monitor whether the cannula has been released or undocked in any way. In this aspect, Figure 6 illustrates a schematic diagram of one exemplary sensor arrangement for detecting any one or more of the aforementioned scenarios or characteristics. Typically, Figure 6 illustrates at least one sensor 602 for detecting a characteristic of locking component or lever 314 and at least one sensor 604 for detecting a characteristic of cannula 404. In one aspect, sensors 602, 604 may be magnetic encoders, and lever 314 and cannula 404 may include magnets 606, 608, respectively, that are detected by the encoders.

[0060] The characteristic of the locking component or lever 314 detected by sensor 602 may be the angle of the locking component or lever 314. For example, any angle within a range of angles (A) may be detected. The angle of the locking component or lever 314 may be further used to determine, for example, whether the lever 314 is open or closed, whether the cannula is properly docked, or other characteristics associated with cannula attachment. For example, if the lever 314 is detected at angle 610, the system may determine that the lever 314 is in a locked-out open position. On the other hand, if the lever 314 is detected at angle 612, the system may determine that the lever 314 is in a closed position. The angle may be measured relative to any point suitable for determining lever position, such as pivot point 436 or the central axis of the lever 314.

[0061] Typically, as discussed above, in operation, when the robotic arm is ready to dock to the cannula, lever 314 may be manually moved to an open position by a user, and a lockout mechanism holds lever 314 in the open position. Detection of this movement by sensor 602 may be used by the system to determine that a gravity compensated active back (GCAB) drive mechanism associated with the surgical robotic arm should be engaged to allow the robotic arm to be positioned on the docking interface or attachment device 212. As discussed above, once the robotic arm is positioned and the cannula is pressed into the opening of device 212, the lockout is disengaged, allowing the latch to close and secure the cannula to the arm. At this point, lever sensor 602 senses that the lever has closed and passed a mechanical overcenter point (e.g., the angle corresponding to position 612). This information may then cause the system to disengage the GCAB to hold the arm in the docked or attached position. The signal from sensor 602 may be actively monitored so that if lever 314 is accidentally depressed after the cannula is attached, the system transitions to an error state where the procedure must be stopped and the user notified.

[0062] Referring hereinafter to the characteristics of the cannula 404 detected by the sensor 604, representative characteristics may include, but are not limited to, (1) the presence of the cannula 404 in the open device 212 and (2) the type of cannula. For example, when the cannula 404 is inserted into the opening, thereby causing the sensor 604 to detect the magnet 608, it may be determined that the cannula 404 is present. When the sensor 604 does not detect the magnet 608, it may be determined that the cannula 404 is not present. The presence (or absence) of the cannula 404 may also be used, for example, to determine whether the cannula has been properly docked and / or released. For example, if the presence of a cannula is detected by the cannula sensor 604 and the lever is determined to be in the closed position based on information from the lever sensor 602, the system may determine that the cannula is properly attached to the device (and the robotic arm). On the other hand, if the cannula sensor 604 does not detect the presence of a cannula and the lever is determined to be in the open position based on information from the lever sensor 602, the system may determine that the cannula is released or is not properly attached to the device (and robotic arm).

[0063] The type of cannula can be detected based on the angle of magnet 608 detected by sensor 604. In addition, sensing the magnetic orientation provides an additional data point that the cannula is present and stable within device 212, but primarily serves to provide specific identification information regarding the type of docked cannula so that information can be communicated to the robotic system and the user. For example, each type of cannula 404 can have its magnet positioned at a different angle, as exemplified by magnets 608A, 608B, and 608C. The angle can be, for example, the angle of the centerline of the magnet's polar axis relative to the orientation of the magnet's north pole. Thus, when sensor 604 detects angled magnet 608A, angled magnet 608B, or angled magnet 608C, the system can match the detected angled magnet to the specific type of cannula it is associated with and notify the user of the cannula type. Representative magnetic field orientations that can be detected by the sensor and their respective cannula types that can be determined by the system are shown in Table 1 below.

[0064] [Table 1]

[0065] By using sensor 604 to monitor the type of cannula, there is an opportunity to detect false or mismatched cannulas, as well as sense problems with the latching that may allow excessive movement of the cannula within the latching mechanism.

[0066] Additionally, sensor 604 provides an additional signal that indicates when a certain magnetic threshold has been reached and can then be used to confirm the presence of cannula 404 in device 212. While this can also be achieved by having a valid cannula type or reading identification information as discussed above, this signal is a more specific binary value and can be the primary signal used for cannula presence. Loss of this signal at any point can indicate cannula release and can cause the system to transition into an error state that halts the procedure and notifies the user.

[0067] As discussed above with reference to FIG. 3 , the sensors 602, 604 may be electrically connected to a sensor board 320 positioned within the device opening 304, or may be positioned anywhere on the device 212 suitable for detecting the desired characteristic. The sensor board 320 may include a microprocessor or other associated processor 614, for example, to control and / or read the sensors 602, 604 of the sensor board 320, to facilitate communication of information from the sensors 602, 604 to a user, and to determine one or more of the above-discussed characteristics based on the sensor information. Additionally, although the sensor 604 is described as a single sensor that outputs two separate signals indicative of the presence and type of cannula, different sensors for separately detecting each of these characteristics may be used. Still further, while only two sensors 602, 604 are illustrated, it is contemplated that at least four or more sensors may be used to provide redundancy for safety reasons.

[0068] Referring now in more detail to the operation of the system based on information detected by the sensors discussed above, Figure 7 illustrates one representative process. In one aspect, process 700 includes an initial state or mode in which the system is considered ready to dock a cannula at operation 702. For example, the system may be considered ready to dock a cannula when the system (e.g., a sensor) detects that attachment device or interface device 212 is in a locked-out open position, thereby preparing to insert a cannula (e.g., lever 314 is engaged with lockout mechanism 430, and lever 314 and / or first clamp 306 are in an open position), and / or when it is determined that a cannula is not present. Once the system determines in operation 702 that it is ready to dock the cannula, in operation 704, one or more associated processors may cause the surgical robotic system to engage or disengage a brake assembly associated with the surgical robotic arm and engage a gravity compensated active back (“GCAB”) drive mechanism associated with the surgical robotic arm to enable positioning of the cannula within a clamp assembly associated with the surgical robotic arm. Additionally, once the GCAB is engaged, if the system (e.g., a sensor assembly) detects a transition of the clamp assembly (e.g., lever 314 or clamp 306 of mounting device 212) to a closed position and / or that the cannula is not present within the clamp assembly, the process returns to operation 702. For example, the one or more processors may cause the surgical robotic system to engage a brake assembly associated with the surgical robotic arm and disengage a GCAB drive mechanism associated with the surgical robotic arm such that the current position of the cannula relative to the clamp assembly is maintained.Alternatively, once the GCAB is engaged, if the system (e.g., a sensor assembly) detects the clamp assembly transitioning to the closed position and a cannula is present, the system may determine that a cannula has been inserted into the clamp assembly in operation 706, and the one or more processors may cause the surgical robotic system to notify a user that a cannula has been inserted. Additionally, once a cannula is detected and the system recognizes that it has been inserted in operation 706, the system may further determine the type of cannula inserted and notify the user of the type of cannula. For example, as discussed above, a sensor assembly associated with the attachment device may determine the type of cannula based on the orientation of a magnet. Once the cannula has been determined to be properly inserted in operation 706, the system may notify a user that the cannula has been docked or otherwise attached to the attachment or clamp assembly of the surgical robotic arm in operation 708. Additionally, in operation 706, the cannula is inserted, but then, if the system determines that it senses the clamp assembly is open, that the presence of a cannula is not detected, or that a cannula identifier (ID) cannot be detected, the system may engage the brake assembly and return to operation 702. Additionally, the system may notify the user that the latch is currently open and / or that a cannula is not detected, and therefore, an error may have occurred and the procedure is stopped. In other words, the system may notify the user that the system is ready to attach a cannula. In this aspect, a sensor assembly integrated into the attachment device (or clamp assembly) is used to drive a finite state machine to detect any scenarios that may indicate the presence of a cannula, proper latch engagement to the cannula, the type of cannula docked, and release of the cannula. Each of these conditions can then be communicated to the user using visual, audio, or other forms of feedback on the robotic arm, as well as via any form of similar feedback on the surgeon bridge.

