Robotic Surgical Systems, Methods, and Apparatus

Abstract

To provide a robotic surgery system, a method and an apparatus.SOLUTION: The present teachings relate to surgery. More specifically, the present teachings relate to an apparatus and a method for providing minimally invasive surgery and robotic surgery. A surgical system may be configured to be a minimally invasive and / or computer assisted surgical system. Operation of the system may be controlled by transmission of a force from a first section to a second section of the system. The first section and the second section may be separated by a partition or a barrier. The first section may be a non-sterile section, and the second section may be a sterile section of the surgical system.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Patent Application No. 62 / 193,959, filed July 17, 2015, entitled Robotic Surgery System, Method, and Apparatus (Attorney Docket No. P64), which is incorporated herein by reference in its entirety.

[0002] The present teachings relate to surgery, and more particularly to devices and methods for providing minimally invasive and robotic surgery. [Background technology]

[0003] The present teachings relate to performing surgical procedures. More specifically, the present teachings relate to devices and methods for performing minimally invasive surgical procedures. In recent years, minimally invasive surgical procedures have gained popularity and are being widely selected over traditional surgical methods. Highly valued benefits include a pronounced reduction in post-operative recovery time and significantly less scarring.

[0004] Typically, minimally invasive surgical procedures are computer-assisted procedures that involve one or more tiny incisions at the surgical site, followed by the insertion of flexible housing tubes that hold the instruments used to perform the surgical procedure. The surgical instruments are controlled remotely by a medical professional or surgeon via a user interface portal. As a result, there is no need for physical contact between the surgical instruments and the supervising surgeon or medical professional during the procedure. The goal of automated surgical procedures is to maintain the versatility and freedom associated with manual surgical procedures and further refine such procedures beyond what would be feasible for a human surgeon.

[0005] Contamination of the surgical site or the surgical instruments used can have serious consequences for the desired progress of the surgical procedure and / or the patient's health. Hygiene can be maintained by medical personnel during manual surgical procedures through the use of surgical gloves, masks, and regular sterilization of surgical instruments during surgery. However, this can pose challenges in minimally invasive surgical procedures. To perform computerized surgical procedures, the instrument drive force is passed from the non-sterile side to the sterile side while keeping the two sides isolated. Summary of the Invention [Means for solving the problem]

[0006] In accordance with the present teachings, aspects of the present disclosure relate to a surgical system that may be configured to be a minimally invasive and / or computer-assisted surgical system. The surgical system may require occasional or continuous intervention from a medical professional. The requirement and extent of such intervention may vary depending on various factors, such as, but not limited to, the nature of the surgical procedure, the anatomical site for performing such a procedure, the duration of the procedure, and the degree to which surgical instruments are automated. In some configurations, the system may be divided into two sections. Operation of the system may be controlled by the transmission of forces from a first section to a second section of the system. The first and second sections may be separated by a partition or barrier. The first section may be a non-sterile section, and the second section may be a sterile section of the surgical system.

[0007] Some configurations of the present teachings of a robotic surgical device may include, but are not limited to, a drive component, including at least one motor and an associated drive element for each of the at least one motor. The associated drive element may have a drive screw, a nut capable of translationally displacing about the longitudinal axis of the drive screw in response to rotation of the drive screw about the longitudinal axis, and a protrusion oriented transverse to the longitudinal axis. The robotic surgical device may also include a manipulator including at least one driven element having a receiving feature capable of engaging the protrusion. The driven element may translate and displace with the protrusion when the protrusion is engaged in the receiving feature. The robotic surgical device may still further include a continuous barrier separating the manipulator and the drive component. At least a portion of the continuous barrier may cover the protrusion so that the protrusion engages the receiving feature through the barrier. The robotic surgical device may also include at least one actuator having a first end coupled to the driven element and a second end coupled to the articulating shaft.

[0008] Optionally, the protrusion can be an integrally formed part of the nut, and the nut can include a receiving structure to which the protrusion can be coupled, possibly removably coupled, and the driven element can be displaced in translation along an axis parallel to the longitudinal axis. The robotic surgical device can optionally include one or more linear bearings along which the nut displaces. Also, optionally, at least a portion of the barrier can move with the protrusion and the driven element, and the barrier can include a pocket-like region including at least one pocket, and the at least one pocket can be surrounded by a variable region including at least one pleat. The manipulator can optionally include only mechanical components. Optionally, the motor can be configured to displace a piston in a master hydraulic cylinder, and an associated drive element can be coupled to a slave piston in a slave hydraulic cylinder for the master hydraulic cylinder.

[0009] A load sensor for measuring a load of the present teachings can include, but is not limited to, a mechanical component having a flexible body that can deform in proportion to the magnitude of the load. The flexible body can include at least one stop protrusion that can extend from a first portion of the flexible body toward a second portion of the flexible body, leaving a gap between the first and second portions, when the magnitude of the load is within a first range. The at least one stop protrusion can contact the second portion when the magnitude of the load is within a second range. The load sensor can further include a protrusion attached to the flexible body. The protrusion can be displaced in response to deformation of the flexible body. The load sensor can also include an electrical component that can be physically separate from the mechanical component. The electrical component can include at least one sensor that can monitor the displacement of the protrusion.

[0010] The protrusion may optionally include a magnet. The electrical component may optionally include at least one Hall Effect sensor capable of generating a Hall voltage based on the position of the magnet. The protrusion may optionally include a fiducial reference marking, and the electrical component may optionally include an optical sensor capable of monitoring the location of the fiducial reference marking. The electrical component may optionally include a potentiometer, the wiper of which may be displaced in response to displacement of the protrusion. The protrusion may optionally include a first end attached to the flexible body and a second end distal to the flexible body. The displacement of a point on the second end may be equal to the length of the projection of the protrusion relative to the unloaded position of the protrusion multiplied by the angle in radians. The load sensor may optionally be constructed of aluminum. The first range may optionally be 0 to 50 pounds. The flexible body may optionally be an S-beam and may include several cutouts and channels. The cutouts and channels may optionally create a parallelogram frame in the flexible body. The flexible body can optionally include a void extending through the flexible body from a first side of the flexible body to a second side of the flexible body.

[0011] In another configuration of the present teachings, a load sensor for measuring a load can include, but is not limited to, a mechanical component, including a flexible body that can deform in proportion to the magnitude of the load. The load sensor can also include an insert extending through the flexible body. The insert can have a first surface of the insert spaced from a first surface of the flexible body by a first gap. The first surface can be a portion of the first end of the flexible body. The load sensor can still further include an adjustable spacer on the insert. The adjustable spacer can have an adjustable insert surface spaced from a second surface of the flexible body by a second gap. The second surface of the flexible body can be positioned opposite the first surface of the flexible body. The load sensor can also include a protrusion attached to the flexible body. The protrusion can be displaced in response to deformation of the flexible body. The load sensor can also include an electrical component physically separate from the mechanical component. The electrical component can include at least one sensor that can monitor the displacement of the protrusion.

[0012] The insert can optionally be a threaded insert. The adjustable spacer can optionally be a nut. The protrusion can optionally include a bend that can divide the protrusion into a pre-bend portion and a post-bend portion. The pre-bend portion can optionally be attached to the flexible body, and the post-bend portion can optionally have a surface that is substantially perpendicular to the first surface of the flexible body.

[0013] Sterile components for robotic surgical systems of the present teachings can include, but are not limited to, a manipulated component having a first proximal portion with a proximal end and an articulating distal portion with a distal end. The articulating distal portion can include at least one articulating section about which the articulating distal portion can be bent. The sterile component can also include at least one displaceable actuator having a first actuator end and a second actuator end. The first actuator end can be anchored to the articulating distal portion. Each displaceable actuator can have a constraining portion including the first actuator end that can be positioned within a guide of the manipulated component, and a second portion including the second actuator end that can be positioned outside the guide. The sterile component can also include a surgical tool and a manipulator that can include at least one driven element that are disposed at the distal end of the manipulated component. The driven element can include an anchoring point to which the second actuator end can be anchored. The driven element can be translationally displaceable along at least one bearing surface within the manipulator. The driven element can have a receiving feature that can be sized to engage at least a portion of the driving element through the barrier.

[0014] At least one articulating section may optionally include a living hinge. At least one articulating section may optionally include a kinematic pair of bodies. The kinematic pair of bodies may optionally include a ball-and-socket joint. At least a portion of a proximal portion of the manipulated component may optionally be housed within the manipulator. At least one displaceable actuator may optionally be a pull wire. Each displaceable actuator may optionally exit a guide in a cutout in the manipulated component. The driven element may optionally include a rail protrusion that may extend into the cutout and ride along the cutout as the driven element is displaced. The driven element may optionally include a channel in which a majority of the second actuator portion is located. The driven element may optionally be a block-like structure. The manipulator may optionally include a housing having at least one slot. Each slot may optionally be aligned with one receiving feature of the at least one driven element. The sterile component can optionally include only mechanical components. The manipulator can optionally include at least one rotationally driven element configured to interact with the rotational drive element through the barrier. The manipulator can optionally include a rotationally driven element including a magnet. The manipulator can optionally include a rotationally driven element having a multi-pocket structure. The manipulator can optionally include a rotational drive element having a shaft that rotates about a first axis. The shaft attached to the barrier interface connection element can optionally have a face with an irregular surface oriented at an acute angle relative to the first axis.

[0015] An apparatus for transmitting forces in a surgical system of the present teachings can include, but is not limited to, a barrier positioned between a non-sterile section and a sterile section of the surgical system. The barrier can include a first surface facing the non-sterile section and an opposing second surface facing the sterile section. The apparatus can also include at least one drive element located in the non-sterile section of the surgical system. The drive element can generate and transmit a predetermined force and can include one or more barrier interface connection members communicating with a first surface of the barrier in the non-sterile section. The apparatus can further include at least one driven element located in the sterile section of the surgical system. The driven element can include one or more cooperating barrier interface connection members communicating with an opposing second surface of the barrier in the sterile section. The driven element can receive a predetermined force from a drive element in the non-sterile section across the barrier. The barrier can maintain its integrity during transmission of the predetermined force. The predetermined force can optionally be linear or rotational. The at least one drive element and one or more first barrier interface connection members can optionally be disposed in a first housing in the non-sterile compartment, and the at least one driven element and one or more cooperating barrier interface connection members can optionally be disposed in a second housing in the sterile compartment. The barrier can optionally be continuous and / or comprise one or more layers and can optionally be in contactless communication with one or more barrier interface connection members in the non-sterile compartment. The one or more barrier interface connection members and the cooperating one or more barrier interface connection members can optionally form a magnetic coupling that can achieve contactless communication across the barrier for the transmission of a predetermined force.

[0016] An apparatus for transmitting torque in a surgical system of the present teachings can include, but is not limited to, a barrier positioned between a non-sterile section and a sterile section of the surgical system. The barrier can include a first surface and an opposing second surface. The apparatus can also include at least one drive element disposed in the non-sterile section of the surgical system. The drive element can generate and transmit torque along a reference axis transverse to an axis parallel to the first surface and the opposing second surface. The reference axis can originate in the non-sterile section and terminate in the sterile section. The drive element can include one or more barrier interface connection members communicating with the first surface of the barrier. The apparatus can also include at least one driven element disposed in the sterile section. The driven element can include one or more cooperating barrier interface connection members communicating with a barrier on an opposing second surface of the barrier. The driven element can receive a predetermined torque from the drive element along the reference axis. The apparatus can also include at least one bridging element aligned within the barrier. The bridging element can connect the driver element and the driven element and can include a first set of accessible parts on the non-sterile section and a second set of accessible parts on the sterile section, where the first set of accessible parts and the second set of accessible parts can mate with one or more barrier interface connection members in the non-sterile section and one or more cooperating barrier interface connection members in the sterile section, respectively. The present specification also provides, for example, the following items: (Item 1) 1. An apparatus for enabling robotic surgery, comprising: a drive component having at least one motor and an associated drive element for each of the at least one motor, the associated drive element having a drive screw, a nut that translates and displaces about a longitudinal axis of the drive screw in response to rotation of the drive screw about the longitudinal axis, and a protrusion oriented transverse to the longitudinal axis; a manipulator including at least one driven element, the driven element having a receiving feature that engages the protrusion, the driven element displacing in translation with the protrusion when the protrusion is engaged in the receiving feature; a continuous barrier separating the manipulator and the drive component, at least a portion of the continuous barrier covering the protrusion, the protrusion engaging the receiving feature through the continuous barrier; at least one actuator having a first end coupled to the driven element and a second end coupled to an articulating shaft; wherein the at least one actuator driven by the drive component enables the robotic surgery. Device. (Item 2) Item 2. The device of item 1, wherein the nut includes the protrusion. (Item 3) Item 1. The device of item 1, wherein the nut includes a receiving structure, and the protrusion is coupled with the receiving structure. (Item 4) Item 10. The apparatus of item 1, further comprising at least one linear bearing, the nut riding on the at least one linear bearing. (Item 5) Item 10. The device of item 1, wherein at least a portion of the barrier moves with the protrusion and driven element. (Item 6) Item 10. The device of item 1, wherein the barrier comprises a pocket-like region, the pocket-like region including at least one pocket, and the at least one pocket including at least one pleat. (Item 7) a load sensor for measuring a load experienced by the at least one actuator, a flexible body, the flexible body deforming in proportion to the magnitude of the load; at least one stop protrusion extending from a first portion of the flexible body toward a second portion of the flexible body, the at least one stop protrusion leaving a gap between the first portion and the second portion when the magnitude of the load is substantially within a first range, and the at least one stop protrusion contacting the second portion when the magnitude of the load is substantially within a second range; a protrusion attached to the flexible body, the protrusion displacing in response to the deformation of the flexible body; an electrical component having at least one sensor that monitors a displacement of the protrusion, the displacement being correlated with the measurement of the load; Load sensors, including Item 1, further comprising: (Item 8) 8. The device of claim 7, wherein the at least one stop protrusion comprises a magnet. (Item 9) Item 8. The apparatus of item 7, wherein the electrical component comprises at least one Hall effect sensor, the Hall effect sensor producing a Hall voltage based on the position of the magnet. (Item 10) Item 8. The apparatus of item 7, wherein the protrusion comprises a fiducial reference marking, and the electrical component has an optical sensor, the optical sensor monitoring the fiducial reference marking. (Item 11) Item 8. The apparatus of item 7, wherein the electrical component comprises a potentiometer, the potentiometer having a wiper, the wiper displacing based on the displacement of the protrusion. (Item 12) 8. The device of claim 7, wherein the flexible body comprises aluminum. (Item 13) Item 8. The device of item 7, wherein the first range comprises a range of 0 to 50 pounds. (Item 14) Item 8. The apparatus of item 7, wherein the flexible body comprises an S-beam. (Item 15) further comprising a load sensor for measuring the load; The load sensor a flexible body that deforms in proportion to the magnitude of the load, the flexible body having a flexible body first side and a flexible body second side, the flexible body first side being disposed opposite the flexible body second side; an insert extending through the flexible body, the insert having an insert first surface spaced from a first surface of the flexible body by a first gap, the insert having an adjustable spacer having an adjustable insert surface spaced from a second surface of the flexible body by a second gap; a protrusion attached to the flexible body, the protrusion displaced based on the deformation of the flexible body, the flexible body, the insert, and the protrusion forming a mechanical component; an electrical component, the electrical component including at least one sensor that monitors a displacement of the protrusion, the displacement being related to the load; Item 1. The device according to item 1, comprising: (Item 16) Item 16. The apparatus of item 15, wherein the electrical components comprise components that are physically separate from the mechanical components. (Item 17) Item 16. The device of item 15, wherein the insert comprises a threaded insert. (Item 18) Item 16. The apparatus of item 15, wherein the adjustable spacer comprises a nut. (Item 19) Item 16. The device of item 15, wherein the protrusion comprises a bend dividing the protrusion into a pre-bend portion and a post-bend portion, the pre-bend portion being attached to the flexible body, and the post-bend portion having a surface, the surface being substantially perpendicular to a first surface of the flexible body. (Item 20) Further comprising a sterile component; The sterile component comprises: a manipulated component having a first proximal portion, the first proximal portion having a proximal end, the manipulated component having an articulating distal portion, the articulating distal portion having a distal end, the articulating distal portion having at least one articulating portion, the manipulated component having a guide; a surgical tool disposed at the distal end of the manipulated component; Including, the manipulator engages the surgical tool and the manipulated component to perform the robotic surgery; Item 1. The device according to item 1. (Item 21) 21. The apparatus of claim 20, wherein the at least one actuator comprises a constraining portion, the constraining portion including the first end, the first end located within the guide, and the constraining portion has a second portion, the second portion including the second end located outside the guide. (Item 22) 21. The apparatus of claim 20, wherein the at least one articulating member comprises a living hinge. (Item 23) 21. The apparatus of claim 20, wherein the at least one articulating member comprises a kinematic pair of bodies. (Item 24) 21. The apparatus of claim 20, wherein the manipulator comprises an enclosure, the enclosure housing at least a portion of the proximal portion of the manipulated component. (Item 25) 21. The device of claim 20, wherein the at least one actuator comprises a pull wire. (Item 26) 21. The apparatus of claim 20, wherein the driven element comprises a rail projection, the rail projection extending into a cutout, and the rail projection riding along the cutout based on displacement of the driven element. (Item 27) Item 22. The apparatus of item 21, wherein the driven element comprises a channel that accommodates at least a portion of the second actuator portion. (Item 28) 21. The apparatus of claim 20, wherein the manipulator comprises a housing, the housing having at least one slot, the at least one slot being aligned with a receiving feature of the at least one driven element. (Item 29) 21. The apparatus of claim 20, wherein the manipulator comprises at least one rotationally driven element that interacts with a rotational drive element through a barrier. (Item 30) 30. The apparatus of claim 29, wherein the at least one rotationally driven element comprises a magnet. (Item 31) 30. The apparatus of claim 29, wherein the manipulator comprises a rotary drive element having a shaft that rotates about a first axis, the shaft being attached to a barrier interface connection element associated with the barrier, the barrier interface connection element having a surface oriented at an acute angle to the first axis. (Item 32) a force transmission system including at least one barrier interface connection member in operable communication with a first surface of the barrier; the barrier is positioned between a non-sterile compartment and a sterile compartment of the surgical system, the first surface facing the non-sterile compartment and the opposing second surface facing the sterile compartment; the drive element located in the non-sterile section generates and transmits a predetermined force; the driven element located within the sterile compartment includes at least one cooperating barrier interface connection member in operative communication with the opposing second surface, the driven element receiving the predetermined force from the driving element across the barrier, and the barrier maintaining integrity during the transmission of the predetermined force; Item 1. The device according to item 1. (Item 33) Item 33. The apparatus of item 32, wherein the predetermined force is selected from the group consisting of a linear force and a rotational force. (Item 34) Item 33. The apparatus of item 32, wherein the non-sterile section comprises a first housing, the first housing containing the at least one drive element and the at least one first barrier interface connection member. (Item 35) Item 33. The apparatus of item 32, wherein the sterile section comprises a second housing, the second housing containing the at least one driven element and the at least one cooperating barrier interface connection member. (Item 36) Item 33. The apparatus of item 32, wherein the barrier comprises a continuous material. (Item 37) Item 33. The device of item 32, wherein the barrier comprises a layered material. (Item 38) Item 33. The device of item 32, wherein the barrier is in contactless communication with the at least one barrier interface connection member. (Item 39) Item 33. The apparatus of item 32, wherein the at least one barrier interface connection member and the at least one cooperating barrier interface connection member comprise a magnetic coupling. (Item 40) a torque transmission system including at least one bridging element on the barrier, the at least one bridging element connecting the driver element and the driven element, the at least one bridging element including a first set of parts on the non-sterile section and a second set of parts on the sterile section, the first set of parts and the second set of parts mating with the at least one barrier interface connection member in the non-sterile section and the at least one cooperating barrier interface connection member in the sterile section. Furthermore, the barrier is positioned between a non-sterile compartment and a sterile compartment of the surgical system, the barrier having a first surface and an opposing second surface; at least one drive element is disposed within the non-sterile section, the drive element generating and transmitting torque along a reference axis, the reference axis transverse to a parallel axis, the parallel axis being parallel to the first surface and the second opposing surface, the reference axis originating in the non-sterile section and terminating in the sterile section, the at least one drive element having at least one barrier interface connection member, the barrier interface connection member in operative communication with the first surface; at least one driven element is disposed within the sterile compartment, the driven element having at least one cooperating barrier interface connection member in operative communication with the barrier on the opposing second surface, the at least one driven element receiving the predetermined torque from the driving element along the reference axis; Item 1. The device according to item 1. (Item 41) 1. A method for controlling movement of an articulating compartment in a robotic surgical system, the articulating compartment including at least one actuator; receiving, by the robotic surgical system, at least one command signal, the at least one command signal being based on a user-directed movement command; determining a desired angle of rotation and a desired angle of flexion of the articulating compartment based at least in part on the command signal; determining a change in length value of the articulating segment based on the desired rotation angle and the desired flexion angle; calculating a desired length value for the at least one actuator based on the change in length value; calculating a length error value for the at least one actuator based on the desired length value; generating a displacement command for the articulating partition based on the length error value; A method comprising: (Item 42) Item 42. The method of item 41, further comprising the step of transmitting the displacement command to at least one motor assembly to control movement of at least one actuator. (Item 43) Item 43. The method of item 42, further comprising controlling the movement of the at least one actuator based on a mode of the robotic surgical system. (Item 44) a flexible body that deforms in proportion to the magnitude of the load, the flexible body having a flexible body first side and a flexible body second side, the flexible body first side being disposed opposite the flexible body second side; an insert extending through the flexible body, the insert having an insert first surface spaced from a first surface of the flexible body by a first gap, the insert having an adjustable spacer having an adjustable insert surface spaced from a second surface of the flexible body by a second gap; a protrusion attached to the flexible body, the protrusion displaced based on the deformation of the flexible body, the flexible body, the insert, and the protrusion forming a mechanical component; an electrical component, the electrical component including at least one sensor that monitors a displacement of the protrusion, the displacement being related to the load; A load sensor for measuring a load, comprising: (Item 45) Item 45. The load sensor of item 44, wherein the electrical component comprises a physically separate component from the mechanical component. (Item 46) Item 45. The load sensor of item 44, wherein the insert comprises a threaded insert. (Item 47) Item 45. The load sensor of item 44, wherein the protrusion comprises a bend dividing the protrusion into a pre-bend portion and a post-bend portion, the pre-bend portion being attached to the flexible body, and the post-bend portion having a surface, the surface being substantially perpendicular to a first surface of the flexible body. (Item 48) 1. A sterile component for a robotic surgical system, comprising: a manipulated component having a first proximal portion, the first proximal portion having a proximal end, the manipulated component having an articulating distal portion, the articulating distal portion having a distal end, the articulating distal portion having at least one articulating portion, the manipulated component having a guide; at least one displaceable actuator having a first actuator end and a second actuator end, the first actuator end being anchored to the articulating distal portion; a surgical tool disposed at the distal end of the manipulated component; a manipulator having at least one bearing surface, the manipulator having at least one driven element, the driven element having an anchoring point for anchoring the second actuator end, the driven element being translationally displaceable along the at least one bearing surface, the driven element having a receiving feature for engaging at least a portion of a drive element through a barrier; wherein the manipulator engages the surgical tool and the manipulated component to perform the robotic surgery. Sterile components. (Item 49) Item 49. The sterile component of item 48, wherein the at least one articulating member comprises a living hinge. (Item 50) Item 49. The sterile component of item 48, wherein the at least one articulating member comprises a kinematic pair of bodies. (Item 51) Item 49. The sterile component of item 48, wherein the at least one displaceable actuator comprises a pull wire. (Item 52) Item 49. The sterile component of item 48, wherein the manipulator comprises a housing, the housing having at least one slot, the at least one slot being aligned with a receiving feature of the at least one driven element. (Item 53) Item 49. The sterile component of item 48, wherein the manipulator comprises at least one rotationally driven element that interacts with a rotational drive element through a barrier. (Item 54) Item 49. The sterile component of item 48, wherein the at least one rotationally driven element comprises a magnet. (Item 55) 1. An apparatus for the transmission of forces in a surgical system, comprising: a barrier positioned between a non-sterile compartment and a sterile compartment of the surgical system, the barrier having a first surface facing the non-sterile compartment and an opposing second surface facing the sterile compartment; at least one drive element located in the non-sterile section, the at least one drive element generating and transmitting a predetermined force; one or more barrier interface connection members in operative communication with the first surface; at least one driven element located within the sterile compartment, the driven element comprising at least one cooperating barrier interface connection member in operative communication with the opposing second surface, the at least one driven element receiving the predetermined force from the driving element across the barrier, the barrier maintaining its integrity during the transmission of the predetermined force; An apparatus comprising: (Item 56) 1. An apparatus for transmitting torque in a surgical system, comprising: a barrier positioned between a non-sterile compartment and a sterile compartment of the surgical system, the barrier having a first surface and an opposing second surface; at least one drive element located in the non-sterile section, the drive element generating and transmitting torque along a reference axis transverse to a parallel axis, the parallel axis being parallel to the first surface and the second opposing surface, the reference axis originating in the non-sterile section and terminating in the sterile section, the at least one drive element having at least one barrier interface connection member, the barrier interface connection member in operative communication with the first surface; at least one driven element disposed within the sterile compartment, the driven element having at least one cooperating barrier interface connection member in operative communication with the barrier on the opposing second surface, the at least one driven element receiving the predetermined torque from the drive element along the reference axis; at least one bridging element in the barrier, said at least one bridging element connecting said driver element and said driven element, said at least one bridging element including a first set of parts on said non-sterile section and a second set of parts on said sterile section, said first set of parts and said second set of parts mating with said at least one barrier interface connection member in said non-sterile section and said at least one cooperating barrier interface connection member in said sterile section; An apparatus comprising: [Brief explanation of the drawings]

[0017] These and other aspects will become more apparent from the following detailed description of various configurations of the present disclosure, taken in conjunction with the drawings.

