Surgical coupler assembly

Abstract

A coupler assembly for interconnecting an instrument drive unit and a surgical tool assembly, includes an outer housing; a plurality of proximal couplers rotatably positioned within respective proximal openings defined in a proximal end portion of outer housing, the plurality of proximal couplers are arranged in a non-linear configuration which matches a non-linear configuration of a plurality of drive motors of the instrument drive unit; a plurality of distal couplers rotatably supported in a distal end portion of the outer housing and projecting distally from the outer housing, the plurality of distal couplers are arranged in a linear configuration which matches a linear configuration of rotational drive receiving members of the surgical tool assembly; and a plurality of torque transmitting members supported within the outer housing and interconnecting the plurality of proximal couplers and the plurality of distal couplers.

Description

SURGICAL COUPLER ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 675,761, filed July 26, 2024, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure relates to a surgical coupler assembly. More specifically, the present disclosure relates to a surgical coupler assembly for interconnecting a powered drive system of a robotic-assisted surgical system and a surgical tool assembly (or adapter assembly) from a handheld electromechanical surgical device.

[0003] Robotic-assisted surgical systems may be used to help overcome limitations of traditional, hand-held (e.g., laparoscopic) surgical instruments, providing greater control and operability, and are operated by surgeons seated at a surgical console which is located away from the operating table and / or the patient. Handheld electromechanical surgical devices, which typically include a powered handle assembly, have a surgical tool assembly attached thereto, which is physically held by a surgeon or user, is operated by the surgeon or user while located immediately adjacent to the operating table and / or patient. Certain surgical tool assemblies which are configured to be used with powered handle assemblies of handheld electromechanical surgical devices may require substantial redesigning in order to be adapted for use with robotic- assisted surgical systems.

[0004] Accordingly, a need exists for an economical and efficient manner to connect surgical tool assemblies, which are configured to be used with powered handle assemblies of handheld electromechanical surgical devices, with robotic-assisted surgical systems.SUMMARY

[0005] According to an aspect of the disclosure, a coupler assembly, for interconnecting an instrument drive unit and a surgical tool assembly, is provided. The instrument drive unit includes a plurality of drive motors arranged in a non-linear configuration, wherein each drive motor provides a respective rotational output which defines a respective rotation axis, and thesurgical tool assembly includes a plurality of rotational drive receiving members arranged in a linear configuration.

[0006] The coupling assembly includes an outer housing having a proximal end portion and a distal end portion, wherein the proximal end portion of the outer housing is configured for selective connection to the instrument drive unit, and wherein the distal end portion is configured for selective connection to the surgical tool assembly. A plurality of proximal couplers rotatably is positioned within respective proximal openings defined in the proximal end portion of outer housing. The proximal couplers are arranged in a non-linear configuration which matches the non-linear configuration of the plurality of drive motors of the instrument drive unit. A plurality of distal couplers is rotatably supported in the distal end portion of the outer housing and projects distally from the outer housing, the distal couplers are arranged in a linear configuration which matches the linear configuration of the rotational drive receiving members of the surgical tool assembly. A plurality of torque transmitting members is supported within the outer housing and interconnects the proximal couplers and the distal couplers.

[0007] Each torque transmitting member includes a shaft, a first connector, and a second connector. The first connector is supported at a proximal end of the shaft, wherein the first connector is non-rotatably connected to a proximal coupler of the plurality of proximal couplers. The second connector is supported at a distal end of the shaft, wherein the second connector is non-rotatably connected to a distal coupler of the plurality of distal couplers.

[0008] The first connector of each torque transmitting member may be a first ball connector and may be configured for receipt in a complementary socket defined in the corresponding proximal coupler. The second connector of each torque transmitting member may be a second ball connector and may be configured for receipt in a complementary socket defined in the corresponding distal coupler.

[0009] Each first ball connector may include a pin projecting from opposed sides thereof. The pin of the first ball connector may define a first pin axis which is oriented transverse to a longitudinal axis of the shaft. The first pin may be slidably and pivotably received within slots defined in the socket of the corresponding proximal coupler.

[0010] Each second ball connector may include a pin projecting from opposed sides thereof. The pin of the second ball connector may define a second pin axis which is oriented transverse to a longitudinal axis of the shaft. The second pin may be slidably and pivotably received within slots defined in the socket of the corresponding distal coupler.

[0011] The torque transmitting members may be configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

[0012] The shaft of each torque transmitting member may be rigid.

[0013] The coupler assembly may further include an inner housing. The inner housing may define at least one recess for rotatably receiving the shaft of each torque transmitting member.

[0014] Each proximal coupler may define an axis of rotation, wherein the axes of rotation of the proximal couplers are parallel to one another. Each distal coupler may define an axis of rotation, wherein the axes of rotation of the distal couplers are parallel to one another. The shaft of each torque transmitting member defines an axis of rotation, wherein the axis of rotation of the shaft of each torque transmitting member may be angled with respect to the axis of rotation of the corresponding proximal coupler, and may be angled with respect to the axis of rotation of the corresponding distal coupler.

[0015] The coupler assembly may further include an electrical connector supported in the distal end portion of the outer housing, wherein the electrical connector of the distal end portion of the outer housing may be configured to connect to a complimentary electrical connector of the tool assembly. An electrical connector may be supported in the proximal end portion of the outer housing, wherein the electrical connector of the proximal end portion of the outer housing may be configured to connect to a complimentary electrical connector of the instrument drive unit. The electrical connector of the distal end portion of the outer housing and the electrical connector of the proximal end portion of the outer housing may be connected to one another.

[0016] The shaft of each torque transmitting member may be flexible and capable of transmitting torque.

[0017] The coupler assembly may further include a pair of release levers positioned on opposed sides of the outer housing.

[0018] The coupler assembly may further include a pair of ramped camming surfaces disposed on opposed side surfaces of the outer housing, the pair of ramped camming surfaces being in registration with the pair of release levers.

[0019] According to another aspect of the disclosure, a coupler assembly, for interconnecting an instrument drive unit and a surgical tool assembly, is provided. The instrument drive unit includes a plurality of drive motors arranged in a non-linear configuration, wherein each drive motor provides a respective rotational output which defines a respective rotation axis. The surgical tool assembly includes a plurality of rotational drive receiving members arranged in a linear configuration.

[0020] The coupling assembly includes an outer housing having a proximal end portion and a distal end portion, wherein the proximal end portion of the outer housing is configured for selective connection to the instrument drive unit, and wherein the distal end portion is configured for selective connection to the surgical tool assembly. A plurality of proximal couplers is rotatably supported in the proximal end portion of outer housing, the plurality of proximal couplers is arranged in a non-linear configuration which matches the non-linear configuration of the plurality of drive motors of the instrument drive unit. Each proximal coupler defines an axis of rotation, wherein the axes of rotation of the proximal couplers are parallel to one another. A plurality of coupling shafts rotatably is supported in the distal end portion of the outer housing and projects distally from the outer housing. The coupling shafts are arranged in a linear configuration which matches the linear configuration of the rotational drive receiving members of the surgical tool assembly. Each distal coupler defines an axis of rotation, wherein the axes of rotation of the distal couplers are parallel to one another. A plurality of torque transmitting members is supported within the outer housing and interconnects the plurality of proximal couplers and the plurality of coupling shafts.