[0069] Returning to additional aspects of the attachment device below, FIGS. 8A-8B illustrate an overcenter configuration of the attachment device. FIGS. 8A-8B illustrate the same attachment device or interface 212 described with reference to FIGS. 4A-4B, but the overcenter configuration is shown in more detail below. The overcenter configuration ensures reliable and secure attachment of the cannula to the surgical robotic arm, while also allowing the user to disconnect and reconnect the two items as needed. For example, the overcenter configuration may prevent the attachment or clamping mechanism (e.g., a lever) from being back-driven to an open position by force applied to the cannula. Once overcenter, any increase in load applied to the cannula causes the lever to gradually close itself. This helps ensure that the cannula is firmly and securely held to the robotic arm during surgery. Typically, FIG. 8A illustrates the attachment device or interface 212 in the locked-out open position, as discussed above with reference to FIG. 4A. In this open position, the attachment device or interface 212 is not considered to be in an overcenter configuration. Figure 8B illustrates the attachment device or interface 212 in a closed position, as discussed above with reference to Figure 4B. For example, in the closed position, the actuators or levers all rest forward relative to the base. For example, the actuators or levers push a first clamping component forward, which then clamps the cannula lug against a second clamping component, holding it securely with the attachment device or interface 212. In this closed position, the attachment device or interface 212 is considered to be in an overcenter configuration because the associated four-bar linkage mechanism is designed to be overcenter.

[0070] Typically, as discussed above, the attachment device or interface 212 includes a locking component, actuator, or lever 314 movably connected to a base 420 at a pivot point 422 near one end, which allows the other end of the lever 314 to move between an open (rearward position) and a closed (forward position). In one embodiment, the end 314A of the lever 314 moves between the open and closed positions and can be manually controlled by a user. The pivot point 422 can be near the other end 314B of the lever 314, which can be coupled to a lockout mechanism when the device is in the locked-out open position. Additionally, the first clamping component 306 is movably connected to the base 420 at a pivot point 402 on one end 306A, which allows the other end 306B of the first clamping component 306 to move between an open (unclamped) position and a closed (clamped) position. The lever 314 and first clamp component 306 are also movably connected to one another by a link 424. The link 424 is connected to the lever 314 at a pivot point 428 at one end and to the first clamp component 306 at a pivot point 426. In other words, the linkage mechanism of the device 212 may include at least four pivot points 402, 422, 426, and 428 that form a four-bar linkage mechanism. Accordingly, the linkage mechanism pivot points may also be referred to herein as the first pivot point 426, the second pivot point 428, the third pivot point 402, and the fourth pivot point 422. In operation, at the start of a closing stroke (e.g., as the lever 314 moves forward toward the base 420 as illustrated by the arrows), the pivot point 426 (e.g., the first pivot point) moves in front of the pivot point 428 (e.g., the second pivot point) through the rotation of the mechanism. As the mechanism approaches its fully closed position, as shown in FIG. 8B, pivot point 428 (e.g., second pivot point) overtakes pivot point 426 (e.g., first pivot point), at which point the mounting device 212 (e.g., lever 314) is said to be over-center.For example, in some embodiments, the attachment device 212 may be considered fully closed (latched) when the pivot point 428 (e.g., the second pivot point) is over-center with respect to the pivot point 426 (e.g., the first pivot point) by an over-center angle (OCA) of less than or at least 1 degree. This particular over-center angle (OCA) is important to ensure that the device is indeed over-centered but does not reach a maximum over-center angle at which the clamping force on the cannula lugs begins to decrease. As discussed above, this over-center configuration results in the attachment device causing itself (e.g., the first clamp component 306) to gradually close with any increase in load applied to the cannula.

[0071] A lockout mechanism for retaining the attachment device in a locked open position is described in more detail below with reference to FIGS. 9A-9D. Representatively, FIGS. 9A-9B illustrate enlarged cross-sectional side views of the lockout mechanism, and FIGS. 9C-9D illustrate enlarged cross-sectional side views of the adjustment mechanism of the lockout mechanism of FIGS. 9C-9D. The lockout mechanism of FIGS. 9A-9D may be substantially similar to, and therefore include the same features as, lockout mechanism 430 described with reference to FIGS. 4A-4B. However, for clarity, certain features of the lockout mechanism may be omitted from FIGS. 9A-9D.

[0072] 9A , lockout mechanism 430 may be a trigger-type locking mechanism including hooks 432 on one and the other ends pivotally coupled to the base of the mounting device at pivot point 434. Hook 432 is configured to hook around or otherwise engage a bearing 436 of lever 314 to hold lever 314 (and associated clamp components) in a locked-out open position. Lockout mechanism 430 further includes a protruding member 438 between hook 432 and pivot point 434 and a spring 902 at pivot point 434. Spring 902 may bias lockout mechanism 430 toward the locked-out open position (e.g., a position where hook 432 is hooked around bearing 436). Protruding member 438 faces the opening in the attachment device and may be pressed by the cannula during insertion, causing lockout mechanism 430 to pivot at pivot point 434 as shown by the arrow, causing hook 432 to unhook or otherwise disengage from bearing 436 of lever 314. This, in turn, biases the attachment device toward the closed position (e.g., clamping the first clamp component onto the cannula), as discussed above, thereby allowing the attachment device to automatically transition to the closed position.

[0073] In this manner, the lockout mechanism 430 can be actuated tens of thousands of times. Accordingly, the various components of the lockout mechanism 430 are selected or configured to withstand such use without wear or loss of reliability. Typically, to prevent the interface between the hook 432 of the lockout mechanism 430 and the bearing 436 of the lever 314 from wearing down over time, the bearing 436 can be a ball bearing that can roll along the surface of the hook 432 instead of sliding. For example, if the hook 432 hooks around a fixed structure instead of the ball bearing 436, the two structures will slide along each other until they disengage, releasing the trigger. This sliding action can wear down these interfaces over time. Accordingly, the lockout mechanism 430 includes a ball bearing 436 that rotates with any triggering action and movement of the hook 432 to ensure that static metal surfaces do not rub against and wear against each other.