[0018] [Figure 1] FIG. 1 is a schematic block diagram of a system in accordance with the present teachings. [Figure 2] FIG. 2 is a schematic block diagram of another configuration of a system of the present teachings. [Figure 3] FIG. 3 is a schematic block diagram of the configuration of a robot of the present teachings. [Figure 4-1] 4A-4E are schematic block diagrams of the configuration of manipulated components of the present teachings. [Figure 4-2] 4A-4E are schematic block diagrams of the configuration of manipulated components of the present teachings. [Figure 5] 5-9 are schematic diagrams of living hinges of the present teachings. [Figure 6] 5-9 are schematic diagrams of living hinges of the present teachings. [Figure 7] 5-9 are schematic diagrams of living hinges of the present teachings. [Figure 8] 5-9 are schematic diagrams of living hinges of the present teachings. [Figure 9] 5-9 are schematic diagrams of living hinges of the present teachings. [Figure 9A] 9A and 9B are schematic illustrations of another configuration of the articulating section of the present teachings. [Figure 9B] 9A and 9B are schematic illustrations of another configuration of the articulating section of the present teachings. [Figure 10] FIG. 10 is a schematic illustration of an articulating compartment configuration, including an elongated structure and a lumen, of the present teachings. [Figure 11] FIG. 11 is a schematic illustration of another configuration of an articulating compartment including a lumen of the present teachings. [Figure 12] FIG. 12 is a schematic diagram of yet another configuration of an articulating compartment, including a lumen. [Figure 13] FIG. 13 is a schematic diagram of a cross section of the articulating compartment of FIG. [Figure 14] FIG. 14 is a schematic diagram of a detailed view of area O of FIG. [Figure 15] FIG. 15 is a schematic block diagram of the drive components and manipulator of the present teachings. [Figure 16] FIG. 16 is a schematic block diagram of several configurations of the system of the present teachings. [Figure 17A] FIG. 17A is a schematic block diagram of another configuration of the system of the present teachings. [Figure 17B]FIG. 17B is a schematic block diagram of yet another configuration of the system of the present teachings. [Figure 18] FIG. 18 is a schematic diagram of the drive components, including the motor or motor assembly. [Figure 19] FIG. 19 is a schematic diagram of a motor assembly and drive element of the present teachings. [Figure 20] FIG. 20 is a schematic diagram of the drive component with a portion of the drive component housing. [Figure 21] FIG. 21 is a schematic diagram of an alternative configuration of the motor assembly and drive element of the present teachings. [Figure 22] FIG. 22 is a schematic diagram of inner cross section II (FIG. 21) including a nut of the present teachings. [Figure 23] FIG. 23 is a schematic diagram of an exploded view of several linear needle bearing assemblies of the present teachings. [Figure 24] FIG. 24 is a schematic diagram of a drive element that can be electrohydraulic operated. [Figure 25] FIG. 25 is a schematic diagram of a cross-sectional view of a motor assembly and hydraulic master cylinder of the present teachings. [Figure 26] FIG. 26 is a schematic block diagram of a load sensor of the present teachings. [Figure 27] FIG. 27 is a schematic block diagram of a configuration in which a load is applied. [Figure 28A] FIG. 28A is a schematic block diagram of the mechanical components, including a deformable body and a stop protrusion. [Figure 28B] FIG. 28B is a schematic block diagram of a mechanical component that includes a threaded insert instead of a stop protrusion. [Figure 28C] FIG. 28C is a schematic block diagram of the machine components, including a threaded insert that provides a tension stop. [Figure 28D] FIG. 28D is a schematic block diagram of a configuration in which a force is applied to a deformable body. [Figure 28E] FIG. 28E is a schematic block diagram of a deformable body of the present teachings. [Figure 29]FIG. 29 is a schematic block diagram of a load sensor, including electrical components such as a potentiometer. [Figure 30A] FIG. 30A is a schematic block diagram of a load sensor including electrical components such as an optical sensor. [Figure 30B] FIG. 30B depicts a representational configuration of a load sensor including electrical components having a light emitter and a reflective light receiver. [Figure 30C] FIG. 30C depicts a representation of a load sensor including electrical components with a light emitter and an optical sensor. [Figure 31A] FIG. 31A is a schematic block diagram of a load sensor, including electrical components such as a Hall sensor. [Figure 31B] FIG. 31B is a representational configuration of a load sensor including electrical components with a non-contact sensor. [Figure 32] FIG. 32 is a schematic diagram of a right front top perspective view of the mechanical components of a load sensor of the present teachings, including an "S" beam. [Figure 33] FIG. 33 is a schematic diagram of a left rear bottom perspective view of the mechanical components of a load sensor of the present teachings. [Figure 34] FIG. 34 is a schematic diagram of an enlarged view of a transverse piece including a thinned portion proximal to the body of an "S" beam of the present teachings. [Figure 35A] FIG. 35A is a schematic diagram of the mechanical components of the load sensor, including the deformable body. [Figure 35B] FIG. 35B is a schematic diagram of a load sensor mechanical component including a threaded insert extending into the deformable body. [Figure 35C] FIG. 35C is a schematic diagram of a threaded insert and nut showing the tension stop gap and compression stop gap. [Figure 35D] FIG. 35D is a schematic illustration of a compression stop gap occupying the space between the nut and the deformable body. [Figure 35E] FIG. 35E is a schematic diagram of a cross-sectional view taken at a horizontal mid-plane of the mechanical components of the load sensor shown in FIG. 35B. [Figure 35F]FIG. 35F is a cross-sectional view taken from FIG. 35C. [Figure 36] FIG. 36 is a schematic diagram of a motor assembly arranged to drive a drive screw. [Figure 37] FIG. 37 is a schematic diagram of an inner cross section of the configuration depicted in FIG. [Figure 38] FIG. 38 is a schematic diagram of the "S" beam of several load sensors. [Figure 39] FIG. 39 is a schematic diagram of a motor assembly and associated drive elements. [Figure 40] FIG. 40 is a schematic diagram of an inner cross section of the configuration depicted in FIG. [Figure 40A] 40A-1, 40A-2, and 40A-3 are diagrammatic representations of actuator pins responding to double cam rotation of the present teachings. [Figure 40B] FIG. 40B is a schematic diagram of a double cam of the present teachings. [Figure 40C] FIG. 40C is an exploded schematic view of the double cam of FIG. 40B. [Figure 40D] FIG. 40D is a graphical representation of the path of the double cam of FIG. 40C in operation. [Figure 40E] FIG. 40E is a diagrammatic representation of an actuation assembly including a flexure of the present teachings. [Figure 40F] FIG. 40F is a cross-sectional schematic view of the actuation assembly of FIG. 40E. [Figure 40G] FIG. 40G is an exploded schematic view of the ball screw / flexure section of the actuation assembly of FIG. 40E. [Figure 40H] FIG. 40H is a schematic diagram of a ball screw of the present teachings. [Figure 40I] FIG. 40I is a schematic diagram of a flexure of the present teachings. [Figure 40J] 40J and 40K are schematic diagrams of the cable tension and lumen paths of the present teachings. [Figure 40K] 40J and 40K are schematic diagrams of the cable tension and lumen paths of the present teachings. [Figure 40L-1]FIG. 40L-1 is a schematic diagram of a cable-driven actuator module of the present teachings. [Figure 40L-2] FIG. 40L-2 is an exploded schematic view of the cable-driven actuator module of FIG. 40L-1. [Figure 40M] FIG. 40M is a schematic diagram of a lumen of the present teachings. [Figure 40N] FIG. 40N is a schematic diagram of a swing arm of the present teachings. [Figure 40O] FIG. 40O is a schematic diagram of a first configuration of a capstan housing of the present teachings. [Figure 40P] FIG. 40P is a schematic diagram of a swing arm pulley of the present teachings. [Figure 40Q] FIG. 40Q is a schematic diagram of a pulley of the present teachings. [Figure 40R] FIG. 40R is a schematic diagram of a sheave drive shaft bearing of the present teachings. [Figure 40S] FIG. 40S is a schematic diagram of a pulley box drive shaft of the present teachings. [Figure 40T] FIG. 40T is a schematic diagram of a capstan shaft of the present teachings. [Figure 40AA] 40AA and 40BB are schematic illustrations of a second configuration of a tensioning assembly of the present teachings, including a cam. [Figure 40BB] 40AA and 40BB are schematic illustrations of a second configuration of a tensioning assembly of the present teachings, including a cam. [Figure 40CC] FIG. 40CC is a schematic diagram of a strain relief cam of the present teachings. [Figure 40DD] FIG. 40DD is a schematic diagram of another configuration of the capstan housing of the present teachings. [Figure 41] FIG. 41 is a schematic diagram of a bottom perspective view of a manipulator and some manipulated components of the present teachings. [Figure 42] FIG. 42 is a schematic diagram of a manipulator housing shell that captures and retains a driven element of the present teachings. [Figure 43] FIG. 43 is a schematic diagram of a portion of a manipulator housing exposing a driven element of the present teachings. [Figure 44] FIG. 44 is a schematic diagram of a driven element and an operated component of the present teachings. [Figure 45] FIG. 45 is a schematic diagram of a driven element including an anchoring point of the present teachings. [Figure 46] FIG. 46 is a schematic diagram of a rail extending from a surface of the present teachings. [Figure 47] FIG. 47 is a diagrammatic representation of a routing insert having an outer wall and several different routing channels of the present teachings. [Figure 48] FIG. 48 is a schematic diagram of a manipulator including a manipulator housing and several driven elements of the present teachings. [Figure 49] FIG. 49 is a schematic diagram of a manipulator and drive components aligned for operable engagement of the present teachings. [Figure 50] FIG. 50 is a schematic diagram of a manipulator seated on an interface plate of the present teachings. [Figure 51] FIG. 51 is a schematic block diagram of a driven element held in a known position to facilitate docking of a manipulator of the present teachings. [Figure 52] FIG. 52 is a schematic block diagram of a flange that holds a protrusion in a retracted position according to the present teachings. [Figure 53] FIG. 53 is a schematic diagram of a hydraulically powered system of the present teachings. [Figure 54] FIG. 54 is a schematic block diagram of a force transmission arrangement of the present teachings. [Figure 55] FIG. 55 is a schematic block diagram of another force transmission arrangement of the present teachings. [Figure 56A] FIG. 56A is a schematic block diagram of yet another force transmission arrangement of the present teachings. [Figure 56B] FIG. 56B is a schematic block diagram of the housing of a surgical system of the present teachings. [Figure 57] FIG. 57 is an exploded view of an embodiment of a force transfer contact arrangement of the present teachings. [Figure 58] FIG. 58 is a representation of allowing linear displacement of the protrusions of the present teachings. [Figure 59] FIG. 59 is a detailed view of a pocket displaced toward the pleated section of the present teachings. [Figure 60] FIG. 60 is a detailed view of the area of ​​FIG. [Figure 61] FIG. 61 is an alternate detail view of the area of ​​FIG. [Figure 62A] FIG. 62A is a perspective view of an exemplary configuration of a magnetic coupling. [Figure 62B] FIG. 62B is an enlarged view of a region of FIG. 62A. [Figure 62C] FIG. 62C is a cross-sectional view of an exemplary barrier interface connection including several magnets. [Figure 63A] FIG. 63A is an exploded perspective view of a torque transmission arrangement of the present teachings. [Figure 63B] FIG. 63B is a cross-sectional view of the view of FIG. 63A. [Figure 64A] FIG. 64A is a representation of an exemplary torque transmission arrangement of the present teachings. [Figure 64B] FIG. 64B is a pictorial representation of nutation explained relative to possible axes. [Figure 64C] 64C-64F are pictorial representations of the displacement of the barrier as the driving and driven elements rotate about a reference axis. [Figure 64D] 64C-64F are pictorial representations of the displacement of the barrier as the driving and driven elements rotate about a reference axis. [Figure 64E] 64C-64F are pictorial representations of the displacement of the barrier as the driving and driven elements rotate about a reference axis. [Figure 64F] 64C-64F are pictorial representations of the displacement of the barrier as the driving and driven elements rotate about a reference axis. [Figure 65A] FIG. 65A is a schematic diagram of an exemplary torque transmission arrangement of the present teachings. [Figure 65B] FIG. 65B is a schematic diagram of an exploded view of the torque transfer arrangement of FIG. 65A. [Figure 65C]FIG. 65C is a schematic diagram of a cross-sectional view of the torque transmission arrangement shown in FIG. 65A. [Figure 65D] FIG. 65D is a schematic diagram of an enlarged view of the area depicted in FIG. 65C. [Figure 65E] FIG. 65E is a schematic illustration of an exploded view of the first barrier interface connection of the torque transmission arrangement illustrated in FIGS. 65A-65D. [Figure 65F] FIG. 65F is a schematic diagram of an exploded view of another configuration of the torque transfer arrangement of FIG. 65A. [Figure 65G] FIG. 65G is a schematic diagram of an exploded view of yet another configuration of the torque transfer arrangement of FIG. 65A. [Figure 66A] 66A and 66B are diagrammatic representations of a bridging element and flexible diaphragm of the present teachings. [Figure 66B] 66A and 66B are diagrammatic representations of a bridging element and flexible diaphragm of the present teachings. [Figure 67A] FIG. 67A is a schematic diagram of a side view of a torque transfer assembly of the present teachings. [Figure 67B] FIG. 67B is a schematic diagram of an exploded view of the torque transmission arrangement of FIG. 67A. [Figure 67C] FIG. 67C is a cross-sectional perspective view of a first receiving structure engaging a portion of a bridging element of the present teachings. [Figure 67D] FIG. 67D is a schematic diagram of an exploded view of the cross-sectional view of FIG. 67C. [Figure 67E] FIG. 67E is a schematic diagram of a rotating element configuration of the present teachings. [Figure 67F] FIG. 67F is a schematic diagram of another configuration of a rotating element of the present teachings. [Figure 67G] FIG. 67G is a schematic diagram of yet another configuration of a rotating element of the present teachings. [Figure 68] FIG. 68 is a pictorial representation of a gear train of rotating elements of the present teachings. [Figure 69] FIG. 69 is a schematic diagram of a manipulator seated on an interface plate of the present teachings. [Figure 70]FIG. 70 is a schematic diagram of a manipulator positioned for docking onto an interface plate of the present teachings. [Figure 71] FIG. 71 is a pictorial representation of an articulating portion of an actuated component of the present teachings. [Figure 72] FIG. 72 is a diagrammatic representation of the bending plane of the present teachings. [Figure 73] FIG. 73 is a pictorial representation of an initial position of an articulating compartment of the present teachings. [Figure 74] FIG. 74 is a pictorial representation of the articulation of an articulating compartment of the present teachings. [Figure 75] FIG. 75 is a plan view of the actuator relationships of the present teachings. [Figure 76] FIG. 76 is a flow chart of a method for controlling the movement of an articulating compartment. [Figure 76A] 76A, 76B, and 76C are geometric diagrams of the cable length calculation parameters of the present teachings. [Figure 76B] 76A, 76B, and 76C are geometric diagrams of the cable length calculation parameters of the present teachings. [Figure 76C] 76A, 76B, and 76C are geometric diagrams of the cable length calculation parameters of the present teachings. [Figure 77] FIG. 77 is a flowchart of a method for tensioning an actuator for a surgical robot. [Figure 78] FIG. 78 is a flow chart of a method for sensing the status of a load sensor. [Figure 79A] FIG. 79A is a schematic block diagram of a control system configuration for applying tension to an actuator to cause displacement. [Figure 79B] FIG. 79B is a schematic block diagram of another configuration of a control system for applying tension to an actuator to cause displacement. [Figure 79C] FIG. 79C is a schematic block diagram of a tensioning system of the present teachings. [Figure 80A] FIG. 80A is a schematic diagram of an instrument tunnel of the present teachings. [Figure 80B] FIG. 80B is a schematic illustration of an instrument tunnel engaged with a drive component of the present teachings. [Figure 81A] FIG. 81A is a schematic diagram of an operating setup of the present teachings. [Figure 81B] FIG. 81B is a schematic diagram of an actuation setup of the present teachings in exploded form. [Figure 81C] FIG. 81C is a schematic illustration of the actuation setting of FIGS. 81A and 81B with a second configuration of the driven component of the present teachings. DETAILED DESCRIPTION OF THE INVENTION

[0019] In accordance with some configurations of the present teachings, and referring now to FIG. 1 , a surgical system 10 for performing surgical procedures is shown. The system 10 may also be used for other medical procedures, such as endoscopic procedures. Generally, the surgical system 10 may include, but is not limited to, a user interface 12A and a surgical robot 16. The robot 16 may include at least one controllable element that can be used to perform surgery on a patient 18. Such an element may be introduced into an anatomical feature or cavity of the patient 18 to operate on a surgical target or may help position other portions of the robot 16 for surgery. The user interface 12A may communicate with the robot 16 to control and receive feedback and / or data from the robot 16. Multiple displays and user input devices may be included in the user interface 12A. Similarly, multiple robots 16 may be included in the surgical system 10. Multiple displays and / or user input devices may be desirable, for example, for teaching / educational purposes or for scenarios in which the robot 16 includes more controllable elements than can be easily controlled by a single surgeon.

[0020] Continuing to refer to FIG. 1 , user interface 12A can display images captured and relayed to it from imaging or vision system 13. Imaging system 13 may be part of robot 16 or may be installed within robot 16 during surgery. Imaging / vision system 13 may be controlled by robot 16. In an alternative configuration, imaging / vision system 13 may be an optional auxiliary component 20 that may not be directly controlled by robot 16. Images displayed in user interface 12A can provide a view of the surgical site that allows surgeon 22 to control robot 16 with visual feedback. User interface 12A can include any of a variety of displays, such as a monitor, touchscreen, tablet, or the like. In a configuration in which user interface 12A is capable of receiving user input (e.g., a touchscreen), a user, such as surgeon 22, may interact with user interface 12A to pan, zoom, or otherwise manipulate the field of view shown on the display of user interface 12A. In addition, other display functionality (eg, taking pictures, recording videos, controlling the robot 16) may also be commanded through the user interface 12A.

[0021] Continuing to refer to FIG. 1 , the surgeon 22 can interact with the user interface 12A to control the operation of the robot 16. In an exemplary configuration, the user interface 12A can move controllable elements of the robot 16 (e.g., arms or surgical tools) about and / or along various degrees of freedom during a surgical procedure. The user interface 12A can have multiple portions that are separately controllable by different parts of the surgeon's 22's body (e.g., right hand, left hand, right foot, left foot, etc.). In addition, the user interface 12A can have multiple portions that can control different parts or functionality of the robot 16. If the user interface 12A does not include a touchscreen, the user interface 12A can include one or more structures that can be displaced by the surgeon 22 to provide input commands to the robot 16. These structures can vary depending on the configuration, and any suitable type of interface can be used. In some configurations, one or more joysticks, triggers, scroll wheels, balls, etc. can be displaced by the surgeon 22 to control the robot 16. In an alternative configuration, user interface 12A may mimic the working end of a surgical tool being used in the procedure. This may allow surgeon 22 to operate the surgical tool as if performing open surgery. In yet another configuration, user interface 12A may be an exoskeleton. In such a configuration, user interface 12A may be worn by surgeon 22, and input may be provided to user interface 12A as the surgeon's 22 body moves.

[0022] Continuing to refer to FIG. 1 , in various configurations, the user interface 12A can provide feedback to the surgeon 22, such as haptic feedback. This feedback may be, but is not limited to, force feedback, which can provide the effort required to displace a portion of the user interface 12A in proportion to the amount of force being exerted through the drive system of the robot 16. Vibration feedback or other haptic feedback may also be utilized. Auxiliary components 20 can optionally be included in or interfaced with the surgical system 10. The auxiliary components 20 can include, but are not limited to, a vision or imaging system 13, such as an endoscope, an irrigation or insufflation system, an illumination system, and / or a suction system. An API may be provided to facilitate interfacing between components of the surgical system 10 and the auxiliary components 20. Any components described herein as auxiliary components 20 may, in alternative configurations, be included as part of the robot 16, or vice versa. At least one controller 15 may also be included as part of the surgical system 10. At least one controller 15 may perform several functions, including, but not limited to, analyzing user inputs to user interface 12A and generating commands for robot 16 based on those inputs, image processing based on data received from lighting / vision system 13, and controlling the delivery of feedback to a user, such as physician 22.

[0023] Still further referring to FIG. 1 , the barrier 24 can isolate a portion of the surgical system 10 from the remainder of the surgical system 10. In some configurations, the barrier 24 may separate single-use or multi-use disposable components of the robot 16 from durable components of the robot 16 that may not be intended for periodic disposal. The barrier 24 may be a sterile barrier that can, for example, separate sterile portions of the surgical system 10 from non-sterile portions of the surgical system 10, creating a sterile field. In some configurations, the barrier 24 can be a sterile barrier that can isolate the sterile portions of the robot 16 and the patient 18 from other components of the surgical system 10. In configurations involving disposables, the disposables may be a sterile portion of the surgical system 10 that can be isolated from other portions of the surgical system 10 by the barrier 24. In the representational example shown in FIG. 1 , the barrier 24 is depicted with a line break. This is done to illustrate that while the sterile barrier 24 will generally have portions of the robot 16 on the sterile side as well as the patient 18 on the sterile side, the barrier 24 may surround, cover, or otherwise isolate different components of the surgical system 10 from the sterile field, depending on the configuration.

[0024] 2, user interface 12A (FIG. 1) can include, but is not limited to, a display 12 and a user input device 14, which can be, but are not limited to being, physically and electrically remote from each other and can interface through a network 21, among other ways. Additionally, lighting / vision 13 can be integral to robot 16 and can cross barriers 24 to illuminate the procedure on patient 18 for surgeon 22. Auxiliary components 20 can optionally be included in system 110.

[0025] Referring primarily to FIG. 3 , a surgical robot 16 may be incorporated into the surgical system 10 ( FIG. 1 ). The surgical robot 16 may include a base 30, which may support other components of the robot 16. Additionally, in some configurations, the base 30 may act as a cart, which may allow the surgical team to maneuver the robot 16 to a desired location. The cart may be a motorized cart that can be driven to a desired location, or a non-motorized cart that can be moved manually. The base 30 may also include the electronic components of the robot 16, such as a processor or controller 15, memory components, and power components. The robot 16 may also include drive components 34, which may drive the movement of a manipulator 36. The drive components 34 may include various motors, hydraulic components, and linkages for driving the manipulator 36. The manipulator 36 may control the movement of a manipulated component 38, which may be located within the manipulator 36. The manipulated component 38 may include an articulating shaft or lumen (not shown) that can direct a surgical tool or device attached to or extending through it. Possible surgical tools may include an endoscope, such as, but not limited to, the endoscope described in U.S. Patent Publication No. 2014 / 0221749, filed January 31, 2014, entitled "Endoscope with Pannable Camera." Other surgical tools may include, but are not limited to, an imaging device, a cutting tool (e.g., a shaver), a retractor, a grasper, an ablator, an illumination source, an electrocautery device, a stapler, a suturing tool, a milling cutter, an excavating tool, a rotary cutter, an irrigation system outlet, and / or an insufflation system outlet. For illustrative purposes, three manipulated components 38 are shown. Any number of manipulated components 38 may be controlled by a manipulator 36. Multiple manipulators 36 may be driven by a single drive component 34. Multiple drive components 34 may also be included to drive at least one manipulator 36.

[0026] Continuing to refer primarily to FIG. 3 , the arm 32 may optionally include several joints that can be positionable by the user and enable rotational or translational movement of various sections of the arm 32. Such joints can enable the arm 32 to position the manipulator 36 in the appropriate position for a surgical procedure. In some configurations, the base 30 can support the robot 16 against tipping when the arm 32 is fully extended. The arm 32 may include actuators that can be manually moved into position or controlled to drive the arm 32 to a desired location. In various configurations, the arm 32 may include at least one wiring 19 to transmit, for example, without limitation, power, data, hydraulic power, fluid, and / or light between the base 30 and the driven component 34. The at least one wiring 19 may also be a fiber optic line, which in some configurations may be used for data transmission or light transmission. At least one wire 19 can allow power, data / commands, force, fluid (e.g., irrigation fluid or insufflation gas), and / or light to be communicated from the base 30 or another portion of the surgical system 10 (FIG. 1) to the driven component 34. The power, data, hydraulic force, fluid, lighting, etc. can be controlled by, for example, but not limited to, the user input device 14 (FIG. 1).

[0027] Continuing to refer to FIG. 3 , with regard to hydraulic power, in some configurations, the base 30 can include a master cylinder and motor that drive hydraulic fluid through at least one wire 19. With regard to fiber optics, light can be transmitted through the at least one wire 19 and can pass through the barrier 24 into the manipulator 36 to be used in various ways. The inclusion of at least one fiber optic line can also enable the transmission of data. With regard to data, for example, sensors within the drive component 34 may collect data and transmit it to the controller 15 within the base 30 via the at least one wire 19. Additionally or alternatively, sensors located within the manipulator 36 and the manipulated component 38 can collect data and transmit it through the barrier 24 to the at least one wire 19 for processing within the base 30. In another example, with regard to thermal management, the at least one wire 19 can be configured to contain liquid and / or gas between the base 30 and the drive component 34 to cool the drive component 34, for example, by heat conduction. The at least one wire 19 can conduct water / gas for insufflation and irrigation. At least one wire 19 can be used for aspirating and / or removing fluid or debris from the surgical site. Controller 15 can control at least one wire 19, for example, to provide the services outlined herein.

[0028] Still further and continuing to refer primarily to FIG. 3 , the barrier 24 can act as a sterility barrier and isolate the manipulator 36 and manipulated component 38 from the rest of the robot 16. In some configurations, a portion of the barrier 24 can be retained or captured between the drive component 34 and the manipulator 36. Forces may be transmitted to the manipulator 36 through this portion of the barrier 24 to drive the manipulator 36. The portion of the barrier 24 retained between the drive component 34 and the manipulator 36 can be a solid and continuous portion of the barrier 24. That is, the portion of the barrier 24 between the drive component 34 and the manipulator 36 may not include voids, orifices, openings, holes, passages, or other such interruptions. The integrity of the barrier 24 can be maintained as forces are transmitted therethrough. The manipulator 36 may hang over the drive component 34, trapping the barrier 24 between the two during setup of the robot 16. The manipulator 36 and manipulated component 38 may be supplied as single or multiple use disposable items. The manipulated component 38 may be pre-installed or pre-assembled within the manipulator 36. These portions of the surgical system 10 (FIG. 1) may be provided in sterile packaging. The manipulator 36 and manipulated component 38 may be installed into the system 10 (FIG. 1) prior to surgery.

[0029] 4A-4E depict representations of several manipulated components 38. The manipulated components 38 can be at least partially inserted into a patient to perform a procedure. In the exemplary configuration, the manipulated components 38 are depicted including a shaft 50 for simplicity.

[0030] 4A , the articulating section 40 may include, but is not limited to, any combination of a shaft, a jointed or otherwise articulating shaft, several nested shafts, several vertebrae or other pivoting / hinging members, a ball-and-socket member, and / or one or a series of living hinges. The manipulated component 38 may be hollow or may include at least one lumen (not shown) and may pass through a trocar 37. The lumen (or several lumens) may serve as a pathway through which a surgical tool 52 can be introduced to the surgical site. The lumen may also be used to facilitate insufflation, irrigation, illumination, etc. of the surgical site. Utility components 54 operably connected to the manipulated component 38 may be mechanical control, light transmission, information transmission, fluid transmission, and power transmission components. The utility components 54 may extend through a lumen (not shown) shared with one or more other utility components 54, or each may have its own dedicated lumen. There may be a variety of different utility components 54 housed within the manipulated component 38. Light-transmitting components may include, for example, fiber optic bundles, ribbons, light pipes, light projection elements, and / or the like. Information-transmitting components may include, for example, electrical cable bundles or ribbons. Such cables or bundles may connect to a surgical tool 52 having an imaging device positioned at the end of the manipulated component 38. Such cables may also be used to transmit power to the surgical tool 52. Fluid-transmitting components may provide a path for fluid (e.g., insufflation gas or irrigation fluid) to be introduced into the patient's anatomical features.

[0031] Still referring primarily to FIG. 4A , the manipulated component 38 can include an articulating section, segment, or region 40 that can be connected to a variable portion 39 of the manipulated component 38. The variable portion 39 can extend into the manipulator 36 or through a trocar 37 to facilitate introduction into the patient. The variable portion 39 can be, for example, without limitation, bendable, articulating, or non-bendable. The manipulated component 38 can be pre-assembled to the manipulator 36. Similarly, the manipulated component 38 can be pre-assembled with the utility components 54 already located therein. As described above, these can be provided in sterile packaging. In configurations where at least one or a portion of the utility components 54 is not pre-installed in the manipulator 36 or manipulated component 38, that utility component 54 or a portion of the utility component 54 can be similarly packaged. The utility component 54 can be, but is not limited to, a mechanical control component or actuator. The actuator can extend into and along the length of the manipulated component 38. Additionally, the actuator may extend into the manipulator 36 through a gap or opening in the deformable portion 39 .

[0032] Referring now primarily to FIG. 4B , any suitable number of actuators 54A, 54B, 54C may be included in various configurations. The number of actuators 54A, 54B, 54C may be determined, at least in part, by the number of individually actuatable components or features in the actuated component 38. In some configurations, a first actuator 54A, a second actuator 54B, and a third actuator 54C are shown and are depicted as wires for simplicity. In some configurations, the actuators 54A, 54B, 54C may be push rods or any other suitable material. Multiple different types of actuators may also be used within the same configuration. For example, some actuated components 38 may actuate some features with pull wires and actuate other features using actuators that can exert both pulling and pushing forces to achieve actuation. One or more actuators 54A, 54B, 54C may be associated with the surgical tool 52. In the exemplary configuration shown in Figure 4B, actuating the second actuator 54B may actuate the surgical tool 52 or an end effector included as part of the surgical tool 52. This is shown representatively by the surgical tool 52 changing shape (relative to Figure 4A) in response to the displacement of the second actuator 54B.

[0033] 4C , the first actuator 54A, the second actuator 54B, and the third actuator 54C may be actuated to actuate a feature of the manipulated component 38. Such actuation may cause, for example, the opening or closing of jaws or clamps on the surgical tool 52 (see FIG. 4B ), the panning of an imaging device, camera, and / or lighting system included in the surgical tool 52, the deployment of a retractor, etc. One or more of the first actuator 54A, the second actuator 54B, and / or the third actuator 54C may be actuated to cause displacement of the articulating segment 40 about one or more articulation parts or joints 51 within the articulating segment 40. In response to displacement of the first actuator 54A and the third actuator 54C in the illustrative configuration, the articulating segment 40 will be caused to assume the orientation of the dotted outline articulating segment representation 56A. Controlling the articulating compartment 40 via mechanical control components allows the procedure to be minimally invasive, and in some cases, such articulation may allow the procedure to be performed through only a single incision in the patient.

[0034] Referring now to FIG. 4D , the manipulated component 38 may have multiple regions or sections, each capable of articulation to various degrees. For example, the manipulated component 38 may be comprised of a variable section 39 and an articulating section 40A. The articulating section 40A may comprise only a small portion of the manipulated component 38. Alternatively, the manipulated component 38 may include several articulating sections 40A, which may be interspersed with intervening variable sections 39. In such a configuration, each articulating section 40A may be articulated to a different degree. Each region of the manipulated component 38 may or may not be independently controllable. The articulating section 40A may also include gradations of articulation within the articulating section 40A. That is, one or more of the sections of the articulating section 40A may be more tightly articulated or articulated than other sections. Alternatively, the density of articulations or joints may gradually increase or decrease along the length of the articulating section 40A. The manipulated component 38 may include at least one first articulating subsection 41 and at least one second articulating subsection 42. The second articulating subsection 42 may be a distal articulating subsection, and the first articulating subsection 41 may be a proximal articulating subsection. The second articulating subsection 42 may, for example, without limitation, be more tightly articulated than the other sections of the articulating section 40A, allowing for precise control of the surgical tool 52 when performing surgery. In a configuration in which the second articulating subsection 42 is more tightly articulated than the rest of the manipulated component 38, the second articulating subsection 42 may be used to perform the majority of the fine movement and control during surgery. One or more actuators 54A, 54B, 54C, 54D, 54E may be used to control the first articulating subsection 41, and one or more actuators 54A, 54B, 54C, 54D, 54E may be used to control the second articulating subsection 42.For example, the first actuator 54A and the fifth actuator 54E can be used to control the second articulating subsection 42, while the second actuator 54B and the fourth actuator 54D can be used to control the first articulating subsection 41. The remaining third actuator 54C may control the surgical tool 52. In the exemplary configuration, the first actuator 54A and the fifth actuator 54E are displaced. Orientation 56B is shown for illustrative purposes to indicate the position of the second articulating subsection 42 as a result of this actuation.

[0035] Referring now to FIG. 4E , the second articulating subsection 42 may be displaced as a result of any articulation of the first articulating subsection 41 or other sections of the articulating section 40A. Any of the at least one first articulating subsection 41 may be controlled to more macroscopically position the surgical tool 52 and the second articulating subsection 42. The manipulated component 38 may include several actuators 54A, 54B, 54C, 54D, 54E that, when actuated, cause articulation of portions of the manipulated component 38. Additional actuators 54A, 54B, 54C, 54D, 54E can be used to achieve more complex articulation of the manipulator 38 and attached surgical tool 52. The actuators 54A, 54B, 54C, 54D, 54E are arranged to control the articulating section 40A of FIG. 4E as described above in connection with FIG. 4D . In the illustrated configuration, actuators 54B and 54D that control first articulating subsection 41 are actuated. Orientation 56C is shown for illustrative purposes to show the position of articulating section 40A as a result of this actuation.

[0036] Referring now primarily to FIG. 5 , the articulating compartment or section 40B may be constructed in several different ways. In some configurations, the articulating compartment 40B may incorporate one or several living hinges 300 that can be acted upon to articulate the articulating compartment 40B to a desired configuration or orientation. The living hinges 300 of the articulating compartment 40B may span several intermediary bodies 302. The intermediary bodies 302, for non-limiting examples, may be rigid and may provide one or more anchoring points 80 for one or more actuators 54 ( FIG. 4A ). Some of the intermediary bodies 302 may instead include a pass-through portion 304A, 304B or multiple pass-through portions 304A, 304B through which an actuator (e.g., see 54A in FIG. 4B ) can extend. Applying a force via an actuator (e.g., see 54A in FIG. 4B ) can bend one or more of the living hinges 300 (e.g., depending on the actuator's anchor point 80). By selectively applying a force through the actuator (e.g., see 54A in FIG. 4B ), the articulating section 40B may bend to a desired orientation. Such a stack of living hinges 300 may be used to form part or the entire articulating section 40B. Depending on the configuration, the articulating section 40B is constructed from a stack of living hinges 300, which may be manufactured as a single part. This part may, in some configurations, be a molded part. Alternatively, the part may be machined or printed using a material additive process such as three-dimensional printing. The interface body 302 can be, for example, without limitation, a disk-like member. Although only three living hinges 300 are shown, any suitable number of living hinges 300 and intermediate bodies 302 may be included to create an articulating section 40B of a desired length.

