Packaging system with sterile barrier assembly for use in connecting surgical components - Patents.com

Abstract

A mounting system for coupling first and second surgical components, the mounting system including: a first mounting portion associated with the first surgical component; a second mounting portion associated with the second surgical component and including a tensioner movable between a first position and a second position; and a sterile barrier assembly, the sterile barrier assembly including a coupling portion configured to be releasably secured to the first mounting portion and to releasably receive the second mounting portion when the tensioner of the second mounting portion is in the first position; and a plurality of kinematic couplers configured to engage the mounting portions and positioned to provide a kinematic coupling between the mounting portions through the sterile barrier assembly to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in the second position.

Description

[Technical Field]

[0001] (Related Applications) This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 775,126, filed December 4, 2018, U.S. Provisional Patent Application No. 62 / 934,771, filed November 13, 2019, and U.S. Provisional Patent Application No. 62 / 937,529, filed November 19, 2019, the contents of each of which are incorporated by reference herein in their entirety.

[0002] The present disclosure relates generally to a mounting system for surgical components, and more particularly to a mounting system with a sterile barrier assembly for use in coupling surgical components. [Background technology]

[0003] Sterile barrier assemblies, such as surgical drapes, are known to establish a barrier between surgical components during surgery. For example, a surgical drape may be used to provide a barrier between a robotic arm and an end effector attached to the robotic arm. During surgery, the robotic arm is treated as non-sterile, while the end effector is sterile. The surgical drape creates a barrier between the robotic arm and the end effector to prevent contamination of the sterile field in which the end effector is operating.

[0004] Typically, the surgical drape placed between the robotic arm and the end effector has perforations or other openings through which various connections, such as mechanical and / or electrical connections, can be made between the robotic arm and the end effector. Such perforations are acceptable as long as they are covered during surgery. If the end effector malfunctions during surgery and requires replacement, or if a different end effector is desired and the perforations become uncovered, standard operating room sterilization protocols may dictate that the surgical drape must be changed before the different end effector is installed. Removing the surgical drape and installing a new one consumes valuable time, making replacement undesirable.

[0005] Other surgical drapes are not intentionally opened, but instead are compressed between the robotic arm and the end effector. If the surgical drape is made of thin plastic, it may unintentionally tear or rip when compressed. Even if the surgical drape remains intact, the compressibility of the surgical drape can cause imprecise positioning of the end effector on the robotic arm. For example, the surgical drape may compress unevenly. Furthermore, thick drapes made from conventional drape materials may shift under typical end effector loads. Small shifts are magnified at the tool center point (TCP) of the end effector and may become unacceptable due to errors in the TCP positioning accuracy.

[0006] Therefore, there is a need in the art to address one or more of these deficiencies. Summary of the Invention

[0007] A mounting system is provided for coupling the first and second surgical components. The mounting system includes a first mounting portion connected to the first surgical component and a second mounting portion connected to the second surgical component. The second mounting portion includes a tensioner movable between a first position and a second position. The mounting system further includes a sterile barrier assembly. The sterile barrier assembly includes a coupling portion configured to be releasably secured to the first mounting portion and to releasably receive the second mounting portion when the tensioner of the second mounting portion is in the first position. A plurality of kinematic couplers are configured to engage the mounting portions and are arranged to provide a kinematic coupling between the mounting portions through the sterile barrier assembly to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in the second position.

[0008] The end effector is provided for releasably attaching to a first mounting portion of a surgical robot through a sterile barrier assembly having a coupling portion and a plurality of kinematic couplers. The end effector includes a housing for supporting an energy applicator and a second mounting portion attached to the housing. The second mounting portion includes a tensioner movable between a first position and a second position. The second mounting portion is configured to releasably couple to the coupling portion of the sterile barrier assembly when the tensioner of the second mounting portion is in the first position. The second mounting portion includes a plurality of contact surfaces for engaging with the plurality of kinematic couplers of the sterile barrier assembly.

[0009] A sterile barrier assembly is provided for releasably attaching to a first mounting portion of a first surgical component and to a second mounting portion of a second surgical component having a tensioner. The sterile barrier assembly includes an interface configured to receive a drape and a coupling portion operably attached to the interface and configured to be releasably secured to the first mounting portion and to releasably receive the second mounting portion when the tensioner of the second mounting portion is in a first position. A plurality of kinematic couplers are supported by the interface and configured to engage the mounting portions. The plurality of kinematic couplers are arranged to provide a kinematic coupling between the mounting portions to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in a second position.

[0010] The surgical robot is configured to releasably receive a second mounting portion of the end effector via a sterile barrier assembly having a joint and a plurality of kinematic couplers. The second mounting portion has a tensioner movable from a first position to a second position. The surgical robot includes a robot arm having a first mounting portion configured to releasably receive the second mounting portion of the end effector via the sterile barrier assembly. The first mounting portion includes a plurality of contact surfaces for engaging the plurality of kinematic couplers of the sterile barrier assembly. The first mounting portion further includes a loading mechanism configured to apply a preload force to the second mounting portion through the sterile barrier assembly upon movement of the tensioner from the first position to the second position.

[0011] A surgical system is provided that includes: a second mounting portion connected to a surgical component, a sterile barrier assembly, a surgical robot including a robotic arm having a first mounting portion configured to releasably receive the sterile barrier assembly and the first mounting portion via the sterile barrier assembly, a lighting device coupled to the robotic arm, and one or more controllers coupled to one or more sensors and configured to use measurements from the one or more sensors to detect conditions associated with placement of one or more of the sterile barrier assembly and the second mounting portion on the first mounting portion and control the lighting device to display the conditions to a user.

[0012] A method is provided for operating a surgical system, the surgical system including a surgical robot including a robotic arm having a second mounting portion connected to a surgical component, a sterile barrier assembly, a first mounting portion configured to releasably receive the sterile barrier assembly and the first mounting portion via the sterile barrier assembly, an illumination device coupled to the robotic arm, and one or more controllers coupled to one or more sensors, the method including the one or more controllers including using measurements from the one or more sensors to detect a condition associated with placement of one or more of the sterile barrier assembly and the second mounting portion on the first mounting portion, and controlling the illumination device to display the condition to a user.

[0013] The advantages of the present disclosure will be better understood and readily appreciated by reference to the following detailed description considered in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a perspective view of a robotic surgical system including a mounting system interposed between a robotic arm and an end effector. [Figure 2]FIG. 1 is a partially exploded perspective view of a mounting system showing a first mounting portion attached to a robotic arm, a second mounting portion attached to an end effector, and a sterile barrier assembly for interconnecting the mounting portions. [Figure 3] 2 is a perspective view of the mounting system of FIG. 1 showing the first and second mounting portions and the sterile barrier assembly arranged in a mounted configuration. FIG. [Figure 4] FIG. 4 is a partially exploded perspective view of the mounting system of FIG. 3 showing the first mounting portion, the second mounting portion, and the sterile barrier assembly spaced apart from one another. [Figure 5] 4 is another partially exploded perspective view of the mounting system of FIG. 3. [Figure 5A] FIG. 10 is a partial exploded cross-sectional view illustrating a kinematic coupler contained within an interface of a sterile barrier assembly. [Figure 5B] FIG. [Figure 5C] FIG. [Figure 5D] 5D is a cross-sectional view of one of the connectors taken generally along line 5D-5D of FIG. 5C. [Figure 6] 5 is an exploded perspective view of a first set of components of the first mounting portion of FIG. 4. FIG. [Figure 7] 5 is another exploded perspective view of the first set of components of the first mounting portion of FIG. 4. FIG. [Figure 8] 5 is an exploded perspective view of a second set of components of the first mounting portion of FIG. 4. FIG. [Figure 9] 5 is another exploded perspective view of the second set of components of the first mounting portion of FIG. 4. FIG. [Figure 10] FIG. 5 is an exploded perspective view of the sterility barrier assembly of FIG. [Figure 11] FIG. 5 is another exploded perspective view of the sterility barrier assembly of FIG. [Figure 12] FIG. 5 is an exploded perspective view of the second mounting portion of FIG. 4 (the holding plate is omitted). [Figure 13] 5 is another exploded perspective view of the second mounting portion of FIG. 4 (the holding plate is omitted). FIG. [Figure 14A]14 is a perspective cross-sectional view illustrating the connection of the sterility barrier assembly to the first mounting portion taken generally along line 14-14 of FIG. 4. FIG. [Figure 14B] 14 is a perspective cross-sectional view illustrating the connection of the sterility barrier assembly to the first mounting portion taken generally along line 14-14 of FIG. 4. FIG. [Figure 14C] 14 is a perspective cross-sectional view illustrating the connection of the sterility barrier assembly to the first mounting portion taken generally along line 14-14 of FIG. 4. FIG. [Figure 15A] 15A is a perspective cross-sectional view taken generally along line 15A-15A of FIG. 4 illustrating the second mounting portion, the first mounting portion, and the sterility barrier assembly shown coupled to the first mounting portion. [Figure 15B] 15B is another perspective cross-sectional view illustrating the connection of the second mounting portion to the sterile barrier assembly taken generally along line 15B-15B of FIG. 4. FIG. [Figure 16A] 15B-15B is a cross-sectional view taken generally along line 15B-15B of FIG. 4, except that many components have been omitted to illustrate the preload force applied to the mounting system to attract the second mounting portion toward the first mounting portion. [Figure 16B] 15B-15B in FIG. 4, except that many components have been omitted to illustrate the preload force applied to the mounting system to attract the second mounting portion toward the first mounting portion, and also illustrates the load path of the preload force. [Figure 16C] FIG. 16C is an enlarged view of FIG. 16B showing the biasing element. [Figure 17] FIG. 2 is a partial perspective cross-sectional view illustrating a load actuator. [Figure 18] FIG. 10 is a top perspective view of the second hub. [Figure 19] FIG. 2 is a bottom perspective view of the first hub. [Figure 20A] FIG. 16B is an enlarged cross-sectional view taken from FIG. 16A. [Figure 20B] FIG. 16C is an enlarged cross-sectional view taken from FIG. 16B. [Figure 21A]FIG. 10 is a plan view of a second mounting portion illustrating the tensioner including the lever and activator link in a first open position. [Figure 21B] FIG. 10 is a plan view of the second mounting portion illustrating the tensioner in a second, closed position. [Figure 22] FIG. 10 is an exploded perspective view of the release mechanism of the second mounting portion. [Figure 23] FIG. 10 is a bottom perspective view of the retaining plate of the release mechanism. [Figure 24A] 10 is a perspective view of a second mounting portion illustrating a release actuator of the release mechanism moving from a first position to a second position. FIG. [Figure 24B] 10 is a perspective view of a second mounting portion illustrating a release actuator of the release mechanism moving from a first position to a second position. FIG. [Figure 25A] FIG. 10 is a perspective view illustrating a release actuator of the release mechanism moving from a first position to a second position to move the release link and release element so that the second mounting portion can be removed from the sterile barrier assembly. [Figure 25B] FIG. 10 is a perspective view illustrating a release actuator of the release mechanism moving from a first position to a second position to move the release link and release element so that the second mounting portion can be removed from the sterile barrier assembly. [Figure 25C] 10 is a partial perspective cross-sectional view illustrating the actuation of one of the release elements; FIG. [Figure 26] FIG. 1 is a partially exploded perspective view of a robotic surgical system having a mounting system showing an illumination device. [Figure 27] FIG. 27 is a perspective view of the robotic surgical system of FIG. 26 showing the illumination device. [Figure 28] FIG. 27 is a perspective view of the robotic surgical system of FIG. 26 showing an illumination device of a first illumination embodiment. [Figure 29] FIG. 27 is a perspective view of the robotic surgical system of FIG. 26 showing an illumination device of a second illumination embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0015] 1-3 , a mounting system 20 is shown for kinematically coupling first and second surgical components with a sterile barrier assembly 22. In the example described herein, the first surgical component is a surgical robot having a robotic arm R, and the second surgical component is an end effector EE attached to the robotic arm R. The robotic arm R and end effector EE may be similar to those described in U.S. Patent Application Publication No. 2018 / 0110572, filed October 20, 2017, and entitled “Systems and Tools for Use with Surgical Robotic Manipulators,” the entire disclosure of which is hereby incorporated by reference. It should be understood that the mounting system 20 can be employed to kinematically couple any surgical component with a sterile barrier assembly 22.

[0016] 2 and 3, the robotic arm R includes a first mounting portion 24 and the end effector EE includes a second mounting portion 26. A sterile barrier assembly 22 is positioned between the first and second mounting portions 24, 26 to establish a barrier between the robotic arm R and the end effector EE during surgery. The barrier separates the robotic arm R from the sterile field S in which the end effector EE operates. During surgery, the robotic arm R is considered non-sterile, and the barrier reduces the possibility of transfer of contaminants from the robotic arm R into the sterile field S.

[0017] To facilitate releasable attachment of the sterile barrier assembly 22 and end effector EE to the robot arm R, the second mounting portion 26 includes a tensioner 28 movable between a first position 28F and a second position 28S, as described in more detail below, and the sterile barrier assembly 22 includes a coupling portion 30 and a plurality of kinematic couplers 32.