[0074] Additionally, the hook 432 can be configured to reduce wear and increase reliability. For example, the geometry of the hook 432 is selected to engage and disengage with the bearing 436 as needed while minimizing wear at the interface. Exemplarily, reference is now made to FIG. 9B , which shows a close-up of the hook / bearing interface indicated by the dashed line in FIG. 9A . As can be seen in FIG. 9B , when the lockout mechanism 430 is engaged and waiting to be triggered, the tip 904 of the hook 432 is above (or beyond) the contact point 906 of the bearing 436. This positions the hook 432 so that the bearing 436 is fully nested within the hook 432. As the lockout mechanism 430 begins to be triggered and moves along its rotational path 912, the hook tip 904 moves in a disengagement direction 908, approaching the contact point 906 of the bearing 436. Once the hook tip 904 reaches its contact point 906, the bearing 436 rapidly rotates, causing the lockout mechanism 430, which is biased by the spring 902 to disengage the bearing 436, to release the bearing 436. Upon release, the bearing 436 moves along a rotational path 914 (as a result of the rotation of the lever 314 about the pivot point 422), thereby allowing the lever 314 (and first clamp component) to automatically transition to the closed position. The lockout mechanism 430 moves the hook tip 904 in the engagement direction 910 to re-engage with the lever 314 as it passes (e.g., extends beyond) the contact point 906. Thus, the geometry of the hook 432 can be selected to match the (e.g., curved) outer surface of the bearing 436 and to have a depth (D), measured from the tip 904 to the bottom of the hook 916, that allows the tip 904 to extend beyond the bearing contact point 906 when the bearing is fully seated within the hook 432. Additionally, as discussed above, throughout this process, hook 432 is biased into an engaged position by spring 902 to ensure that it does not release the trigger until it is intentionally triggered. Thus, the weight of spring 902 may also be selected to provide a secure engagement without significantly affecting the force required to release lockout mechanism 430.

[0075] In still further aspects, lockout mechanism 430 may provide audible and / or tactile feedback when engaged / disengaged. For example, when bearing 436 is released from hook 432, the rotational action allows the bearing to smoothly snap out of the hook, creating audible and / or tactile feedback notifying the user that the mechanism has been released. Additionally, when lockout mechanism 430 is re-engaged, bearing 436 may act in the same manner as when released, with the rotational action of the bearing allowing it to smoothly snap back into place, providing feedback.

[0076] Additionally, in some aspects, the force required to trigger the lockout mechanism may be adjustable. As discussed above, lockout mechanisms have several usability benefits within the docking workflow. The force required to trigger the lockout mechanism and complete docking is important to the workflow. Too much force requirement can make it very difficult for surgical staff to complete the docking procedure, while too little force requirement can result in inadvertent triggering of the lockout mechanism and premature closure of the latch before docking is complete. Allowing this force to be adjusted during assembly allows for the exact level desired from a usability perspective.

[0077] An exemplary force adjustment mechanism is shown in FIGS. 9C-9D. In some embodiments, the force adjustment mechanism 920 can be a mechanism or structure that, when tightened, biases the lockout mechanism 430 toward disengagement. For example, the force adjustment mechanism 920 can be a set screw in some embodiments. As illustrated in FIG. 9C, the set screw can extend through the lockout mechanism 430 into the hook / bearing interface when tightened in the direction of arrow 922. Typically, when the lockout adjustment set screw is tightened, it compresses the lockout bearing 436, shifting the hook 432 to have less engagement with the lockout bearing 436 than before tightening. In other words, the distance (D1) between the bottom 916 of the hook 432 and the bearing 436 increases. This reduces the distance that must be traveled to disengage the hook 432, and therefore the force required to disengage the lockout mechanism 430. The opposite can be achieved by loosening the set screw in the direction of arrow 924, as shown in FIG. 9D. 9D, when the screw is loosened, the distance (D2) between the hook 432 and the bearing 436 decreases, resulting in greater engagement between the hook 432 and the bearing 436. This results in an increase in the force required to disengage the lockout mechanism 430. The position of the adjustment mechanism 430 can be set after assembly of the mounting device, and the actuation force can be verified before assembling the mechanism into the robotic arm.

[0078] Additionally, as discussed above, the interface between the clamp component and the cannula can also play an important role in ensuring a secure attachment between the cannula and the attachment device (and associated surgical robotic arm). Specific aspects of several exemplary clamp / cannula alignment or interface structures are described in more detail below with reference to Figures 10A-10C. While not shown, it should be understood that the attachment device or interface described with reference to Figures 10A-10C may be substantially similar to the attachment device or interface 212 discussed above with reference to Figures 4A-4B, albeit with certain components not shown and / or omitted.

[0079] FIG. 10A illustrates a side cross-sectional view of one embodiment of an interface or alignment structure for a cannula lug. Typically, as discussed above with reference to FIGS. 4A-4B, the top side of the cannula lug 406 can include an alignment structure 408. From this view, it can be seen that the alignment structure 408 can be considered to have a reverse taper formed by angled surfaces 1002, 1004. The angled surfaces 1002, 1004 form a triangular-shaped recessed area on the top side of the cannula lug 406. The first clamp component 306, in turn, can include a complementary cannula mating structure 442 that interfaces with structure 408 when the clamp is in the closed position. For example, the mating structure 442 can be a triangular-shaped end that is angled to draw the cannula lug 406 into the attachment device. For example, the reverse taper formed by structure 408 mated with the angle of clamp structure 442 is designed to draw cannula lugs 406 into the latch in the direction of arrow 1006 when first clamp component 306 is closed so that the cannula is fully seated within the attachment device. The angle of the interface of structures 408, 442 also keeps cannula 404 securely seated within the attachment device (and relative to second clamp component 308) when external forces on cannula 404 may attempt to pull it up and out of the attachment device.

[0080] 10B-10C illustrate perspective views of another embodiment of an interface or alignment structure of a cannula lug. Typically, as discussed above with reference to FIGS. 4A-4B, the bottom side of the cannula lug 406 may include an alignment structure 414 that interfaces with the alignment structure 444 of the second clamp component 308. From this view, it can be seen that the alignment structure 414 may include a keel-shaped protrusion 1008 formed on the bottom side of the cannula lug 406. The keel-shaped protrusion 1008 may be formed by a bottom wall 1008A and a side wall 1008B. It should be understood that, due to the perspective view, the second side wall 1008B is hidden from view. The bottom wall 1008A may taper inward toward the cannula body 416 such that its width (W1) near the end 414 is greater than its width (W2) near the body 416. 10A , the sidewall 1008B may taper inwardly toward the end 412 such that the structure 414 is sloped. The interface or complementary alignment structure 444 on the top side of the second clamp component 308 may then include a recessed region 1010 having a complementary configuration to the protrusion 1008 such that the protrusion 1008 can be inserted into the recessed region 1010. Typically, the recessed region 1010 may be formed by a bottom wall 1010A that tapers inwardly from the end 1012 to the end 1014, and a sidewall 1010B that tapers inwardly toward the end 1012 to be complementary to the structure 414. This complementary configuration of the structures 414, 444 helps to provide rotational stability as well as guide the insertion of the cannula 404 into the attachment device 212. Additionally, this configuration helps prevent deflection or twisting of cannula lugs 406 within attachment device 212 when cannula 404 is side-loaded.