[0037] Continuing to refer primarily to FIG. 5, each intervention body 302 of the articulating section 40B can include a first pass-through portion 304A and a second pass-through portion 304B. The first pass-through portion 304A and the second pass-through portion 304B of adjacent interface bodies 302 can be substantially axially aligned with one another. Each actuator (e.g., see 54A in FIG. 4B ) for the articulating section 40B can be anchored into an anchoring point 80. In the exemplary configuration of FIG. 5 , the anchoring point 80 is shown in the terminal interface body 302A. The actuator 54 (e.g., see 54A in FIG. 4B ) can be anchored into an interface body 302 other than the terminal interface body 302A, depending on the configuration. As described above, when forces are exerted by one or more actuators (e.g., see 54A in FIG. 4B ) in a coordinated manner, the articulating section 40B can bend in a desired manner. In some configurations, the series of living hinges 300 and intermediary body 302 may be covered by a tube, sheath, or flexible sleeve 50 (FIG. 4A) when the articulating section 40B is fully assembled.

[0038] Referring now to Figure 6, another configuration of an articulating section 40C is shown, with an interface body 302 including a first living hinge 300A, a second living hinge 300B, and a pass-through portion 304. Similar to that shown in Figure 5, the distal interface body 302A of the articulating section 40C includes an anchoring point 80 for an actuator (e.g., see 54A in Figure 4B). The first living hinge 300A can be angularly offset relative to the second living hinge 300B. By way of non-limiting example, the first and second living hinges 300A, 300B may be positioned perpendicular to or substantially perpendicular to any directly adjacent living hinges 300A, 300B. The first living hinge 300A can flex the articulating section 40C in a first plane (e.g., up and down), and the second living hinge 300B can flex the articulating section 40C in a second plane (e.g., side to side). Each of the intermediary bodies 302 can include, for example, without limitation, four pass-throughs 304. Each pass-through 304 can extend through either the first living hinge 300A or the second living hinge 300B. The actuators (e.g., see 54A in FIG. 4B ) can be organized into cooperating sets that can be operated to flex the articulating section 40C in a set of directions. For example, actuators (e.g., see 54A in FIG. 4B ) extending through oppositely positioned pass-throughs 304 can be interlocked to enable coordinated flexion of the articulating section 40C in a plane. By operating a set of ganged actuators (see, eg, 54A in FIG. 4B) in conjunction with one another, articulating section 40C may be positioned in a wider range of orientations than articulating section 40B (FIG. 5).

[0039] In a configuration including an articulating section 40C with multiple articulating subsections, a first articulating subsection 41 (FIG. 4D) may include several first living hinges 300A that are coincident with each other or that all allow bending in the same plane. A second articulating subsection 42 (FIG. 4D) may include several second living hinges 300B that are coincident with each other but at an angle (e.g., a right angle) to the first living hinges 300A (FIG. 5) in the first articulating subsection 41 (FIG. 4D).

[0040] Referring now to FIG. 7 , an articulating section 40D is shown in which living hinges 300C are separated by an intermediary body 302. The living hinges 300C can be, for example, but not limited to, cylindrical or columnar bodies and can be made, for example, but not limited to, from a flexible material. The living hinges 300C can be bent in any direction using substantially the same force. If desired, the living hinges 300C can be given an elliptical cross-sectional shape or any other cross-sectional shape. Having an asymmetric cross-sectional shape can allow the living hinges 300C to bend more freely in a first set of planes compared to a second set of planes. The intermediary body 302 can be, for example, but not limited to, disc-like. Each intermediary body 302 can include several, for example, four, pass-through portions 304. In some configurations, the intermediary body 302 need not include four pass-through portions 304. Instead, the intermediary body 302 can include three pass-through portions 304. The number of pass-throughs 302 included may depend on the number of actuators (see, e.g., 54A in FIG. 4B ) that will be included for the articulating section 40D. The actuators (see, e.g., 54A in FIG. 4B ) may extend through the pass-throughs 304 and be anchored, for example, without limitation, into anchoring points 80 of the terminal interface body 302A. The actuators (see, e.g., 54A in FIG. 4B ) may be organized into cooperating sets that may be used alone or together to bend the articulating section 40D to a desired orientation. An actuator (see, e.g., 54A in FIG. 4B ) may extend through each set of pass-throughs 304 and be operated in conjunction with one another to bend the articulating section 40D to a desired orientation.

[0041] Referring again primarily to FIG. 4A , various articulating sections 40 may also be used that are jointed. Such configurations may incorporate one or several joint members that are coupled together to act as a set of kinematic pairs. These joint members may be acted upon to displace the articulating section 40 to a desired configuration or orientation. Applying a force via an actuator (e.g., see 54A in FIG. 4B ) included in the articulating section 40 can move one or more joint members within the articulating section 40 relative to one another. The number of joint members displaced may depend on the anchoring points 80 ( FIG. 5 ) of the actuators (e.g., see 54A in FIG. 4B ) and the type of joint involved. By selectively applying a force via the actuators (e.g., see 54A in FIG. 4B ), the articulating section 40 may be bent to a desired orientation.

[0042] Referring now to FIG. 8 , an articulating section 40E constructed with several kinematically connected joint members 310 is shown. The joint members 310 can be, by way of non-limiting example, ball-and-socket type joints. Any other variety or combination of joint types may be used in other configurations. The illustrated articulating section 40E includes four joint members 310. Any number of joint members 310 may be included to create an articulating section 40E of a desired length. Each joint member 310 may include a ball 312 and a socket 314. The ball 312 may be sized to fit and be retained within the socket 314 of an adjacent joint member 310. The joint members 310 may also include a flange 316, which may include several passages 304. An alternative configuration may not include a flange 316, but may include any type of protrusion within which the passages 304 may be located. Such protrusions may be radially displaced.

[0043] 9, an assembly view of the articulating section 40E is shown. Several actuators 54A, 54B, 54C may extend, for example, through passages 304 in the joint members 310. The first actuator 54A, the second actuator 54B, and the third actuator 54C may each be anchored into an anchoring point 80 in one of the joint members 310. In an exemplary configuration, the actuators 54A, 54B, 54C are anchored into an anchoring point 80 in the distal joint member 310A. In some configurations, the actuators 54A, 54B, 54C may be wires. The actuators 54A, 54B, 54C may be actuated in coordination with one another to cause the articulating section 40E to assume a desired orientation. The articulating section 40E is shown in an actuated position. The first actuator 54A is retracted while the second actuator 54B and the third actuator 54C are delivered out, causing the articulating section 40E to bend.

[0044] 9A , the articulating segment 40E can include joint members 310 that are aligned such that, when assembled, the ball 312 and socket 314 of the subsequent joint member 310 mate. The joint members 310 can be configured with channels 311 that can extend from the socket 314 to the ball 312 of the joint member 310. When the articulating segment 40E is assembled, the channels 311 in each joint member can align with one another to provide a continuous pathway through the articulating segment 40E. In some configurations, the channels 311 can be configured to receive at least a portion of a surgical tool 52 ( FIG. 4A ) or auxiliary component 20 ( FIG. 1 ) used during a surgical procedure. The portion received within the channel 311 can be substantially flexible or pliable, but is not limited to being so, and may passively flex as the articulating segment 40E is articulated. A portion of the surgical tool 52 ( FIG. 4A ) or auxiliary component 20 ( FIG. 1 ) received in the channel 311 can move relative to the movement of the coupling member 310. For example, the portion of the surgical tool 52 ( FIG. 4A ) or auxiliary component 20 may rotate relative to the coupling member 310 when force is applied thereto via the rotational drive component 34C ( FIG. 69 ). Additionally, the surgical tool 52 ( FIG. 4B ) or auxiliary component 20 ( FIG. 1 ) may be actuated or controlled via an associated actuator 54B ( FIG. 4B ). For example, displacing one or more actuators 54B ( FIG. 4B ) may open and / or close the jaws of a surgical grasper. In some configurations, the channel 311 may house a flexible cannula or tube configured to receive at least a portion of the surgical tool 52 ( FIG. 4A ) or auxiliary component 20 ( FIG. 1 ).

[0045] 9B, a cross section of an articulating segment 40E is depicted. A channel 311 is shown extending from the socket 314 to the ball 312 of each joint member 310 of the articulating segment 40E. In some configurations, more than one channel 311 may be included in each joint member 310 of the articulating segment 40E. A surgical tool 52 may be inserted through the path created by the channel 311 to introduce the tool 52 to the surgical site. Alternatively, a portion of the surgical tool 52 or auxiliary component 20 (FIG. 1) may reside within the path created by the channel 311.

[0046] Referring now primarily to FIG. 10 , the articulating section 40K can include an elongated structure 330 with a first lumen 332A and a second lumen 332B. The elongated structure 330 can be, for example, approximately square or rectangular in cross-section, but can have any other cross-sectional shape (e.g., circular, hexagonal, octagonal). The articulating section 40K can be, for example, without limitation, a single piece (e.g., extruded). In various configurations, the articulating section 40K can be, for example, without limitation, nylon or a similarly bendable material. The second lumen 332B and the first lumen 332A can be a plurality of different diameters. The first lumen 332A can act as an actuator guide path through which individual actuators 54 ( FIG. 3A ) can extend. The actuators (e.g., see 54A in FIG. 4B ) can be, for example, without limitation, wires or cables. The second lumen 332B may, for example, be of a larger diameter than the first lumen 332A. The second lumen 332B may be used to introduce one or more surgical tools into the articulating section 40K or the manipulated component 38 (FIG. 3A). The second lumen 332B may be centrally located, while the first lumen 332A may be peripherally located.

[0047] Still referring to FIG. 10 , the articulating section 40K can include a living hinge 335. The living hinge 335 can be created by various cutouts 337. This arrangement can allow the elongated structure 330 to bend about the living hinge 335 when an actuator (e.g., see 54A in FIG. 4B ) attached to a portion of the elongated structure 330 is displaced. The cutouts 337 can include sets of holes 334L, 334R that can be located on opposite sides of the elongated structure 330. The set of holes 334L, 334R can include a left hole 334L and a right hole 334R located on sides of an inner partition that form the living hinge 335. Each living hinge 335 can be continuous with the remainder of the elongated structure 330. In a configuration in which the elongated structure 330 is circular in cross section, each hole in the set of holes 334L, 334R can be located 180° from each other. The left holes 334L and the right holes 334R may be angularly offset from one another by, for example, but not limited to, 20 to 50 degrees. The left holes 334L and the right holes 334R may be circular or any other shape. The size and / or spacing of the left holes 334L and the right holes 334R may vary, but in the exemplary configurations, the holes 334L, 334R are depicted as having uniform size and spacing. In some configurations, the first face 339A, the second face 339B, the third face (not shown), and the fourth face (not shown) may include holes. The holes may be arranged in an alternating relationship, if desired. For example, every other set of holes 334L, 334R may be angularly offset from one another by, for example, but not limited to, 90 degrees. In an exemplary configuration, every other set of holes 334L, 334R may be on the first face 339A and the opposing third side face (not shown), while the intervening set of holes would be on the second side face 339B and the fourth face opposite the second face 339B (not shown). Other permutations are possible. For example, every second or third set of holes 334L, 334R may be angularly offset from one another. Other shapes of the elongated structure 330 may offer additional possibilities. For example, a hexagonal shape may allow the sets of holes 334L, 334R to alternate around three pairs of opposing faces.

[0048] 10 , the cutout 337 can include several channels 336. Each channel 336 can be associated with a set of holes 334L, 334R. Each channel 336 can be continuous with at least one of the left holes 334L and the right holes 334R, for example, without limitation. Each channel can extend from either the left holes 334L or the right holes 334R to an axially aligned hole on the opposing face of the elongated structure 330. In an exemplary configuration, the channel 336 can extend from one of the right holes 334R or the left holes 334L to an axially aligned left hole 334L or right hole 334R on a third face (not shown) of the elongated structure 330. The spacing of the channels 336, the relationship between the channel 336 and the set of holes 334L, 334R, and the relationship between the channel 336 and the face can vary in various configurations. The set of holes 334L, 334R and the arrangement of channels 336 (and thus living hinges 335) can be selected to provide the ability to bend elongated structure 330 in a desired orientation. Channels 336 can also act as stops. The width of channels 336 can be adjusted to increase or decrease the range of motion. As the width is decreased, the allowable range of motion can also decrease. Thus, the point at which the stop will be encountered can be controlled by the width of channels 336.

[0049] Continuing to refer to FIG. 10 , channel 336 can also include features that can act as interlocks, creating barriers or obstructions that can prevent torsional distortion during operation. Specifically, geometric features 338A, 338B, 338C can require that rotation about the long axis of elongated structure 330 be accompanied by translation about that axis. Because torsional forces generally do not favor translational displacement, geometric features 338A, 338B, 338C can effectively lock articulating section 40K in a certain orientation when torsional forces are applied. Geometric features 338A, 338B, 338C can include protrusions or ridges 342 that can be received by receiving recesses 343. In an exemplary configuration, ridges 342 can extend from a first wall of channel 336, while receiving recesses 343 can be recessed into the opposing surface of channel 336. The shape of the geometric features 338A, 338B, 338C may vary in other configurations.

[0050] Referring now to FIG. 11 , articulating section 40L can include first and second lumens 332A and 332B that can extend along the length of elongated structure 330B. Elongated structure 330B can include holes 334BL, 334BR, and a channel 336B that can create living hinge 335B. When an actuator (e.g., see 54A in FIG. 4B ), which can be anchored to elongated structure 330B, is displaced in a controlled manner, elongated structure 330B can bend about living hinge 335B to a desired orientation. Geometric feature 338D within channel 336B can be, but is not limited to, wavy or toothed. Each wave 344 can interlock sections of elongated structure 330B. Such an arrangement helps ensure that one or more of geometric features 338D are engaged regardless of the orientation of elongated structure 330B.

[0051] 12, articulating section 40M can include first and second lumens 332B and 332A that can extend along the length of elongated structure 330C. Elongated structure 330C can include holes 334CL, 334CR, and channel 336C that can create living hinge 335C. When an actuator (e.g., see 54A in FIG. 4B), which can be anchored to elongated structure 330C, is displaced in a controlled manner, elongated structure 330C can bend about living hinge 335C to a desired orientation. Channel 336C can be shaped to interlock sections of elongated structure 330C. Channel 336C can be a curvilinear slot recessed into elongated structure 330C. Channel 336C can be continuous with the set of holes 334CL, 334CR. The width of channel 336C can be selected to limit the range of articulation within elongated structure 330C.

[0052] 13 and 14, the channel 336C in the articulating section 40M is recessed into the elongated structure at an angle 345 (FIG. 14). The angle 345 may be, for example, an acute angle (e.g., 30-60° or 45°) relative to the face of the elongated structure 330C in which the channel 336C is disposed. The channel 336C may be cut into the elongated structure 330C using a hole saw-type angle cutter. Alternatively, the elongated structure 330C may be a single molded piece. The angle 345 may be selected to increase or decrease the range of motion of the articulating section 40M.

[0053] Referring now to FIG. 15 , a drive component 34 and a manipulator 36 are shown with an operably coupled manipulated component 38. The drive component 34 can be separated or isolated from the manipulator 36 by a barrier 24. A portion of the barrier 24 can be retained between the drive component 34 and the manipulator 36. The drive component 34 can include several drive elements 60, which can be arranged to act on driven elements 62. The drive elements 60 can be driven by at least one force- or motion-generating element 64. Each driven element 62 can cause actuation of an actuator (e.g., see 54A in FIG. 4B ) in the manipulated component 38. Alternatively, the driven element 62 can function as an actuator (e.g., see 54A in FIG. 4B ) and directly actuate the manipulated component 38. The drive element 60 and the driven element 62 can each be a single element or a grouped collection of elements. For example, each drive element 60 can include several individually actuable components. Each of these individually actuatable components may act on individual or multiple accompanying components of individual driven elements 62. As a result, each drive element 60 may be controllable to cause actuation of one or more independently actuatable features of the manipulated component 38 via the driven element 62. The number of individually actuatable elements within each drive element 60 and driven element 62 may be determined, at least in part, based on the number of independently actuatable features within the manipulated component 38.

[0054] Continuing to refer to FIG. 15 , the force- or motion-generating element 64 may be, for example, one or more or a combination of a motor, a hydraulic actuation system, or any other arrangement. In the exemplary configuration, the force- or motion-generating element 64 is shown as part of the drive component 34. In other configurations, such as those in which a hydraulic system is used, the force- or motion-generating element 64 may not be completely housed in the drive component 34. For example, a hydraulic master cylinder may be located within the base 30 ( FIG. 3 ) or at another location remote from the drive component 34. Hydraulic lines may then extend from the master cylinder to the drive component 34 to act on the drive element 60. It may be desirable to use a fluid-based system for the force- or motion-generating element 64 because it may aid in thermal management. Additionally, because the master cylinder can be located external to the robot 16 ( FIG. 3 ), a fluid-based system may allow the drive component 34 to be made in a smaller form factor.

[0055] Continuing to refer to FIG. 15 , the driving element 60 can transfer force to a driven element 62 on the opposite side of the barrier 24. The force may be transmitted from a first barrier side 24A to a second barrier side 24B (and vice versa) in any of a variety of ways. In some configurations, the force is transmitted by a translational displacement of at least a portion of the driving element 60. This displacement, in turn, may cause a displacement of the driven element 62. In other configurations, the force is transmitted by a rotational displacement of at least a portion of the driving element 60. A torque may then be transmitted across the barrier 24 to drive the driven element 62. In yet other configurations, both translational and rotational displacements may be transmitted. The driven element 62 may be driven by both the rotational and translational displacements of the driving element 60. Additionally, some driving elements 60 may be controlled by different types of force- or motion-generating elements 64. For example, some may be motor-driven, while others are controlled by a hydraulic system. In some configurations, the barrier 24 may be substantially or completely stationary when a force is transmitted from the first barrier side 24A to the second barrier side 24B, and vice versa. That is, the barrier 24 may displace slightly, but the displacement of the barrier 24 is not necessary or the primary means by which the force is transmitted. In other configurations, the barrier 24, or a portion of the barrier 24, may displace about one or more degrees of freedom when a force is transferred, for example, from the first barrier side 24A to the second barrier side 24B. In some configurations, the degrees of freedom about which the barrier 24 displaces may be the same as those of the driving element 60 and / or the driven element 62. In other configurations, the driving element 60 and / or the driven element 62 may displace about one or more first degrees of freedom, while the barrier 24 displaces about one or more second degrees of freedom. For a specific embodiment, the driving element 60 and accompanying driven element 62 may be displaced about the roll axis, while the barrier 24 may nutate about an axis transverse to (e.g., perpendicular to) the roll axis.

[0056] 15 , in configurations in which torque is transferred from the drive element 60 to the second barrier side 24B, the torque can be substantially or completely transferred without rotating the barrier 24 material or requiring a rotating seal within the barrier 24. That is, while rotation of the barrier 24 may occur to a small extent, it is neither necessary nor is it the primary means by which torque is transmitted, for example, to the second barrier side 24B. Various configurations for transferring such forces across the barrier 24 without rotating the barrier 24 or portions of the barrier 24 will be described elsewhere herein.

[0057] Referring now to FIG. 16 , the system 1000 can include a drive component 34 and a manipulator 36 that can be engaged with one another through the barrier 24. The drive component 34 can include a drive element 60. The drive element 60, the driven element 62, and the barrier 24 can displace with the same degree of freedom when motion is transmitted across the barrier 24. The drive element 60 can be driven by a motion-generating element, such as, for example, but not limited to, a motor assembly 70. The motor assembly 70 can include a portion of the drive element 60, such as, for example, but not limited to, a motor 70A for a drive screw 74, a gearhead 70B, and bearings 70C. The motor 70A can be any suitable variety of motor, such as, for example, but not limited to, a brushless DC motor. The gearhead 70B can be, but is not limited to, a planetary gearhead. The gear ratio of the gearhead 70B can be selected to suit the needs of a given application, as would be understood by one of ordinary skill in the art. In some configurations, the gear ratio can be 1:1. The bearing 70C may be, for example, a spindle bearing. The drive element 60 may include, but is not limited to, a drive screw 74 and a nut 76. The drive screw 74 may be, for example, but is not limited to, a lead screw or a ball screw. When the motor 70A is commutated, the drive screw 74 may rotate. In turn, the nut 76 may move along the length of the drive screw 74. Various encoders and sensors may be included in the configuration to measure the movement of the nut 76 along the drive screw 74 as well as the amount of force being transmitted at one or more points in the load path. To prevent the nut 76 from displacing in an undesired degree of freedom, the nut 76 may also ride along a bearing, such as a linear bearing, that may run parallel to the drive screw 74. The motor assembly 70 and drive screw 74 may be replaced by a hydraulic cylinder and piston, respectively, if a hydraulic configuration is desired.

[0058] Continuing to refer to FIG. 16 , the system 1000 can further include, but is not limited to, the nut 76, which can include a protrusion 92 that can extend outward from the drive component housing 72. In the system 1000, the protrusion 92 can be a blade-shaped protrusion. A portion of the nut 76 outside the drive component housing 72 (i.e., the protrusion 92) can be covered by the barrier 24. In some configurations, the barrier 24 can include a pre-formed or internally bonded pocket or sleeve that is continuous with the remainder of the barrier 24. These pre-formed or internally bonded pockets can fit around the blade or protrusion 92. Various configurations of the barrier 24 are further described elsewhere herein. The protrusion 92 can protrude into the manipulator housing 78 and engage the driven element 62. In such a configuration, the driven element 62 can be a block with a slot that can receive the blade or protrusion 92. In other configurations, the nut 76 and / or the drive element 60 can be magnetically coupled to the driven element 62 through the barrier 24. As the nut 76 advances along the length of the drive screw 74, the driven element 62 may be displaced. The driven element 62 may ride along one or more bearings within the manipulator 36 to constrain the driven element 62 from moving in undesired degrees of freedom.

[0059] Still further, and continuing to refer primarily to FIG. 16 , the driven element 62 may be attached to one or more actuators 54A that can actuate a feature of the manipulated component 38 or surgical tool 52. The actuators 54A may be fixedly anchored to the driven element 62 at anchor points 80. As the driven element 62 is displaced, the actuators 54A may advance into or out of the cutouts 266 of the manipulated component. Because the manipulated component 38 may be fixedly attached to the manipulator 36, the displacement of the actuators 54A can exert an actuation force on or at the actuated feature of the manipulated component 38 or surgical tool 52. As will be understood by one of ordinary skill in the art, any number of driven elements 62 may be included in the manipulator 36 and may be driven by any suitable number of drive elements 60 in the drive component 34.

[0060] Still referring to FIG. 16 , each motor assembly 70 can also be associated with one or more position sensors 90 that can be used to provide feedback regarding the position of components of the drive element 60. The position sensors 90 can be motor encoders that can sense rotation as the motor 70A commutates. Feedback from the position sensors 90 can be communicated to a location remote from the drive component 34, for example, via suitable cables or wiring 19 ( FIG. 3 ) in the arm 32 or through wireless communication. Any suitable variety of position sensors 90 can be used. For example, if the position sensor 90 is a motor encoder, any suitable variety of encoders can be used, such as optical, magnetic, or capacitive types. In other configurations, the drive element 60 can additionally or alternatively be associated with, for example, a potentiometer. In yet other configurations, the nut 76 can include a magnet whose progress is monitored by a position sensor 90 that includes one or more magnetic sensors, such as a Hall-effect sensor, a Hall-effect sensor array, or the like.

[0061] 17A , the system 1100 can include a drive component 34 and a manipulator 36 that can engage with one another through the barrier 24. The system 1100 can further include a utility component 54 that can enter the manipulated component 38 through the manipulator housing 78. The utility component 54 can be, for example, a mechanical control, light transmission, information transmission, fluid transmission, and / or power or data transmission component. As shown, the utility component 54 does not pass through the barrier 24 but is depicted entirely on one side of the barrier 24. In configurations where the barrier 24 serves as a sterile barrier, the utility component 54 can be pre-packaged in a sterile environment. For example, the utility component 54 can be included as part of an assembly that can include the manipulator 36 and the manipulated component 38, where the assembly can be packaged in a sterile package. Alternatively, the utility component 54 can be packaged individually in its own sterile package. The utility component 54 can be connected to a supply source 55, which can vary depending on the type of utility component 54. In configurations where the utility component 54 is a mechanical control component, the source 55 may be a motion-generating element. In configurations where the utility component 54 may be a fluid-transmission component, the source 55 may be an irrigation pump or an insufflation gas supply / reservoir. In configurations where the utility component 54 is an optically-transmitting component, the source 55 may be a light source, for example, for a fiber optic line. In configurations where the utility component 54 is a power-transmission component, the source 55 may be a power outlet, a battery or battery bank, or other power source. In configurations where the utility component 54 is a data-transmission component, the source 55 may be, for example, a processor that may transmit data to and receive data from the surgical tool 52, for example, but not limited to, an imaging device.

[0062] Referring now primarily to FIG. 17B , system 1200 can include a drive component 34 and a manipulator 36 that can be engaged with one another through barrier 24. In some configurations, drive element 60 is hydraulically driven. System 1200 can include, but is not limited to, a motor assembly 70 that can be attached to a master cylinder 70D. Master cylinder 70D can be in communication with a hydraulic line 70E. Hydraulic line 70E can extend from master cylinder 70D to a slave cylinder 70F. When motor assembly 70 displaces piston 70G, piston 70G can displace fluid in hydraulic line 70E, which can in turn cause displacement of slave piston 70H. In system 1200, slave piston 70H can include a protrusion 92 that extends into manipulator housing 78 and can cause displacement of driven element 62. The motor assembly 70 and master cylinder 70D can be located remotely from the driven component 34, for example, to reduce the size of the driven component 34 and simplify thermal management. The motor assembly 70 and master cylinder 70D may be located in any suitable location. In some configurations, any motor assembly 70 and master cylinder 70D may be located within the base 30 (FIG. 3). One or more hydraulic lines 70E from the master cylinder 70D may extend, for example, along the arm 32 (FIG. 3) to one or more slave cylinders 70H.

[0063] Referring now primarily to FIG. 18 , the drive component 34 can include a motor assembly 70. The motor assembly 70 can be powered and commanded from a location remote from the drive component 34. For example, power and commands from the base 30 ( FIG. 3 ) of the controller 15 ( FIG. 3 ) can be communicated to the drive component 34 via various cables or wiring 19 ( FIG. 3 ) in the arm 32 ( FIG. 3 ). Each motor assembly 70 can also be associated with a motor encoder 90A that senses rotation as the motor of the motor assembly 70 commutates. Feedback from the motor encoder 90A can be communicated to a location remote from the drive component 34, for example, via suitable cables or wiring 19 ( FIG. 3 ) in the arm 32 ( FIG. 3 ). The motor assembly 70 can be arranged into a first deck 71A and a second deck 71B, which can be positioned above the first deck 71A to minimize the size of the drive component 34. The drive component 34 may include, for example, without limitation, several first protrusions 92A and several second protrusions 92B. When the motor assemblies 70 are powered, the first protrusions 92A and second protrusions 92B controlled by each motor assembly 70 may be displaced. In some configurations, each first protrusion 92A and each second protrusion 92B may be driven by an individual motor assembly 70. In other configurations, one motor assembly 70 may drive multiple first protrusions 92A and multiple second protrusions 92B (e.g., using a suitable gearing arrangement). For example, in some configurations, one motor assembly 70 may be used to drive two protrusions 92A, 92B to displace equally in the same or opposite directions. This may be desirable in configurations where an actuator 54A (FIG. 4B), such as a pull wire, is used to actuate an operated component 38 (FIG. 16), as this will help ensure that one actuator (e.g., see 54A in FIG. 4B) can be pulled or wound at the same speed as another actuator (e.g., see 54A in FIG. 4B) is wound in or out.

[0064] Referring now primarily to FIG. 19 , the motor assembly 70 and drive element 60 are shown. The drive element 60 can include a drive screw 74 and a nut 76 that can interface with the drive screw 74. The drive screw 74 can generally be coaxial with the motor assembly 70. The motor assembly 70 can drive the screw 74, and rotation of the drive screw 74 can advance the nut 76 along the drive screw 74. The protrusions 92 can be shaped so that forces generated in the drive element 60 can be transmitted off-axis to the drive screw 74 and motor assembly 70. In the specific configuration shown, the protrusions 92 can exert a force along an axis that is substantially parallel to the axes of the motor assembly 70 and drive screw 74. The protrusions 92 can be an integral part of each nut 76, or the protrusions 92 can be separate components coupled onto each of the nuts 76. The protrusions 92 can also be attached to each nut 76 in a modular manner. For example, if the nut 76 drives two driven elements 62, an additional protrusion 92 may be coupled to the nut 76 (or may be coupled to a protrusion 92 already attached to the nut 76). The nut 76 may ride along a bearing. In an exemplary configuration, each nut 76 may have at least one bearing saddle 96, either attached to the nut 76 or, for example, as an integral part thereof. The nut 76 may have, for example, without limitation, two saddles 96 coupled to the nut 76. A load sensor 98 may be located in the load path associated with each motor assembly 70. The load sensor 98 may be, for example, without limitation, a load cell, a strain gauge, or any of the load sensor 98 configurations described herein. The load sensor 98 may provide information about the amount of force being transmitted to the operated component 38 ( FIG. 16 ). The load sensor 98 is further described elsewhere herein.

[0065] Referring now primarily to FIG. 20 , the drive component 34 is depicted with a portion of the drive component housing 72 removed. Each bearing saddle 96 of the nut 76 can travel along a linear motion bearing 94. The linear motion bearings 94 can be, but are not limited to, dovetail slide bearings. The nuts 76 can be spaced apart on the linear motion bearings 94 so that they do not contact and / or interfere with each other during operation of the drive component 34. The linear motion bearings 94 for the drive component 34 can include inner and outer linear motion bearings to reduce the longitudinal dimension of the drive component 34. In some configurations, the linear motion bearings 94 may include two pairs of outer and inner bearings. The outer and inner bearings can be parallel to each other. Each bearing can be shared by two nuts 76. Thus, while the configuration accommodates eight nuts 76, the longitudinal dimension of the linear motion bearings 94 need not be larger than necessary to accommodate two nuts 76 with sufficient spacing between them. The inner distance 93 between the protrusions 92A, 92B can be minimized to reduce the footprint of the manipulator 36 ( FIG. 16 ). The first protrusion 92A and the second protrusion 92B can each be “L” shaped. The legs 99 of the “L” shape can be sized so that the vertical span 101 can be aligned in a desired plane. The shape of the protrusions 92A, 92B can vary depending on the configuration. For example, instead of including a bend or forming an “L,” the protrusions 92A, 92B can extend at an angle from the body of the nut 76. The angle can allow for a linear path from the nut 76 to an axis through which force can be transmitted. Arc-shaped, “S” shaped, and other non-linear protrusions 92A, 92B may also be used. In other configurations, such as those in which the number of protrusions 92A and 92B on the nut 76 is greater than one, not all of the protrusions 92A, 92B need to be aligned in the same plane. Alternatively, the projections 92A, 92B connected to a single nut 76 may lie, for example, on parallel planes.

