Surgical tool holder for an intraocular robotic surgical system

Abstract

Several different surgical tool holder assemblies are provided. Some configurations are suitable for use in intraocular robotic surgery. The assembly includes a housing, a kinematic alignment feature on a right side of the housing, and a kinematic alignment feature on a left side of the housing. There is also a tool sleeve coupled to a surgical instrument and a tool collar coupled to the tool sleeve. There is also a rotational transmission connector on the proximal end of the housing coupled to a drive shaft and a drive gear, the drive gear engaging a driven gear. There can also be an alignment plate on the tool holder, with at least one kinematic alignment feature on the alignment plate. Some of the kinematic alignment features are bidirectionally operable.

Description

[Technical Field]

[0001] Priority claims

[0001] This application claims priority to U.S. Provisional Application No. 63 / 478,770, entitled "SURGICAL TOOL HOLDER FOR INTRAOCULAR ROBOTIC SURGICAL SYSTEMS," filed January 6, 2023, the contents of which are incorporated herein by reference in their entirety.

[0002] Incorporation by Reference

[0002] All publications and patent applications mentioned in this specification are herein incorporated by reference in their entirety to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

[0003]

[0003] The present disclosure relates generally to a tool exchange mechanism for surgical instruments or tools in an intraocular robotic surgical system. In particular, the present disclosure relates to facilitating tool exchange in an accurate, repeatable, and rapid manner within a robotic microsurgery environment. [Background technology]

[0004] Automated microsurgery using robotic systems requires rapid and accurate exchange of surgical tools between surgical procedures. The design of a surgical tool interface is important not only for rapid and accurate exchange of tools, but also for additional functionality incorporated into the interface, such as tool actuation, fluid exchange, and alignment.

[0005] However, intraocular surgical procedures are multi-step processes that utilize several tools, including, among others, retinal picks, vitreous cutters, and injection and aspiration probes of various sizes and shapes. Additionally, a given surgical procedure typically involves (at most) three entry points into the eye, limiting the surgical instruments or tools used for the procedure to pass through these points. Therefore, due to both the multi-step nature of intraocular microsurgery procedures and the limited number of entry points in such procedures, it is desirable to provide a mechanism for exchanging one surgical instrument for another to perform different functions, or for retaining any of the various instruments used and enabling each instrument's function. Furthermore, a mechanism for rapid tool exchange is desirable for the safety and effectiveness of the surgical procedure. In light of these additional unmet needs, continuous improvement is needed in the field of surgical tools for microsurgery and related robotic systems. Summary of the Invention [Means for solving the problem]

[0006]

[0006] Embodiments of the present disclosure are directed to a standardized interface mechanism for quickly, accurately, and repeatably removing and replacing surgical instruments or tools during surgical procedures, such as intraocular surgical procedures. Various surgical tool holder assemblies may be equipped for manual use or in combination with end effectors of robotic surgical systems and / or tool exchange systems. Due to commonality of couplings and other interfaces, each surgical tool holder assembly can accommodate the size, shape, and functionality of any surgical tool, while still providing accurate and precise actuation of the translational and rotational movements of the associated surgical tool.

[0007] In one embodiment, a surgical tool holder assembly for intraocular robotic surgery is provided, the housing having a proximal end, a distal end, an upper surface, a lower surface, a left side extending between the proximal and distal ends, and a right side extending from the proximal end to the distal end. Also provided are kinematic alignment features on the right side of the housing and kinematic alignment features on the left side of the housing. Also provided are a tool sleeve coupled to a surgical instrument and a tool collar coupled to the tool sleeve. Front and rear support walls on the upper surface of the housing, a driven gear between the front and rear support walls, a drive gear, the front and rear support walls are sized to receive and support the tool collar. Also provided is a rotational transmission connector on the proximal end of the housing coupled to the drive shaft and the drive gear, the drive gear engaging the driven gear. There may also be an alignment plate above the tool holder, the alignment plate having a top surface, a proximal end, a distal end, a left side extending between the proximal end and the distal end, and a right side extending from the proximal end to the distal end, and at least one kinematic alignment feature.

[0008] Additionally, there can be at least one kinematic alignment feature disposed along the top surface of the alignment plate, the right side of the alignment plate, or the left side of the alignment plate. In another aspect, the at least one alignment feature is either a right distal alignment feature on the right side adjacent the distal end, a left distal alignment feature on the left side adjacent the distal end, a right proximal alignment feature on the right side adjacent the proximal end, or a left proximal alignment feature on the left side adjacent the proximal end. In yet another aspect, the kinematic alignment feature on either the bottom or top surface is one or a combination of a pin, a slot, a magnetic feature, or a portion of a releasable mechanical link, or the kinematic alignment feature on either the left or right side of the base or the left or right side of the alignment plate is one or a combination of a pin, a slot, a magnetic feature, or a portion of a releasable mechanical link. There may also be kinematic alignment features on the right side of the housing including a right distal alignment feature on the right side adjacent the distal end and a right proximal alignment feature on the right side adjacent the proximal end, and further kinematic alignment features on the left side of the housing including a left distal alignment feature on the left side adjacent the distal end and a left proximal alignment feature on the left side adjacent the proximal end. It may also be provided that the right side kinematic alignment feature and the left side kinematic alignment feature couple with a robotic end effector, and that a driver of the robotic end effector couples with the rotational transmission mechanism connector. Another further variation includes the option where the surgical instrument is a surgical tool suitable for and configured for intraocular surgery, or the surgical tool has a distal end that includes a hook, expeller, cystotome, needle, knife, or curette. Advantageously, the surgical tool holder assembly may include a low power wireless communication element, a near field communication element, or an RFID element electronic identification disposed on the housing and containing machine readable information regarding the surgical tool assembly.In another aspect where a particular orientation or alignment of the surgical instrument is advantageous, there may be a configuration of the tool sleeve including a plurality of alignment fins along its exterior surface, and the tool collar further including an arrangement of alignment slots sized and positioned for engagement with the plurality of alignment fins when the tool sleeve is secured within the tool collar.

[0009] In yet another embodiment, a method of preparing a surgical instrument for use with a surgical tool holder assembly is provided, the method beginning with inserting the surgical instrument into a tool sleeve sized to fit around the shaft or handle of the surgical instrument. Next, there is the step of inserting the surgical instrument into a tool collar and positioning the tool sleeve within the tool collar. There is then the step of securing the tool collar between the front and rear support walls, such that rotation of a driven gear of the surgical tool holder assembly rotates the distal end of the surgical tool within the tool collar. In one aspect, the surgical instrument is a surgical tool suitable for and configured for intraocular surgery. In another aspect, the distal end of the surgical instrument tool comprises a hook, a compressing tool, a cystotome, a needle, a knife, or a curette.

[0010] In yet another embodiment, a method is provided for preparing a surgical instrument for use with a surgical tool holder assembly by first inserting the surgical instrument into a tool sleeve sized to fit around the shaft or handle of the surgical instrument, with alignment fins on the tool sleeve providing a preselected orientation for the distal end of the surgical instrument. There is then the step of inserting the surgical instrument into a tool collar and positioning the alignment fins on the tool sleeve within corresponding alignment slots on the tool sleeve to maintain the preselected orientation of the distal end of the instrument. There is then the step of securing the tool collar between the front and rear support walls, whereby rotation of a driven gear on the surgical tool holder assembly rotates the distal end of the surgical tool. In one variation, the surgical instrument is a surgical tool suitable for and configured for intraocular surgery. In yet another alternative, the distal end of the surgical instrument tool includes a hook, expeller, cystome, needle, knife, or curette. [Brief explanation of the drawings]

[0011] [Figure 1A]

[0011] FIG. 1 is a schematic overview of the functionality required for a surgical tool holder having a tool changer interface and a robot end effector interface on either side of the tool holder. [Figure 1B]

[0012] FIG. 1 is a schematic overview of the features required for a surgical tool holder with a tool changer interface on the side of the tool holder and a robot end effector interface on one end. [Figure 2]