[0021] Each torque transmitting member includes a shaft defining an axis of rotation, wherein the axis of rotation of the shaft is angled with respect to the axis of rotation of eachrespective proximal coupler, and wherein the axis of rotation of the shaft is angled with respect to the axis of rotation of each respective coupling shaft. A proximal drive yoke interconnects the shaft and a respective proximal coupler of the plurality of proximal couplers. A distal drive yoke interconnects the shaft and a respective distal coupler of the plurality of distal couplers.

[0022] The proximal drive yoke of each torque transmitting member may be a ball connector configured for receipt in a complementary socket defined in the corresponding proximal coupler. The distal drive yoke of each torque transmitting member may be a ball connector configured for receipt in a complementary socket defined in the corresponding distal coupler.

[0023] The ball connector of each proximal drive yoke may include a pin projecting from opposed sides thereof. The pin of the ball connector of each proximal drive yoke may define a first pin axis which is oriented transverse to a longitudinal axis of the shaft. The first pin of each proximal drive yoke may be slidably and pivotably received within slots defined in the socket of the corresponding proximal coupler.

[0024] The ball connector of each distal drive yoke may include a pin projecting from opposed sides thereof. The pin of the ball connector of each distal drive yoke may define a second pin axis which is oriented transverse to a longitudinal axis of the shaft. The second pin of each distal drive yoke may be slidably and pivotably received within slots defined in the socket of the corresponding distal coupler.

[0025] The torque transmitting members may be configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

[0026] The shaft of each torque transmitting member may be rigid.

[0027] The coupler assembly may further include an inner housing defining at least one recess for rotatably receiving the shaft of each torque transmitting member.

[0028] According to yet another aspect of the disclosure, a coupler assembly, for interconnecting an instrument drive unit and a surgical tool assembly, is provided. The instrument drive unit includes a plurality of drive motors arranged in a non-linear configuration,wherein each drive motor provides a respective rotational output which defines a respective rotation axis, and wherein the rotation axes of the drive motors are not in a common plane. The surgical tool assembly includes three rotational drive receiving members arranged in a linear configuration.

[0029] The coupling assembly includes an outer housing having a proximal end portion and a distal end portion. The proximal end portion of the outer housing is configured for selective connection to the instrument drive unit, and the distal end portion is configured for selective connection to the surgical tool assembly.

[0030] The coupling assembly includes three proximal couplers rotatably positioned within respective proximal openings defined in the proximal end portion of outer housing. Each drive coupler defines a drive coupler rotation axis, wherein the drive coupler rotation axes are parallel to one another and are not in a common plane, and wherein the three proximal couplers are axially aligned with a corresponding three motors of the instrument drive unit.

[0031] The coupling assembly includes three coupling shafts rotatably supported in the distal end portion of the outer housing and projecting distally from the outer housing. Each distal coupler including a shaft and defining a coupling shaft rotation axis, wherein the coupling shaft rotation axes are parallel to one another and are in a common plane, and wherein the three coupling shafts are axially aligned with a corresponding three rotational drive receiving members of the surgical tool assembly.

[0032] The coupling assembly includes a plurality of torque transmitting members supported within the outer housing and interconnecting the plurality of proximal couplers and the plurality of coupling shafts. Each torque transmitting member includes a shaft, a first connector, and a second connector. The first connector is supported at a proximal end of the shaft and is non-rotatably connected to a proximal coupler of the plurality of proximal couplers. The second connector is supported at a distal end of the shaft and is non-rotatably connected to a distal coupler of the plurality of distal couplers.

[0033] The torque transmitting members may be configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

[0034] The shaft of each torque transmitting member may be rigid.BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:

[0036] FIG. 1 is a schematic illustration of a robotic surgical system including a robotic surgical assembly in accordance with the disclosure;

[0037] FIG. 2 is a perspective view of a robotic arm having an interface, where the robotic arm is disposed on a movable cart in accordance with embodiments of the disclosure;

[0038] FIG. 3 is a perspective view of a handheld electromechanical surgical device;

[0039] FIG. 4 is a rear, perspective view of an adapter assembly for a surgical stapling device, for connection with the handheld electromechanical surgical device of FIG 3;

[0040] FIG. 5 is a perspective view illustrating a connection of the adapter assembly and the handheld electromechanical surgical device;

[0041] FIG. 6 is a perspective view of a loading unit for connection to the adapter assembly of FIG. 4;

[0001] FIG. 7 is a side, elevational view, with parts separated, of a robotic surgical assembly according to the disclosure;

[0042] FIG. 8 is a front view of a portion of the robotic surgical assembly of FIG. 7;

[0002] FIG. 9 is a longitudinal, cross-sectional view of the robotic surgical assembly ofFIG. 8, as taken through 9-9 of FIG. 8;

[0043] FIG. 10 is a perspective view, with parts assembled, of the robotic surgical assembly illustrated in FIG. 7;

[0044] FIG. 11 is a front, perspective view of a coupler assembly of the disclosure;

[0045] FIG. 12 is a rear, elevational view of the coupler assembly of FIG. 11;

[0046] FIG. 13 is a front, elevational view of the coupler assembly of FIGS. 11-12;

[0047] FIG. 14 is a front, perspective view of the coupler assembly of FIGS. 11-13, with a housing thereof shown in phantom;

[0048] FIG. 15 is a side, elevational view of the coupler assembly of FIG. 14;

[0049] FIG. 16 is a perspective view of the coupler assembly of FIGS. 11-15, with the housing thereof removed;

[0050] FIG. 17 is a perspective view of a drive shaft assembly of the coupler assembly of FIGS. 11-16;

[0051] FIG. 18 is a perspective view of an alternate coupler assembly, with a housing thereof removed, according to the disclosure;

[0052] FIG. 19 is a perspective view of another alternate coupler assembly, with a housing thereof removed, according to the disclosure;

[0053] FIG. 20 is a perspective view of an arrangement of alternative drive shaft assemblies for use in the coupler assembly of FIGS. 11-16;

[0054] FIG. 21 is a perspective view of a drive shaft of the drive shaft assemblies of FIG. 20; and

[0055] FIG. 22 is a perspective view of an inner end of either a distal coupler or a proximal coupler of the drive shaft assemblies of FIG. 20.DETAILED DESCRIPTION

[0056] Embodiments of the disclosed coupler assembly are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein the term “distal” refers to that portion of the coupler assembly, or component thereof, farther from the clinician (and generally closer tothe patient), while the term “proximal” refers to that portion of the coupler assembly, or component thereof, closer to the clinician (and generally farther from the patient).