[0018] Coupling 30 is configured to be releasably secured to first mounting portion 24 and to releasably receive second mounting portion 26 when tensioner 28 of second mounting portion 26 is in first position 28F. Kinematic coupler 32 is configured to engage mounting portions 24, 26 and is positioned to provide a kinematic coupling between mounting portions 24, 26 through sterile barrier assembly 22 to constrain six degrees of freedom of movement between the surgical components when tensioner 28 of second mounting portion 26 is in second position 28S.

[0019] As described above, the mounting portions 24, 26 are configured to be releasably kinematically coupled by the sterile barrier assembly 22. The kinematic coupling provides a rigid connection between the mounting portions 24, 26 such that positioning between the mounting portions 24, 26 can be deterministic and repeatable. As a result of this rigid, deterministic, and repeatable connection, errors in positioning of the end effector EE that may be associated with a more flexible connection between the end effector and the robot arm can be reduced. The kinematic coupling constrains just the number of degrees of freedom that should be constrained, i.e., the degrees of freedom are not over-constrained. For example, in the representative example illustrated herein, there are six degrees of freedom (three translational and three rotational) between the mounting portions 24, 26. Therefore, the kinematic coupling constrains just those six degrees of freedom for the end effector EE.

[0020] In certain examples, different end effectors EE can be used for different purposes. For example, multiple end effectors, each equipped with a different energy applicator EA (e.g., burrs, drills, reamers, saws, ultrasonic tips, impactors, etc.), can be used with the same robotic arm R to perform various functions during a surgical procedure, such as burring, drilling, reaming, sawing, ablation, impaction, etc., all of which have the same second mounting portion 26 and are releasably attached to the first mounting portion 24, as described herein. In the illustrated form, the second mounting portion 26 is attached to or integral with the housing 27 of the end effector EE. The energy applicator EA is supported and carried by the housing 27 to perform its function during a surgical procedure.

[0021] 4 and 5, the sterile barrier assembly 22 employs a plurality of kinematic couplers 32 to kinematically couple the mounting portions 24, 26. In the representative example illustrated herein, the kinematic couplers 32 are implemented as three spherical balls configured to constrain six degrees of freedom of motion between the surgical components. In one example, the balls have polished, corrosion-resistant surfaces, thus enabling sub-micron repeatability in positioning the mounting portions 24, 26 under certain loads. The balls can be formed of ceramic, stainless steel, or other suitable materials. As a non-limiting example, the balls may be formed of silicon carbide or tungsten carbide. The balls can be precision-machined to very tight tolerances, e.g., less than 50 millionths of an inch. During use, the balls seat in the first and second plurality of receptacles 34, 36 of the first and second mounting portions 24, 26, respectively. The receptacles 34 , 36 are sized and shaped to receive the ball 32 .

[0022] In the illustrated example, the first mounting portion 24 includes a first mounting plate 38 and a hub mount 40 secured to the first mounting plate 38. The hub mount 40 is adapted for attachment to the robot arm R via one or more fasteners or bolts (not shown), or the like, wherein the first plurality of receptacles 34 are operably attached to the first mounting plate 38 (e.g., secured to the first mounting plate 38 by fasteners, welding, a press fit, or the like). The second mounting portion 26 similarly includes a second mounting plate 42 (see FIG. 5 ) having a cover 41, and is adapted for attachment to the end effector EE via one or more fasteners or bolts (not shown), or the like, wherein the second plurality of receptacles 36 are operably attached to the second mounting plate 42 (e.g., secured to the second mounting plate 42 by fasteners, welding, a press fit, or the like). The first mounting portion 24 includes a first plurality of contact surfaces defined by a first plurality of receivers 34 for engaging the plurality of kinematic couplers 32. Similarly, the second mounting portion 26 includes a second plurality of contact surfaces defined by a second plurality of receivers 36 for engaging the plurality of kinematic couplers 32. The contact surfaces are shaped to cooperate with the kinematic couplers 32 to constrain six degrees of freedom of motion between the end effector EE and the robot arm R. In one form, the second plurality of contact surfaces is configured to provide only six points of contact with the plurality of kinematic couplers 32.

[0023] The first plurality of receptacles 34 of the first mounting portion 24 each have a contact surface with a conical configuration (also referred to as conical receptacles). The second plurality of receptacles 36 of the second mounting portion 26 each have a contact surface with a generally V-shaped groove (also referred to as V-grooved receptacles). More specifically, the contact surfaces of these V-grooved receptacles 36 are in the shape of a Gothic arch. The contact surfaces act as constraint surfaces for the kinematic coupling described above. It will be understood that different types, arrangements, and configurations of receptacles 34, 36 can be employed to provide the kinematic coupling between the mounting portions 24, 26. As a non-limiting example, flat or planar receptacles can be utilized for certain applications.

[0024] While the representative example illustrated herein shows the first mounting portion 24 with three conical receptors and the second mounting portion 26 with three V-grooved receptors, it will be understood that each mounting portion 24, 26 can utilize different types of receptors 34, 36 arranged in different ways. As a non-limiting example, it is also envisioned that the first mounting portion 24 employs two V-grooved receptors and one conical receptor. The first mounting portion 24 could also employ three V-grooved receptors. Similarly, it will be understood that the second mounting portion 26 can employ receptors configured in any manner sufficient to reliably constrain six degrees of freedom for the kinematic coupler 32. As a non-limiting example, the second mounting portion 26 can employ one conical receptor to constrain three degrees of freedom, one V-grooved receptor to constrain two degrees of freedom, and one flat receptor to constrain one degree of freedom, for a total of six degrees of freedom.

[0025] The receivers 34, 36 may be formed of steel or other suitable rigid material and may be formed as separate components rigidly connected to the mounting portions 24, 26, or may be integral with the mounting portions 24, 26, in which case the receivers 34, 36 simply include constraint surfaces integral with the mounting portions 24, 26 for securing the balls. The receivers 34, 36 may be attached to the mounting portions 24, 26 in numerous ways via numerous structures, arrangements, or configurations. When the mounting portions 24, 26 are brought together in a near-final orientation with the sterile barrier assembly 22 disposed therebetween, as shown in FIG. 3, the kinematic couplers 32, e.g., balls, of the sterile barrier assembly 22 self-seat within the receivers 34, 36. The kinematic coupler 32, receivers 34, 36, and their arrangement may be similar to those described in U.S. Patent Application Publication No. 2016 / 0242861, filed February 19, 2016, entitled "Sterile Barrier Assembly, Mounting System, and Method for Coupling Surgical Components," which is hereby incorporated by reference in its entirety.

[0026] In the representative example illustrated herein, the sterile barrier assembly 22 includes an interface 48 and a drape 50 operably attached to the interface 48. The drape 50 shown in FIGS. 1-3 can be secured between first and second interface plates 52, 54 of the interface 48, which are secured to one another by fasteners to hold the drape 50 therebetween; alternatively, the drape 50 can be attached to one of the interface plates 52, 54, e.g., to a side or outer surface thereof. Additionally or alternatively, the drape 50 may be attached to a separate component, such as a ring assembly 49 (see FIG. 2), that is releasably attached to the interface 48 prior to a surgical procedure. One example of a ring assembly 49 is shown and described in U.S. Patent Application No. 16 / 151,439, filed October 4, 2018, entitled "Sterile Drape Assembly for Surgical Robot," which is hereby incorporated by reference in its entirety. It will be appreciated that the interface plates 52, 54 may be operably attached to one another in any suitable manner, such as by welding.

[0027] The drape 50 has an inner surface and an outer surface. The inner surface is placed adjacent to the robotic arm R during surgery. In the example shown in FIG. 1 , the drape 50 is attached to the robotic arm R to generally surround the robotic arm R. The drape 50 is formed of at least one of polyethylene, polyurethane, and polycarbonate. The drape 50 can be attached to the interface 48 by ultrasonic welding, tape, adhesive, or the like, or the drape 50 can be attached to a ring assembly 49 that is removably coupled to the interface 48. The drape 50 is attached to the interface 48 such that there are no perforations, i.e., the drape forms a continuous barrier with the interface 48. The drape 50 is not shown in some of the drawings to better illustrate other components.

[0028] The kinematic coupler 32 is contained between the interface plates 52, 54. To this end, referring to FIG. 5A , which shows the mounting portions 24, 26 secured together via the sterile barrier assembly 22, the sterile barrier assembly 22 includes a seal 58 associated with each of the kinematic couplers 32 (one is shown in FIG. 5A ). Each of the interface plates 52, 54 includes a pocket 60 and a ball aperture 62 defined by the interface plates 52, 54 and positioned adjacent the pocket 60. The kinematic coupler 32 protrudes through the ball aperture 62, which cooperates with the seal 58 to retain the kinematic coupler 32 between the interface plates 52, 54. The kinematic coupler 32 is positioned such that the barrier between the interface plates 52, 54, the seal 58, and the kinematic coupler 32 remains intact to reduce the likelihood of contaminant migration through the interface 48. In this manner, the drape 50 and interface 48 provide a continuous barrier to the transfer of contaminants from the robotic arm R into the sterile field S.

[0029] 4 and 5 , in one example, the sterility barrier assembly 22 includes one or more indexing fingers 64, and at least one of the mounting portions 24, 26 defines one or more indexing recesses 66 configured to receive the indexing fingers 64 for aligning the kinematic coupler 32 relative to at least one of the mounting portions 24, 26 and the associated receiver 34, 36. In the representative example illustrated herein, the sterility barrier assembly 22 includes a total of six indexing fingers 64, three of which correspond to the indexing recesses 66 formed in the second mounting plate 42 of the second mounting portion 26 and three of which correspond to the indexing recesses 66 formed in the first mounting plate 38 of the first mounting portion 24.

[0030] It will be understood that the indexing fingers 64 and / or indexing recesses 66 can have any suitable shape, arrangement, or configuration sufficient to facilitate proper orientation of the sterility barrier assembly 22 and the mounting portions 24, 26. For example, the indexing fingers 64 can be provided on the mounting portions 24, 26, with corresponding indexing recesses 66 formed in the sterility barrier assembly 22. In the illustrated form, one of the indexing fingers 64 has a different size and / or shape than the other indexing finger 64, and the indexing recesses 66 on the mounting portions 24, 26 are correspondingly sized / shaped, such that the sterility barrier assembly 22 can be aligned in only one orientation relative to the mounting portions 24, 26.

[0031] 4 and 5, alignment and orientation of the sterile barrier assembly 22 and mounting portions 24, 26 may be advantageously performed prior to or simultaneously with attachment therebetween to facilitate corresponding alignment of one or more communication interfaces employed to facilitate communication between the end effector EE and the robotic arm R. Here, the first mounting portion 24, the second mounting portion 26, and the sterile barrier assembly 22 may each employ one or more connectors, such as sealed electrical connectors, adapted to provide an electrical connection between the first mounting portion 24 and the second mounting portion 26 to facilitate communication between the robotic arm R and the end effector EE during use. In the illustrated form, first, second, and third connectors C1, C2, C3 are employed. Different types of communication through connectors C1, C2, C3 are contemplated, including but not limited to electrical, pneumatic, optical, hydraulic, etc., and may include, represent, or consist of signals, power, data, and / or other types of information communicated between the robotic arm R and the end effector EE. It will be appreciated that the use of sealed connectors, which may be integrated into the coupling portion 30 and mounting portions 24, 26 of the sterile barrier assembly 22, for example, ensures that contaminants do not enter the sterile field S when the end effector EE is removed from the sterile barrier assembly 22.

[0032] In the illustrated form, the third connector C3 is supported by the sterile barrier assembly 22 and rotatably supported within the coupling portion 30 for rotation relative to the interface 48 about a longitudinal axis L1 defined through the mounting portions 24, 26 and the sterile barrier assembly 22. One or both of the first and second connectors C1, C2 are fixed against or at least partially restricted against rotation on their corresponding mounting portions 24, 26. Referring to Figures 5B and 5C, the connectors C1, C2, C3 have mating castellated projections 67, and the rotatable nature of the third connector C3 allows at least the third connector C3 to self-align with the first connector C1 when the sterile barrier assembly 22 is attached to the first mounting portion 24. In other words, because the third connector C3 is free to rotate at the coupling 30, the protrusions 67 clock the third connector C3 into one of a plurality of discrete positions, for example, one of four discrete positions, relative to the first connector C1 when the sterile barrier assembly 22 is attached to the first mounting portion 24. To this end, as shown in FIG. 5D, the third connector C3 can have a symmetrical arrangement of pins about a central plane CP that passes through the third connector C3.

[0033] 2 and 3 , during use, the first mounting portion 24 can be a generally permanent fixture of the robotic arm R. When medical personnel begin preparation for a surgical procedure, the sterile barrier assembly 22 is first attached to the first mounting portion 24, and the robotic arm R is covered with the drape 50 of the sterile barrier assembly 22. The mounting system 20 is configured to facilitate releasable attachment of the sterile barrier assembly 22 to the first mounting portion 24, as well as the releasable attachment of the second mounting portion 26 to the sterile barrier assembly 22, in order to ensure repeatable and deterministic kinematic coupling of the end effector EE (and / or other end effectors EE during a procedure) without disrupting the sterile field S surrounding the robotic arm R provided by the sterile barrier assembly 22. Additionally, rotating tensioner 28 from first position 28F (FIG. 2) to second position 28S (FIG. 3) applies a preload force to secure second mounting portion 26 to first mounting portion 24 via sterile barrier assembly 22. Figures 6 through 13 are exploded views of first mounting portion 24, sterile barrier assembly 22, and second mounting portion 26, with some components omitted for clarity. The components of first mounting portion 24, sterile barrier assembly 22, and second mounting portion 26 facilitate coupling and attachment of sterile barrier assembly 22 to first mounting portion 24 and second mounting portion 26 to sterile barrier assembly 22, as described below.