[0013] 1A-1C are diagrams of various components and subassemblies of the surgical tool holder assembly and end effector interface. [Figure 3A]

[0014] FIG. 1 is a right perspective view of the attachment mechanism of version 1 (V1). [Figure 3B] FIG. 1 is a left perspective view of the attachment mechanism of version 1 (V1). [Figure 3C]FIG. 1 is an exploded view of the mounting mechanism for version 1 (V1). [Figure 4A]

[0015] FIG. 10 is a left perspective view of an assembled surgical tool holder assembly with a version 2 (V2) mounting mechanism, the clamping nut secured to the tool collar and adjacent the rear support wall. [Figure 4B]

[0016] FIG. 4B is a left perspective view of the surgical tool holder of FIG. 4A with the tool sleeve removed. [Figure 4C1]

[0017] FIG. 4C is a perspective view of an open tool collar of the surgical tool holder assembly of FIGS. 4A and 4B. [Figure 4C2] 4C1, with arrows indicating the direction of each separate segment when the locking nut of FIG. 4C3 is advanced along the tool collar to the position shown in FIG. 4A. FIG. [Figure 4C3] FIG. [Figure 5]

[0018] FIG. 1 is a perspective view of a surgical tool holder assembly that provides tool-specific functionality for linear movement of a surgical tool tip. [Figure 6A]

[0019] FIG. 10 is a top view of a surgical tool holder assembly having an upper coupling plate adapted as a mechanical interface with an automatic tool changing system. [Figure 6B]

[0020] FIG. 6B is a bottom view of the surgical tool holder assembly of FIG. 6A showing the lower linkage plate for mechanical interface with a robotic end effector. [Figure 7A]

[0021] FIG. 10 is a proximal end view of an exemplary surgical tool holder assembly having a single connecting plate. [Figure 7B] FIG. 10 is a distal end view of an exemplary surgical tool holder assembly having a single connecting plate. [Figure 8A]

[0022] FIG. 1B is a proximal end view of an exemplary surgical tool holder assembly having an upper connecting plate and a lower connecting plate. [Figure 8B] FIG. 1B is a distal end view of an exemplary surgical tool holder assembly having an upper connecting plate and a lower connecting plate. [Figure 9]

[0023] FIG. 10 is a flow diagram illustrating a method for surgical tool exchange and tool function transfer. [Figure 10]

[0024] FIG. 1 is a flow diagram illustrating different modes of surgical tool operation. DETAILED DESCRIPTION OF THE INVENTION

[0012]

[0025] Embodiments of the surgical tool holder assembly provide a common mechanical and electromechanical interface for a range of different surgical tools. In particular implementations, the surgical tool holder assembly is suitable for and configured for the tools required to perform intraocular surgical procedures.

[0013]

[0026] For example, there is a surgical tool changing system that includes a tool changer, a tool holder assembly having an assembly frame configured to mount, align, and transfer functions to one or more of a plurality of tools in the tool holder assembly, and a robotic end effector configured to identify and manipulate one or more of the plurality of tools, wherein the robotic end effector and one or more of the tool holder assemblies send signals to one or more of the plurality of tools, and the tool holder assembly mechanically interacts with the robotic end effector and the tool changer via one or more interfaces.

[0014]

[0027] According to one example of a surgical tool exchange system, the transmission of functionality to one or more of the plurality of tools includes one or more of mechanical, electrical, or hydraulic functions, and the tool holder assembly transmits to one or more of the plurality of tools specific characteristics and functions including one or more of a signal to inject fluid through the tool, a signal to generate movement at the tip of the tool, and intraocular lens insertion.

[0015]

[0028] According to another example of a surgical tool exchange system, one or more interfaces, a tool exchanger, and a robotic end effector are oriented toward various surfaces of a tool holder assembly. In one aspect, the surgical tool is suitable for and configured for intraocular surgery. In yet another embodiment, the surgical tool has a distal end including a hook, an expeller, a cystotome, a needle, a knife, or a curette. In one aspect, depending on the desired orientation and operation of the tool, the tool is placed into the tool holder without tip alignment considerations (i.e., FIGS. 3A-3C) or with tip alignment considerations (i.e., FIGS. 4A-4C3). Stated differently, the distal end or tip of the instrument can be oriented with respect to the tool assembly housing to provide a first level of alignment of the tool tip for use when coupled with the robotic end effector (see FIGS. 1A, 1B, and 2).

[0016]

[0029] According to another example of a surgical tool exchange system, a tool holder assembly includes a holder housing configured to receive one or more of a plurality of tools, a tool sleeve, a tool collar, and an alignment tube configured to adjust the alignment of an axis of the tool relative to the holder housing.

[0017]

[0030] According to another example of a surgical tool exchange system, one or more transmission mechanisms of a tool holder assembly are coupled to an actuator of a robotic end effector, including a rotational transmission mechanism of the tool holder assembly having a driver gear and a driven gear, and further configured with an alignment tube to function as one or more of the transmission mechanisms.

[0018]

[0031] According to another example of a surgical tool exchange system, the robotic end effector includes one or more of a sterile barrier, a carriage, and a base plate, and further, the actuator of the robotic end effector includes one or more of a rotary actuator, a tool actuator, and a linear actuator.

[0019]

[0032] According to another example of a surgical tool exchange system, the one or more interfaces include a tool changer interface between the tool holder assembly and the tool exchanger, and a robot end effector interface between the tool holder assembly and the robot end effector.

[0020]

[0033] According to another example of a surgical tool exchange system, the tool holder assembly includes a cover that at least partially surrounds one or more of the plurality of tools, the tool sleeve, the tool collar, the alignment tube, and the holder housing.

[0021]

[0034] According to another example of a surgical tool changing system, one or more of the tool holder assembly, the tool changer, and the robot end effector have one or more coupling plates having coupling hardware configured to couple and align the tool holder assembly with one or more of the tool changer and the robot end effector, the coupling hardware including magnets, pins, cutouts, and dowel pins.

[0022]

[0035] According to another example of a surgical tool exchange system, one or more of the tool holder assembly and the tool sleeve accommodate the size and movement requirements of one or more of the multiple tools.

[0023]

[0036] According to another example of a surgical tool exchange system, the tool holder assembly includes connection points to external accessories.

[0024]

[0037] According to another example of a surgical tool exchange system, a tool holder assembly includes mounting hardware for kinematic coupling and alignment, the mounting hardware coupling with an assembly frame of the tool holder assembly.

[0025]

[0038] According to another example of a surgical tool exchange system, mounting and alignment with a tool holder assembly includes coupling a tool sleeve to a tool collar via one or more of a threaded nut, a support wall, a driver gear and a driven gear, a drive shaft, and a rotational transmission mechanism, the rotational transmission mechanism configured to engage a rotational actuator of a robotic end effector.

[0026]

[0039] According to another example of a surgical tool exchange system, the intraocular lens insertion signal is a rotational signal applied to a tool transmission mechanism coupling having a driven gear that interfaces with a lead screw and a linear actuator, where continuous rotation generates linear movement of the tool tip toward the surgical site, and reversing the rotation of the tool transmission mechanism and driven gear advances the lead screw and linear actuator away from the tool holder assembly to generate linear movement of the tool tip away from the surgical site, where the driven gear and lead screw are configured to adapt in size and proportion to provide fine movement of the tool tip.

[0027]

[0040] As shown in FIGS. 1A and 1B, embodiments of a surgical tool holder assembly provide three functions. First, the surgical tool holder assembly is a point of tool attachment and tool alignment. Second, the surgical tool holder enables the transfer of tool function to the surgical site. Examples of such functions include mechanical, electrical, electromechanical, hydraulic, ultrasonic, optical, etc., depending on the performance characteristics of the particular tool. In some embodiments, the surgical tool holder assembly can also include appropriate connection points to external accessories, such as a phacoemulsification system, or other systems, depending on the surgical procedure being performed. Third, the surgical tool holder assembly also provides a mechanical interface for attachment to and detachment from a robotic end effector. Additionally, the surgical tool holder assembly also provides a mechanical interface for attachment to and detachment from a tool changer.