[0057] As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or - 10 degrees from true parallel and true perpendicular.

[0058] As used herein, the term “clinician” refers to a surgeon, doctor, nurse, or other care provider and may include support personnel. In the following description, well-known functions or construction are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

[0059] As will be described in detail below, the disclosure relates to coupler assemblies that interconnect an interface of a robotic-assisted surgical system with tool assembly (or adapter assembly) normally used with a handheld electromechanical surgical device. When the coupler adapter assembly is attached to the interface of the robotic-assisted surgical system, tool assemblies and adapter assemblies constructed for use with the handheld electromechanical surgical device are capable of being used (or connected to) the robotic-assisted surgical system.

[0060] Referring initially to FIGS. 1-2, a surgical system, such as, for example, a robotic- assisted surgical system 1, generally includes one or more surgical robotic arms 2, 3 each supported on a respective robotic arm cart 20 (see FIG. 2), a control device 4, and an operating console 5 coupled with control device 4. Any of the surgical robotic arms 2, 3 may have a robotic surgical assembly 100 and an electromechanical surgical instrument or tool assembly 200 coupled thereto. In some embodiments, the robotic surgical assembly 100 may be removably attached to a slide rail 40 of one of the surgical robotic arms 2, 3. In certain embodiments, the robotic surgical assembly 100 may be fixedly attached to the slide rail 40 of one of the surgical robotic arms 2, 3.

[0061] Operating console 5 includes a display device 6, which is set up to display three- dimensional images, and manual input devices 7, 8, by means of which a clinician (not shown), is able to telemanipulate the robotic arms 2, 3 in a first operating mode, as known in principle to a person skilled in the art. Each of the robotic arms 2, 3 may be composed of any number ofmembers, which may be connected through joints. The robotic arms 2, 3 may be driven by electric drives (not shown) that are connected to control device 4. The control device 4 (e.g., a computer) is set up to activate the drives, for example, by means of a computer program, in such a way that the robotic arms 2, 3, the attached robotic surgical assembly 100, and thus the electromechanical surgical instrument 200 (including the electromechanical end effector, not shown) execute a desired movement according to a movement defined by means of the manual input devices 7, 8. The control device 4 may also be set up in such a way that it regulates the movement of the robotic arms 2, 3 and / or of the drives.

[0062] The robotic-assisted surgical system 1 is configured for use on a patient “P” positioned (e.g., lying) on a surgical table “ST” to be treated in a minimally invasive manner by means of a surgical instrument, e.g., the electromechanical surgical instrument 200. The robotic- assisted surgical system 1 may also include more than two robotic arms 2, 3, the additional robotic arms likewise connected to the control device 4 and telemanipulatable by means of the operating console 5. A surgical instrument, for example, the electromechanical surgical instrument 200 (including the electromechanical end effector thereof), may also be attached to any additional robotic arm(s).

[0063] The control device 4 may control one or more motors, e.g., motors (Motor l...n), each motor configured to drive movement of the robotic arms 2, 3 in any number of directions. Further, the control device 4 may control an instrument drive unit 110 including motors 52, 54, 56 and 58 of a motor pack 50 (only 2 of the 4 motors being shown in FIG. 9) disposed within a sterile barrier housing of the robotic surgical assembly 100. The motors 52, 54, 56 and 58 of the motor pack 50 drive various operations of an end effector of the electromechanical surgical instrument 200. The motors 52, 54, 56 and 58 may include a rotation motor, such as, for example, a canister motor. One or more of the motors 52, 54, 56 and 58 may be configured to drive a relative rotation of the electromechanical surgical instrument 200, or components thereof, along a longitudinal axis “X” thereof. In some embodiments, each motor of motor pack 50 can be configured to actuate a drive screw (or, for example, a linear drive, a capstan, etc.) which is operatively connected to a drive rod or a lever arm to effect operation and / or movement of the electromechanical end effector of the electromechanical surgical instrument 200.

[0064] Each motor 52, 54, 56 and 58 provides a respective rotational output which defines a respective rotation axis. The rotational outputs of the motors 52, 54, 56 and 58 are used to drive rotational drive receiving members or inputs of the electromechanical surgical instrument 200 (e.g., connector sleeves 356a, 356b, 356c of adapter assembly 350, as described below).

[0065] In accordance with the present disclosure, the electromechanical surgical instrument 200 is rotated about a longitudinal axis of rotation thereof by a motor (not shown) having a rotation axis that is offset a radial distance from the longitudinal axis of rotation of the electromechanical surgical instrument 200.

[0066] For a detailed discussion of the construction and operation of a robotic surgical system, reference may be made to U.S. Patent 8,828,023, entitled “Medical Workstation,” the entire contents of which are incorporated by reference herein.

[0067] Turning now to FIGS. 3-6, a handheld electromechanical surgical device, in accordance with the disclosure, is generally designated as 300, and is configured for selective attachment to of a plurality of different end effectors (e.g., surgical stapler 400, see FIG. 6) that are each configured for actuation and manipulation by the powered handheld electromechanical surgical device. Specifically, surgical device 300 is configured for selective connection with an adapter assembly 350, and, in turn, adapter assembly 350 is configured for selective connection with end effectors or single use loading units (“SULU’s”) 400.

[0068] While surgical device 300 is shown being used in combination with an adapter assembly 350 and replaceable SULU 400, it is envisioned and contemplated that surgical device 300 may be used in combination with a tool assembly 404 which includes a non-removable reload having either a non-replaceable staple cartridge (i.e., thus being only able to be used once during a surgical procedure and thereafter being disposed) or which includes a replaceable staple cartridge (i.e., thus being able to be used multiple times during a surgical procedure and thereafter being reprocessed or disposed of).

[0069] Surgical device 300 may include a power-pack, and an outer shell housing configured to selectively receive and sealingly encase the power-pack to establish a sterilebarrier about the power-pack. The outer shell housing defines a connecting portion 302 configured to accept a corresponding drive coupling assembly 352 of adapter assembly 350. Surgical device 300 includes a toggle control button 304.

[0070] Surgical device 300 includes three coupling shafts 306a, 306b, 306c located within connecting portion 302. The three coupling shafts 306a, 306b, 306c are arranged in a single row. The three coupling shafts 306a, 306b, 306c are non-circular so as to be able to transmit rotational forces from motors of the surgical device 300 to rotation receiving connector sleeves of the adapter assembly 350, as will be described in greater detail below.

[0071] Surgical device 300 further includes a first motor, a second motor, and a third motor (not shown) each electrically connected to a controller circuit board and battery (not shown). Each motor is configured to drive a respective coupling shaft 306a, 306b, 306c. As such, the motors of surgical device 300 are configured to, for example, drive shafts and / or gear components of adapter assembly 350 in order to selectively move tool assembly 404 of SULU 400 relative to proximal body portion 402 of SULU 400, to rotate SULU 400 about a longitudinal axis “X,” to move cartridge assembly 408 relative to anvil assembly 406 of SULU 400, and / or to fire staples from within cartridge assembly 408 of SULU 400.