[0081] Referring now to the sterile adapter briefly discussed above with reference to FIGS. 4A-4B, specific details of the sterile adapter will now be described with reference to FIGS. 11A-11D. Representatively, FIGS. 11A-11B illustrate bottom and top perspective views, respectively, of the sterile adapter. FIGS. 11C-11D illustrate side cross-sectional views of the sterile adapter illustrated in FIGS. 11A-11B, which serves as a barrier between the cannula and the attachment device. As discussed above, the sterile adapter is necessary to maintain a sterile barrier between the robotic arm and the surgical field. The cannula must be securely secured through the sterile barrier, but a generally rigid or generally flexible barrier can make it difficult to securely clamp the attachment device to the cannula. To address this issue, the sterile adapter 450 is configured with a hard plastic region molded with a flexible elastomeric region to form a molded sterile barrier that is both rigid and flexible. The hard plastic / flexible elastomer sterility barrier 450 may be formed, for example, by overmolding a rigid plastic component to form a rigid portion and then molding a soft, flexible elastomer, such as thermoplastic polyurethane (TPU), between the plastic components. In this embodiment, any rigid plastic components not directly molded together as a single rigid component are connected to the single rigid component by the flexible elastomer, resulting in an integrally formed sterility barrier having inseparable rigid and flexible portions. Typically, the sterility adapter 450 may include a rigid barrier portion 1102 molded to a flexible barrier portion 1104, which in combination surround the cannula lug and provide a sterility barrier between the attachment device 212 on one side and the cannula 404 on the other side. The rigid barrier portion 1102 may include a cannula interface portion 1106 defining an opening 452 through which the cannula lug is inserted.Cannula interface portion 1106 may be a substantially flat or plate-like member that, when inserted into an attachment device opening (e.g., opening 314 of device 212 as shown in FIGS. 4A-4B ), has one side facing the cannula (e.g., cannula side 1108) and an opposite side facing the attachment device and / or surgical robotic arm (e.g., arm side 1110). Rigid barrier portion 1102 may also include alignment interface portion 1112 and external alignment portion 1013 extending from opposite sides of cannula interface portion 1106. For example, external alignment portion 1013 may be a lip extending from cannula side 1108 of cannula interface portion 1106, and alignment interface portion 1112 may extend from arm side 1110 of rigid portion 1102 into the device opening (e.g., opening 314 of device 212). Alignment interface portion 1112 may include mating features or alignment structures 1114 that are dimensioned to mate with alignment structures on the cannula lugs and second clamp component. Typically, alignment structures 1114 may be configured to be positioned between and mate with alignment structures 414 and 444 on cannula lugs 406 and second clamp component 308, as discussed above with reference to FIGS. 4A-4B and 10B-10C. In this embodiment, alignment structures 1114 may be on or form the bottom side of sterilization adapter 450 so that they can mate with structures 414, 444. Alignment structures 1114 may be as rigid and precise as possible so that minimal compression occurs and clamping force on the cannula lugs is not lost. For example, similar to alignment structure 444, alignment structure 1114 may be formed by a tapered bottom wall 1114A and tapered sidewalls 1114B to receive alignment structure 414.

[0082] Additionally, as can be seen from the top perspective view of FIG. 10B , the opposite side (or top side) of sterilization adapter 450 includes another rigid alignment structure 1116 that interfaces with a clamping component during clamping. Typically, top rigid alignment structure 1116 can be configured to align with or otherwise interface with alignment structure 442 of first clamp component 306 and alignment structure 408 of cannula lug 406 (see FIGS. 4A-4B and 10A ) during clamping. Thus, top alignment structure 1116 can have any size, shape that allows it to interface with structures 408, 442. For example, top alignment structure 1116 can have a similar size and shape to structure 408 or structure 442, such as an elongated shape, a polygonal shape, or any other suitable shape. Top alignment structure 1116 is made of the same material as the rest of rigid portion 1102 and is designed to have as little compression as possible, since this is the surface where the clamp contacts the cannula lug when clamped, and any compression results in reduced and sustained clamping force. However, top alignment structure 1116 is entirely surrounded by flexible barrier portion 1104 to allow top alignment structure 1116 to rotate as easily as possible to the angle of the clamp / lug interface region (e.g., the angle between alignment structure 442 of clamp 306 and structure 408 of lug 406). The modifiable angle of top alignment structure 1116 is illustrated in more detail with reference to FIGS. 11C-11D. 11C , it can be seen that when the attachment device 212 and first clamp component 306 are in the open configuration, the top alignment feature 1116 may be substantially aligned with the remainder of the sterile adapter top formed by the surrounding flexible barrier portion 1104 to form a substantially flat surface. However, as shown in FIG. 11D , when the first clamp component 306 is moved to the closed configuration, the first clamp component 306 presses against the top alignment feature 1116, which in turn presses the top alignment feature 1116 against the surface 1002 of the alignment feature 408 of the cannula lug 406.In other words, top alignment feature 1116 is angled relative to the rest of the top side so that it rotates downward to match the angle of surface 1002 that forms alignment feature 408 on cannula lug 406. This can occur because top alignment feature 1116 is entirely surrounded by flexible barrier portion 1104. For example, flexible barrier portion 1104 can act as a hinge, allowing top alignment feature 1116 to change position. The rigid / flexible nature of this portion of sterile adapter 450 is important because the shape of the sterile adapter in the open position is designed to make cannula insertion and removal as easy as possible, and further because the flexible design ensures that critical mating surfaces of the sterile adapter can conform to the shape required for secure attachment (e.g., clamping) with as little force as possible and as reliable as possible.

[0083] Returning now to flexible barrier portion 1104, as discussed above, flexible barrier portion 1104 is molded to rigid portion 1102 and configured to surround the remainder of the cannula lug. In this embodiment, flexible barrier portion 1104 may be molded to arm side 1110 of rigid cannula interface portion 1106 and around and extending from opening 452. In this embodiment, flexible barrier portion 1104 may form a cavity 1120 around opening 452 of rigid interface portion 1106 that is sized to receive the cannula lug. Cavity 1120 may have a bottom side defined by rigid alignment portion 1114, a portion of a top side defined by rigid alignment portion 1116, and the remainder of the cavity substantially defined by flexible barrier portion 1104.

[0084] An additional aspect of the sterile adapter 450 may include a rigid retention bump 1130 molded into the arm side 1110 of the rigid interface portion 1106 and positioned along the top side of the flexible barrier portion 1104. The retention bump 1130 may mate with a complementary mating structure near the opening of the attachment device 212, for example, to help keep the sterile adapter seated on the attachment device 212 during cannulation and removal. Additionally, the sterile adapter 450 may include one or more rigid mating datums 1132 molded into the arm side of the rigid cannula interface portion 1106 and positioned along the sides of the flexible barrier portion 1104. For example, at least one datum 1132 may be positioned along a different side and / or top and bottom sides of the adapter than the bump 1130, for example, on a third side connecting the top and bottom sides. The rigid mating datum 1132 may be configured in a specific orientation designed to keep the cannula properly aligned with the tool axis.

[0085] 12 is a block diagram of the computer portion of a surgical robotic system operable to perform the operations discussed above, according to one embodiment. The exemplary surgical robotic system 1200 may include a user console 102, a surgical robot 120, and a control tower 103. The surgical robotic system 1200 may include other or additional hardware components. Thus, the diagram is provided as an example and not a limitation on this system architecture.

[0086] As described above, the user console 102 may include a console computer 1211, one or more UIDs 1212, a console actuator 1213, a display 1214, a foot pedal 1216, the console computer 1211, and a network interface 1218. In addition, the user console 102 may include several components, such as a UID tracker 1215, a display tracker 1217, and a console tracker 1219, for detecting various surgical conditions required for operation of the system (e.g., UID orientation, surgeon orientation relative to the display, console seat orientation, etc.). It should further be understood that a user or surgeon seated at the user console 102 can manually adjust the ergonomic settings of the user console 102, or the settings can be automatically adjusted according to a user profile or preferences. Manual and automatic adjustments can be achieved through actuation of the console actuator 1213 based on user input or configurations stored by the console computer 1211. A user may perform robotic-assisted surgery by controlling the surgical robot 120 using one or more master UIDs 1212 and foot pedals 1216. The position and orientation of the UIDs 1212 are continuously tracked by a UID tracker 1215, and changes in state are recorded as user input by the console computer 1211 and sent to the control tower 103 via a network interface 1218. Real-time surgical video of the patient's anatomy, instruments, and associated software applications can be presented to the user on a high-resolution 3D display 1214, including an open or immersive display.