[0066] Referring now primarily to FIG. 21 , an alternative exemplary configuration of the motor assembly 70 and drive element 60 is shown. The linear motion bearing 94 ( FIG. 20 ) configuration, which can guide the progression of the nut 76, can be a first linear needle bearing assembly 91A and a second linear needle bearing assembly 91B. The linear needle bearing assemblies 91A, 91B can be highly rigid and capable of bearing high moment loads, which can be present with the nut 76 having protrusions 92 that transmit forces to off-axis locations. Each linear needle bearing assembly 91A, 91B can have a housing 79, which can be, for example, but not limited to, a “V” shape and includes an inner surface 79A that can serve as a wireway for the roller cage 71D ( FIG. 23 ) of the linear needle bearing 91A, 91B. In other configurations, another component of the linear needle bearing assemblies 91A, 91B can provide the wireway instead of the housing 79. The outer surface 79B of the housing 79 may be arcuate or rounded to allow the linear needle bearing assemblies 91A, 91B to be compact. The nut 76 can be held in place between the linear needle bearing assemblies 91A, 91B. A gap 79C between the first and second linear needle bearing assemblies 91A, 91B can allow the protrusion 92 to extend away from the nut 76 and transmit force to a desired axis. The desired axis can be an axis along which the driven element 62 (FIG. 16) can be displaced. A travel limiter 57 (FIG. 23) can be included on the linear needle bearing assemblies 91A, 91B to prevent movement of the nut 76 outside a predetermined range. The travel limiter 57 (FIG. 23) can be a mechanical stop, such as a wall, that blocks the travel of the nut 76 in various configurations.

[0067] Referring now primarily to FIG. 22 , the interior cross section taken at II ( FIG. 21 ) is shown. A nut 76 is included that can be constructed to be used with any of a variety of different protrusions 92. Specifically, the nut 76 can include a receiving feature 75 into which the protrusion 92 can be coupled. Each of the various different protrusions 92 may include a portion that can fit within the receiving feature 75. The desired protrusion 92 can be removably coupled to the nut 76 via, for example, but not limited to, a fastener 77. Any suitable fastener 77 may be used. In an alternative configuration, the protrusion 92 need not be removably coupled but may be ultrasonically welded, solvent bonded, glued, or otherwise permanently attached to the nut 76. Also included in FIG. 22 is a load sensor 98 that can measure the load in the load path of the drive element 60.

[0068] Referring now primarily to FIG. 23 , an exploded view of several linear needle bearing assemblies 91A, 91B is shown. The linear needle bearing assemblies 91A, 91B can include a housing 79. The outer surface 79B of the housing 79 can be arcuate or rounded. A first recess 79D and a second recess 79E can be included in the outer surface 79B and sized to cooperate with a retainer 79F that can hold the two housings 79 together when the linear needle bearing assemblies 91A, 91B are fully assembled. In an exemplary configuration, the retainer 79F can be a retaining ring or any other suitable retainer 79F, such as, but not limited to, a C-clip, a pin, and / or a threaded fastener. The inner surface 79A can be generally “C” shaped, but is not limited to being so, and can serve as a raceway for the needle bearings 71C of the linear needle bearing assemblies 91A, 91B. Each linear needle bearing assembly 91A, 91B may include, for example, 12 needle bearings 71C. The number of linear needle bearings 71C in each linear needle bearing assembly 91A, 91B may vary depending on the size of the needle bearings 71C and the forces expected to be present on the needle bearings 71C. In some configurations, the needle bearings 71C may be 1 to 2 mm in diameter, and 12 needle bearings 71C may be included per linear needle bearing assembly 91A, 91B. Each needle bearing 71C may be received within a needle bearing cage 71D when the linear needle bearing assemblies 91A, 91B are fully assembled. The needle bearing cage 71D may be shaped to fit against the inner surface 79A of the housing 79, allowing the needle bearings 71C to utilize the inner surface 79A as a wireway.

[0069] Continuing to refer to FIG. 23 , the nut 76 may include a first portion 76A and a second portion 76B. The first portion 76A and the second portion 76B may be coupled together when assembled. In an alternative configuration, the nut 76 may be a single monolithic component. The nut 76 may be shaped to allow the needle bearing cage 71D to fit around the nut 76 when the linear needle bearings 91A, 91B are fully assembled. In an exemplary configuration, the first portion 76A of the nut 76 may be shaped to accommodate the “C”-like shape of the needle bearing cage 71D and to allow the needle bearing 71C to use the exterior of the first portion 76A of the nut 76 as a guide channel. The first portion 76A may be, but is not limited to, an octagonal cross section. The nut 76 may be adapted to translate and displace in response to rotational displacement of the drive screw 74. In an exemplary configuration, the second portion 76B may be engaged with the drive screw 74, and the second portion 76B may be displaced in translation. When the second portion 76B is attached to the first portion 76A, the nut 76 may be displaced. The second portion 76B may vary depending on the type of drive screw 74 being used. For example, the second portion 76B may be a ball nut if a ball screw is used. If a lead screw is used, the second portion 76B may be a split nut, half nut, or other suitable type of nut. Alternatively, the second portion 76B may include a threaded receiving feature that may be threaded onto the drive screw 74.

[0070] Still further, and continuing to refer primarily to FIG. 23 , each needle bearing cage 71D can include a slot 71E (only the slot 71E of the linear needle bearing assembly 91A is visible in FIG. 23 ). The slot 71E can cooperate with a travel limiter 57 extending from the first portion 76A. The travel limiter 57 can be, for example, without limitation, a protrusion or ridge that can extend outward from the first portion 76A. When fully assembled, the travel limiter 57 extends into the slot 71E. As the nut 76 advances within the linear needle bearing assemblies 91A, 91B, the travel limiter 57 can prevent the needle bearing cage 71D and needle bearing 71C seated therein from moving beyond a predetermined range. For example, the travel limiter 57 can be employed to prevent the needle bearing cage 71D and needle bearing 71C from advancing outward from the housing 79. At the end of the range of displacement permitted by the travel limiter 57, the travel limiter 57 may abut against the edge of the slot 71E. At this point, the needle bearing cage 71D and the needle bearing 71C may be unable to further displace in that direction, and travel would be effectively limited using a mechanical stop. The length of the slot 71E may be substantially equal, but is not limited to being so. In an alternative configuration, the travel limiter 57 may not be included on the nut 76, but may be included on the housing 79. For example, in some configurations, a ridge that can serve as the travel limiter 57 may extend from the inner surface 79A into the slot 71E. In other configurations, the inner surface 79A may include one or several raised features that can limit the range of displacement of the needle bearing 71C and the needle bearing cage 71D. At least one keyed feature may be included on one or both of the linear needle bearing assemblies 91A, 91B to prevent them from rotating about the axis of the drive screw 74. This key feature may be, for example, a protrusion extending from the housing 79 that would encounter a stationary element to act as a mechanical interference. Alternatively, the protrusion from the stationary element may extend into a receiving structure within the linear needle bearing assemblies 91A, 91B.In some configurations, rotation may be prevented by fitting a protrusion 92 into a notch 75B in the receiving structure 75 of the nut 76.

[0071] Still referring to FIG. 23 , the nut 76 can be constructed so that it can be used with any of a variety of different protrusions 92. Specifically, the nut 76 can include a receiving feature 75 into which the protrusion 92 can be coupled. The receiving feature 75 can be a recess into the nut end 75A. The receiving feature 75 can also include a notch 75B to accommodate a portion of the protrusion 92 when the protrusion 92 is coupled into the receiving feature 75. Any suitable method for coupling the protrusion 92 into the receiving feature 75 can be used. A fastener 77 ( FIG. 22 ) can be used in some configurations. Alternatively, the protrusion 92 can be permanently coupled into the receiving feature 75.

[0072] Referring now primarily to FIG. 24 , the drive element 60 can be electrohydraulic operated. The drive element 60 can include, for example, but not limited to, a hydraulic slave cylinder 70F. The slave cylinder 70F can include a piston 70H (see FIG. 17B ) that can be displaced to cause displacement of a protrusion 92. The protrusion 92 can actuate the driven element 62 ( FIG. 17B ) to actuate a feature of the operated component 38 ( FIG. 17B ). The slave piston 70H can be guided by at least one linear motion bearing 94. Any suitable linear motion bearing 94 can be used, such as, but not limited to, those described in FIG. 23 and elsewhere herein. The protrusion 92 can be an integral part of the slave piston 70H ( FIG. 17B ) in some configurations. In an alternative configuration, the slave piston 70H ( FIG. 17B ) can be constructed to be usable with any of a variety of different protrusions 92. Specifically, slave piston 70H (FIG. 17B) may include a receiving feature (similar to receiving feature 75 of FIG. 23) into which protrusion 92 may be coupled. In some configurations, an intervening body (not shown) may be included between slave piston 70H (FIG. 17B) and protrusion 92. In such configurations, displacement may be transmitted to protrusion 92 through the intervening body. A hydraulic master cylinder 70D may be included and may drive slave cylinder 70F through hydraulic line 70E. Hydraulic master cylinder 70D may be driven by motor assembly 70. Motor assembly 70 may cause displacement of piston 70G (see FIG. 17B) within master cylinder 70D. When piston 70G (FIG. 17B) is displaced, slave piston 70H (FIG. 17B) within hydraulic slave cylinder 70F may be displaced as a result, because master cylinder 70D and slave cylinder 70F are connected via hydraulic line 70E. To monitor displacement, position sensor 90 may be associated with another component, such as part of motor assembly 70 or drive element 60. At least one pressure sensor 70I may also be included to monitor pressure in hydraulic line 70E.

[0073] Referring now to FIG. 25 , the motor assembly 70 may include a motor 70A, a gearhead 70B, and a bearing 70C for a drive screw 74A. Rotation of the drive screw 74A may, in turn, cause translational displacement of a nut 76A. The nut 76A may move in conjunction with a master cylinder piston 70G. In some configurations, the master cylinder piston 70G and the nut 76A may be coupled to one another. When the master cylinder piston 70G displaces, fluid within the attached hydraulic line 70E may also be displaced. The head 70J of the master cylinder piston 70G may include several sealing members 70K, such as, but not limited to, an O-ring or similar gasket member, which may ensure that fluid does not escape from the hydraulic line 70E. A pressure tap 70L may be attached to wiring 70M leading to at least one pressure sensor 70I. The pressure sensor 70I may collect data related to the pressure within the hydraulic line 70E via the pressure tap 70L and wiring 70M. Data from the at least one pressure sensor 70I may be provided as feedback to the controller.

[0074] Referring primarily to FIG. 26 , a load sensor 98 ( FIG. 20 ) may be associated with each motor 70 ( FIG. 20 ) in the drive component 34 ( FIG. 20 ). The load sensor 98 ( FIG. 20 ) may be any of a variety of conventional load sensor types. Alternatively, the load sensor 98 ( FIG. 20 ) may have electrical components that are remote from the load path and can be physically isolated, for example. The load sensor 98 ( FIG. 20 ) may include, for example, a mechanical component 150 disposed in the load path that can deform or displace proportionally to the load. This deformation may in turn be sensed or monitored by the electrical components of the load sensor 98 ( FIG. 20 ) located remote from the load path. The mechanical component 150 may include, but is not limited to, a flexible member, which may be a deformable body 152A. The deformable body 152A may have a first end 151A and a second end 151B. The example deformable body 152A shown in FIG. 26 is unloaded. The deformable body 152A can be shaped as an "S" beam, for example. In other configurations, the shape of the deformable body 152A can be any shape or configuration. The mechanical component 150 may optionally include a protrusion or flag 154 that can amplify any deformation of the deformable body 152A. The protrusion 154 may be coupled onto the deformable body 152A or may be an integral part of the deformable body 152A.

[0075] Referring primarily to FIG. 27 , when a load 156 is applied to at least one of the first end 151A and the second end 151B, at least a portion of the deformable body 152A can distort from its unloaded shape (see, for example, FIG. 26 ). The shape of the deformable body 152A may be selected based on where the distortion is desired to occur or how it is desired that the deformable body 152A will distort. The transverse piece 153A can distort under the load 156. More specifically, the angle 153B of the transverse piece 153A relative to the first end 151A and the second end 151B can be changed. The amount of distortion may be sensed or monitored to determine the load 156 being applied to the mechanical component 150.

[0076] Still referring to FIG. 27 , the amount of deflection that can occur for various ranges of load 156 on deformable body 152A may be controlled by modifying the shape and / or structure of deformable body 152A. In some configurations, it may be desirable for deformable body 152A to deform a greater amount or a greater percentage under a first range of load conditions as opposed to a second range of load conditions. For example, it may be desirable for deformable body 152A to deflect a greater amount or a greater percentage under low load conditions than under high load conditions. This may allow deformable body 152B to deflect a greater amount under load conditions that can be expected in a given device. In a specific configuration, deformable body 152A can be constructed such that the first range of load 156 can include loads from 0 to 50 pounds. The second range of load 156 can include, for example, any load 156 above 50 pounds. In the first range of load 156, deformable body 152A may be free to deflect in proportion to load 156. In a second range of the load 156, the deformable body 152A may be more resilient to deflection or may be substantially unable to deflect.

[0077] Referring now to FIG. 28A , the mechanical component 150B may include a deformable body 152C that may include a stop protrusion 153 that may extend toward a cross piece 153A. As the load 156 increases on the deformable body 152C, the gap 153D between the stop protrusion 153 and the cross piece 153A may decrease. Eventually, the cross piece 153A will contact the stop protrusion 153 and be prevented from continuing to displace as the load 156 increases. The amount of load 156 at which this contact can occur may be the upper limit of a first load range. In some specific configurations, the amount of load 156 at which contact occurs may be, for example, but not limited to, 50 pounds. The amount of load at which contact occurs can be controlled based on the structure, materials, and geometry of the deformable body 152C. The deformable body 152C may therefore be constructed such that distortion of the deformable body 152C can provide greater resolution of the load 156 at low load conditions or within a first range of loads. The target resolution can be, for example, without limitation, less than 0.1 pounds. In some configurations, the target resolution within a first range of load conditions may be less than 0.1 pounds, while mechanical component 150B may provide a more binary indication within a second range of load conditions. For example, within the second range of load conditions, mechanical component 150B may serve to provide a "yes" or "no" indication of whether the amount of applied load 156 is within the second range.

[0078] Referring primarily to FIG. 28B, mechanical component 150C can include a threaded insert 166A in place of stop protrusion 153 (FIG. 28A). The threaded insert 166A can be advanced or retracted a desired amount out of deformable body 152D to alter the size of gap 153D. Movement of threaded insert 166A can change the point at which stop 166E can be encountered and can alter the force required before stop 166E is encountered. Thus, the load range can be flexible and perhaps user-defined, for example. The threaded insert 166A and / or deformable body 152D can include markings 166G that can indicate the amount of load 156 at which stop 166E will be contacted to facilitate defining the desired range. In the exemplary configuration, the threaded insert 166A shown provides a compression stop.

[0079] 28C , the mechanical component 150D can include a threaded insert 166A to provide a tension stop. The threaded insert 166A can be inserted through the deformable body 152E and anchored into the stationary element 166H. This can be achieved using a threaded engagement. The threaded insert 166A can also be partially, fully, or not threaded at all, but instead can be glued / welded to the stationary element 166H, or can be coupled to the stationary element 166H using a fastening, interference fit, or any other arrangement. The threaded insert 166A can have no effect on the deflection of the deformable body 152E until the gap 153E is reduced to zero and the deformable body 152E encounters the head or stop 166E of the threaded insert 166A.

[0080] 28D, the deformable body 152E may distort when tension 156 is applied within the mechanical component 150E. The angle 153B (FIG. 27) of the cross piece 153A relative to the first end 151A and second end 151B of the deformable body 152E may be changed. Applying tension can stretch and elongate the deformable body 152E. Because the threaded insert 166A can be fixedly coupled to the stationary element 166H, the deformable body 152F may only be stretched by tension until the first end 151A of the deformable body 152E abuts the head 166E of the threaded insert 166A.

[0081] Referring now to FIG. 28E, the manner in which the deformable body 152G may distort can also be affected by the shape of the deformable body 152G. In some configurations, the deformable body 152G may be coupled to or mounted to a component of the drive system that may distort due to runout of a portion of the drive system. To mitigate any effects of runout or allow for more generous runout tolerances, the mechanical component 150F may be constructed to have a low tendency to distort due to any rotation about a secondary axis or as a result of any other rotational eccentricity of the drive shaft. The deformable body 152G may include several thinned spans 162, which may be defined by channels 164 recessed or cut through the deformable body 152G. The outer portion 163 of the deformable body 152G may be relatively thick and serve as a buttress against distortion due to runout. The outer portion 163 of the deformable body 152G may also serve to receive a threaded insert 166A ( FIG. 28D ). At least one side of the deformable body 152G may include a gap 168. The configuration of the deformable body 152G and the arrangement of the channels 164 and thinned spans 162 may be selected to make the deformable body 152G resilient against undesired distortion. In some configurations, the configuration of the deformable body 152G and the arrangement of the channels 164 and thinned spans 162 may cause the deformable body 152G to behave generally as several four-bar links. Such a parallelogram frame configuration may strengthen the deformable body 152G against undesired deformation. Additional channels 164 and thinned sections 162 may be added to increase the amount of distortion caused by a given load. The mechanical component 150F may also include a stop surface 166. When the deformable body 152G is distorted under pressure, the gap 168 between the stop surface 166 and the remainder of the deformable body 152G may decrease until contact is made with the stop surface 166. The stop surface 166 can limit or prevent distortion of the deformable body 152G when the load on the deformable body 152G reaches a desired amount.The mechanical component 152G may be, for example, without limitation, more responsive to a first range of load than to a second range of load. The stop surface 166 may be replaced or supplemented with a threaded insert 166A (FIG. 28D). In configurations including a flag or protrusion 154, the protrusion 154 may be sized to generate a desired amount of amplification of deflection of the deformable body 152G. When a load 156 (FIG. 28D) is present, the displacement of a point on a portion of the protrusion 154 that is distal-most of the deformable body 152G relative to its unloaded position is proportional to the displacement of the protrusion 154. Nora Jiang Angle protrusion multiplied by A longer protrusion 154 may be used to generate further amplification.

[0082] 29, the load sensor 98A may include an electrical component 160A, for example, but not limited to, a potentiometer. If the electrical component 160A is a potentiometer, when the protrusion 154 is displaced, a wiper may be moved across a resistive element of the potentiometer, changing the resistance. By measuring the resistance, it is possible to determine the amount of displacement of the protrusion 154. Because the amount of displacement is proportional to the load 156, the load sensor 98A may use the value of the measured resistance to determine the load 156.

[0083] 30A , the load sensor 98B can include electrical components 160B, such as, but not limited to, an optical sensor. Any of a variety of optical sensors may be used, such as, but not limited to, a laser displacement sensor. Alternatively, a camera may be used to monitor and track the location of the protrusion 154 over time. In some configurations, the protrusion 154 may include a fiducial reference 157, such as, but not limited to, a grid or pattern, color markings, or the like, that can aid in tracking the displacement of the protrusion 154 and, therefore, determining the load 156.

[0084] Referring now to FIG. 30B , the load sensor 98D can include an electrical component 160E. The electrical component 160E can include a light emitter 160F and a light receiver 160G. The light emitter 160F can shine light onto a reflective protrusion 154A on the mechanical component 150. The reflective protrusion 154A can reflect light from the light emitter 160F to the light receiver 160G. As the load 156 on the mechanical component 150 changes, the orientation of the reflective protrusion 154A can also change. As a result, light reflected from the reflective protrusion 154A can be reflected to a different portion of the light receiver 160G. The light emitter 160F can include, for example, one or more lasers or focused light beam emitters. The reflective protrusion 154A can include a light-colored or mirrored surface onto which light from the light emitter 160F can be projected. The receiver 160G may include one receiver 160G or an array of receivers 160G, which may be a reflective receiver such as an optical sensor. As the mechanical component 150 distorts proportionally to the load 156, the location and / or intensity of the reflected light may be tracked and a determination of the load 156 may be made accordingly.

[0085] 30C, the load sensor 98E can include an electrical component 160H. The electrical component 160H can include a light source 160I and an optical sensor 160J. The optical sensor 160J can include, for example, a camera having a CCD or CMOS chip. The light source 160I can generate light that can illuminate a portion of the protrusion 154. The optical sensor 160J can be positioned such that the shadow of the protrusion 154 is within the field of view of the optical sensor 160J. The position of the shadow can be tracked by the optical sensor 160J, and a determination of the load 156 can be made accordingly. In some configurations, the light source 160I can be positioned on one side of the protrusion 154, while the optical sensor 160J can be positioned on the opposite side of the protrusion 154. Alternatively, or in addition, the protrusion 154 can include one or more slits, slots, gaps, openings, or the like 154B through which light from the light source 160I can pass. Slit 154B may change location as protrusion 154 displaces in proportion to load 156 on mechanical component 150. Optical sensor 160J may monitor the location of slit 154B instead of, or in addition to, the location of the shadow of protrusion 154 to determine the amount of distortion of mechanical component 150. The distortion may be analyzed to determine the load 156 on mechanical component 150.

[0086] 31A , the load sensor 98C may include an electrical component 160C, such as, but not limited to, a magnetic sensor, such as a Hall Effect sensor or a Hall Effect sensor array. In such a configuration, at least one magnet 158, such as, but not limited to, a neodymium rare earth magnet, may be attached to or embedded in the protrusion 154. In a configuration in which the electrical component 160C includes a Hall Effect sensor, the Hall Effect sensor may be used to determine the position of the protrusion 154 based on a Hall voltage generated by the magnetic field of the at least one magnet 158 ​​as the protrusion 154 is displaced. Any number of other sensing arrangements may be used, such as, but not limited to, capacitive, ultrasonic, and inductive sensing.

[0087] 31B, the load sensor 98F may include an electrical component 160K with a non-contact sensor. The sensor may be, for example, an inductive or capacitive sensor. As the protrusion 154 displaces proportionally to the load 156 on the mechanical component 150, the capacitance and inductance may change predictably based on the location of the protrusion 154. The capacitance and inductance values ​​may be monitored to determine the location of the protrusion 154 and, consequently, the amount of load 156 on the mechanical component 150.

[0088] 32 and 33 , the mechanical component 150H may include an “S” beam 170. A protrusion 174 may be coupled to a central transverse piece 172 of the “S” beam 170. The protrusion 174 may be attached to the central transverse piece 172 in any suitable manner, such as, but not limited to, via fasteners. Alternatively, the protrusion 174 may be integrally formed as part of the “S” beam 170. The ratio of the length of the protrusion 174 to the “S” beam 170 may be approximately 3:1, but is not limited to being so. A void 176 may extend through the “S” beam 170 in a direction substantially parallel to the protrusion 174 when the protrusion 174 is in the unloaded position. The void 176 may be sized to accommodate the drive screw 74 ( FIG. 16 ) or other portions of the drive element 60 ( FIG. 16 ). In some configurations, the void 176 may be sized such that at least a portion of the motor assembly 70 ( FIG. 16 ) may be positioned inside the void 176. The "S" beam 170 may also include a stop protrusion 175 (described elsewhere herein). The mechanical component 150H may also include a mounting feature 178, which may include, but is not limited to, a raised plateau with a threaded hole 178A. The "S" beam 170 can be attached to a stationary housing (e.g., the drive component housing 72 ( FIG. 18 )) using the mounting feature 178 to help ensure that any displacement of the "S" beam 170 is the result of load deviations in the load path associated with the "S" beam 170. In other configurations, the mounting feature 178 may be a mounting bracket or rail. In other configurations, multiple mounting features 178 may be included. For example, mounting features 178 may be included on both the first side 170A ( FIG. 32 ) and the second side 170B ( FIG. 33 ) of the "S" beam 170. The "S" beam 170 may also include a number of threaded holes 179 that may allow the "S" beam 170 to be coupled to the motor assembly 70 (FIG. 16), bearings (such as linear needle bearing assemblies 91A (FIG. 21) and 91B (FIG. 21)), or other portions of the drive element 60 (FIG. 16).

[0089] Referring now to FIG. 34, an enlarged view of region J in FIG. 33 is depicted. The "S" beam 170 can include a stop projection 153. A gap 153D can exist between the stop projection 153 and the cross piece 172. The cross piece 172 can include a thinned or flexible portion 180 that is most proximal to the body of the "S" beam 170. A thinned portion 180 may be included at each end of the cross piece 172. The thinned portion 180 can act as an elastically deformable section. For structural strength, the thinned portion 180 can have, for example, without limitation, an arched wall 180A. This need not be the case in other configurations. The location and thickness of the thinned portion 180 can be selected to help the "S" beam 170 have a desired displacement behavior under given load conditions. Additionally, the material selected for the "S" beam 170 can be selected for its elastic modulus and yield strength, among other properties. Possible materials can include, but are not limited to, any metal, composite material, and other materials such as plastic, magnesium, steel, aluminum, and titanium. In applications where low loads are expected, materials such as plastic or magnesium may be used. In high load applications, materials such as steel may be used. In other applications, materials such as aluminum or titanium may be used.

[0090] Referring primarily to FIG. 35A , mechanical component 150I can include a deformable body 173, which can be designed to mitigate any effects of runout on deformable body 173 during operation. Deformable body 173 can also include a number of mounting points 181, which can allow deformable body 173 to be attached to a stationary housing (e.g., drive component housing 72 ( FIG. 16 )), a motor assembly 70 (see FIG. 35B ) for an associated driveline, and / or bearings (e.g., linear needle bearings 91A and / or 91B ( FIG. 21 )). Cavity 176 can be sized such that motor assembly 70 ( FIG. 35B ) can be at least partially housed within deformable body 173. Additionally, cavity 176 can be sized to allow drive screw 74 to extend into deformable body 173 and engage with motor assembly 70 ( FIG. 35B ) housed therein.

[0091] Still referring to FIG. 35A , the deformable body 173 can include a flag or protrusion 174A that can be coupled thereto. The protrusion 174A can be mounted within a shoe 175A. The protrusion 174A and / or the shoe 175A can include a detent or step feature that can help position and / or lock the protrusion 174A in a fixed position when the mechanical component 150I is assembled. In an alternative configuration, the shoe 175A can allow the protrusion 174A to slide back and forth along, for example, but not limited to, the axis 175C of the protrusion 174A. Thus, the amount of displacement of the magnet 158 ​​within the protrusion 174A for a given load can be modified. One or more set screws or the like can be used to hold the protrusion 174A in place when the protrusion 174A has been slid into position. The protrusion 174A may also include a cutout 173A, which may allow the protrusion 174A to be slightly compressed when in the shoe 175A. The cutout 173A may allow the section of the protrusion 174A received in the shoe 175A to act as a spring, which may exert a force against the wall 175D of the shoe 175A. This force may help retain the protrusion 174A within the shoe 175A. The protrusion 174A may include a bent portion 175E, which may allow for placement of the magnet 158 ​​behind and / or along the motor assembly 70 (FIG. 5), possibly allowing for space savings. The bent portion 175E may divide the protrusion 174A into a pre-bend portion 174F and a post-bend portion 174G. If necessary, a magnetic shielding material, such as mu metal, may be included to shield the motor assembly 70 (FIG. 16) and / or a portion of the protrusion 174A. The protrusion 174A may have a shape different from that described herein. The shape or configuration of the protrusions 174A can be selected to best fit any space constraints that may exist in various applications.

[0092] 35B, the load sensor 98 may include a mechanical component 150J and an electrical component 160. A gap 176 within the mechanical component 150J may be sized to allow the motor assembly 70 to be at least partially housed within the deformable body 173. The motor assembly 70 may be attached to the mechanical component 150J via a mounting point 181. Additionally, the gap 176 may be sized to allow the drive screw 74 to extend into the deformable body 173 and engage with the motor assembly 70. As the flag or protrusion 174B is displaced, the magnet 158 ​​attached to the protrusion 174B may sweep along a path within several Hall effect sensors 160D arrayed on a PCB 210 included as part of the electrical component 160 of the load sensor 98. Data provided from the Hall effect sensors 160D may be processed by the controller 15 (FIG. 1) to determine the location of the magnet 158. Since the location of the magnet 158 ​​depends on the amount of load 156 (FIG. 31) applied to the mechanical component 150J, the position data can be used to determine the amount of load 156 (FIG. 31). The electrical component 160, which comprises a Hall Effect sensor array, is disclosed in US Pat. No. 6,499,499, filed Dec. 21, 2012, entitled "System, Part Number: 150J." The method may be similar to that described in U.S. Patent Publication No. 20130184676, entitled "Method, and Apparatus for Estimating Liquid Delivery."

[0093] 35C, mechanical component 150J can include insert 166A, which can be a threaded insert, extending into or through deformable body 173. Mechanical component 150J can also include an adjustable spacer, such as nut 167, on threaded insert 166A. Threaded insert 166A and nut 167 can provide compression and tension stops for deformation of deformable body 173. Threaded insert 166A can be used to deform deformable body 173 to a greater amount or at a greater rate under a first range of load conditions as opposed to a second range of load conditions.

[0094] 35D-35E (enlarged views of enlarged views of regions 35D and 35E, respectively, of FIG. 35C), in an exemplary configuration, the threaded insert 166A and the nut 167 are positioned such that a tension stop gap 166B (FIG. 35D) and a compression stop gap 166C (FIG. 35E) exist. The tension stop gap 166B (FIG. 35D) can occupy the space between the threaded insert first surface 166D (FIG. 35D) and the deformable body first surface 173C (FIG. 35D). The compression stop gap 166C (FIG. 35E) can occupy the space between the nut surface 167A (FIG. 35E) and the deformable body second surface 173D (FIG. 35E). The second surface 173D (FIG. 35E) can be on the opposite side of the deformable body 173 from the first surface 173C (FIG. 35D). The size of the tension stop gap 166B (FIG. 35D) can be selected to define a first range of tensile loading conditions across which the deformable body 173 can be substantially free to deflect or deform. Loads within a second tensile loading range outside the first tensile loading range can cause little or no distortion of the deformable body 173 because a stop provided by the threaded insert 166A (FIG. 35D) can be encountered and prevent further deflection. The size of the compression stop gap 166C (FIG. 35E) can be selected to define a first range of compressive loading conditions across which the deformable body 173 can be substantially free to deflect or deform. Loads within a second compressive load range outside the first compressive load range may cause little or no distortion of deformable body 173 because stops provided by threaded insert 166A ( FIG. 35D ) and nut 167 ( FIG. 35E ) may be encountered and prevent further distortion. In some configurations, threaded insert 166A ( FIG. 35D ) may be advanced or retracted a desired amount into or out of deformable body 173 to alter the size of gaps 166C ( FIG. 35E ) and 166B ( FIG. 35D ). The advancement or retraction can, in turn, alter the load at which the stop is encountered. The ranges are flexible and may be, for example, user-defined.The threaded insert 166A (FIG. 35D) and / or the deformable body 173 may include markings 166G (FIG. 28B) that can indicate the amount of load 156 (FIG. 28A) that the stop will be contacted at to facilitate defining the desired range.