[0028]

[0041] We now turn to additional aspects of the interface between the surgical tool holder assembly and one or both of (a) the surgical robot end effector and (b) the automatic tool changer.

[0029]

[0042] 1A and 1B illustrate the unique location of the functional interface between a surgical tool holder assembly and the external system with which it interacts. FIGS. 1A and 1B provide exemplary interface orientations to a tool changer and a robotic end effector. Generally, a tool changer is a container used to store one or more surgical tool holder assemblies in a manner readily adapted for manual or automated loading and unloading operations. In certain embodiments, both the tool changer and the surgical tool assemblies employ standardized form factors and design features to simplify the tool changing process. In yet other implementations, the interface between the tool changer (surgical tool holder assembly and end effector) and the surgical tool holder assembly is designed and implemented to minimize robotic actuator movement and enable reliable, rapid exchange of the surgical tool assembly.

[0030]

[0043] 1A shows a surgical tool holder assembly 100 that interacts with a tool changer system 102 on one side and a robot end effector 104 on the other side. In a horizontal orientation, the tool changer interface 106 is located at one end and the robot end effector interface 108 is located at the opposite end. In a vertical orientation, the interface 106 to the tool changer can be at the top or upper surface (see FIG. 6A), and the interface 108 to the robot end effector can be at the bottom or lower surface (see FIG. 6B). In a particular example, the various functions of the tool holder 110 can include tool attachment and alignment 110A, tool transfer functions 110B, including mechanical, electrical, hydraulic, and other types of functions, and a mechanical interface 110C that attaches and detaches the tool holder 110 to the robot end effector 104 and tool changer 102.

[0031]

[0044] Optionally, in another exemplary embodiment shown in FIG. 1B , the surgical tool holder assembly 150 can have an interface 106 to the tool changer on the side and an interface 108 to the robot interface at the end between the sides. In the embodiment of FIG. 1B , the tool changer 102 can have a tool holder assembly dock (see FIGS. 4A and 5 ) adapted and configured to engage features on the side of the tool holder assembly 150, with the robot end effector 108 engaging the bottom and end surfaces of the surgical tool assembly 150. A side-facing tool changer 102 can provide a series of surgical tool assembly holders in a linear tray arrangement or stacked like a shelf arrangement. An exemplary end effector movement to disengage from the side tool changer 102 is to lift from underneath the surgical tool holder assembly 150, disengage the side holder, and then move it away from the tool holder.

[0032]

[0045] FIG. 2 is a schematic diagram of an exemplary robot end effector and surgical tool holder assembly 200. The robot end effector 204 includes a base plate 204A, which supports all electrical, mechanical, or electromechanical drivers to enable the functionality of a particular surgical tool holder assembly 210. Advantageously, the surgical end effector 204 provides a variety of different types of actuation from unique locations on the end effector 204. One aspect of the tool assembly—the end effector interface 208—is the standardization of the location of actuators on the end effector 204 and the location of corresponding interfaces on the tool holder assembly 210. In the illustrated embodiment, the base plate supports a linear actuator 204B coupled to a linear stage or carriage 204C. The linear stage 204C supports a rotary actuator 204D and a tool actuator 204E. The interface to the robot end effector 204 is plate 204F, which also serves as a sterile barrier. Referring now to the surgical tool holder assembly interface 202, The end effector rotation actuator 204D is coupled to the tool assembly's rotation transmission mechanism 202D. The end effector tool actuator 204E is coupled to the tool transmission mechanism 202E of the surgical tool holder assembly 210. The interface between each transmission mechanism 202D-202E used in a particular surgical tool assembly 210 is provided by a tool sleeve 202A and a tool collar 202B, or a combination of a tool sleeve 202A, a tool collar 202B, and an alignment tube 202C. In this exemplary embodiment, a surgical tool 202F is positioned within the tool sleeve 202A. The tool sleeve 202A is held in place by the tool collar 202B. An alignment tube 202C may also be included to ensure proper alignment of the tool 202F with respect to the transmission mechanism of the particular tool holder assembly 210. Each tool assembly 210 also includes a base sized and configured to support the various components of the tool holder assembly 210.Each tool assembly 210 also includes one or more front and rear support walls positioned and sized relative to the alignment tube 202C, tube collar 202B, and surgical tool 202F and functioning as bearings to support the rotation of the components of the surgical tool holder assembly 210. Also shown within the holder housing 202G and cover 202H of the tool holder assembly 210. According to a specific example, the holder housing 202G can house at least a portion of the tool 202F, tool sleeve 202A, tool collar 202B, and alignment tube 202C. Similarly, the cover 202H can be positioned over the tool 202F, tool sleeve 202A, tool collar 202B, and alignment tube 202C, as well as at least a portion of the holder housing 202G.

[0033] Tool installation and alignment (110A, Figure 1A-1B)

[0046] Prior to a surgical procedure, each surgical tool 202F to be used is assembled into a correspondingly designed surgical tool holder assembly 210. Advantageously, the various alternative tool assembly embodiments enable an assembly process that is (a) simple to perform and (b) provides safe and accurate alignment of the surgical tool shaft relative to the central axis of rotation and movement. The central axis of the tool holder 210 is structurally defined by the tool collar 202B. The tool sleeve 202A is an adapter between the shaft shapes and sizes of the various different surgical tools 202F and the tool collar 202B. Thus, the tool sleeve 202A has an internal size and shape that matches the external size and shape of the surgical tool 202F and an external size and shape that matches the internal size and shape of the tool collar 202B. Because there are multiple sizes and shapes of surgical tools 202F, there are an equal number of specifically configured tool sleeves 202A that are custom-fit to fit each tool shaft into the tool collar 202B. Version 1 (V1) and Version 2 (V2) are two exemplary attachment mechanisms for tool sleeve 202A to tool collar 202B. Each will be described in turn.

[0034]

[0047] Figures 3A, 3B, and 3C are right perspective, left perspective, and exploded views, respectively, of the Version 1 (V1) attachment mechanism. The final or "ready-to-use" version of the V1 attachment mechanism is best seen in Figures 3A and 3B. A pair of front and rear threaded nuts 304A and 304B secure the tool 302, tool sleeve 302A, tool collar 302B, and alignment tube 302C between the front and rear support walls 306 and 308. Additionally, a driven gear 310 is positioned around alignment tube 302C. Figure 3B shows the location of the rotational transmission mechanism connector 302D, drive shaft 312S, and driver gear 312. In use, the rotary transmission mechanism connector 302D engages the rotary actuator 204D (from FIG. 2) of the end effector 204 (from FIG. 2), which in turn rotates the drive shaft 312S and driver gear 312. The driver gear 312 couples with the driven gear 310, which couples with the alignment tube 302C. Thus, rotating the rotary transmission mechanism connector rotates the assembled tool sleeve 302A, tool collar 302B, alignment tube 302C, and associated surgical tool 302. Also visible in FIGS. 3A and 3B is an exemplary single-mount kinematic coupling 320A. In this embodiment, the single coupling 320A is located along the side of the surgical tool assembly frame 320. Pairs of pins 302P and magnets 302M on the left and right sides of the tool assembly frame 320 provide the kinematic alignment 320A.

[0035]

[0048] In another example, the single-mount kinematic coupling 320A of the tool assembly base 320 includes one or more pins 302P with a magnet 302M adjacent to the distal-most pin 302P on the left side and a magnet 302M adjacent to the rear support wall 308 on the right side.