[0034] 14A through 15B, the first and second locking assemblies are provided for releasably locking the sterile barrier assembly 22 to the first mounting portion 24 (see progression from FIG. 14A to FIG. 14C) and subsequently releasably locking the second mounting portion 26 to the sterile barrier assembly 22 (see progression from FIG. 15A to FIG. 15B). The locking assemblies serve to facilitate releasable coupling between the sterile barrier assembly 22 and the mounting portions 24, 26 in the absence of the kinematic coupling achieved upon movement of the tensioner 28 to the second position 28S. This configuration contributes to ease of use in that the sterile barrier assembly 22 can be secured to the first mounting portion 24 and the second mounting portion 26 can be secured to the sterile barrier assembly 22 prior to movement of the tensioner 28 to the second position 28S to apply a preload force, which may be desirable in certain applications, such as when the end effector EE is relatively heavy or cumbersome for one person to handle.

[0035] The first and second locking assemblies include first and second ball subassemblies 74, 76 and first and second ball detents 78, 80 (see FIGS. 14A and 15A, and also FIGS. 6, 11, and 12). The first locking assembly is interposed between the first mounting portion 24 and the mating portion 30 of the sterile barrier assembly 22 to releasably secure the mating portion 30 to the first mounting portion 24. Similarly, the second locking assembly is interposed between the mating portion 30 and the second mounting portion 26 to releasably secure the second mounting portion 26 to the mating portion 30 when the tensioner 28 is in the first position 28F. In the illustrated configuration, the ball subassemblies 74, 76 are operably attached to the mounting portions 24, 26, and the ball detents 78, 80 are defined in the mating portion 30 to receive the ball subassemblies 74, 76. As such, coupling portion 30 is configured to be disposed in communication with each of ball sub-assemblies 74, 76 when sterile barrier assembly 22 is secured to first mounting portion 24 and second mounting portion 26 is secured to sterile barrier assembly 22. It will be appreciated that this configuration can be reversed, with one or both ball sub-assemblies 74, 76 strapped to coupling portion 30 and ball detents 78, 80 strapped to mounting portions 24, 26.

[0036] Each locking assembly further includes a release collar 84, 86 (see FIG. 14A) arranged to secure one of the ball subassemblies 74, 76 received in one of the ball detents 78, 80. The release collars 84, 86 are each operably attached to the sterility barrier assembly 22 and are axially biased away from each other. To this end, one or more biasing elements, generally designated by reference numerals 88 and 89, are provided force-transferably interposed between the coupling 30 and the release collars 84, 86. In the representative example illustrated herein, the biasing elements 88, 89 are formed as stacked wave washers. Any suitable number of biasing elements 88, 89 of any suitable type, configuration, or arrangement may be utilized.

[0037] To facilitate assembly of the sterility barrier assembly 22, each of the release collars 84, 86 includes a collar body, generally designated 90, and a collar keeper, generally designated 92, configured to engage and rotate with the collar body 90 via a tab-and-pocket arrangement (see FIGS. 10 and 11). The collar keepers 92 are concentrically disposed with the respective collar bodies 90, with a collar biasing element 88 abutting each of the collar bodies 90 to bias the collar bodies 90 axially away from each other and against the interface plates 52, 54, and a keeper biasing element 89 abutting each of the collar keepers 92 to bias the collar bodies 90 axially away from each other and against corresponding rings 94, which may be integral with the coupling portion 30 or seat in respective grooves formed in the coupling portion 30 and act to axially bias and retain the coupling portion 30 against the interface plates 52, 54. It will be appreciated that this arrangement allows for rotation of the coupling portion 30 relative to the interface plates 52, 54. Moreover, this arrangement allows for axial movement of the release collars 84, 86 relative to the interface plates 52, 54 and / or the coupling portion 30, which facilitates releasable attachment / detachment of the sterile barrier assembly 22 to the mounting portions 24, 26, as described above and in more detail below. In some examples, such as those shown, either side of the sterile barrier assembly 22 can be attached to the first mounting portion 24, i.e., the sterile barrier assembly 22 can be inverted from the orientation shown in FIG. 14A and still successfully attached to the first mounting portion 24.

[0038] 14A-14C, upon attachment of the sterility barrier assembly 22 to the first mounting portion 24, one end of the coupling portion 30 first contacts the first ball subassembly 74, and more specifically, the ball 75 of the first ball subassembly 74. As this occurs, the balls 75 are biased radially outward within their carriers, as shown in FIG. 14B. As a result, the balls 75 engage one end of the collar bodies 90, and as the user applies more force to the interface 48, the corresponding collar bodies 90 compress against the biasing force of the collar biasing element 88 (compare FIG. 14A with FIG. 14B). As the user continues to apply force to interface 48, now referring to FIG. 14C , first ball detent 78 (e.g., a groove formed in coupling portion 30) aligns with ball 75, such that ball 75 engages first ball detent 78, and collar body 90 subsequently moves axially to a position rearward of ball 78, retaining ball 75 within first ball detent 78. The sterility barrier assembly 22 is now releasably attached to first mounting portion 24. Referring to FIG. 15A , a similar action occurs, locking second mounting portion 26 to sterility barrier assembly 22 via the other release collar 86 and second ball subassembly 76, including ball 77.

[0039] 15B through 21B, once the sterile barrier assembly 22 is secured to the first mounting portion 24 and the second mounting portion 26 is secured to the sterile barrier assembly 22, movement of the tensioner 28 from a first position 28F (see FIG. 2) toward a second position 28S (see FIG. 3) via the kinematic coupler 32 and via a preload force applied to the mounting portions 24, 26 kinematically couples the end effector EE to the robot arm R and holds the mounting portions 24, 26 fixed to one another in their kinematically coupled configuration. To this end, in one example, the first mounting portion 24 includes a loading mechanism, generally designated 98 (see FIGS. 15B, 16A and 16B), to assist in the application of the preload force. When activated, the loading mechanism 98 axially biases at least one of the second mounting portion 26 and the sterile barrier assembly 22 toward the robot arm R in response to movement of the tensioner 28 toward the second position 28S.

[0040] The coupling 30 of the sterile barrier assembly 22 is force-transducingly interposed between the tensioner 28 and the loading mechanism 98, such that actuation of the tensioner 28 from the first position 28F toward the second position 28S applies a rotational force through the coupling 30 to the loading mechanism 98, thereby imparting a preload force through the coupling 30 to axially translate the second mounting portion 26 toward the first mounting portion 24 and fixedly holding the second mounting portion 26 in a kinematically coupled arrangement with the first mounting portion 24 via the kinematic coupler 32.

[0041] In the illustrated example, the loading mechanism 98 is configured to axially move the first ball subassembly 74 relative to the first mounting plate 38 in response to movement of the tensioner 28 toward the second position 28S (compare FIG. 16A with FIG. 16B ), urging the second mounting portion 26 toward the first mounting portion 24. Thus, the coupling portion 30, which is axially locked to the first ball subassembly 74, also moves axially with the first ball subassembly 74. Simultaneously, the second ball subassembly 76, which is also axially locked to the coupling portion 30, also moves axially with the first ball subassembly 74 and the coupling portion 30. The second ball subassembly 76 has a flange sized to be axially supported by the second mounting plate 42 via a loading ring 97, such that actuation of the loading mechanism 98 pulls the second mounting plate 42 toward the first mounting plate 38.

[0042] The loading mechanism 98 includes a driver 102 and a load actuator 104. The driver 102 is operably attached to the first ball subassembly 74. In the illustrated example, the driver 102 is fixed to the first ball subassembly 74 by press fitting, welding, or the like. The driver 102 may also be operably attached to the first ball subassembly 74 by being integrally formed therewith. The driver 102 is configured to be disposed in rotational engagement with the coupling portion 30 of the sterile barrier assembly 22 when the sterile barrier assembly 22 is releasably attached to the first mounting portion 24. In the illustrated form, the driver 102 and the coupling portion 30 have corresponding spline formations, generally designated 82, configured to facilitate simultaneous rotation about the longitudinal axis L1 in use. Specifically, coupling portion 30 has end splines or teeth that engage corresponding end splines or teeth on driver portion 102. Any suitable type of rotational engagement can be employed to facilitate rotational transmission between coupling portion 30 and driver portion 102. Driver portion 102 is positioned such that, in response to movement of tensioner 28 toward second position 28S, rotation of driver portion 102 about longitudinal axis L1 applies a preload force between first mounting portion 24 and second mounting portion 26, causing first ball subassembly 74 to move axially along longitudinal axis L1.

[0043] 16A through 20B , the load actuator 104 includes a first hub 106 and a second hub 108 opposite the first hub 106. The first hub 106 is operably attached to the first ball subassembly 74. In some examples, the first hub 106 is operably attached to the first ball subassembly 74 by being integrally formed therewith. The second hub 108 is operably attached to the first mounting plate 38. More specifically, the second hub 108 and the first mounting plate 38 have corresponding geometric shapes (e.g., corresponding flats 101, 103 shown in FIGS. 6 and 7 ) that restrict relative rotation between the second hub 108 and the first mounting plate 38, but allow slight axial movement between the second hub 108 and the first mounting plate 38. The amount of axial movement allowed is limited by the size of the grooves in the first mounting plate 38 and second hub 108 in which the retaining ring 105 sits. The retaining ring 105 couples the second hub 108 to the first mounting plate 38.

[0044] The load actuator 104 further includes a plurality of ball bearings 110 disposed between the first hub 106 and the second hub 108. Ramps 112 are defined on one or more of the first hub 106 and the second hub 108. In the illustrated example, a first set of ramps 112 is defined on the first hub 106, and a second set of ramps 112 is defined on the second hub 108, effectively doubling the axial travel between the hubs 106, 108 during actuation (compared to using only one set of ramps), as described below. Of course, a single set of ramps is also possible. The ball bearings 110 roll along the ramps 112 in response to movement of the tensioner 28 toward the second position 28S. 17-19, ball bearings 110 (six shown) are disposed on first and second sets of opposing ramps 112 (six shown in each set) formed in hubs 106, 108. In some embodiments, ramps 112 have linear ramp slopes, although ramps 112 can also have non-linear ramp slopes or a combination of linear and non-linear ramp slopes. Non-linear ramp slopes can be advantageous, for example, to reduce the sensitivity of loading mechanism 98 to tolerance stack-up.

[0045] The ball bearings 110 and ramps 112 are sized and shaped so that relative rotation between the hubs 106, 108 causes the ball bearings 110 to roll along the ramps 112, such that rotation in one direction causes the hubs 106, 108 to axially separate from one another, while rotation in the opposite direction causes the hubs 106, 108 to move axially toward one another (compare FIGS. 20A and 20B). A return spring 114 (e.g., one or more wave washers) acts between the first hub 106 and the hub mount 40 to move the hubs 106, 108 toward one another when the tensioner 28 returns to the first position 28F (see FIG. 15B). More specifically, the return spring 114 acts between the hub mount 40 and the roller bearing assembly 115 to facilitate smooth rotation of the first hub 106 relative to the second hub 108, and thus the return spring 114 can more easily return the first hub 106 to its normal, non-operating position.

[0046] 16A and 16B, because the driver 102 is fixed to the first hub 106, rotation of the driver 102 relative to the first mounting plate 38 causes rotation of the first hub 106 about the longitudinal axis L1 relative to the first mounting plate 38. Similarly, because the second hub 108 is constrained from rotation relative to the first mounting plate 38, rotation of the driver 102 relative to the first mounting plate 38 also causes rotation of the first hub 106 relative to the second hub 108. This relative rotational motion causes relative axial movement between the hubs 106, 108 along the longitudinal axis L1 as the ball bearings 110 roll along their corresponding ramps 112: the hubs 106, 108 move axially apart as the ball bearings 110 roll up the ramps 112, and the hubs 106, 108 move axially closer together as the ball bearings 110 roll down the ramps 112 (compare FIGS. 16A and 16B). The ball bearings 110 rest at the innermost ends of the ramps 112 when the tensioner 28 is in the first position 28F. The load actuator 104 is positioned and configured to move the hubs 106, 108 axially away from each other in response to movement of the tensioner 28 toward the second position 28S.

[0047] The loading mechanism 98 further includes a biasing element 116 positioned to act between the second hub 108 and the first mounting plate 38. In the illustrated example, the biasing element 116 includes a conical spring washer (also called a Belleville washer / spring). As shown in FIG. 16C , in one example, the biasing element 116 includes inner and outer annular side surfaces 116a, 116b. The inner side surface 116a abuts the sloped annular surface 108a of the second hub 108. The outer side surface 116b abuts the sloped annular surface 38a of the first mounting plate 38. The side surfaces 116a, 116b can have a cross-sectional profile that is square, chamfered, rounded, or the like (see the rounded profile in FIG. 16C ). The annular surfaces 38a, 108a can be conical in shape. The annular surfaces 38a, 108a can have cross-sectional profiles that are flat, concave, convex, or the like (see the flat profile in FIG. 16C). The annular surfaces 38a, 108a can be angled relative to the longitudinal axis L1 at angles between 5 and 85 degrees, between 10 and 80 degrees, between 30 and 70 degrees, or between 40 and 70 degrees, or the like. The annular surfaces 38a, 108a can be disposed at the same acute angle or at different acute angles relative to the longitudinal axis L1. The arrangement of the biasing element 116, including abutment and compression between the annular surfaces 38a, 108a, can cause a biasing element normally designed to exhibit a linear load-deflection relationship to exhibit a nonlinear load-deflection relationship.