[0095] 35D, when tension is applied to the deformable body 173, the tension stop gap 166B can decrease. A mechanical stop can be encountered when the first surface 166D of the head 166E of the threaded insert 166A and the first surface 173C of the deformable body 173 come into contact. The force at which the surfaces 166D, 173C meet can be the boundary between the first and second tensile load ranges. Additionally, the head 166E of the threaded insert 166A can be replaced with a second nut (not shown) that can engage with threads (not shown) on the end of the threaded insert 166A. The second nut can be advanced along the threads to modify the size of the tension stop gap 166B. The second nut can be placed in a position suitable for the desired first tensile load range.

[0096] Referring now to FIG. 35E , a compression stop gap 166C can occupy the space between the first surface 167A of the nut and the second surface 173D of the deformable body. The size of the compression stop gap 166C can be selected to define a first range of compressive load conditions across which the deformable body 173 can be substantially free to deflect or deform. When a compressive force is exerted on the deformable body 173, the compression stop gap 166C can decrease. A mechanical stop can be encountered when the first surface 167A of the nut 167 and the second surface 173D of the deformable body 173 contact. The force at which these surfaces 167A, 173D contact can be the boundary between the first and second compressive load ranges. Different size nuts 167 can be used to modify the size of the compression stop gap 166C. The nut 167 used can be selected to match the force value desired for the first compressive load range.

[0097] Referring primarily to FIG. 35F , the threaded insert 166A may extend through the threaded insert-receiving hole 173E. In some configurations, less than the entire threaded insert 166A can be threaded, and the threaded insert 166A may not be in threaded engagement with the threaded insert-receiving hole 173E. Configurations in which less than the entire threaded insert 166A can be threaded can allow the deformable body 173 ( FIG. 35C ) to freely deflect over a desired load range. In some configurations, only the portion of the threaded insert 166A onto which the nut 167 is engaged may be threaded. The threaded insert 166A may include a threaded mounting hole 166F. The threaded mounting hole 166F can allow a fastener 169 to couple into the threaded insert 166A. The fastener 169 may fixedly couple the threaded insert 166A to a stationary element or structure 166H that can ensure that the threaded insert 166A does not displace during loading of the deformable body 173 (FIG. 35C). In other configurations, any other suitable method of fixing the position of the threaded insert 166A may be used.

[0098] Referring now primarily to FIG. 36 , the motor assembly 70 can be arranged to apply a force to the drive screw 74. The arrangement including the motor assembly 70 and the drive screw 74 can include a mechanical component 150K. The mechanical component 150K can include an “S” beam 170. A coupling block 203 can be attached to the motor assembly 70 and, in some configurations, can be used to facilitate coupling of the motor assembly 70 to the “S” beam 170. The coupling block 203 can include, for example, without limitation, a threaded hole 209 that can allow a fastener (not shown) to couple the “S” beam 170 to the coupling block 203. Any other suitable means of coupling the motor assembly 70 to the “S” beam 170 may be used. A flag or protrusion 174A attached to the “S” beam 170 can extend parallel to the longitudinal axis 200A of the motor assembly 70 and has a gap 200B ( FIG. 37 ) over the motor assembly 70. This configuration can allow for a reduction in the size of the load sensor 98 (FIG. 35B) and motor assembly 70 pair.

[0099] Referring now primarily to FIG. 37 , the drive screw 74 can pass through a gap 176 in the “S” beam 170. Mounting features 178 can be included on the “S” beam 170 and used to couple a portion of the “S” beam 170 to a stationary structure or housing 166H. In some configurations, the motor assembly 70 is self-floating and not fixedly coupled to the stationary housing 166H. As the load in the drive path increases, the motor assembly 70 and drive screw 74 can displace. Because the “S” beam 170 is coupled to the motor assembly 70 but fixed to the stationary housing 166H, the “S” beam 170 can deform as a result of this displacement. In other configurations, another portion of the drive train can be floating. For example, the end 202C of the lead screw 74 driven by the motor assembly 70 can be retained in a slip coupling (not shown). Alternatively, motor assembly 70 may include a gearhead 70B (FIG. 36) whose gears are wide enough to allow some axial displacement between them during operation.

[0100] Referring now to FIG. 38 , the “S” beam 170 of some load sensors 98 ( FIG. 35B ) can be included on the drive component 34. In configurations where the motor assembly 70 is free-floating or not fixedly coupled to the drive component 34, when a load is exerted on the motor assembly 70 through an associated drive screw 74 ( FIG. 37 ), the motor assembly 70 may displace slightly. The displacement may distort the “S” beam 170 ( FIG. 37 ). The distortion of the “S” beam can displace a protrusion 174 from an orientation that is substantially parallel to the motor assembly 70. The displacement of the protrusion 174 may be read by a sensor on the electrical component 160 ( FIG. 35B ) of the load sensor 98 ( FIG. 35B ). In some configurations, the sensor may be at least one Hall Effect sensor 160D that can track the position of the magnet 158 ​​on the protrusion 174. One or more sensors, such as Hall effect sensors 160D, can be included on PCB 210 of electrical component 160 (FIG. 35B) to enable intercomparison between Hall effect sensors 160D as any one of prongs 174 moves. Such intercomparison can help detect the displacement of prongs 174 with an additional degree of certainty, providing redundancy in the system and being useful in fault detection. A pair of tracks 214B, 214C can be included as a pair of drive components 34 and can include slots 214A into which the ends of prongs 174 extend. Tracks 214B, 214C may constrain the movement of prongs 174 during operation, which can help increase the accuracy of load sensor 98 (FIG. 35B). Accuracy in this context refers to minimizing deviations of magnet 158 ​​from the expected path, which can alter the output from Hall effect sensors 160D and distort the load reading.

[0101] 39-40, a diagram of the driving motor assembly 70 and associated drive element 60, including the lead screw 74, is shown. "V"-shaped linear needle bearing assemblies 91A and 91B can be attached to a mechanical component 150I for a load sensor 98 (FIG. 35B). The motor assembly 70 can be partially housed within and mounted to the mechanical component 150I. The outer portion 173B of the mechanical component 150I can be thickened to prevent distortion of the mechanical component 150I due to runout. The nut 76 of the driven element 60 can be constructed to be used with any of a variety of different protrusions 92 (FIG. 40). The protrusions 92 (FIG. 40) do not have to be an integral part of the nut 76. The protrusions 92 (FIG. 40) can be attached to the nut 76 using any coupling method, for example, but not limited to, fasteners. The coupling method may allow the same nut 76 to be used with any of multiple protrusions 92 (FIG. 40). The protrusion 92 (FIG. 40) can include a protrusion body 92D and an interface connection portion 92E. The protrusion body 92D can span the distance from the nut 76 to the axis along which it is desired to transmit the force. The interface connection portion 92E can be positioned along the axis along which it is desired to transmit the force and can be the portion of the protrusion 92 (FIG. 40) through which the force is ultimately transferred.

[0102] Still referring to FIGS. 39-40 , drive element 60 can include, for example, but not limited to, position sensors 90A ( FIG. 39 ) and 90B ( FIG. 40 ). Specifically, motor encoder 90A ( FIG. 39 ) and linear potentiometer 90B ( FIG. 40 ) can be included. Linear potentiometer 90B ( FIG. 40 ) can have a wiper 90C ( FIG. 40 ) that can move with or be connected to nut 76. Wiper 90C ( FIG. 40 ) can move across a resistance element of potentiometer 90B ( FIG. 40 ) as nut 76 is reciprocated back and forth within linear needle bearing assemblies 91A, 91B. Linear potentiometer 90B ( FIG. 40 ) can provide feedback regarding the position of nut 76 and protrusion 92 as they are displaced by operation of motor assembly 70. The position of the nut 76 and lug 92 (FIG. 40) may be tracked by encoder counter counts from the motor encoder 90A (FIG. 39). When used in conjunction with the linear potentiometer 90B (FIG. 40), encoder counter tracking may provide a level of redundancy and allow for cross-checking of feedback data from either of the position sensors 90A (FIG. 39) and 90B (FIG. 40) that monitor the movement of the drive element 60.

[0103] 40A-1, 40A-2, and 40A-3, in some configurations, one motor 15B1 can be used and cams 15B2 / 15B13 can drive jaw opening / closing drive pins 15B3 / 15B4, respectively. In some configurations, there can be a segment of rotation of cams 15B2 / 15B13 that can park pins 15B3 / 15B4 in retracted position 15B5 (FIG. 40A-1). Jaw opening / closing pins 15B3 / 15B4 can be positioned at jaw closing extreme advance 15B9 (FIG. 40A-2) based on the position of cams 15B2 / 15B13 in jaw closed position 15B10 (FIG. 40A-2). Jaw opening / closing pin 15B3 / 15B4 can be positioned at the opposite extreme of travel 15B11 (FIG. 40A-3) based on the position of cam 15B2 / 15B13 at the opposite extreme of travel 15B12 (FIG. 40A-3). In some configurations, a subassembly including cam 15B2 / 15B13 and motor 15B1 can be floated axially along output pin 15B3 / 15B4, and a spring (not shown) can be applied to the subassembly to remove repulsion from the system.

[0104] 40B, cams 15B2 / 15B3 can be shaped according to the desired positioning of jaw opening / closing pins 15B3 / 15B4, which can be positioned within cams 15B3 / 15B4, respectively, based on the desired relative movement of jaw opening / closing pins 15B3 / 15B4.

[0105] 40C, the jaw opening / closing pin 15B3 / 15B4 can include a roller 15B6 that can be mounted on the jaw opening / closing pin 15B3 / 15B4 on a mounting peg 15B7. The roller 15B6 can enable movement of the jaw opening / closing pin 15B3 / 15B4 within a path defined by the cam 15B2 / 15G13.

[0106] Referring now to FIG. 40D, the path of jaw opening / closing pin 15B3 (FIGS. 40A-1 to 15A-3) (and therefore the height of jaw opening / closing pin 15B3 (FIGS. 40A-1 to 15A-3)) can be traced for cam 15B2 according to cam centerline 15D1, and the path of jaw opening / closing pin 15B4 (FIGS. 40A-1 to 15A-3) can be traced for cam 15B13 according to cam centerline 15D4. The negative slope segment 15D3 of cam centerline 15D1 indicates that jaw opening / closing pin 15B3 (FIGS. 40A-1 to 15A-3) is descending during its travel in the main portion of the cam path of cam 15B2. The positive slope segment 15D2 of cam centerline 15D4 indicates that jaw opening / closing pin 15B3 (FIGS. 40A-1 to 15A-3) is ascending during its travel in the main portion of the cam path of cam 15B13. In some configurations, a 115° offset between cams 15B2 and 15B13 (indicated by the 11.54 dimension) can position jaw opening / closing pins 15B3 / 15B4 to rise and fall according to a predefined schedule, for example, in opposite directions as indicated by opposing track ramps 15D3 / 15D2. Cams 15B2 / 15B13 (FIG. 40B) can rotate 240°, as indicated by the 24.09 dimension, for a total cam rotation of 355°. The stroke of each jaw opening / closing pin 15B3 / 15B4 (FIGS. 40A-1 through 40A-3) is indicated by the 10 mm dimension.

[0107] Referring now to Figures 40E and 40F, with respect to rotational compliance, the reaction torque generated by the motor / gearbox / ballscrew can be measured by the rotary flexure 15E12. Specifically, the torque applied to the ballscrew shaft can be measured by measuring the reaction torque applied to the housing of the gearbox 15E2. The actuator assembly 15E1 can include, but is not limited to, a motor 15E9 coupled to the gearbox 15E2 and an integrated ballscrew shaft 15E3. A ball nut 15E4 can travel within the rotary flexure 15E12. A gooseneck arm 15E5 can transfer axial load from the ball nut 15E4 to a pin 15E10, which can be guided through a linear ball bearing 15E6. A sensor driver mounted on the printed circuit board 15E7 can receive sensor data through sensors 15E8-1 to 15E8-3, such as, but not limited to, Hall sensors. Sensors 15E8-1 and 15E8-2, in conjunction with magnet 15E11, can collect sensor data that can be used, for example, to measure the approximate absolute position of ball nut 15E4 and, therefore, the approximate absolute position of actuator pin 15E10. Sensor 15E8-3 can collect sensor data that can be used to measure the rotational displacement of the gearbox 15E2 and motor 15E9 assembly. The axial force in the shaft of ball screw 15E3 can be determined based on the rotational spring constant of flexure 15E12 and the pitch and efficiency of ball screw 15E3. Rotation of flexure 15E12 near gearbox 15E2 can have travel limits that can prevent over-rotation and yielding of flexure 15E12. The coupling between gearbox 15E2 and flexure 15E12 can include bushing material to allow flexure 15E12 to rotate freely.

[0108] Referring now to FIG. 40G, the flexure assembly 15G1 may include, but is not limited to, a motor 15E9, a gearbox 15E2, a ball screw 15E3, a PCB 15E7, a flexure 15E12, and a PCB spacer 15G2. The motor 15E9 coupled to the gearbox 15E2 may drive the ball screw 15E3. The flexure 15E12 may surround the ball screw 15E3 and provide rotation of the flexure assembly 15G1, which may be measured based on data collected from the sensor 15E8-3. The sensor 15E8-3 may be mounted on the PCB 15E7. The PCB 15E7 may be mounted on the flexure using, for example, the PCB spacer 15G2. The PCB 15E7 may process data from the sensor 15E8-3 to determine the rotation of the flexure assembly 15G1.

[0109] 40H, the ball screw 15E3 can include a connecting shaft 15H1 that can operably couple the ball screw 15E3 with a gearbox 15E2 (FIG. 40G). The parameters of the ball screw 15E3 can vary according to the requirements of the ball nut 15E4 (FIG. 40E).

[0110] Referring now to FIG. 40I, flexure 15E12 can include, but is not limited to, gearbox mounting cavity 15J1 and housing mounting cavity 15J6. PCB 15E7 (FIG. 40E) can be mounted on flexure 15E12 in mounting cavity 15J5. Flexure 15E12 can include sensor recess 15J7, which can provide space for sensor 15E8-3 (FIG. 40E). Flexure 15E12 can include legs 15J8, which can flexibly couple flexure gearbox end 15J9 with flexure PCB mount end 15J10. Cutouts 15J11 can control the flexibility of flexure 15E12. The cavity 15J2 between the surrounding legs 15J12 / 15J13 can accommodate a ball nut 15E4 (FIG. 40E) and a gooseneck arm 15E5 (FIG. 40E).

[0111] Referring now to FIG. 40J, the tensioning assembly 15K1 can enable controlled movement of the control cable 15K8 through the lumen 15K5. The layout of the tensioning assembly 15K1 on the cable drive capstan housing 15T1 can allow for sheave engagement and unobstructed access through the lumen 15K5, which can allow, for example, but not limited to, the introduction and passage of instruments through the lumen 15K5. The tensioning assembly 15K1 can include, but is not limited to, a swing arm 15K4, which can allow tension to be supplied to the cable 15K8 around the capstan shaft 15K6, the cable idler groove 15K2, and the cable take-up idler 15K9. The cable 15K8 can terminate within the capstan shaft 15K6. The pulley box drive shaft 15K21 can terminate flush with the cable drive capstan housing 15T1. The spur gear 15Y5 (FIG. 40S) of the pulley box drive shaft 15K21 can operably couple the cable drive actuator module 15K20 (FIG. 40L) to the cable / pulley assembly through gear meshing with a gear (not shown) mounted on the capstan shaft 15K6 at the shaft collar 15T10 (FIG. 40T). The cable drive actuator module 15K20 (FIG. 40L) can propel the control cable 15K8 within the lumen 15K5. The cable drive capstan housing 15T1 can provide a mounting and coupling platform for elements of the tensioning assembly 15K1. The deployment cable 15K3 can be used in the deployment phase of flexure and allows for manual tensioning. The pulley box assembly 15K1 can include at least one pulley box drive shaft 15Y1 that can operably couple the cable drive capstan housing 15T1 to the cable drive assembly 15W1 in the cavity 15T2.

[0112] Referring now to FIG. 40K, the cable drive actuator module 15K20 can be operatively coupled to the cable drive capstan housing 15T1 through the cable drive actuator plate 15W2.

[0113] Referring now to FIG. 40L-1, the cable drive actuator module 15K20 can include a cable drive actuator plate 15W2 and at least one cable drive assembly 15W1-1 / 15W1-2.

[0114] Referring now to FIG. 40L-2, the first configuration of cable drive assembly 15W1-1 can include, but is not limited to, a hollow shaft actuator 15W3-1, such as, for example, but not limited to, a HARMONIC DRIVE FHA-C size 11. The first configuration of cable drive assembly 15W1-1 can include a friction interface that can include a combination of a harmonic drive output shaft 15W6 / 15W7, a retaining ring 15W8, a first harmonic drive output hub 15W4, and a wave washer 15W5. The wave washer 15W5 can be positioned between the first harmonic output drive 15W4 and the harmonic drive output shaft 15W6 to provide a spring action that reduces / avoids rebound. The retaining ring 15W8 can be positioned on the harmonic drive output shaft 15W6. A second harmonic drive output hub 15W9 can be mounted on harmonic drive 15W3-1, optionally followed by first harmonic output drive 14W4, depending on the shaft interconnection type. A friction interface can be disposed within second harmonic drive output hub 15W9.

[0115] Now, referring to FIG. 40M, the lumen 15K5 may include, but is not limited to, a cable extension portion 15M1 that may accommodate the control cable 15K8 and a cable accommodating portion 15M2 that may accommodate the deployment cable 15K3.

[0116] 40N, the swing arm 15K4 can include, but is not limited to including, a pivot pin cavity 15N1 that can enable rotation of the swing arm 15K4. The swing arm 15K4 can include pulley cavities 15N2-1 / 15N2-2 that can each accommodate one of the pulleys 15K9 (FIG. 40P). A control cable 15K8 (FIG. 40J) can be threaded through the pulley 15K9 (FIG. 40P) and can be tensioned by the swing arm 15K4 as it rotates.

[0117] 40O, the capstan housing 15T1 can include a drive shaft cavity 15T2 that can receive the pulley box drive shaft 15K21 (FIG. 40J). The capstan housing 15T1 can include a first geometry 15T3 that can accommodate gear meshing, a second geometry 15T4 that can accommodate the lumen 15K5 (FIG. 40M), and a third geometry 15T5 that can accommodate the cable drive assembly 15W1-1 / 15W1-2 (FIG. 40L-1).

[0118] 40P, the swing arm pulleys 15K9 can include a cable extension 15U2 that can accommodate the control cable 15K8 (FIG. 40J). In some configurations, one of the swing arm pulleys 15K9 can be mounted in a first pulley cavity 15N2-1 (FIG. 40N) in one of the swing arms 15K4, and another of the swing arm pulleys 15K9 can be mounted in a second pulley cavity 15N2-2 (FIG. 40N) in another of the swing arms 15K4.

[0119] 40Q, pulley 15K2 can include cable extensions 15V2 / 15V3 that can accommodate control cable 15K8 (FIG. 40J) along a path from lumen 15K5 (FIG. 40M) through swing arm pulley 15K9 to capstan shaft 15K6 (FIG. 40T). Control cable 15K8 (FIG. 40J) can extend through one of cable extensions 15V2 / 15V3 depending on which of pulley cavities 15N2-1 / 15N2-2 (FIG. 40N) houses swing arm pulley 15K9 (FIG. 40P).

[0120] Referring now to FIG. 40R, the pulley drive shaft bearing 15R1 can be mounted on the pulley box drive shaft 15K21 (FIG. 40S), and the pulley box drive shaft 15K21 (FIG. 40S) can be coupled to the cable drive actuator module 15K20 (FIG. 40L-1).

[0121] 40S, the pulley box drive shaft 15K21 can include a housing shaft 15Y4 that can be received by the capstan housing 15T1 (FIG. 40O) in a drive shaft cavity 15T2 (FIG. 40O). The pulley box drive shaft 15K21 can include a spur gear 15Y5 that can mesh with at least one gear mounted in a shaft collar 15T10 (FIG. 40T) to drive movement of the control cable 15K8 (FIG. 40J). The pulley box drive shaft 15K21 can include a drive key 15Y2 that can operably couple with a shaft key 15W10 (FIG. 40L-2) to position the pulley box drive shaft 15K21.

[0122] Referring now to FIG. 40T, the capstan shaft 15K6 can include a cable termination cavity 15Z2 that can accommodate the termination point of the control cable 15K8 (FIG. 40J). The control cable 15K8 (FIG. 40J) can traverse either or both of the cable extensions 15Z3 / 15Z4 on its way to the termination point 15Z2. The capstan shaft 15K6 can accommodate at least one gear at the shaft collar 15T10, which is meshed with the spur gear 15Y5 (FIG. 40S), the movement of which can be driven by the harmonic drive assembly 15W1-1 / 15W1-2 (FIG. 40L-2).

[0123] 40AA and 40BB, second configuration of tensioning assembly 15AA1 can include components described herein with respect to tensioning assembly 15K1. Additionally, tensioning assembly 15AA1 can include cam 15AA2, which can enable reducing tension on swing arm 15K4 (FIG. 40N) to accommodate the placement of control cable 15K8. Second configuration of tensioning assembly 15AA1 can include second configuration of capstan housing 15AA3, which can enable a second configuration of pulley placement and cable routing geometry.

[0124] 40CC, cam 15AA2 can include cam ears 15CC1-1 / 15CC1-2 that, when oriented flush with swing arm 15K4 (FIG. 40AA), can spread swing arm 15K4 (FIG. 40AA) to reduce force on cable 15K8 (FIG. 40AA). Cam 15AA2 can include a camshaft 15CC2 that can be received by capstan housing second configuration 15AA3 (FIG. 40DD) in cavity 15DD1 (FIG. 40DD).

[0125] Referring primarily to FIG. 41 , a bottom perspective view of the manipulator 36B and several manipulated components 38A, 38B is depicted. The manipulator 36B can include a manipulator housing 78C that can include or be coupled to a trocar 225, through which the first manipulated component 38A and the second manipulated component 38B and / or the auxiliary component 20 ( FIG. 1 ) can be introduced into the patient 18 ( FIG. 1 ). An outer conduit 227 of the trocar 225 can line the interior of the trocar 225, which can house any number of internal lumens. The manipulator housing 78C can be, for example, without limitation, “V” shaped and can include several perforations 230 in each arm 232 of the “V.” The perforations 230 can allow the drive element 60 ( FIG. 16 ) to interface with a driven element 62 ( FIG. 16 ) located within the manipulator 36B. In other configurations, the manipulator housing 78C can be any other shape. For example, the manipulator housing 78C may have a thin, box-like shape. In such a configuration, the perforations 230 may be organized in two parallel rows. Other configurations may have at least one manipulated component 38, or three or more manipulated components 38, and may include a suitable number of perforations 230 for the number of manipulated components 38. For example, in a configuration with three manipulated components 38, the manipulator housing 78C may have a thin, box-like shape with three rows of perforations 230.

[0126] Still referring primarily to FIG. 41 , several ports 234A, B can be included in the manipulator housing 78C for inserting surgical tools 52 or auxiliary components 20 ( FIG. 1 ) into the patient 18 ( FIG. 1 ). In some configurations, port 234A can extend to a lumen in the trocar 225. Port 234B in the arm of the “V” of the manipulator housing 78C can also extend into a lumen in the trocar 225. The ports 234A, B can enable the surgeon 22 ( FIG. 1 ) to insert and / or remove any number of tools 52 into and / or from the patient 18 ( FIG. 1 ) during surgery. In some configurations, one or more of ports 234A or 234B may not be included. For example, in some configurations, port 234B may not be included. In such a configuration, the surgical tools 52 manipulated by the manipulated component 38 may not be interchangeable during surgery. The manipulator 36B may include a preselected surgical tool 52 for a particular procedure already attached to the manipulated component 38.

[0127] Still referring primarily to FIG. 41 , the manipulator 36B may also include a number of recesses 236 that may mate with the drive component 34 ( FIG. 16 ). The recesses 236 may serve as locating features to align with pins or other protrusions on the drive component 34 ( FIG. 16 ). The recesses 236 may help ensure that the manipulator 36B is properly seated on the drive component 34 ( FIG. 16 ) during setup. In some configurations, a latch or equivalent may be included to retain the manipulator 36B in a fixed position on the drive component 34 ( FIG. 16 ). Alternatively, an interface structure 290 ( FIG. 49 ) may be included between the manipulator 36B and the drive component 34 ( FIG. 16 ).

[0128] Referring now primarily to FIG. 42 , the manipulator housing 78D can be a shell that can capture and retain the driven element 62 ( FIG. 16 ) of the manipulator 36C. The manipulator housing 78D shell can provide a lumen for the port 234. The proximal ends of the manipulated components 38A, 38B can be retained within the manipulator housing 78D. The manipulator housing 78D can include, but is not limited to, a first housing part 78A and a second housing part 78B that can be coupled together with several fasteners (not shown). The first housing part 78A and the second housing part 78B can each be the same for ease of manufacturing. Alternatively, the first housing part 78A and the second housing part 78B can be different. The first housing part 78A and the second housing part 78B can be snap-fit, friction-fit, or glued together to form the manipulator housing 78D in various configurations. Additionally, in some configurations, the manipulator housing 78D may be a clamshell that can hinge closed around the portions of the manipulator 36C and / or manipulated components 38A, 38B housed within the manipulator housing 78D. The manipulator housing 78D can be optimized for manufacturing as a molded part.

[0129] Still referring primarily to FIG. 42 , the manipulator housing 78D can include a slotted plateau structure 242. The slots 244 in the slotted plateau structure 242 can be arranged in substantially parallel pairs and can allow the drive element 60 ( FIG. 16 ) to interface with the driven element 62 ( FIG. 16 ) housed within the manipulator housing 78D. In some configurations, the slotted plateau structure 242 may be included only on the side of the manipulator housing 78D that is intended to be adjacent the drive component 34 ( FIG. 16 ).

[0130] Referring primarily to FIG. 43 , the configuration of the manipulator 36D is depicted. A portion of the manipulator housing 78E is not shown to expose the driven element 62A. The driven element 62A can be a block-like structure, and a face of the driven element 62A proximal to the manipulated components 38A, 38B can be contoured to fit securely against the first ends 38C of the manipulated components 38A, 38B. The driven element 62A can include a receiving structure 250 into which a portion of the drive element 60 ( FIG. 16 ) can be inserted. The configuration of the receiving structure 250 can be selected based on the portion of the drive element 60 ( FIG. 16 ) that is intended to interface with the driven element 62A. The receiving structure 250 can be, for example, without limitation, a rectangular slot or socket into which the drive element 60 ( FIG. 16 ) can extend when the manipulator 36D is in position on the drive component 34 ( FIG. 16 ).

[0131] Still referring primarily to FIG. 43 , a divider 252 can be included inside the trocar 225. The outer conduit 227 ( FIG. 41 ) of the trocar 225 has been removed in FIG. 43 to expose the divider 252. Multiple dividers 252 may be used in alternative configurations. The divider 252 can separate the interior of the trocar 225 into several individual lumens, for example, but not limited to, a first lumen 225A and a second lumen 225B. Each individual lumen may or may not be fluidly isolated from the other lumens, depending on the configuration. The divider 252 can have a cross-sectional shape selected, for example, to create a desired number of lumens and to define a cross-sectional shape for each lumen. In some configurations, the divider 252 can be “X” shaped and may partially define the first lumen 225A and an opposing lumen (not shown). The divider 252 may also partially define a laterally disposed second lumen 225B and another lumen (not shown) opposite the second lumen 225B. The first lumen 225A and the opposing lumen may have a larger cross-sectional area than the second lumen 225B and the other laterally disposed lumen. The side lumen may be dedicated to the manipulated components 38A, 38B, for example.

[0132] Referring now to FIG. 44, an enlarged detailed view of one of the driven elements 62A and a portion of the manipulator 36D is shown. The side 281 of the driven element 62A adjacent the proximal end 38C of the manipulated component 38D can be shaped so that the side 281 can fit around and accommodate at least a portion of the manipulated component 38D. The driven element 62A can fit, for example, into a recess or trough 260 in the manipulator housing 78E. When the manipulator 36D is fully assembled, the driven element 62A can be captured within the manipulator housing 78E. In some configurations, the driven element 62A can be captured between two manipulator housings 78E. Only one manipulator housing 78E is shown in FIG. 44. The receiving structure 250 of the driven element 62A can align with the slot 244. The driven element 62A can be displaced within the manipulator 36D. During displacement, the driven element 62A may ride along bearings. For example, the outer surface 270 of the proximal end 38C of the manipulated component 38D may serve as a bearing for the driven element 62A. A recess or trough 260 in the manipulator housing 78E may also serve as a bearing surface for the driven element 62A. The bearings can, among other things, constrain the driven element 62A from displacement in undesired degrees of freedom. In some configurations, the driven element 62A may ride along a different number and / or type of bearings. For example, in some configurations, one of the driven element 62A or the manipulated component 38D may include rails or similar structures that can cooperate with recessed tracks in the other of the driven element 62A and the manipulated component 38D. In some configurations, the driven element 62A may not contact the manipulator housing 78E. A rail or track may also be included on a portion of the manipulator housing 78E, such as the trough 260.

[0133] Continuing to refer primarily to FIG. 44 , the driven element 62A can include a channel 262, which can lead to an anchoring point or anchoring feature 80. The anchoring point 80 can be, for example, without limitation, a recess or well. The channel 262 can be cut into the driven element 62, and the anchoring feature 80 can be recessed into the top surface of the driven element 62 at a location that can coincide with the cutout 266. The channel 262 can be, for example, without limitation, located in the same horizontal or vertical plane as the cutout 266. When assembled, the anchoring point 80 may be anchored to an actuator 54A, which can be a pull wire. The actuator 54A can extend from the well / anchoring point 80 through the channel 262 and into the cutout 266. The actuator 54A can extend the length of the actuated component 38D until it reaches the feature of the actuated component 38D that the actuator 54A actuates. When the driven element 62A is displaced, the actuator 54A can pull an actuated feature of the manipulated component 38D or can be fed back into the manipulated component 38D to control the manipulated component 38D. Such an arrangement can allow for relatively simple control of the manipulated component 38D, in that pulling the actuator 54A directly can affect the actuation of the manipulated component 38D. This arrangement can simplify manufacturing and allow the system to operate predictably, which can facilitate processor-assisted control of the manipulated component 38D. A cutout 266 in the outer surface 270 of the manipulated component 38D may be used as a path for a rail, such as rail 282B ( FIG. 46 ). As the driven element 62A is displaced within the manipulator 36D, the rail 282B ( FIG. 46 ) may travel along the length of the wall of the cutout 266 and be guided thereby.