[0036]

[0049] 3C is an exploded view of the components of the V1 attachment mechanism. The alignment tube 302C and rear threaded nut 304B have been removed. The tool sleeve 302A and associated elastomeric ring 302A1 are visible on the surgical tool shaft 302. The tool collar 302B is shown in place with the front threaded nut 304A secured to the associated threaded end of the tool collar 302B and tool sleeve 302A. As in the illustrated embodiment, two threaded nuts 304A / 304B are used to clamp the angled flexible flange 304A1 to the tool collar 302B, optionally from only one end or both ends. Once the tool 302, tool sleeve 302B, and alignment tube 302C are properly positioned between the front support wall 306 and the rear support wall 308, the threaded nuts 304A / 304B are threaded. As the nuts 304A / 304B are advanced, the angled flexible flange 304A1 is forced radially into the tool sleeve 302A, frictionally securing the sleeve 302A. Additionally, one or more features on the tool sleeve 302A axially align the tool sleeve 302A with the locking nuts 304A / 304B. Similarly, the alignment tube 302C includes features to ensure proper alignment of the driven gear 310 with the driver gear 312.

[0037]

[0050] FIG. 4A is a left perspective view of an assembled surgical tool holder assembly having a version 2 (V2) attachment mechanism. A locking nut 404B is secured to the tool collar 402B and is adjacent to the rear support wall 408. FIG. 4B is a left perspective view of the surgical tool holder of FIG. 4A with the tool sleeve 402A removed. The locking nut 404B is now shown spaced apart from the rear support wall 408. In this position, the tool collar 402B is in the open configuration, as shown in FIG. 4C1. The threads of the locking nut 404B are visible in the internal view of FIG. 4C3. The locking nut 404B is threaded to engage the threads of the tool collar 402B. In the open configuration, the alignment slots and adjacent segments of the tool collar 402B are open and spaced apart. To complete the assembly, the tool tip 402F1 is inserted through the opening in the locking nut (404B0, right side in FIG. 4B) and into the open tool collar (FIG. 4C1). At this stage, the alignment fin 402Z on the proximal end of the surgical tool 402F is positioned to enter the alignment slot 422 in the tool collar 402B. Rotating the locking nut 404B compresses a segment of the tool collar 402B onto the outer surface of the tool sleeve 402A, a movement 422F shown in FIG. 4C2.

[0038]

[0051] Also shown in Figure 4A is an exemplary single-mount kinematic coupling 420A. In this embodiment, the single coupling 420A is along the side of the surgical tool assembly frame 420. Pairs of pins 402P and magnets (not shown) on the left and right sides of the tool assembly frame 420 provide the kinematic alignment 420A.

[0039]

[0052] Aspects of the attachment mechanism described herein reliably and naturally align the axis of the surgical tool with the central axis of the tool collar 402B without requiring any subsequent adjustment of the alignment. Additionally, or optionally, additional elements may be provided that allow for fine adjustment of the alignment of the axis of the surgical tool relative to the holder housing 402G. In one embodiment, there is an adjustment tube included in the surgical tool holder assembly. In one embodiment, the adjustment tube is a hollow cylinder that surrounds the tool collar 402B and couples with the tool collar 402B to allow adjustment of the relative orientation of the central axes of the surgical tool 402+tool sleeve 402A+tool collar 402B subassembly. In the event of misalignment, the central axis of the tool collar 402B itself must be adjusted relative to the holder housing 402G to correct the misalignment of the surgical tool 402F.

[0040] Transfer of function to surgical tool (110B, Figures 1A-1B)

[0053] With reference to FIGS. 1A, 1B, and 2, it should be understood that each of the various surgical tool holder assemblies is suitable for and configured for use with a robotic end effector having a standardized interface for common engagement with any of the various surgical tool assembly embodiments. The robotic end effector provides multiple different multimodal signals to the surgical tool via the tool holder assembly. In some embodiments, these signals may include mechanical, electrical, and hydraulic signals. In still other embodiments, there are specific sets of signals sent to and by particular tool holder assembly embodiments based on the particular characteristics and capabilities of the associated surgical tool.

[0041] Transmission of rotational action (110C, Figures 1A to 1B)

[0054] In one embodiment of a surgical tool holder assembly, the tool holder assembly transmits a mechanical signal to rotate the tool about the central axis of the tool collar. The signal is provided by a rotary actuator and transmitted to the tool via rotary transmission element 202D (from FIG. 2). In a specific embodiment best seen in FIG. 3B, rotary transmission element 302D couples to a drive shaft 312S, which in turn couples to a drive gear or pinion 312. Driven gear 310 couples to drive gear 312. Driver gear 312 is a gear whose axis of rotation coincides with that of drive shaft 312S, which couples to an external shaft driven by a rotary actuator in the end effector (not shown, but which engages transmission element 302D in use). Driven gear 310 has an axis of rotation that coincides with that of tool collar 302B. Additionally or optionally, in some embodiments, alignment tube 302C functions as a transmission element and supports driven gear 310 as shown in FIG. 3A above.

[0042] Transfer of tool-specific functions: Fluid exchange

[0055] In certain embodiments, the set of tool-specific signals includes a signal to inject a fluid through the tool.

[0043]

[0056] In one embodiment, the fluid is held in a reservoir local to the surgical tool holder assembly. In one aspect, the tool-specific signal is a mechanical movement that creates hydraulic pressure within the tool to expel the fluid. In one implementation, the source of this mechanical signal is an actuator located on the robot end effector via an interface (not shown) and is transmitted to the surgical tool via an appropriately configured tool transmission mechanism element of the surgical tool holder assembly. (See, e.g., FIGS. 7A and 8A.)

[0044]

[0057] In yet another fluid exchange embodiment, an external pressure source may be adapted and configured to provide an appropriately configured hydraulic signal to the surgical tool holder assembly to expel the fluid.

[0045] Tool tip movements (grasping, bending, manipulation, and other movements)

[0058] In another alternative configuration of a surgical tool holder assembly embodiment, a signal is provided that generates movement at the distal end of the surgical tool relative to the body of the surgical tool. In one implementation of this movement, the central axis of the surgical tool maintains position while the tip of the surgical tool is actuated. Examples of this type of tool-specific actuation include grasping of two opposing distal ends, movement of the tip curvature away from the tool axis, and engaging or manipulating tissue at a surgical site, along with other types of movement adapted for tool-specific actuation.

[0046] Intraocular lens (IOL) insertion

[0059] In another alternative embodiment, the surgical tool holder assembly includes a signal for IOL injection. In one implementation, the mechanical signal is generated by a tool actuator of a robot end effector via a tool transmission mechanism element. FIG. 5 is a right-side perspective view of an embodiment of a surgical tool holder assembly configured, for example, for IOL insertion. The embodiment of FIG. 5 is also an example of a transmission mechanism for a surgical tool assembly adapted to convert rotation to linear motion. FIG. 5 shows a housing 520H with an open top surface 520U. According to a specific example, the top surface 520U can have components for an upper kinematic coupler 520K, such as magnets 520M / 620MA and pins 520P / 620P (see also FIGS. 6A-6B). A side kinematic coupler 520A (which may also be realized via magnets 520M and pins 520P) is also shown on the side of the tool assembly base 520. In this configuration, the mechanical signal is, for example, a rotational signal applied to the tool transmission mechanism coupler via a tool transmission mechanism 502E. When actuated, the tool transmission linkage may rotate the driven gear 510. The driven gear may be a threaded hub or drive gear 508 engaged with the lead screw 502F. The drive gear 509 may abut the support wall 506 of the housing 520H. Continued rotation draws the lead screw 502F and, according to certain embodiments, the linear actuator / drive shaft 502L toward the tool assembly base 520, thereby causing linear movement 530 of the surgical tool tip 502F1 toward the surgical site 532. According to certain examples, the drive shaft 502L may be coupled to the end effector 204D. Reversing the rotation of the tool transmission linkage 502E and driven gear 510 advances the lead screw 502F and linear actuator / drive shaft 502L away from the tool assembly, thereby causing linear movement 530 of the surgical tool tip 502F1 away from the surgical site 534. The size and ratio of the threads of the lead screw 502F and the driven gear 510 can be adapted and configured to provide the precise movement of the surgical tip 502F1 required for IOL insertion.

