Sterile Adapter Mechanical Lockouts for Predictable Instrument Mounting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing teleoperated surgical systems face challenges in securely engaging instruments due to unpredictable movements during installation, requiring complex and unpredictable motor interactions, which can lead to unacceptable instrument behavior and space constraints.

Innovation Solution

A computer-assisted surgical apparatus with a preload assembly and controller that manages preload engagement and disengagement, featuring a preload engage/disengage mechanism, a surgical instrument manipulator assembly, and mechanical lockouts to ensure secure and predictable instrument mounting, reducing backlash and improving user interface simplicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If motorized axes are used to control instrument mounting, then automation is improved, but device complexity increases and unpredictable movements occur

Engineering Contradiction:

Improveautomation of instrument mountingVSAvoidcomplexity of drive system

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent replaces motorized axes with a purely mechanical mounting mechanism. The instrument is mounted using a mechanical interface with engagement features that physically guide and secure the instrument without requiring motorized control during the mounting process itself. This substitution eliminates the complexity of motor control while maintaining automation through the mechanical design's inherent guidance features.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical interface is pre-configured with engagement features, alignment elements, and guidance structures that automatically guide the instrument into the correct position upon approach. The preliminary mechanical design ensures that when the instrument is brought to the mounting interface, the engagement occurs predictably without requiring complex real-time motor control or feedback during the actual mounting action.

Inventive Principle:

Principle #10Preliminary action

2Extent of automation

If motorized axes are used for instrument mounting, then automation is improved, but instrument behavior becomes unpredictable

Engineering Contradiction:

Improveautomation of instrument mountingVSAvoidpredictability of instrument behavior

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

By replacing motorized control with a mechanical engagement system, the patent eliminates the sources of unpredictability inherent in motorized systems (such as control delays, positioning errors, and feedback loops). The mechanical interface provides deterministic, repeatable engagement through physical constraints and geometric fitting, ensuring that the instrument's behavior during mounting is fully predictable and reliable.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical interface is designed in advance with built-in guidance features, alignment elements, and engagement structures that predetermined the exact path and position of instrument mounting. This preliminary mechanical configuration ensures that the instrument follows a predictable trajectory and settles into a known, repeatable position, eliminating behavioral unpredictability.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If complex motor interactions are used, then engagement capability is improved, but space requirements increase

Engineering Contradiction:

Improveengagement capabilityVSAvoidspace requirements

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent replaces complex motorized engagement mechanisms with a compact mechanical interface. The engagement features, such as interlocking elements, bayonet-style connectors, or friction-fit interfaces, achieve reliable instrument securing in a much smaller volume than motorized systems would require. This mechanical approach eliminates the need for motors, gearboxes, and control electronics, dramatically reducing the space needed for the mounting mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If mechanical lockouts are added, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvesecurity of instrument mountingVSAvoidcomplexity of mounting mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates the lockout function directly into the primary mechanical engagement mechanism rather than adding it as a separate system. The engagement features that secure the instrument also inherently provide the lockout function through their geometric design. For example, the same interlocking elements that mount the instrument also prevent its removal, combining two functions into a single mechanical structure and avoiding additional complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12502238B2Surgical apparatus including a sterile adapter having mechanical lockouts

Publication Date: 2025.12.23 INTUITIVE SURGICAL OPERATIONS INC

AI summary

A surgical system comprises a sterile adapter assembly comprising a mechanical surgical instrument removal lockout and a mechanical sterile adapter assembly removal lockout. The mechanical sterile adapter assembly removal lockout is activated on a condition of a surgical instrument mounted in the sterile adapter assembly. The mechanical surgical instrument removal lockout is activated by a surgical instrument manipulator assembly on a condition of the surgical instrument being mounted in the sterile adapter assembly and movement of the surgical instrument manipulator assembly by a predetermined distance.