[0087] The user console 102 may be communicatively coupled to the control tower 103. The user console also provides additional features for improved ergonomics. For example, the user console may be an open architecture system including a flexible display, or in some cases, an immersive display may be provided. Additionally, for improved ergonomics, the user console 102 includes a highly adjustable seat for the surgeon and a master UID that is tracked via an electromagnetic or optical tracker.

[0088] The control tower 103 can be a treatment site mobile cart housing a touchscreen display, a computer that controls the surgeon's operation of the robotic instruments, a safety system, a graphical user interface (GUI), a light source, and a video and graphics computer. As shown in FIG. 12 , the control tower 103 can include a central computer 1231 including at least a visualization computer, a control computer, and an auxiliary computer; various displays 1233 including a team display and a nurse display; and a network interface 1218 that couples the control tower 103 to both the user console 102 and the surgical robot 120. The control tower 103 can provide additional features for user convenience, such as a nurse display touchscreen, soft power and E-hold buttons, a user-facing USB for video and still images, and an electronic caster control interface. The auxiliary computer can also run real-time Linux and provide logging / monitoring and interaction with cloud-based web services.

[0089] The surgical robot 120 may include an operating table 1224 with multiple integrated robotic arms 1222 that can be positioned over the target patient anatomy. A set of compatible tools 1223 can be attached to or detached from the distal ends of the arms 1222, allowing the surgeon to perform a variety of surgical procedures. The surgical robot 120 may also include a control interface 1225 for manual or automated control of the arms 1222, table 1224, and tools 1223. The control interface may include items such as, but not limited to, a remote control, buttons, panels, and touch screens. Other accessories, such as trocars (sleeves, seal cartridges, and obturators) and drapes, may also be required to perform procedures with the system. In some variations, the multiple arms 1222 include four arms attached to either side of the operating table 1224, with two arms on each side. For a particular surgical procedure, an arm mounted on one side of the table can be positioned on the other side of the table by extending under and crossing the table and the arm mounted on the other side, resulting in a total of three arms being positioned on the same side of the table 1224. The surgical tool can also include a table computer 1221 and a network interface 1218, which enable the surgical robot 120 to communicate with the control tower 103.

[0090] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that many of the specific details are not required in order to practice the present invention. Thus, the foregoing descriptions of specific aspects of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Clearly, many modifications and variations are possible in light of the above teachings. The embodiments described herein were chosen and described to provide the best explanation of the principles of the invention and its practical application, so that others skilled in the art can best utilize the invention in various embodiments and with various modifications as suited to the particular uses contemplated.

[0091] [Embodiment] (1) An apparatus for attaching a cannula to a robotic surgical system, said apparatus comprising: a first clamp component configured to transition between an open position and a closed position; a second clamp component spaced from the first clamp component, the first clamp component and the second clamp component defining an area, the area configured to receive a portion of the cannula and to retain the portion of the cannula within the area when the first clamp component is in the closed position; a locking component configured to lock the first clamp component in the open position and allow the first clamp component to automatically transition to the closed position based on a position of the portion of the cannula within the region. (2) The device of embodiment 1, wherein the locking component locks the first component in the open position when the position of the portion of the cannula is misaligned within the region. (3) The device of embodiment 1, wherein the first clamp component automatically transitions from the open position to the closed position when the position of the portion of the cannula is aligned within the region. (4) The device of embodiment 1, wherein the cannula contacts a portion of the locking component when aligned within the region to disengage the locking component from the first clamping component and allow the first clamping component to transition from the open position to the closed position. (5) The device of embodiment 1, wherein the locking component mechanically detects whether the portion of the cannula is in an aligned or misaligned position within the region.

[0092] (6) The device of embodiment 1, further comprising one or more processors configured to signal the robotic surgical system that a user is attaching the cannula to the robotic surgical system when the first clamp component is in the open position and the portion of the cannula is within the region. (7) A system for attaching a cannula to a robotic surgical system, the system comprising: a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a locking assembly coupled to the clamping assembly, the locking assembly configured to lock the clamping assembly in the open position and to allow the clamping assembly to automatically transition to the closed position based on a position of the cannula within the clamping assembly; one or more processors configured to signal to the robotic surgical system whether the clamp assembly is in a docking mode when the clamp assembly is locked in the open position or a clamping mode when the clamp assembly is locked in the closed position. (8) The system of embodiment 7, wherein in the docking mode, the clamp assembly remains locked in the open position until the detected position of the cannula is suitable for attachment to the surgical robot system. (9) The system of embodiment 7, wherein in the clamping mode, the surgical robotic system notifies the user that the cannula is attached to the robotic surgical system. (10) The system of embodiment 7, wherein the locking assembly locks the clamping assembly in the open position when the detected position of the cannula is misaligned.

[0093] (11) The system of embodiment 7, wherein the locking assembly is further configured to transition the clamping assembly from the open position to the closed position when the detected position of the cannula is aligned. (12) The system of embodiment 7, wherein the locking assembly comprises a lever coupled to a lockout mechanism that locks or unlocks the clamping assembly based on the position of the cannula. (13) A system for detecting cannula attachment to a robotic surgical system, the system comprising: a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a sensor assembly operable to sense a characteristic of the clamp assembly; one or more processors configured to determine a status of the clamping assembly based on the characteristics sensed by the one or more sensors and provide feedback to the user regarding the status of the clamping assembly. (14) The system of claim 13, wherein the clamp assembly includes a lever operable to transition the clamp assembly between the open position and the closed position, and the sensor assembly includes a position sensor coupled to the lever. (15) The system of claim 14, wherein the characteristic sensed by the position sensor is the angle of the lever.

[0094] (16) The system of claim 15, wherein the state of the clamp assembly determined by the one or more processors is the open position or the closed position and is determined based on the angle of the lever. (17) The system of claim 13, further comprising a visual or audio feedback mechanism that indicates to the user that the state of the clamp assembly is either (1) the cannula is present in the clamp assembly or (2) the cannula is released from the clamp assembly. (18) A system for detecting cannula attachment to a robotic surgical system, the system comprising: a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a sensor assembly operable to sense a characteristic of the cannula when received by the clamp assembly; one or more processors configured to determine a status of the cannula based on the characteristics sensed by the one or more sensors and provide feedback to the user regarding the status of the cannula. (19) The system of embodiment 18, wherein the position sensor is a magnetic encoder and the cannula includes a magnet that is sensed by the magnetic encoder to sense the characteristic of the cannula. (20) The system of embodiment 19, wherein the characteristic of the cannula includes the presence of the cannula within a receiving portion of the clamp assembly.

[0095] (21) The system of embodiment 19, wherein the state of the cannula determined based on the characteristic is whether the cannula is properly attached to the robot arm or whether the cannula is released from its attachment to the robot arm. (22) The system of embodiment 19, wherein the characteristics of the cannula include a type of cannula in the receiving portion of the clamp assembly. (23) The system of embodiment 22, wherein the type of the cannula in the receiving portion of the clamping assembly is determined based on the angle of the magnet coupled to the cannula. (24) The system of embodiment 18, wherein the robotic surgical system is equipped with a visual feedback mechanism or an audio feedback mechanism. (25) A system for controlling the attachment of a cannula to a robotic surgical system, the system comprising: a clamp assembly configured to attach a cannula to a robotic surgical system, the clamp assembly operable to transition between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system; a sensor assembly operable to detect whether the clamp assembly is in the open position, the closed position, or the presence of the cannula received by the clamp assembly; one or more processors configured to control attachment of the cannula to the robotic surgical system based on the detection by the sensor assembly.