[0048] The biasing element 116 may include any suitable resilient element or spring to provide the preload force required to properly secure the second mounting portion 26 to the first mounting portion 24. In some examples, the biasing element 116 may include one or more diaphragm springs, buckling springs, or the like. Additionally, in some forms, the biasing element 116 may be slotted or may have one or more openings between the inner and outer peripheries.

[0049] In use, when the loading mechanism 98 is actuated, the first hub 106 initially moves axially away from the second hub 108 to position the kinematic coupler 32 in better contact with the receivers 34, 36 of the mounting plates 38, 42 by taking up slack between them (compare FIGS. 16A and 16B). Once the kinematic coupler 32 is secured to the receivers 34, 36 and achieves the desired contact with the surfaces of the receivers 34, 36, the mounting plates 38, 42 are in their desired relative positions and are not further attracted to each other due to the rigidity of the kinematic coupler 32 and the receivers 34, 36, which may be formed of metal, which are rigidly secured to the mounting plates 38, 42. As a result, further actuation of the loading mechanism 98, i.e., further rotation of the drive 102, now causes the second hub 108 to move axially away from the first hub 106. This is a result of the mounting plates 38, 42 no longer moving axially toward one another and the axial movement of the first hub 106 being fixed. Therefore, because the second hub 108 is in contact with the biasing element 116, further actuation of the loading mechanism 98 causes the biasing element 116 to compress. As a result, the biasing element 116 provides a preload force, or a resistance that defines at least a portion of the preload force, that holds the mounting portions 24, 26 together. The biasing element 116 acts between the second hub 108 and the first mounting plate 38 and continuously engages the second hub 108 and the first mounting plate 38 throughout the movement of the tensioner 28.

[0050] In one example, the conical spring washer provides a preload force of 200 lbs to 500 lbs, a preload force of 350 lbs to 450 lbs, or a preload force of approximately 400 lbs. The conical spring washer can have a nonlinear relationship of preload force to compression distance such that the preload force can vary only by approximately + / - 10% for axial compression of the conical spring washer of 2 millimeters or less. As a result, a consistent preload force can be applied regardless of tolerances in the assembly of the loading mechanism 98 or other components, and users can expect a consistent preload force with each use.

[0051] 21A and 21B, the tensioner 28 includes a lever 118 (also referred to as a handle), an activator 120, and an activator link 122 interposed between the lever 118 and the activator 120 in a force-transducing manner, and when the second mounting portion 26 is releasably secured to the coupling portion 30 (the coupling portion 30 is not shown in FIGS. 21A and 21B), movement of the tensioner 28 from the first position 28F (FIG. 21A) to the second position 28S (FIG. 21B) rotates the activator 120 about the longitudinal axis L1, causing simultaneous rotation of the coupling portion 30 and the drive portion 102 about the longitudinal axis L1, thereby applying a preload force.

[0052] Lever 118 extends outward from second mounting plate 42 in a first position (FIG. 21A) and engages second mounting plate 42 in a second position (FIG. 21B). Lever 118 is pivotally coupled to second mounting plate 42 at a first pivot joint P1 for pivoting about a first pivot axis perpendicular to second mounting plate 42. Lever 118 is further pivotally coupled to activator link 122 at a second pivot joint P2 for pivoting about a second pivot axis parallel to the first pivot axis. Activator link 122 is pivotally coupled to activator 120 at a third pivot joint P3 for pivoting about a third pivot axis parallel to the first and second pivot axes.

[0053] When the lever 118 is rotated / pivoted about the first pivot axis from the first position 28F to the second position 28S, the activator link 122 is biased to rotate (e.g., counterclockwise in the plan view shown in FIGS. 21A and 21B), thereby rotating the activator 120 (again, counterclockwise). The arrangement of pivot joints P1, P2, and P3 between the lever 118 and the second mounting plate 42, between the lever 118 and the activator link 122, and between the activator link 122 and the activator 120 provides a mechanical advantage to the tensioner 28. The pivot joints P1, P2, and P3 can be formed by connecting pins, shafts, or the like. The loading mechanism 98 and tensioner 28 can be configured to limit the relatively high force required to be applied by a user to the lever 118 and to maximize the travel of the lever 118 during relatively low forces.

[0054] A biasing element 124, such as a compression spring, acts between a spring block 126 fixed to the second mounting plate 42 and the activator 120 to bias the tensioner 28 toward the first position 28F until the tensioner 28 subsequently moves to the second position 28S to provide kinematic coupling of the end effector EE. A lever lock 128 is operably coupled (e.g., via a pivotal connection) to the lever 118 and locks the lever 118 to the second mounting portion 26 when the tensioner 28 is in the second position 28S (see FIG. 21B).

[0055] 15A and 15B, the activator 120 is seated for selective rotational movement within the second mounting plate 42. More specifically, the activator 120 is disposed between a centering member 130 (e.g., a centering plate) and a rotational locking plate 132. The centering member 130 and the locking plate 132 are secured to the second mounting plate 42 such that when the activator 120 is actuated for rotation via the lever 118, the activator 120 rotates relative to the centering member 130 and the locking plate 132 about a longitudinal axis L1.

[0056] The locking plate 132 is positioned and configured to prevent the activator 120 from rotating once the second mounting portion 26 is disconnected from the sterile barrier assembly 22. In other words, once the lever 118 is returned to the first position 28F and the second mounting portion 26 is removed from the sterile barrier assembly 22, the lever 118 cannot rotate to the second position 28S due to interference between the activator 120 and the locking plate 132. This facilitates cleaning of the second mounting portion 26, for example, by autoclaving, by leaving the lever 118 open and allowing detergent (e.g., steam) to penetrate into the internal components of the second mounting portion 26. Additionally, it prevents a user from attempting to install the second mounting portion 26 into the sterile barrier assembly 22 with the lever 118 in the closed second position 28S, which is impossible and can be confusing and frustrating for the user.

[0057] The activator 120 is constrained from rotation relative to the locking plate 132 and second mounting plate 42 by a flat 134 of the locking plate 132 that is axially aligned with a flat 136 of the activator 120 in the rotationally locked position (see FIGS. 12 and 15A). The flat 134 is located on a flange 135 of the locking plate 132, and the flat 136 is located on a flange 137 of the activator 120. In the unlocked position, the axially offset flats 134, 136 allow the activator 120 to rotate relative to the locking plate 132 and second mounting plate 42. A biasing element 138 (e.g., a wave spring) biases the activator 120 toward the locked position.

[0058] The activator 120 is positioned to engage the coupling portion 30 when securing the second mounting portion 26 to the sterile barrier assembly 22, and thus the coupling portion 30 biases the activator 120 to the unlocked position when the connection between the sterile barrier assembly 22 and the second mounting portion 26 is made via the second locking assembly. In particular, the coupling portion 30 axially engages the activator 120, and the flange 137 of the activator 120 moves axially below the flange 135 of the locking plate 132, so that the flats 134, 136 no longer abut and interfere (compare FIG. 15A with FIG. 15B). Once unlocked, the activator 120 can rotate in response to movement of the tensioner 28 toward the second position 28S, and the activator 120, coupling portion 30, driver 102, and first hub 106 simultaneously rotate relative to the mounting plates 38, 42 to apply a preload force.

[0059] The activator 120 is configured to be placed in rotational engagement with the coupling portion 30 of the sterility barrier assembly 22 when the second mounting portion 26 is releasably secured to the coupling portion 30. To this end, the coupling portion 30 and the activator 104 have corresponding spline formations, generally designated by the reference numeral 82 (see FIG. 15A ), that are configured to facilitate simultaneous rotation about the longitudinal axis L1 during use. Specifically, the coupling portion 30 has end splines or teeth that engage corresponding end splines or teeth on the activator 120. However, any suitable type of rotational engagement can be employed to facilitate rotational transmission between the coupling portion 30 and the activator 120.

[0060] The first mounting portion 24 may include electronics required to perform certain functions of the surgical component. In one form, with reference to FIGS. 7 and 8 , a Hall effect sensor 140 (see FIG. 8 ) may be supported by a printed circuit board PCB affixed to the mounting hub 40. A corresponding magnet 142 (see FIG. 7 ) is supported by the first hub 106 for rotation therewith. Alternatively, the sensor may be supported by the first hub 106 for movement relative to a magnet affixed to the printed circuit board PCB. The sensor 140 is coupled to a controller 144, which may be located on the printed circuit board PCB or elsewhere to receive an appropriate signal from the sensor 140. The sensor 140 is positioned to cooperate with the magnet 142 to generate a signal indicative of the amount of rotation of the first hub 106 relative to the hub mount 40 and first mounting plate 38. This provides the controller 144 with information regarding whether the second mounting portion 26 is properly secured to the first mounting portion 24. In one example, the controller 144 monitors the rotation via the sensor 140 to determine whether the first hub 106 has rotated at least a predetermined amount, such as at least 10 degrees, at least 20 degrees, or at least 30 degrees. One or more windows or grooves 146 (see FIG. 8 ) can be formed in the bottom wall of the hub mount 140 to facilitate reading the movement of the magnet 142 via the sensor 140 through the bottom wall.

[0061] 22 through 25B, the second mounting portion 26 includes a release mechanism 148 operable to move one or more of the release collars 84, 86 (see FIG. 15B) to release the second mounting portion 26 from the coupling 30 after the lever 118 of the tensioner 28 is opened to the first position 28F. The release mechanism 148 includes a release actuator 150, a release link 152, a biasing element 154 (e.g., a compression spring), and one or more release elements 156. The one or more release elements 156 are operably disposed between the release actuator 150 and the one or more release collars 84, 86 such that actuation of the release actuator 150 moves the release link 152 against the bias of the biasing element 154, displacing one or more of the release collars 84, 86 and releasing one or more of the ball subassemblies 74, 76 from one or more of the ball detents 78, 80. In the illustrated form, the release mechanism 148 operates to move the second release collar 86 to release the second ball subassembly 76 from the second ball detent 80 .

[0062] 24A and 24B, the release actuator 150 is positioned such that movement of the lever 118 to the second position 28S at least partially covers the release actuator 150, and the release actuator 150 is not normally accessible to a user when the lever 118 is in the second position 28S. When the lever 118 is opened to the first position 28F, the release actuator 150 is accessible and actuatable by a user. In the illustrated form, the release actuator 150 is in the form of a push button actuator configured to be depressed by a user to release the second mounting portion 26 from the sterile barrier assembly 22, although any suitable form of actuator could be employed. In this configuration, when the release actuator 150 is depressed (compare FIG. 24A with FIG. 24B ), one or more release elements 156 protrude through a retaining plate 158 secured to the second mounting plate 42 to engage and move the second release collar 86, thus removing the second mounting portion 26 from the sterility barrier assembly 22. When the release actuator 150 is released, the one or more release elements 156 are biased via their own biasing elements 160 (e.g., torsion springs shown in FIG. 22 ) to return beneath the retaining plate 158. In this manner, the release elements 156 are arranged to move relative to the second mounting plate 42 and the retaining plate 158 between a first, non-protruding position and a second, protruding position.

[0063] 25A-25C (with the lever removed for clarity), the release link 152 is configured to engage one or more release elements 156 to move the one or more release elements 156 to their second positions in response to actuation of the release actuator 150. More specifically, the release link 152 includes a pair of release arms 162, each having a cam engaging end 164. As the cam engaging ends 164 slide relative to the second mounting portion 42, the cam engaging ends 164 engage the release elements 156 (see FIG. 25C). In this configuration, the release elements 156 are in the form of a cam disc that is eccentrically mounted to a retaining plate 158 for rotation about an eccentric axis A1. The cam engagement end 164 is spaced apart from the eccentric axis A1 and the cam disc, and when the cam engagement end 164 abuts the cam disc, the cam disc rotates about the eccentric axis A1, protrudes through the slot in the retaining plate 158, and pops over the retaining plate 158 to engage the second release collar 86, i.e., its collar body, lifting the collar body 90 until the ball 77 of the second ball subassembly 76 is withdrawn from the detent pocket 80 (compare FIG. 15B, which shows the collar body 90 resting on the retaining plate 158).

[0064] In some situations, it may be necessary to actuate the release actuator 150 when the lever 118 is in the second position 28S (e.g., closed). This may be desired, for example, when the lever 118 is stuck in the second position 28S, which may occur when the second mounting portion 26 is attached to the sterile barrier assembly 22 before coupling the sterile barrier assembly 22 to the first mounting portion 24. To this end, the lever lock 128 is positioned so that an elongated tool (such as a screwdriver) can be used to pry up on the lever lock 128 and pivot the lever lock 128, causing a rear portion of the lever lock 128 to engage the release actuator 150 and move the second release collar 86 as described above. Figure 24A shows the proximity of the rear portion of the lever lock 128 to the release actuator 150, which enables this action. Prying up the lever lock 128 as described above releases the second release collar 86, allowing the second mounting portion 26 to be released from the sterile barrier assembly 22, thereby allowing the lever 118 to return to the first position 28F (e.g., the open position). Another option is to include a through-hole in the second mounting portion 26 that directs an elongated tool to the second release collar 86, and manually move the second release collar 86 along with the elongated tool to release the sterile barrier assembly 22 from the second mounting portion 26.