[0072] The mating of the three coupling shafts 306a, 306b, 306c of surgical device 300 with respective rotational drive receiving members or connector sleeves 356a, 356b, 356c of adapter assembly 350 allows rotational forces to be independently transmitted via each of the three respective connector interfaces.

[0073] Since each of the three coupling shafts 306a, 306b, 306c of surgical device 300 has a keyed and / or substantially non-rotatable interface with respective connector sleeves 356a, 356b, 356c of adapter assembly 350, when adapter assembly 350 coupled to surgical device 300, rotational force(s) are selectively transferred from the motors of surgical device 300 to adapter assembly 350.

[0074] The selective rotation of coupling shaft(s) 306a, 306b, 306c of surgical device 300 allows surgical device 300 to selectively actuate different functions of SULU 400. For example, selective and independent rotation of first coupling shaft 306a of surgical device 300 maycorrespond to the selective and independent opening and closing of tool assembly 404 of SULU 400, and driving of a stapling / cutting component of tool assembly 404 of SULU 400. Also, the selective and independent rotation of second coupling shaft 306b of surgical device 300 may correspond to the selective and independent articulation of tool assembly 404 of SULU 400 transverse to longitudinal axis “X”. Additionally, the selective and independent rotation of third coupling shaft 306c of surgical device 300 corresponds to the selective and independent rotation of SULU 400 about longitudinal axis “X” relative to surgical device 300.

[0075] With reference to FIGS. 3-5, surgical device 300 includes an electrical connector 310 supported within connecting portion 302 of surgical device 300 and electrically connected to control circuitry (not shown) of surgical device 300. The electrical connector 310 is configured for selective connection to a complementary electrical assembly 358 of adapter assembly 350.

[0076] Turning now to FIGS. 7-17, in order to be able to use a tool assembly 404, which is typically used in combination with surgical device, in combination with instrument drive unit 110 of robotic surgical assembly 100, a coupler assembly 500 is provided: for interconnecting tool assembly 404 to instrument drive unit 110; for transmitting rotational forces from instrument drive unit 110 to tool assembly 404; and for transmitting electrical communi cation / power between instrument drive unit 110 and tool assembly 404.

[0077] In use, interposed between coupler assembly 500 and instrument drive unit 110 is a sterile interface module 130 which functions to provide an interface between the instrument drive unit 110 and the coupler assembly 500. This interface advantageously maintains sterility, provides a means to transmit electrical communication between the robotic surgical assembly 100 and the tool assembly 404, provides a means for transferring rotational force from the instrument drive unit 110 to the coupler assembly 500 for performing a function with the electromechanical surgical instruments, and / or provides a means to selectively attach / remove coupler assembly 500 to the instrument drive unit 110 (e.g., for rapid instrument exchange).

[0078] Coupler assembly 500 includes an outer housing 502 having a proximal end portion 510 configured for selective connection to the sterile interface module 130 of robotic surgical assembly 100, and a distal end portion 520 configured for selective connection with thetool assembly 404. Alternatively, proximal end portion 510 of outer housing 502 may be configured for selective connection to the instrument drive unit 110 and to the motors thereof.

[0079] The proximal end portion 510 of outer housing 502 of coupler assembly 500 rotatably supports a plurality of proximal couplers 516 positioned within respective proximal openings 512. In order to interface with the motors 52, 54, 56 and 58 of motor pack 50 of the instrument drive unit 110 (via the sterile interface module 130) which are arranged in a nonlinear or rectangular array, the proximal openings 512 of outer housing 502 are also arranged in a rectangular array. While four potential proximal openings 512 are possible (see FIG. 12), to correspond one each to a respective motor 52, 54, 56 and 58 of the instrument drive unit 110, any number of openings 512 may be provided from 1 to 4, for rotatably supporting a corresponding number of proximal couplers 516, e.g., three proximal couplers 516a, 516b, 516c shown. For example, if only three of the four motors 52, 54, 56 and 58 of the instrument drive unit 110 are needed, then the three motors 52, 54, 56 and / or 58 of the instrument drive unit 110 may be arranged in a non-linear or triangular array.

[0080] The proximal couplers 516a, 516b, 516c of the coupler assembly 500 define respective axes of rotation which are parallel to one another, and which are not disposed in a common plane.

[0081] Each proximal coupler 516 includes a feature, such as, for example, at least one tooth, slot, cross, non-circular projection or non-circular recess, for connection with and to receive rotational forces from complimentary rotational output members of the four motors 52, 54, 56 and 58 of the instrument drive unit 110.

[0082] In accordance with the disclosure, coupler assembly 500 is configured to connected with an instrument drive unit 110 which includes motors (and respective rotational outputs) which are arranged in a non-linear array or configuration, such as, for example, triangular, rectangular, pentagonal, etc.)

[0083] The proximal end portion 510 of outer housing 502 of coupler assembly 500 supports a proximal electrical connector 542 configured for selective connection to acomplementary electrical connector of the sterile interface module 130 of robotic surgical assembly 100.

[0084] The proximal end portion 510 of outer housing 502 includes a pair of ramped camming surfaces 518 disposed on opposed side surfaces thereof for transverse connection / disconnection with corresponding ramp surfaces of the sterile interface module 130 of robotic surgical assembly 100 for connecting the coupler assembly 500 to the sterile interface module 130. In use, proximal end portion 510 of outer housing 502 is configured to be slid transversely into coupling engagement with the sterile interface module 130, e.g., side loaded, as depicted in FIG. 7.

[0085] The distal end portion 520 of outer housing 502 of coupler assembly 500 defines a distally facing recess 520a configured to selectively receive the drive coupling assembly 352 of the tool assembly 404 therein. The distal end portion 520 of outer housing 502 rotatably supports a plurality of distal couplers 526a, 526b, 526c located within recess 520a of coupler assembly 500. The three distal couplers 526a, 526b, 526c are arranged in a single row. Each of the three distal couplers 526a, 526b, 526c includes a shaft extending axially therefrom with the shaft having a non-circular transverse cross-sectional profile so as to be able to transmit rotational forces from a respective three motors of motors 52, 54, 56 and 58 of the instrument drive unit 110 to rotation receiving connector sleeves of the tool assembly 404. In order to interface with connector sleeves 356a, 356b, 356c of the tool assembly 404, which are arranged in a linear array, the distal couplers 526a, 526b, 526c of the coupler assembly 500 are also arranged in a linear array. Specifically, the rotational axes of each of the distal couplers 526a, 526b, 526c of the coupler assembly 500 are parallel to one another and are disposed in a common plane.

[0086] The distal couplers 526a, 526b, 526c of the coupler assembly 500 define respective axes of rotation which are parallel to one another, and which are parallel to the axes of rotation of the proximal couplers 516a, 516b, 516c.