[0096] (26) When the sensor assembly detects that the clamp assembly is in the open position, the one or more processors instruct the surgical robot system to: disengaging a brake assembly associated with a surgical robotic arm coupled to the clamp assembly; 26. The system of claim 25, further comprising: engaging a gravity compensated active back drive mechanism associated with the surgical robot arm to enable positioning of the cannula within the clamp assembly. (27) When the sensor assembly detects the transition of the clamp assembly to the closed position, the one or more processors instruct the surgical robot system to: engaging a brake assembly associated with the surgical robotic arm; and disengaging the gravity compensated active back drive mechanism associated with the surgical robot arm so that the current position of the cannula relative to the clamp assembly is maintained. (28) When the sensor assembly detects the transition of the clamp assembly to the closed position, the one or more processors instruct the surgical robot system to: engaging a brake assembly associated with a surgical robotic arm coupled to the cannula; and disengaging the gravity compensated active back drive mechanism associated with the surgical robot arm. (29) The system of embodiment 28, wherein the sensor assembly further detects that the cannula is present in the clamp assembly, and upon detecting the presence of the cannula, the one or more processors cause the surgical robotic system to notify a user that the cannula has been attached to the surgical robotic system. (30) The sensor assembly further detects that the cannula is present in the clamp assembly, and upon detecting the presence of the cannula, the one or more processors instruct the surgical robot system to: Determining the type of cannula; 29. The system of embodiment 28, further comprising: informing the user of the type of cannula.

[0097] (31) When the sensor assembly detects the clamp assembly moving to the open position, when the sensor assembly detects that the cannula is not present in the clamp assembly, or when the sensor assembly does not detect a cannula identifier, the one or more processors may instruct the surgical robot system to: engaging a brake assembly associated with the surgical robotic arm; 29. The system of claim 28, wherein the surgical robotic system notifies the user that the cannula is ready to be attached. (32) An apparatus for attaching a cannula to a robotic surgical system, said apparatus comprising: a clamp operable to transition between an open position configured to receive a cannula and a closed position for attaching the cannula to a robotic surgical system; an actuator operable to transition the clamp between the open and closed positions; a link member pivotally coupled to the clamp at a first pivot point and to the actuator at a second pivot point, wherein in the closed position, the second pivot point is over-center with respect to the first pivot point. (33) The device of embodiment 32, wherein in the closed position, the second pivot point is over-center with respect to the first pivot point by an angle of 1 degree or less. (34) The device of embodiment 32, having the second pivot point over-centered relative to the first pivot point, such that any increase in load applied to the cannula attached to the robotic surgical system causes the clamp to gradually move itself to the closed position. (35) The device of embodiment 32, having the second pivot point over-centered relative to the first pivot point, prevents the clamp from transitioning to the open position when a force is applied to the cannula attached to the robotic surgical system.

[0098] (36) The device of embodiment 32, wherein the clamp comprises a first end rotatably coupled to a base member at a third pivot point and a second end that rotates to an advanced position to attach the cannula to the robotic surgical system. (37) The device of embodiment 36, wherein the second end includes a cannula-mating feature configured to reinforce the attachment of the cannula to the robotic surgical system. (38) The apparatus of embodiment 36, wherein the actuator is coupled to the base member at a fourth pivot point to form a four-bar linkage mechanism. (39) The device of embodiment 38, wherein the actuator has a first end configured to allow a user to manually cause the actuator to transition the clamp to the open position and a second end proximate a lockout mechanism, the lockout mechanism engaging the actuator to lock the clamp in the open position and disengaging from the actuator to allow the clamp to transition to the closed position upon contact with the cannula. (40) The device of embodiment 32, further comprising a base member having a cannula receiving chamber in which the cannula is positioned when attached to the robotic surgical system by the clamp, the receiving chamber including a cannula mating feature for guiding the cannula into the receiving chamber and preventing displacement of the cannula.

[0099] (41) A cannula sterilization adapter for attaching a cannula to a robotic surgical system, the adapter comprising: a rigid barrier portion having a cannula interface defining an opening dimensioned to receive a cannula lug, a first cannula interface structure extending from the cannula interface, and a second cannula interface, the first cannula interface and the second cannula interface dimensioned to interface with alignment structures on the cannula lug; a flexible barrier portion molded to the rigid barrier portion, the flexible barrier portion defining a cavity around the opening in the rigid barrier portion that is dimensioned to receive a cannula lug inserted therein, the cavity having a first side defined by the first cannula interface structure and a second side on which the second cannula interface structure is located, the second cannula interface structure being entirely surrounded by the flexible barrier portion. (42) The adapter of embodiment 41, wherein the cannula interface comprises a plate having an arm side facing a robotic surgical arm of the robotic surgical system and a cannula side facing the cannula lug, and the first cannula interface structure extends from the arm side toward the robotic surgical arm. (43) The adapter of embodiment 41, wherein the flexible barrier portion is molded into the arm side of the plate and defines at least three sides of the cavity. (44) The adapter of embodiment 41, wherein the first cannula interface structure comprises a keel-shaped structure dimensioned to interface with a complimentary recessed region of the cannula lug. (45) The adapter of embodiment 41, wherein the rigid clamp interface portion comprises a plate molded onto the second side.

[0100] (46) The adapter of embodiment 45, wherein the angle of the plate is modifiable to the angle of the alignment structure of the cannula lug. (47) The adapter of embodiment 41, further comprising a retention bump coupled to the second side of the flexible barrier portion, the retention bump being dimensioned to retain the cannula sterilization adapter within the clamp assembly during insertion and removal of the cannula lug within the clamp assembly. (48) The adapter of embodiment 41, further comprising a mating datum coupled to a third side of the flexible barrier portion and configured to maintain alignment of the cannula lug inserted therein with an axis of an associated tool. (49) The adapter of embodiment 41, wherein the rigid barrier portion is formed from a plastic material. (50) The adapter of embodiment 41, wherein the flexible barrier portion is formed by a flexible elastomeric material overmolded onto the rigid barrier portion.

[0101] 51. The adapter of claim 41, wherein the flexible barrier portion comprises a thermoplastic polyurethane. (52) An apparatus for attaching a cannula to a robotic surgical system, said apparatus comprising: a clamp assembly configured to attach a cannula to a robotic surgical system, the clamp assembly including an actuator coupled to the clamp to transition the clamp between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system; a lockout assembly coupled to the clamp assembly to control the transition of the clamp, the lockout assembly having a hook dimensioned to engage a bearing coupled to the actuator when the clamp is in the open position and to disengage the bearing to allow the clamp to automatically transition to the closed position. (53) The device of embodiment 52, wherein the hook includes a tip that extends beyond the contact point of the bearing and engages the bearing, and when the tip is aligned with the contact point, the hook disengages the bearing, allowing the clamp to move to the closed position. (54) The device of embodiment 52, wherein aligning the tip with the contact causes rotation of the bearing, the rotation enabling the hook to disengage the bearing. (55) The apparatus of claim 52, wherein the hook is coupled to a spring that biases the hook into engagement with the bearing.

[0102] (56) The device of embodiment 52, wherein the engagement or disengagement of the hook and the bearing provides audible or tactile feedback notifying the user of the engagement state of the lockout assembly. (57) The device of embodiment 52, wherein the lockout assembly is disengaged from the bearing when contacted by a cannula inserted into the clamp assembly. (58) The device of claim 52, further comprising an adjustment mechanism operable to adjust the force required to engage or disengage the hook from the bearing. (59) The apparatus of embodiment 58, wherein the adjustment mechanism comprises a set screw adjustable between a first position that increases the spacing between the hook and the bearing and a second position that decreases the spacing between the hook and the bearing. (60) The device of embodiment 59, wherein in the first position, the force required to engage and disengage the bearing from the hook is reduced.