[0134] Still referring primarily to FIG. 44 , the manipulated component 38D may include an outer wall 270 that may define a conduit through which various utility components 54 ( FIG. 4A ), such as an actuator 54A, a surgical tool 52 ( FIG. 4A ), or an auxiliary component 20 ( FIG. 1 ), may extend. A routing insert 272A may be disposed within the manipulated component 38D and may extend along the length of the manipulated component 38D. The routing insert 272A may abut an interior surface of the manipulator sheath 38E, leaving a lumen within the manipulated component 38D. In other configurations, the routing insert 272A may not be disposed within the manipulated component 38D, but rather may be an integral part of the sheath 38E of the manipulated component 38D. The routing insert 272A may include at least one routing channel 274 that may provide a path for the actuator 54A. At least one routing channel 274 may be recessed into the routing insert 272A and may be sized to be only slightly larger in diameter than the actuator 54A that may extend along the routing channel 274, for example, but not limited to, 10-30% larger. The actuator 54A may be a wire or other element that may not be compressively stiff along its longitudinal axis. If the at least one routing channel 274 is only slightly larger than the actuator 54A, the possibility of the actuator 54A binding and getting stuck when releasing slack may be minimized as the actuator 54A extends along the routing channel 274. Sizing the at least one routing channel 274 slightly larger than the actuator 54A may allow the actuator 54A to displace without excessive friction, possibly helping to ensure smooth and predictable actuation. The actuator 54A may extend along and through the entire length of the routing channel 274. The point at which actuator 54A exits routing channel 274 may coincide with and be in close proximity to anchoring point 80.Because no pulleys or other routing elements external to the manipulator 36D are required, the actuators 54A can be constrained within a controlled path over their entire length.

[0135] Referring primarily to FIG. 45 , the driven element 62D can include a first anchoring point 80A and a second anchoring point 80B. Each of the anchoring points 80A, 80B can anchor a separate actuator 54A. The actuator 54A can be terminated, for example, with a crimp or bead 280, which can be sized to fit within one or both of the anchoring points 80A, 80B, for example, but is not limited to. The crimp or bead 280 can be adhesively or otherwise glued in place. In a configuration with two or more actuators 54A attached to the driven element 62D, a piece of material can form a bridge 263 spanning the channel 262, for example, to the second anchoring point 80B. The bridge 263 can be positioned proximal to the outer surface 270 ( FIG. 44 ) of the manipulated component 38D ( FIG. 44 ) when the device is fully assembled. The actuator 54A may be routed under a bridge 263 to constrain the actuator 54A so that it exits the manipulated component 38D (FIG. 44) at a controlled angle. The driven element 62D can be used with multiple anchoring points 80A, 80B, even if the actuator 54A is not anchored to each anchoring point 80A, 80B. Thus, the same die can be used to machine the driven element 62D for each side of the manipulated component 38D (FIG. 44). Rails 282A, 282B can extend from the face 281 of the driven element 62D. The rails 282A and 282B may ride in a track that is recessed into the outer wall or outer surface 270 (FIG. 44) of the manipulated component 38D (FIG. 44). The rails 282A, 282B can be, for example, without limitation, dovetail-shaped. Other types of rails 282A, 282B are also possible.

[0136] 46, a shelf- or blade-like rail 282C is shown extending from a face 281 of a driven element 62E. The shelf-like rail 282C may ride in a track that is recessed into an outer surface 270 (FIG. 44) of a manipulated component 38D (FIG. 44). In some configurations, the shelf-like rail 282C may ride in a channel 262 in a manipulator 36D (FIG. 44).

[0137] Referring primarily to FIG. 47 , the manipulator sheath 38E and routing insert 272A can include several different routing channels 274A-E. Any of the routing channels 274A-E or a combination of the routing channels 274A-E can be used. The first routing channel 274A can have a first portion 275A recessed into the outer surface 272A of the routing insert 272 and a second portion 275B recessed into the inner surface 270A of the manipulator sheath 38E. The second routing channel 274B can be disposed entirely within the wall of the manipulator sheath 38E. In some configurations, the routing insert 272A may be omitted. The third routing channel 274C can be a trough that can be recessed into the outer surface 272A of the routing insert 272. The fourth routing channel 274D can be a trough recessed into the interior surface 270A of the wall of the manipulator sheath 38E. The third routing channel 274C and the fourth routing channel 274D can be, for example, without limitation, "U" shaped. The fifth routing channel 274E can be disposed entirely within the routing insert 272A.

[0138] Referring primarily to FIG. 48 , the manipulator 36E may include a manipulator housing 78E and several driven elements 62E. Each of the manipulated components 38A, 38B may include at least one cutout 266A, 266B, 266C, 266D. An actuator 54A ( FIG. 44 ), such as a wire, may exit through the cutouts 266A-D and be tethered to the driven element 62E. The cutouts 266A, 266B, 266C, 266D may be substantially parallel to one another and may be interleaved in different planes. The cutouts 266A, 266B, 266C, 266D may correspond to the location of at least one routing channel 274 ( FIG. 44 ). The number of cutouts 266A, 266B, 266C, 266D may correspond to the number of driven elements 62E used to actuate the manipulated components 38A, 38B. The cutouts 266A, 266B, 266C, and 266D can have substantially equal cutout lengths 267, or the cutout lengths 267 of each of the cutouts 266A, 266B, 266C, and 266D can be different. The cutout lengths 267 can define the displacement range 63 of each driven element 62E. The exit point of the actuator 54A ( FIG. 44 ) from the cutouts 266A, 266B, 266C, and 266D can change as the driven element 62E is displaced during operation. The cutout lengths 267 can be selected such that the actuator 54A can exit the cutouts 266A, 266B, 266C, and 266D into the driven element 62E at any location along the travel path or displacement range 63 of the associated driven element 62E.

[0139] Referring primarily to FIG. 49 , the manipulator 36E, first drive component 34A, and second drive component 34B can be aligned for operable engagement. A barrier 24 ( FIG. 16 ), such as, but not limited to, a sterility barrier, may be interposed between the manipulator 36E and the drive components 34A, 34B. The first manipulator housing portion 78F may include an anticline or arch structure 243 that may prevent ingress of fluid or debris into the manipulator housing 78 while still accommodating the protrusion of the first protrusion 92A and the second protrusion 92B into the manipulator housing 78. A second manipulator housing portion 78G may be joined to the first manipulator housing portion 78F to complete the manipulator housing 78. The second manipulator housing portion 78G may include, for example, perforations 230 (FIG. 41) or slotted plateau features 242 (FIG. 42) to allow the protrusions 92A, 92B of the drive component to enter the manipulator 36E.

[0140] Still referring primarily to FIG. 49 , an interface plate 290, for example, but not limited to, a relatively planar, rigid element, can accommodate the manipulator 36E and drive components 34A, 34B. The drive components 34A, 34B may be attached to the interface plate 290 in any suitable manner. The protrusions 92A, 92B can extend through openings 292A, 292B in the interface plate 290. The interface plate 290 can include a number of positioning protrusions 294 that can seat into recesses 236 ( FIG. 41 ) of the manipulator 36E.

[0141] 50, when the manipulator 36E is seated on the interface plate 290, the protrusions 92A, 92B may extend into the manipulator housing 78 and engage the driven element 62 (FIG. 51). The interface plate 290 may be omitted in some configurations. In configurations without the interface plate 290, the manipulator 36E may be mounted or placed directly on one or more drive components 34A, 34B.

[0142] 51 , the driven element 62 may be held at a known position within the manipulator 36 to facilitate docking of the manipulator 36 onto the drive component 34 during setup. The known position may also be referred to as a docking position. Constraining the driven element 62 in the docking position may allow the drive element 60 to be easily pre-aligned for engagement with the driven element 62 upon docking of the manipulator 36 onto the drive component 34. The drive component 34 may, for example, displace the protrusion 92 to an engagement position that will align with the docking position of the driven element 62. When the manipulator 36 is docked onto the drive component 34, the protrusion 92 may engage the driven element 62 as a result of the pre-alignment. Once the manipulator 36 is docked and the protrusion 92 and driven element 62 are engaged, the constraint holding the driven element 62 in the docking position may be removed so as not to further hinder displacement of the driven element 62. Any of a variety of different constraints may be used. The constraint, in some configurations, may be a mechanical interference that may contact a portion of the driven element 62 and inhibit movement of the driven element 62 prior to engagement with the drive component 34. After the manipulator 36 and drive component 34 are engaged, the constraint may be locked in a retracted or non-interfering position. In some configurations, displacement of the driven element 62 by the drive component 34 may provide a force that drives the constraint into the retracted position.

[0143] Continuing to refer to FIG. 51 , the driven element 62 may include a detent 62Z. The detent 62Z may be engaged by a protrusion 78Z included on the manipulator 36 or the manipulator housing 78. In some configurations, the protrusion 78Z may include a ridge 78Y that may seat in the detent 62Z. When the protrusion 78Z is engaged in the detent 62Z, the protrusion 78Z may hold the driven element 62 in a known or docked position. In some configurations, the protrusion 78Z may be a beam that may be cantilevered relative to a portion of the manipulator housing 78. The protrusion 78Z may be integrally molded with the manipulator housing 78 such that it can extend into the detent 62Z away from the face of the manipulator housing 78. Alternatively, the protrusion 78Z may be biased into the detent 62Z using a biasing member, such as a torsion spring.

[0144] 52 , when the drive element 60 displaces the driven element 62, the protrusion 78Z may disengage from the detent 62Z. When the protrusion 78Z disengages from the detent 62Z, the protrusion 78Z may be pushed to a retracted position where it is out of physical contact with the driven element 62 and may be retained there. In some configurations, there may be a gap 62Y between the driven element 62 and the manipulator housing 78. When the protrusion 78Z disengages from the detent 62Z, the protrusion 78Z, the ridge 78Y, may not fit within the gap 62Y and the protrusion 78Z may be pushed to the retracted position. The protrusion 78Z may include a flange 78X that can retain the protrusion 78Z in the retracted position once disengaged from the detent 62Z. When the driven element 62 disengages from the protrusion 78Z, the flange 78X may first abut the catch 78W and then flex around the catch 78W to allow the protrusion 78Z to reach the retracted position. In the retracted position, the protrusion 78Z may be subjected to a restoring force that can urge the protrusion 78Z toward the driven element 62. The restoring force may result from the bending protrusion 78Z attempting to return to its original position or may be the result of a biasing member such as a torsion spring (not shown). The flange 78X may be sufficiently rigid to substantially resist deformation under the restoring force. That is, the flange 78X may deform slightly, but not to the extent that it flexes around the catch 78W.

[0145] Referring primarily to FIG. 53 , the hydraulically powered system 1300 can include, but is not limited to, a manipulator 36E, a first drive component 34A, a second drive component 34B, and an interface plate 290. A barrier 24 ( FIG. 17B ) can also be included. The drive components 34A, 34B can each communicate with several hydraulic lines 70E. Each hydraulic line 70E can be operatively connected to a master cylinder 70D, which can be driven by a respective motor assembly 70. When a piston 70G ( FIG. 17B ) in the master cylinder 70D is displaced by operation of the motor assembly 70, a slave piston 70H ( FIG. 17B ) in the slave cylinder 70F can be displaced, which can displace the drive element 60 ( FIG. 17B ) and the driven element 62 ( FIG. 17B ) in the drive components 34A, 34B. As a result, the operated component 38 can be actuated. In some configurations of the system 1300, the motor assembly 70 may be remote from the drive components 34A, 34B, allowing the drive components 34A, 34B to be made more compact. Additionally, in some configurations of the system 1300, heat generated by the drive components 34A, 34B may be reduced. The motor assembly 70 and master cylinder 70D may be located within a remote enclosure 30A, which may be located in any suitable location within the surgical system 10 (FIG. 1). The hydraulic lines 70E may extend from the remote enclosure 30A to the drive components 34A, 34B. In some configurations, the motor assembly 70 and master cylinder 70D may be contained within the base 30 (FIG. 3) of the surgical robot 16 (FIG. 3), and the hydraulic lines 70E may extend along or within the arm 32 (FIG. 3).

[0146] Referring now primarily to FIG. 54 , force transmission may occur in several ways, for example, but not limited to, via linear or rotational displacement of a component in a first segment, which may cause displacement of a component in a second segment. Generally, a surgical system may employ at least one device comprising one or more shafts with two ends, such as a manipulated component 38 ( FIG. 16 ). The first end of the manipulated component 38 ( FIG. 16 ) may provide one or more end tools or end effectors, which may be surgical tools 52 ( FIG. 16 ). The second end of the manipulator 38 ( FIG. 16 ) may interface with a control system, which may be configured to control (either manually or with the aid of a processor) the manipulator 38 ( FIG. 16 ) and any one or more end tools 52 ( FIG. 16 ) on the first end. The first end may be referred to herein as the distal end, and the second end may be referred to herein as the proximal end. The manipulator 36 (FIG. 16) may be articulated or steerable due to multiple joints provided therein. The manipulator 36 (FIG. 16) may also serve as a lumen through which a target anatomical site may be accessed. Surgical instruments 52 (FIG. 16) and / or irrigation / insufflation fluids may be introduced into the patient 18 (FIG. 1) via this lumen. Additionally, or alternatively, the lumen may carry one or more utility components 54 (FIG. 16) (e.g., optical, power, or data transmission components, mechanical control components, fluid conduits, etc.; see FIG. 4A). In other configurations, one or more surgical instruments 52 (FIG. 16) may be engaged at the distal end of the manipulator 36 (FIG. 16). In some configurations, the manipulator 38 may include several wire or cable actuators 54A (FIG. 4B) that may be configured to operate an end tool or end effector 52 (FIG. 16) disposed at the distal end. The actuators 54A (FIG. 16) in the manipulator 36 (FIG. 16) may be controlled using electromechanical or electrohydraulic drive systems in various configurations.During a surgical procedure, a portion of the manipulator 36 (FIG. 16) and / or the endotool 52 (FIG. 16) may be fully or partially inserted into an anatomical cavity or opening in the patient 18 (FIG. 1).

[0147] Continuing to refer primarily to FIG. 54 , the surgical system 10 ( FIG. 1 ) may include, but is not limited to including, a barrier 24 configured to separate a first section of the surgical system 10 ( FIG. 1 ) from a second section. In some configurations, the barrier 24 may serve as a sterile barrier, isolating the non-sterile section 513 from the sterile section 515. The location of the sterile barrier 24 may vary depending on the surgical procedure, but the primary purpose may remain the same (i.e., isolating the non-sterile section 513 from the sterile section 515). In some configurations, the barrier 24 may be located at a location where a disposable portion of the surgical system 10 ( FIG. 1 ) can be attached to a durable portion of the surgical system 10 ( FIG. 1 ). Force may be transmitted across the barrier 24 from the durable portion to the disposable portion to control components within the disposable portion. The non-sterile section 513 may comprise a durable portion of the system 10 ( FIG. 1 ) that may be used for some surgical procedures without requiring a sterilization process, such as autoclaving. Non-sterile section 513 may include components such as, but not limited to, electro-mechanical or electro-hydraulic drive components, processing components, other electronic components, user interfaces, etc. Sterile section 515 may include, but is not limited to, disposable portions of system 10 (FIG. 1) that may require replacement or sterilization at the end of a procedure.

[0148] Still further and continuing to refer primarily to FIG. 54, alternatively, the barrier 24 may be located at a location where the actuator 54A (FIG. 16) (which may also be used as a connector) may be configured to engage the endotool 52 (FIG. 16) or endotool. Engagement of the actuator 54A (FIG. 16) and endotool 52 (FIG. 16) may be provided at one of the first or second ends of the manipulated component 38 (FIG. 16). In other configurations, the barrier 24 may be located anywhere toward the distal end of the actuator 54A (FIG. 16). The location of the barrier 24 may also be selected based on which components of the surgical system 10 (FIG. 1) can be easily sterilized or replaced after one or a limited number of uses and which are more difficult to replace and sterilize.

[0149] Continuing to refer to FIG. 54, the barrier 24 may maintain its integrity as a force is transmitted from the first barrier side 24A to the second barrier side 24B. In some configurations, the barrier 24 may be, for example, without limitation, a single continuous blanket, drape, or curtain of material. In other configurations, the barrier 24 may be compartmentalized while being functionally equivalent to a single continuous blanket or drape. The barrier 24 may be made of a flexible film, which may be soft, durable, abrasion-resistant, impermeable, and lightweight. In some configurations, the barrier 24 may be composed of multiple layers of the same or different materials. Materials that may be used for the barrier 24 may include, but are not limited to, polyurethane. At least a portion of the barrier 24 may include a coating or material containing an antimicrobial agent, and / or the barrier 24 may be provided in a sterile package.

[0150] Continuing to refer to FIG. 54 , in some configurations, the barrier 24 may not require any adjustment or modification for the transmission of forces across it. In some configurations, the barrier 24 may provide one or more pockets that may accept and / or cover components on one side of the barrier 24. In some configurations, the barrier 24 may be configured to undergo modification or may include integral or attached elements to complement and facilitate force transmission using specific mechanisms. Such modifications may include, but are not limited to, fixedly attaching or integrally forming the barrier 24 and the element during manufacturing. Such elements may be attached to the barrier 24 in a manner that can maintain the integrity of the barrier 24. That is, after attachment of the elements, there may be no gaps or other paths within the barrier 24 that provide communication from one side of the barrier 24 to the other. The elements may be attached to the barrier 24 in any of a variety of suitable manners. For example, in some configurations, the barrier 24 and at least a portion of the elements may be made of similar materials that can be ultrasonically welded to one another. The barrier 24 and the element may be laser welded together. The barrier 24 and the element may be solvent bonded together. The element may be attached to the barrier 24 using an adhesive. The barrier 24 and the element may be integrally formed with one another during manufacturing. In some configurations, the element may be overmolded onto the barrier 24. Any other suitable attachment method may also be used. The element may be an integral bridging element, which may be surrounded by a flexible membrane or diaphragm. The bridging element may be configured to engage one or more components in the non-sterile section 513 and / or one or more components on the sterile section 515.

[0151] Continuing to refer primarily to FIG. 54 , the sterile section 515 may include an endotool 52 ( FIG. 16 ) or end effector, which may be configured to perform surgical tasks during a surgical procedure. In some configurations, movement of the endotool 52 ( FIG. 16 ) may be governed by a drive system, which may be manually operated or controlled by or with the assistance of at least one processor. A first set of components, which may be configured to direct the surgical procedure, may be collectively referred to as drive elements 60. Correspondingly, a second set of components, which may be configured to be automatically driven, manually, or automatically assisted, may be referred to as driven elements 62. The drive elements 60 may be located entirely or partially within the non-sterile section 513, and the driven elements 62 may be located entirely or partially within the sterile section 515 of the surgical system 10 ( FIG. 1 ). In some configurations, the drive elements 60 may operate one or more driven elements 62. Alternatively, a single drive element 60 may operate corresponding driven elements 62. The surgical system 10 (FIG. 1) may include a plurality of drive elements 60 and a plurality of associated driven elements 62.

[0152] Continuing to refer to FIG. 54 , the drive element 60 and the driven element 62 may be arranged to transmit force across the barrier 24 with or without physical contact with the barrier 24. In other configurations, force may be transmitted across the barrier 24 with only one of the drive element 60 and the driven element 62 in contact with the barrier 24. Regardless of the manner in which the barrier 24 interacts with the drive element 60 and the driven element 62, the barrier 24 can maintain its integrity as force is transmitted from one side of the barrier 24 to the other. Durable components, which may be within the non-sterile section 513, may be substantially responsible for directing and controlling aspects of the surgical procedure. For example, the durable components may guide one or more endotools 52 ( FIG. 16 ) or end effectors to perform a desired surgical task. The drive element 60 may be included as one of the durable components. One or more of the disposable components that may be in sterile section 515 may be employed to perform a desired surgical procedure at a target anatomical location. At least some of the disposable components that may be in sterile section 515, such as surgical tools 52 (FIG. 16), may be replaced or exchanged during surgery if desired. Driven element 62 may be included as a disposable component.

[0153] Continuing to refer to FIG. 54 , the drive element 60 may be configured to translate or rotate to displace, causing the transmission of force through the barrier 24 to the driven element 62. In some configurations, the barrier 24 may be partially or completely stationary as a predetermined force or torque is passed across the barrier 24. In some configurations, the barrier 24 may displace, but the displacement of the barrier 24 need not be the primary means by which force is transmitted across the barrier 24. The primary function of the barrier 24 may be to isolate the non-sterile section 513 from the sterile section 515. In some configurations, multiple pairs of drive element 60 and driven element 62 may be engaged with a single barrier 24 at several locations on the barrier 24. The barrier 24 may be positioned between the drive element 60 and the driven element 62, and in some configurations, may be confined. In some configurations, a portion of the drive element 60 may be positioned adjacent to the first barrier side 24A of the barrier 24 on the non-sterile side or section 513. A portion of the cooperating driven element 62 may be disposed adjacent to the second barrier side 24B of the barrier 24 on the sterile side or section 515. Such an arrangement may provide a series of mechanisms for force transfer interaction between the drive element 60, the barrier 24, and the driven element 62. One of the force transfer interaction mechanisms may require physical contact or engagement of the drive element 60 and / or the driven element 62 with the barrier 24. Another force transfer interaction mechanism may not require physical contact of a portion of the drive element 60 and a portion of the driven element 62 with the barrier 24.

[0154] Referring primarily to FIG. 55 , a representation of a force transmission arrangement 500 is depicted, including a drive element 60, a barrier 24, and a driven element 62. The barrier 24 may be disposed at an intermediate location between the drive element 60 and the driven element 62. The barrier 24 may further include a first barrier side 24A and a second barrier side 24B. The first barrier side 24A may serve as a first barrier interface connection surface on the non-sterile side 513 of the surgical system 10 ( FIG. 1 ). The second barrier side 24B may serve as a second barrier interface connection surface on the sterile side 515 of the surgical system 10 ( FIG. 1 ). The barrier 24 may be large enough to accommodate multiple drive element 60 and driven element 62 pairs, and the barrier sides 24A, 24B may provide multiple locations where these pairs may transmit force across the barrier 24. In some configurations, the site of interaction on the first barrier side 24A may be directly opposite the site of interaction with the second barrier side 24B for a given drive element 60 and driven element 62 pair. In other configurations, the site of interaction on the first barrier side 24A may not be directly opposite the site of interaction on the second barrier side 24B. The non-sterile side 513 may also include a first portion 503 of the drive element 60, which may be configured to fully or partially interact with the barrier 24. The first portion 503 may also be referred to herein as a first barrier interface connection 503. In some configurations, the drive element 60 may include more than one first barrier interface connection 503. The drive element 60 may be displaced by, for example, but not limited to, an electromechanical or electrohydraulic assembly capable of exerting a force on the drive element 60. The sterile side 515 may also include a second portion 504 on the driven element 62, which may receive a force transmitted from the first barrier interface connection 503. The second portion 504 may also be referred to herein as the second barrier interface connection 504 and may be disposed on the sterile side 515 of the surgical system 10 (FIG. 1). The first barrier interface connection 503 in conjunction with the second barrier interface connection 504 may effect the transmission of force across the barrier 24 as the drive element 60 is displaced.

[0155] Continuing to refer to FIG. 55 , the first barrier interface connection 503 may be positioned to interact with the first barrier side 24A of the barrier 24. The second barrier interface connection 504 may be positioned to interact with the second barrier side 24B of the barrier 24. The mechanism and extent to which the first barrier interface connection 503 interacts with the first barrier side 24A may be similar to or different from the mechanism and extent to which the second barrier interface connection 504 interacts with the second barrier side 24B of the barrier 24. In some configurations, a first mechanism for engagement between the first barrier interface connection 503 and the first barrier side 24A may be configured to complement a second mechanism for engagement between the second barrier interface connection 504 and the second barrier side 24B.

[0156] 56A , the force transmission arrangement 650 can include a drive element 60 that can communicate with the first barrier interface connection 503 via a first force carrier 525, and a driven element 62 that can communicate with the second barrier interface connection 504 via a second force carrier 527. The force carriers 525, 527 can be any coupling component capable of transmitting and / or receiving force, including, but not limited to, a solid or hollow shaft, a drive shaft, a piston shaft, a tube or lumen including one or more actuators 54A ( FIG. 16 ) (e.g., cables) that can operate in conjunction with or independently of one another, a housing including actuators 54A ( FIG. 16 ) configured to affect the first barrier interface connection 503 and / or the second barrier interface connection 504, a gear train, or any suitable combination thereof. In other configurations, force carriers 525, 527 may be configured to increase or decrease the forces transmitted to and / or received by driving element 60 and driven element 62, respectively.

[0157] 56B, a first housing 541 may be provided on the non-sterile side 513, and a second housing 542 may be provided on the sterile side 515 of the surgical system 10 (FIG. 1). The drive element 60 may be at least partially disposed within the first housing 541, and the driven element 62 may be at least partially disposed within the second housing 542. Transmission of force across the barrier 24 may occur with a portion of the drive element 60 and a portion of the driven element 62 in physical contact with the barrier 24 and / or elements within the barrier 24. Such an arrangement may be referred to as a contact mode for force transmission. In other configurations, only one or neither of the drive element 60 and the driven element 62 may contact the barrier 24 or elements within the barrier 24. In an arrangement in which neither the drive element 60 nor the driven element 62 contacts the barrier 24, force may be transmitted across the barrier 24 in a non-contact mode. Regardless of the mode used for force transmission, the barrier 24 may be at least partially disposed or held / confined between the first housing 541 and the second housing 542. The housings 541, 542 may couple together across the barrier 24, thereby confining the barrier 24. The housings 541, 542 may house various other components of the surgical system 10 (FIG. 1). For example, the first housing 541 may house, for example, but not limited to, electromechanical or electrohydraulic components of the system 10 (FIG. 1). The second housing 542 may at least partially house the manipulated component 38 (FIG. 16). In some configurations, the plurality of drive elements 60 and the first barrier interface connection 503 may be disposed within the first housing 541. A plurality of driving elements 60 and a first barrier interface connection 503 in the first housing 541 may interact with a plurality of driven elements 62 and a second barrier interface connection 504 in the second housing 542 .

[0158] 57, a contact arrangement for force transmission can include, but is not limited to, a manipulator 36E, an interface plate 290, a first drive component 34A, and a second drive component 34B. The drive components 34A, 34B may include several drive elements 60 (FIG. 16) that can be operated to displace protrusions 92A, 92B. In some configurations, the protrusions 92A, 92B can resemble first barrier interface connections 503 (FIG. 56A). When the manipulator 36E is docked onto the interface plate 290, the protrusions 92A, 92B of the drive components 34A, 34B may extend through the manipulator housing 78 into corresponding driven elements 62 (FIG. 16), which can act as second barrier interface connections 504 (FIG. 56A). Linear displacement of the protrusions 92A, 92B can cause linear displacement of the driven elements 62. The displacement may actuate a feature of the actuated components 38A, 38B or may be transmitted down a force carrier such as actuator 54A (FIG. 16).

[0159] Continuing to refer to FIG. 57, the barrier 24 can isolate the manipulator 36E from the drive components 34A, 34B and the interface plate 290. The barrier 24 can be a sterile barrier that can separate the manipulator 36E on the sterile side 515 and the drive components 34A, 34B on the non-sterile side 513. The barrier 24 can be captured between the manipulator 36E and the drive components 34A, 34B when the manipulator 36E is docked onto the interface plate 290. The barrier 24 can include a pocket-like region 24C for each drive component 34A, 34B. The pocket-like region 24C can be an integral part of the barrier 24 or can be attached to the barrier 24 by any suitable means, such as, but not limited to, solvent bonding, overmolding, and ultrasonic welding. The pocket-like region 24C can include several pockets 900 that can be shaped to receive the protrusions 92A, 92B. The pockets 900 may each extend into the manipulator 36E, for example, and may project into the receiving structure 250 (FIG. 43) of the driven element 62 (FIG. 16).

[0160] Referring now primarily to FIG. 58 , to allow for linear displacement of protrusions 92A, 92B ( FIG. 57 ) and the resulting displacement of their respective driven elements 62 ( FIG. 16 ), barrier 24 may include several variable regions that can accommodate displacement of associated pocket 900. The variable regions may be made of a stretchable material or may be bellows-like, for example. The variable regions may be pleated sections 24D, 24E of barrier 24 ( FIG. 57 ). Pleated sections 24D, 24E may flank or encompass pocket 900 within barrier 24, allowing pocket 900 to be displaced. The amount of displacement may depend on the surface area of ​​the pleats within pleated sections 24D, 24E. As pocket 900 is displaced in one direction, pleated section 24D may, for example, be folded or compressed, while pleated section 24E may flatten to allow pocket 900 to be displaced.

[0161] Referring now to Figure 59, pocket 900 has been displaced relative to pocket 900 in Figure 58 toward pleated section 24D. As a result, pleated section 24D can be folded and compressed. Pleated section 24E can flatten to allow the displacement.

[0162] 60, in region Y of FIG. 57, each of the pockets 900 in the pocket-like region 24C can be contained by a pleated section 24F of the barrier 24. The pleated section 24F can be folded flat to allow the pockets 900 to be displaced. The pleated section 24F can include a single pleat or multiple pleats.

[0163] Referring now to FIG. 61 , the barrier 24 may include a pocket-like region 24G. The pocket-like region 24G may include a pocket 900A, which may be encompassed by a pleated section 24H. The pleated section 24H may include multiple pleats 24I, 24J, and 24K. The multiple pleats 24I, 24J, and 24K may allow for increased displacement of the pocket 900A. Additionally, the multiple pleats 24I, 24J, and 24K may help limit the amount of stress applied to any one pleat 24I, 24J, and 24K for a given displacement position of the pocket 900A. The pleated section 24H may also include an outer cusp 24L. The outer cusp 24L may protrude from the pocket 900A in a direction transverse to the linear displacement path of the pocket 900A, for example, but not limited to, a direction transverse to the linear displacement path of the pocket 900A. The outer cusps 24L may help direct the folding and flattening of the pleats 24I, 24J, 24K, and may reduce and / or avoid bunching or distortion of the non-pleated portions of the barrier 24.