[0087] Since the instrument drive unit 110 includes four motors 52, 54, 56 and 58 arranged in a rectangular array, and since the tool assembly 404 includes three connector sleeves356a, 356b, 356c arranged in a linear array, coupler assembly 500 includes torque transmitting members 536 interconnecting the three proximal couplers 516a, 516b, 516c (arranged in a rectangular array) with the three distal couplers 526a, 526b, 526c (arranged in a rectangular array). Specifically, coupler assembly 500 includes: a first torque transmitting member 536a interconnecting proximal coupler 516a with distal coupler 526a; a second torque transmitting member 536b interconnecting proximal coupler 516b with distal coupler 526b; and a third torque transmitting member 536c interconnecting proximal coupler 516c with distal coupler 526c.

[0088] As illustrated in FIG. 17, each torque transmitting member 536 includes a rigid shaft 538, a first ball connector 540 supported at a proximal end of the shaft 538, and a second ball connector 542 supported at a distal end of the shaft 538. The first ball connector 540 is received within a socket 517 formed in the proximal coupler 516, and the second ball connector 542 is received within a socket 527 formed in the distal coupler 526.

[0089] The first ball connector 540 includes a pair of pins 540a, 540b diametrically extending therefrom, and which define a first pin axis which is orthogonal to a longitudinal axis of the shaft 538. The second ball connector 542 includes a pair of pins 542a, 542b diametrically extending therefrom, and which define a second pin axis which is orthogonal to the longitudinal axis of the shaft 538. Pins 540a, 540b of the first ball connector 540 are slidably and rotatably received within elongate slots 517a defined in socket 517 of the proximal coupler 516 (defining a proximal drive yoke), and pins 542a, 542b of the second ball connector 542 are slidably and rotatably received within elongate slots 527a defined in socket 527 of the distal coupler 526 (defining a distal drive yoke).

[0090] The longitudinal axis of the shaft 538 of the first torque transmitting member 536a is angled with respect to the axis of rotation of the corresponding proximal coupler 516a and with respect to the axis of rotation of the corresponding distal coupler 526a, the longitudinal axis of the shaft 538 of the second torque transmitting member 536b is angled with respect to the axis of rotation of the corresponding proximal coupler 516b and with respect to the axis of rotation of the corresponding distal coupler 526b, and the longitudinal axis of the shaft 538 of the third torque transmitting member 536c is angled with respect to the axis of rotation of thecorresponding proximal coupler 516c and with respect to the axis of rotation of the corresponding distal coupler 526c.

[0091] In operation, as proximal couplers 516a, 516b, 516c are rotated, due to activation of a respective motor of motors 52, 54, 56 and 58 of instrument drive unit 110, the rotation is transmitted to a corresponding distal coupler 526a, 526b, 526c via respective torque transmitting member 536a, 536b, 536c. The combination of proximal coupler 516a, distal coupler 526a and torque transmitting member 536a may define a first drive train, the combination of proximal coupler 516b, distal coupler 526b and torque transmitting member 536b may define a second drive train, and the combination of proximal coupler 516c, distal coupler 526c and torque transmitting member 536c may define a third drive train.

[0092] Coupler assembly 500 further includes an inner housing 507 for rotatably supporting the proximal couplers 516a, 516b, 516c, the distal couplers 526a, 526b, 526c, and the torque transmitting member 536a, 536b, 536c. The inner housing 507 defines recesses or slots 507a (FIG. 16) against which the shafts 538 of the torque transmitting member 536a, 536b, 536c are seated so as to provide structures support to the torque transmitting member 536a, 536b, 536c.

[0093] The distal end portion 520 of outer housing 502 of coupler assembly 500 supports a distal electrical connector 544 which is configured for selective connection to a complementary electrical connector of the tool assembly 404. The distal electrical connector 544 is electrically connected to the proximal electrical connector 542. The coupler assembly 500 may include electronics, including, and not limited to, a memory (for storing identification information, usage information, and the like), wired or wireless communication circuitry (for receiving and transmitting data or information from / to the tool assembly 404, from / to control device 4, and / or from / to a remote central processing system). The proximal electrical connector 542 may include and is not limited to conductive connectors, magnetic connectors, resistive connectors, capacitive connectors, Hall sensors, reed switches or the like.

[0094] With reference to FIGS. 11-13, the outer housing 502 of the coupler assembly 500 supports at least one, in aspects a pair of release levers or paddles 514 on opposed sides thereof.Each release paddle 514 includes a first end 514a pivotally connected to the outer housing 502, and a second end 514b movable to / from an outer surface of the outer housing 502. The second end 514b of each release paddle 514 defines a tapered camming surface configured to act on a respective arm or tab of the sterile interface module 130, to disengage the coupler assembly 500 from the robotic surgical assembly 100. Specifically, as illustrated in FIG. 8, when the coupler assembly 500 is connected to the sterile interface module 130, arms or tabs 132 of the sterile interface module 130 are aligned and in registration with respective paddles 514 of the coupler assembly 500. Further, the free ends of the arms or tabs 132 of the sterile interface module 130 act on the respective tapered camming surfaces of the paddles 514 to press or urge the paddles 514 outwardly.

[0095] Disconnection of the coupler assembly 500 from the robotic surgical assembly 100 includes pressing the paddles 514 of the coupler assembly 500 toward the outer housing 502 whereby the tapered camming surfaces of the paddles 514 act on the free ends of the arms or tabs 132 of the sterile interface module 130. As the paddles 514 act on the free ends of the arms or tabs 132, the paddles 514 urge the coupler assembly 500 to disengage from the sterile interface module 130, and components thereof.

[0096] Turning now to FIG. 18, in accordance with another aspect of the disclosure, the rigid torque transmitting member 536a, 536b, 536c of respective first drive train, second drive train, and third drive train may be replaced by a respective first, second and third flexible torque transmitting shaft 539a, 539b, 539c. Specifically, for example, first flexible torque transmitting shaft 539a includes a first end non-rotatably connected to first proximal coupler 516a and a second end non-rotatably connected to first distal coupler 526a, second flexible torque transmitting shaft 539b includes a first end non-rotatably connected to second proximal coupler 516b and a second end non-rotatably connected to second distal coupler 526b, and third flexible torque transmitting shaft 539c includes a first end non-rotatably connected to third proximal coupler 516c and a second end non-rotatably connected to third distal coupler 526c.

[0097] Turning now to FIG. 19, in accordance with another aspect of the disclosure, the rigid torque transmitting member 536a, 536b, 536c of respective first drive train, second drive train, and third drive train may be replaced by a respective first, second and third gear train 541a,541b, and 541c. Specifically, for example, first gear train 541a includes a first rotatable shaft connected to first proximal coupler 516a, a second rotatable shaft connected to first distal coupler 526a, and a first gear set interconnecting the first rotatable shaft and the second rotatable shaft of the first gear train 541a. Second gear train 541b includes a first rotatable shaft connected to second proximal coupler 516b, a second rotatable shaft connected to second distal coupler 526b, and a second gear set interconnecting the first rotatable shaft and the second rotatable shaft of the second gear train 541b. Third gear train 541c includes a first rotatable shaft connected to third proximal coupler 516c, a second rotatable shaft connected to third distal coupler 526c, and a third gear set interconnecting the first rotatable shaft and the second rotatable shaft of the third gear train 541c.