[0047]

[0060] In yet other embodiments, there are a variety of appropriately configured surgical tool holder assemblies utilizing linear motion, rotational motion, a combination of rotation, and translation only, or in any combination with any of a variety of tool-specific features or accessories, to provide both functional requirements and provide a specially configured surgical tool holder assembly designed to accommodate the size and motion requirements of the entire set of associated surgical tools. An additional aspect is that surgical tools having common functional requirements may use similar surgical tool holder assemblies with different tool sleeves suited to and configured for the size and characteristics of the surgical tools.

[0048] External Mechanical Interface

[0061] Referring again to FIGS. 1A and 1B, various surgical tool assembly embodiments may be equipped with one or a series of external mechanical interfaces to facilitate manual, semi-autonomous, or fully autonomous integration with other systems, such as robotic handlers and end effectors, and tool changers, as described above. Generally, surgical tool holder assemblies can be considered to have a single linkage plate or dual linkage plates. Examples of single linkage plates are provided and discussed above in the various embodiments of FIGS. 3A, 3B, 4A, 4B, and 5. It should be understood that the pin size, shape, orientation, and magnet location can be varied to accommodate a variety of different interface configurations. Additionally or optionally, there are configurations in which the bottom surface of the surgical tool holder assembly is adapted and configured to accommodate an additional linkage plate.

[0049]

[0062] FIGS. 6A and 6B are top and bottom views, respectively, of a surgical tool holder assembly having two link plates. FIG. 6A is a view of the upper link plate 602 along the top surface of the tool assembly housing 602G. The tool assembly housing in this embodiment covers or encloses the components of the tool assembly, such as those shown in FIGS. 3A, 3B, 4A, and 4B. The upper link plate 602 has one or more kinematic features disposed along or within its surface, as described herein. For example, the upper link plate 602 includes three alignment cutouts 620C and three magnets 620M. One alignment cutout 620C is located in the center portion of the left side of the assembly. The other two alignment cutouts 620C are located in the right front corner and the right-left corner. One magnet 620M is located in the center portion of the right side. Two magnets 620M are located in the left front corner and the left rear corner. 6A also shows an exemplary link plate 620T mated for releasable joining with upper link plate 602, with pin 620P positioned to engage alignment cutout 620C and magnet or metal target 620MA located opposite magnet 620M on the upper link plate. In one embodiment, link plate 620T mated for joining with upper link plate 602 may be suitably positioned as part of a tool changer adapted and configured to hold one or more surgical tool holder assemblies, as described herein.

[0050]

[0063] FIG. 6B shows a bottom view of the surgical tool holder of FIG. 6A. The tool holder housing includes a bottom connection plate 604 configured similarly to that described above. The bottom connection plate 604 includes one or more kinematic features disposed along or within its surface, as described herein. A pair of pins 620DP are disposed along the sides of the base adjacent the front and rear corners. According to a specific example, the pins 620DP may be smooth-walled or shaped pins with a specific contoured surface similar to a dowel. Additionally or optionally, the cross-section of the pins used as kinematic features can have a circular cross-section (as shown in FIG. 6B) or an oval, rectangular, or polygonal shape to provide the desired connection to a corresponding kinematic feature on the end effector (see FIGS. 1A, 1B, and 2). Additionally, a magnet 620M is disposed in the center portion of each of the left and right sides. In one exemplary embodiment, the pin 620DP can slide vertically into an appropriately sized and positioned cutout in the end effector plate (i.e., in the sterile barrier 204F shown in FIG. 2) to kinematically constrain movement. Referring again to FIG. 2, it will be appreciated that the interface 208 between the tool holder assembly housing 202G and the end effector plate 204F incorporates a number of differently sized and positioned clearances and chamfers to allow for easy alignment. Additionally, one or a series of magnets can be placed on the holder housing 202G and plate 204F to provide unique interlocking configurations as well as repeatably and precisely align the holder 210 relative to the plate 204F. In one exemplary coupling operation, magnet 620M (from FIG. 6B) is positioned to push / pull tool holder assembly 210 to one side of end effector plate 204F, pulling tool holder assembly 210 to the back of plate 204F, where the pin secures in the cutout in plate 620C (from FIG. 6A).

[0051]

[0064] Considering the top and bottom connection plates 602, 604 together, it should be understood that the top surface of the surgical tool holder 602 includes a series of magnets, pins / extrusions, and / or cutouts / holes that correspond to corresponding ones on various surfaces (e.g., 620T) of an appropriately configured tool changer. When placed near the tool changer, the magnets 620M / 620MA function to pull the tool holder toward the changer and insert dowel pins 620DP into the dowel holes in each part. Advantageously, the coupling movement of these pins / holes 620DP / 620P / 620C and the top connection plate 602 is positioned to kinematically prevent the motion used to connect / disconnect the robot end effector 204 from FIG. 2 (at plate 204F from FIG. 2) to the tool holder 210 from FIG. 2 (at holder housing 202G from FIG. 2), which is accomplished by the coupling movement of the bottom connection plate 604. Thus, embodiments of the surgical tool assembly may use one set of linkage movements for the upper linkage plate and a different, non-conflicting set of linkage movements for the lower linkage plate. In this manner, various surgical tool holder assembly embodiments provide the surgeon with a wide variety of different tools and functions, all with a common set of linkage exchanges unique to each tool changer and robotic end effector.

[0052]

[0065] 7A and 7B are proximal and distal end views, respectively, of an exemplary surgical tool holder assembly having a single linkage plate. In various alternative embodiments, one or more pins 704AC of different sizes, shapes, orientations, and positions can be located along either the side or bottom surface to facilitate desired connectivity 704E to a robotic end effector or tool changer. Additionally or optionally, the linkage plate 704F may include electronic identification means and a set of instructions in computer-readable code appropriately disposed thereon for interrogation and communication with an end effector, tool changer, or other accessory. Examples of electronic identification means include, for example, but are not limited to, low-power wireless communication, near field communication (NFC), or RFID suitable for identification or interrogation between a robotic end effector and a surgical tool holder assembly.

[0053]

[0066] 8A and 8B are proximal and distal end views, respectively, of an exemplary surgical tool holder assembly having dual link plates. In various alternative embodiments, one or more pins 804AC of different sizes, shapes, orientations, and positions can be located along either the side or bottom surface of the lower link plate 804F or the top surface of the upper link plate 804CP to facilitate desired connectivity 804E to a robot end effector or tool changer. Additionally or optionally, either or both of the upper link plate 804CP and the lower link plate 804F may include electronic identification means and a set of instructions in computer-readable code appropriately disposed on the link plate for interrogating and communicating with an end effector, tool changer, or other accessory.

[0054]

[0067] FIG. 9 is a flow diagram illustrating a method 900 for surgical tool exchange and tool function transfer.

[0055]

[0068] The method 900 begins at block 902 with mechanically interfacing a tool holder assembly having an assembly frame with a robot end effector and a tool changer via one or more interfaces.

[0056]

[0069] The method 900 continues at block 904 with sending a signal via one or more of the robot end effector and the tool holder assembly to one or more of the plurality of tools in the tool holder assembly.

[0057]

[0070] The method 900 continues at block 906 with identifying and manipulating one or more of the plurality of tools via signals transmitted from the robot end effector.

[0058]

[0071] Finally, at block 908, the method 900 includes mounting, aligning, and transferring the function to one or more of the plurality of tools via the tool holder assembly.

[0059]

[0072] According to another example of method 900, the transmission of functionality to one or more of the plurality of tools includes one or more of mechanical, electrical, or hydraulic functions, and the tool holder assembly transmits to one or more of the plurality of tools specific characteristics and functions including one or more of a signal to inject fluid through the tool, a signal to generate movement at the tip of the tool, and intraocular lens insertion.