[0164] Referring now primarily to FIG. 62A , some configurations of the non-contact torque transmission array 660 may include the use of one or more magnetic couplings. The use of magnetic couplings may serve a secondary function of helping to position and secure the first housing 541 ( FIG. 56B ) to the second housing 542 ( FIG. 56B ) during setup. In some configurations, the magnetic coupling for the torque transmission array 660 may provide a magnet on one of the sides 513, 515 ( FIG. 56B ) and a metallic material on the other of the sides 513, 515 ( FIG. 56B ). The metallic material may also be a magnetized material. In configurations with magnetic coupling, one or more magnets may function as the first barrier interface connection 503, and another magnet or magnets may function as the second barrier interface connection 504. One or more magnets in each of the barrier interface connections 503, 504 may be aligned with a magnet with opposing magnetic poles on the other of the barrier interface connections 503, 504. Any suitable material exhibiting magnetic properties may be used, such as an appropriate transition metal, rare earth metal, or alloy. Neodymium-containing magnets may be used in some configurations, but are not limited to such. In some configurations, the types of magnets used in each of the barrier interface connections 503, 504 may be different. A first variety of magnets or magnetic materials may be included in the first barrier interface connection 503, and a second variety of magnets or magnetic materials may be included in the second barrier interface connection 504.

[0165] Continuing to refer primarily to FIG. 62A , the magnetic coupling can transmit torque across the gap 502. The barrier 24 ( FIG. 56B ) may be positioned in the gap 502. The barrier interface connections 503, 504 may each be positioned a predetermined distance from the barrier 24 ( FIG. 56B ) to transmit a predetermined force from the first barrier interface connection 503 to the second barrier interface connection 504. The barrier 24 ( FIG. 56B ) may be positioned in the gap 502 such that the portion of the gap 502 on the non-sterile side 513 ( FIG. 56B ) may be substantially equal to that on the sterile side 515 ( FIG. 56B ). The force may be transmitted as a result of magnetic attraction and / or repulsion between the poles of one or more magnets that make up each of the barrier interface connections 503, 504. In some configurations, the first barrier interface connection 503 may include, but is not limited to, a first set of magnets or magnetic segments, and the second barrier interface connection 504 may include, but is not limited to, a second set of magnets or magnetic segments. The barrier interface connections 503, 504 may be aligned such that poles in the first set of magnets or magnetic segments face opposing poles in the second set of magnets or magnetic segments. Such alignment may facilitate torque transfer from the first barrier interface connection 503 to the second barrier interface connection 504. Additionally, adjacent magnets or magnetic segments within each barrier interface connection 503, 504 may be aligned such that their poles are oriented in opposite directions. In other configurations, the first barrier interface connection 503 may include, but is not limited to, a first single continuous magnet, and the second barrier interface connection 504 may include, but is not limited to, a second continuous magnet. In still other configurations, a monolithic piece of material that is magnetized to contain multiple north and south poles (e.g., a radially sintered magnetic ring) may be used for each of the first barrier interface connection 503 and the second barrier interface connection 504.

[0166] Continuing to refer primarily to FIG. 62A , the barrier interface connections 503, 504 may be coupled to one or more force carriers 525, 527 on respective sides of the barrier 24 ( FIG. 56B ). In some configurations, the force carriers 525, 527 can be drive shafts. In other configurations, the force carrier 525 disposed on the non-sterile side 513 ( FIG. 56B ) may be included in the drive element 60 ( FIG. 16 ), which may rotate the force carrier 525. The rotation may in turn rotate the first barrier interface connection 503. As a result of the magnetic coupling that exists between the first barrier interface connection element 503 and the second barrier interface connection element 504, the second barrier interface connection element 504 and the second force carrier 527 may rotate in unison with the first barrier interface connection element 503. Thus, the magnetic relationship between the barrier interface connection elements 503, 504 can allow torque to be transmitted across the barrier 24 (FIG. 56B). Movement of the second force carrier 527 may be transmitted to an actuated component, such as the surgical tool 52 (FIG. 16).

[0167] Referring primarily to FIG. 62B , the barrier 24 ( FIG. 56B ) may be positioned within the gap 502 during surgery, which may be referred to as the barrier-positioning gap 502. The gap 502 may be a predetermined distance that remains substantially constant during operation. The predetermined distance may be selected such that the barrier 24 may be positioned between the barrier interface connections 503, 504 but may not contact either of the barrier interface connections 503, 504. The predetermined distance may be selected such that a desired amount of torque may be transmitted across it. As the predetermined distance increases, the amount of torque transferred may decrease. In some configurations, the gap 502 may be approximately 0.10 to 0.50 inches. In some configurations, the gap 502 may be approximately 0.125 to 0.30 inches. The gap 502 may not be symmetrical on either side of the barrier 24. Transmission of force across the gap 502 may occur without any disruption of the barrier 24. As a result, barrier 24 may function to keep sterile section 515 (FIG. 56B) isolated from non-sterile section 513 (FIG. 56B). The distance of gap 502 may depend on the various magnetic couplings used.

[0168] Referring primarily to FIG. 62C, the first barrier interface connection 503 will be described, although the description may apply to any barrier interface connection 503, 504 ( FIG. 62A ) that can serve as part of a magnetic coupling. Magnet 509A may be arranged to have opposite polarity to adjacent magnet 509B. The number of magnets may vary in various configurations. For example, some configurations may include six magnets 509A, 509B in each barrier interface connection element 503, 504 ( FIG. 62A ). Each magnet 509A, 509B may be contained in a housing 662, which may include a gap 661 into which the magnet 509A, 509B may be placed during assembly. The housing 662 may be made of any suitable material, including, but not limited to, metal, ceramic, glass, and plastic. In some configurations, the material selected for the housing 662 may be selected from materials that are compatible for bonding or ultrasonic welding to the force carrier 525, for example. The housing 662 may also be constructed to influence the magnetic flux path of the magnets 509A, 509B in a desired manner. For example, the magnetic flux path may be influenced to create one or more closed loop paths. In such a configuration, a portion of the housing 662 (e.g., face 664 (FIG. 62A)) may be made of a metallic material that can create a magnetic circuit within the barrier interface connection 503. In some configurations, the housing 662 may be constructed so that the magnets 509A, 509B can be positioned approximately 180° from each other and grouped together in a magnetic circuit. For example, in a configuration with three sets of magnets 509A, 509B, three magnetic circuits may be created under the influence of the housing 662. For example, the barrier interface connection 503 can include a receiving feature 666 for a force carrier 525, such as, for example, but not limited to, a drive shaft. The receiving feature 666 can be key-like. In some configurations, the receiving feature 666 can include a notch 668 into which a cooperating feature of the force carrier 525 can seat. In some configurations, the force carrier 525 can include a ridge 670 that can be received in the notch 668 when fully assembled, for example, to ensure that the force carrier 525 and the barrier interface connection 503 do not rotate relative to one another.

[0169] 63A, torque transfer arrangement 672 may include one or more force carriers 525, 527, barrier interface connections 503, 504, and barrier 24. Barrier interface connections 503, 504 may each include one or more magnets and may magnetically couple to one another when assembled. Barrier placement gap 502 (FIG. 63B) may be configured to receive barrier 24 and allow torque transfer from non-sterile side 513 to sterile side 515. Force transfer may occur without any disruption of barrier 24 and / or contamination of sterile side 515. As a result, barrier 24 may function to keep sterile section 515 separated from non-sterile section 513.

[0170] 63B, the first barrier interface connection 503 may provide a first receiving cavity 523 capable of receiving a first force carrier 525. The second barrier interface connection 504 may provide a second receiving cavity 526 capable of receiving a second force carrier 527. The barrier interface connections 503, 504 may also include one or more fastener receiving cavities 528, 529 or similar features. Any suitable fasteners may be inserted into the fastener receiving cavities 528, 529 to inhibit rotation of the force carriers 525, 527 relative to the barrier interface connections 503, 504. In some configurations, different mechanisms may be used to couple the force carriers 525, 527 to the barrier interface connections 503, 504. In some configurations, one or both of the force carriers 525, 527 may be permanently coupled to the barrier interface connections 503, 504. In such a configuration, the components may be welded together (ultrasonic or otherwise), bonded using an adhesive, or solvent glued together. In addition, threaded connections or nut and bolt type arrangements may also be used. Any other mechanism that would be apparent to one skilled in the art may be used to couple the barrier interface connections 503, 504 with the force carriers 525, 527.

[0171] 64A , torque transmission arrangement 520 can include a drive element 60 with a first barrier interface connection 503, a barrier 24, and a driven element 62 with a second barrier interface connection 504. Torque transmission arrangement 520 can be a contact arrangement in which a portion of drive element 60 and a portion of driven element 62 contact barrier 24. In operation, barrier 24 can be in physical contact with one or more components of drive element 60 and / or one or more components of driven element 62. The contacted portions of barrier 24 can be referred to as engagement sites. Contact through the engagement sites can enable the transmission of torque from drive element 60 in non-sterile section 513 to driven element 62 in sterile section 515. Second barrier interface connection 504 can be configured to receive the transmitted torque and pass it on to an actuated feature, such as end tool 52 ( FIG. 16 ), to facilitate a surgical task. In some configurations, barrier 24 may not be subject to any modification or adjustment. Force may be transferred from first barrier side 24A to second barrier side 24B with at least a portion of barrier 24 in physical contact and confinement between one or more portions of drive element 60 and one or more portions of driven element 62. In other configurations, barrier 24 may be adjusted or modified, for example, but not limited to, configured to provide a receptacle or receiver for receiving one or more portions from non-sterile side 513 and / or one or more portions from sterile side 515. In other configurations, a bridging element or multiple bridging elements may be provided as part of barrier 24. The bridging element may be configured to engage a portion of drive element 60 and / or a portion of driven element 62.

[0172] Continuing to refer to FIG. 64A, reference axis 535 may serve as an axis of rotation about which driving element 60 and driven element 62 may rotate. When torque is transmitted from driving element 60 to driven element 62, barrier 24 may be displaced. Specifically, as torque is transferred, a nutation "wobble" occurs, allowing torque to be transferred without requiring barrier 24 to rotate and without the need for a rotating seal within barrier 24. Displacement of barrier 24 may be described relative to several different reference axes, for example, a second reference axis or tilt axis 539. Second reference axis 539 may be perpendicular to barrier surfaces 24A, 24B. Barrier 24 may be tilted such that angle O is formed between reference axis 535 and tilt axis 539. The tilt axis 539 may be maintained between the first barrier interface connection element 503 and the second barrier interface connection element 504 such that the angle O is maintained as torque is transmitted from the first barrier side 24A to the second barrier side 24B. The first barrier side 24A of the barrier 24 may nutate about the reference axis 535 according to a nutation path 537. The tilt axis 539 may also maintain a substantially perpendicular orientation to the first barrier side 24A and the second barrier side 24B. A dotted line indicator 538 shows the position of the tilt axis 539 and the barrier 24 after approximately 180° rotation of the driving element 60 and the driven element 62 about the reference axis 535. The barrier angle α between the first surface 24A of the barrier 24 and the reference axis 535 may also be substantially constant during torque transmission across the barrier 24.

[0173] Continuing to refer now to FIG. 64B , nutation may also be described relative to various other axes. For example, a third reference axis or barrier nutation axis 541 may be used to describe the displacement of the barrier 24 as torque is transmitted through the torque transmission arrangement 520. The barrier nutation axis 541 may be substantially perpendicular to the reference axis 535 and may be positioned to intersect the reference axis 535 at a point where the barrier 24 intersects the reference axis 535. The barrier nutation axis 541 may also be referred to as the barrier nutation axis 541. The barrier nutation axis 541 may form an angle β with the barrier 24. Torque transmitted from the first barrier interface connection 503 to the second barrier interface connection 504 may nutate at least a portion of the barrier sides 24A, 24B about the barrier nutation axis 541 according to the second nutation path 536. Dotted outline 501A shows the position of barrier 24 after approximately 180° rotation of driving element 60 and driven element 62 about reference axis 535. As barrier 24 displaces while torque is being transmitted, angle β may remain substantially constant.

[0174] Referring now to FIGS. 64C-64F, the barrier 24 is displaced as rotation of the driving element 60 (FIG. 64B) and the driven element 62 (FIG. 64B) about the reference axis 535 occurs. Specifically, the progression of FIGS. 64C-64F illustrates the nutation “wobble” of the barrier 24 as torque is transmitted from the first barrier side 24A to the second barrier side 24B. The nutation “wobble” of the barrier 24 can be of any magnitude and is not limited by any illustrated configuration herein. In some configurations, only a small section of the barrier 24 at and around the engagement site may be displaced. The displacement of the drive rotation indicators A, B, C, and D, corresponding to the respective driven rotation indicators A′, B′, C′, and D′, represents the rotation of the driving element 60 and the driven element 62. In FIG. 64C, the torque transmission array 520 is in an initial position. The driving element 60 (FIG. 64B) and the driven element 62 (FIG. 64B) in each of FIGS. 64C-64F are rotationally displaced approximately 90° from their positions in each of the previous figures. Torque can be transmitted across the barrier 24 by rotational displacement of the driving element 60 (FIG. 64B). Reference markings 674 on the barrier 24 indicate that torque can be transmitted without the need for the barrier 24 to rotate and without the need for a rotating seal within the barrier 24. Additionally, nutational displacement of the barrier 24 may facilitate torque transmission without any distortion or impact to the integrity of the barrier 24.

[0175] 65A-65D, the torque transmission arrangement 530 can transmit torque from the non-sterile side 513 to the sterile side 515 of the barrier 24 in a contact mode. With specific reference to FIG. 65A, the torque transmission arrangement 530 can include multiple components on the non-sterile side 513 that cooperate with multiple mating components on the sterile side 515. The components on the non-sterile side 513 can be included in a first barrier interface connection element 503. The mating components on the sterile side 515 can be included in a second barrier interface connection element 504. The first barrier interface connection element 503 can include, for example, but not limited to, a first force carrier 555, a first planar body 543, a first cap base 551, and a first engagement cap 547. The second barrier interface connection element 504 may include a second engagement cap 549, a second cap base 553, a second planar body 545, and a second force carrier 557. In some configurations, the first and second force carriers 555, 557 may be torque-transmitting agents (e.g., drive shafts). The first and second force carriers 555, 557 may be coupled to the planar bodies 543, 545 such that the force carriers 555, 557 and the planar bodies 543, 545 cannot rotate relative to one another. Any suitable coupling method may be used, such as, but not limited to, threaded couplings, fasteners (e.g., set screws), interference fits, snap fits, adhesives / glues / epoxies, welding procedures such as ultrasonic or laser welding, solvent bonding, spring-loaded bayonet mounts, and others. Alternatively, each set of force carriers 555, 557, planar bodies 543, 545, and cap bases 551, 553 may be formed as a single piece, which may be machined or molded depending on the configuration, for example.

[0176] Continuing to refer primarily to FIG. 65A , at least a portion of the barrier 24 separating the non-sterile side 513 from the sterile side 515 may be captured between the caps 547, 549. The first barrier interface connection cap 547 and the second barrier interface connection cap 549 may contact the barrier 24 when assembled and engage or interlock with each other through the barrier 24. Rotation of the barrier interface connections 503, 504 about the reference axis 535 can cause displacement of the barrier 24. The barrier 24 may be displaced in a manner that can nutate the tilt axis 539 about the reference axis 535. The tilt axis 539 may form an angle O ( FIG. 64A ) with the reference axis 535, and this angle is determined by the angle θ when the tilt axis 539 is nutated. The first force carrier 555 may be configured to receive torque from a torque generator (e.g., a motor) and transmit the torque to the first planar body 543. The first planar body 543 may further include a base 551 extending from the first planar body 543 and having a surface 551A that is at an angle 551B relative to the reference axis 535. The surface 551A may serve as a mounting platform or platform for a first bearing assembly 565 ( FIG. 65C ) housed within the end cap 547. A first bearing assembly 565 (FIG. 65C) may allow rotational displacement of the end cap 547 relative to the base 551. In some configurations, the end cap 547 may provide an outer surface for the bearing assembly 565 (FIG. 65C).

[0177] Continuing to refer primarily to FIG. 65A , the sterile side 515 may provide cooperating components that may be configured to receive torque transmitted from the non-sterile side 513. These components may be collectively referred to as the barrier interface connection 504 and may be included in the driven element 62 ( FIG. 64B ). These components may be similar to or the same as those on the non-sterile side 513 of the barrier 24. For example, the driven barrier interface connection 504 may include a second bearing assembly 567 ( FIG. 65C ), which may be enclosed in the second cap 49, which may be referred to as a second barrier interface connection cap 549. The second bearing assembly 567 ( FIG. 65C ) may allow for rotational displacement of the second end cap 549 relative to the second base 553. The second barrier interface connection cap 549 and the housed bearing 567 ( FIG. 65C ) may be mounted on the second base 553. The second base 553 may include a surface 551D oriented at an angle 551C relative to the reference axis 535 and extending from the second planar body 545. The second planar body 545 may be attached to a second force carrier 557, such as, for example, but not limited to, a drive shaft. The second force carrier 557 may be configured to receive the transmitted torque and advance it to an actuated component, such as the end effector 52 ( FIG. 16 ). Additionally, the barrier interface connection caps 547, 549 may be disposed on the respective bases 551, 553 such that the respective faces of the end caps 547, 549 may be perpendicular to the tilt axis 539. During torque transmission, the torque transmission array 530 may be configured to rotate about the reference axis 535. Movement of the torque transmission array 530 may cause, for example, but not limited to, a responsive nutation movement of the barrier 24. Torque may be transmitted without the need for rotation of the barrier 24, a rotating seal in the barrier 24, or a discontinuity (e.g., a hole) in the barrier 24. The torque transmission arrangement 530 may allow the faces of the end caps 547, 549 to remain perpendicular to the tilt axis 539 during transmission of torque from the non-sterile side 513 to the sterile side 515.

[0178] Referring now to FIG. 65B, the end caps 547, 549 may include cooperating engaging or interlocking features. For example, one of the end caps 547, 549 may include a grooved recess or indentation 546. The other of the end caps 547, 549 may include a raised feature 548 that can interlock into the grooved recess 546. Such interlocking of 547, 549 can help maintain the engagement of the end caps 547, 549 during the transmission of torque through the torque transmission arrangement 530. In some configurations, the grooved recess 546 can be included in a surface 580, and the raised feature 548 can be included in a surface 581 ( FIG. 65D ). The surfaces 580, 581 ( FIG. 65D ) can engage the barrier 24 during operation. The grooved feature 546 may partially or completely occupy the surface of the end caps 547, 549. In some configurations, the grooved feature 546 can be an annular feature, which may be located near the periphery of the end caps 547, 549, but is not limited to being so. The raised feature 548 may partially or completely occupy the surface of the end caps 547, 549. In some configurations, the raised feature 548 can be an annular feature, which may be located near the periphery of the end caps 547, 549, but is not limited to being so. The grooved recess 546 and raised feature 548 and the end caps 547, 549 can be smooth, rounded, or have rounded edges. In some configurations, the grooved recess 546 and raised feature 548 and the end caps 547, 549 can be made from or coated with a soft, compliant material or a material with a low coefficient of friction. In other configurations, the cooperating engaging or interlocking features can be different. The barrier 24 may be trapped between the end caps 547, 549 when the torque transmitting arrangement 530 is engaged with the barrier 24. The location where the barrier 24 may be trapped may be referred to as the engagement location 563. Optional engagement members may alternatively be included on the barrier interface connections 503, 504 in addition to the end caps 547, 549. Alternative engagement members may be smooth and have rounded edges. The engagement members may also be made from or coated with a soft, compliant material or a material with a low coefficient of friction.

[0179] 65C, a cross-sectional view of the torque transmission arrangement 530 shown in FIG. 65A is depicted. The barrier 24 can be trapped or held between an end cap 547 on the non-sterile side 513 and an end cap 549 on the sterile side 515. A first bearing assembly 565 can be provided on the non-sterile side 513, and a second bearing assembly 567 can be provided on the sterile side 515. The first cap base 551 and the second cap base 553 can provide a first support post 570 and a second support post 571. The support posts 570, 571 can protrude from the surfaces of the cap bases 551, 553. The first support post 570 can abut an internal guide groove of the first bearing assembly 565. The second support post 571 can abut an internal guide groove of the second bearing assembly 567. First bearing assembly 565 may facilitate low-friction displacement of end cap 547 relative to cap base 551 and support post 570. Similarly, second bearing assembly 567 may facilitate low-friction displacement of end cap 549 relative to cap base 553 and support post 571. Bearing assemblies 565, 547 may be selected to support predetermined axial and moment loads on non-sterile side 513 and sterile side 515, respectively. In some configurations, bearing assemblies 565, 567 may be roll element bearing assemblies such as, but not limited to, ball bearing assemblies or needle bearing assemblies. In some configurations, angular contact bearings may be used.

[0180] 65D , the barrier 24 can be trapped between the first barrier interface cap 547 and the second barrier interface cap 549. When the first barrier interface connection 503 and the second barrier interface connection 504 approach the barrier 24, the grooved recess 546 and the raised feature 548 may interlock and hold the barrier 24 therebetween. During torque transmission, the end caps 547, 549 may remain engaged and the barrier 24 may remain trapped between the end caps 547, 549.

[0181] 65E, the first barrier interface connection 503 (FIG. 65C) of the torque transfer arrangement 530 (FIG. 65C) may include a planar body 543 and a base 551, which may be a single continuous structure that may be machined or molded together as a single piece. The components of the second barrier interface connection 504 (FIG. 65C) may be similar to, the same as, or different from those of the first barrier interface connection 503 (FIG. 65C).

[0182] 65F and 65G, additional configurations related to the interlocking features of end caps 547, 549 are shown. FIG. 65F depicts radially arranged grooved features 546 on a surface 580 of end cap 547. A cooperating radial arrangement of raised features 548 on a surface 581 of the opposing end cap 549 is also included. Note that the grooved features 546 and raised features 548 may be interchangeably arranged on the surfaces 580, 581 of end caps 547, 549. In operation, end caps 547, 549 of torque transfer arrangement 530A may contact barrier 24. The radial grooved features 546 and the radially arranged raised features 548 may lock together through barrier 24. This may help prevent rotation of one of end caps 547, 549 relative to the other. As with other configurations, the radially arranged grooved and raised features 546, 548 may have rounded edges, may be coated with a flexible and / or low coefficient of friction material, etc. The radially arranged grooved and raised features 546, 548 may be, but are not limited to being, spaced at equal angular intervals.

[0183] Referring now to FIG. 65G, another configuration of interlocking features between surfaces 580 and 581 of end caps 547, 549 is shown. FIG. 65G illustrates an asymmetric distribution of grooved features 546 and raised features 548 on the surfaces of end caps 547, 549. Dimples or receptacles form grooved features 546 on surface 580 of end cap 547. There is a cooperative asymmetric distribution of raised features 548 on surface 580 of end cap 549. Raised features 548 may be protrusions or projections that project high from surface 581. Note that grooved features 546 and raised features 548 may be interchangeably arranged on surfaces 580, 581 of end caps 547, 549. In operation, end caps 547, 549 of torque transfer arrangement 530B may contact barrier 24. The raised feature 548 may seat within the groove feature 546 and lock the end caps 547, 549 together through the barrier 24. This may help prevent rotation of one of the end caps 547, 549 relative to the other. As in other configurations, the grooved and raised features 546, 548 may have rounded edges, may be coated with a flexible and / or low coefficient of friction material, etc. While the grooved and raised features 546, 548 are shown as asymmetrically positioned around the periphery of the cap faces 580, 581 in other configurations, they may be symmetrically spaced, for example, at equal angular intervals, but are not limited to being so. In some configurations, such as any of those shown in FIGS. 65A-G, the end caps 547 and 549 may be or include magnets. In addition to the mechanical interlocking provided by the grooved and raised features 546, 548, a magnetic coupling may also be formed. This may further help prevent relative rotation of one of the end caps 547, 549 with respect to the other. Additionally, the magnetic coupling may help position the end caps together when configuring the torque transfer arrangement 530B. The magnetic coupling between the two end caps 546, 548 may also help to confine the barrier 24 between the two end caps 546, 548.

[0184] 66A , barrier 24 may include at least one element, for example, but not limited to, bridging element 600, which may interact with portions of drive element 60 and driven element 62. Bridging element 600 may be configured to couple components on non-sterile side 513 with those on sterile side 515 of torque transmission array 573. Torque transmission array 573 may be isolated into non-sterile side 513 and sterile side 515 using barrier 24. Drive element 60 may be positioned on non-sterile side 513, and driven element 62 may be positioned on sterile side 515. Drive element 60 may further include, but is not limited to, a first barrier interface connection 503, and driven element 62 may include, but is not limited to, a second barrier interface connection 504. Bridging element 600 may be partially or fully affixed onto barrier 24 such that bridging element portion 600A may be accessible on non-sterile side 513 and bridging element portion 600B may be accessible on sterile side 515. In some configurations, bridging element 600 may be a rod or pin-like member, and the accessible portions of bridging element 600 on each side of barrier 24 may be coaxial. In some configurations, first barrier interface connection 503 may provide a pocket or port configured to receive a first receptacle 625, for example, but not limited to, the accessible portion of bridging element 600 on non-sterile side 513. Similarly, second barrier interface connection 504 on sterile side 515 may also provide a pocket or port for receiving a second receptacle 630, for example, but not limited to, the accessible portion of bridging element 600 on sterile side 515. In other configurations, the bridging element 600 may be coupled on both sides using alternative means, which may include, but are not limited to, restraining structures, permanent fasteners, and threaded couplings. If the bridging element 600 is configured to be metal, such as, but not limited to, a metal pin, magnetic components on either or both sides of the barrier 24 may be included as part of the first and second receptacles 625, 630.

[0185] Continuing to refer to FIG. 66A , in some configurations, multiple bridging elements 600 may be provided on the barrier 24. Multiple bridging elements 600 may allow multiple pairs of barrier interface connection elements 503, 504 to engage in force transmission across the barrier 24. In some configurations, the bridging elements 600 may be bifurcated or split. Such an arrangement may, for example, allow one of the driving elements 60 to drive multiple driven elements 62. The bridging elements 600 may facilitate torque transmission across the barrier 24. The bridging elements 600 may be secured within the barrier 24 so that they cannot undergo rotational movement relative to the barrier 24. The tilt axis 539 may be disposed perpendicular to the barrier sides 24A, 24B of the barrier 24. In some configurations, the longitudinal axis of the bridging element 600 may be coaxial with the tilt axis 539. In some configurations, the bridging element 600 may be disposed perpendicular to the barrier 24. Nutational movement may occur as torque is transmitted. For example, the bridging element axis may nutate about the reference axis 535 as the barrier interface connections 503, 504 rotate about the reference axis 535. The angle between the bridging element 600 and the barrier 24 relative to the reference axis 535 may remain constant as torque is transmitted through the torque transfer assembly 573.

[0186] Continuing to refer to FIG. 66A , the bridging element 600 may be secured within the barrier 24 using any of a variety of processes. The bridging element 600 may be attached to the barrier 24 using, for example, but not limited to, an adhesive, or may be molded as part of the barrier 24. In some configurations, the bridging element 600 may be ultrasonically welded, laser welded, heat bonded, or solvent bonded to the barrier 24. The bridging element 600 may be made of a variety of materials. For example, the bridging element 600 may be made from a metal material. Alternatively, the bridging element 600 may be made from a plastic material or a fiber-reinforced plastic, for example, but not limited to, fiberglass. The material choice for the bridging element 600 may depend on the amount of force expected to be transferred through the bridging element 600. In some configurations, the bridging element 600 may be constructed from or coated with a material with a low coefficient of friction.

[0187] 66B, in some configurations, bridging element 600 may optionally include or be attached to flexible diaphragm 605. Flexible diaphragm 605 may include an orifice of predetermined dimensions. The orifice may be configured to receive bridging element 600 such that first branch or portion 600A of bridging element 600 may be accessible on non-sterile side 513 and second branch or portion 600B may be accessible on sterile side 5153. Flexible diaphragm 605 may be configured to be integrally formed with barrier 24, and bridging element 600 may later be attached to flexible diaphragm 605 after its location within the orifice. Alternatively, flexible diaphragm 605 may be attached to bridging element 600, for example, but not limited to, being overmolded thereon. In some configurations, flexible diaphragm 605 may aid in the attachment of bridging element 600 to barrier 24. When attached to the barrier 24, the flexible diaphragm 605 and the barrier 24 may form a seal that can isolate the environments on each side of the barrier 24 from each other. The material used for the flexible diaphragm 605 may include, but is not limited to, polyurethane or any other suitable material that can be flexible, durable, and inert toward metal. The flexible diaphragm 605 may be made of a material with properties that facilitate ultrasonic welding, laser welding, and solvent bonding to the barrier 24, for example, but is not limited to. For example, in configurations where the barrier 24 is a polyurethane material, the flexible diaphragm 605 may also be constructed from polyurethane to facilitate ultrasonic welding of the flexible diaphragm 605 to the barrier 24.

[0188] Referring now primarily to FIG. 67A , the torque transfer assembly 5580 can include a barrier 24 with a bridging element 600. The bridging element 600 can be partially or completely secured to the barrier 24. In some configurations, the bridging element 600 can be secured to the barrier 24 at an attachment site 603. The manner of attachment at the attachment site 603 can prevent rotational displacement of the bridging element 600 relative to the barrier 24. A first part or portion 600A of the bridging element 600 can be accessible on the non-sterile side 513, and a second part or portion 600B of the bridging element 600 can be accessible on the sterile side 515. The first part 600A of the bridging element 600 can be received by a receiving structure 611, which can be part of a barrier interface connection element 503, which can be included in the drive element 60 ( FIG. 66A ). The receiving structure 611 may be disposed on the non-sterile side 513 of the barrier 24 and may be configured to interface with the barrier 24 via the first portion 600A of the bridging element 600. The second portion 600B of the bridging element 600 may be received by the second receiving structure 613. The second receiving structure 613 may be disposed on the sterile side 515 of the torque transmission arrangement 5580. In some configurations, the second receiving structure 613 may be configured to serve as the barrier interface connection 504 on the sterile side 515 and may be included as part of the driven element 62 ( FIG. 66A ). To facilitate the transmission of torque, the first receiving structure 611 and the second receiving structure 613 may rotate about the reference axis 535. The transmitted torque across the barrier 24 may be received by the multi-pocket receiver 613A via the bridging element 600. Torque supplied to the second receiving structure 613 may, for example, cause rotation of the end tool 52 (FIG. 16). When the first receiving structure 611 rotates about the reference axis 535 and transmits torque to the second receiving structure 613, the longitudinal axis 600C of the bridging element 600 may nutate about the reference axis 535.