[0065] In use, the sterile barrier assembly 22 is first secured to the first mounting portion 24 connected to the robotic arm R. Thus, axial movement of the coupler 30 toward the robotic arm R brings the first ball detent 78 into engagement with the ball 75 of the first ball subassembly 74, such that the first locking assembly holds the sterile barrier assembly 22 on the first mounting portion 24 and the kinematic coupler 32 loosely seats in the first plurality of receptacles 34. The drape 50 can then be placed around the robotic arm R to facilitate subsequent movement within the sterile field S. Next, axial movement of the second mounting portion 26 and its connected end effector EE toward the fixed sterile barrier assembly 22 causes the second ball detent 80 to engage with the ball 77 of the second ball subassembly 76, and thus the second locking assembly holds the second mounting portion 26 on the sterile barrier assembly 22, and the second plurality of receivers 36 are loosely seated in the kinematic coupler 32.

[0066] The tensioner 28 of the second mounting portion 26 is biased by the biasing element 124 toward the first position 28F until the tensioner 28 subsequently moves to the second position 28S, resulting in kinematic coupling of the end effector EE to the robotic arm R. As the tensioner 28 moves toward the second position 28S, the activator 120 rotates the coupling portion 30, which rotates the drive portion 102 via the spline arrangement 82. This rotation actuates the loading mechanism 98, axially separating the hubs 106, 108 and attracting the first and second mounting portions 24, 26 toward one another, resulting in kinematic coupling as the tensioner 28 enters the second position 28S. The end effector EE is now kinematically coupled to the robotic arm R and can be used within the sterile field S.

[0067] If the end effector EE needs to be replaced or exchanged within the sterile field S during a procedure, the second mounting portion 26 can be removed from the sterile barrier assembly 22 without allowing contaminants to pass over the sterile barrier assembly 22 to or from the robotic arm R. Now, to remove the second mounting portion 26, the tensioner 28 can be moved out of the second position 28S to release the kinematic coupling. While the tensioner 28 is returned to the first position 28F, the second locking assembly holds the second mounting portion 26 secured to the sterile barrier assembly 22, and the sterile barrier assembly 22 remains secured to the first mounting portion 24 by the first locking assembly. To release the second mounting portion 26 from the sterile barrier assembly 22, the tensioner 28 can be moved from the first position 28F to expose the release actuator 150, which can be depressed to engage the release element 156 with the second release collar 86 which releases the second locking assembly, thereby allowing the ball 77 of the second ball subassembly 76 to retract from the second ball detent 80 of the coupling 30. More specifically, the axial force applied by the release element 156 urges the second release collar 86 axially away from the second ball subassembly 76 until the second release collar 86 no longer restrains the ball 77 of the second ball subassembly 76 on the second ball detent 80. At this point, the second mounting portion 26 and the end effector EE to which it is connected can be removed and a different second mounting portion and second end effector can then be re-secured to the sterile barrier assembly 22.

[0068] To remove the sterile barrier assembly 22 from the first mounting portion 24, such as after a surgical procedure is completed, the second mounting portion 26 and connected end effector EE are first removed from the sterile barrier assembly 22, as described above. Next, to remove the sterile barrier assembly 22 from the first mounting portion 24, the interface 48 is pulled axially away from the first mounting portion 24 by the user, disengaging the first locking assembly. An axial force applied to the interface 48 now displaces the first release collar 84 axially relative to the coupling portion 30 against the bias of the biasing elements 88, 89, releasing the first locking assembly, and thus the first ball detent 78 of the coupling portion 30 retracting from the first ball sub-assembly 74 of the first mounting portion 24. More specifically, the user applies an axial force by grasping around the periphery of interface 48, thereby pulling first release collar 84 (both collar body 90 and collar keeper 92) axially away from first ball sub-assembly 74 until first release collar 84 no longer restrains ball 75 of first ball sub-assembly 74 in first ball detent 78.

[0069] I. Lighting for Mounting Systems 26-29, a robotic surgical system 200 including a robotic arm R and an end effector EE is utilized with an illumination system to assist a user in properly implementing one or more components of the implementation system described herein. More specifically, the robotic surgical system 200 can include an illumination device 202 configured to emit light and change its emission between at least a first illumination state S1 (see FIG. 28) and a second illumination state S2 (see FIG. 29).

[0070] In the examples shown in FIGS. 26 to 29 , the lighting device 202 is coupled to the robot arm R. More specifically, the robot arm R, and even more specifically, any link of the arm disposed between the robot joints, has an outer surface 206, and the lighting device 202 is disposed on or within the outer surface 206. The lighting device 202 can have an annular configuration surrounding the outer surface 206. In other words, the lighting device 202 is configured like a ring wrapped around the outer surface 206 and coaxial with the robot joint axis, and is easily recognizable to a user in any position of the arm R. As shown in the figures, the lighting device 202 can be flush with (or integral with) the outer surface 206. However, the lighting device 202 may also protrude above or extend below the outer surface 206 of the robot arm R.

[0071] In the example shown in FIGS. 26 through 29 , the lighting device 202 is adjacent to the first mounting portion 24 near the distal end of the robotic arm R, so that the lighting device 202 is easily visible to a user manipulating the end effector EE. However, the lighting device 202 can be disposed anywhere along the robotic arm R, including the second mounting portion 26. Further, other examples are contemplated, in which the lighting device 202 is coupled to the end effector EE, the sterile barrier assembly 22, or any other suitable portion of the robotic surgical system 200. Moreover, the lighting device 202 can be separate from the robotic arm R, the end effector EE, and the sterile barrier assembly 22. In other words, the lighting device 202 can be a separate component within the user's field of view during use of the robotic surgical system 200. Furthermore, any number of lighting devices 202 can be utilized, and they can have the same or different shapes or configurations. For example, various lighting devices 202 can be positioned at different joints of the robotic arm R.

[0072] The lighting device 202 can include any suitable light source for emitting light perceptible to a user. For example, the lighting device 202 can include an array of LEDs or OLEDs, a display device (e.g., an LCD screen), the displayed content of which is controlled by software, fiber optics, or any other type of suitable technology. The LEDs or OLEDs can emit light in the full visible range or a combination of infrared and visible wavelength ranges, and can produce any color within the visible range.

[0073] The robotic surgical system 200 further includes one or more controllers 204 (referred to herein for simplicity as controller 204) in communication with or coupled to the lighting device 202 and configured to receive signals (as described below) from other electronic or electrical components or sensors to determine how to control the lighting device 202. The controller 204 is configured to control the lighting device 202 to change between the first and second lighting states S1, S2 in response to fluctuations in the signals. The controller 204, or any ancillary components thereof, can be coupled to any one or more of the components of the mounting system 20, including the end effector EE, the robot arm, the robot base, the first and second mounting portions 24, 26, and the sterile barrier assembly 22, or can be integrated into the lighting device 202. In one example, the controller 204 can encompass, be the same as, or be in communication with the controller 144 located in the first mounting portion 24, as described above.

[0074] The controller 204 can include or otherwise communicate with any portion of the surgical system in addition to the illumination device 202, including any one or more of a robotic control system, a navigation system, and a tool control system that cooperate to facilitate positioning, moving, and / or driving the end effector EE, via the robotic system's arm R, relative to the target site and other portions of the robotic surgical system 200. The controller 204 can be similar to that described in U.S. Pat. No. 10,327,849, entitled "Robotic System and Method for Backdriving the Same," the disclosure of which is incorporated herein by reference in its entirety. The controller 204 can be implemented as or include various configurations, such as computers, processors, and control units, and can include separate components or integrate them (e.g., sharing hardware, software, inputs, outputs, etc.). Furthermore, the controller 204 may be implemented with any suitable hardware, including a computer with a processor (e.g., a central processing unit) and / or other processors, memory, and / or storage devices (not shown), and may be loaded with software capable of functioning as described in more detail below. The processor may include one or more processors for controlling the operation of the robot, navigation system, or end effector EE. The processor may be any type of microprocessor, multiprocessor, and / or multicore processing system. The controller 204 may additionally or alternatively include one or more microcontrollers, field programmable gate arrays, systems-on-chips, discrete circuits, and / or other suitable hardware, software, and / or firmware capable of performing the functions described herein. The term "processor" is not intended to limit any embodiment to a single processor.The controller 204 may also include, define, or otherwise employ a user interface with one or more output devices (e.g., screens, displays, status indicators, etc.) and / or input devices (e.g., push buttons, keyboards, mice, microphones, voice-activated devices, gesture-controlled devices, touchscreens, foot pedals, pendants, etc.). Other configurations are contemplated.

[0075] 27-29, the lighting device 202 communicates with the controller 204 to change its illumination between at least first and second illumination modes S1, S2. The illumination modes provide visual feedback to the user to inform the user of the status of the robotic surgical system 200. The user interprets the illumination and reacts accordingly (e.g., by reinstalling an improperly installed component in the mounting system).

[0076] The operation of the lighting device 202 may change between conditions associated with the mounted system, as described below. In one example, one of the lighting aspects S1, S2 indicates an error condition, while another of the lighting aspects S1, S2 indicates a proper or positive state, such as the correct installation of a system component. The description herein does not necessarily limit either the first or second lighting aspects S1, S2 to a specified error condition, and therefore the terms “first” and “second” are interchangeable. The aspects S1, S2 may also indicate conditions independent of the presence or absence of an error. For example, a condition may convey information to a user (e.g., confirmation before or after a user action). In one example, the first and second lighting aspects S1, S2 are in an “on / off” state, and the lighting device 202 emits light through one of the first and second lighting aspects S1, S2 and does not emit light through the other of the first and second lighting aspects S1, S2. In another example, the lighting device 202 may flash in one or both of the first and second lighting states S1, S2. Moreover, when the lighting device 202 flashes in one or both of the first and second lighting states S1, S2, the flashing rate of the lighting device 202 may be varied between the first and second lighting states S1, S2 to differentiate between the states. In another example, the lighting device 202 emits light having a first color in the visible color spectrum in the first lighting state S1 and emits light having a second color in the visible color spectrum, different from the first color, in the second lighting state S2. In another example, the light emitted in the first and second lighting states S1, S2 may vary in brightness to differentiate between the first and second lighting states S1, S2.

[0077] The examples provided above are not mutually exclusive and can be utilized in conjunction with each other in any suitable configuration (e.g., the lighting device 202 can flash a first color having a first intensity in a first lighting manner S1, while the lighting device 202 can emit stable light of a second color having a second intensity (different from the second intensity) in a second lighting manner S2). Moreover, the lighting device 202 can be configured to emit light in more than just the first and second lighting manners S1, S2. Indeed, the lighting device 202 can be configured to emit light in multiple lighting manners to alert the user to many different conditions of the robotic surgical system 200.

[0078] In one example, the lighting device 202 is controlled to be in a first lighting mode S1 when the end effector EE is coupled to the robot arm R, and is controlled to be in a second lighting mode S2 when the end effector EE is not coupled or improperly coupled to the robot arm R. In this way, the lighting device 202 in the second lighting mode S2 communicates to a user that the end effector EE is properly coupled to the robot arm R and is operable. On the other hand, the lighting device 202 in the first lighting mode S1 communicates to a user that the end effector EE is not properly or improperly coupled to the robot arm R and that further manipulation of the end effector EE and the robot arm R is required to couple the end effector EE with the robot arm R, e.g., to prevent inoperability or damage to the end effector EE and / or the robot arm R. In some examples, the controller 204 can additionally allow operation of the end effector EE while the lighting device 202 is in the first lighting mode S1, and the controller 204 can inhibit operation of the end effector EE while the lighting device 202 is in the second lighting mode S2.

[0079] The controller 204 can communicate with the electronics of the first mounting portion 24 to detect coupling between the end effector EE and the robot arm R. As described above, a sensor 140 (see FIG. 8 ), such as, but not limited to, a Hall Effect sensor, can be supported by a printed circuit board PCB affixed to the mounting hub 40. A corresponding magnet 142 (see FIG. 7 ) can be supported by the first hub 106 for rotation therewith. Alternatively, the sensor 140 can be supported by the first hub 106 for movement relative to a magnet affixed to the printed circuit board PCB. As described above, the sensor 140 is positioned to cooperate with the magnet 142 to generate a signal indicative of the amount of rotation of the first hub 106 relative to the hub mount 40 and the first mounting plate 38. This provides the controller 204 (potentially including the controller 144) with information regarding whether the second mounting portion 26 is properly secured to the first mounting portion 24 (i.e., ensuring proper coupling between the robot arm R and the end effector EE). This allows the controller 204 to wirelessly detect coupling between the robot arm R and the end effector EE. Other examples of the controller 204 wirelessly detecting coupling between the end effector EE include, but are not limited to, inductive sensing and capacitive sensing.

[0080] Based on the signal of the sensor 140 (indicating the rotation of the first hub 106), the controller 204 can control the lighting device 202 to the first mode S1 when the controller 204 determines that the second mounting portion 26 is properly secured to the first mounting portion 24. On the other hand, the controller 204, 144 can control the lighting device 202 to the second mode S2 when the controller 204, 144 determines that the second mounting portion 26 is not properly secured to the first mounting portion 24.