[0060]

[0073] According to another example of the method 900, one or more interfaces, tool changers, and robot end effectors are directed at various surfaces of the tool holder assembly.

[0061]

[0074] According to another example of method 900, a tool holder assembly includes a holder housing configured to receive one or more of a plurality of tools, a tool sleeve, a tool collar, and an alignment tube configured to adjust the alignment of an axis of the tool relative to the holder housing.

[0062]

[0075] According to another example of method 900, the one or more transmission mechanisms of the tool holder assembly include a rotational transmission mechanism of the tool holder assembly that couples with an actuator of the robot end effector and has a driver gear and a driven gear, and further, an alignment tube is configured to function as one or more of the transmission mechanisms.

[0063]

[0076] According to another example of method 900, the robotic end effector includes one or more of a sterility barrier, a carriage, and a base plate, and further, the actuator of the robotic end effector includes one or more of a rotary actuator, a tool actuator, and a linear actuator.

[0064]

[0077] According to another example of method 900, the one or more interfaces include a tool changer interface between the tool holder assembly and the tool changer, and a robot end effector interface between the tool holder assembly and the robot end effector.

[0065]

[0078] According to another example of the method 900, the tool holder assembly includes a cover that at least partially surrounds one or more of the plurality of tools, the tool sleeve, the tool collar, the alignment tube, and the holder housing.

[0066]

[0079] According to another example of method 900, one or more of the tool holder assembly, the tool changer, and the robot end effector have one or more coupling plates having coupling hardware configured to couple and align the tool holder assembly with one or more of the tool changer and the robot end effector, the coupling hardware including magnets, pins, cutouts, and dowel pins.

[0067]

[0080] According to another example of the method 900, one or more of the tool holder assembly and the tool sleeve accommodates the size and movement requirements of one or more of the multiple tools.

[0068]

[0081] According to another example of the method 900, the tool holder assembly includes connection points to external accessories.

[0069]

[0082] According to another example of method 900, the tool holder assembly includes mounting hardware for kinematic coupling and alignment, the mounting hardware coupling with an assembly frame of the tool holder assembly.

[0070]

[0083] According to another example of method 900, mounting and alignment with the tool holder assembly includes coupling the tool sleeve to the tool collar via one or more of a threaded nut, a support wall, a driver gear and a driven gear, a drive shaft, and a rotational transmission mechanism, the rotational transmission mechanism configured to engage a rotational actuator of the robot end effector.

[0071]

[0084] According to another example of method 900, the intraocular lens insertion signal is a rotational signal applied to a tool transmission mechanism coupling having a driven gear that interfaces with a lead screw and a linear actuator, where continuous rotation generates linear movement of the tool tip toward the surgical site, and reversing the rotation of the tool transmission mechanism and driven gear advances the lead screw and linear actuator away from the tool holder assembly to generate linear movement of the tool tip away from the surgical site, where the driven gear and lead screw are configured to adapt in size and proportion to provide fine movement of the tool tip.

[0072]

[0085] Those skilled in the art will recognize that any process or method disclosed herein can be modified in many ways. The process parameters and order of steps described and / or illustrated herein are given by way of example only and can be modified as needed. For example, although the steps illustrated and / or described herein may be shown or discussed in a particular order, these steps do not necessarily have to be performed in the order illustrated or discussed.

[0073]

[0086] Additional aspects of the operation and utilization of the surgical tool holder assembly and robotic end effector may be understood with reference to U.S. Provisional Patent Application No. 63 / 478,581 (the "'0569 Application"), entitled "Autonomous Tool Exchange System for Automated and Semi-Automated Intraocular Surgical Procedures," filed January 5, 2023, and corresponding Patent Cooperation Treaty Application No. PCT / US2024 / 010569 (Attorney Docket No. 14843-704.600), entitled "Autonomous Tool Exchange System for Automated and Semi-Automated Intraocular Surgical Procedures," filed January 5, 2024. Each of these applications is incorporated herein by reference in its entirety. In one example, the various kinematic couplers and bidirectional kinematic couplers described herein are suitable for and can be configured for use in a hybrid configuration in which each particular tool assembly dock is configured for top-bottom or side-side engagement and release, depending on the particular kinematics of the particular tool assembly. As a result, the various configurations of tool carousels detailed in "Autonomous Tool Exchange System for Automated and Semi-Automated Intraocular Surgical Procedures" can include all tool assembly docks for top-bottom engagement, all tool assembly docks for side-side engagement, or a combination thereof (a mixture of top-bottom and side-side kinematic tool assemblies can be included on the same tool carousel).

[0074]

[0087] The various exemplary methods described and / or illustrated herein may omit one or more of the steps described or illustrated herein or may include additional steps in addition to those disclosed. Furthermore, one step of any method disclosed herein may be combined with any one or more steps of any other method disclosed herein. For example, consider the variation of the operation of the surgical tool described in FIG. 10.

[0075]

[0088] FIG. 10 is a flow diagram of an exemplary method 1000 illustrating various modes of operation of a surgical tool through a robotic end effector interface. It should be understood that there may be several different modes of operation depending on the particular surgical instrument in the tool holder assembly and the surgical step or procedure being performed. Beginning in step 1002, there is a process of mechanically interfacing the surgical tool holder assembly with the robotic end effector. This may involve various techniques for engaging one or more kinematic couplings to complete the mechanical interface and fully dock the tool assembly to the end effector. See Figures 5A-5D of the '0569 application for examples of engagement between a robotic end effector and a surgical tool assembly.

[0076]

[0089] Next, depending on the particular capabilities of the surgical tool assembly and its usage requirements, the robotic end effector can drive the tool assembly to generate axial translation of the surgical tool (step 1004). Additionally, or optionally, depending on the particular capabilities of the surgical tool assembly and its usage requirements, the robotic end effector can drive the tool assembly to generate rotational movement of the surgical tool (step 1006). Additionally, or optionally, depending on the particular capabilities of the surgical tool assembly and its usage requirements, the robotic end effector can drive the tool assembly to generate mixed rotational-translational movement of the surgical tool (step 1008).

[0077]

[0090] The processors described herein may be configured to perform one or more steps of any of the methods disclosed herein. Alternatively, or in combination, the processor may be configured to combine one or more steps of one or more of the methods disclosed herein.

[0078]

[0091] As used herein, when a feature or element is referred to as being "on" another feature or element, it can be directly on the other feature or element, or there may be intervening features and / or elements. In contrast, when a feature or element is referred to as being "directly on" another feature or element, there are no intervening features or elements. Also, when a feature or element is referred to as "connected," "attached," or "coupled" to another feature or element, it will be understood that it can be directly connected, attached, or coupled to the other feature or element, or there may be intervening features or elements. In contrast, when a feature or element is referred to as "directly connected," "directly attached," or "directly coupled" to another feature or element, there are no intervening features or elements. Although described or illustrated with respect to one embodiment, features and elements so described or illustrated may be applicable to other embodiments. Additionally, it will be understood by those skilled in the art that a reference to a structure or feature being disposed "adjacent" another feature may have portions that overlap or underlie the adjacent feature.

[0079]

[0092] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting of the invention. For example, as used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. Furthermore, it will be understood that the terms "comprise" and / or "comprising," as used herein, 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. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items and may be abbreviated as " / ."

[0080]

[0093] For ease of description, spatially relative terms such as "below," "below," "lower," "above," and "above" may be used herein to describe the relationship of one element or feature shown in the figures to another. It will be understood that spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures were inverted, 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 "above" and "below" orientation. A device may be oriented in other ways (rotated 90 degrees or to other orientations), and the spatially relative descriptors used herein will be interpreted accordingly. Similarly, terms such as "upper," "lower," "vertical," "horizontal," and the like are used herein for descriptive purposes only, unless otherwise noted.