[0189] 67B , the barrier 24 can include a flexible diaphragm 605. The first receiving structure 611 can include a receiving pocket 612 that can be configured to receive the first portion 600A of the bridging element 600. In some configurations, the receiving pocket 612 can be defined by an inner guide groove of the bearing assembly 610. The presence of the bearing assembly 610 can enable low-friction rotation of the first receiving structure 611 relative to the first portion 600A of the bridging element 600 during operation. In some configurations, the bearing assembly 610 can be, for example, without limitation, a needle bearing assembly. Roller bearings, such as ball bearings, can also be used. Alternatively, the first receiving structure 611 can include a receiving pocket 612 without a rolling bearing element. In some configurations, the bridging element 600 and / or the walls of the pocket 612 can be made of or coated with a material with a low coefficient of friction. In some configurations, the first receiving structure 611 can be made of a strong, durable material, such as a metallic material.

[0190] Still referring to FIG. 67B , the second receiving structure 613 may be a multi-pocket receiver that can include several individual receiving pockets 615. The second receiving structure 613 may be made of materials, including, but not limited to, various types of rigid plastics. A plastic may be selected that has a low coefficient of friction when interfacing with the bridging element 600 material. In some configurations, the second receiving structure 613 may be made of a material, such as, but not limited to, surgical-grade stainless steel, that is resistant to degradation after repeated sterilization. Each of the pockets 615 of the second receiving structure 613 may be sized and shaped to receive the second portion 600B of the bridging element 600. The pockets 615 may also be contoured to guide the second portion 600B of the bridging element 600 into the pocket 615. Including multiple pockets 615 in the second receiving structure 613 may allow for increased ease of setup because the second receiving structure 613 does not need to be precisely oriented in a specific location. Alternatively, the second receiving structure 613 may be positioned in various rotational orientations and may be able to easily mate with the second portion 600B of the bridging element 600. The first receiving structure 611 may, in some configurations, include multiple receiving pockets 615 to reduce any set load. The bearing assembly 610 may also, in some configurations, be included in the second receiving structure 613.

[0191] 67C and 67D, there are shown two cross-sectional views of the torque transfer arrangement 5580. Fig. 67C is an assembled view, while Fig. 67D is an exploded view.

[0192] 67C , the first receiving structure 611 can engage with a first portion 600A of the bridging element 600, and the second receiving structure 613 can engage with a second portion 600B of the bridging element 600 within one of its plurality of receiving pockets 615. The first receiving structure 611 can be configured to engage with the drive element 60 ( FIG. 56A ). Torque can be supplied to the drive element 60 ( FIG. 66A ) and transmitted to the first receiving structure 611. Engagement between the drive element 60 ( FIG. 66A ) and the first receiving structure 611 can be established using, for example, but not limited to, a keyed shaft, such as a splined shaft, that can be received within the first receptacle 616. The first receiving structure 611 can further provide a bearing assembly 610 configured to be disposed within a recess or cavity 633 within the first receiving structure 611. In some configurations, the bearing assembly 610 may be, but is not limited to, a needle bearing or an angular contact needle bearing. Torque supplied to the first receiving structure 611 may be advanced to the second receiving structure 613 (having a second receptacle 617) using the bridging element 600. The second receiving structure 613 may pass the received torque through the driven element 62 (FIG. 56A) to an actuated feature, such as the surgical tool 52 (FIG. 16).

[0193] 67E, the ratio of the length of the first portion 600A of the bridging element 600 to the second portion 600B of the bridging element 600 may be modified to alter the amount of torque transferred. By increasing the length of the first portion 600A relative to the second portion 600B, a greater amount of torque may be transferred from the first side 24A to the second side 24B. Shortening the first portion 600A of the bridging element 600 relative to the second portion 600B may have the opposite effect. In some configurations, the first portion 600A may be longer than the second portion 600B, for example, having a length ratio of about 2:1.

[0194] 67F, modifying the angle 600D of the major axis 640 of the bridging element 600 relative to the reference axis 535 may alter the amount of torque transmitted. Holding the lengths of the first and second portions 600A, 600B of the bridging element 600 constant, the amount of torque transmitted may increase as the angle 600D of the major axis 640 relative to the reference axis 535 increases. In some configurations, the angle 600D can be, for example, 55-60 degrees.

[0195] 67G, other modifications may also be made to alter the amount of torque transmitted. For example, in some configurations, one of the first portion 600A or the second portion 600B of the bridging element 600 may include an extension arm 641. The extension arm 641 may be attached to an end of the bridging element 600. The extension arm 641 may extend from the bridging element 600 at an angle that can cause the extension arm 641 to extend away from and be substantially perpendicular to the reference axis 535. Placing the extension arm 641 on the driving side of the bridging element 600, e.g., the non-sterile side 513, may increase the amount of torque transmitted. Placing the extension arm 641 on the driven side, e.g., the sterile side 515, may decrease the amount of torque transmitted.

[0196] Referring now to FIG. 68, in some configurations, a gear train 676 may be included as part of the driven element 62. The gear train 676 may couple a force carrier 678 attached to the second barrier interface connection 504 to a drive shaft 680. The drive shaft 680 may either directly or indirectly control an actuated feature, such as the end tool 52 (FIG. 16). The gear train 676 may be employed to reduce the backlash felt during operation. Without the gear train 676, the drive element 60 may rotate at a first speed. The rotational speed of the drive element 60 may be increased, similar to a gear reduction, for the gear train 676 to reduce the backlash felt. The gears in the gear train 676 may be anti-backlash gears. In some configurations, the gear train 676 may be included with a 10:1 gear reduction. If the drive element 60 is driven ten times faster at the first speed, the backlash felt can be reduced by approximately 90% (removing any backlash in the gear train 676). Instead of a gear reduction, gear train 676 may instead be used as a mechanical amplifier to increase torque. Any suitable gear ratio may be selected to amplify torque by the desired amount.

[0197] Referring now to FIG. 69, a manipulator 36E may be seated on an interface plate 290. The drive component 34A may be operated to cause displacement of a driven element 62 ( FIG. 68 ) within the manipulator 36E. This, in turn, may actuate features of the manipulated components 38A, 38B and / or an end tool 52 on one of the manipulated components 38A, 38B. The top portion 78A of the manipulator housing 78 is exploded to depict the internal components of the manipulator 38E. The rotational drive component 34C may transmit torque to components within the manipulator 36E, the manipulated components 38A, 38B, or the end tool 52. For example, rotation of a barrier interface connection 503 of the rotational drive component 34C may rotate the end tool 52. The barrier interface connection 503 may be, but is not limited to, any of those described herein. The barrier interface connection 503 may be adjacent to the end 78V of the manipulator 36E. The barrier interface connection 503 may be positioned to transfer torque to a second barrier interface connection 504 in the manipulator 36E at or near the end 78V of the manipulator 38E. The barrier interface connection 504 may be, but is not limited to, any of those described herein.

[0198] Continuing to refer to FIG. 69 , in some configurations, the rotary drive component 34C may be covered by a rotary drive component cover or housing 290A. The rotary drive component housing 290A may, in some configurations, be a portion of the interface plate 290 that rises from the plane of the interface plate 290. The rotary drive component housing 290A may allow the drive component 34A and rotary drive component 34C associated with the manipulator 36E to be below the interface plate 290. In some configurations, all of the rotary drive components 34C for the manipulator 36E may be covered by the rotary drive component housing 290A. In some configurations, the manipulator 36E may have a “V” shaped housing 78. In such a configuration, the rotational motion transferred from the rotary drive component 34C to the second barrier interface connection 504 may need to be passed around a bend 78U. A universal joint (not shown) may be included in the rotating portion (e.g., a force carrier such as force carrier 527 (FIG. 56B)) to facilitate this transfer of rotational motion about the flexure. Manipulator 36E need not be "V" shaped, but instead may be constructed to avoid having to transfer any rotational motion about flexure 78U.

[0199] 70 , the manipulator 36E positioned for docking on the interface plate 290 may include a barrier 24. The barrier 24 may include a rotary drive component cover or shroud 24M in addition to the pocket-like region 24C. The rotary drive component cover 24M of the barrier 24 may be sized to surround the rotary drive component housing 290A or the rotary drive component 34C. Additionally, when the manipulator 36E is docked on the interface plate 290, the shroud 24M may extend between the rotary drive component housing 290A and the end 78V of the manipulator housing 78. The first barrier interface connection 503 ( FIG. 69 ) and the second barrier interface connection 504 ( FIG. 69 ) may transmit torque between the rotary drive component housing 290 and the end 78V of the manipulator housing 78 through a portion of the barrier 24. The barrier 24 may maintain isolation of the manipulator 36E from the drive components 34A, 34C. In some configurations, an element within the barrier 24, such as bridging element 600 (FIG. 66A), may extend into the rotary drive component housing 290A and / or the end 78V of the manipulator 36E. Similarly, in some configurations, a portion of the first barrier interface connection 503 (FIG. 69) or the second barrier interface connection 504 (FIG. 69) may extend out of the rotary drive component housing 290A or out of the end 78V of the manipulator 36E, respectively.

[0200] Referring primarily to FIG. 71 , at least a portion of the manipulated component 38 may be articulated to facilitate use of the manipulated component 38 to perform surgery on the patient 18 ( FIG. 1 ). Articulation may involve moving or displacing the manipulated component 38 or a portion of the manipulated component 38 in any of several degrees of freedom. Moving or displacing the manipulated component 38 may be achieved by displacing an actuator 54A ( FIG. 4B ) connected to an articulating section 40 ( FIG. 4B ) of the manipulated component 38. The manipulated component 38 may extend from the manipulator 36 and, for example, bend away from a neutral axis 400. The neutral axis 400 may be aligned with the longitudinal axis of the manipulated component 38 when the manipulated component 38 is in an unactuated, or “home,” position. The degree to which the manipulated component 38 is bent away from the neutral axis 400 is determined by a flexion angle Θ b It can be referred to as 403.

[0201] 72, the bending plane 402, or the plane about which the manipulated component 38 can bend, may be altered. The bending plane 402 may be rotated about the neutral axis 400. The amount by which the bending plane 402 is rotated from the reference plane 404 is determined by the rotation angle Θ r 405. In a configuration in which the articulating section 40 (FIG. 4B) is controlled by an actuator 54A (FIG. 4B), the articulating section 40 (FIG. 4B) can be actuated to a desired position by displacing the actuator 54A (FIG. 4B) in a controlled manner. The rotation angle Θ r 405 and bending angle Θ b 403 (FIG. 71), the amount of displacement of actuator 54A (FIG. 4B) can be determined. r 405 and bending angle Θ b The actuator 54A (FIG. 4B) can be commanded to displace the actuator 54A by the determined amount needed to achieve 403 (FIG. 71). Thus, the manipulated component 38 may be articulated to a desired orientation or configuration.r 405 and / or bending angle Θ b 403 (FIG. 71) may be defined manually or automatically. For example, a user may use any suitable user interface or input structure, such as, but not limited to, a joystick, roller ball, jog wheel, knob, touch screen, or other user input device 14 (FIG. 1) described herein, to input the rotation angle Θ. r 405 and / or bending angle Θ b 403 (FIG. 71) can be entered.

[0202] Referring primarily to FIG. 73 , the manipulated component 38 can include an articulating section 40. The control of the configuration described herein with three actuators 54A ( FIG. 8 ) can be expanded to include any number of actuators 54A ( FIG. 8 ). The manipulated component 38 can include a variable section 39 and an articulating section or section 40. The variable section 39 can extend and articulate. The manipulated component 38 can be fully articulated or can include a variable articulation section. The variable section 39 can be located proximal to the manipulator 36, and the articulating section 40 can be located distal to the manipulator 36. The variable section 39 can be, for example, without limitation, rigid or non-jointed. The articulating section 40 can have a neutral or home position and a flexion angle Θ b 403 ( FIG. 74 ). The articulating section 40 can start from a starting plane 408. For reference, two points 412, 414 on the manipulated component 38 are shown that lie on the starting plane 408. The nominal length 43, represented by “L,” is the length of the articulating section 40 when the articulating section 40 is aligned in a home or neutral position along the neutral axis 400.

[0203] Referring primarily to FIG. 74 , during articulation of the articulating section 40, the points 412, 414 may remain stationary. A point on the articulating section 40 distal to the starting plane 408 may move during articulation. A first movable point 420 and a second movable point 418 at the distal end of the articulating section 40 are also shown for reference. In some configurations, the plane 408, the first stationary point 412, and the second stationary point 414 may move in response to user interaction with the robot 16 ( FIG. 1 ) of the surgical system ( FIG. 1 ). In some configurations, the first stationary point 412 and the second stationary point 414 may translate and displace as the manipulated component 38 is moved anteriorly or posteriorly (e.g., telescoping in or out). In some configurations, there may be more than one articulatable section 40 in the manipulated component 38. In such a configuration, the starting plane 408 for one of the articulating segments 40 may move as the other of the articulating segments 40 is articulated. As the plane 408 moves, any points on the manipulated component 38 distal to the plane 408 may also move in kind. When the articulating segment 40 is not in the neutral or home position (shown in FIG. 73 ), the nominal length 43 may, in some configurations, be the arc length. In some configurations, when not in the home position, the nominal length 43 is the arc length at a given flexion angle Θ b The nominal length 43 may be equal to the length of the arc between the second stationary point 414 and the second movable point 418 relative to 403. b 403, may be substantially constant.

[0204] Continuing to refer primarily to Figure 74, the bending angle Θ b 403, the desired length L of the actuators 54A, 54B (e.g., cables or wires) des can be determined. The desired length L des is (rotation angle Θ r72) is 0°). The term "cable length" is used herein to refer to the length of the portion of the actuators 54A, 54B within the articulating section 40. The cable length is generally the arc length when the articulating section 40 is displaced from its home or neutral position (FIG. 73). The arc 421 between the first movable point 420 and the first rest point 412 is the L for the example flex angle 403 shown. des 16 represents actuator 54A with a length of 1 / 4" (FIG. 16). The total actuator length can be substantially longer than the cable length of actuators 54A, 54B within articulating section 40. For example, actuators 54A, 54B in many configurations can extend not only along articulating section 40 but also along variable portion 39. Actuators 54A, 54B can also exit manipulated component 38 such that they can be tethered to driven element 62 (FIG. 16).

[0205] Continuing to refer primarily to Figure 74, L des The offset 419 of the actuators 54A, 54B from the neutral axis 400 can be used to determine . The offset 419 is represented herein by "Ω." For example, the bending angle Θ b Considering 403, L des L may be equal to the length of the arc 421 between the first movable point 420 and the first stationary point 412 for the actuator 54A spanning between points 420 and 412. des can be determined using the following relationship:

[0206] r-Ω=L des / Θ b In the formula, r is L / Θ b or a given bending angle Θ in radians b L / Θ is equal to the radius that defines the nominal length L43 for 402. b can be substituted for r and the relationship can be rearranged as follows:

[0207] LL des =Ω*Θb=Δ length

[0208] Nominal length L43, offset Ω419, and bending angle Θ b 403 can be grasped, so L des may be calculated. length L and L des is the difference between Δ length The value is the bending angle Θ b 403 and rotation angle Θ r To achieve 405, it may be used to calculate the desired length of any number of actuators 54A, 54B that may be present in the articulating section 40. The construction of one method for doing so is described herein.

[0209] 75, the manipulated component 38 may include, for example, a first actuator 54A, a second actuator 54B, and a third actuator 54C. The desired lengths of the first actuator 54A, the second actuator 54B, and the third actuator 54C may be, respectively, L des1 , L des2 , and L des3 The distance between point 426 on neutral axis 400 (FIG. 74) and actuators 54A, 54B, 54C can be referred to as cable offsets 419A, 419B, 419C, respectively. When bending plane 402 (FIG. 72) is fixed or when rotation angle Θ r In the configuration where 405 is zero, L des1 can be calculated as follows:

[0210] Δ length * cos0

[0211] The first actuator 54A, the second actuator 54B, and the third actuator 54C can each be angularly offset from one another by, for example, but not limited to, 120°. The angular offsets may all be defined relative to one of the actuators 54A, 54B, 54C, e.g., actuator 54A. As used herein, "Θ" offset2 The first angular offset 427A, represented as "Θ", is the angle between the first actuator 54A and the second actuator 54B. offset3 The second angular offset 427B, represented as Θ, is the angle between the first actuator 54A and the third actuator 54C. offset2 is 120°, and Θ offset3 is -120°. Therefore, L des2 =Δ length * cos(Θ offset2 ) and L des3 =Δ length * cos(Θ offset3 ) Θ r If 405 (Figure 72) ≠ 0, L des1 =Δ length * cos(0+Θ r ), L des2 =Δ length * cos(Θ offset2 +Θ r ), and L des3 =Δ length * cos(Θ offset3 +Θ r ) If the articulating section 40 includes additional actuators (not shown in FIG. 75), the desired lengths of the additional actuators can be calculated in the same general manner. These lengths are used to move the articulating section 40 to the desired flexion angle Θ b 403 (Fig. 74) and the rotation angle Θ r 405 (FIG. 72). b 403 and the desired rotation angle Θ r405 may be defined either manually (e.g., by a user) or automatically. After the desired lengths of actuators 54A, 54B, 54C are determined, the desired lengths may be compared to the current lengths of each of actuators 54A, 54B, 54C. The calculated difference between the desired actuator lengths and the current actuator lengths may be referred to as length errors. These length errors may be, for example, the lengths of the first actuator 54A, the second actuator 54B, and the third actuator 54C, respectively. err1 , length err2 , and length err3 The length error value may be used to command the drive component 34 (FIG. 71) to cause displacement of the actuators 54A, 54B, 54C. As the actuators 54A, 54B, 54C are displaced, the manipulated component 38 adjusts the desired flexion angle Θ by displacing the actuators 54A, 54B, 54C such that the length error value is zeroed. b 403 (Fig. 71) and the rotation angle Θ r 72. The device can be transported to the location designated by 405 (FIG. 72).

[0212] Continuing to refer primarily to FIG. 75, the desired bending angle Θ b 403 (FIG. 71) can be recorded over time to define a set of exercises that can be later played back. For example, the exercises of an experienced operator can be recorded to provide a program for use by a trainee, or the operator's own exercises can be recorded to reduce the number of repetitive exercises required by the operator during the procedure or other procedures.

[0213] Referring primarily to FIG. 76 , a method 450 for controlling the movement of, for example, an articulating section 40 ( FIG. 74 ) having three wires may include, but is not limited to, receiving 431 at least one command signal by a robotic surgical system. The at least one command signal may be provided by, for example, but not limited to, a user input device 14 ( FIG. 2 ) and may be a representation of a user-directed movement command. In some configurations, one or more sensors associated with the user input device 14 ( FIG. 1 ) may output a representation of the at least one user-directed movement command. The sensor output may represent an amount a portion of the user input device 14 ( FIG. 1 ) is displaced, a location of a user's finger on a touchscreen, etc. The method 450 may include filtering 432 the at least one command signal. The command signal may be subject to filtering, including, for example, a deadband, in some configurations. A gain may also be applied to the command signal. The method 450 determines a desired rotation angle Θ based, at least in part, on the command signal. r and bending angle Θ b The method 450 may also include a step 433 of determining Δ length The method 450 may also include a step 435 of determining a value, for example, but not limited to, a Δ length Based on the value, the length of each actuator des The method 450 may also include a step 437 of calculating a value of length des Based on the value, the length of each actuator err Step 439 calculates the value of length err and generating 441 a displacement command based on the value. errThe method 450 may further include a step 443 of transmitting the displacement commands to various motor assemblies (e.g., in the drive components 34 (FIG. 71)). The commands may be addressed to specific motors in the drive components 34 (FIG. 71) that can control the movement of specific actuators. The drive components 34 (FIG. 71) of the robot 16 (FIG. 3) may be configured to transmit the displacement commands to the respective length assemblies of the actuators. err The actuators may be driven until the controller 15 (FIG. 1) determines that the value is equal to zero. Encoder counts, potentiometers, other displacement sensors, or a combination of displacement sensors may be used to determine the length of each wire or actuator.

[0214] Continuing to refer to FIG. 76, in some configurations, it may be desirable for the controller 15 (FIG. 1) to be programmed to control the articulation of the manipulated component 38 (FIG. 75) in a number of different modes. These modes may be user-selected or may be automatically entered based on data collected from sensors within the robot 16 (FIG. 3). For example, the controller 15 (FIG. 1) may have a macro-movement mode and a fine-tuning mode. The processing of the command signal received in step 431 may differ in each of the multiple modes. In various configurations, each mode may be definable by several prescribable parameters or sets of prescribable parameters that can dictate how the command signal will be handled by the controller 15 (FIG. 1). For example, the length of each actuator may be err The rate at which the value is zeroed may depend on the mode selected. The rate may be a parameter that can vary for each of the modes. The rate may be user definable in some configurations. In other configurations, the rate is determined from a desired rotation angle Θ given user input. r and bending angle Θ b may vary depending on the mode selected. r and bending angle Θ bmay be subjected to a gain that can increase or decrease these values. This gain may be a prescribable parameter for each mode.

[0215] Still further referring to FIG. 76 , using examples of macro and fine movement modes, the macro movement mode would allow for rapid and / or large displacement movements of the articulating portion of the manipulated component 38 ( FIG. 75 ). This mode may be used, for example, to move the manipulated component 38 ( FIG. 75 ) within a surgical site and may be useful in getting the end effector 52 ( FIG. 16 ) on the manipulated component 38 ( FIG. 16 ) into the general location needed to perform surgery. The fine movement mode would allow for small, precise movements of the articulating portion 40 ( FIG. 74 ) of the manipulated component 38 ( FIG. 75 ). This mode may be used in confined spaces or during the performance of surgical procedures such as cutting, suturing, cauterization, etc. In some configurations, functionality associated with some or all surgical procedures may be disabled when the system is not in the fine movement mode. For example, actuation of the end effector 52 ( FIG. 16 ) on the robot 16 ( FIG. 3 ) may be disabled. Continuing to refer to macroscopic and fine motor movements, the desired rotation angle Θ r and bending angle Θ b may be scaled up or down depending on the mode in which the controller 15 (FIG. 1) is operating. Additionally or alternatively, the length of each actuator err The speed at which the values ​​are zeroed can be different. For example, in macroscopic movement mode, the length of each actuator err While the value can be zeroed relatively quickly, this speed can be relatively slow in fine movement mode.

[0216] 76A, 76B, and 76C, the controller 15 (FIG. 3) can determine the length of each of the actuators 76A32 in the cable 76A14 from the start position 76A3 to the desired position 76A2 by determining the neutral length 76A4 of each of the actuators 76A32. The controller 15 (FIG. 3) can determine the neutral length 76A4 by dividing the actuator 76A32 into straight lengths 76C3 (FIG. 76C) and multiplying the number of straight lengths forming the actuator by the size of the straight lengths 76C3 (FIG. 76C). The controller 15 (FIG. 3) can determine the pitch angle 76B1 (FIG. 76B) as the angle between the tensioned length 76A5 and its projection 76B4 (FIG. 76B) onto a horizontal axis 76B3 (FIG. 76B). The controller 15 (FIG. 3) can determine the yaw angle 76B2 as the angle between the horizontal axis 76B3 (FIG. 76B) and the projection 76B4 (FIG. 76B). The controller 15 (FIG. 3) can calculate the rotation angle 76C1 (FIG. 76C) as atan(sin(pitch angle) / sin(yaw angle)). The controller 15 (FIG. 3) can determine the bend arc 76A6 as the intersection 76A8 between the projection from the first end 76A3 of the actuator and the projection 76A10 of the second end of the actuator, drawn at the rotation angle 76C1 (FIG. 76C), and the bend radius 76A7 as the neutral length 76A4 / the bend arc 76A6. The controller 15 (FIG. 3) can determine the cable offset 76A12 as the distance between the actuator 76A4 and the center 76A13 of the cable 76A14, which may house, for example, but not limited to, four of the actuators 76A4. The controller 15 (FIG. 3) can determine the actuator angle 76A30, for example, as the acute angle between the actuator 76A12 and a Cartesian axis 76A31 drawn within the cable 76A14. In some configurations, the controller 15 (FIG. 3) determines the actuator angle 76A30 as the neutral length 76A4 + the flexion arc 76A6. * Cable offset 76A12 * The length of each actuator can be calculated as sin(rotation angle 76C1+actuator angle 76A30).

[0217] Referring now primarily to FIG. 77 , a method 475 for tensioning actuators for a surgical robot can include, but is not limited to, step 451 of commanding a drive component to tension a first actuator until the force in the load path reaches a predetermined threshold. The force may be determined, for example, but not limited to, by sensing the displacement of a flexible member, such as, for example, but not limited to, a mechanical component 150 ( FIG. 26 ) located in the load path. If the force value has not reached the threshold at 453, method 475 can include repeating step 453 of monitoring the force value. If the force value has reached the predetermined threshold at 453, method 475 can include step 455 of identifying another actuator to tension. In some configurations, actuators may be tensioned in a cross-tension sequence or pattern. In configurations using cross-tension, actuators can be identified in step 455 by finding an actuator that affects a feature of the manipulated component 38 ( FIG. 75 ) that is substantially opposite to the feature controlled by the previously tensioned actuator. The actuators would thus be tensioned in a crisscross fashion similar to tightening lug nuts on a wheel. As a result, when the actuators are tensioned, the articulating portion of the operated component can remain in substantially the same orientation or position throughout the process. A helical sequence may also be used when the actuators are arranged in a non-circular pattern. In an alternative configuration, tensioning can be pre-programmed in a desired sequence and no determination of the actuators by the processor is required.

[0218] 77 , method 475 may further include step 457 of applying tension to the identified actuator until the force in the identified actuator load path exceeds a predetermined threshold. If the force in the load path has not reached the predetermined threshold at 459, method 475 may include repeating step 459 of monitoring the force. If the force in the load path has reached the predetermined threshold at 459, and if there are additional actuators to apply tension at 461, method 475 may include step 455 of identifying another actuator to apply tension. When all of the actuators have been tightened to their respective thresholds, additional stages of applying tension may be pre-configured. In such a configuration, the actuators may be incrementally increased in one or more increments to a desired final tension value. If the force in the load path reaches a predetermined threshold at 459, and if there are no additional actuators applying tension at 461, and if there is applying additional tension at 463, method 475 may possibly include adapting the predetermined threshold to a next predetermined threshold at 465 and repeating the step of applying tension of the first actuator by, for example, sending a command to the motor 451. If there is no additional tension at 463, method 475 may end.

[0219] Continuing to refer to FIG. 77 , for example, the first stage of tensioning may tension the actuators to one-quarter of the desired final tension value, the second stage may tension the actuators to one-half the desired final tension value, etc. The number of tensioning stages may vary depending on the configuration. Additionally, the increments for each step may vary depending on the configuration. All of the actuators may be tensioned by equal increments in each tensioning stage, or the actuators may be assigned individual tension increments for each stage. Because the tension on each of the actuators may be controllable to a desired amount, the stiffness of the manipulated component 38 ( FIG. 75 ) can be varied to best suit the needs of the surgery. Variable stiffness may allow some tools 52 ( FIG. 16 ) (e.g., retractors) or tools to be stiffer, while other tools (e.g., shavers or cauteries) may be more flexible. Variable stiffness can be useful in controlling the amount of bounce that a given tool can experience when a force across the axis of the manipulated component 38 (FIG. 75) is suddenly removed. A transaxial force can occur when an obstacle is encountered and overcome. For example, when cutting through target tissue, the transaxial force will no longer be present when the cut is complete. By lowering the actuator tension (making the manipulated component 38 (FIG. 75) more flexible), the resulting bounce can be attenuated. In some configurations, the cable tension on the actuator can be, for example, without limitation, up to 80 pounds.

[0220] Still further referring to FIG. 77 , the ability to vary stiffness may enable dynamic stiffness control. The stiffness of the manipulated component 38 ( FIG. 75 ) may be modified in situ to be appropriate for a given situation. In some configurations, the manipulated component 38 ( FIG. 75 ) can have a default stiffness setting that is active when the manipulated component 38 ( FIG. 75 ) is introduced into the patient 18 ( FIG. 1 ). The default setting may define a tension that can allow the tool to be substantially flexible. The default setting may be a general setting or tool-specific. If suitable, the stiffness may be modified to change the flexibility of the manipulated component 38 ( FIG. 75 ) when the tool is performing a surgical task, such as cutting, separating, or holding tissue in place. The stiffness of the manipulated component 38 ( FIG. 75 ) may be set or changed in various manners. In some configurations, the controller 15 ( FIG. 1 ) can be configured to control the manipulated component 38 ( FIG. 75 ) in multiple modes. The stiffness may be a definable parameter for each of the mu...

Claims

1. A surgical robot, the surgical robot comprising: a drive component having at least one drive element disposed therein, the drive element including a drive screw; a motor assembly disposed within the drive component for operating the drive element; the motor assembly comprises: The motor assembly includes: A motor; Gear head and A bearing, a manipulator operably coupled to the drive component and the at least one drive element; a controller communicatively coupled to the drive components and the manipulator; a load sensor disposed between the motor assembly and the drive element for measuring a load; The load sensor includes: a flexible body, the flexible body deforming in proportion to the magnitude of the load; an insert extending through the flexible body, the insert including an adjustable spacer and providing a compression and tension stop for deformation of the flexible body; a protrusion coupled to the flexible body, the protrusion displaced based on the deformation of the flexible body, the flexible body, the insert, and the protrusion forming a mechanical component; an electrical component including at least one sensor for detecting a displacement of the protrusion, the displacement being associated with a load; Including, the adjustable spacer adjusts for a range of compressive and tensile loading conditions; The surgical robot, wherein the drive screw extends into the flexible body, the motor assembly engages the flexible body, and the mechanical component is driven by the drive screw.

2. The surgical robot of claim 1 , wherein the manipulator further comprises at least one manipulated component and the at least one driving element further comprises at least one driven element.

3. The surgical robot of claim 2 , wherein the at least one driven element is operably coupled to the at least one manipulated component.

4. The surgical robot of claim 2 , wherein an actuator couples the driven element to the manipulated component.

5. The surgical robot of claim 1 , wherein the flexible body deforms at a first rate and a second rate.

6. The surgical robot of claim 5 , wherein when deforming at the first rate, the flexible body deforms in proportion to the magnitude of a first range of loads.

7. The surgical robot of claim 5 , wherein when deforming at the second rate, the flexible body deforms in proportion to the magnitude of a second range of loads.

8. The surgical robot of claim 1 , wherein the at least one sensor monitors displacement of the protrusion.

9. The surgical robot of claim 1 , wherein a continuous barrier separates the manipulator and the drive component.

10. The surgical robot of claim 1 , wherein the insert further comprises a threaded insert.

11. The surgical robot of claim 1 , further comprising sterile components for robotic surgery.

12. The surgical robot of claim 1 , further comprising a barrier disposed between the drive component and the manipulator.

13. The surgical robot of claim 1 , wherein the drive element further comprises a drive screw and a nut.

14. The surgical robot of claim 1 , wherein the motor assembly is associated with a position sensor for providing feedback regarding the position of the drive element.

Images