[0098] Turning now to FIGS. 20-23, in accordance with another aspect of the disclosure, the rigid torque transmitting member 536a, 536b, 536c of respective first drive train, second drive train, and third drive train may be replaced with respective torque transmitting members 636a, 636b, 636c. Each torque transmitting member 636a, 636b, 636c includes a respective proximal coupler 616a, 616b, 616c, a respective distal coupler 626a, 626b, 626c, and a respective rigid shaft 638a, 638b, 638c interconnecting the proximal couplers 616a, 616b, 616c with respective distal couplers 626a, 626b, 626c. Specifically, for example, first torque transmitting shaft 636a includes a first end non-rotatably connected to first proximal coupler 616a and a second end non-rotatably connected to first distal coupler 626a, second torque transmitting shaft 636b includes a first end non-rotatably connected to second proximal coupler 616b and a second end non-rotatably connected to second distal coupler 626b, and third torque transmitting shaft 636c includes a first end non-rotatably connected to third proximal coupler 616c and a second end non-rotatably connected to third distal coupler 626c.

[0099] A first end portion of each shaft 638a, 638b, 638c includes three pins or bosses 640a extending radially outward therefrom. A second end portion of each shaft 638a, 638b, 638c includes three pins or bosses 640b extending radially outward therefrom. Pins 640a of each shaft 638a, 638b, 638c are slidably and pivotably received within corresponding elongate, axially extending, slots or grooves 617 formed in proximal couplers 616a, 616b, 616c, and pins 640b of each shaft 638a, 638b, 638c are slidably and pivotably received within corresponding elongate,axially extending, slots or grooves 627 (see FIG. 22) formed in proximal couplers 626a, 626b, 626c. Each pin or boss 640a, 640b may have a circular, rectangular, trapezoidal or other profile.

[0100] With reference to FIGS. 20 and 22, each of the proximal couplers 616a, 616b, 616c and each of the distal couplers 626a, 626b, 626c includes a recess or socket 650 configured to receive the first end portion or the second end portion of shafts 638a, 638b, 638c therein. Each socket 650 includes three axially extending recesses or channels 650a formed in and radially about an inner wall of the socket 650. Each recess 650a is configured and dimensioned to slidably and pivotably receive a corresponding pin 640a, 640b of shafts 638a, 638b, 638c.

[0101] As illustrated in FIGS. 20 and 21, each shaft 638a, 638b, 638c includes a first ring or collar 642 located an axial distance away from the first end thereof and proximally of the first pins or bosses 640a, and a second ring or collar 644 located an axial distance away from the second end thereof and proximally of the second pins or bosses 640b. First collar 642 and second collar 644 define a surface against which a rim 650b (see FIG. 22) of sockets 650 of each of the proximal couplers 616a, 616b, 616c and each of the distal couplers 626a, 626b, 626c may abut and to help maintain shafts 638a, 638b, 638c potted within the proximal couplers 616a, 616b, 616c and each of the distal couplers 626a, 626b, 626c.

[0102] It should be understood that the foregoing description is only illustrative of the disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, this disclosure is intended to embrace all such alternatives, modifications and variances. The embodiments described with reference to the attached drawing figures are presented only to demonstrate certain examples of the disclosure. Other elements, steps, methods and techniques that are insubstantially different from those described above and / or in the appended claims are also intended to be within the scope of the disclosure.

[0103] The following examples are illustrative of the techniques described herein.

[0104] Example 1. A coupler assembly for interconnecting an instrument drive unit and a surgical tool assembly, wherein the instrument drive unit includes a plurality of drive motors arranged in a non-linear configuration, wherein each drive motor provides a respectiverotational output which defines a respective rotation axis, and wherein the surgical tool assembly includes a plurality of rotational drive receiving members arranged in a linear configuration, the coupling assembly comprising: an outer housing having a proximal end portion and a distal end portion, wherein the proximal end portion of the outer housing is configured for selective connection to the instrument drive unit, and wherein the distal end portion is configured for selective connection to the surgical tool assembly; a plurality of proximal couplers rotatably positioned within respective proximal openings defined in the proximal end portion of outer housing, the plurality of proximal couplers arranged in a non-linear configuration which matches the non-linear configuration of the plurality of drive motors of the instrument drive unit; a plurality of distal couplers rotatably supported in the distal end portion of the outer housing and projecting distally from the outer housing, the plurality of distal couplers arranged in a linear configuration which matches the linear configuration of the rotational drive receiving members of the surgical tool assembly; and a plurality of torque transmitting members supported within the outer housing and interconnecting each proximal coupler of the plurality of proximal couplers with a corresponding distal coupler of the plurality of distal couplers, each torque transmitting member including: a shaft; a first connector supported at a proximal end of the shaft, wherein the first connector is non-rotatably connected to a proximal coupler of the plurality of proximal couplers; and a second connector supported at a distal end of the shaft, wherein the second connector is non-rotatably connected to a distal coupler of the plurality of distal couplers.

[0105] Example 2. The coupler assembly of example 1, wherein: the first connector of each torque transmitting member is a first ball connector and is configured for receipt in a complementary socket defined in a corresponding proximal coupler; and the second connector of each torque transmitting member is a second ball connector and is configured for receipt in a complementary socket defined in a corresponding distal coupler.

[0106] Example 3. The coupler assembly of example 2, wherein: each first ball connector includes a pin projecting from opposed sides thereof, wherein the pin of the first ball connector defines a first pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the first pin is slidably and pivotably received within slots defined in the socket of the corresponding proximal coupler; and each second ball connector includes a pin projectingfrom opposed sides thereof, wherein the pin of the second ball connector defines a second pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the second pin is slidably and pivotably received within slots defined in the socket of the corresponding distal coupler.

[0107] Example 4. The coupler assembly of example 3, wherein the torque transmitting members are configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

[0108] Example 5. The coupler assembly of example 4, wherein the shaft of each torque transmitting member is rigid.

[0109] Example 6. The coupler assembly of example 5, further comprising an inner housing, wherein the inner housing defines at least one recess for rotatably receiving the shaft of each torque transmitting member.

[0110] Example 7. The coupler assembly of example 5, wherein: each proximal coupler defines an axis of rotation, wherein the axes of rotation of the proximal couplers are parallel to one another; each distal coupler defines an axis of rotation, wherein the axes of rotation of the distal couplers are parallel to one another; and the shaft of each torque transmitting member defines an axis of rotation, wherein the axis of rotation of the shaft of each torque transmitting member is angled with respect to the axis of rotation of the corresponding proximal coupler, and angled with respect to the axis of rotation of the corresponding distal coupler.