[0081]

[0094] As used herein, the terms "first" and "second" may be used to describe various features / elements (including steps), but these features / elements should not be limited by these terms unless the context dictates otherwise. These terms may be used to distinguish one feature / element from another. Thus, a first feature / element described below could be referred to as a second feature / element, and similarly, a second feature / element described below could be referred to as a first feature / element, without departing from the teachings of the present invention.

[0082]

[0095] Throughout this specification and the claims that follow, unless the context requires otherwise, the word "comprise," and variations such as "comprises" and "comprising," refer to various components that can be used together in methods and articles (e.g., compositions and apparatuses that include devices and methods). For example, the term "comprising" will be understood to mean the inclusion of any specified element or step, but not the exclusion of other elements or steps.

[0083]

[0096] In general, any apparatus and methods described herein should be understood to be inclusive, although all or a subset of the components and / or steps may alternatively be exclusive and may be expressed as "consisting of" or "consisting essentially of" various components, steps, subcomponents, or substeps.

[0084]

[0097] As used in this specification and claims (including in the examples and unless expressly specified otherwise), all numbers may be read as if preceded by the word "about" or "approximately," even if that term does not explicitly appear. The phrase "about" or "approximately," when describing a size and / or location, may be used to indicate that the described value and / or location is within a reasonable expected range of value and / or location. For example, a numerical value may have a value that is + / - 0.1% of the stated value (or range of values), + / - 1% of the stated value (or range of values), + / - 2% of the stated value (or range of values), + / - 5% of the stated value (or range of values), + / - 10% of the stated value (or range of values), etc. Additionally, any numerical value provided herein should be understood to include about or approximately that value, unless the context dictates otherwise. For example, if the value "10" is disclosed, "about 10" is also disclosed. Any numerical ranges referred to herein are intended to include all subranges contained therein. It is also understood that when a value is disclosed, "less than or equal to" that value, "greater than or equal to" that value, and possible ranges between values ​​are also disclosed, as would be appropriately understood by one of ordinary skill in the art. For example, if a value "X" is disclosed, "less than or equal to X" and "greater than or equal to X" (e.g., X is a numeric value) are also disclosed. It is also understood that throughout the application, data is provided in several different formats, and this data represents endpoints and starting points, and may range between any combination of data points. For example, when a specific data point "10" and a specific data point "15" are disclosed, it is understood that not only values ​​between 10 and 15 are disclosed, but also values ​​greater than, greater than, less than, less than, less than, and equal to 10 and 15, and values ​​greater than, equal to, and equal to 10 and 15 are disclosed. It is also understood that each unit between two specified units is disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0085]

[0098] While various exemplary embodiments have been described above, any of several modifications may be made to the various embodiments without departing from the scope of the claimed invention. For example, the order in which the various described method steps are performed may often be changed in alternative embodiments, and one or more method steps may be omitted entirely in other alternative embodiments. Optional features of the various device and system embodiments may be included in some embodiments and not in other embodiments. Therefore, the above description has been provided primarily for illustrative purposes and should not be construed as limiting the scope of the claimed invention.

[0086]

[0099] The examples and illustrations contained herein indicate, by way of illustration, not limitation, specific embodiments in which the subject matter may be practiced. As noted above, other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of the present disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively under the term "invention" merely for convenience, and without any intention to intentionally limit the scope of the present application to a single invention or inventive concept when multiple inventions or inventive concepts are actually disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiment shown. This disclosure is intended to cover any and all adaptations or variations of the various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those skilled in the art upon reviewing the above description.

Claims

1. 1. A surgical tool holder assembly for intraocular robotic surgery, comprising: a housing having a proximal end, a distal end, an upper surface, a lower surface, a left side extending between the proximal end and the distal end, and a right side extending from the proximal end to the distal end; a kinematic alignment feature on a right side of the housing; a kinematic alignment feature on a left side of the housing; a tool sleeve coupled to the surgical instrument; a tool collar coupled to the tool sleeve; front and rear support walls on a top surface of the housing, a driven gear located between the front and rear support walls, the drive gear, the front and rear support walls sized to receive and support the tool collar; a rotary transmission connector on the proximal end of the housing coupled to a drive shaft and a drive gear, the drive gear engaging the driven gear; and 1. A surgical tool holder assembly comprising:

2. 10. The surgical tool holder assembly of claim 1, further comprising an alignment plate above the tool holder, the alignment plate having a top surface, a proximal end, a distal end, a left side extending between the proximal and distal ends, and a right side extending from the proximal end to the distal end, and at least one kinematic alignment feature.

3. The surgical tool holder assembly of claim 2 , wherein the at least one kinematic alignment feature is along a top surface of the alignment plate, a right side of the alignment plate, or a left side of the alignment plate.

4. 4. The surgical tool holder assembly of claim 2, wherein the at least one alignment feature is one of: a right distal alignment feature on the right side adjacent the distal end; a left distal alignment feature on the left side adjacent the distal end; a right proximal alignment feature on the right side adjacent the proximal end; and a left proximal alignment feature on the left side adjacent the proximal end.

5. 5. The surgical tool holder assembly of claim 1, wherein the kinematic alignment feature on either the lower surface or the upper surface is one or a combination of a pin, a slot, a magnetic feature, or part of a releasable mechanical linkage.

6. 5. The surgical tool holder assembly of claim 1, wherein the kinematic alignment feature on either the left or right side of a base or the left or right side of the alignment plate is one or a combination of a pin, a slot, a magnetic feature, or part of a releasable mechanical linkage.

7. 2. The surgical tool holder assembly of claim 1, wherein the kinematic alignment features on the right side of the housing include a right distal alignment feature on the right side adjacent the distal end and a right proximal alignment feature on the right side adjacent the proximal end, and further wherein the kinematic alignment features on the left side of the housing include a left distal alignment feature on the left side adjacent the distal end and a left proximal alignment feature on the left side adjacent the proximal end.

8. 2. The surgical tool holder assembly of claim 1, wherein when the kinematic alignment features of the right side and the kinematic alignment features of the left side couple to a robotic end effector, a driver of the robotic end effector couples with the rotational transmission mechanism connector.

9. The surgical tool holder assembly of claim 1 , wherein the surgical instrument is a surgical tool suitable and configured for intraocular surgery.

10. The surgical tool holder assembly of claim 1 , wherein the surgical tool has a distal end comprising a hook, a compressing device, a cystotome, a needle, a knife, or a curette.

11. 11. The surgical tool holder assembly of claim 1, further comprising a low power wireless communication element, a near field communication element, or an RFID element electronic identification disposed on the housing and including machine readable information regarding the surgical tool assembly.

12. 12. The surgical tool holder assembly of claim 1, wherein the tool sleeve further includes a plurality of alignment fins along an exterior surface, and the tool collar further includes an arrangement of alignment slots sized and positioned for engagement with the plurality of alignment fins when the tool sleeve is secured within the tool collar.

13. 1. A method of preparing a surgical instrument for use in a surgical tool holder assembly, comprising: Inserting the surgical instrument into a tool sleeve sized to fit around the shaft or handle of the surgical instrument; inserting the surgical instrument into a tool collar to position the tool sleeve within the tool collar; securing the tool collar between a front support wall and a rear support wall, wherein rotation of a driven gear of the surgical tool holder assembly rotates a distal end of a surgical tool within the tool collar; A method comprising:

14. The method of claim 13 , wherein the surgical instrument is a surgical tool suitable and configured for intraocular surgery.

15. The method of claim 13 , wherein the distal end of the surgical instrument tool comprises a hook, a compressing device, a cystotome, a needle, a knife, or a curette.

16. 1. A method of preparing a surgical instrument for use in a surgical tool holder assembly, comprising: inserting the surgical instrument into a tool sleeve sized to fit around the shaft or handle of the surgical instrument, wherein alignment fins on the tool sleeve provide a preselected orientation of the distal end of the surgical instrument; inserting the surgical instrument into a tool collar and positioning alignment fins on the tool sleeve within corresponding alignment slots on the tool sleeve to maintain the preselected orientation of the distal end of the instrument; securing the tool collar between a front support wall and a rear support wall whereby rotation of a driven gear of the surgical tool holder assembly rotates a distal end of a surgical tool; A method comprising:

17. 17. The method of claim 16, wherein the surgical instrument is a surgical tool suitable and configured for intraocular surgery.