[0103] (61) The device of embodiment 59, wherein in the second position, the force required to disengage the bearing from the hook is increased. (62) An apparatus for attaching a cannula to a robotic surgical system, said apparatus comprising: a clamp operable to transition between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system; a locking assembly coupled to the clamp assembly for holding the clamp in the open position and releasing the clamp to the closed position upon application of force by a cannula, the locking assembly having a lockout hook that engages a lockout bearing of the clamp in the open position and disengages the lockout bearing to release the clamp to the closed position; an adjustment member operable to adjust the force required to disengage the lockout bearing. (63) The device of embodiment 62, wherein the lockout hook is biased toward engagement of the lockout bearing by a spring. (64) The device of embodiment 63, wherein the adjustment member shifts the position of the lockout hook away from the lockout bearing to reduce the force required to disengage the lockout bearing. (65) The device of embodiment 63, wherein the adjustment member shifts the position of the lockout hook toward the lockout bearing to increase the force required to engage and disengage the lockout bearing.

[0104] (66) The apparatus of embodiment 63, wherein the adjustment member comprises a set screw extending through the lockout hook to an interface between the lockout hook and the lockout bearing. (67) The device of embodiment 66, wherein tightening the set screw shifts the position of the lockout hook away from the lockout bearing. (68) The device of embodiment 66, wherein loosening the set screw shifts the position of the lockout hook toward the lockout bearing. (69) The device of embodiment 62, wherein the lockout bearing is a ball bearing. (70) The apparatus of embodiment 62, wherein the clamp includes an actuator coupled to a first clamp component of the clamp.

[0105] (71) The apparatus of embodiment 70, wherein the actuator is operable to move the first clamp component between the open position and the closed position, and the ball bearing is coupled to the actuator.

Claims

1. 1. A system for attaching a cannula to a robotic surgical system, the system comprising: a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a locking assembly coupled to the clamping assembly, the locking assembly configured to lock the clamping assembly in the open position and to allow the clamping assembly to automatically transition to the closed position based on a position of the cannula within the clamping assembly; one or more processors configured to signal to the robotic surgical system whether the clamp assembly is in a docking mode when the clamp assembly is locked in the open position or a clamping mode when the clamp assembly is locked in the closed position.

2. 2. The system of claim 1, wherein in the docking mode, the clamp assembly remains locked in the open position until the detected position of the cannula is suitable for attachment to the robotic surgical system.

3. The system of claim 1 , wherein in the clamping mode, the robotic surgical system notifies a user that the cannula is attached to the robotic surgical system.

4. The system of claim 1 , wherein the locking assembly locks the clamping assembly in the open position when the detected position of the cannula is misaligned.

5. The system of claim 1 , wherein the locking assembly is further configured to transition the clamping assembly from the open position to the closed position when the detected position of the cannula is aligned.

6. The system of claim 1 , wherein the locking assembly comprises a lever coupled to a lockout mechanism that locks or unlocks the clamping assembly based on the position of the cannula.

7. 1. A system for detecting cannula attachment to a robotic surgical system, the system comprising: a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a sensor assembly operable to sense a characteristic of the clamp assembly; one or more processors configured to determine a status of the clamp assembly based on the characteristic sensed by the sensor assembly and provide feedback to the user regarding the status of the clamp assembly.

8. 8. The system of claim 7, wherein the clamp assembly comprises a lever operable to transition the clamp assembly between the open position and the closed position, and the sensor assembly comprises a position sensor coupled to the lever.

9. The system of claim 8 , wherein the characteristic sensed by the position sensor is the angle of the lever.

10. 10. The system of claim 9, wherein the state of the clamp assembly determined by the one or more processors is the open position or the closed position and is determined based on the angle of the lever.

11. 8. The system of claim 7, further comprising a visual or audio feedback mechanism that indicates to the user that the status of the clamp assembly is either (1) the cannula is present in the clamp assembly, or (2) the cannula is released from the clamp assembly.

12. 1. A system for detecting cannula attachment to a robotic surgical system, the system comprising: a clamp assembly having an open position configured to receive a cannula and a closed position configured to attach the cannula to a robotic arm of the robotic surgical system; a sensor assembly operable to sense a characteristic of the cannula when received by the clamp assembly; one or more processors configured to determine a status of the cannula based on the characteristic sensed by the sensor assembly and provide feedback to the user regarding the status of the cannula.

13. 13. The system of claim 12, wherein the position sensor is a magnetic encoder and the cannula includes a magnet that is sensed by the magnetic encoder to sense the characteristic of the cannula.

14. The system of claim 13 , wherein the characteristic of the cannula includes a presence of the cannula within a receiving portion of the clamp assembly.

15. 14. The system of claim 13, wherein the state of the cannula determined based on the characteristic is whether the cannula is properly attached to the robotic arm or whether the cannula is released from attachment to the robotic arm.

16. The system of claim 13 , wherein the characteristics of the cannula include a type of cannula in the receiving portion of the clamp assembly.

17. The system of claim 16, wherein the type of cannula in the receiving portion of the clamping assembly is determined based on the angle of the magnet coupled to the cannula.

18. The system of claim 12 , wherein the robotic surgical system comprises a visual feedback mechanism or an audio feedback mechanism.

19. 1. A system for controlling the attachment of a cannula to a robotic surgical system, the system comprising: a clamp assembly configured to attach a cannula to a robotic surgical system, the clamp assembly operable to transition between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system; a sensor assembly operable to detect whether the clamp assembly is in the open position, the closed position, or the presence of the cannula received by the clamp assembly; one or more processors configured to control attachment of the cannula to the robotic surgical system based on the detection by the sensor assembly.

20. When the sensor assembly detects that the clamp assembly is in the open position, the one or more processors instruct the robotic surgical system to: disengaging a brake assembly associated with a surgical robotic arm coupled to the clamp assembly; and engaging a gravity compensated active back drive mechanism associated with the surgical robotic arm to enable positioning of the cannula within the clamp assembly.

21. When the sensor assembly detects the transition of the clamp assembly to the closed position, the one or more processors instruct the robotic surgical system to: engaging a brake assembly associated with the surgical robotic arm; and disengaging the gravity compensated active back drive mechanism associated with the surgical robotic arm such that a current position of the cannula relative to the clamping assembly is maintained.

22. When the sensor assembly detects the transition of the clamp assembly to the closed position, the one or more processors instruct the robotic surgical system to: engaging a brake assembly associated with a surgical robotic arm coupled to the cannula; and disengaging the gravity compensated active back drive mechanism associated with the surgical robotic arm.

23. 23. The system of claim 22, wherein the sensor assembly further detects the presence of the cannula in the clamp assembly, and upon detecting the presence of the cannula, the one or more processors cause the robotic surgical system to notify a user that the cannula has been attached to the robotic surgical system.

24. The sensor assembly further detects that the cannula is present in the clamp assembly, and upon detecting the presence of the cannula, the one or more processors instruct the robotic surgical system to: Determining the type of cannula; and informing a user of the type of cannula.

25. When the sensor assembly detects the clamp assembly transitioning to the open position, detects that the cannula is not present in the clamp assembly, or does not detect a cannula identifier, the one or more processors instruct the robotic surgical system to: engaging a brake assembly associated with the surgical robotic arm; 23. The system of claim 22, wherein the robotic surgical system notifies a user that the robotic surgical system is ready for cannula attachment.

26. 1. An apparatus for attaching a cannula to a robotic surgical system, said apparatus comprising: a clamp operable to transition between an open position configured to receive a cannula and a closed position for attaching the cannula to a robotic surgical system; an actuator operable to transition the clamp between the open and closed positions; a link member pivotally coupled to the clamp at a first pivot point and to the actuator at a second pivot point, wherein in the closed position, the second pivot point is over-center with respect to the first pivot point.