[0111] Example s. The coupler assembly of example 4, further comprising: an electrical connector supported in the distal end portion of the outer housing, wherein the electrical connector of the distal end portion of the outer housing is configured to connect to a complimentary electrical connector of the tool assembly; and an electrical connector supported in the proximal end portion of the outer housing, wherein the electrical connector of the proximal end portion of the outer housing is configured to connect to a complimentary electrical connector of the instrument drive unit, wherein the electrical connector of the distal end portion of the outerhousing and the electrical connector of the proximal end portion of the outer housing are connected to one another.

[0112] Example 9. The coupler assembly of example 4, wherein the shaft of each torque transmitting member is flexible and capable of transmitting torque.

[0113] Example 10. The coupler assembly of example 4, further comprising a pair of release levers positioned on opposed sides of the outer housing.

[0114] Example 11. The coupler assembly of example 10, further comprising a pair of ramped camming surfaces disposed on opposed side surfaces of the outer housing, the pair of ramped camming surfaces being in registration with the pair of release levers.

[0115] Example 12. A coupler assembly for interconnecting an instrument drive unit and a surgical tool assembly, wherein the instrument drive unit includes a plurality of drive motors arranged in a non-linear configuration, wherein each drive motor provides a respective rotational output which defines a respective rotation axis, and wherein the surgical tool assembly includes a plurality of rotational drive receiving members arranged in a linear configuration, the coupling assembly comprising: an outer housing having a proximal end portion and a distal end portion, wherein the proximal end portion of the outer housing is configured for selective connection to the instrument drive unit, and wherein the distal end portion is configured for selective connection to the surgical tool assembly; a plurality of proximal couplers rotatably supported in the proximal end portion of outer housing, the plurality of proximal couplers arranged in a non-linear configuration which matches the non-linear configuration of the plurality of drive motors of the instrument drive unit, each proximal coupler defining an axis of rotation, wherein the axes of rotation of the plurality of proximal couplers are parallel to one another; a plurality of distal couplers rotatably supported in the distal end portion of the outer housing and projecting distally from the outer housing, the plurality of distal couplers arranged in a linear configuration which matches the linear configuration of the rotational drive receiving members of the surgical tool assembly, each distal coupler defines an axis of rotation, wherein the axes of rotation of the plurality of distal couplers are parallel to one another; and a plurality of torque transmitting members supported within the outer housing and interconnecting eachproximal coupler of the plurality of proximal couplers with a corresponding distal coupler of the plurality of distal couplers, each torque transmitting member including: a shaft defining an axis of rotation, wherein the axis of rotation of the shaft is angled with respect to the axis of rotation of each respective proximal coupler, and wherein the axis of rotation of the shaft is angled with respect to the axis of rotation of each respective distal coupler; a proximal drive yoke interconnecting the shaft and a respective proximal coupler of the plurality of proximal couplers; and a distal drive yoke interconnecting the shaft and a respective distal coupler of the plurality of distal couplers.

[0116] Example 13. The coupler assembly of example 12, wherein: the proximal drive yoke of each torque transmitting member is a ball connector configured for receipt in a complementary socket defined in a corresponding proximal coupler; and the distal drive yoke of each torque transmitting member is a ball connector configured for receipt in a complementary socket defined in a corresponding distal coupler.

[0117] Example 14. The coupler assembly of example 13, wherein: the ball connector of each proximal drive yoke includes a pin projecting from opposed sides thereof, wherein the pin of the ball connector of each proximal drive yoke defines a first pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the first pin of each proximal drive yoke is slidably and pivotably received within slots defined in the socket of the corresponding proximal coupler; and the ball connector of each distal drive yoke includes a pin projecting from opposed sides thereof, wherein the pin of the ball connector of each distal drive yoke defines a second pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the second pin of each distal drive yoke is slidably and pivotably received within slots defined in the socket of the corresponding distal coupler.

[0118] Example 15. The coupler assembly of example 14, wherein the torque transmitting members are configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

[0119] Example 16. The coupler assembly of example 15, wherein the shaft of each torque transmitting member is rigid.

[0120] Example 17. The coupler assembly of example 16, further comprising an inner housing, wherein the inner housing defines at least one recess for rotatably receiving the shaft of each torque transmitting member.

[0121] Example 18. A coupler assembly for interconnecting an instrument drive unit and a surgical tool assembly, wherein the instrument drive unit includes a plurality of drive motors arranged in a non-linear configuration, wherein each drive motor provides a respective rotational output which defines a respective rotation axis, wherein the rotation axes of the drive motors are not in a common plane, and wherein the surgical tool assembly includes three rotational drive receiving members arranged in a linear configuration, the coupling assembly comprising: an outer housing having a proximal end portion and a distal end portion, wherein the proximal end portion of the outer housing is configured for selective connection to the instrument drive unit, and wherein the distal end portion is configured for selective connection to the surgical tool assembly; three proximal couplers rotatably positioned within respective proximal openings defined in the proximal end portion of outer housing, each proximal coupler defining a coupler rotation axis, wherein the coupler rotation axes are parallel to one another and are not in a common plane, and wherein the three proximal couplers are axially aligned with a corresponding three motors of the instrument drive unit; three distal couplers rotatably supported in the distal end portion of the outer housing and projecting distally from the outer housing, each distal coupler including a shaft and defining a coupling shaft rotation axis, wherein the coupling shaft rotation axes are parallel to one another and are in a common plane, and wherein the three distal couplers are axially aligned with a corresponding one of three rotational drive receiving members of the surgical tool assembly; and a plurality of torque transmitting members supported within the outer housing and interconnecting a proximal coupler of the three proximal couplers with a corresponding distal coupler of the three distal couplers, each torque transmitting member includes: a shaft; a first connector supported at a proximal end of the shaft, wherein the first connector is non-rotatably connected to a proximal coupler of the three proximal couplers; and a second connector supported at a distal end of the shaft, wherein the second connector is non- rotatably connected to a distal coupler of three of distal couplers.

[0122] Example 19. The coupler assembly of example 18, wherein the torque transmitting members are configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

[0123] Example 20. The coupler assembly of example 19, wherein the shaft of each torque transmitting member is rigid.