18. The method of claim 16, wherein the distal end of the surgical instrument tool comprises a hook, a compressing device, a cystotome, a needle, a knife, or a curette.

19. 1. A surgical tool exchange system comprising: A tool changer; a tool holder assembly having an assembly frame configured to mount, align, and transfer function to one or more of a plurality of tools in the tool holder assembly; a robot end effector configured to identify and manipulate the one or more of the plurality of tools, wherein the robot end effector and one or more of the tool holder assemblies transmit signals to the one or more of the plurality of tools, and the tool holder assemblies mechanically interact with the robot end effector and the tool changer via one or more interfaces; A surgical tool exchange system comprising:

20. 20. The system of claim 19, wherein the transmission of functions to the one or more of the plurality of tools includes one or more of mechanical, electrical, or hydraulic functions, and the tool holder assembly transmits specific characteristics and functions to the one or more of the plurality of tools including one or more of a signal to inject fluid through the tool, a signal to generate movement at the tip of the tool, and intraocular lens insertion.

21. 20. The system of claim 19, wherein the one or more interfaces, the tool changer, and the robot end effector are directed toward different surfaces of the tool holder assembly.

22. 20. The system of claim 19, wherein the tool holder assembly includes a holder housing configured to receive one or more of the plurality of tools, a tool sleeve, a tool collar, and an alignment tube configured to adjust alignment of an axis of the tool relative to the holder housing.

23. 23. The system of claim 22, wherein one or more transmission mechanisms of the tool holder assembly include a rotational transmission mechanism of the tool holder assembly that couples with an actuator of the robot end effector and that has a driver gear and a driven gear, and further wherein the alignment tube is configured to function as one or more of the transmission mechanisms.

24. 20. The system of claim 19, wherein the robotic end effector comprises one or more of a sterile barrier, a carriage, and a base plate, and further wherein the actuator of the robotic end effector comprises one or more of a rotary actuator, a tool actuator, and a linear actuator.

25. 20. The system of claim 19, wherein the one or more interfaces include a tool changer interface between the tool holder assembly and the tool changer, and a robot end effector interface between the tool holder assembly and the robot end effector.

26. 23. The system of claim 22, wherein the tool holder assembly includes a cover, the cover at least partially enclosing one or more of the plurality of tools, the tool sleeve, the tool collar, the alignment tube, and the holder housing.

27. 20. The system of claim 19, wherein one or more of the tool holder assembly, the tool changer, and the robot end effector include one or more coupling plates having coupling hardware configured to couple and align the tool holder assembly with one or more of the tool changer and the robot end effector, the coupling hardware including magnets, pins, cutouts, and dowel pins.

28. 23. The system of claim 22, wherein one or more of the tool holder assembly and tool sleeve accommodate size and movement requirements for the one or more of the plurality of tools.

29. 20. The system of claim 19, wherein the tool holder assembly includes a connection point for an external accessory.

30. 20. The system of claim 19, wherein the tool holder assembly includes mounting hardware for kinematic coupling and alignment, the mounting hardware coupling with the assembly frame of the tool holder assembly.

31. 24. The system of claim 23, wherein the mounting and alignment by the tool holder assembly includes coupling the tool sleeve with the tool collar via one or more of a threaded nut, a support wall, the driver and driven gears, a drive shaft, and the rotational transmission mechanism, the rotational transmission mechanism configured to engage a rotational actuator of the robot end effector.

32. 21. The system of claim 20, wherein the intraocular lens insertion signal is a rotational signal applied to a tool transmission mechanism coupling having a driven gear that interfaces with a lead screw and a linear actuator, wherein continuous rotation generates linear movement of the tool tip toward the surgical site, and reversing the rotation of the tool transmission mechanism and the driven gear advances the lead screw and the linear actuator away from the tool holder assembly to generate linear movement of the tool tip away from the surgical site, and wherein the driven gear and the lead screw are configured to adapt in size and proportion to provide fine movement of the tool tip.

33. 1. A method for surgical tool exchange, comprising: mechanically interfacing a tool holder assembly having an assembly frame with a robot end effector and a tool changer via one or more interfaces; transmitting a signal to one or more of a plurality of tools in the tool holder assembly via one or more of the robot end effector and the tool holder assembly; identifying and manipulating the one or more of a plurality of tools via the signal transmitted from the robot end effector; mounting, aligning, and transferring functionality to the one or more of the plurality of tools via the tool holder assembly; A method comprising:

34. 34. The method of claim 33, wherein the transmission of functions to the one or more of the plurality of tools includes one or more of mechanical, electrical, or hydraulic functions, and the tool holder assembly transmits to the one or more of the plurality of tools specific characteristics and functions including one or more of a signal to inject fluid through the tool, a signal to generate movement at the tip of the tool, and intraocular lens insertion.

35. 34. The method of claim 33, wherein the one or more interfaces, the tool changer, and the robot end effector are directed toward different surfaces of the tool holder assembly.

36. 34. The method of claim 33, wherein the tool holder assembly includes a holder housing configured to receive one or more of the plurality of tools, a tool sleeve, a tool collar, and an alignment tube configured to adjust alignment of an axis of the tool relative to the holder housing.

37. 37. The method of claim 36, wherein one or more transmission mechanisms of the tool holder assembly include a rotational transmission mechanism of the tool holder assembly that couples with an actuator of the robot end effector and that has a driver gear and a driven gear, and further wherein the alignment tube is configured to function as one or more of the transmission mechanisms.

38. 34. The method of claim 33, wherein the robotic end effector comprises one or more of a sterile barrier, a carriage, and a base plate, and further wherein the actuator of the robotic end effector comprises one or more of a rotary actuator, a tool actuator, and a linear actuator.

39. 34. The method of claim 33, wherein the one or more interfaces include a tool changer interface between the tool holder assembly and the tool changer, and a robot end effector interface between the tool holder assembly and the robot end effector.

40. 37. The method of claim 36, wherein the tool holder assembly includes a cover, the cover at least partially enclosing one or more of the plurality of tools, the tool sleeve, the tool collar, the alignment tube, and the holder housing.

41. 34. The method of claim 33, wherein one or more of the tool holder assembly, the tool changer, and the robot end effector have one or more coupling plates having coupling hardware configured to couple and align the tool holder assembly with one or more of the tool changer and the robot end effector, the coupling hardware including magnets, pins, cutouts, and dowel pins.

42. 37. The method of claim 36, wherein one or more of the tool holder assembly and tool sleeve accommodate size and movement requirements for the one or more of the plurality of tools.

43. 34. The method of claim 33, wherein the tool holder assembly includes connection points to external accessories.

44. 34. The method of claim 33, wherein the tool holder assembly includes mounting hardware for kinematic coupling and alignment, the mounting hardware coupling with the assembly frame of the tool holder assembly.

45. 38. The method of claim 37, wherein the mounting and aligning with the tool holder assembly includes coupling the tool sleeve with the tool collar via one or more of a threaded nut, a support wall, the driver and driven gears, a drive shaft, and the rotational transmission mechanism, the rotational transmission mechanism configured to engage a rotational actuator of the robot end effector.

46. 35. The method of claim 34, wherein the intraocular lens insertion signal is a rotational signal applied to a tool transmission mechanism coupler having a driven gear that couples with a lead screw and a linear actuator, wherein continuous rotation generates linear movement of the tool tip toward the surgical site, and reversing rotation of the tool transmission mechanism and the driven gear advances the lead screw and the linear actuator away from the tool holder assembly to generate linear movement of the tool tip away from the surgical site, and wherein the driven gear and the lead screw are configured to adapt in size and proportion to provide fine movement of the tool tip.

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