[0081] In another example, the sensor data can more generally detect proximity between the second mounting portion 26 and the first mounting portion 24. The controller 204, 144 can control the lighting device 202 to the first mode S1 when the controller 204, 144 determines that the second mounting portion 26 is not within a threshold proximity to the first mounting portion 24, and can control the lighting device 202 to the second mode S2 when the controller 204, 144 determines that the second mounting portion 26 is within a threshold proximity to the first mounting portion 24.

[0082] Alternatively, coupling between the end effector EE and the robot arm R can be detected through a direct electrical (wired) connection between the end effector EE and the robot arm R. For example, as described above, the first mounting portion 24, the second mounting portion 26, and the sterile barrier assembly 22 can each employ one or more connectors, such as sealed electrical connectors, adapted to provide an electrical connection between the first mounting portion 24 and the second mounting portion 26 to facilitate communication between the robot arm R and the end effector EE. In the configuration shown in FIGS. 5B and 5C, first, second, and third connectors C1, C2, and C3 are employed. However, different types of communication through the connectors C1, C2, and C3 are also contemplated without limitation. Furthermore, in other examples, electrical connection between the end effector EE and the robot arm R can be achieved without the sterile barrier assembly 22.

[0083] The presence of a direct wired connection between the electrical components of the mounting portions 24, 26 may indicate a proper coupling between the mounting portions 24, 26, whereas the absence of a direct wired connection may indicate an improper coupling between the mounting portions 24, 26. The controller 204 may control the lighting device 202 to a first mode S1 when the controller 204 determines the absence of a direct wired connection between the electrical components of the mounting portions 24, 26, and may control the lighting device 202 to a second mode S2 when the controller 204 determines the presence of a direct wired connection between the electrical components of the mounting portions 24, 26.

[0084] Alternatively, the wired connection between the mounting portions 24, 26 may indicate both a proper and improper installation condition, but the controller 204 and / or any other sensors employed by the controller can detect electrical conditions (e.g., current, voltage, signal frequency / phase / amplitude, capacitance, impedance, etc.) to differentiate between proper and improper installation. The controller 204 can then control the lighting device 202 accordingly in such cases.

[0085] 28 and 29 , in yet another example, coupling between the end effector EE and the robotic arm R can be detected via actuation of a mechanical component, such as a switch, button, trigger, or plunger, in electronic communication with the controller 204. For example, as described above, the tensioner 28 of the second mounting portion 26 is movable between a first position 28F and a second position 28S (as shown in FIGS. 2 and 3 ). The coupling portion 30 of the sterile barrier assembly 22 is releasably secured to the first mounting portion 24 and configured to releasably receive the second mounting portion 26 when the tensioner 28 of the second mounting portion 26 is in the first position 28F. The kinematic coupler 32 is configured to engage the mounting portions 24, 26 and is positioned to provide a kinematic coupling between the mounting portions 24, 26 through the sterile barrier assembly 22 when the tensioner 28 of the second mounting portion 26 is in the second position 28S to constrain six degrees of freedom of movement between the surgical components. Here, the position of the tensioner 28 can be detected by any sensor (e.g., a position sensor, a proximity sensor, a switch sensor) coupled to the controller 204. When the controller 204 determines that the tensioner 28 is in the first position 28F while the second mounting portion 26 is mounted to the sterile barrier assembly 22, the controller 204 can control the lighting device 202 to the first mode S1, and when the controller 204 determines that the tensioner 28 is in the second position 28S, the controller 204 can control the lighting device 202 to the second mode S1.

[0086] In a related example, the lighting device 202 can be controlled to indicate the status of the sterile barrier assembly 22 relative to the first or second mounting portion 24, 26. In one example, the controller 204 can employ sensors (e.g., proximity, position, inertial, or force sensors) to determine the position or proximity of the sterile barrier assembly 22 relative to the first mounting portion 24. The sensors can be coupled to one or more of the sterile barrier assembly and the first mounting portion 24. From the sensors, the controller 204 can determine when the coupling 30 of the sterile barrier assembly 22 is properly secured to the first mounting portion 24 (with or without regard to the second mounting portion 26). The controller 204 can also determine from the sensors when the coupling 30 of the sterile barrier assembly 22 is not properly secured to the first mounting portion 24 (or not secured at all). In such a case, the controller 204 can control the lighting device 202 to a first mode S1 when the sterile barrier assembly 22 is properly secured to the first mounting portion 24, and can control the lighting device 202 to a second mode S2 when the sterile barrier assembly 22 is improperly secured or not secured to the first mounting portion 24.

[0087] With respect to any of the examples described above related to controlling the lighting device 202 in accordance with the implementation system, the lighting device 202 may be further controlled to any other lighting manner to indicate the status of the end effector EE and / or the robotic arm R before, during, or after surgery. For example, the lighting device 202 may emit light in a different lighting manner when the end effector EE and / or the robotic arm R are operating properly or within a range of proper conditions. On the other hand, the lighting device 202 may emit light in a different lighting manner when the end effector EE and / or the robotic arm R are not operating properly or within a range of improper conditions (e.g., loss of precision, potential collision condition, etc.). Any other appropriate or error status of the end effector EE and / or the robotic arm R may be indicated by the lighting device 202.

[0088] While the above provides a number of examples illustrating states of the robotic surgical system 200 that facilitate control of the lighting device 202, the list is not definitive and many other states may exist for which the light emitted by the lighting device 202 may be altered.