Claims

What is claimed is:

1. A coupler assembly (500) for interconnecting an instrument drive unit (110) and a surgical tool assembly (404), wherein the instrument drive unit (110) includes a plurality of drive motors (52, 54, 56, 58) arranged in a non-linear configuration, wherein each drive motor (52, 54, 56, 58) provides a respective rotational output which defines a respective rotation axis, and wherein the surgical tool assembly (404) includes a plurality of rotational drive receiving members arranged in a linear configuration, the coupling assembly comprising: an outer housing (502) having a proximal end portion and a distal end portion, wherein the proximal end portion of the outer housing (502) is configured for selective connection to the instrument drive unit (110), and wherein the distal end portion is configured for selective connection to the surgical tool assembly; a plurality of proximal couplers (516) rotatably positioned within respective proximal openings defined in the proximal end portion of outer housing, the plurality of proximal couplers (516) arranged in a non-linear configuration which matches the non-linear configuration of the plurality of drive motors (52, 54, 56, 58) of the instrument drive unit (110); a plurality of distal couplers (526) rotatably supported in the distal end portion of the outer housing and projecting distally from the outer housing (502), the plurality of distal couplers (526) arranged in a linear configuration which matches the linear configuration of the rotational drive receiving members of the surgical tool assembly (404); and a plurality of torque transmitting members (536) supported within the outer housing (502) and interconnecting each proximal coupler (516) of the plurality of proximal couplers with a corresponding distal coupler (526) of the plurality of distal couplers, each torque transmitting member (536) including: a shaft (538); a first connector supported at a proximal end of the shaft, wherein the first connector is non-rotatably connected to a proximal coupler of the plurality of proximal couplers; anda second connector supported at a distal end of the shaft, wherein the second connector is non-rotatably connected to a distal coupler of the plurality of distal couplers.

2. The coupler assembly of claim 1, wherein: the first connector of each torque transmitting member is a first ball connector and is configured for receipt in a complementary socket defined in a corresponding proximal coupler; and the second connector of each torque transmitting member is a second ball connector and is configured for receipt in a complementary socket defined in a corresponding distal coupler.

3. The coupler assembly of claim 2, wherein: each first ball connector includes a pin projecting from opposed sides thereof, wherein the pin of the first ball connector defines a first pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the first pin is slidably and pivotably received within slots defined in the socket of the corresponding proximal coupler; and each second ball connector includes a pin projecting from opposed sides thereof, wherein the pin of the second ball connector defines a second pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the second pin is slidably and pivotably received within slots defined in the socket of the corresponding distal coupler.

4. The coupler assembly of claim 3, wherein the torque transmitting members are configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

5. The coupler assembly of claim 4, wherein the shaft of each torque transmitting member is rigid.

6. The coupler assembly of claim 5, further comprising an inner housing, wherein the inner housing defines at least one recess for rotatably receiving the shaft of each torque transmitting member.

7. The coupler assembly of claim 5, wherein: each proximal coupler defines an axis of rotation, wherein the axes of rotation of the proximal couplers are parallel to one another; each distal coupler defines an axis of rotation, wherein the axes of rotation of the distal couplers are parallel to one another; and the shaft of each torque transmitting member defines an axis of rotation, wherein the axis of rotation of the shaft of each torque transmitting member is angled with respect to the axis of rotation of the corresponding proximal coupler, and angled with respect to the axis of rotation of the corresponding distal coupler.

8. The coupler assembly of claim 4, further comprising: an electrical connector supported in the distal end portion of the outer housing, wherein the electrical connector of the distal end portion of the outer housing is configured to connect to a complimentary electrical connector of the tool assembly; and an electrical connector supported in the proximal end portion of the outer housing, wherein the electrical connector of the proximal end portion of the outer housing is configured to connect to a complimentary electrical connector of the instrument drive unit, wherein the electrical connector of the distal end portion of the outer housing and the electrical connector of the proximal end portion of the outer housing are connected to one another.

9. The coupler assembly of claim 4, wherein the shaft of each torque transmitting member is flexible and capable of transmitting torque.

10. The coupler assembly of claim 4, further comprising a pair of release levers positioned on opposed sides of the outer housing.

11. The coupler assembly of claim 10, further comprising a pair of ramped camming surfaces disposed on opposed side surfaces of the outer housing, the pair of ramped camming surfaces being in registration with the pair of release levers.

12. A coupler assembly (500) for interconnecting an instrument drive unit (110) and a surgical tool assembly, wherein the instrument drive unit (110) includes a plurality of drive motors (52, 54, 56, 58) arranged in a non-linear configuration, wherein each drive motor (52, 54, 56, 58) provides a respective rotational output which defines a respective rotation axis, and wherein the surgical tool assembly includes a plurality of rotational drive receiving members arranged in a linear configuration, the coupling assembly comprising: an outer housing (502) having a proximal end portion and a distal end portion, wherein the proximal end portion of the outer housing is configured for selective connection to the instrument drive unit, and wherein the distal end portion is configured for selective connection to the surgical tool assembly; a plurality of proximal couplers (516) rotatably supported in the proximal end portion of outer housing (502), the plurality of proximal couplers (516) arranged in a non-linear configuration which matches the non-linear configuration of the plurality of drive motors of the instrument drive unit, each proximal coupler defining an axis of rotation, wherein the axes of rotation of the plurality of proximal couplers are parallel to one another; a plurality of distal couplers (526) rotatably supported in the distal end portion of the outer housing and projecting distally from the outer housing (502), the plurality of distal couplers arranged in a linear configuration which matches the linear configuration of the rotational drive receiving members of the surgical tool assembly, each distal coupler (526) defines an axis of rotation, wherein the axes of rotation of the plurality of distal couplers (526) are parallel to one another; and a plurality of torque transmitting members (536) supported within the outer housing and interconnecting each proximal coupler (516) of the plurality of proximal couplers with a corresponding distal coupler (526) of the plurality of distal couplers, each torque transmitting member including:a shaft (538) defining an axis of rotation, wherein the axis of rotation of the shaft is angled with respect to the axis of rotation of each respective proximal coupler, and wherein the axis of rotation of the shaft is angled with respect to the axis of rotation of each respective distal coupler; a proximal drive yoke interconnecting the shaft (538) and a respective proximal coupler (516) of the plurality of proximal couplers; and a distal drive yoke interconnecting the shaft (538) and a respective distal coupler (526) of the plurality of distal couplers.

13. The coupler assembly of claim 12, wherein: the proximal drive yoke of each torque transmitting member is a ball connector configured for receipt in a complementary socket defined in a corresponding proximal coupler; and the distal drive yoke of each torque transmitting member is a ball connector configured for receipt in a complementary socket defined in a corresponding distal coupler.

14. The coupler assembly of claim 13, wherein: the ball connector of each proximal drive yoke includes a pin projecting from opposed sides thereof, wherein the pin of the ball connector of each proximal drive yoke defines a first pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the first pin of each proximal drive yoke is slidably and pivotably received within slots defined in the socket of the corresponding proximal coupler; and the ball connector of each distal drive yoke includes a pin projecting from opposed sides thereof, wherein the pin of the ball connector of each distal drive yoke defines a second pin axis which is oriented transverse to a longitudinal axis of the shaft, and wherein the second pin of each distal drive yoke is slidably and pivotably received within slots defined in the socket of the corresponding distal coupler.

15. The coupler assembly of claim 14, wherein the torque transmitting members are configured to transmit rotational inputs received by the proximal couplers to rotational outputs of the distal couplers.

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