27. 27. The device of claim 26, wherein in the closed position, the second pivot point is over-center with respect to the first pivot point by an angle of 1 degree or less.

28. 27. The apparatus of claim 26, having the second pivot point over-centered relative to the first pivot point, such that any increase in load applied to the cannula attached to the robotic surgical system causes the clamp to gradually move itself into the closed position.

29. 27. The apparatus of claim 26, having the second pivot point over-centered relative to the first pivot point prevents the clamp from transitioning to the open position when a force is applied to the cannula attached to the robotic surgical system.

30. 27. The apparatus of claim 26, wherein the clamp comprises a first end rotatably coupled to a base member at a third pivot point and a second end that rotates to an advanced position to attach the cannula to the robotic surgical system.

31. 31. The device of claim 30, wherein the second end comprises a cannula-mating feature configured to reinforce the attachment of the cannula to the robotic surgical system.

32. 31. The apparatus of claim 30, wherein the actuator is coupled to the base member at a fourth pivot point to form a four-bar linkage mechanism.

33. 33. The device of claim 32, wherein the actuator comprises a first end configured to allow a user to manually cause the actuator to transition the clamp to the open position, and a second end proximate to a lockout mechanism, the lockout mechanism engaging the actuator to lock the clamp in the open position and disengaging from the actuator to allow the clamp to transition to the closed position upon contact with the cannula.

34. 27. The apparatus of claim 26, further comprising a base member having a cannula receiving chamber in which the cannula is positioned when attached to the robotic surgical system by the clamp, the receiving chamber including a cannula mating feature to guide the cannula into the receiving chamber and prevent displacement of the cannula.

35. 1. A cannula sterilization adapter for attaching a cannula to a robotic surgical system, said adapter comprising: a rigid barrier portion having a cannula interface defining an opening dimensioned to receive a cannula lug, a first cannula interface structure extending from the cannula interface, and a second cannula interface, the first cannula interface and the second cannula interface being dimensioned to interface with alignment structures on the cannula lug; a flexible barrier portion molded to the rigid barrier portion, the flexible barrier portion defining a cavity around the opening in the rigid barrier portion that is dimensioned to receive a cannula lug inserted therein, the cavity having a first side defined by the first cannula interface structure and a second side on which the second cannula interface structure is located, the second cannula interface structure being generally surrounded by the flexible barrier portion.

36. 36. The adapter of claim 35, wherein the cannula interface comprises a plate having an arm side facing a robotic surgical arm of the robotic surgical system and a cannula side facing the cannula lug, the first cannula interface structure extending from the arm side toward the robotic surgical arm.

37. 36. The adapter of claim 35, wherein the flexible barrier portion is molded into the arm side of the plate and defines at least three sides of the cavity.

38. 36. The adapter of claim 35, wherein the first cannula interface structure comprises a keel-shaped structure dimensioned to interface with a complementary recessed area of ​​the cannula lug.

39. 36. The adapter of claim 35, wherein the rigid clamp interface portion comprises a plate molded into the second side.

40. 40. The adapter of claim 39, wherein the angle of the plate is modifiable to the angle of the alignment structure on the cannula lug.

41. 36. The adapter of claim 35, further comprising a retention bump coupled to the second side of the flexible barrier portion, the retention bump being dimensioned to retain the cannula sterilization adapter within the clamp assembly during insertion and removal of the cannula lug within the clamp assembly.

42. 36. The adapter of claim 35, further comprising a mating datum coupled to a third side of the flexible barrier portion and configured to maintain alignment of the cannula lug inserted therein with an axis of an associated tool.

43. 36. The adapter of claim 35, wherein the rigid barrier portion is formed from a plastic material.

44. 36. The adapter of claim 35, wherein the flexible barrier portion is formed by a flexible elastomeric material overmolded onto the rigid barrier portion.

45. 36. The adapter of claim 35, wherein the flexible barrier portion comprises a thermoplastic polyurethane.

46. 1. An apparatus for attaching a cannula to a robotic surgical system, said apparatus comprising: a clamp assembly configured to attach a cannula to a robotic surgical system, the clamp assembly including an actuator coupled to the clamp to transition the clamp between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system; a lockout assembly coupled to the clamp assembly to control the transition of the clamp, the lockout assembly having a hook dimensioned to engage a bearing coupled to the actuator when the clamp is in the open position and to disengage the bearing to allow the clamp to automatically transition to the closed position.

47. 47. The device of claim 46, wherein the hook includes a tip that extends beyond a contact point of the bearing to engage the bearing, and when the tip is aligned with the contact point, the hook disengages the bearing to allow the clamp to move to the closed position.

48. 47. The device of claim 46, wherein aligning the tip with the contact point causes rotation of the bearing, the rotation enabling the hook to disengage the bearing.

49. 47. The apparatus of claim 46, wherein the hook is coupled to a spring to bias the hook into engagement with the bearing.

50. 47. The device of claim 46, wherein the engagement or disengagement of the hook and the bearing provides audible or tactile feedback notifying the user of the engaged state of the lockout assembly.

51. 47. The apparatus of claim 46, wherein the lockout assembly is disengaged from the bearing upon contact with a cannula inserted into the clamp assembly.

52. 47. The device of claim 46, further comprising an adjustment mechanism operable to adjust the force required to engage or disengage the hook from the bearing.

53. 53. The apparatus of claim 52, wherein the adjustment mechanism comprises a set screw adjustable between a first position that increases the spacing between the hook and the bearing and a second position that decreases the spacing between the hook and the bearing.

54. 54. The device of claim 53, wherein in the first position, a reduced force is required to disengage the bearing from the hook.

55. 54. The device of claim 53, wherein in the second position, the force required to disengage the bearing from the hook is increased.

56. 1. An apparatus for attaching a cannula to a robotic surgical system, said apparatus comprising: a clamp operable to transition between an open position configured to receive the cannula and a closed position for attaching the cannula to the robotic surgical system; a locking assembly coupled to the clamp assembly for holding the clamp in the open position and releasing the clamp to the closed position upon application of force by a cannula, the locking assembly having a lockout hook that engages a lockout bearing of the clamp in the open position and disengages the lockout bearing to release the clamp to the closed position; an adjustment member operable to adjust the force required to disengage the lockout bearing.

57. 57. The device of claim 56, wherein the lockout hook is biased toward engagement of the lockout bearing by a spring.

58. 58. The device of claim 57, wherein the adjustment member shifts the position of the lockout hook away from the lockout bearing to reduce the force required to disengage the lockout bearing.

59. 58. The device of claim 57, wherein the adjustment member shifts the position of the lockout hook toward the lockout bearing to increase the force required to disengage the lockout bearing.

60. 58. The apparatus of claim 57, wherein the adjustment member comprises a set screw extending through the lockout hook to an interface between the lockout hook and the lockout bearing.

61. 61. The apparatus of claim 60, wherein tightening the set screw shifts the position of the lockout hook away from the lockout bearing.

62. 61. The device of claim 60, wherein loosening the set screw shifts the position of the lockout hook toward the lockout bearing.

63. 57. The apparatus of claim 56, wherein the lockout bearing is a ball bearing.

64. 57. The apparatus of claim 56, wherein the clamp comprises an actuator coupled to a first clamp component of the clamp.

65. 65. The apparatus of claim 64, wherein the actuator is operable to move the first clamp component between the open position and the closed position, the ball bearing being coupled to the actuator.

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