[0089] Several examples have been discussed in the foregoing description. However, the examples discussed herein are not intended to be exhaustive or to limit the invention to any particular form. The terminology used is intended to be in the nature of descriptive rather than limiting. Many modifications and variations are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described. The scope of the claims at the time of filing is as follows: [Claim 1] A mounting system for coupling first and second surgical components, comprising: a first mounting portion connected to the first surgical component; a second mounting portion connected to the second surgical component and including a tensioner movable between a first position and a second position; a sterile barrier assembly; Including, The sterility barrier assembly comprises: a coupling portion configured to be releasably secured to the first mounting portion and to releasably receive the second mounting portion when the tensioner of the second mounting portion is in the first position; a plurality of kinematic couplers configured to engage the mounting portions and positioned to provide a kinematic coupling between the mounting portions through the sterile barrier assembly to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in the second position; , an implementation system. [Claim 2] 10. The mounting system of claim 1, wherein the first mounting portion further comprises a loading mechanism configured to bias at least one of the second mounting portion and the sterile barrier assembly against the first surgical component in response to movement of the tensioner from the first position toward the second position when the sterile barrier assembly is secured to the first mounting portion and the second mounting portion is secured to the sterile barrier assembly. [Claim 3] 3. The mounting system of claim 2, wherein the loading mechanism of the first mounting portion biases the second mounting portion against the plurality of kinematic couplers of the sterile barrier assembly in response to movement of the tensioner toward the second position. [Claim 4] 3. The mounting system of claim 2, wherein the coupling of the sterile barrier assembly is force-transferably interposed between the tensioner and the loading mechanism. [Claim 5] The first mounting portion is a first mounting plate adapted to attach to the first surgical component; 3. The mounting system of claim 2, further comprising: a first ball subassembly configured to releasably secure to the coupling portion of the sterile barrier assembly. [Claim 6] 6. The mounting system of claim 5, wherein the loading mechanism is configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position. [Claim 7] the loading mechanism includes a driver operably attached to the first ball subassembly; 6. The mounting system of claim 5, wherein the drive portion is configured to be disposed in rotational engagement with the coupling portion of the sterile barrier assembly. [Claim 8] 8. The mounting system of claim 7, wherein the driver is positioned such that, in response to movement of the tensioner toward the second position, rotation of the driver axially moves the first ball subassembly and applies a preload force between the first mounting portion and the second mounting portion. [Claim 9] 9. The mounting system of claim 8, wherein the loading mechanism includes a loading actuator configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position. [Claim 10] The load actuator a first hub operably attached to the first ball subassembly; a second hub operably attached to the first mounting plate; a plurality of ball bearings disposed between the hubs; and a ramp defined on one or more of the hubs along which the ball bearing rolls in response to movement of the tensioner toward the second position. [Claim 11] The mounting system of claim 10 , including a sensor for detecting rotation of the first hub relative to the second hub. [Claim 12] 11. The mounting system of claim 10, wherein the loading mechanism includes a conical spring washer positioned and shaped to act between the second hub and the first mounting plate in a force-to-compression relationship such that the preload force changes by no more than 10% for an axial compression of no more than 2 millimeters. [Claim 13] each of the second hub and the first mounting plate includes a conical surface; The mounting system of claim 10 , wherein the conical spring washer has inner and outer sides that abut the conical surface. [Claim 14] the second mounting portion includes a second ball subassembly configured to be releasably secured to the coupling portion of the sterile barrier assembly; 9. The mounting system of claim 8, wherein the tensioner includes an activator positioned to rotationally engage the coupling portion of the sterile barrier assembly when the coupling portion is releasably secured to the second mounting portion. [Claim 15] the second mounting portion includes a second mounting plate; 15. The mounting system of claim 14, wherein the activator is movable between a locked position in which the activator is prevented from rotating relative to the second mounting plate and an unlocked position in which the activator can rotate relative to the second mounting plate. [Claim 16] a biasing element that biases the activator toward the locked position; 16. The mounting system of claim 15, wherein the activator is positioned to engage the coupling when securing the second mounting portion to the sterile barrier assembly such that the coupling biases the activator to the unlocked position. [Claim 17] 15. The mounting system of claim 14, wherein the activator is configured to rotate in response to movement of the tensioner toward the second position such that the activator, the coupling portion, and the driver portion simultaneously rotate relative to the first mounting plate to apply the preload force. [Claim 18] 18. The mounting system of claim 17, wherein the tensioner further includes a lever and an activator link force-transducingly interposed between the lever and the activator, and wherein movement of the tensioner to the second position rotates the activator to co-rotate the coupling and the drive portion to apply the preload force when the second mounting portion is releasably secured to the coupling portion. [Claim 19] the second mounting portion includes a second mounting plate; 20. The mounting system of claim 18, wherein the lever extends outward from the second mounting plate in the first position and retracts into the second mounting plate in the second position. [Claim 20] 20. The mounting system of claim 18, including a lever lock operably coupled to the lever for locking the lever when the tensioner is in the second position. [Claim 21] a first locking assembly configured to be interposed between the first mounting portion and the mating portion of the sterile barrier assembly to releasably secure the mating portion to the first mounting portion; a second locking assembly configured to be interposed between the coupling portion and the second mounting portion to releasably secure the second mounting portion to the coupling portion when the tensioner is in the first position; The mounting system of claim 1 further comprising: [Claim 22] Each of the locking assemblies comprises: a ball subassembly operably attached to one of the coupling portion and the corresponding mounting portion; 22. The mounting system of claim 21, including a ball detent defined on the other of the coupling portion and the corresponding mounting portion that is shaped to receive the ball subassembly. [Claim 23] 23. The mounting system of claim 22, wherein the coupling portion is configured to be disposed in communication with each of the ball subassemblies when the sterile barrier assembly is secured to the first mounting portion and the second mounting portion is secured to the sterile barrier assembly. [Claim 24] 23. The mounting system of claim 22, wherein each of the ball detents of the locking assembly is defined in the coupling portion of the sterile barrier assembly. [Claim 25] 23. The mounting system of claim 22, wherein each of the locking assemblies further includes a release collar positioned to secure one of the ball sub-assemblies received in one of the ball detents. [Claim 26] 26. The mounting system of claim 25, wherein each of the release collars of the locking assembly is operably attached to the sterile barrier assembly. [Claim 27] 26. The mounting system of claim 25, wherein the release collars of the locking assemblies are axially biased away from each other. [Claim 28] 28. The mounting system of claim 27, wherein the sterility barrier assembly further includes a collar biasing element force-transformably interposed between the coupling portion and the release collar to axially bias the release collars away from each other. [Claim 29] 28. The mounting system of claim 27, wherein the second mounting portion includes a release mechanism operable to move one of the release collars to release the second mounting portion from the coupling. [Claim 30] 30. The mounting system of claim 29, wherein the release mechanism includes a release actuator and one or more release elements configured to be disposed between the release actuator and the one release collar when the second mounting portion is releasably attached to the sterile barrier assembly, and wherein actuation of the release actuator moves the one or more release elements to displace the one release collar and allow the one ball sub-assembly to be removed from the one ball detent. [Claim 31] the tensioner includes a lever movable between the first and second positions; 31. The mounting system of claim 30, wherein the release actuator is positioned such that movement of the lever to the second position at least partially covers the release actuator. [Claim 32] the second mounting portion includes a second mounting plate; 31. The mounting system of claim 30, wherein the release mechanism includes a release link force-transducibly interposed between the release actuator and the one or more release elements, and moves the one or more release elements from a rest position to a release position relative to the second mounting plate. [Claim 33] 33. The mounting system of claim 32, wherein the release link is configured to engage the one or more release elements to move the one or more release elements to the release position in response to actuation of the release actuator. [Claim 34] 10. The mounting system of claim 1, wherein the sterile barrier assembly further comprises an interface and a drape operably attached to the interface. [Claim 35] 35. The mounting system of claim 34, wherein the coupling and the kinematic coupler are operably attached to the interface. [Claim 36] the sterility barrier assembly further includes an indexing finger; 10. The mounting system of claim 1, wherein at least one of the mounting portions defines an indexing recess shaped to receive the indexing finger to align the kinematic coupler with respect to the at least one of the mounting portions. [Claim 37] The mounting system of claim 1 , wherein the plurality of kinematic couplers is further defined as a plurality of balls. [Claim 38] 38. The mounting system of claim 37, wherein the plurality of balls is further defined as three balls configured to constrain the six degrees of freedom of movement between the surgical components. [Claim 39] the first mounting portion includes a first plurality of contact surfaces for engaging the plurality of kinematic couplers; the second mounting portion includes a second plurality of contact surfaces for engaging the plurality of kinematic couplers; 39. The mounting system of claim 38, wherein the contact surfaces are shaped to cooperate with the plurality of kinematic couplers to constrain the six degrees of freedom of motion between the surgical components. [Claim 40] the first mounting portion includes a first plurality of receptacles having the first plurality of contact surfaces; 40. The mounting system of claim 39, wherein the second mounting portion includes a second plurality of receptacles having the second plurality of contact surfaces. [Claim 41] 40. The mounting system of claim 39, wherein the second plurality of contact surfaces is configured to provide only six points of contact with the plurality of kinematic couplers. [Claim 42] an end effector releasably attached to a first mounting portion of a surgical robot via a sterile barrier assembly having a coupling portion and a plurality of kinematic couplers, a housing for supporting the energy applicator; a second mounting portion attached to the housing and including a tensioner movable between a first position and a second position; the second mounting portion is configured to releasably couple to the coupling portion of the sterility barrier assembly when the tensioner of the second mounting portion is in the first position; an end effector, the second mounting portion including a plurality of contact surfaces for engaging the plurality of kinematic couplers of the sterile barrier assembly; [Claim 43] the second mounting portion includes a ball subassembly configured to releasably secure to the coupling portion of the sterile barrier assembly; 43. The end effector of claim 42, wherein the tensioner includes an activator positioned for rotational engagement with the coupling portion of the sterility barrier assembly when the second mounting portion is releasably secured to the coupling portion. [Claim 44] the second mounting portion includes a second mounting plate; 44. The end effector of claim 43, wherein the activator is movable between a locked position in which the activator is prevented from rotating relative to the second mounting plate and an unlocked position in which the activator can rotate relative to the second mounting plate. [Claim 45] a biasing element that biases the activator toward the locked position; 45. The end effector of claim 44, wherein the activator is positioned to engage the coupling when securing the second mounting portion to the sterility barrier assembly such that the coupling biases the activator to the unlocked position. [Claim 46] 44. The end effector of claim 43, wherein the activator is configured to rotate in response to movement of the tensioner toward the second position. [Claim 47] 47. The end effector of claim 46, wherein the tensioner further includes a lever and an activator link interposed between the lever and the activator in a force-transducing manner. [Claim 48] the second mounting portion includes a second mounting plate; 48. The end effector of claim 47, wherein the lever extends outwardly from the second mounting plate in the first position and telescopes into the second mounting plate in the second position. [Claim 49] 48. The end effector of claim 47, comprising a lever lock operably coupled to the lever to lock the lever when the tensioner is in the second position. [Claim 50] 43. The end effector of claim 42, wherein the second mounting portion includes a release mechanism operable to release the second mounting portion from the coupling portion. [Claim 51] 51. The end effector of claim 50, wherein the release mechanism includes a release actuator and one or more release elements. [Claim 52] the tensioner includes a lever movable between the first and second positions; 52. The end effector of claim 51, wherein the release actuator is positioned such that movement of the lever to the second position at least partially covers the release actuator. [Claim 53] the second mounting portion includes a second mounting plate; 52. The end effector of claim 51, wherein the release mechanism includes a release link force-transducibly interposed between the release actuator and the one or more release elements to move the one or more release elements from a rest position to a release position relative to the second mounting plate. [Claim 54] 54. The end effector of claim 53, wherein the release link is configured to engage the one or more release elements to move the one or more release elements to the release position in response to actuation of the release actuator. [Claim 55] 43. The end effector of claim 42, wherein the second mounting portion defines an indexing recess shaped to receive an indexing finger of the sterile barrier assembly to align the kinematic coupler relative to the second mounting portion. [Claim 56] the second mounting portion includes a plurality of receivers having the plurality of contact surfaces for engaging the plurality of kinematic couplers; 43. The end effector of claim 42, wherein the plurality of contact surfaces are shaped to cooperate with the plurality of kinematic couplers. [Claim 57] 43. The end effector of claim 42, wherein the plurality of contact surfaces are configured to provide only six points of contact with the plurality of kinematic couplers. [Claim 58] a sterility barrier assembly releasably attachable to a first mounting portion of a first surgical component and a second mounting portion of a second surgical component having a tensioner; an interface configured to receive a drape; a coupling portion operably attached to the interface and configured to releasably secure to the first mounting portion and to releasably receive the second mounting portion when the tensioner of the second mounting portion is in a first position; a plurality of kinematic couplers supported by the interface and configured to engage the mounting portions and arranged to provide a kinematic coupling between the mounting portions to constrain six degrees of freedom of motion between the surgical components when the tensioner of the second mounting portion is in a second position; 1. A sterile barrier assembly comprising: [Claim 59] The coupling portion is one of a first ball subassembly and a first ball detent for releasably attaching to the first mounting portion; one of a second ball subassembly and a second ball detent for releasably attaching to the second mounting portion; 59. The sterility barrier assembly of claim 58, comprising: [Claim 60] 60. The sterility barrier assembly of claim 59, wherein the coupling portion includes the first ball detent and the second ball detent. [Claim 61] 61. The sterility barrier assembly of claim 60, including a release collar disposed about the joint. [Claim 62] 62. The sterility barrier assembly of claim 61 including a collar biasing element for biasing the release collars axially away from one another. [Claim 63] 59. The sterility barrier assembly of claim 58, including indexing fingers extending from the interface for mating with indexing recesses in the mounting portion. [Claim 64] 59. The sterility barrier assembly of claim 58, wherein the plurality of kinematic couplers is further defined as a plurality of balls. [Claim 65] 65. The sterility barrier assembly of claim 64, wherein the plurality of balls is further defined as three balls configured to constrain six degrees of freedom of movement between the surgical components. [Claim 66] 1. A surgical robot that releasably receives a second mounting portion of an end effector through a sterile barrier assembly having a coupling and a plurality of kinematic couplers, the second mounting portion having a tensioner movable from a first position to a second position; The surgical robot comprises: a robotic arm having a first mounting portion configured to releasably receive the second mounting portion of the end effector through the sterile barrier assembly; the first mounting portion includes a plurality of contact surfaces for engaging the plurality of kinematic couplers of the sterile barrier assembly; the first mounting portion further comprising a loading mechanism configured to apply a preload force to the second mounting portion through the sterile barrier assembly upon movement of the tensioner from the first position to the second position. [Claim 67] 67. The surgical robot of claim 66, wherein the loading mechanism is configured to bias the second mounting portion relative to the first mounting portion in response to movement of the tensioner toward the second position. [Claim 68] 67. The surgical robot of claim 66, wherein the first mounting portion further includes a first mounting plate and a first ball subassembly configured to releasably secure to the coupling portion of the sterile barrier assembly. [Claim 69] 69. The surgical robot of claim 68, wherein the loading mechanism is configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position. [Claim 70] the loading mechanism includes a driver operably attached to the first ball subassembly; 70. The surgical robot of claim 69, wherein the drive portion is configured to be positioned in rotational engagement with the coupling portion of the sterile barrier assembly when the sterile barrier assembly is coupled to the first mounting portion. [Claim 71] 71. The surgical robot of claim 70, wherein the drive portion is positioned such that, in response to movement of the tensioner to the second position, rotation of the drive portion axially moves the first ball subassembly to impart the preload force between the first mounting portion and the second mounting portion. [Claim 72] 70. The surgical robot of claim 69, wherein the loading mechanism includes a loading actuator configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position. [Claim 73] The load actuator a first hub operably attached to the first ball subassembly; a second hub operably attached to the first mounting plate; a plurality of ball bearings disposed between the hubs; and a ramp defined in one or more of the hubs along which the ball bearing rolls in response to movement of the tensioner toward the second position. [Claim 74] 74. The surgical robot of claim 73, wherein the loading mechanism includes a biasing element positioned to act between the second hub and the first mounting plate. [Claim 75] 75. The surgical robot of claim 74, wherein the biasing element comprises a conical spring washer. [Claim 76] 76. The surgical robot of claim 75, wherein the conical spring washer is positioned and shaped to have a force versus compression relationship such that the change in force is no more than 10% for a compression of 2 millimeters or less. [Claim 77] 74. The surgical robot of claim 73, including a sensor for detecting rotation of the first hub relative to the second hub. [Claim 78] 67. The surgical robot of claim 66, wherein the first mounting portion includes a first plurality of receivers having the plurality of contact surfaces for engaging the plurality of kinematic couplers. [Claim 79] a second mounting portion connected to the surgical component; a sterile barrier assembly; a surgical robot including a robotic arm having a first mounting portion configured to releasably receive the sterile barrier assembly and a first mounting portion through the sterile barrier assembly; a lighting device coupled to the robotic arm; one or more controllers coupled to one or more sensors; and the controller comprises: using measurements from the one or more sensors to detect conditions associated with installation of one or more of the sterility barrier assembly and the second mounting portion on the first mounting portion; Controlling the lighting device to indicate the status to a user It is configured as follows: Surgical systems. [Claim 80] The surgical component is further defined as an end effector; The end effector a housing for supporting the energy applicator; the second mounting portion attached to the housing; 80. The surgical system of claim 79, comprising: [Claim 81] the second mounting portion includes a tensioner movable from a first position to a second position, and urges the second mounting portion against the first mounting portion in response to movement of the tensioner toward the second position; the one or more controllers detect the condition related to installation of the second mounting portion on the first mounting portion using measurements from the one or more sensors; and Detecting a first condition in which the tensioner is in the first position; controlling the lighting device in a first manner to indicate the first state to the user; Detecting a second condition in which the tensioner is in the second position; controlling the lighting device in a second manner to indicate the second state to the user; 80. The surgical system of claim 79, configured to: [Claim 82] the sterile barrier assembly further comprising a coupling and a plurality of kinematic couplers; The first mounting portion is a plurality of contact surfaces for engaging the plurality of kinematic couplers of the sterile barrier assembly; a loading mechanism configured to apply a preload force to the second mounting portion through the sterile barrier assembly upon movement of the tensioner from the first position to the second position; a first mounting plate and a first ball subassembly configured to releasably secure to the coupling portion of the sterility barrier assembly; the loading mechanism includes a loading actuator configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position; The load actuator a first hub operably attached to the first ball subassembly; a second hub operably attached to the first mounting plate; a plurality of ball bearings disposed between the hubs; a ramp defined on one or more of the hubs along which the ball bearing rolls in response to movement of the tensioner toward the second position; The one or more controllers: detecting the first condition that the tensioner is in the first position by further detecting a first position or amount of rotation of the first hub relative to the second hub using measurements from the one or more sensors; and detecting the second condition that the tensioner is in the second position by further detecting a second position or amount of rotation of the first hub relative to the second hub using measurements from the one or more sensors. 82. The surgical system of claim 81, configured to: [Claim 83] The one or more controllers: detecting the first state of the tensioner being in the first position by further detecting a first position or movement of the tensioner using measurements from the one or more sensors; and detecting the second state of the tensioner being in the second position by further detecting a second position or movement of the tensioner using measurements from the one or more sensors. 82. The surgical system of claim 81, configured to: [Claim 84] the lighting device emits a first color in the first aspect; 82. The surgical system of claim 81, wherein the lighting device emits a second color different from the first color in the second aspect. [Claim 85] the lighting device is controlled to be inactive in the first aspect; 82. The surgical system of claim 81, wherein the illumination device is controlled to operate in the second mode to emit light. [Claim 86] 80. The surgical system of claim 79, wherein the illumination device is disposed on the robotic arm adjacent to the first mounting portion. [Claim 87] 80. The surgical system of claim 79, wherein the illumination device has an annular configuration that surrounds an outer surface of the robotic arm. [Claim 88] the sterility barrier assembly having a coupling portion configured to releasably secure to the first mounting portion; the one or more controllers use measurements from the one or more sensors to detect the condition associated with placement of the sterility barrier assembly on the first mounting portion; and detecting a first condition in which the coupling portion of the sterility barrier assembly is secured to the first mounting portion; controlling the lighting device in a first manner to indicate the first state to the user; detecting a second condition in which the coupling portion of the sterility barrier assembly is not secured to the first mounting portion; controlling the lighting device in a second manner to display the second condition to the user; 80. The surgical system of claim 79, configured to: [Claim 89] a second mounting portion associated with the surgical component; and a sterile barrier assembly; a surgical robot including a robotic arm having a first mounting portion configured to releasably receive the sterile barrier assembly and a first mounting portion through the sterile barrier assembly; a lighting device coupled to the robotic arm; one or more controllers coupled to one or more sensors; 1. A method of operating a surgical system comprising: The method includes the one or more controllers: using measurements from the one or more sensors to detect conditions associated with installation of one or more of the sterility barrier assembly and the second mounting portion on the first mounting portion; and controlling the lighting device to indicate the status to a user. [Claim 90] the second mounting portion includes a tensioner movable from a first position to a second position, and urges the second mounting portion against the first mounting portion in response to movement of the tensioner toward the second position; The method includes the one or more controllers, further comprising: using measurements from the one or more sensors to detect the condition associated with installation of the second mounting portion on the first mounting portion, which includes: Detecting a first condition in which the tensioner is in the first position; controlling the lighting device in a first manner to indicate the first state to the user; detecting a second condition in which the tensioner is in the second position; controlling the lighting device in a second manner to indicate the second state to the user; 90. The method of claim 89, comprising: [Claim 91] the sterile barrier assembly further comprising a coupling and a plurality of kinematic couplers; The first implementation part is a plurality of contact surfaces for engaging the plurality of kinematic couplers of the sterile barrier assembly; a loading mechanism configured to apply a preload force to the second mounting portion through the sterile barrier assembly upon movement of the tensioner from the first position to the second position; a first mounting plate and a first ball subassembly configured to releasably secure to the coupling portion of the sterility barrier assembly; the loading mechanism includes a loading actuator configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position; The load actuator a first hub operably attached to the first ball subassembly; a second hub operably attached to the first mounting plate; a plurality of ball bearings disposed between the hubs; a ramp defined on one or more of the hubs along which the ball bearing rolls in response to movement of the tensioner toward the second position; The method includes the one or more controllers, further comprising: detecting the first condition that the tensioner is in the first position by further detecting a first position or amount of rotation of the first hub relative to the second hub using measurements from the one or more sensors; detecting the second condition that the tensioner is in the second position by further detecting a second position or amount of rotation of the first hub relative to the second hub using measurements from the one or more sensors; and 91. The method of claim 90, comprising: [Claim 92] the one or more controllers, and detecting the first state of the tensioner being in the first position by further detecting a first position or movement of the tensioner using measurements from the one or more sensors; detecting the second state of the tensioner being in the second position by further detecting a second position or movement of the tensioner using measurements from the one or more sensors; and 91. The method of claim 90, comprising: [Claim 93] the one or more controllers, and controlling the lighting device in the first manner to emit a first color; controlling the lighting device in the second manner to emit a second color different from the first color; 91. The method of claim 90, comprising: [Claim 94] the one or more controllers, and controlling the lighting device to be inactive in the first aspect; controlling the lighting device to operate in the second manner to emit light; 91. The method of claim 90, comprising: [Claim 95] the sterility barrier assembly having a coupling portion configured to releasably secure to the first mounting portion; The method includes the one or more controllers, further comprising: using measurements from the one or more sensors to detect the condition associated with placement of the sterility barrier assembly on the first mounting portion, which includes: Detecting a first condition in which the coupling portion of the sterility barrier assembly is secured to the first mounting portion; controlling the lighting device in a first manner to indicate the first condition to the user; detecting a second condition in which the coupling portion of the sterility barrier assembly is not secured to the first mounting portion; controlling the lighting device in a second manner to indicate the second condition to the user; 90. The method of claim 89, comprising:

Claims

1. 1. A mounting system for coupling first and second surgical components, comprising: a first mounting portion connected to the first surgical component; a second mounting portion connected to the second surgical component and including a tensioner movable between a first position and a second position; 1. A sterility barrier assembly comprising: A joint; a plurality of kinematic couplers configured to engage the first and second mounting portions and positioned to provide a kinematic coupling between the first and second mounting portions through the sterile barrier assembly to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in the second position; a sterile barrier assembly including: a first locking assembly including a first ball subassembly operably attached to one of the first mounting portion and the coupling portion to releasably secure the coupling portion to the first mounting portion, and a first ball detent defined in the other of the first mounting portion and the coupling portion; a second locking assembly including a second ball subassembly operably attached to one of the second mounting portion and the coupling portion to releasably secure the second mounting portion to the coupling portion when the tensioner is in the first position, and a second ball detent defined in the other of the second mounting portion and the coupling portion; Including, the first mounting portion further comprising a loading mechanism configured to bias at least one of the second mounting portion and the sterile barrier assembly against the first surgical component in response to movement of the tensioner from the first position toward the second position when the sterile barrier assembly is secured to the first mounting portion and the second mounting portion is secured to the sterile barrier assembly.

2. 2. The mounting system of claim 1, wherein the loading mechanism of the first mounting portion biases the second mounting portion against the plurality of kinematic couplers of the sterile barrier assembly in response to movement of the tensioner toward the second position.

3. The mounting system of claim 1 , wherein the coupling of the sterile barrier assembly is force-transferably interposed between the tensioner and the loading mechanism.

4. The first mounting portion is a first mounting plate adapted to attach to the first surgical component; The mounting system of claim 1 , wherein the first ball subassembly is operably coupled to the first mounting portion, and the first ball detent is defined in the coupling portion.

5. The mounting system of claim 4 , wherein the loading mechanism is configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position.

6. the loading mechanism includes a driver operably attached to the first ball subassembly; The mounting system of claim 4 , wherein the drive portion is configured to be disposed in rotational engagement with the coupling portion of the sterile barrier assembly.

7. the driver is positioned such that, in response to movement of the tensioner toward the second position, rotation of the driver axially moves the first ball subassembly to apply a preload force between the first mounting portion and the second mounting portion; the loading mechanism includes a loading actuator configured to axially move the first ball subassembly in response to movement of the tensioner toward the second position; The load actuator a first hub operably attached to the first ball subassembly; a second hub operably attached to the first mounting plate; a plurality of ball bearings disposed between the hubs; and a ramp defined on one or more of the hubs along which the ball bearing rolls in response to movement of the tensioner toward the second position.

8. a sensor for detecting rotation of the first hub relative to the second hub; the loading mechanism includes a conical spring washer positioned and shaped to act between the second hub and the first mounting plate; each of the second hub and the first mounting plate includes a conical surface; The mounting system of claim 7 , wherein the conical spring washer has inner and outer sides that abut the conical surface.

9. the second ball subassembly is operably coupled to the second mounting portion, the second ball detent being defined in the coupling portion; 8. The mounting system of claim 7, wherein the tensioner includes an activator positioned for rotational engagement with the coupling portion of the sterile barrier assembly when the coupling portion is releasably secured to the second mounting portion.

10. the second mounting portion includes a second mounting plate; the activator is movable between a locked position in which rotation of the activator is restricted relative to the second mounting plate and an unlocked position in which rotation of the activator is permitted relative to the second mounting plate; a biasing element that biases the activator toward the locked position; 10. The mounting system of claim 9, wherein the activator is positioned to engage the coupling when securing the second mounting portion to the sterile barrier assembly such that the coupling biases the activator to the unlocked position.

11. the activator is configured to rotate in response to movement of the tensioner toward the second position such that the activator, the coupling portion, and the driver simultaneously rotate relative to the first mounting plate to apply the preload force; the tensioner further includes a lever and an activator link interposed between the lever and the activator in a force-transducing manner, and when the second mounting portion is releasably secured to the coupling portion, movement of the tensioner to the second position rotates the activator to simultaneously rotate the coupling portion and the drive portion to apply the preload force; the second mounting portion includes a second mounting plate; the lever extends outward from the second mounting plate in the first position and engages with the second mounting plate in the second position; The mounting system of claim 9 including a lever lock operably coupled to the lever for locking the lever when the tensioner is in the second position.

12. 2. The mounting system of claim 1, wherein the coupling portion is configured to be disposed in communication with each of the first and second ball subassemblies when the sterile barrier assembly is secured to the first mounting portion and the second mounting portion is secured to the sterile barrier assembly.

13. 10. The mounting system of claim 1, wherein each of the first and second ball detents of the first and second locking assemblies is defined in the coupling portion of the sterile barrier assembly.

14. A mounting system for coupling first and second surgical components, comprising: a first mounting portion connected to the first surgical component; a second mounting portion connected to the second surgical component and including a tensioner movable between a first position and a second position; 1. A sterility barrier assembly comprising: A joint; a plurality of kinematic couplers configured to engage the first and second mounting portions and positioned to provide a kinematic coupling between the first and second mounting portions through the sterile barrier assembly to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in the second position; a sterile barrier assembly including: a first locking assembly including a first ball subassembly operably attached to one of the first mounting portion and the coupling portion to releasably secure the coupling portion to the first mounting portion, and a first ball detent defined in the other of the first mounting portion and the coupling portion; a second locking assembly including a second ball subassembly operably attached to one of the second mounting portion and the coupling portion to releasably secure the second mounting portion to the coupling portion when the tensioner is in the first position, and a second ball detent defined in the other of the second mounting portion and the coupling portion; Including, the first locking assembly includes a first release collar positioned to secure the first ball subassembly received in the first ball detent; the second locking assembly includes a second release collar positioned to secure the second ball subassembly received in the second ball detent; each of the first and second release collars of the locking assembly is operably attached to the sterile barrier assembly; the first and second release collars of the locking assembly are axially biased away from each other; the sterility barrier assembly further includes a collar biasing element force-transferably interposed between the coupling portion and the first and second release collars to axially bias the first and second release collars away from one another; The second mounting portion includes a release mechanism operable to move one of the first and second release collars to release the second mounting portion from the coupling.

15. the release mechanism includes a release actuator and one or more release elements configured to be disposed between the release actuator and one of the first and second release collars when the second mounting portion is releasably attached to the sterile barrier assembly, wherein actuation of the release actuator moves the one or more release elements to displace the one of the first and second release collars and allow one of the first and second ball subassemblies to be disengaged from one of the first and second ball detents; the tensioner includes a lever movable between the first and second positions; the release actuator is positioned such that movement of the lever to the second position at least partially covers the release actuator; the second mounting portion includes a second mounting plate; the release mechanism includes a release link interposed between the release actuator and the one or more release elements in a force-transducing manner, and moves the one or more release elements from a rest position to a release position relative to the second mounting plate; The mounting system of claim 14 , wherein the release link is configured to engage the one or more release elements to move the one or more release elements to the release position in response to actuation of the release actuator.

16. A mounting system for coupling first and second surgical components, comprising: a first mounting portion connected to the first surgical component; a second mounting portion connected to the second surgical component and including a tensioner movable between a first position and a second position; 1. A sterility barrier assembly comprising: A joint; a plurality of kinematic couplers configured to engage the first and second mounting portions and positioned to provide a kinematic coupling between the first and second mounting portions through the sterile barrier assembly to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in the second position; a sterile barrier assembly including: a first locking assembly including a first ball subassembly operably attached to one of the first mounting portion and the coupling portion to releasably secure the coupling portion to the first mounting portion, and a first ball detent defined in the other of the first mounting portion and the coupling portion; a second locking assembly including a second ball subassembly operably attached to one of the second mounting portion and the coupling portion to releasably secure the second mounting portion to the coupling portion when the tensioner is in the first position, and a second ball detent defined in the other of the second mounting portion and the coupling portion; Including, the sterile barrier assembly further includes an interface and a drape operably attached to the interface; A mounting system, wherein the coupling and the kinematic coupler are operably attached to the interface.

17. the sterility barrier assembly further includes an indexing finger; 2. The mounting system of claim 1, wherein at least one of the mounting portions defines an indexing recess shaped to receive the indexing finger to align the kinematic coupler with the at least one of the mounting portions.

18. A mounting system for coupling first and second surgical components, comprising: a first mounting portion connected to the first surgical component; a second mounting portion connected to the second surgical component and including a tensioner movable between a first position and a second position; 1. A sterility barrier assembly comprising: A joint; a plurality of kinematic couplers configured to engage the first and second mounting portions and positioned to provide a kinematic coupling between the first and second mounting portions through the sterile barrier assembly to constrain six degrees of freedom of movement between the surgical components when the tensioner of the second mounting portion is in the second position; a sterile barrier assembly including: a first locking assembly including a first ball subassembly operably attached to one of the first mounting portion and the coupling portion to releasably secure the coupling portion to the first mounting portion, and a first ball detent defined in the other of the first mounting portion and the coupling portion; a second locking assembly including a second ball subassembly operably attached to one of the second mounting portion and the coupling portion to releasably secure the second mounting portion to the coupling portion when the tensioner is in the first position, and a second ball detent defined in the other of the second mounting portion and the coupling portion; Including, the plurality of kinematic couplers are further defined as a plurality of balls; the plurality of balls is further defined as three balls configured to constrain the six degrees of freedom of movement between the surgical components; the first mounting portion includes a first plurality of contact surfaces for engaging the plurality of kinematic couplers; the second mounting portion includes a second plurality of contact surfaces for engaging the plurality of kinematic couplers; the contact surfaces are shaped to cooperate with the plurality of kinematic couplers to constrain the six degrees of freedom of motion between the surgical components; the first mounting portion includes a first plurality of receptacles having the first plurality of contact surfaces; the second mounting portion includes a second plurality of receptacles having the second plurality of contact surfaces; the second plurality of contact surfaces are configured to provide only six points of contact with the plurality of kinematic couplers.

19. a surgical robot including a robotic arm having a first mounting portion configured to releasably receive the sterile barrier assembly and the first mounting portion through the sterile barrier assembly; a lighting device coupled to the robotic arm; one or more controllers coupled to one or more sensors and configured to use measurements from the one or more sensors to detect conditions associated with installation of one or more of the sterility barrier assembly and the second mounting portion on the first mounting portion and to control the lighting device to indicate the conditions to a user; The mounting system of claim 1 .

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